Page 1
D
SERVICE
D-NET
22.0KW
17.0KW
at
--
60
SINGLE
DIESEL
- -
Hertz
EDE
EDE
AND
THREE
MANUAL
GENERATORS
17.0KW
13.5KW
at
50
Hertz
"PHASE
EDE
EDE
:
~
----
NAII'A
...
WO.
FIRST EDITION
JULY 2008
WESTERBEKE
WESTERBEKE CORPORATION· MYLES STANDISH INDUSTRIAL PARK
150 JOHN
FAX 1-508-884-9688' WEBSITE: WWWWESTERBEKE.COM
Member National
HANCOCK
Marine
ROAD'
TAUNTON
Manufacturers Association
MA
02780-7319'
TEL.
1-508-823-7677
Page 2
A
WARNING
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:
-Dip/ness
-Nausea
-Headache
-
Throbbing
in
Temples
•
Muscu/ar
Twitching
•
Vomiting
-
Weakness
and
Sleepiness
-Inability
to
Think
Coherently
/F
YOU
OR
ANYONE
ELSE
EXPERIENCE
ANY
OF
THESE
SYMPTOMS,
6ET
OUT
INTO
THE
FRESH
AIR
IMMEDIATELY.
If
symptoms
persist,
seek
medical
attention.
Shut
down
the
unit
and
do
not
restart
until
it
has
been
inspected
and
repaired.
:WARNING
Generatoffi
Pnx1UC6!CARBON
MONOXIDE
Regular
Maintenanca
Required
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/s/eeping
quarters
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.
Page 3
TABLE
OF
CONTENTS
Testing
for
Overhaul
.........................................................
2
Engine
Troubleshooting
...................................................
3
Disassembly
Procedures
.................................................
5
Assembly
Procedures
......................................................
6
Assembly
Instructions
.....................................................
7
Disassembly/Assembly
....................................................
8
Servicing
..........................................................................
21
Wiring
Diagrams
.............................................................
34
Engine
Adjustments
......................................................
.36
Glow Plugs .................................................................
36
Drive Belt Adjustment ...............................................
36
Fuel Injectors ............................................................. .37
Valve Clearance ......................................................... .38
Testing Engine Compression ...................................... 39
Testing
Oil Pressure ................................................... 39
Oil Pressure Sensor .................................................... 39
Testing Magnetic
Pick-up Coil .................................. 40
Air
Intake Silencer .................................................... .40
Specifications
.................................................................
43
Raw
Water
Pump
...........................................................
.45
Starter
Motor
..................................................................
.46
Alternator
Testing
.........................................................
.52
SpeCial
Tools
.......................... , ........................................
59
Service/Standards
and
Limits
......................................
61
Torque
Specifications
....................................................
67
Generator
Information
...................................................
68
Electronic Regulation ................................................. 69
Exciter Rotor Troubleshooting ................................... 71
Terminal Board Connections
...................................... 72
Hertz Voltage Change ................................................. 73
Internal
Schematic ......................................................
74
Wiring Diagrams ........................................................ 75
Generator Assembly ................................................... 76
BE
Troubleshooting ................................................... 78
Metric
Charts
..................................................................
79
Hardware
Torques
...........................................................
81
SERIAL
NUMBER
LOCATION
The engine's model number and serial number are located
on
a nameplate mounted on the side
of
the engine's manifold.
The engine's serial number can also
be
found stamped into
the engine block on the flat surface
of
the block just above
and inboard
of
the injection pump.
SPECIACATION
MODEL~.
_____
_
RPM
__________
_
KW
___________
_
KVA
_______ • __
_
VOLTS
________
_
AMPS • _______
_
ENG.
HP
______
_
ENG.
SER.
NO.
GEN.
SER.
NO.
PF/PHASE
___
_
WIRES
________
_
RATING
_______
_
INSUL
CLASS
__
TEMP.
RISE
___
_
BAlTERY
_____
_
C.1.0.
_________
_
50
HZ.
60 HZ.
I
An identification plate on the top
of
the engine air intake also
displays the engine model and serial number.
NOTE:
Use
the
two
name plates above
to
write
in
the
data
from
your
engine
while it
is
accessable.
In
years
to
come
it
will always be available
in
your
manual.
Engines & Generators
1
Page 4
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,
in
the
case
of
diesel
engines,
is
not
necessarily due
to
trouble
with
the engine
itself,
but
is
sometimes caused
by
injector
nozzle
wear
or
injection
pump
wear.
It
is
most reasonable to
judge
by
a decrease
in
compression pressure. The decrease
in
compression pressure
is
caused
by
many
factors.
It
is,
therefore,
necessary
to
determine 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 excessive
fuel
injection, improper
injection timing, and wear of plugs and nozzles.
They
are
caused
also
by
defective electrical devices
such
as
the
battery,
alternator, starter and glow
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.
In
diesel engines,
satisfactory combustion
is
obtained
only
under sufficient
compression pressure.
If
an
engine lacks compression
pressure, incomplete combustion
of
fuel
will
take
place even
if other parts
of
the engine are operating
properly.
To
determine 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
Compression pressure tends
to
increase a little
in a new
engine
until
piston rings and valve seats have been broken
in.
Thereafter, it decreases gradually
with
the progress of wear
of
these
parts.
When
decrease of compression
reaches
the
repair
limit,
the engine must
be
overhauled. The engine
requires overhaul when
oil
consumption
is
high,
blowby
evident, and compression valves are at minimum
or
below.
Engine compression should be
512
to 583 psi/36 to
41
kgflcm2
@290
rpm
(difference between cylinders must
not exceed 10%).
Precautions
for
Disassembly
and
Reassembly
When
servicing
an
engine,keep
in
mind
the
fonowing
precautions.
Disassembly
1.
Before disassembly
and
cleaning, carefully check
for
defects
which
cannot
be
found
after disassembly
and
cleaning.
2.
Drain
water,
fuel
and
oil
before
disassembly.
3.
Clean
or
wash
the engine exterior.
4.
Do
not
remove or disassemble
parts
that
do
not
require
disassembly.
5.
Perform disassembly
in
a proper order
using
proper
tools.
Keep
disassembled
parts
in
order.
Apply
oil
when
neces-
sary.
Take
special care
to
keep
the
fuel
system
parts
from
intrusion
of
dust
and
dirt.
Reassembly
1.
Carefully check gaskets, packings
and
oil
seals
even
if checking
is
not
specified.
Replace
with
new
ones
if
defective.
~
2.
Be
sure
to
install components
in
proper
directions
and
positions.
(Pay
attention
to
dowel
pins,
mating
marks
and
specified directions.) Where tightening
torque
is
not
specified, tighten evenly
to
an
ordinary
torque.
Apply
sealant
where
specified.
3. After completion of reassembly, recheck
for
any
abnormalities. Prepare
for
starting
the
engine,
and
idle
the
engine sufficiently
for
a test
run.
PRECAUTIONS
• Be careful
not
to
mix
bolts
and
nuts.
Metric
and
SAE.
bolts
are
used
on
various
engine assemblies.
• During
assembly,
recheck clearances
and
insure that
pints
are
being
assembled
in
their proper order
and
facing
in
the correct direction
in
relation
to
the engine
block,
such
as,
pistons, piston rings, bearings
and
bearing
caps.
•
Apply
lublicating
oil
to
moving parts
during
assembly.
Insure
that
moving parts,
when
assembled
on
the
engine,
fQtate
Of
slide and
are
not
subject
to
binding
or
excessive
tension.
• If there
are
mating marks scribed during
disassembly,
ref-
erence
them
cOlTectly
for
assembly
..
•
Use
new
gaskets, lockwashers, o-rings,
etc.
• Tighten
the
bolts
and
nuts
on
important
parts
of engine to
specified
torques
using a reliable torque
wrench.
•
Use
liquid sealants when required
on
nuts,
bolts
and
gas-
kets.
Refrain
from
using
tape sealants.
Engines & Generators
2
Page 5
ENGINE
TROUBLESHOOTING
The following troubleshooting chart describes certain problems relating to engine service, the probable causes
of
these problems,
and
the
recommendations
to
overcome
these
problems.This
chart
may
be
of
assistance
in
determining
the
need
for
an
engine
overhaul.
PROBLEM
PROBABLE
CAUSE
VERIFICATION/REMEDY
HARD
STARTING
LOW
CRANKING
SPEED
1.
Engine
oil
viscosity
too
high.
1.
Replace
engine
oil
with
less
viscous
oil.
2.
Run-down
battery.
2.
Recharge
battery.
3.
Worn
battery.
3.
Replace
battery.
4.
Battery
terminals
loosely
connected.
4.
Clean
terminals
and
correct
cables.
6.
Defective
starter.
5.
Repair
or
replace
starter.
6.
Defective
main
drive
section.
6.
Check
clutch
for
disengagement.
«-~
DEFECTIVE
INJECTION
SYSTEM
1.
Air
trapped
in
fuel
passage.
1.
Bleed
air
from
fuel
system.
2.
Clogged
fuel
filter.
2.
Clean
or
replace
fHter.
3.
Low
injection
pressure.
3.
Adjust
injection
pressure.
4.
Inadequate
spray.
4.
Clean
or
replace
nozzle.
5.
Injection
pump
delivering
insufficient
fuel.
6.
Repair
or
replace
injection
pump.
6.
Injection
too
early.
6.
Adjust injection
timing.
MAIN
ENGINE
TROUBLES
1.
Low
compression.
a.
Incorrect
valve
clearance.
a.
Adjust
valve
clearance.
b.
Inadequate
contact
of
valve
seat.
b.
Lap
valve.
c.
Valve
stern
seized.
c.
Replace
valve
and
valve
guide.
d.
Broken
valve
spring.
d.
Replace
valve
spring.
e.
Compression
leaks
through
cylinder
head
gasket.
e.
Replace
gasket.
f.
Piston
ring
seized.
f.
Replace
piston
and
piston
ring.
g.
Worn
piston
ring
and
cylinder.
g.
Overhaul
engine.
2.
Burnt
glow
plug.
2.
Replace
glow
plug.
3.
Faulty
glow
plug
operation.
3.
Correct
lead
wire
connection.
4.
Incorrect
governor
lever
position.
4.
Set
lever
to
starting
position.
5.
Governor
spring
out
of
POSITION
5.
Correct
spring
LOW
OUTPUT
LOW
COMPRESSION
See
HARD
STARTING
INJECTION
SYSTEM
OUT
OF
ADJUSTMENT
1.
Incorrect
injection
timing.
1.
Adjust injection
timing.
2.
Insufficient
injection.
2.
Repair
or
replace
injection
pump.
3.
Low
injection
pressure.
3.
Check
injection
nozzle
and
adjust
pressure.
INSUFFICIENT
FUEL
1.
Air
trapped
in
fuel
system.
1.
Check
and
retighten
connector.
2.
Clogged
filter.
2.
Clean
or
replace
filter.
3.
Contaminated
fuel
tank.
3.
Clean
tank.
INSUFFICIENT
INTAKE
AIR
1.
Clogged
air
cleaner.
1.
Clean
or
replace
air
cleaner.
(continued)
Engines & Generators .
3
Page 6
ENGINE
TROUBLESHOOTING
PROBLEM
PROBABLE
CAUSE
VERIFICATION/REMEDY
LOW
OUTPUT
{tont.}
OVERHEATING
1.
Low
coolant
level.
1.
Add
coolant.
2.
Loose
V-belt
2.
Adjust
or
replace
V-belt.
3.
Incorrect
injection
timing.
3.
Adjust
injection
timing.
4.
Low
engine
oil
level.
6.
Add
engine
oil.
EXCESSIVE
OIL
OIL
LEAKAGE
CONSUMPTION
1.
Defective
oil
seals.
1.
Replace
oil
seals.
2.
Broken
gear
case
gasket.
2.
Replace
gasket.
3.
Loose
gear
case
attaching
bolts.
3.
Retighten
bolts.
4.
Loose
drain
plug.
4.
Retighten
plug.
5.
Loose
oil
pipe
connector.
5.
Retighten
oil
connections.
6.
Broken
rocker
cover
gasket.
6.
Replace
gasket.
7.
Loose
rocker
cover
attaching
bolts.
7.
Retighten
attaching
bolts.
OIL
LEVEL
RISING
1.
Incorrectly
positioned
piston
ring
gaps.
1.
Correct
ring
gap
positions.
2.
Displaced
or
twisted
connecting
rod.
2.
Replace
connecting
rod.
3.
Wom
piston
ring.
3.
Replace
ring.
4.
Worn
piston
or
cylinder.
4.
Replace
piston
and
rabore
cylinder.
OIL
LEVEL
FALLING
1.
Defective
stem
seal.
1.
Replace
stem
seal.
2.
Worn
valve
and
valve
guide.
4.
Replace a valve
and
valve
guide.
EXCESSIVE
FUel
ENGINE
BODY
TROUBLES
CONSUMPTION
1.
Noisy
knocking.
1.
See
KNOCKING.
2.
Smoky
exhaust.
2.
See
SMOKY
EXHAUST.
3.
Moving
parts
nearly
seized
or
excessively
wom.
3.
Repair
or
replace.
4.
Poor
compression.
4.
See
LOW
COMPRESSION;
HARD
STARTING.
5.
Improper
valve
timing.
5.
Adjust.
6.
Improper
valve
clearance.
6.
Adjust.
INSUFACIENT
INTAKE
AIR
1.
Air
intake
obstructed.
1.
Remove
obstruction.
NOZZLE
TROUBLES
1.
Seized
nozzle.
1.
Replace.
2.
Worn
nozzle.
2.
Replace.
IMPROPER
FUel
Replace
with
proper
fuel.
FUEL
LEAKS
Rnd
fuel
leaks.
SMOKY
EXHAUST
WHITISH
OR
PURPLISH
1.
Excessive
engine
oil.
1.
Correct
ai/level.
2.
Excessive
rise
of
oil
into
com
bustion
chamber.
a.
Poor
piston
contact.
a.
Check.
b.
Seized
piston
ring.
b.
Replace
or
clean.
c.
Excessive
piston-to-cylinder
clearance.
c.
Replace
or
correct.
(continued)
Engines & Generators
4
Page 7
ENGINE
TROUBLESHOOTING
PROBLEM
PROBABLE
CAUSE
PROBLEM
PROBABLE
CAUSE
Low
oil
pressure.
1.
Low
oil
level.
Blue
exhaust
smoke
1.
Lube
oil
is
diluted.
2.
Wrong
SAE
type
oil
in
the
engine.
discharge
from
the
2.
High
lube
oil
level.
3.
Faulty
or
wrong
type
oil
filter.
engine.
3.
Crankcase
breather
hose
is
clogged.
4.
Relief
valve
is
stuck.
4.
Valves
are
worn
or
adjusted
5.
Faulty
oil
pump.
incorrectly.
6.
Faulty
engine
bearings.
7.
Faulty
oil
filter.
5.
Piston
rings
are
worn
or
unseated.
High
oil
pressure.
1.
Dirty
oil
or
wrong
SAE
type
oif
in
the
engine.
2.
Relief
valve
is
stuck.
Black
exhaust
smoke
1.
Dirty
flame
arrester.
discharge
from
the
2.
Lube
oil
is
diluted.
engine.
3.
Valves
are
worn
or
incorrectly
No
DC
charge
to
the
1.
Loose/corroded
battery
charge
starting
battery.
circuit
connection(s).
2.
Faulty
alternator
regulator.
adjusted.
4.
Piston
rings
are
worn
or
unseated.
5.
Cankcase
breather
hose
is
clogged.
3.
Faulty
DC
alternator.
Poor
Performance
1.
Fuel
pump
clogged.
Remove
and
4.
Slipping
alternator
drive
belt.
at
generator
speed.
replace.
5.
Broken
alternator
drive
belt.
2.
Throttle
body
filter
screen
dirty.
3.
Fuel
filter
contaminated.
Engines & Generators
43
Page 8
DISASSEMBLY
PROCEDURES
GENERATOR
PISTON
The piston's skirt
is
coated with molybdenum disulfied,
which
reduces the piston slap noise
and
the
entire operating
noise.
This
serves
as
a solid lubricant, like graphite
or
teflon
and
helps resist metal wear even with little lube
oil.
DYNAMIC
BALANCER
An engine
will
vibrate due
to
piston reciprocation. Three-
cylinder engines
are
much
less prone
to
cause vibration
than
a four-cylinder engine (second inertia).
However,
every
engine
has
many
moving
parts
in addition to its pistons and
cannot
be
completely free from vibration. These engines
are
fitted
with
two
balancers to absorb
the
second inertia and
reduce vibration.
One is
on
the
intake side
and
the other
is
at
the exhaust
side.
DRAINING
THE
COOLANT
Drain
the
coolant by removing
the
coolant drain plug
on
the
engine
block.
Also remove the manifold pressure
cap
and
open both drain plugs
on
the heat exchanger.
A
WARNING:
Beware
of
the
hot
engine
coolant.
Wear
protective
gloves.
COOLANT
DRAIN/
DRAINING
THE
OIL
Drain the oil using the sump drain hose attached
to
the
front of the engine. The oil can also
be
pumped
up
thru
the
dipstick hole.
REMOVE
USING
AN
8MM
(11116")
SOCKET
TO
DRAIN
THE
OIL
OR
PUMP
THE
WARMED
OIL
UP
THRU
THE
HOSE.
Always observe the
used
oil
as
it
is
removed. A yellow/gray
emulsion indicates
the
presence of water
in
the
oiL
Although
this condition
is
rare,
it
does require prompt attention
to
prevent serious
damage.
Call a qualified mechanic should
water
be
present in
the
oiL
Raw
water present in
the
oil can
be
the result
of
a fault
in
the exhaust system attached
to
the
engine and/or a siphoning of
raw
water through the
raw
water cooling circuit into the exhaust,
filling
the
engine.
This
problem
is
often caused
by
the absence of
an
anti-siphon
valve,
its
poor location or lack of maintenance.
PREPARATION
FOR
DISASSEMBLY
•
Clean
or
wash
the engine exterior.
• Do not remove or disassemble the parts that require
no
disassembly.
•
When
disconnecting sensor wires,
label
and
tape
the
ends.
• 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
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 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
accurately during removal or cleaning.
DISASSEMBLY
With
the engine securely mounted
on
an
engine
stand,
begin
disassembling the engine in a logical
order.
When removing
electrical components (alternator, start
motor,
etc)
carefully
label
the
cables and
wires.
With
the
exterior components removed, use the detailed
instructions
in
this
manual
to
disassemble/assemble
the
main
engine.
CAREFULLY
LABEL
TERMINAL
CONNECTIONS
AND
CABLES
BOLTS
BACK
PLATE---.
Engines & Generators
5
Page 9
ASSEMBLY
PROCEDURES
GENERAL
INFORMATION
Surface
Preparation
Thoroughly
remove
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
flat.
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.
ASSEMBLY
•
Wash
all
parts, except
for
oil
seals,
O-rings,
rubber
sheets,
etc.
with cleaning solvent
and
dry
them
with
air
pressure.
•
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
which
torques
are
specified.
•
When
the
engine
is
assembled,
new
gaskets
and
O-rings
must
be
installed.
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 of location causing blocking or
narrowing
of
the
fluid
feed
lines.
To
eliminate
the
possibility of
leaks
from
a joint,
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 l40z
(400
grarn)
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.
APPLY
GREASE
EXTERNAL
SNAP
RING
INTERNAL
SNAP
RING
PLACE
THE
SHARP
EDGE.
AGAINST
THE
DIRECTION
aFFORCE
When
reassembling external
or
internal
snap
rings,
position
them
so
that
the
sharp
edge
faces
against
the
direction
from
which
force
is
applied.
ALTERNATOR
INSPECTION
When rebuilding
the
engine,
the
alternator
should
be
cleaned
and
inspected.
The housing can
be
wiped
off
with a solvent
and
the
alternator terminal
studs
should be cleaned
with
a
wire
brush.
Make
certain
the
studs
are
tight
and
clean
the
wiring
connections that connect
to
the
wiring
harness.
Turn
the
rotor
pulley
by
hand.
It should
turn
smoothly.
Depending
on
when
the
alternator
was
last
serviced,
the
brushes
may
need
replacing.
If
the altemator
is
at
all
suspect,
send it
to a service
shop
for
testing
and
overhaul,
or
the
more
detailed alternator section in
this
manual.
Engines & Generators
6
Page 10
ASSEMBLY
INSTRUCTIONS
Be
aware
of
these
common
problems
that
can
occur
during
assembly.
Insufficient Lubrication. Heavily oil sliding and
reciprocating parts, lightly oil head bolts and other fasteners,
except those that penetrate into the water jacket. These
fasteners should be sealed with Permatex
No.2
or the
high-tech equivalent.
Reversed orientation. Most gaskets, many bolt washers, and
all thermostats are asymmetrical.
Mechanical damage. Run fasteners down in approved '
torque sequences and in three steps-ll2,
213,
and
111
torque.
Exceptions are torque-to-yield bolts and rocker
arm
shaft
fasteners. The former are torqued as indicated. The
latter-rocker shaft fasteners should be brought down in very
small increments, working from the center bolts out. Gaskets,
especially head gaskets, might also be damaged during
assembly, they should be positioned with great care.
ASSEMBLY
NOTE:
The
exhaust manifold, which
was
disassembled from
the
cylinder
head,
should be inspected
before
re-assembly.
a. Remove
the
exhaust elbow
from
the
lower surface
of
the
manifold. Clean
and
inspect
for
cracks
and
defects.
Replace as needed.
b.
Remove
the
exhaust
nipples~
elbows
and
plugs
from
the
manifold
and
heat
exchanger.
c.
Remove
water
connectors
from
the ends
of
the
manifold. Be
sure
to
note
the
proper
location
and
arrangement
of
each for
proper
alignment.
d.· Examine all
parts
for defects, corrosion
and
wear
and
replace
as
needed.
e. Flush
out
the
coolant recovery
tank
and
clear
its hose
passage. Set aside
to
re-install
on
the
boat.
HEAT
EXCHANGER
Install thc heat exchanger, replace the heat exchanger zinc
and attach new hoses with new clamps to the cooling system.
Refer to the
COOLING
SECTION in this manual for HEAT
EXCHANGER
service.
ENGINE
TUNING
OPERATION
After re-assembly, the engine must
be
tuned. This will ensure
that the engine operates at its maximum efficiency. Fill the
engine cooling system with an antifreeze mixture and the
engine oil sump with a lube oil API specification
of
CF,
CG-4,
CH-4, CZ-4,
or
SAE
lSW-4C.
1.
Mount
the
engine
on
a test bench
and
connect the fuel
lines.
2. Connect
the
electrical wiring. Refer
to
the
WIRlN(f
DIAGRAM.
3. Connect
the
air
intake
line to
the
air
cleaner.
4. Connect
the
exhaust pipe.
5.
Crank
the engine with
the
starter
(non-ignition
operation)
for
about
twenty seconds.
This
will
pre-lubricate the engines internal components and
fill
the fuellincs.
6.
Start
the
engine
and
allow
it
to
run
at a rated
rpm
for
five minutes.
7. Remove
the
cylinder
head
cover while
tbe
engine
is
running.
S.
Check
that
the
engine oil continuously circulating
from
the
oil
pump
to
the valve rockers
through
the
cylinder head.
If there
is
no oil circulation
or
if
the oil circulation is
sluggish, stop the engine and make the appropriate repairs
or adjustment.
Re-install the cylinder head cover.
9.
Monnt
the
engine
on
a test
bench
and
connect
the
fuel
lines.
lO.Check
the
engine
for
oil, fuel, coolant
and
air
intake
leakage.
1l.Check
for
abnormal
noise
and
odor.
12.Check for
abnormal
electrical charging.
13.Check
the
engine fastening
parts
for
looseness.
14.When
the
engine coolant
temperature
reaches
7SoC (l67°F)
or
more,
increase
the
engine speed to
2000
rpm
and
allow
it
to
run
for
twenty seconds. .
This
will
give the engine the essential run-in operating
time.
15.Adjust the engine operation speed to
the
specific
value.
16.stop
the
engine
to
comp!ete
the
tuning procedure.
Refer
to
the
following pages for details
of
sub-assemblies.
These
sections also include:
Wiring
Diagrams, Engine
Specifications,
Torque
Diagrams,
Starter
Motor,
Alternator
and Raw
Water
Pump.
Engines & Generators
7
Page 11
DISASSEMBLY/ASSEMBLY
CYLINDER
HEAD
COVER
1.
Remove the
top
of each
glow
plug and remove the
glow
plug
strap.
2.
Remove the breather
hose.
3. Remove the head cover bolts.
4. Remove the cylinder head
cover.
BREATHER.
HOSE
When Reassembling
HEAD
COVER
SCREWS
Check
to
see
if
the cylinder head cover gasket
is
not
defective.
TIGHTENING
TORQUE
CYLINDER
HEAD
COVER
SCREW
__
6.9
-11.3
N-m
0.7
-1.15
Kgf-m
5.1 -8.32
ft-Ibs
BREATHER
VALVE
COVER
GASKET
HEAD
COVER
.
COVER
GASKET
CYLINDER
HEAD
COVER
SCREWS
INJECTION
PIPES
1.
Loosen
the
scerws
on
the pipe clamps.
2.
Detach the injection pipes.
When Reassembling
Blowout dust inside the pipes.
TIGHTENING
TORQUE
INJECTION
PIPE
RETAINING
NUT
__
24.5 -34.3
N-m
2.5 -3.5
Kgf-m
18.1 • 25.3
ft-Ibs
NOZZL~
HOLDER
ASSEMBLY
AND
GLOW
PLUG
1.
Remove the
overflow
pipe
assembly.
2.
Remove the nozzle holder assemblies
using a 21mm
socket
wrench.
3. Remove the copper gasket
and
heat
seal.
4.
Remove the glow plugs
When Reassembling
Replace the copper gasket and heat seal with a
new
one.
TIGHTENING
TORQUE
NOZZLE
HOLDER
ASSEMBLY_49.0 -
68.6
N-m
5.0 -7.0
Kgf-m
36.2 -50.6
ft-Ibs
OVERFLOW
PIPE
ASSEMBLY
RETAINING
NUT
19.6
-
24.5
N-m
2.0 -2.5
Kgf-m
14.5
-18.1
ft-Ibs
GLOW
PLUG
19.6 -24.5
N-m
2.0
-
2.5
Kgf-m
14.5
-18.1
ft-I~s
_.
&
/~.f1.b~'f
I
!
NOZZLE
n
HOLDER
~
ASSEMBlY
..
~
(/("'
..
Engines & Generators
,'(:f'l)
c/
8 i
~.:o,I~"'-.
Page 12
DISASSEMBLY/ASSEMBLY
NomE
HEAT
SEAL
REMOVAL
PROCEDURE
NOTE:
Use a Phillips
head
screw
driver
that
has a
diameter
that
is
bigger
than
the
seal
hole.
Approximately
1/4"
(6mm)
1.
Place
the
screw driver lighly into
the
heat
seal
hole.
2.
Tum
the
screw
driver three or four times
each
way.
3.
While
turning,
slowly pull the heat
seal
out together
with
the
copper
gasket.
4. If
the
heat seal
drops,
repeat
the
procedure.
When Reassembling
The
heat
seal
and
the
copper gasket must be changed
when
the
injection nozzle
is
removed for cleaning or
service.
SCREW
DRIVER
NOZZLE
HOLDER
ASSEMBLY
GOPPER
GASKET
CYLINDER
HEAD
1.
Loosen
the
pipe clamp
and
remove
the
water return
pipe.
2.
Remove
the
cylinder head screw
in
the
order of R or N
toA.
3. Lift
up
the
cylinder
to
detach.
4.
Remove
the
cylinder head
gasket.
When Reassembling
1.
Replace
the
cylinder head gasket
with a new
one.
2. Tighten
the
cylinder head
screws
after
applying
sufficient
oil.
3.
Tighten
the
cylinder head'screws
in
a diagonal sequence
starting
from
the center
in
the
order of A
to N or
R.
4.
Tighten
them
uniformly or
the
head
may
deform
in
the
long
run.
TIGHTENING
TORQUE
CYLINDER
HEAD
SCREW
__
93.1 -98.0
N-m
9.5
-10.0
Kgf-m
68.7·72.3
ft-Ihs
ROCKER
ARM
AND
PUSH
ROD
R
OR N TO A :TO
LOOSEN
1.
Remove
the rocker
arm
bracket mounting
bolts.
2.
Detach
the
rocker
arm
assembly.
3.
Remove
the
push
rods.
When Reassembling
After installing
the
rocker
arm,
be sure
to
adjust
the
valve
clearance.
TIGHTENING
TORQUE
ROCKER
ARM
BRACKET
SCREW
__
23.5 -37.5
N-m
2.4 -2.8
Kgf-m
17.4
-
20.3
ft-Ibs
~
GROOVE
~j
C!)b
E!)g
n ef
~c
~
(A)
00
00
00
em
0
(!';:le 0 6d,o
~I
3Cylinder~1
0 a
-U0h
(8)
. A
TO N OR
R:
TO
TIGHTEN
R
OR N TO A :TO
LOOSEN
en
eu
€:Ij
®b
00
00
(A)
4 Cylinder
~m
00e~d
q01
J
eq
0
E!li
0 ¥
O.h
0
lOP
~
. A
TO N OR
R:
TO
TIGHTEN
ER
HEAD
MAKER
CERTAIN
THE
PUSH
RODS
ARE
PROPERLY
ENGAGED
IN
THE
GROOVES
WHEN
REASSEMBLINGV'
WESTERBEKE
\
Engines & Generators
9
Page 13
DISASSEMBLY
/ASSEMBLY
TAPPETS
1.
Remove
the
tappets
from
the
crankcase.
When Reassembling
1.
Visually
check the contact between
the
tappets
and
cams
for
proper rotation.
If
a defect
is
found,
replace
the
tappets.
2.
Before
installing
the
tappets,
apply
engine
oil
thinly
around
them.
NOTE:
Do
not change
the
combination
of
the tappet and
the
tappet
guide.
VALVE
SPRING
REPLACER
VALVES
STEM
SEAL
~~COLLET
VALVE
CAP
1.
Remove
the
valve
caps.
2.
Remove
the
valve spring collet, pushing
the
valve
spring
retainer
by
the
valve
spring
replacer.
3.
Remove
the valve spring
retainer,
valve
spring
and
valve
stem
seal.
4.
Remove
the
valve
When Reassembling
1.
Wash
the
valve
stem
seal
and
the
valve
guide
hole
and
apply
engine oil
sufficiently.
2.
After
installing
the
valve
spring collets, lightly
tap the
stem
to
assure
proper
fit
with
a plastic
hammer.
NOTE:
Do
not change
the
combination
of
the
valve and
the
valve
guide.
INJECTION
PUMP
1.
Remove
the
stop solenoid
and
the
hi-idling
body.
2.
Remove
the
engine stop lever and
stop
solenoid
guide.
3.
Remove
the
fuel
injection pump
assembly.
NOTE:
Before removing
the
injection pump
assembly,
be
sure
to
remove
the
stop
solenoid,
hi-idling
body,
engine
stop
lever
and stop solenoid
guide.
HI-IDLING
BODY
WfO
-
When Reassembling I
II
n
1.
Before attaching the stop solenoid, hi-idling
body
and
solenoid
guide,
install the injection
pump
first
into
position.
2.
Replace
the
hi-idling body gasket
with a new
one.
3.
Before
fitting
the
stop
lever
to
the
gear
case,
install
the
solenoid guide
first
into position.
Then
attach
the
stop
lever
and
use
it
to
see
if
it
functions
well.
4.
Before
fitting
the
idling limiter in place,
attach
the
solenoid guide
and
the
engine stop lever
in
their
respective positions.
5.
When
installing
the
stop solenoid, be careful
to
keep
the
O-ring
in
place.
6.
Be
sure
to
insert
the
push
rod
of
the
stop
solenoid
into
the
hole
at
the
center of
the
solenoid
guide.
TIGHTENING
TORQUE
HI-IDLING
800Y
__
_
o
Engines & Generators
10
Page 14
DISASSEMBLY
I
ASSEMBLY
INJECTION
PUMP
(CO
NT.)
U
STOP
SOlENOID-4::::::='~~~
GOVERNOR
SPRINGS
AND
SPEED
CONTROL
PLATE
NOTE:
Use
a l.2mm diameter hard
wire
with
its
end
hooked,
overall length of200mm (7.87
in).
The
tip
of a wire
is
bent t
like a hook
to
grasp
the
governor springs.
1.
Remove
the
injection
pump
cover.
2.
Remove
the
speed control plate mounting
nuts
and
bolts.
3.
Using
the
special
tool,
undo
the
large governor spring
from
the
fork
lever.
4.
Using
the
special
tool,
undo
the
small
governor
spring
from
the
fork
lever.
S.
Set
the
speed
control lever
as
shown.
6.
Take
out
the
speed control plate
with
care
and
do
not let
the
large
and
small
governor springs come off
this
plate
and
fall into
the
gear
case.
lVhen Reassembling
1.
Hook
the
small spring
first
and
then
the large governor
spring
on
the
speed
control
plate.
2.
Put
the
specific
tool
from
the
injection pump
side
to
catch
the
large governor spring.,
Keep
this
spring slightly
extended
and
place the speed control plate
in
its specified
position.
3.
Using
the special
tool,
hook
the
small
governor spring
onto
the
fork
lever.
NOTE:
Be
careful not
to
stretch
the
small governor spring
too
long
because it
may
get deformed permanently.
Using
the
specific
tool,
hook the
large
governor spring onto
the
fork
lever.
Make
sure
both
the
governor springs
are
tight on
the
fork
lever.
Apply
and
tighten
up
the
two
bolts and two nuts on
the
speed
control panel.
Check
that
the
speed control lever positions at low idle after
assembling
the
governor springs.
Check that
the
speed control lever
returns
to
the
high idle
position rather than
the
low idle position after moving
the
lever
to
the
maximum speed position.
Finally attach the injection pump cover
in
position.
SPECIAL
TOOL
WIRE
HOOK
STEP
1
STEP
3
INJECTION
PUMP
LARGE·
@~rG
STEP
5
STEP
6
~
STEP
4
SPEED
CONTROL'
PLATE
Page 15
DISASSEMBLY/ASSEMBLY
GOVERNOR
SPRINGS
AND
SPEED
CONTROL
PLATE
(CO
NT.)
STEPS
DRIVE
PULLEY
1. Lock
the
flywheeL
2.
Remove
the
drive
pulley
mounting
nut.
SPECIAL
__
TOOL
3.
Remove
the
drive
pulley
with
gear
puller.
4.
Remove
the
feather
key
When
Reassembling
Apply
grease
to
the
splines of the coupling.
TIGHTENING
TORQUE
FAN
DRIVE
PULLEY
MOUNTING
NUT
137.3
-156.9
N-m
14.0
-16.0
Kgf-m
101.3
-115.7
ft·lbs
DRIVE
PULLEY
LARGE
SPRING
STEP
Engines & Generators
12
SPECIAL
TOOL
PEED
CONTROL
LEVER
DRIVE
PULLEY
STEP
10
SPRING
Page 16
DISASSEMBLY
I
ASSEMBLY
GEAR
CASE
1.
Remove the hour meter gear case (if equipped).
2.
Remove
the
gear case.
3. Remove the O-rings.
When
Reassembling
IDLE
GEAR
CAM
GEAR
1.
Apply
liquid gasket (Three bond
1215
or equivalent)
INJECTION
PUMP
GEAR
both
sides
of
the
hour meter gear case gasket.
CRANK
GEAR
2.
Check
to
see if there
are
four O-rings inside
the
gear
case.
3.
Apply
a thin
film
of engine oil
to
the
oil seal
and
install
it.
4.
Before
installing the gear case gasket, apply a non-drying
adhesive.
CRANKSHAFT
OIL
SLINGER
1.
Remove the crankshaft
collar.
2.
Remove the
O-ring.
3. Detach
the
crankshaft oil
slinger.
When
Reassembling
1.
Insert
the
crankshaft collar after installing the gear case
to
the cylinder
body.
CRANKSHAFT
OIL
SLINGER
~~~~~,
....
(..--CRANKSHAFT
COLLAR
OIL
PUMP
DRIVE
GEAR·--I-+~""""
IDLER
GEAR
1.
Remove the external snap
ring.
2.
Detach the idler gear
collar.
3.
Detach
the idler
gear.
When
Reassembling
1.
Check
to
see
that each gear below
is
aligned with
its
aligning
mark.
Idle gear and crank gear
Idle gear and camshaft gear
Idle gear and injection
pump
gear
IDLER
GEAR
(FOR
BALANCER
MODEL)
1.
Remove the external snap
ring.
2.
Detach the idler gear
collar.
3. Detach the idler
gear.
When
Reassembling
1.
Check
to
see that each gear below
is
aligned with
its
aligning
mark.
Idle gear and crank gear
Cam
gear and balancer gear
Idle gear and injection pump gear
Idler gear and balancer gear
INJECTION
PUMP
GEAR
\1
Engines & Generators
13
Oil
PUMP
DRIVE
GEAR
Page 17
DISASSEMBLY
I
ASSEMBLY
CAMSHAFT
SET
BOLT
CAMSHAFT
1.
Remove
the
camshaft set
bolts
and
draw
out
the
camshaft.
When
Reassembling
1.
When
installing
the
idler
gear,
be
sure
to
align
the
alignment
marks
on
the
gears.
TIGHTENING
'tORQUE
CAMSHAFT
SET
BOLT
23.5 -27.5
N-m
2.4 -2.8
Kgf-m
17.4 -20.3
ft-Ibs
CAMSHAFT
AND
BALANCER
SHAFT
1.
Remove
the
camshaft set bolts
and
draw out
the
camshaft.
2.
Remove
the
balancer
shaft
1 set bolts
and
draw
out
the
balancer shaft
1.
3.
Remove
balancer shaft 2 set bolts
and
draw
out
the
balancer shaft
2.
When
Reassembling
1.
When
installing
the
balancer shaft 1
and
2, be sure
to
place
the
1st
and
4th
cylinder
pistons
at
the
top
dead
center
in
compression, then align
all
marks
on
each
gear
to
assemble
the
timing
gears,
set
the
idle gear
last.
TIGHTENING
TORQUE
CAMSHAFT
SET
BOLT
23.5·27.5
N·m
2.4 -2.8
Kgf·m
17.4·
20.3
ft-Ibs
BALANCER
SHAFT
SET
BOLT_23.5 -
27.5
N-m
2.4 -2.8
Kgf-m
ClCs::=~=~===::=,
17.4 -
20.3
ft-rbs
FORK
LEVER
HOLDER
FUEL
CAMSHAFT
AND
FORK
LEVER
ASSEMBLY
1.
Remove
the
fuel
feed
pump.
2.
Detach
the
fuel
camshaft
retainer.
3.
Remove
the
three
fork
lever holder
mounting
screws.
4.
Draw
out
the
fuel
camshaft
assembly
and fork lever
assembly
at
the
same
time.
When
Reassembling
1.
After installation, check to
see
that
the
fork
lever is
fixed
to
the
fork lever shaft and that
they
can
tum
smoothly
in
the
holder.
1.
2.
3.
FORK
LEVER 1 FORK
LEVER
2
BALANCER
SHAFT
1
BALANCER
SHAFT
2
STERBEKE
ines & Generators
OIL
PUMP
14
Page 18
DISASSEMBLY
I
ASSEMBLY
CRANK
GEAR
1. Draw out the crank.
gt<ar
with a puller.
2. Remove the feather key.
OIL
PAN
AND
OIL
STRAINER
1. Remove the oil pan mounting screws.
2. Remove the oil pan
by
lightly tapping the rim
of
the pan
with a wooden hammer.
3. Remove the oil pan gasket.
4. Remove the oil strainer and
O-ring.
OIL
STRAINER
After cleaning the oil strainer, check to see that the filter
mesh is clean and install it.
2.
Visually check the O-ring, apply engine oil and install it.
3. Securely fit the O-ring to the oil strainer.
4. Apply a liquid gasket (Three bond 1215 or equivalent) to
the oil pan side
of
the oil pan gasket.
S.
To avoid uneven tightening, tighten the oil pan mounting
screws in diagonal order from the center.
OIL
PISTONS
1.
Completely clean the carbon out
of
the cylinders.
2. Remove the connecting rod cap.
3. Tum the flywheel to bring the piston to top dead center.
4. Draw the piston upward
by
lightly tapping it from the
bottom
of
the crankcase with the handle
of
a hammer.
S. Draw out the other piston in the same method as above.
When
Reassembling
1.
Before inserting the piston into the cylinder, apply
enough engine oil to the piston.
2. When inserting the piston into the cylinder, face the mark
on the connecting rod to the injecting pump.
NOTE:
Do
not change
the
combination
of
cylinder and piston.
Make
sure
of
the
position
of
each
piston
by
marking
it.
Place
the
piston
rings
with
their gaps at 0.79
rad
(45°) from
the
pistons pin
direction.
Carefully
insert
the
pistons using a piston
ring
compressor.
When
inserting
the
piston
in
place,
be
careful not
to
scrape
the
molybdenum disulfide coating off
its
skirt.
This
coating
is
useful
in
minimizing
the
clearance
with
the
cylinder
liner.
Just after
the
piston pin has been ptess-fitted,
the
piston
is
still hot and
the
coating easily peels
off.
Wait
until
the
piston
cools
down.
TIGHTENING
TORQUE
CONNECTING
ROO
SCREW
__
44.1 -49.0
N-m
4.5 -5.0
Kgf-m
32.5 -36.2
ft-Ibs
CONNECTING
ROD
CAP
CONNECTING
ROD
SCREW
Engines & Generators
15
Page 19
DISASSEMBLY
I
ASSEMBLY
PISTON
RING
AND
CONNECTING
ROD
1.
Remove
the
piston rings using a piston ring
tooL
2.
Remove
the piston
pin
and
separate
the
connecting
rod
from
the
piston.
When
Reassembling
0.79 rad (45 ")
0.79
rad (45
0)
1.
When
installing
the
rings, assemble
the
rings
so
that
the
manufacturers
mark
near
the
gap
faces
the
top
of
the
piston.
-L--f--l'c---r--.L.T----I-t-l-PISTON
PIN
HOLE
2.
When
installing the oil ring onto
the
piston, place
the
expander joint
on
the
opposite side of
the
oil
ring
gap.
3.
Apply
engine oil
to
the
piston
pin.
4.
When
installing
the
piston pin, immerse
the
piston
in
80°C
(176"F)
oil
for
10-15 minutes
and
insert
the
piston
pin into the piston.
S.
When
installing
the
connecting rod to
the
piston,
align
the
mark
on
the
connecting rod to
the
fan-shaped
concave.
NOTE:
Mark
the
same
number
on
the
conneeting
rod
and
the
piston
so
lwt
to
change
the
combination.
SECOND
RING
Engines & Generators
16
0:79 rad (45
0)
PISTON
RING
COMPRESSOR
CONNECTING
ROD
~
PISTON
\.
~
~'STONPIN
PISTON
PIN
SNAP
RING
'e
MARK
FAN-SHAPED
CONCAVE
Page 20
MARK
DISASSEMBLY
I
ASSEMBLY
PISTON
RING
AND
CONNECTING
ROD
(CONT.)
/
EXPANDER
JOINT
-.0
FLYWHEEL
1. Lock the flywheel.
2. Remove two
of
the flywheel screws.
3. Insert two flywheel guide screws in the holes.
4. Remove the remaining flywheel screws.
5. Remove the flywheel slowly along the guide screws.
Wlzen
Reassembling
1. Insert two
of
the flywheel guide screws.
2. Check to see that there are no metal
particles, on the
flywheel mounting surfaces.
3. Apply engine oil to the threads and the undercut surface
of
the flywheel bolt and fit the bolt.
TIGHTENING
TORQUE
FLYWHEEL
SCREWS
98.0
-107.8
N-m
10.0
-11.0
Kgf·m
72.3 -79.5
ft·lbs
FLYWHEEL
SCREW
BEARING
CASE
COVER
1. Remove the bearing case cover mounting screws.
Remove the inside screws first and then the outside
screws.
2.
Screw the two removed screws into the screw hole
of
the
bearing case cover to remove it.
NOTE:
The
length
of
the
inside
screws
and
outside
screws
are
different
sizes.
Be
aware
of
the
size
of
the
inside
and
outside
screws.
BEARING
CASE
COVER
MOUNTING
SCREW~
OIL
SEAL
BEARING
CASE
COVER
GASKET
BEARING
CASE
GASKET
BEARING
CASE
COVER
~~
··~\)t\
J)
When
Reassembling
1.
Align the bearing case gasket and the bearing case cover
gasket.
2. Install the bearing case cover positioning the casting
markUP.
3. Apply engine oil
to
the oil seal lip and
be
careful that it is
not rolled when installing.
4. Tighten the bearing case cover mounting screws evenly
in a diagonal order.
TIGHTENING
TORQUE
BEARING
CASE
COVER
___
23.5 • 27.5
N·m
MOUNTING
SCREW
2.4 • 2.8
Kgf·m
17.4 -20.3
ft-Ibs
/
o
FLYWHEEL
GUIDE
SCREW
)
Engines & Generators
17
Page 21
DISASSEMBLY
I
ASSEMBLY
CRANKSHAFT
NOTE:
Before
disassembling
and
during
reassembly,
check
the
side
clearance
of
the
crankshaft.
4 Cylinder
1.
Remove
the
main
bearing case
screw.
2.
Pull
out the crankshaft
assembly,
take care not
to
damage
the
crankshaft bearing.
3 Cylinder
1.
Remove
the
main
bearing case
screw.
2. Turn
the
crankshaft to set
the
crank pin of the third
cylinder
to
the bottom dead
center.
Then
draw
out
the
crankshaft until
the
crank pin of
the
second
cylinder
comes
to
the
center of
the
third
cylinder.
3. Turn
the
crankshaft by 2.09
rad
(120")
counterclockwise
to
set
the
crank
pin
of
the
second
cylinder
to
the
bottom
dead
center.
Draw
out the crankshaft until
the
crank
pin
of
the
first
cylinder comes
to
the
center of
the
third
cylinder.
4. Repeat
the
above
steps
to
draw
the crankshaft completely
out.
When
Reassembling
1.
Install
the
crankshaft
sub
assembly,
aligning
the
screw
hole
of
the
main
bearing case 2 with
the
screw
hole
of
the
cylinder
block.
2.
When
tightening
the
main
bearing
case
screw
2,
apply'
oil
to
the
screw
and
screw
by
hand
before
tightening
the
specific
torque.
IT
it
is
not
smooth
to
screw
by
hand,
align
the
screw
holes
between
the
cylinder block
and
the
main
bearing
case.
TIGHTENING
TORQUE
MAIN
BEARING
CASE
,SCREWS 2 __
68.6·73.5
N-m
7.0·7.5
Kgf·m
50.6 • 54.2
ft-Ihs
MAIN
BEARING
CASE
SCREW
2---,
~~;"';~~;:+:~f,...c=:;;T::iilIoMAIN
BEARING
CASE
2
Engines & Generators
18
",-
CRANKSHAFT
BEARING
1
CUT
PLACE
FOR
REMOVING
AND
INSTALLING
THE
CRANKSHAFT
y-
f 3 Cylinder
\ \
;",~
CUT
PLACE
FOR
REMOVING
AND
INSTALLING
THE
CRANKSHAFT
3 Cylinder
Page 22
DISASSEMBLY
I
ASSEMBLY
MAIN
BEARING
CASE
ASSEMBLY
1.
Remove
the two
main
bearing
case
screws
and remove
the main bearing case assembly being cautious
with
the
thrust bearing and crankshaft
bearing.
2.
Remove
the main bearing case.
When Reassembling
1.
Clean
the
oil passage in the
main
bearing
case.
2.
Apply
clean engine oil
on
the bearings.
3. Install the main bearing case assemblies
in
the original
positions. The diameters
of
the
main
bearing cases
may
vary
so
install them
in
the
order of the markings
(A,
B
for
3 cylinders
and
A, B, C
for
4 cylinders)
from
the
gear case side.
4. Match the alignment numbers
and
mark
on
the
main
bearing
case.
S.
When
installing the
main
bearing
case,
face
the
mark
FLYWHEEL
to
the
flywheel.
6,
Install the thrust bearing with
its
oil groove facing
out-
ward.
7.
Confirm
that the
main
bearing case moves smoothly after
tightening
the
main
bearing case screw
to
the
specified
torque.
TIGHTENING
TORQUE
A
MAIN
BEARING
CASE
SCREW
.46.1 -50.9
N·m
4.7 -5.2
Kgf-m
34.0 -37.6
ft·lbs
Engines & Generators
19
7
OIL
GROOVE
Page 23
DISASSEMBLY
I
ASSEMBLY
THERMOSTAT
ASSEMBLY
1. Remove the thermostat cover mounting screws and
remove the thermostat cover.
2.
Remove the thermostat assembly.
LOOSEN
THIS
HOSE
CLAMP
TWIST
THE
THERMOSTAT
ASSEMBLY
THERMOSTAT
ASSEMBLY
WATER
PUMP
ASSEMBLY
1. Loosen the alternator mounting bolts and remove the
belt.
2.
Remove the pulley.
3.
Remove the water pump assembly from the gear case
cover.
4. Remove the water pump flange.
5. Press out the water pump shaft with the impeller on
it.
6.
Remove the impeller from the water pump shaft.
7.
Remove the mechanical seal.
When
Reassembling
1. Apply a liquid gasket (Three bond
1215
or equivalent)
to
the both sides
of
the gasket.
2.
Replace the mechanical seal with a
new
one.
When
Reassembling
1. Apply a liquid gasket (Three bond
1215
or equivalent)
only
at
the thermostat cover side
of
the thermostat cover
gasket.
WATER
PUMP
SHAFT
Engines & Generators
20
Page 24
SERVICING
VALVE
RECESSING
1.
Clean
the
cylinder
head
surface,
valve
face
and
valve
seat.
2.
Insert
the
valve
into
the
valve
guide.
3.
Measure
the
valve
recessing
with a depth
gauge.
4.
If
the
measurement
exceeds
the
allowable
limit,
replace
the·valve.
5.
If it still
exceeds
the
allowable
limit after
replacing
the
valve,
replace
the
valve
seat.
VALVE
RECESSING
FACTORY
SPECIFICATIONS
__
0.05mm
(protrusion)
to
0.15mm
(
recessing)
0.002Din
(protrusion)
to
0.0059in
(recessing)
ALLOWABLE
LlMIT
____
O.40mm
(recessing)
0.01571n
(recessing)
.........
~_C>
.....
0 C
C> • 0 C>
<>
~Q
o 0 Q
~
~
o
~o
<
00
°
0
°
~
CYLINDER
HEAD
SURFACE
"'CYLlNDE;~EAD
SURFACE
t
RECESSING
\ I
~~~=:i::--.....
-~
PROTRUSION
CLEARANCE
BETWEEN
VALVE
STEM
AND
VALVE
GUIDE
1.
Remove
carbon
from
the
valve
guide
section.
2.
Measure
the
valve
stem
O.D.
with
an
outside
micrometer.
3.
Measure
the
valve
guide
LD.
with a small
hole
gauge
and
calculate
the
clearance.
4.
If
the
clearance
exceeds
the
allowable
limit,
replace
the
valves.
If
it still
exceeds
the
allowable
limit,
replace
the
valve
guide.
+
CLEARANCE
BEWTEEN
VALVE
STEM
AND
VALVE
GUIDE
FACTORY
SPECIFICATIONS
O.040-0.070mm
0.00157 -0.002761n
ALLOWABLE
LlMII
____
0.10mm
0.00391n
VALVE
STEM
0.0.
FACTORY
SPECIFICATlONS
__
7.960·
7.975mm
0.31339·0.31398In
VALVE
STEM
1.0.
FACTORY
SPECIFlCATIONS-8.01S·
8.030mm
0.31555 -0.316141n
REPLACING
VALVE
GUIDE
When
Removing
1.
Press
out
the
used
valve
guide
using a valve
guide
replacing
tool
When
Installing
1.
Clean a new
valve
guide
and
valve
guide
bore
and
apply
engine
oil
to
them.
2.
Press
in a new
valve
guide
using a valve
guide
replacing
tool.
3.
Ream
precisely
the
LD.
of
the
valve
guide
to
the
specified
dimension.
Engines & Generators
21
Page 25
SERVICING
VALVE
GUIDE
1.0.
(INTAKE
AND
EXHAUST)
FACTORY
SPECIFICATIONS
__
8.015 -8.030mm
0,31555 -O.31614in
Do
not hit
the
valve guide with a hammer
during
replacement.
WHEN
REMOVING
WHEN
INSTALLING
VALVE
SEATING
1. Coat the valve face lightly with prussian blue
and
put the
valve on its seat to check the contact.
2.
If
the valve does not seat all the way around the valve
seat or the valve contact is less than 70%, correct the
valve seating
as
follows.
3. If the valve contact does not comply with the reference
valve, replace the valve or correct the contact
of
the valve
seating.
VALVE
SEATING
(CONT.)
Before
correcting
the
valve
and
seat,
check the
valve
stem
and
the
I.D.
of
the
valve
guide
section,
repair
them
if
necessary.
After
correcting
the
valve
seat,
be
sure
to
check
the
valve
recessing.
Correcting
the
Valve.
1. Correct the valve with a valve refacer ..
Correcting
the
Valve Seat.
1. Slightly correct the seat surface
with
a 1.047 rad (60°)
intake valve or a 0.785 rad
(45°)
exhaust valve seat
cutter
too!.
2. Resurface the seat surface with a 0.523 rad
(300)
valve
seat cutter to the intake valve seat and with a 0.262 rad
(15°)
valve seat cutter to the exhaust valve seat
so
that the
width is close to the specified valve seat width
(2.12lllID.
0.0835in).
3. After resurfacing the seat, inspect for even valve seating.
Apply a thin
film
of
compound between the valve face
and valve seat and
fit
them with a lapping tool.
4. Check the valve seating with prussian blue. The valve
seating surface should show good contact all the
way
around .
.....--
......
"11---..,
0.523
RAD
(3UO)
OR
-0.262
RAO
(15°)
CHECK
CONTACT
~
. l •
~(a)
. ' • ;
IDENTICAL
~~~~~
SE~\.:{:.:
DIMENSIONS
'
....
'WESJERBEICE
r Engines & Generators
22
Page 26
SERVICING
VALVE
LAPPING
1.
Apply
compound evenly
to
the
valve
lapping
surface.
2.
Insert
the
valve
into
the
valve
guide.
Lap
the
valve
onto
its
seat
with
a valve
flapper
or
screwdriver.
3.
After
lapping the
valve,
wash
the
compound
away
and
apply
oil, then repeat
valve
lapping with
oil.
4.
Apply
prussian blue to
the
contact surface
to
check
the
seated
rate.
If
it
is
less
than 70%, repeat
the
valve
lapping
again.
When
valve
lapping
is
peiformed,
be
sure
to
check
the
valve
recessing
and adjust the
valve
clearance
after
assembling
the
valve.
FREE
LENGTH
AND
TILT
OF
THE
VALVE
SPRING
1.
Measure
the
free
length of
the
valve
spring
with
vemier
calipers.
If
the
measurement is
less
than
the
allowable
limit, replace
it.
2.
Put
the
valve spring
on
a surface plate,
place a square
on
the
side
of the
valve
spring.
3.
Check
to
see
if the entire
side
is
in
contact
with
4.
the
square.
Rotate
the
valve
spring
and
measure
the
maximum
tilt.
If
the
measurement exceeds
the
allowable
limit,
replace it.
FREE
LENGTH
FACTORY
SPECIFICATlONS
__
41.
7 -
42.2mm
1.6417 • 1.6614in
ALLOWABLE
LlMIT
____
.41.2mm
1.6220in
TILT
ALLOWABLE
LlMIT
____
1.0mm
0.039in
VALVE
SPRING
SETTING
LOAD
1.
Place
the
valve spring on a tester
and
compress
it
to
the
same
length it is actually compressed in
the
engine.
2.
Read
the
compression load
on
the
gauge.
3. If
the
measurement is less than
the
allowable
limit,
replace
it.
SETTING
LOAD/SETTING
LENGTH
FACTORY
SPECIFICATIONS_117.6NJ35.0mm
12.0kgfJ35.0mm
26.4IbsJ1.3780in
ALLOWABLE
lIMIT
____
100NJ35.Dmm
10.2kgfJ35.0mm
22.5IbsJ1.3780in
OIL
CLEARANCE
BETWEEN
THE
ROCKER
ARM
AND
ROCKER
ARM
SHAFT
1.
Measure
the
rocker
arm
0.0.
with
an
outside
micrometer.
2.
Measure
the
rocker
arm
I.D.
with
an
inside micrometer
and
then
calculate
the
oil clearance.
3.
If
the
oil
clearance exceeds
the
allowable
limit,
replace
the
rocker
arm
and
measure
the
oil
clearance
again.
If
it still
exceeds
the
allowable limit, replace
the
rocker
arm
shaft.
OIL
CLEARANCE
BETWEEN
ROCKER
ARM
AND
ROCKER
SHAFT
FACTORY
SPECIFICATIONS
__
O.016 -O.045mm
0.00063 -0.001771n
ALLOWABLE
LlMIT
____
O.10mm
ROCKER
ARM
SHAFT
0.0.
FACTORY
SPECIFICATIONS
ROCKER
ARM
SHAFT
1.0.
O.0039in
13.973 -13.984mm
0.55012 -0.55055in
FACTORY
SPECIFICATIONS
__
14.0DO
-14.018mm
0.55118 -0.551891n
/"fIIY'IWESTERBEKE
i Engines & Generatol'/l
23
Page 27
SERVICING
PUSH
ROD
ALIGNMENT
1.
Place
the
push
rod
on V blocks
on a surface
plate.
2.
Measure
the
push
rod
alignment.
3.
If the
measurement
exceeds
the
allowable
limit,
replace
the
push
rod.
PUSH
ROO
ALIGNMENT
ALLOWABLE
LlMIT
__
O.25mm
O.D098in
OIL
CLEARANCE
BETWEEN
THE
TAPPET
AND
TAPPET
GUIDE
BORE
1.
Measure
the
tappet
D.D.
with
an
outside
micrometer.
2.
Measure
the
I.D.
of
the
tappet
guide
bore
with
a cylinder
gauge
and
calculate
the
oil
clearance.
3.
If
the
oil
clearance exceeds
the
allowable limit or
the
tappet
is
damaged,
replace
the
tappet.
OIL
CLEARANCE
BETWEEN
TAPPET
AND
THE
TAPPET
GUIDE
BORE
FACTORY
SPECIFICATIONS
0.020 -0.062mm
0.00079·o.11244in
ALLOWABLE
LlMIT
__
0.07mm
0.00281n
TAPPET
0.0.
FACTORY
SPECIFICATlONS
__
23.959 -23.9S0mm
00.94327 -0.9441
Din
TAPPET
GUIDE
BORE
1.0.
FACTORY
SPECIFICATIONS
__
24.000 -24.021mm
0.94488 -0.94571in
000
0
5;O~(
TIMING
GEAR
BACKLASH
1.
Set a dial indicator (lever
type)
with
its
tip
on
the
gear
tooth.
2.
Move
the
gear
to
measure
the
backlash,
holding
its
mating
gear.
3.
If
the
backlash
exceeds
the allowable
limit,
cheek
the
oil
clearance
of
the
shafts
and
the
gear.
4.
If
the
oil
clearance
is
not
proper,
replace
the
gear.
BACKLASH
BETWEEN
IDLER
GEAR
AND
CRANK
GEAR
FACTORY
SPECIFICATIONS
__
0.0415 -0.1122mm
0.00163·0.00442in
ALLOWABLE
LIMIT
0.15mm
0.0059in
BACKLASH
BETWEEN
IDLER
GEAR
AND
CAM
GEAR
FACTORY
SPEClfICATIONS
__
0.0415 -0.1154mm
0.00163 -o.00454ln
ALLOWABLE
LIMIT
0.15mm
0.00591n
BACKLASH
BETWEEN
IDLER
GEAR
AND
INJECTION
PUMP
GEAR
FACTORY
SPECIFICATIONS
__
O.0415 -0.1154mm
0.00163 -O.oo454in
ALLOWABLE
LIMIT
0.15mm
0.0059in
BACKLASH
BETWEEN
IDLER
GEAR
AND
INJECTION
PUMP
GEAR
FACTORY
SPECIFICATlONS
__
0.0415 -0.1090mm
0.00163 -0.004291n
ALLOWABLE
LlMIT
____
0.15mm
0.0059in
For
Balancer
Model
Only
BACKLASH
BETWEEN
10LER
GEAR
AND
BALANCER
GEAR
FACTORY
SPECIFICATIONS
__
0.0350 -0.1160mm
0.00138 -0.00457In
ALLOWABLE
LlMIT
___
-..JJO.15mm
0.0059in
oC?OoO
~
i\'"
r-"")
!l
r'-w'JwesJZ:RBEKE
Y Engines
&'
Generators
24
Page 28
SERVICING
IDLER
GEAR
SIDE
CLEARANCE
1. Set a dial indicator with
its
tip
on
the idle
gear.
2.
Measure the side clearance by
moving
the idle gear
to
the
front
and
rear.
3.
If
the
measurement exceeds the allowable limit, replace
the
idle gear
collar.
IDLER
GEAR
SIDE
CLEARANCE
FACTORY
SPECIFICATlONS
__
O.12·
O.48mm
0.0047 -0.01891n
ALLOWABLE
LlMIT
___
_
() 0 \
__
«(~
l."~O)
CAMSHAFT
SIDE
CLEARANCE
1.
Set a dial indicator with its
tip
on
the cam
gear.
2.
Measure the side clearance
by
moving
the cam gear
to
the
front and
rear.
3.
If
the
measurement exceeds the allowable limit, replace
the camshaft
stopper.
CAMSHAfT
SIDE
CLEARANCE
FACTORY
SPECIFICATIONS----.D.07 -O.22mm
0.0028 -0.00871n
ALLOWABLE
LlMIT
____
O.30mm
0.01181n
BALANCER
SHAFT
SIDE
CLEARANCE
(For
Balancer
Models
Only)
1.
Set a
dial
indicator
with
the
tip
on
the balancer
shaft.
2.
Measure
the
side clearance
by
moving the balancer shaft
to
the
front
and
rear.
3.
If
the
measurement exceeds
the
allowable limit, replace
the balancer shaft.
SIDE
CLEARANCE
OF
BALANCER
SHAfT
FACTORY
SPECIFICATIONS_
0.07 -0.22mm
0.0028·
0.00871n
ALLOWABLE
LlMIT
____
0.3mm
0.01181n
-0
0g)
l:
°00Q)
ao'
)I;g,~,~oo
l
M
Oo
JO
0 0
0
)
~
1
--
Q 0
~
ocJ:o
a
00
00
OIL
CLEARANCE
OF
THE
BALANCER
SHAFT
JOURNAL
(For
Balancer
Models
Only)
1.
Measure the balancer shaftjoumal
O.D.
with
an
outside
micrometer.
2.
Measure
the
cylinder block bore
I.D.
for
i:1alancer
shaft
with
an
inside micrometer or cylinder
gauge.
3.
If
the
clearance exceeds the allowable limit, replace the
balancer
shaft.
(WlWESTERBEKE
i Engines &
Genel11tors
25
Page 29
SERVICING
(CO
NT.)
OIL
CLEARANCE
OF
BALANCER
SHAFT
JOURNAL
1
FACTORY
SPECIFICATION8.....-..0.030 -0.111mm
0.00118·o.00437in
ALLOWABLE
lIMIT
__ ' 0.2mm
0.00791n
BALANCER
SHAFT
JOURNAL
1 0.0.
FACTORY
SPECIFICATIONS
__
43.934 -43.950mm
1.72968
-1.73031In
BALANCER
SHAFT
JOURNAL
11.0.
FACTORY
SPECIFICATIONS
__
43.980 -44.o45mm
1.73149
·1.73405In
OIL
CLEARANCE
OF
BALANCER
SHAFT
JOURNAL
2
FACTORY
SPECIFICATlONS
__
0.030·
0.111mm
0.00118 -0.004371n
ALLOWABLE
LlMIT
__
0.2mm
0.00791n
BALANCER
SHAFT
JOURNAL
2 0.0.
FACTORY
SPECIFICATlON3_
41.934 -4U50mm
1.65D94
-1.65157In
BALANCER
SHAFT
JOURNAL
21.0.
FACTORY
SPECIFICATlONS
__
41.980 -42.045mm
1.65275
-1.65531In
OIL
CLEARANCE
OF
BALANCER
SHAFT
JOURNAL
3
FACTORY
SPECIFICATIONS~
0.020 -0.094mm
0.00079 -0.003701n
ALLOWABLE
LlMIT
__
0.2mm
0.00791n
BALANCER
SHAFT
JOURNAL
30.0.
FACTORY
SPECIFICATIONS
__
21.947 -21.960mm
0.86405 -0.864561n
BALANCER
SHAFT
JOURNAL
3/.0.
FACTORY
SPECIFICATlONS
__
21.980 • 22.041mm
0.86535 -0.86775in
OIL
CLEARANCE
BETWEEN
IDLER
GEAR
SHAFT
AND
IDLER
GEAR
BUSHING
1.
Measure
the
idler
gear
bushing
0.0.
with
an
outside
micrometer.
2.
Measure
the
idler gear bushing 1.0.
with
an
inside
micrometer
and
calculate
the
oil
clearance.
3. If
the
oil
clearance
exceeds
the
allowable
limit,
replace
the
bushing.
4.
If
it
still
exceeds
the
allowable
limit,
replace
the
idler
gear
shaft.
REFER
TO
THE
DATA
IN
THE
UPPER
RIGHT
OIL
CLEARANCE
BETWEEN
THE
IDLER
GEAR
SHAFT
AND
THE
IDLER
GEAR
BUSHING
FACTORY
SPECIFICATlONS
__
0.025 • 0.066mm
0.00098 • 0.00260in
ALLOWABLE
LlMIT
__
0.10mm
0.0039in
IDLER
GEAR
SHAFT
0.0.
FACTORY
SPECIFICATIONS_37.959·
37.975mm
1.49445 • 1.49508in
.
IDLER
GEAR
BUSHING
1.0.
FACTORY
SPECIFICATIONS_
38.000 • 38.025mm
1.49606
-
REPLACING
THE
IDLER
GEAR
BUSHING
When
Removing
1.
Press
out
the
used
idler gear bushing
using
an
idler
gear
bushing
replacing
tool.
When
Installing
1.
Clean a new
idler gear bushing
and
idler
gear
bore
and
apply
engine oil to
them.
2.
Press
in a new
bushing using
an
idler gear
bushing
replacing
tool,
until
it
is
flush
with
the
end
of
the
idler
gear.
CAMSHAFT
ALIGNMENT
1.
Support
the
camshaft
with V blocks
with
both
ends
of
the
journals sitting
on
a surface
plate.
2.
Use a dial
indicator or a
micrometer.
3.
Measure
the
camshaft
alignment.
4.
If
the
measurement
exceeds
the
allowable
limit,
replace
the
camshaft.
CAMSHAFT
ALIGNMENT
ALLOWABLE
lIMIT
__
O.01mm
-
0.0004in
1-wIWESJERBEICE
I Engines & Generators
26
Page 30
SERVICING
CAM
HEIGHT
1.
Measure
the
height
of
the
cam
at
its
highest
point
with
an
outside
micrometer.
2.
If
the
measurement
is
less
than
the
allowable
limit,
replace
the
camshaft.
CAM
HEIGHT
OF
INTAKE
ANO
EXHAUST
FACTORY
SPECIFICATIONS----33.90mm
1.3346in
___
---..33.
85mm
1.3327in
OIL
CLEARANCE
OF
THE
CAMSHAFT
JOURNAL
1.
Measure
the
camshaft
journal
O.D.
with
an
outside
micrometer.
2.
Measure
the
cylinder block bore
LD.
for
the
camshaft
with
a cylinder
gauge
and
calculate
the
oil
clearance.
3.
If
the
oil
clearance
exceeds
the
allowable
limit,
replace
the
camshaft.
OIL
CLEARANCE
OF
CAMSHAFT
JOURNAL
FACTORY
SPECIFICATIONS
__
0.050 -0.091mm
0.00197 -0.00358in
ALLOWABLE
lIMIT
____
O.15mm
0.00591n
CAMSHAFT
JOURNAL
0.0.
FACTORY
SPECIFICATIONS
__
39.934 -39.950mm
1.57221 • 1.572841n
CAMSHAFT
BLOCK
BORE
1.0.
FACTORY
SPECIFICATIONS
__
40.000 -40.025mm
1.57480
-1.57579In
PISTON
PIN
BORE
1.0.
1.
Measure
the
piston
pin
bore
I.D.
in
both
the
horizontal
and
vertical directions
with
a cylinder
gauge.
2.
If
the
measurement
exceeds
the
allowable
limit,
replace
the
piston.
PISTON
PIN
BORE
1.0.
FACTORY
SPECIFICATlONS
__
25.00 -25.013mm
0.98425 -0.984771n
ALLOWABLE
lIMIT
____
25.0Smm
0.98621n
PISTON
PIN
OIL
CLEARANCE
BETWEEN
THE
PISTON
PIN
AND
THE
SMALL
END
BUSHING
1.
Measure
the piston pin
0.0.
where
it
contacts
the
bushing
with
an
outside
micrometer.
2.
Measure
the
small
end bushing
I.D.
with
an
inside
micrometer
and
calculate
the
oil
clearance.
3. If
the
oil clearance exceeds
the
allowable
limit,
replace
the
bushing.
If
it still
exceeds
the
allowable
limit,
replace
the
piston
pin.
OIL
CLEARANCE
BETWEEN
PISTON
PIN
AND
SMALL
END
BUSHING
\
FACTORY
SPECIFICATIONS---..O.014 -O.038mm
\
0.00055 -0.00150in
AlLOWABLE
LlMIT
__
0.15mm
0.005910
PISTON
PIN
0.0.
FACTORY
SPECIFICATIONS
__
25.002 -25.011mm
0.98433 • 0.9846810
SMALL
END
BUSHING
1.0.
FACTORY
SPECIFICATIONS
__
25.025 -25.040mm
0.98523·O.98582in
lw-,WESTERBEICE
I Engines & Generators
27
Page 31
SERVICING
CONNECTING
ROD
SMAll
END
/"
WHEN
REMOVING
WHEN
INSTALLING
REPLACING
THE
CONNECTING
ROD
SMALL
END
BUSHING
When
Removing
1.
Press
out
the
small
end bushing
with
a connecting
rod
small
end
bushing
replacing
tool.
When
Installing
1.
Clean a new
small
end
bushing
and
bore,
apply
engine
oil
to
them.
2.
PISTON
RING
GAP
1. Insert
the
piston
ring
into
the
lower
part
of
the
liner
(the
least
worn
out
part)
with
the
piston.
2.
Measure
the
ring
gap
with a feeler
gauge.
3.
If
the
gap
exceeds
the
allowable
limit,
replace
the
ring.
TOP
RING
FACTORY
SPECIFICATIONS
__
O.25·
0.40mm
0.0098 -0.0157in
ALLOWABLE
lIMIT
__
1.25mm
0.0492in
SECONORING
FACTORY
SPECIFICATlONS
__
0.30 -0.45mm
0.0118 -0.01791n
ALLOWABLE
LlMIT
__
:1.25mm
0.04921n
OIL
RING
FACTORY
SPECIFICATlONS
__
O.25
·O.45mm
0.0098 -0.0177In
MEASURING
PISTON
0.0.
FEELER
GAUGE
CLEARANCE
BETWEEN
PISTON
RING
AND
GROOVE
1.
Remove
the
carbon
from
the
ring
grooves.
2.
Measure
the
clearance
between
the
ring
and
the
groove
with
a feeler
gauge
or depth
gauge.
3.
If
the
clearance
exceeds
the
allowable
limit,
replace
the
ring.
4.
If
the
clearance
still
exceeds
the
allowable
limit
after
replacing
the
ring,
replace
the
piston.
SECOND
RING
FACTORY
SPECIFICATIONS
__
O.093
·0.128mm
0.0037 -O.005Din
ALLOWABl~
lIMIT.
__
0.2mm
0.0079in
OIL
RING
FACTORY
SPECIFICATIONS
__
0.020 -0.060mm
0.0008·
0.0021
in
ALLOWABLE
lIMIT
__
-"O.l5mm
0.00591n
CONNECTING
ROD
ALIGNMENT
Since the
I.D.
of
the connecting rod small end bushing
is
the
basis
of
this
check,
check the bushing for
wear
beforehand.
1.
Install
the
piston
pin
into
the
connecting
rod.
2.
Install
the
connecting rod
on
the
connecting
rod
alignment
tool.
3.
Put a gauge
over
the
piston pin
and
move
it
against
the
face
plate.
4.
If
the
gauge
does
not
fit
squarely
against
the
face
plate,
measure
the
space between
the
pin
of
the
gauge
and
the
face
plate.
S.
If
the
measurement
exceeds
the
allowable
limit,
replace
the
connecting
rod.
ALLOWABLE
LlMIT
__
1.25mm
0.0492in
l..v-IWESJERBEKE
r Engines & &enerators
28
Page 32
SERVICING
SIDE
CLEARANCE
OF
THE
CRANKSHAFT
1. Move the crankshaft to the flywheel side.
2.
Set
a dial indicator on the crankshaft.
3. Measure the end play by pulling the crankshaft toward
the crank
gear.
4.
If
the measurement exceeds the allowable limit, replace
the thrust bearing 1 and
2.
CRANKSHAFT
SIDE
CLEARANCE
FACTORY
SPECIFICATlONS_O.15 -O.31mm
0.0059·0.0122In
ALLOWABLE
LlMIT.
__
0.5mm
0.01971n
OVERSIZE
DIMENSIONS
OF
CRANKSHAFT
JOURNAL
OVERSIZE
__
O.2mm
______
0.4mm
O.OOSin
0.0161n
DIMENSION
A_26.20
·26.25mm
26.40·
26.45mm
-
1.0315
-1.0335in
1.0394
·1.0413In
DIMENSION
B_.54.5 -54.7mm
54.6·
54.Smm
-
2.1456·
2.1535in
2.1496 -2.15741n
DIMENSION
C_2.B -3.2mm
2.B -3.2mm
(RADIUS)
~
0.1102·
0.12601n
0.1102 -0.1260in
The
crankshaft
journal
must
be
fine-finished
to
higher
than
(O.S-S)
VV'TV
CRANKSHAFT
JOURNAL
o
CRANKSHAFT
ALIGNMENT
1.
Support the crankshaft with V blocks on a surface plate
and set a dial indicator with
its
tip
on
the intennediate
journal
at a right
angle.
2. Rotate the crankshaft on the V blocks and get
the
mis-
alignment (half the measurement).
3.
If
the
misalignment exceeds the allowable limit, replace
the crankshaft.
4.
If
the measurement exceeds the allowable limit, replace
the
thrust bearing 1 and
2.
CRANKSHAFT
ALIGNMENT
ALLOWABLE
LlMIT.
__
O.02mm
0.00079in
l ....
'WESTERBEICE
I Engines & Generators
29
Page 33
SERVICING
OIL
CLEARANCE
BETWEEN
THE
CRANKPIN
AND
THE
CRANKPIN
BEARING
1.
Clean
the
crankpin and crankpin bearing.
2.
Put
a strip of plastigage
on
the
center of
the
crankpin in
each
direction
as
shown.
3.
Install the connecting
rod
cap
and
tighten
the
connecting
rod
screws
to
the
specified torque
and
remove
the
cap
again.
4.
Measure
the
amount
of
the
flattening
with
the
scale
to
get
the
oil
clearance.
5.
If
the
oil
clearance exceeds
the
allowable
limit,
replace
the crankpin
bearing.
6.
If
the
same
size
bearing
is
useless because of
the
crankpin
wear,
replace it
with
an undersize bearing, refer-
ring
to
the
specifications
below.
Never
insert
the
plastigage
into
the
crankpill
oil
hole.
Be
sure
not
to
move
the crankshaft
while
the
connecting
rod
screws
are
tightened.
OIL
CLEARANCE
BETWEEN
CRANK
PIN
AND
CRANKPIN
BEARING
FACTORY
SPECIFICATIONS_
0.025·
0.087mm
0.00098 -O.OOO343ln
ALLOWABLE
lIMIT
__
O.2mm
0.0079in
CRANK
PIN
0.0.
FACTORY
SPECIFICATIONS
__
46.959 -46.975mm
1.84878 -1.84941
in
CRANK
PIN
BEARING
1.0.
FACTORY
SPECIFICATIONS
__
47.000 -47.046mm
1.85039 -1.852201n
UNDERSIZE
DIMENSIONS
OF
CRANKPIN
UNDERSIZE
__
0.2mm
0.4mm
DIMENSION
A
(RADIUS)
DIMENSION
B
(RADIUS)
DIMENSION
C
(DIA.)
0.008in
0.0161n
3.3 -3.7mm
3.3 -3.7mm
0.1299 -0.14571n
__
0.1299 -0.14571n
1.0
-1.5mm
1.0
-1.5mm
0.0394 -0.05911n
_0.0394
-
0.0591
In
46.759 -46.775mm
__
46.559
·46.575mm
1.84091
-1.84154in
__
1.83303
-1.83366In
The
crankpln
must
be
fine-finished
to
higher
than
(0.8-S)
V'V
""
OIL
CLEARANCE
BETWEEN
THE
CRANKSHAFT
JOURNAL
AND
THE
CRANKSHAFT
BEARING
1
1.
Measure
the
D.D. of
the
crankshaft journal
with
an
out-
side
micrometer.
2.
Measure
the
lD.
of the crankshaft bearing 1
with
an
inside
micrometer
and
calculate
the
oil
clearance.
3.
If
the
clearance exceeds
the
allowable limit, replace
crankshaft bearing
1.
4.
If
the
same
size
bearing
is
useless
because of
the
crankshaft journal
wear,
replace it
with
an
undersize
bearing referring
to
the
specifications
below.
Be
sure
not
to
move
the crankshaft
while
the
bearing
case
screws
are
tightened.
OIL
CLEARANCE
BETWEEN
CRANKSHAFT
AND
CRANKSHAFT
BEAR/NGt
FACTORY
SPECIFICATIONS
__
.0.040 -0.118mm
0.00157 -0.00465In
ALLOWABLE
LlMI'I'-
___
0.20mm
0.0079in
CRANKSHAFT
0.0.
FACTORY
SPECIFICATIONS
__
59.921 -59.940mm
2.35909 -2.359841n
CRANKSHAFT
BEARING
11.0.
ALLOWABLE
LIMIT
.
59.980 -60.039mm
2.36142 -2.36374in
Engines & Generators
30
Page 34
SERVICING
UNDERSIZE
DIMENSIONS
OF
CRANKSHAFT
JOURNAL
UNDERSIZE
__
D.2mm
0.4mm
0.DD8in
D.016in
DIMENSION
A _ 2.8·
3.2mm
2.8·
3.2mm
(RADIUS
~
0.1102·
0.1260in
0.1102·
0.1260in
DIMENSION B _1.0
-1.5mm
1.0 -1.5mm
(RADIUS)
-
0.0394 -0.0591in.
0.0394·
0.0591in
DlMENSIONk,Q:_59.721 -59.740mm
__
59.521
·59.54Dmm
2.35122 -2.35197in_
2.34335 -2.344D9in
The
crankshaft
journal
must
be
fine-finished
to
higher
than
(0.8-S)
'V'<r
V\!
REPLACING
THE
CRANKSHAFT
BEARING
1
Whell
Removillg
1.
Press
out
the
used
crankshaft
bearing 1 using a crankshaft
bearing 1 replacing
tool.
Whell
Jrutalling
1.
Clean a new
crankshaft
bearing 1 and
crankshaft
journal
bore,
apply
engine
oil
to
them.
.
2.
Using a crankshaft
bearing 1 replacing
tool,
press
in
a
new
bearing 1 so
that
its
seam
directs
toward
the
exhaust
manifold
side.
DIMENSION
A
4.2 -4.5MM
(A)
0.1654 -0.1772in-
CRANKSHAFT
BEARING
1
(CYLINDER
BLOCK
Engines & Generators
31
Page 35
SERVICING
OIL
CLEARANCE
BETWEEN
THE
CRANKSHAFT
JOURNAL
AND
THE
CRANKSHAFT
BEARING
2
1. Put a strip of plastigage
on
the center of the journal.
2.
Install
the
bearing
case
and
tighten
the
bearing
case
screws
to
the
specified torque
and
remove the bearing case
agaiun.
3. Measure
the
amount of the flattening with the scale
to
get
the oil clearance.
4.
If
the
clearance exceeds the allowable
limit,
replace crank-
shaft bearing
2.
5.
If
the
same size bearing
is
useless because
of
the
crankshaft journal
wear,
replace
it
with
an
undersize
bearing referring
to
the specifications
below.
.
Be
sure
not
to
move the crankshaft
while
the bearing
case
screws
are
tightened.
OIL
CLEARANCE
BETWEEN
CRANKSHAFT
AND
CRANKSHAFT
BEARING
2
FACTORY
SPECIFICATIONS~
0.040 -O.lD4mm
0.00157 -0.004091n
ALLOWABLE
LlMIT
____
0.20mm
0.00791n
CRANKSHAFT
0.0.
FACTORY
SPECIFICATlONS_59.921 -59.940mm
2.35909 -2.359841n
CRANKSHAFT
BEARING
21.0.
FACTORY
SPECIFICATIONS
__
59.980 -60.D25mm
2.36142 -2.363180in
REFER
TO
THE
DATA
IN
THE
UPPER
RIGHT
STOPPER
UNDERSIZE
DIMENSIONS
OF
CRANKSHAFT
JOURNAL
UNDERSIZE
___
D.2mm
______
0.4mm
DIMENSION
A
(RADIUS
-
0.008in
0.0161n
2.8 -3.2mm
2.8 • 3.2mm
0.1102 -0.1260in
0.1102 -0.1260in
1.0
-1.5mm
1.0
-1.5mm
DIMENSIONB
(RADIUS)
-
0.0394
-0~0591in
0.0394 -0.05911n
DIMENSION
~,I!
59.721 -59.740mm
__
59.521 -59.540mm
2,35122 -2.35197In_
2.34335 -2.34409in
The
crankshaft
journal
must
be
fine-finished
to
higher
than
(0.8-S)
'VV'TV
CRANKSHAFT
SLEEVE
WEAR
1.
Check
the
wear
on
the crankshaft
sleeve.
2.
If
the
wear exceeds
the
allowable limit or if
the
engine
oil
leaks, replace the crankshaft
sleeve.
WEAR
OF
SLEEVE
ALLOWABLE
LlMIT_---,,0.1mm
0.00039in
CRANKSHAFT
SLEEVE
.
CRANKSHAFT
REPLACING
THE
CRANKSHAFT
SLEEVE
1.
Remove the used crankshaft sleeve using a special
puller
set.
2. Set the sleeve guide
to
the
crankshaft.
3. Set the stopper
to the crankshaft
as
shown.
4. Heat a
new
sleeve
to
a temperature between
1500 -2000C
(302
0
-
3920 F)
5.
Press
fit
the sleeve using the auxiliary socket for
pushing.
Mount the
sleeve
with
its
largely
chamfered suiface facing
outward.
CRANKSHAFT
SLEEVE
/
CRANKSHAFT
Engines & Generators
32
Page 36
SERVICING
CYLINDER
WEAR
1.
Measure
the
LD. of
the
cylinder
at
the
six positions
with
a cylinder
gauge
to
find
the
maximum
and
minimum
LD.
2.
Get
the
difference
(maximum
wear)
between
the
maximum
and
the
minimum
10.
3.
If
the
wear exceeds the allowable
limit,
bore
and
hone
to
the oversize dimension. Refer
to
CORRECTING
THE
CYLINDER.
4.
Visually
check the cylinder
wall
for
scratches.
If
deep
scratches are
found,
the
cylinder should be
bored.
CYLINDER
1.0.
FACTORY
SPECIFICATIONS
__
87.00D -87.022mm
3.42519 -3.426061n
MAXIMUM
WEAR
ALLOWABLE
LlMIT
__
+D.15mm
+0.0059In
TOP
,...
.-
MIDDLE
-
BOTTOM
(SKIRT
'"'
---
t--
lX-'
~;\\
CORRECTING
THE
CYLINDER
(Oversize
+0.25mm)
1.
When
the
cylinder
is
worn
beyond
the
allowable
limit,
bore and hone
it
to
the
specified
dimension.
OVERSIZE
CYLINDER
1.0.
FACTORY
SPECIFICATIONS
__
87.250 -87.272mm
3.43503 -3.43590in
MAXIMUM
WEAR
ALLOWABLE
LlMIT
____
"'O.15mm
+0.0059In
FINISHING
HORN
TO
2.2 • 3.0
UM
Rmax
~.00g!l7
-
0.00118
in
Rma~
_V"'r-VV
2.
Replace
the
piston
and
piston
rings
with
oversize
(+O.2Smm)
ones.
When the oversize cylinder
is
worn
beyond the allowable
limit, sleeve the block
to
standard dimensions.
I
I
•
I
,
I
I
I
I
~
I
I
,-
·
\
I
,
•
•
I
I
I
t
I
·
,
•
•
•
I
I
,
·
I-
I
I
I
•
I
,
1
,
·
I
,
,I
,....
i-
'"'
CYLINDER
1.0.
(BEFORE
CORRECTION)
OVERSIZE
CYLINDER
1.0.
ROTOR
LOBE
CLEARANCE
1. Measure
the
clearance between
the
lobes
of
the
inner
rotor
and
outer rotor with a feeler
gauge.
2.
Measure
the
clearance between
the
outer rotor and
the
pump
body
with
a feeler
gauge.
3. If
the
clearance exceeds
the
factory
specifications,
replace
the
oil
pump
rotor
assembly.
CLEARANCE
BETWEEN
THE
INNER
ROTOR
AND
OUTER
ROTOR
FACTORY
SPECIFICATIONS
__
O.03 -D.14mm
0.0012 -0.0055in
ALLOWABLE
LlMIT
____
0.2mm
0.0079in
CLEARANCE
BETWEEN
THE
OUTER
ROTOR
AND
PUMP
BODY
FACTORY
SPECIFICATIONS
__
0.11 -0.19mm
0.0012 -0.0055in
ALLOWABLE
LlMIT
____
0.25mm
.'
0.0098in
~
f-
Engines & Generators
33
Page 37
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Engines & Generators
34
Page 38
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#fiiN;I!I
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_____
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Page 39
ENGINE
ADJUSTMENTS
GLOW
PLUGS
GLOW
PLUG
·CONNECTION
STRAP
A
WARNING:
These
glow
plugs
will
become
very
hot
.
to
the
touch.
Be
careful
not
to
burn
your
fingers
when
testing
plugs.
To inspect the plug, remove the electrical terminal connections,
then unscrew or unclamp each plug from the cylinder head.
Thoroughly clean each plug's tip and threads with a soft brush
and cleaning solution to remove all the carbon and oil deposits.
While cleaning, examine the tip for wear and
bum
erosion;
if
it
has eroded too much, replace the plug.
An accurate way to test glow plugs is with an ohmmeter.
Touch one prod to the glow plug's wire connection, and the
other to the body
of
the glow plug, as shown. A good glow plug
will have a
0.9 ohm resistance. This method can be used with
the plug in
or
out
of
the engine. You can also use an ammeter to
test the power drain (13 amps per plug).
Re-install the plugs in the engine and test them again. The
plugs should get very hot (at the terminal end) within 5 to 10
seconds.
If
the plugs
don't
heat up quickly, check for a short
circuit. When reinstalling the glow plugs, use anti-seize
compound on the threads.
A
CAUTION:
Do
not
keep
glow
plug
on
for
mOle
than
30
seconds.
WIRE
CONNECTION
BODY
TIGHTENING
TORQUE
2.0
-
2.5
m-kg
(14.5
-18.0
ft-Ib)'
Drive belt adjustment. Proper inspection, service and
maintenance
of
the drive belts is important for the efficient
operation
of
your engine.
Drive belts must be properly tensioned. Loose drive belts
will not provide proper alternator charging and will
eventually damage the alternator. Drive belts that are too
tight will pull the alternator out
of
alignment and/or cause
the alternator to wear out prematurely. Excessive drive
belt tension can also cause rapid wear
of
the belt and
reduce the service life
of
the coolant pump's bearing. A
slack belt or the presence
of
oil on the belt can cause belt
slipping, resulting in high operating temperatures and
tachometer variations.
The drive belt is properly adjusted
if
the belt can be
deflected no less than 3/8 inch (lOmm) and no more than
112
inch (12mm) as the belt is depressed with the thumb
at the midpoint between the two pulleys on the longest
span
of
the belt. A spare belt or belts should always be
carried on board.
A
WARNING:
Never
attempt
to
check
or
adjust
the
drive
belt's
tension
while
the
engine
is
in
operation.
Adjusting
Belt
Tension
a. Loosen the alternator adjusting strap bolt and the base
mounting bolt.
h.
With the belt loose, inspect for
wear,
cracks and frayed
edges.
c. Pivot the alternator on the base mounting bolt to the
left or right as required, to loosen or tighten.
d. Tighten the base mounting bolt and the adjusting strap
bolt.
e. Run the engine for about 5 minutes, then shut down
and recheck the belt tensions.
ADJUSTING
STRAP
BOLT
ALTERNATOR
In
case
of
severe vibrations and detonation noise, have the
injectors checked and overhauled by an authorized fuel
injection service center.
Poor fuel quality, contaminant's and
loss
of
positive fuel pressure to the injection pump can result
in injector faults. Since fuel injectors must be serviced in a
clean room environment, it is best to carry at least one extra
injector as a spare should a problem occur.
Refer to the
following page for injector testing.
Engines
&.
Generators
36
Page 40
ENGINE
ADJUSTMENTS
REMOVING
THE
INJECTORS
NOTE:
Injector
must
be
selViced
in
a
It
clean
room"
erMmnment.
1. Disconnect the high pressure
lines
from
the injectors
and
loosen
the
lines at their attachment to the injection pump
and
move
them
out of the
way
of
the
injectors.
Avoid
bending
the
lines.
2.
Using a 17mm
long socket,
removy the
fuel
return line
in
its entirety
from
the top
of
the injectors.
Take
care not
to
Jose
the
two
sealing washers
and
banjo bolt that attaches
the
fuel
return line
to
each
injector.
NOTE:
Clean
the
area around the
base
afthe injector
prior
to
lifting
it out
of
the
cylinder head
to
help prevent
any
rust
or deblis
[rom
falling
down
i.nto
the
inj{[ctor
hole.
If
the
injector will not lift out easily and
is
held
in
by
carbon
build
up
or
the
like,
work
the
injector side
to
side
with
the
aid
of
the
17mm
deep
socket
wrench
to
free
it
and
then
lift
it
out.
3.
The
injector seats
in
the cylinder
head
on
a copper seal·
ing
washer.
This washer should
be
removed with the
injector and replaced with a
new
washer when the injec-
tor
is
reinstalled.
INJECTION
TESTING
1.
Using
the nozzle
tester,
check the spray pattern
and
injec·
tion
starting
preSsure
of nozzle
and,
if it exceeds the
limit,
adjust or replace the nozzle. When using nozzle
tester,
take the following precautions:
a.
'If
the
diesel
fuel
of
the nozzle tester
is
discolored,
replace
it.
At the same time, clean
or
replace the
filter.
b. Set the nozzle tester in a clean place where there is
no
dust or dirt.
c. Mount the nozzle and nozzle holder
on
the nozzle
tester.
d
Use
the
fuel
at
the approximate temperature
of
68°
F (20
0
C)
e.
Operate the hand lever of nozzle tester several times to
bleed
the air in the nozzle
line,
then
move the
hand
lever
at intervals
of
one stroke per second while read·
ing tile injection starting pressure.
A
CAUTION:
The
spray
injected
from
the
norzle
is
Df
such
velocity
that
it
may
penetrate
deeply
into
the
skin
of
fingers
and
hands,
destroying
tissue.
If
it
enters
the
bloodstream,
it
may
cause
blood
poisoning.
FUEL
INJECnON
PRESSURE
FACTORY
SPECIFICATIONS
NOZZLE
INJECTION
TESTER
Inspecting
Spray
Pattern
1.
Operate
the
hand
lever
of
the
nozzle
tester
at
intervals
of
one stroke per
second
to
check if
the
fuel
is
injected
cor-
rectly
in
its
axial
direction. A
nozzle
is
defective
if
it
injects
fuel
in
an
oblique direction
or
in
several
separate
strips.
Also,
a spray
in
the
fonn of particles
indic81es
a
defect. These defects
may
sometimes
be
caused
by
clog.
ging
with
dust
and,
therefore,
all
parts
should
be
carefully
cleaned before
reassembly.
(Care should'be
taken
not
to
expose
ones
skin
to
this
spray
as
it
may
penetrate
the
skin
and
cause infection.)
2.
Apply
the
pressure of
1991
kglcm2
(140
Ib/in
2
)
to
nozzle
by operating the
hand
lever,
and
check the
drips
from
the
nozzle
tip.
If
it
drips
or
has a large
accumulation of
fuel
on
the
bottom,
it
is
considered defective
and
should
be
replaced. A very
small amount of
fuel
may
sometimes
remain
on
the
tip
of
the
nozzle;
however,
this
does
not
indicate a
defect.
DRIP
TEST
The
injection starting pressure for
the
injectors
is
adjusted
by
increasing or decreasing
the
thickness of
the
adjusting
shim.
Pressure variation with O.Olmm
(O.004in)
difference
of
adjusting washer thickness. 235
kPa
(2.4
kgfi'cml,
4 psi)
ADJUSTING
TYPICAL
INJECTOR
VALVE
TIGHTNESS
1.
Set
the
injector
nozzle
to a nozzle
tester.
2.
Raise
the
fuel
pressure
and
keep
it
at
12.75
MPa
(l30kgf/Cnf,
1849
psi)
for
10
seconds.
3.
If a fuel
leak
is
found,
replace
the
nozzle
piece.
~~-~
FACTORY
SPECIFICATlONS
1W'IWESJEHBEKE
No
fuel
leak
at:
12.75MPA
I Engines & Generators
130
kgf/crri
2
37
1849
psi
Page 41
ENGINE
ADJUSTMENTS
CHECKING
VALVE
CLEARANCE
Valve
clearance must
be
checked and adjusted
when
engine
is
cold.
1. Remove the head cover.
2. Align the
ITC
mark line on the flywheel and projection
on the housing so that the No.1 piston comes to the
compression
or
overlap top dead center.
3. Check the following valve clearance (1) marked with
using a feeler gauge.
4.
If
the clearance is not within the factory specification,
adjust with the adjusting screw.
VALVE
CLEARANCE
0.18·
0.22mm
(0.0071
·0.0087
in)
The
TC
marking line on the flywheel is
just
for the
No.1
There is no
TC
marking for the other cylinders. The No.1
piston comes to the top dead center position when the
TC
marking is aligned with the projection in the window on
the
flywheel-housing.
Turn
the
flywheel
0.26
radius
(ISO)
.
clockwise and counterclockwise to see
if
the piston is at
the compression top dead center or the overlap position.
Now, referring to the table below, readjust the valve
clearance. The piston is at the top dead center when both
the IN. and EX. valves do not move.
It
is at the overlap
position when both the valves move.
Finally, tum the flywheel 6.28 radius
(360°) and align the
TC
marking and the projection perfectly. Adjust all the other
valve clearances
as
required.
After turning the flywheel counterclockwise twice or three
times, recheck the valve clearance.
After adjusting the valve clearance, firmly tighten the locknut
of
the adjusting screw.
Adjustable
Valve arrangement
cylinder
3
GYl.
4
CYL.
location
of
piston
IN.
EX.
IN.
EX.
No.1
* *
* *
When
No.
1 piston is
No.2
*
*
compression top dead
center
No.3
*
*
NO.4
-
-
No.1
When No.1 piston is
No.2
*
*
overlap position
NO.3
* *
~
No.4
-
-
* *
PROJECTION
~
ITC
MARK
Engines & Generators
38
TIMING
WINDOW
\ \
FLYWHEEL
\1
I
FLYWHEEL
j
HOUSING
ADJUSTING
SCREW
;-::<-~"'~'?rfl!ll-.l
VALVE
CLEARANCE
~,
t
0.18 -0.22mm
(0.0071 -0.0087
in)
Page 42
INE
ADJUSTMENTS
TESTING
ENGINE
COMPRESSION
Check
the
compression pressure.
To
do
this
wann
the
engine,
remove
all
fuel
injectors, or glow plugs, disconnect
the
fuel
shut-off solenoid wire,
and
install a compression adapter
in
the injector hole or
glow
plug hole. Connect a compression
tester
on
the adapter and crank
the
engine with the starter
motor until the pressure reaches a maximum
value.
Repeat
this
process for each cylinder. Look
for
cylinders
with
dra-
matically (at least 20%) lower compression
than
the
average
of
the
others. Compression pressure should
not
differ
by
more
than
35.5 psi (2.5
kglcm2)
at
280
rpm.
STANDARD
CDMPRESSIO~
PRESSURE
512 -583
PSI
(370
PSI
LIMIT)
If a weak cylinder is flanked by healthy cylinder,
the
problem
is
either valve or piston related. Check the valve clearances
for
the weak cylinder, adjust
as
needed and test
again.
If
the
cylinder
is
still
low,
apply
a small amount of
oil
into
the.
cylinder
to
seal
the
rings and repeat
the
test.
If
compressIOn
comes
up
- the rings
are
faulty.
Abnormally high readings
on
all
cylinders indicates heavy
carbon accumulations, a condition that might
be
accompanied
by
high pressures and noise.
NOTE:
In
case
of
severe vibrations and detonation
noise.
the
cause
may
be
fuel injector problems,
see
FUEL
INJEC-
TORS.
Poor fuel
quality,
contaminates and
loss
ofpositive
fuel pressure
to
the
injection pump will result
in
injector
faults.
When re-installing the glow plugs
use
anti-seize compound.
NOTE:
Do
not guess
the
conditions
of
other cylinders
from
a
result
of
testing
one
cylinder.
Be
sure
to
measure
the
compression
pressure for each
cylinder.
Look for cylinders
with
dramatically
(at
least
20%)
lower compression
than
the
average
of
the
other
cylinders.
If
the
weak cylinder is flanked
by healthy cylinders,
the
problem
is
either valve or head-
gasket
related.
very
low
compression in
an
adjacent cylinder
indicates gasket
failure.
Abnormally
high
readings
on
all
cylinders indicate heavy carbon accumulations, a condition
that might
be
accompanied by high pressure and
noise.
TESTING
OIL
PRESSURE
To
test
oil
pressure, remove the
hex
head plug from the oil
gallery
and
install a mechanical oil pressure gauge
in
its
place. After warming
up
the engine, set the engine speed
at
1800
rpm
and read the oil pressure gauge.
Oil
PRESSURE
BETWEEN
30
AND
40
PSI
AT
1800/1500
RPM
NOTE:
A newly started, cold engine may have
an
oil pressure
reading
up
to
70
or 80
psi.
A warmed engine
can
have
an
oil
pressure
reading
as
low
as
30 psi.
Oil
pressure will
vary
depending
upon
the
load placed
on
the
generator.
OIL
PRESSURE
SENSOR
An oil pressure sensor is mounted on the oil manifold for
the
engine. It sends a voltage signal to the ECU that
is
interpreted
as
pressure. Should this signal fall below a set
point
in
the ECU, the ECU will open the K2
run
relay,
shutting
the
unit
down.
It
will
then
display
the
fault
on
the
LCD Display screen. Engine oil pressure dropping
10
-15
psi
will cause this to
occur.
En~ines
& Generators
39
Page 43
ENGINE
ADJUSTMENTS
TESTING
THE
MAGNETIC
PICK
UP
COIL
Test the speed sensor connector for voltage and resistance
values.
If
the values are correct, remove and inspect the magnetic
pick up. With the wires disconnected, unscrew the
magnetic pick up from the generator housing and visually
inspect the contact end.
If
any damage is detected, replace
the unit.
NOTE:
Carefully follow the installation instructions
provided with the new magnetic pick up coil.
SPEED
SENSOR
TEST
VALUES
VOLTAGE
(while
cranking)
1.5
-
2.5
VAC
RESISTANCE
(at
rest)
950 -1000
ohm
MAGNETIC
PICK-UP
[MPU]
INSTALLATION
The MPU is installed in the threaded opening on the side
of
the flywheel bellhousing. This positions the MPU over
the teeth
of
the flywheel ring gear.
Viewing through this opening, manually rotate the engine
crankshaft so as to position the flat
of
one
of
the ring
gear's teeth directly under the opening. Thread the
MPU
into the opening until it gently contacts the flat
of
this
tooth (Thread is
3/8" x 24). Back the MPU out
of
the
opening one
tum
and then lock it in this position with
the
jam
nut. This will position the end
of
the MPU
approximately 0.030 inches away from the flats
of
the
ring gear teeth.
To ensure the
MPU is positioned correctly, slowly rotate
the crankshaft by
3600 by hand to assure there is
no
~
physical contact between the
MPU
and the ring gear teeth.
If
contact is felt between the MPU and the flywheel teeth,
the
MPU
may
be
damaged.
Remove
the
MPU
and
inspect
it. Replace
if
necessary and repeat the above
installation procedure.
NOTE:
When replacing the Magnetic Pick-Up (MPU) it
MUST
be replaced without cutting and splicing into the
existing wiring cable. Doing so will cause a erratic
AC
signal to the controller.
=::'.===
O.030in
AIR
INTAKE/SILENCER
The
air
intake port supplies air to the control panel
electronics. This air flow continues to the engines air
intake/silencer to supply fresh
air
to the engine. This system
requires no maintenance but during a general overhaul,
compressed air can be used to flush out any accumulated
debris.
AIR
INTAKE
PORT
KEEP
FREE
FROM
OBSTRUCTION
Engines & Generators
40
NOTE:
Pages
41
and
42
were
intentionally
removed
from
this
manual.
AIR
INTAKE
SILENCER
Page 44
SPECIFICATIONS
17.0/13.5
EDE
ENGINE
SPECIFICATIONS
Engine
Type
Aspiration
Diesel,
four-cycle,
three-cylinder,
fresh
water-cooled,
vertical
in-line
overhead
valve
mechanism.
Naturally
aspirated
Compression
Ratio
23.8:1
Governor
Combustion
Chamber
Bore & Stroke
Piston
Displacement
Fuel
Consumption
at
rated
amperage
outlet
HP @ 1800/1500
RPM
Engine
Combustion
Air
Requirements
Firing
Order
Inclination
Weight
(dry)
Electronic
Spherical
type
87 x 92.4
mm
(3.43 x 3.64
inches)
2.19
liters
(134.07
cubic
inches)
1.50
gph
(5.7
Iph)
at
1800
pm
1.22
gph
{4.6Iph}
at
1500
rpm
38.0/25.6
1800
rpm
58
cfm
(1.64
cmm)
1500
rpm
48
clm
(1.36
cmm)
1-2-4
.
Continuous
20"
Temporary
30°
(not
to
exceed
10
min.)
829
Ibs
(376.0
kgs)
TUNE-UP
SPECIFICATIONS
Compression
Pressure
(allowable
limit)
Variation
between
cylinders
Injection
Timing
Engine
Speed
Valve
Clearance
(engine
cold)
Injector
Pressure
Valve
Timing
512 -583
psi
(36 -41
kgt/cm
2
)
at
250
rpm
370
psi
(26
kgf/cm
2
)
at
250
rpm
10%
or
less
18°
BTDC
1800
rpm
60
Hertz
1500
rpm
50
Hertz
0.23
to
0.27
mm
(0.00091
to
0.0106
inches)
1991
to
2134
psi
(140
to
150
kgf/cm!)
Intake
Opens
14"
BTDC
Intake
Closes
36°
ABDC
Exhaust
Opens
45"
BBDC
Exhaust
Closes
17°
ATDC
ELECTRICAL
SYSTEM
Starting
Battery
12-Volt
DC
(-j
negative
ground
Battery
Capacity
800-1
000
CCA
DC
Charging
Alternator
40
Amp
rated,
belt-driven
Starter
2.0
Kw,
12VDC
direct
drive
Starting
Aid
Glow
plugs,
sheathed
type
DC
Cranking
Current
240
(includes
glow
plugs)
LUBRICATION
SYSTEM
General
Pressure
fed
system
with
external
relief
valve
Oil
Filter
Sump
Capacity
(includes
oil
filter)
Full
flow,
paper
element,
spin-on
type
6.3
U.S.
qts
(6.0
liters)
.
LUBRICATION
SYSTEM
Operating
Oil
Pressure
28 -57
psi
(2.0 -4.0
kg/cm
2
)
(engine
hot)
Oil
Grade
API
Specification
CF,
CG-4,
CF-4
or
CH-4
SAE
10W-30,
15W-40
General
Operating
Temperature
Fresh
Water
Pump
Raw
Water
Pump
System
Capacity
(fresh
water)
Raw
Water
Row
Rate
(at
1800
rpm)
General
Fuel
Fuel
Injection
Pump
Fuel
Injection
Timing
Injector
Nozzle
Fuel
Filter
Air
Intake
Air
Flow
Combustion
COOLING
SYSTEM
Fresh
water-cooled
engine
block,
themnostatically-controlled
with
heat
exchanger.
160
-180· F
(71 -82·
C)
Centrifugal
type,
metal
Impeller,
belt-driven
Positive
displacement,
rubber
impeller,
gear-driVen.
5
qts
(4.7
liters)
6.0
gpm
(22.7Ipm)
FUEL
SYSTEM
Open
flow,
self
bleeding,
self
priming
(electromagnetic
fllel
pump)
No.2
diesel
(cetane
rating
of
45
or
higher)
Bosch
type
mini-pump
S·
BTDC
(spill)
Bosch
throttle
type
Spin-on
type
Metal
screenlintake
silencer
box
70.0
elm
(1.9
cmm)
GENERATOR
COOLING
Air
ReqUirements
(generator
cooling)
250 -275
elm
(7.08 -7.8
cmm)
NOTE:
Increase
cooling
air
flow
15%
for
slower
tuming
50hz
units.
Generator
Compartment
122· F (50·
C)
maximum
Ambient
Temperature
AC
GENERATOR
(Single
Phase)
General-Single
phase
Voltage -Single
Phase
Voltage
Regulation
Frequency
Regulation
ACAmperage
Brushless,
four-pole,
revolving
field.
Sealed
lubricated,
Single-bearing
design. 6 wire
reconnectable
with
solid
state
voltage
regulator.
120
or
1201240
volts
60
Hz
230
volts
50
Hz
±
2%
no
load
to
full
load.
± 3
Hertz
(.5%)
no
load
to
full
rated
amperage
outlet
120
votts/141.7
amps-
240
volts70.8
amps
230
volts/58.7
amps
Engines & Generators
43
NOTE:
Pages
41
and
42
were
intentionally removed from
this
manual
Page 45
GENERATOR
SPECIFICATION
3
PHASE
17.0/13.5
EDE
22.0/17.0
EDE
AC
GENERATOR
(3
Phase)
AC
GENERATOR
(3
Phase)
Three
Phase
Brushless,
six-
pole,
revoMng
field.
Sealed
Three
Phase
Brushless,
six-
pole,
revolving
field.
Sealed
17.0
Kw -60
Hertz
lubricated,
single-bearing
design.
12
Lead
22.0
Kw -60
Hertz
lubricated,
single-bearing
design.
12
Lead
13.5
Kw -50
Hertz
reconnectable
for
low
voltage
WYE,
high
17.0
Kw -50
Hertz
reconnectable
for
low
voltage
WYE,
high
voltage
Delta.
Solid
state
voltage
regulator
with
voltage
Delta.
Solid
state
voltage
regulator
with
protection
circuitry.
protection
circuitry.
Voltage· 3 phase
Low
Voltage
WYE
240
Volts
Voltage
-3
phase
Low
Voltage
WYE
240
Volts
(60
Hertz)
High
Voltage
WYE
480
Volts
(60
Hertz)
High
Voltage
WYE
480Votts
DELTA
240
Volts
DElTA
240
Volts
Voltage' 3 Phase
High
Voltage
WYE
400
Volts
Voltage
-3
Phase
High
Voltage
WYE
400
Volts
(50
Hertz)
DELTA
230
Volts
(50
Hertz)
DELTA
230
Volts
Amperage 3 phase
Low
Voltage
WYE
51
Amps
Amperage· 3 phase
Low
Voltage
WYE
66
Amps
(60
Hertz)
High
Voltage
WYE
25
Amps
(60
Hertz)
High
Voltage
WYE
33
Amps
DELTA
51
Amps
DELTA
66
Amps
Amperage' 3 phase
High
Voltage
WYE
24
Amps
Amperage
-3
phase
High
Voltage
WYE
30
Amps
(50
Hertz)
DELTA
42
Amps
(50
Hertz)
DELTA
53
Amps
Generator
Compartment
122°F
(50·G)
maximum
Generator
Compartment
122~
(50°C)
maximum
Ambient
Temperature
Ambient
Temperature
Recommendations
NOTE:
Forced
ventilation
should
be
provided
Recommendations
NOTE:
Forced
ventilation
should
be
provided
to
maint11in
generator
compartment
to
maintain
generator
compartment
temperatures
be/ow
122°F
(50·C).
temperatures
below
122·F
(50cG).
Air
Requirement
250
-275
cfm
Air
Requirement
250 • 300
cfm
Generator
Goaling
(7.08 -7.8
cmm)
Generator
Cooling
(7.08 -8.5
cmm)
NOTE:
Increase
air
flow
by
15%
for
slower
NOTE:
Increase
air
flow
by
15%
for
slower
tuming
50
Hz
units.
turning
50
Hz
units.
Engines & Generators
44
Page 46
RAW
WATER
PUMP
(PN
#042175)
EXPLODED
PARTS
VIEW
MOUNTING
GASKET
Disassembly
KEY
TYPICAL
ASSEMBLY
NOTE:
WHEN
INSTALLING
INSERT
THE
SHAFTS
TANG
INTO
THE
SLOT
ON
THE
DRIVE
SHAFT
Close off the
raw
water intake and remove the pump
from
the
engine. The pump
will
have
hose
attachment
nipples
threaded into
its inlet
and
outlet
ports.
These
may
be
left
in
place
as
they
will
not
interfere
with
the
disassembly.
1.
Remove
the three
cap
screws
and
washers
that
hold
the impeller
housing
to the pump
body.
remove the impeller
housing,
expos-
ing
the impeller.
2.
Remove
the O-ring,
the
inner
wear
plate
and
gasket.
3.
Remove
the cam securing screw along
with
the
cam.
4.
Remove the impeller
and
its
key
from
the
shaft.
S.
R<Mov~
the brass washer
and
slide the ceramic
face
seal
off
the
shaft and then
remove
the
spring loaded porcelain
seal
off
the
shaft.
This
will
leave
the
pressed
in
portion of this
seal
in
the
body
of
the
pump.
Pry this
out.
6.
Remove
the circlip
(#1).
7. Using a suitable
SUppOlt,
press the shaft
and
bearing assembly
out
of
the
pump
body
through the
open
area that
the
circlip
(#1)
was
removed
from.
8.
Remove
the
rubber slinger
washer.
9.
Remove
the
circlip
(#2)
and
using a suitable support.
press
both
bearings
off
the
shaft
NOTE:
A
circlip
(#2)
is
located
on
the shaft between
the
two
bear-
ings.
Inspection
Clean
and
il1~pect
all
the
parts
and
replace
any
parts that
show
wear
or corrosion. Inspect
the
impeller
by
bending each impeller blade.
There should not
be
any
cracks.
TYPICAL
HOSE
ARRANGEMENT
HOUSING
Reassembly
1.
Install
the
shaft into the
first
bearing. Support
the
bearings at
their center race when doing
this.
Install the circlip. Position the
first
bearing so it mates against the circlip. Install
the
shaft into
the second bearing. Position the second bearing so it
also
mates
to
the other side of
the
circlip. Install the next circlip in the
. recess at
the
shafts driven end against
the
shaft
bearing.
2.
Warm
the
pump body
on
a hot plate to expand
the
body.
Then
drop the shaftlbearing assembly into the pump
body
ensuring
that the bearings seat
fully
into the
body.
Allow
to
cool
then
install circlip
(#1).
3. Install
the
rubber sling washer
flush
against
the
inner
bearing.
4.
Apply
some
gasket sealant to the outet meter
body
of
the
spring
loaded porcelain
seal
and
with a suitable
fixture
contacting
the
outer
meal
edge
of
the seal press it into the
pump
body
so
it
full
seats.
NOTE:
If
the
spring loaded seal is removed
from
its metal
base,
note
that
the
base
center
is
similar
to a three
cornered hat
and
that
the
inner circumference
of
the
spring seal
has
three
mating
slots
for
these
comers
when
installing
it
back
into
its
metal
base.
S.
Slide
the
white ceramic
faced
seal onto
the
shaft with
the
white
face contacting
the
spring loaded porcelain
seal.
Slide
the
brass
washer onto the shaft
and
against the seal compressing
it.
Install
the
securing circlip
(#1).
6.
Install
the
shaft
seal.
Apply
sealant
to
the outer
edges
of
the
seal
and
some oil
to
the shaft and lip of the
seal.
then,
with
a
suitable
fixture,
press it into the pump
body
until it
is
flush.
7. Install
the
key
into the shaft
keyway.
S.
Position
the
gasket
and
wear plate into
the
pump
body.
9.
Slide
the
impeller onto the shaft
and
keyway.
10. Place
some
gasket sealant
on
the
inner surface of
the
cam
and
on
the threads of its securing screw
and
secure
the
cam
into the
housing
impeller.
11.
Coat
the
impeller housing over
the
impeller and seeure
it
to
the
pump
body
with
the
three
capscrews
and
washers.
12. Install the impeller housing over the impeller
and
secure
it
to
the
pump body
with
the
three capscrews
and
washers.
13.
Assemble
the
pump
to
the
engine
and
attach the coolant
hoses
securing them properly
to
the pump
hose
nipples
with
stainless
steel
hose
clamps.
/-WIWESJERBEKE
I Engines.& Generators
45
Page 47
STARTER
MOTOR
REFER
TO
THR
WIRING
DIAGRAM
IN
THIS
MANUAL
FOR
WIRE
CONECTIONS
DESCRIPTION
The starting system includes the
battery,
starter
motor!
solenoid,
and
the
ignition
switches
- StartlPreheat.
When
the
start button
is
depressed, current
flows
and
energizes
the starter's solenoid
coil.
The energized
coil
becomes
an
electromagnet, which pulls
the
plunger
into
the
coil,
and
closes a set of contacts
which
allow
high current
to
reach
the
starter
motor.
At
the
same
time,
the
plunger
also
serves
to
push
that starter pinion
to
mesh
with
the
teeth
on
the
flywheel.
To
prevent
damage
to
the
starter
motor
when
the
engine
starts,
the
pinion gear incorporates
an
over-running
(one-
way)
clutch
which
is
splined
to
the
starter armature shaft
The rotation of
the
running
engine
may
speed
the
rotation of
the
pinion but
not
the
starter motor
itself.
Once
the
start switch
is
released,
the
cutTent
flow
ceases,
stopping
the
activation of
the
solenoid. The plunger
is
pulled
out of contact
with
the
battery-to-start cables
by
a coil
spring,
and
the
flow
of electricity
is
intenupted
to
the
starter.
This
weakens
the
magnetic
fields
and
the
starter
ceases
its
rotation.As
the
solenoid plunger
is
released, its
movement
also
pulls
the
starter drive gear
from
its
engagement
with
the
engine
flywheel.
EXHAUST
MANIFOLD
GROUND
WIRES
REFER
TO
THE
WIRING
DIAGRAM
IN
THIS
MANUAL
FOR
WIRING
CONNECTIONS
TROUBLESHOOTING
Prior
to
testing,
make
certain
the
ships
batteries
are
at
full
charge
and
that
the
starting system
wiring
connections
(terminals)
are
clean
and
tight.
Pay
particular attention
to
the
ground wire connections
on
the
engine
block.
To
check
the
wiring, try cranking
the
starter
for a few
seconds,
never
more
than
10
seconds
at
a time,
then
run
your
hand
along
the
wires
and
telTllinals
looking
for
warm
spots
that indicate resistance. Repair or replace
any
trouble
spots.
Using a multimeter,
test the voltage between
the
positive
telTllinal
stud
on
the
start solenoid
and
the
engine block
(ground).
If
you read
12
volts, the starter
is
faulty.
To
test
the
ignition circuit, locate
the
ignition(s)
telTllinal
Use
a screwdriver, don't
touch
the
blade,
to
Jump
from
that
ignition
telTllinal
to
the
positive battery
connection
terminal
on
the
solenoid.
If
the starter cranks, the fault lies
with
the ignition circuit.
If
the solenoid clicks but nothing happens, the starter
motor
is probably faulty.
If
nothing happens
at
all, the solenoid is not getting
current.. Check
the
battery
and
inspect
the
wiring
connections.
It
is
also
possible that
the
solenoid
is
defective.
A
WARNING:
There
will
be
arching
and
sparks
will
fly
when
jumping
terminais.
Be
certain
the
engine
space
is
free
of
potentially
explosive
fumes,
especially
gasoline;
and
that
there
are
NO
flammable
solvents
or
materials
stored
nearby.
Engines & Generators
46
Page 48
STARTER
MOTOR
Test
again
by jumping
the
positive tenninal
to
the
M
tenninaL
Pull back
the
covering
on
the
M tenninal
to
expose
the
connection. Attach a jumper cable
to
the positive (+)
tenninal.
Use
a battery type cable
#8
or
better.
Tap
the
M
tenninal
with
the
opposite
end
to
see
the
results.
Do
not
allow
the
jumper cable
end
to
touch
the
solenoid or.starter
casing.
This
would
cause a
short.
A
WARNING:
There
will
be
arching
as
the
full
starting
cu«ent
should
be
flowing
thfU
the
jumper
If
the
starter
spins, the solenoid is faulty.
If
the
starter
fails to spin, the
motor
is probably faulty.
If
no arching occurred, there is no
cur~nt
reaching the
solenoid.
REFER
TO
THR
WIRING
DIAGRAM
IN
THIS
MANUAL
FOR
WIRE
CONECTIONS
A
WARNING:
When
performing
these
procedures,
posit/on
yourself
safely
away
from
the
moving
parts
of
the
engine
in
case
the
engine
starts-up_
Also
warn
other
crew
members
of
the
danger.
NOTE:
Starter motors
are
either inertia type or pre-engaged.
In
the
pre-engaged
model,
the solenoid also moves
an
arm
that engages the starter motor
to
the
flywheel
of
the
engine.
using a screwdriver
to
bypass
the
solenoid on
such
a starter
will
run
the
motor without engaging
the
flywheel.
SERVICE
WESTERBEKE
uses
a standard starter motor
which
can
be
serviced
or
rebuilt
at
any
starter motor automotive
service
center.
If replacing
the
starter
motor,
make certain
the
new
motor
is
certified
for
marine
use.
Automotive starters
do
not
meet
USCG
standards.
If
in
doubt,
contact
your
WESTERBEKE
dealer.
TO
REMOVE
FOR
SERVICE
1.
Disconneet
the
negative battery
cable.
2.
If
necessary,
remove
any
components
to
gain
full
access
to
the
starter
motor.
3.
Label
and
disconne~t
the
wiring
from
the
starter.
(Do
not
.
allow
wires
to
touch,
tape
over
the
terminals).
4.
Remove
the
starter mounting
bolt~.
5.
Remoye
the starter
from
the
engine.
In
some
cases
the
starter will have
to
be
turned
to
a different
angle
to
clear
obstructions,
Engines & Generators
.
47
Page 49
STARTER
MOTOR
FROM
BAITERY
(+)
POST
BENCH
TESTING
THE
STARTER
MOTOR
When
bench testing the starter motor, make certain it is
securely held in place.
Motor
Test
1.
Using a fully charged battery, run a jumper from the batteries (+) post to the connecting lead that has been
removed from terminal C
..
2. Connect another jumper from the battery (-) post to the
starter motor's housing (momentarily).
If
the motor fails
to run, the motor is the problem.
Magnetic
Switch
Test
1.
Connect a
jumper
lead from the starter's S terminal to the
battery
(+) post.
2.
Connect a
jumper
from the battery (-) post to the starter
motor C terminal (momentarily).
3.
If
the pinion gear fails to pop out, the problem is with the
magnetic switch.
Engines & Generators
48
Page 50
STARTER
MOTOR
NOTE:
To
orden;pare
[farts.
contact your WESTERBEKE
dealer.
STARTER
INSPECTION
Solenoid
Inspect
the
solenoid for continuity
between
terminals S
and
M
and
between
terminals S and
body.
No
continuity should
be
found
between
Sand
M.
Continuity should
be
found
between S and
the
body
and
M and
the
body.
Inspecting
The
Armature
1.
Cheek
the
armature
with a growler
tester.
If
it's short
circuited,
replace
the
armature.
Also
check for insulation
between
the
commutator and its
shaft.
If
poorly
insulated,
replace
the
armature.
3
CYL.
STANDARD:
35.0
mm
(1.378
in)
LIMIT:
34.0
mm
(1.339
in)
4
CYL.
STANDARD:
30.0
mm
(1.181
in)
LIMIT:
29.0
mm
(1.142
in)
2.
Measure
the
commutator
0.0.
and
the
depth of
undercut.·
Repair
or replace
it
if
the
service limit
is
exceeded.
Also
check
the
commutator outside surface for dirtiness
and
roughness.
If
rough,
polish
the
commutator
with
fine
crocus
cloth.
3.
Cheek
the
commutator mica under cut and correct
with
a
hacksaw
blade if
the
under cut has beeome to
shallow.
BAD
GOOD
SmAWB~DE
~tffL
[
~WB~E
3
AND 4 CYL.
MICA
UNDER
CUT
STANDARD:
0.45·0.75
mm
(0.0177·0.0295
in)
LIMIT:
0.20
mm
(0.0079
in)
.
FACING
.
SEGME.NTMICA
R
~.
~
CO"'UTATO~
\~~~!
~
.
BAD?;>
GOOD
Brush
and
Brush
Holder
Inspection
1.
Check
the
brushes.
If
worn
out
beyond
the
service
limit,
replace
the
brushes.
BRUSH
HEIGHT:
3
CYL.STANDARD:
15
mm
(0.591
in)
LIMIT:
9
mm
(0.356
in)
4
CYL.
STANDARD:
15
mm
(0.591
in)
LIMIT:
11
mm
(0.433
in)
2.
Cheek
the
brush
spring tension. A
weak
or
defeetive
spring
will
cause excessive brush
wear;
replace
the
springs if suspeet.
3.
Check
the continuity
across
the
brush holder
and
its
sup-
port
with
an
ohmmeter.
If
it conducts, replace
the
brush
holder.
BRUSH
HOLDER·
SUPPORT
RESISTANCE
....
.lNFINITY
Engines & Generators
49
Page 51
STARTER
MOTOR
FIELD
COIL
1.
Inspect
the
continuity
across
the
lead and brush
with
an
ohmmeter,
if it
does
not conduct, replace
the
yoke
assembly.
2.
Check
the
continuity
across
the
brush
and
yoke,
if
it
conducts,
replace
the
yoke
assembly.
OVERRUNNING
CLUTCH
1.
Inspect
the
pinion gear for
wear
or
damage.
If
there
is
any
defect,
replace
the
overrunning clutch
assembly.
2. Check that
the
pinion gear
turns
freely
and
smoothly
in
the
overrunning direction
and
does
not
slip
in
the
cranking
direction.
If
the pinion slips or
fails
to
rotate
in
both directions, replace the overrunning clutch
assembly.
A
CAUTION:
Before
Installing,
thoroughl,
clean
the
starter
Range
and
mounting
surfaces,
remove
all
oil,
old
paint.
and
rust.
starter
perfonnance
largel,
depends
on
the
quality
of
the
wiring.
Use
wire
of
sufficient
size
and
glade
between
the
battery
and
starter
and
full,
tighten
to
the
terminal.
Engines & Generators
50
Page 52
STARTER
MOTOR
DISASSEMBLING
THE
MOTOR
1. Unscrew the nut and disconnect the connecting lead from
the magnetic switch.
2. Remove the two long bolts and separate the end frame,
yoke, and armature.
3. Remove the two screws that hold the brush holder and
take the brush holder out
of
the end frame.
4.
Remove the brush while holding the spring up.
NOTE:
When
reassembling,
grease
the
spline teeth
of
the
armature.
CONNECTING
LEAD
C
MAGNETIC
SWITCH
GEARS
APPLY
GREASE
ROLLER
RETAINER
ROLLERS
~I
GEARS
APPLY
GREASE
\ t:l
~t~~
DISASSEMBLING
THE
MAGNETIC
SWITCH
1. Remove the drive end frame mounting screws.
2. Disassemble carefully the over-running clutch, ball,
spring, gears, rollers, and retainer.
3. Remove the plunger end cover screws and take out the
plunger.
NOTE:
When
reassembling,
apply
grease
to
all gear
teeth,
the
over-running clutch and
ball.
TIGHTENING
TORQUE B TERMINAL
NUT:
5.9 • 11.8
Nm
(4.3 -8.7
fHb)
SPRING
.PLUNGER
COVER
MAGNETIC
SWITCH
PARTS
BREAKDOWN
1
__
GEARS
APPLY
GREASE
A
CAUTION:
Never
smear
the
statter fitting
surface,
terminals,
brushes,
or
commutator
with
grease.
Engines & Generators
51
.
Page 53
ALTERNATORS
TESTINGrrROUBLESHOOTING
1/10
ORANGE
B
B
<::)
TO
STARTER
SOLENOID
50
AMP
DENSO
ALTERNATOR
DESCRIPTION
REFER
TO
THE
WIRING
DIAGRAM
IN
THIS
MANUAL
FOR
ALL
WIRING
CONNECTIONS
The following information applies
to
the standard alternators
that are supplied with WESTERBEKE'S Engines and
Generators.
ELECTRICAL
CHARGING
CIRCUIT
The charging system consists
of
an
alternator with a voltage
regulator,
an
engine DC wiring harness, a mounted DC
circuit breaker and a battery with connecting cables. Because
of
the
use
of
integrated circuits (IC's), the electronic voltage
regulator is very compact and is mounted internally or
on
the
back of the alternator.
It is desirable
to
test the charging system (alternator and
voltage regulator) using the wiring harness and electrical
loads that are a permanent part
of
the system and will then
provide the technician with an operational test
of
the
charging system
as
well
as
the major components
of
the
electrical system.
ALTERNATOR
DESCRIPTION
The stator is connected
to
a three-phase, full-wave bridge
rectifier package which contains six diodes. The bridge
converts the
AC
generated
in
the stator
to
a DC output for
battery charging and accessories,
Power
to
the regulator and the
field
of
the integral regulator
alternator
is
provided-by the
field
diode (or diode trio)
package contained
in
the alternator.
These alternators produce a rated output
of
50 or
51
amps.
rated output
is
achieved
at
approximately 6000 alternator
rpm
at
an
ambient temperature
of
75°P (23.8°C). The
alternators are designed to operate in
an
ambient temperature
range
of
_40°
to
212°P
(_40"
to
100°C).
VOLTAGE
REGULATOR
The integral voltage regulator is an electronic switching
device which senses the system voltage level and switches
the voltage applied to the
field
in order
to
maintain a proper
system voltage.
The regulator design utilizes all-silicon semi conductors and
thick-film assembly techniques. After the voltage
has
been
adjusted
to
the proper regulating valve, the entire circuit is
encapsulated to protect the circuit and the components from
possible damage due to handling or vibration.
ALTERNATOR
TROUBLESHOOTING
Use this troubleshooting section to determine
if
a problem
exists with the charging circuit or with the alternator. If it is
determined that the alternator or voltage regulator is
faulty,
have a qualified technician check it.
A
WARNING:
A
working
alternator
runs
hot. A failed
alternator
can
become
very
hot.
Do
not
touch
the
alternator
until
if
bas
cooled.
LOW
BATTERY
/fAULTY
CIRCUIT
If
the starter only moans or makes a clicking sound instead
of
spinning the engine
to
life it is likely a low battery or a
faulty connection in the starting circuit and not
an
alternator
problem.
PRELIMINARY
INSPECTION
Before starting the actual alternator and voltage regulator,
testing the following checks are recommended.
1. Make certain your alternator is securely mounted.
2.
Check the drive belts for proper tension. Replace the belt
if
it is worn or glazed.
3. Check that all terminals, connectors and plugs
are
clean
and tight. Loose or corroded connections cause high
resistance and this could cause overcharging,
undercharging or damage to the charging system. Badly
corroded battery cables could prevent the battery
from
reaching a fully charged condition.
4.
Check the condition
of
the battery
and
charge
if
necessary.
A low or discharged battery may cause false or misleading
readings in the tests.
NOTE:
An
isolator with a diode, a solenoid,
or
a battery
selector switch is usually mounted in the circuit to isolate
the batteries so the starting battery is not discharged along
with the house batteries.
If
the isolator is charging the
starting battery but not the house battery, the alternator is
OK
and
the problem is
in
the battery charging circuit.
Engines & Generators
52
Page 54
ALTERNATORS
TESTING/TROUBLESHOOTING
TESTING
THE
ALTERNATOR
A
CAUTION:
Before
starting
the
engine
make
certain
that
everyone
is
clear
of
moving
parts!
Keep
away
from
sheaves
and
belts
during
test
procedures.
1.
Start the Engine.
2.
After
the
engine
has
run
for a
few
minutes, measure
the
starting battery voltage at
the
battery terminals
using
a
multimeter set
on
DC
vol
is.
a. If
the
voltage
is
increasing toward
14
volts,
the
alternator
is
working
.
. b.If
the
voltage remains around 12 volts, a problem
exists
with
either
the
alternator or
the
charging circuit;
continue
with
Steps 3 through
6,.
MEASURING
BATTERY
VOLTAGE
(ENGINE
RUNNING)
3.
'fum
off the engine. Inspect all wiring and connections.
Ensure that
the
battery terminals
and
the
engine ground
connections
are
tight and clean
4.
If
a battery selector switch is in the charging circuit,ensure
that
it
is
on
the
correct setting.
S.
'fum
on the ignition switch,
but
do not start the
engine.
6.
Check
the
battery
voltll;ge.
If
your battery
is
in good
condition
the
reading should be
12
to
13
volts.
MEASURING
BATTERY
VOLTAGE
(IGNITION
ON
ENGINE
OFF)
TESTING
THE
OUTPUT
CIRCUIT
1.
Connect the positive probe to the output terminal
Band
connect the negative probe
to
ground.
2. Wiggle the engine wiring harness while observing the
voltmeter. The meter should indicate the approximate
battery voltage, and should not
vary.
If
no
reading is
obtained, or
if
the reading varies, check.the alternator
output circuit for loose
or dirty connections or
damaged wiring.
3.
Start
the engine.
4.
Repeat the same measurement, the negative probe
to
ground, the positive probe
to
B with the engine running.
The voltage reading should be between
13.5
and
14.5
volts.
If
your alternator is over or under-charging, have
it repaired at a reliable service shop.
5.
If
the previous test reads only battery voltage at
terminal
B, use the meter
to
measure
the
DC
excitatidn
terminal.
If
12
volts
is
not present
at
exciter terminal R,
inspect the wiring for breaks
and poor connections.
Jump
12
volts from a
12
volt source (such
as
the
battery) and operate the alternator.
If
the
voltage output
is
13-14 volts,
..
then the alternator
is
OK.
TESTING
THE
OUTPUT
CIRCUIT
ENG/~E
RUNNING
(+)
Engines & Generators
53"
Page 55
ALTERNATORS
TESTING/TROUBLESHOOTING
TESTING
THE
EXCITATION
CIRCUIT
1. Connect the positive (+) multimeter probe
to
the
excitation terminal R on
the
alternator
and
the
negative
H lead
to
ground.
2.
'fum
the ignition switch to the on position
and
note
the
multimeter reading. The reading should
be
1.3
to
2.5
volts (see illustration).
TESTING
THE
,
EXCITATION
CIRCUIT
(ENGINE
RUNNING)
3.
If
the reading is between
.75
and 1.1 volts, the
rotor
field
circuit probably is shorted or grounded.
4.
If
the reading
is
between
6.0
and 7.0 volts, the rotor
field
circuit probably
is
open.
5.
If
no reading
is
obtained,
an
open exists
in
the
alternator-excitation lead or in the excitation circuit of
the
regulator. Disconnect the lead from exc terminal
R.
Connect
tlie
positive multimeter probe
to
the excitation
lead
and
the negative multimeter probe
to
ground.
If
the multimeter
now
indicates
an
approximate battery
voltage, the voltage regulator is defective
and
must be
replaced. If
no
voltage is indicated, check
the
excitation circuit for loose or dirty connections or
damaged wiring.
TESTING
THE
EXCITATION
CIRCUIT
ENGINE
RUNNING
CHECKING
THE
SERVICE
BATTERY
Check
the
voltage
of the service
battery.
this
battery
should
have a voltage
between
13
and
14
volts
when
the
engine
is
running.
If
not,
there is a problem
in
the
service
battery
charging
circuit. Troubleshoot the
service
battery
charging
circuit
by
checking the
wiring
and
connections,
the
solenoid,
isolator,
battery switch,
and
the
battery
itself.
When
the
problem
has been solved
and
before
the
alternator
is
back in operation, take
the
time
to
tighten
and
clean
the
terminal
studs.
Also
clean
the
connecting
terminals
from
the
wiring
harness.
ALTERNATOR
REPAIR
If
tests indicate a failed
alternator,
it
will
need
to
be
disas-
sembled
and
repaired.
Any
good
alternator
service
shop
can
do
the
job.
NOTE:
WESTERBEKE'S
Service
Manuall1as detailed
instructions
for
the
disassembly
and
repair
of
their
standard
alternators.
BAnERYCARE
The
minimum
recommended
capacity of
the
battery used
in
the
engine's
12
volt
DC
control
circuit
is
800-1000
Cold
Cranking
Amps
(CCA).
Review
the
manufacturer's
recommendations
and
then
establish a systematic maintenance
schedule
foryour
engine's starting batteries
and
house
batteries.
.
• Monitor your voltmeter
for
proper
charging
during
engine operation.
•
Check
the
electrolyte
level
and
specific
gravity
with
a
hydrometer.
• Use
only
distilled water
to
bring
electrolytes
to
a proper
level.
•
Make
certain that battery cable
connections
are
clean
and
tight
to
the
battery
posts
(and
to
your
engine).
A
CAUTION:
To
avoid
damage
to
the
battery
charging
circuit,
never
shut
off
the
engine
battery
switch
while
the
engine
is
running.
Shut
off
the
engine
battery
switch,
however,
to
avoid
electrical
shorts
when
working
on
the
engine's
electrical
circuit.
Engines & Generators
54
Page 56
ALTERNATOR
SERVICE
DISASSEMBLY
1. Secure the hex end of the pulley shaft with a
mtchet wrench,
then
loosen the nut and remove
the
nut and
pulley.
2. Unscrew
the
3 rear end cover screws and the B terminal
nut
and
remove the rear end
cover.
REAR
END
COVER
3. Unscrew the 2
screws
holding
the
brush holder
and
remove the brush
holder.
BRUSH
HOLDER
AND
SCREWS
4. Unscrew the 3 screws holding the
IC
regulator and remove
the
IC
regulator.
5.
Remove the 4 screws holding
the
rectifier
and
the
stator
lead
wires,
remove the
rectifier.
6.
Unscrew the 2
nuts
and
2 screws
that
hold
the drive end frame
and
remove the drive
end
frame.
PRESS
DRIVE
END
FRAME
7. Using a press, remove the rotor
from
the
drive
end
frame.
Take
care
not
to
drop the rotor
as
that could
damage
the
fan
or
slip
ring.
To
prevent
tkmzage
to
the
rotor
and stator windings while
removing
the
rotor,
place cardboard between
the
packages
and
remove
the
rotor
by
pulling it out
gentle.
Engines & Generators
55
Page 57
ALTERNATOR
SERVICE
DISASSEMBLY
8.
Unscrew the 4 screws holding the retainer plate and
remove the
retainer plate.
9.
Press out the bearing from the drive
end
frame with a press and a jig.
~
PRESS
STEP9
10. Lightly secure the rotor with a vise to prevent damage
then remove the bearing with a puller.
STEP
10
ALTERNATOR
TESTING
1.
Check the bearing for smooth rotation and worn
appearance.
if
it
does not rotate smoothly, replace
the bearing.
2. Measure the resistance across each lead
of
the stator coil
with
an
ohmmeter.
If
the
measurement
is
not
within
factory specifications, replace it.
RESISTANCE:
LESS
THAN
1.0
OHM
3. Check for continuity across each stator coil lead and
core.
If
infinity is not indicated, replace it.
\
4. Measure the resistance across
the slip ring.
If
the resistance
does not meet factory
specifications, replace
it.
S.
Check the continuity across the slip rings and core.
If
infinity
is
not indicated, replace
it
Engines & Generators
56
Page 58
ALTERNATOR
TESTING
6.
Inspect
the
slip ring for
scoring.
If
scored,
correct
with
an
emery
paper or
on a lathe.
7.
Measure
the
O.D.
of
the
slip ring
with
calipers, if
the
measurement
is
less
than
the
allowable
limit,
replace
it.
SLIP
RING
0.0.
ALLOWABLE
LIMIT
14MMJD.551
IN
8.
Measure
the
brush length
with
vernier calipers. If
the
measurement
is
less
the the
allowable
limit,
replace
it.
BRUSH
LENGTH
ALLOWABLE
LIMIT
8.4
MM/O.331IN
9.
Inspect
the
brush,
it
should
move
smoothly
and
have
no
defects.
10.
Test
the
continuity
across
each rectifier diode
with
an
analog
olunmeter.
Conduct
the
test
in
the
(Rxl)
setting.
The rectifier
is
nonnal if
the
diode conducts in
one
direction
and
not
in
the
other.
NOTE:
Do
not
use
a 500V Megger for tests as it will
destroy
the
rectifier!
Do not
use
an
auto digital multimeter
as
it
is
difficult
to
check
continuity.
11.
Check
the continuity
across
the B
terminal
and
the
F
terminal
of
the
IC
regulator
with
an
analog
olunmeter
using
the
(Rxl)
setting.
The
IC
regulator
is
nonnal if it
conducts
in
one
direction
and
not
the
other.
NDTE:
Do
not
use
a 500V Megger for tests as it will
destroy
the
rectifier!
Do
not
use
an
auto digital multimeter
as
it
is
difficult
to
check
continuity.
Engines & Generators
57
Page 59
STATOR
DRIVE
END
ALTERNATOR
SERVICE
EXPLODED
PARTS
VIEW
Ie
REGULATOR;
Engines & Generators
58
Page 60
SPECIAL
TOOLS
D
Connecting
Rod
Alignment
Tool
E
Code
No
: 07909-31661
Application:
Use
to
check
the
connecting
rod
alignment.
Applicable:
Connecting
rod
big
end
1.0.
•
F
range
30
to
75
mm
(1.18
to
2.95
in.)
dia.
Connecting
rod
length
65
to
300
mm
(2.56
to
11.81
in.)
~
Oil
Pressure
Tester
j
~
Ii/l
~
Code
No:
07916-32032
®
..
«:ll
Application
:
Use
to
measure
lubricating
oil
pressure.
(gg
r('
~:J):
'"
(4)
(5)
(6)
J.
Lj
A=
=8
(1)
Gauge
(5)
Adaptor 2
~~~J~
If8l
(ji9
(2)
Cable (6) Adaptor 3
(3)
Threaded
Joint
(7) Adaptor 4
..
@
(4)
Adaptor 1 (8) Adaptor 5
R
(1)
(2)
(3)
(7)
(8)
D
E F
Balancer
Metal
Replacing
Tool
(for
Fitting)
Application:Use
to
press
jit
the
metal
bearing.
I
vv
I
I.
I
C2
C1
BI
cia
C
A
C
Valve
Guide
Replacing
Tool
Application : Use
to
press
out
and
press
fit
the
valve
guide.
A 20
rnm
dia. (0.79
in.
dia.)
B
11.7 to 11.9 mm dia. (0.460 to 0.468 in.dia.)
C 6.5 to 6.6 mm dia. (0.256 to 0.259 in.dia.)
D
225 mm (8.86 in.)
E
70
mm (2.76 in.)
45 mm (1.77 in.)
G 25 mm
(0.98 in.)
H 5 mm
(0.197 in.)
6.7 to
7.0 mm d;a. (0.263 to 0.275 in.dia.)
20
mn;t
dia. (0.787 in.dia.)
K
12.5 to 12.8 mm dia. (0.492 to 0.504 in.dia.)
8.9 to
9.1
mm (0.350 to 0.358 in.)
Cl
Chamfer 1.0 mm (0.039 in.)
C2 Chamfer 2.0 mm (0.079 in.)
CO.3
Chamfer 0.3 mm (0.012 in.)
NOTE:
Tools
(dimension drawings)
need
to
be
fabricated.
The
others
are
available from your
WESTERBEKE
dealer.
A 0.52 rad
(30
')
B
10
mm (0.39 in.)
C
Chamter 0.3
mm (0.01 in.)
D
182 mm (7.16 in.)
E
140 mm (5.51in.)
F
35 mm dia. (1.38 in dia.)
G
60
mm
dia. (2.36 in dia.)
H
37 mm (1.46 in.)
I
21.9471021.960
mmdia.
(0.8641 to 0.8646 in. dia.)
J 24.959
to
24.980 mm dia. (0.9826 to 0.9835 in. dia.)
K 8.8 to 9.2 mm (0.346 to 0.362 in.)
L 25
mm
dia.
(O.~8
in. dia.)
M 60 mm dia. (2.36
in.
dia.)
N
46.950 to 46.975 mm dia. (1.8484 to 1.8494 in. dia.)
[1J
I-----~A~--;;---;=-_I
[2J
I--
__
---'A"-
____
~
F
Engines & Generators
59
M
J
H
--
G
N
-~
'-
"r-JA
11
Jl
\
/-~.:
o
p
~
-~-
'NA
Q
c/
\.~c
s
0
P
Q
R
S
T
U
V
W
X
Y
Z
a
w
5 mm (0.20 in.)
3.3 to 3.7 mm
(0.130 to 0.146 in.)
43.934 to
43.950 mm dia. (1.7297 to 1.7303
in.
dia.)
140 mm
(5.51
in.)
36 mm (1.42 in.)
60 mm dia. (2.36 in. dia.)
46.950
to
46.975 mm dia. (1.8484 to 1.8494
in.
dia.)
44.950 to 44.975 mm dia. (1.7697 to 1.7707
in.
dia.)
41.934 to
41.950 mm dia. (1.6509
to
1.6516
in.
dia.)
145 mm
(5.71
in.)
195.25 to 195.75 mm (7.687 to
7.707 in.)
29 mm (1.14 in.)
36 mm (1.42 in.)
Crankshaft
Bearing 1 Replacing
Tool
Application : Use
to
press
out
and
press
fit
the
crankshaft
bearing
1.
1.
Extracting
tool
A
135 mm
(5.31
in.)
B 72 mm (2.83 in.)
C
R40
mm
(Rl.57
in.)
D
10 mm (0.39 in.)
E
20 mm (0.79 in.)
F 20 mm dia. (0.79 in. dia.)
G 64.8 to 64.9
mm
dia. (2.551 to 2.555 in. dia.)
H 59.8 to 59.9 mm dia. (2.354 to 2.358
in.
dia.)
2.
Inserting
tool
A 130 mm (5.12 in.)
B 72 mm (2.83 in.)
C R40 mm
(Rl.57
in.)
D 9 mm
(0.35 in.)
E 4 mm
(0.16 in.)
F 20
mm
(0.79 in.)
G
20
mm dia. (0.79 in. dia.)
H 68 mm dia. (2.68 in.
diO.)
I 59.8 to 59.9 mm dia. (2.354 to 2.358 in. dia.)
J 64.8 to 64.9 mm dia. (2.551 to 2.555 in. dia.)
Page 61
!
I
J.
Al
I
c
B
\
...
A
T
Balancer
Metal Replacing Tool (for Removing)
Applicalion:Use
10
remove the metal bearing.
A
25
mnl
(0.98
In.
dla.)
B
10
mm
(0.39
in.)
c
Chamfer
0.3
mm
(0.01
In.)
D : 0.52
rad
(30
')
E
46.35010
46.975
mm
dla. (1.848410 1.8494
In.
ala.)
F
43.934
to
43.950
mm
dia.
(1.7297 to 1.7303
In.
dla.)
G
41
mOl
(1.61
In.)
H
32.S
mOl
(1
.28
In.)
1
148.5
mm
(5.85
in.)
J 46.50 to 48.75
mOl
dla.
(1.831
to
1.841
in.
dia,)
K
44,9SO
1044.975
mm
dia,
(1.769710 1.7107
In.
d1a.)
SPECIAL
TOOLS
G
~
r--tL-
:
N°
E
I
I
F
i
L
"c
~
---
I-
s
u
L
41.934
to
41.950
mm
dla.
(1.6509 to 1.6518 in. dla.)
M 24.959
to
24.980
mm
dia.
(0.982610
0.9835
in. ala.)
N 21.947
to
21.960
mm
dia.
(0.8641
to
0.8646
In.
dla.)
0
28
mm
(1.10 in.)
p
29mm(1.14In.)
Q
I 5
mOl
(0.20
In.)
R
36
mm
(1.42
In.)
S 195.25 to 195.75
mm
(7.687
to
7.707 in.)
T
145
mm
(5.71
In.)
U 384.75
to
385.25
mm
(15.148 to
15.167
in.)
I
Bushing Replacing Tools
Application: Use to press out and press fit the bushing.
1.
For small end bushing
A
162
mm
(8.38 in.)
B
35
mOl
(1
.38
in.)
C
27
mm
(1.06
in.)
0
35
mm
dia.
(1.38
in.
dia.)
I
E 27.901027.95
mm
di
•.
(1.098 to 1.100 in. dio.)
F
25.00 to
25.01
mm
dia.
(0.984
to
0.9851n.
dia.)
2. For idle gear bushing
A
175
mm
(6.89
In.)
B
40
mm
(1.571n.)
C
38
mm
(1,49
in.)
I D
45mmdla. (1.]7
in.
dla.)
E 41.90
to
41.95
mm
dia.
(1.65010 1
.652
In.
dis.)
F
37.951037.97
mm
dia.
(1.494 to
1,495
in.
dla.)
Flywheel
StQPper
Application: Use to loosen and tighten the flywheel screw.
o
I
I
I
I
Engines
& Generators
60
Diesel Engine Compression Tesler
Code
No : 07909-30208 (Assembly)
07909-30934
(A to F)
07909-31211 (E and F)
07909-31231
(H)
07909-31251 (G)
07909-31271 (I)
07909-31281
(J)
Application: Use to measure diesel engine compression and
diagnostics
OT
ntled
for
major overhaul.
(I)
Gauge
(7) AdaptorF
(2)
'l..JOint
(8)
AdaptorG
(3)
Adaplor A
(9)
AdaptorH
(4)
AdaptorB
(10)
Adaptor I
(5)
AdaptorC, (11) AdaptorJ
(S) Adaptor E
~
Code No : 07909-30241
Application: Use to check the oil clearance between
crankshaft and bearing, etc,.
Measuring: Green,.,..0.025 to 0.076 mm (0.001 to 0.003 in.)
range
Red,..,..,..0.051
to
0.152 mm (0.002 to 0.006 in.)
Blue ...... ,..0.102 to 0.229
mm
(0.004 to
O.OOS
in.)
Bed
Check
Code
No:
07909-31371
Application: Use to check cracks on cylinder head, cylinder
block, etc
..
Page 62
SERVICE
DATA I STANDARDS
AND
LIMITS
ENGINE
BODY
Item
Factory
Specification
Allowable
Limit
Cylinder Head Surface
Flatness
0.05 mm 1500 mm
,
-
0.0020 in. / 19.69 in.
Compression
Pressure 3.53 to 4.02 MPa I 2.55
MPa/
(When Cranking with Starting Motor)
I
290 min·1 (rpm) 290 min·1 (rpm)
-
36 to
41
kgf/cm
2
I 26 kgf/cm
2
/
290 min·1 (rpm)
290 min·1 (rpm)
512 to 583 psi /
370 psi I
290 min-1 (rpm)
290 min-1 (rpm)
Difference among
- 10 % or less
Cylinders
Top Clearance 0.55 to 0.70 mm
I
0.0217 to 0.0276 in.
-
Valve Clearance (When Cold) 0.18 to 0.22 mm
-
0.0071
to
0.0087
in.
Valve Seat
Width (Intake)
2.12
mm
0.0835 in.
-
Width (Exhaust) 2.12 mm
-
0.0835 in.
Valve
Seat
Angle (Intake)
1.047 rad
60
0
Angle (Exhaust)
0.785 rad
I
45
0
-
Valve Face
Angle (Intake)
1.047 rad
60
0
-
Angle (Exhaust)
0.785 rad
45
0 -
Valve .Stem to Valve Guide
I Clearance
0.040 to 0.070
mm
0.1
mm
0.00157 to 0.00276 in.
0.0039 in.
I
~alve
Stem
7.960
to 7.975 mm
O.D.)
0.31339 to 0.31398 in.
Valve Guide
8.015 to 8.030 mm
(I.D.)
0.31555 to 0.31614 in.
-
Valve Recessing Protrusion
0.05 mm
-
0.0020 in.
Recessing
0.15 mm
0.4
mm
0.0059 in. 0.0157 in.
I I
Valve Timing (Intake Valve)
(Open)
0.21
rad (12
0
)
-
before T.D.C.
-"_
..
--
(Close)
0.63 rad (36
0)
-
after B.D.C .
•
Engines
& Generators
61
Page 63
SERVICE
DATA
..
STANDARDS
AND
LIMITS
Item
Factory Specification
Allowable Limit
Valve
Timing (Exhaust
Valve)
(Open)
1.05
rad
(60
0)
-
before B.D.C.
!
(Close)
0.21
rad
(12°)
after T.D.C.
-
Valve
Spring
Free
Length
41.7 to 42.2
mm
41.2
mm
1.6417
to
1.6614
in.
1.6220
in.
Setting
Load
/
117.6
N 135.0
mm
100.0
N / 35.0
mm
Setting
Length
12.0
kgf
/ 35.0
mm
10.2
kgf
/ 35.0
mm
26.4
Ibs
/1.3780
in.
22.5
Ibs
/ 1.3780
in.
I
Tilt
1.0
mm
-
0.039
in.
t
I Rocker Arm
Shaft
to
Rocker
Arm
' Clearance
0.016
to
0.045
mm
0.1
mm
I
0.00063
to
0.00177
in.
0.0039
in.
I Rooker
Ann
Shaft
13.973
to
13.984
mm
!
• (0.0.)
0.55012
to
0.55055
in.
-
Rocker
Arm
14.000 to 14.018
mm
(1.0.)
0.55118
to
0.55189
in.
-
Push
Rod
Alignment
0.25
mm
0.0098
in.
Tappet
to
Tappet
Gl.lide
Clearance
0.020
to 0.062
mm
0.07
mm
0.00079
to
0.00244
in.
0.0028
in.
, Tappet (0.0.)
23.959
to
23.980
mm
-
0.94327
to
0.94410
in.
--
Tappet
Guide
(1.0)
24.000
to
24.021
mm
-
0.94488
to
0.94571
in.
Timing Gear Crank Gear
to
Idle
0.0415
to
0.1122
mm
0.15
mm
Gear (Backlash)
0.00163
to
0.00442
in.
0.0059
in.
Idle
Gear
to
Cam
0.0415
to
0.1154
mm
0.15
mm
Gear (Backlash) 0.00163
to
0.00454
in.
0.0059
in.
Idle
Gear
to
0.0415
to
0.1154
mm
0.15
mm
I
Injection
Pump
0.00163
to
0.00454
in.
0.0059
in.
Gear (Backlash)
Crank Gear to
Oil
0.0415
to
0.1090
mm
0.15
mm
Pump
Gear
0.00163
to
0.00429
in.
0.0059
in.
(Backlash)
Idle
Gear
to
Balancer Gear
0.0350
to
0.1160
mm
i
0.15
mm
(£?acklash)
0.00138
to
0.00457
in.
I
0.0059
in.
(Balancer
Model
Only)
Engines
& Generators
62
Page 64
SERVICE
DATA I STANDARDS
AND
LIMITS
Item
Factory Specification
i
Allowable Limit
Idle Gear
Side Clearance
0.12 to 0,48 mm
0.9mm
0.0047 to 0.0189 in.
0.0354 in.
Idle Gear Shaft to Idle Gear Bushing Clearance
0.025 to 0.066
mm
0.1
mm
0.00098 to 0.00260
in.
0.0039 in.
Idle Gear Shaft
37.959 to 37.975 mm
!
-
(0.0.)
1.49445 to 1.49508 in.
Idle Gear Bushing 38.000 to 38.025 mm
-
(I.D.) 1.49606 to 1.49704 in.
Camshaft
Side Clearance 0.07 to 0.22
mm
0.3mm
0.0028 to 0.0087 in.
0.0118In.
I
Camshaft
Alignment
i
0.01
mm
-
0.0004 in.
Cam
Height
33.90 mm
33.85 mm
(Intake
I Exhaust) 1.3346 in.
1.3327 in.
Item
Factory Specification Allowable Limit
Camshaft Journal to Cylinder Block Bore
Clearance
0.050
to
0.091 mm 0.15 mm
0.00197 to 0.00358 in. 0.0059 in.
Camshaft Journal 39.934 to 39.950 mm
(O.D.)
1.57221 to 1.57284 in.
-
Cylinder Block Bore 40.000 to 40.025 mm
-
(I.D.) 1.57480 to 1.57579 in.
Balancer
Shaft
Side
Clearance 0.07 to 0.22
mm
0.3mm
(Balancer Model Only)
0.0028
to 0.0087 in. 0.0118 in.
Balancer
Shaft Journal 1 to Balancer Shaft
Clearance
0.030 to 0.111 mm
0.2mm
Bearing 1 (Balancer Model Only)
0.00118
to 0.00437 in. 0.0079 in.
Balancer
Shaft 43.934 to 43.950 mm
-
Journal 1 (O.D.)
1.72968 to 1.73031 in.
Balancer
Shaft 43.980 to 44.045 mm
I
Journal 1
(1.0.)
1.73149 to 1.73405 in.
-
I
,.-
I·
Balancer Shaft Journal 2 to Balancer Shaft
Clearance 0.030
to 0.111 mm 0.2 mm
Bearing 2 (Balancer Model
Only)
!
0.00118 to 0.00437 in.
0.0079 in.
Balancer
Shaft
41.934 to 41.950 mm
-
Journal 2 (0.0.)
1.65094 to 1.65157
in.
Balancer Shaft
41.980 to 42.045 mm
~alancer
Shaft Journal 3
to
Balancer Shaft
Journal 2 (I.D.)
1.65275 to 1.65531 in.
Clearance
0.020 to 0.094 mm
0.2mm
Bearing 3 (Balancer Model Only)
0.00079
to 0.00370 in.
0.0079 in.
!
Balancer Shaft
21.947 to 21.960 mm
-
Journal 3 (O.D.)
0.86405
to 0.86456 in.
Balancer
Shaft
21.980
to 22.041 mm
-
Journal 3 (I.D.) 0.86535 to 0.86775 in.
.
..
-
25.000 to 25.013 mm Piston
Pin
Bore
1.0.
25.05 mm
I
0.9862 in.
i I
0.98425 to 0.98476 in.
Engines & Generators
63
Page 65
SERVICE
DATA I STANDARDS
AND
LIMITS
Item
Factory
Specification
Allowable Limit
I
Top Ring
(Ring Gap)
0.25 to 0.40 mm
1.25
mm
0.0098
to
0.0157 in.
0.0492 in.
Second Ring to Ring Groove
Clearance
0.093
to
0.128 mm
0.2mm
1
0.0037 to 0.0050 in.
0.0079 in.
I
Oil Ring to Ring Groove
Clearance
0.020 to 0.060
mm
0.15 ml\l
0.0008
to 0.0021 in .
0.0059 in.
• Second Ring
I
(Ring Gap)
0.30 to 0.45
mm
1.25
mm
I
I
0.0118 to 0.0177 in.
0.0492 in.
r
Ring Gap
0.25 to 0.45 mm 1.25 mm
0.0098 to 0.0177 in.
0.0492 in.
I Connecting Rod
Alignment
-
0.05
rlm
1
0.0020 in.
Piston Pin to
Small End Bushing
Clearance
0.014 to 0.038
mm
0.15
mm
0.00055
to"
0.00150
in.
0.0059 in.
I Piston Pin
(0.0.)
25.002 to 25.011 mm
0.98433 to 0.98468 in.
-
_.
__
....
-
Small End Bushing 25.025 to 25.040 mm
(1.0.)
0.98523 to 0.98582 in.
-
Crankshaft Alignment
I
0.02 mm
-
0.00079 in.
Crankshaft Journal to Crankshaft Bearing 1
Oil Clearance 0.040 to 0.118
mm
0.2mm
0.00157 to 0.00465 in.
0.0079 in.
Crankshaft Journal 59.921
to
59.940 mm
(0.0.)
2.35909 to 2.35984 in.
Crankshaft Bearing
59.980 to
60.039 mm
1
2.36142 to 2.3.6374 in.
-
(1.0.)
Crankshaft Journal to Crankshaft Bearing 2
Oil Clearance 0.040 to 0.104
mm
0.2
mm
0.00157 to 0.00409 in.
0.0079 in.
Crankshaft Journal
59.921 to
59.940 mm
(0.0.)
2.35909 to 2.35984 in.
Crankshaft Bearing
59.980
to
60.025 mm
2
2.36142 to 2.36374 in.
(1.0.)
Engines & Generators
64
Page 66
SERVICE
DATA I STANDARDS
AND
LIMITS
ELECTRICAL SYSTEM
Item
Factory Specification
Allowable Limit
Starter Commutator (0.0.)
30.0 mm
29.0 mm
4 Cylinder
1.181 in.
1.142in.
Commutator
(0.0.)
35.0 mm
34.0 mm
3 Cylinder
1.378 in.
1.339 in.
Mica
0.45 to 0.75 mm
0.20 mm
(Under Cut)
0.0177 to 0.0295 in.
0.0079 in.
Brush
(Length)
15.0 mm
11.0 mm
4 Cylinder
0.591 in.
0.433 in.
BrUSh
(Length)
15.0 mm
9.0mm
3 Cylinder
0.591 in.
0.354 in.
--
-
-
Brush
Ho~der
and
Holder
Support Infinity
-
(Resistance)
Alternator
No-load voltage More than 13.5
V
-
Stator
Less than 1.0 0
(Resistance)
-
Rotor
2.90
(Resistance)
-
Slip Ring
14.4 mm
14.0 mm
i (0.0.) 0.567 in. 0.551 in.
I Brush
10.5 mm
8.4mm
. (Length) 0,413 in.
0.331 in.
Glow
Plug
Resistance Approx. 0.9 Q
-
Stop Solenoid
Pulling Coil
Approx. 0.375 Q
(Resistance)
-
Holding Coil
Approx.
15.60
-
(Resistance)
FUEL
SYSTEM
Item
Factory Specification
Allowable Limit
Injection Pump Injection Timing 0.297 to
0.331
rad
(17 to 19
0
)
-
before T.D.C.
Injection Nozzle
Injection Pressure 13.73 to 14.71 MPa
140
to 150
kgf/cm
2
-
1991 to 2133 psi
Injection Nozzle Valve Seat Valve Seat
When the pressure is
Tightness
12.75
MPa
(130
kgf/cm
2
,
1849 psi),.
-
the valve seat must be
fuel tightness.
Engines & Generators
65
Page 67
SERVICE
DATA I STANDARDS
AND
LIMITS
---
Allowable
Li~
Item
Factory
Specification
I
Crankpin to Crankpin Bearing
Oil Clearance
0.025 to 0.087
mm
O.2mm
,
0.00098 to 0.00343 in.
0.007~
in.
Crankpin 46.959 to 46.975 mm
(O.D.)
1.84878 to 1.84941 in.
Crankpin Bearing
47.000
to 47.046
mm
-
(I.D.)
1.85039
to 1.85220 in.
Crankshaft
ance
0.15to
0.31
mm
0.5mm
I
0.0059 to 0.0122 in.
0.0197 in.
Crankshaft
Sleeve Wear
-
0.1
mm
I
0.0039 in.
,
•
Item
Factory
Specification
Allowable
Limit
Cylinder Bore
I [Standard]
(I.D.)
B7.000
to B7.022 mm + 0.15 mm
3.42519 to 3.42606 in. + 0.0059 in.
I
87.250 to 87.272 mm
+0.15mm
. Cylinder Bore
(I.D.)
[Oversize]
3.43503 to 3.43590 in. + 0.0059 in.
LUBRICATING SYSTEM
Item
Factory
Specification
Allowable
Limit
Engine Oil Pressure
I At Idle Speed
98 kPa or more 49 kPa
1.0
kgf/cm2 or more 0.5 kgf/cm
2
14 psi or more
7
psi
I
Eog'oe
011
Pressure
Switch
At Rated Speed 294 to
441
kPa
245 kPa
3.0
to 4.5
kgf/cm
2
2.5 kgf/cm
2
43 to 64 psi
36
psi
Working
Pressure
49kPa
0.5 kgf/cm
2
-
I
7 psi
J Inner Rotor
to
Outer Rotor
Clearance
I
O.~~13~
to 0.14
mm
0.2mm
2 to 0.0055 in. 0.0079
in.
Outer Rotor to Pump Body
Clearance
0.11toO.19mm
0.25
mm
0.0043 to 0.0075 in. 0.0098 in.
I Inner Rotor to Cover i Clearance
0.105 to 0.150
mm
0.2mm
I I
0.00413 to 0.00591 in.
0.0079 in.
COOLING SYSTEM
Thermostat Valve Opening
69.5 to 72.5
°c
Temperature
157.1 to 162.5
OF
-
(At Beginning)
Valve
Opening
85°C
Temperature
185
OF
-
(Opened Completely)
Engines & Generators
66
Page 68
TORQUE
SPECIFICATIONS
_NOTE
• For
"*"
marked screws, bolts and nuts on the table, apply engine oil
to
their
threads and seats before
tightening.
• The letter
"M"
in Size x Pitch means that
the
screw, bolt
or
nut
dimension stands
for
metric. The size is
the nominal outside diameter in mm of the threads. The pitch is the nominal distance in mm between
two threads.
Item
Size x Pitch
N·m
kgf·m
ft-Ibs
Cylinder head cover screw
M6 x
1.0 6.9 to 11.3
0.7 to 1.15
5.1
to 8.32
*Cylinder head screw
M11
x 1.25 93.1 to 98.0
9.5 to 10.0
68.7 to 72.3
*Main bearing case screw 1
M9 x 1.25
46.1
to 50.9
4.7 to 5.2 34.0 to 37.6
*Main bearing case screw 2
M10 x 1.25 68.6 to 73.5
7.0 to 7.5
50.6 to 54.2
*Flywheel screw.
M12 x 1.25
98.0 to 107.8
10.0
to 11.0
72.3 to 79.5
*Connecting
rod
screw
M8 x
1.0
44.1
to 49.0 4.5 to 5.0
32.5 to 36.2
*Rocker arm bracket screw
M8 x 1.25
23.5 to 27.5
2.4 to 2.8 17.4 to
20.3
*Idle
gear shaft screw
M8 x 1.25
23.5 to 27.5 .
2.4 to 2.8 17.4 to
20.3
drive pulley mounting nut
- 137.3 to 156.9
14.0 to 16.0 101.3 to 115.7
*Bearing case cover screw
M8 x 1.25 23.5 to 27.5 2.4 to 2.8 17.4 to
20.3
Glow plugs
M10 x 1.25 19.6 to 24.5 2.0 to 2.5 14.5 to
18.1
Nozzle holder assembly
M20 x 1.5
49.0 to 68.6
5.0 to 7.0 36.2 to 50.6
Oil
pressure switch
R 1/8
14.7to
19.6
1.5 to
2.0 10.8 to 14.5
Injection pipe retaining nut
M12x1.5
24.5 to 34.3 2.5 to 3.5
18.1
to 25.3
Overflow pipe assembly retaining nut
- 19.6 to 24.5 2.0 to 2.5 14.5 to
18.1
Camshaft set screw
M8 x 1:25
23.5 to 27.5
2.4 to 2.8 17.4 to
20.3
Hi-idling body
-
44.1
to 49.0 4.5 to 5.0 32.5 to 36.2
Balancer shaft set bolt
M8 x 1.25 23.5 to 27.5 2.4 to 2.8 17.4 to
20.3
Alternator pulley nut
-
58.3 to 78.9 5.95 to 8.05 43.0 to 58.2
When the tightening torques are not specified, tighten the screws, bolts and nuts according to the table below.
~
Standard Screw and
Bolt
Special Screw and
Bolt
@
(j)
Nominal
Diameter Unit
N·m
kgf·m
ft-Ibs
N·m
kgf·m
ft-Ibs
M6
7.9 to 9.3
0.80
to
0.95
5.8 to 6.9 9.8 to 11.3 1.00
t01.15
7.23 to 8.32
M8
17.7 to
20.6 1.8 to
2.1
13.0 to 15.2 23.5 to 27.5 2.4 to 2.8 17.4 to 20.3
M10
39.2 to
45.1
4.0 to 4.6
28.9 to 33.3 48.1 to 55.9 4.9 to 5.7 35.4 to 41.2
M12
62.8 to 72.6 6.4 to 7.4
46.3 to 53.5
77.5 to
90.2
7.9 to 9.2
57.1
to 66.5
Screw and bolt material grades are shown by numbers punched on the screw and bolt heads. Prior to tightening,
be
sure
to check out the numbers as shown below.
Punched number
Screw and bolt material grade
None
or
4
Standard screw and bolt SS41, S20C
7
Sp.::cial screw and bolt S43C, S48C (Refined)
Engines & Generators
67
Page 69
GENERATOR
INFORMATION
USE
OF
ELECTRIC
MOTORS
The
power
required
to
start
an
electric
motor
is
considerably
more
than
is
required
to
keep
it
running
after
it
is
started.
Some
motors
require
much
more
current
to
start
tHem
than
others.
Split-phase
CAC)
motors
require
more
current
to
start,
under
similar
circumstances,
than
other
types.
They
are
commonly
used
on
easy-starting
loads,
such
as
washing
machines,
or
where
loads
are
applied
after
the
motor
is
started,
such
as
small
power
tools.
Because
they
require 5 to 7 times
as
much
current
to
start
as
to
run,
their
use
should
be
avoided,
whenever
possible,
if
the
electric
motor
is
to
be
driven
by a small
generator.
Capacitor
and
repulsion-induction
motors
require
from 2 to 4 times
as
much
current
to
start
as
to
run.
The
current
required
to
start
any
motor
varies
with
the
load
cOlmected
to
it.
An
electric
motor
connected
to
an
air
compressor,
for
example,
will
require
more
current
than
a
motor
to
which
no
load
is
connected.
In
general,
the
current
required
to
start
115-
Volt
motors
connected
to
medium
starting
loads
will
tie
approximately
as
follows:
MOTOR
SIZE
AMPS
FOR
AMPS
FOR
(HP)
RUNNING
STARTING
(AMPERES) (AMPERES)
1/6
3.2
6.4
to
22.4'
1/4
4.6
9.2
to
32.2'
113
5.2
10.4
to
72.8'
112
7.2
14.4
to
29.2'
3/4
10.2
2Q.4
to
40.8'
1
13
26
to
52
*NOTE:
In
the
above
table
the
maximum
Amps
for
Starting
is
more
for
some
small
motors
than
for
larger
ones.
The
reason
for
this
is
that
the
hardest
starting
types
(split-phase)
are
not
made
in
larger
sizes.
Because
the
heavy
surge
of
current
needed
for
starting
motors
is
required
for
only
an
instant,
the
generator
will
not
be
damaged
if it
can
bring
the
motor
up
to
speed
in a few
seconds.
If
difficulty
is
experienced
in
starting
motors,
tum
off
all
other
electrical
loads
and,
if
possible,
reduce
the
load
on
the
electric
motor.
REQUIRED
OPERATING
SPEED
Run
the
generator
first
with
no
load
applied,
then
at
half
the
gener-
ator's
capacity,
and
finally
loaded
to
its
full
capacity
as
indicated
on
the
generator's
data
plate.
The
output
voltage
should
be
checked
periodically
to
ensure
proper
operation
ofthe
generating
plant
and
the
appliances
it
supplies.
If
an
AC
voltmeter
or
amp-
meter
is
not
installed
to
mOnltor
voltage
and
load,
check
it
with
a
portable
meter
and
amprobe.
NOTE:
When
the
vessel
in
which
the
generator
is
installed
con-
tains
AC
equipment
of
120
volts
only,
it
is
recommended
that
the
generator s AC
tenninal
block
be
corifigured
to
provide
one
120
volt
AC
hot
legfor
the
vessel's
distribution
panel.
This
will
ensure
good
motor
starting
response
from
the
generator.
GENERATOR
FREQUENCY
ADJUSTMENT
Frequency
is a direct
result
of
engine/generator
speed,
as
indicated
by
the
follmving:
•
When
the
generator
is
run
at
1800
rpm,
the
AC
voltage
output
frequency
is
60
Hertz.
•
When
the
generator
is
run
at
1500
rpm,
the
AC
voltage
output
frequency
is
50
Hertz.
Therefore,
to
change
the
generator's
frequency,
the
generator's
drive
engine's
speed
must
be
changed
along
with a reconfiguring
of
the
AC
output
connections
at
the
generator.
GENERATOR
MAINTENANCE
•
Maintaining
reasonable
cleanliness
is
important.
Connections
of
te:m:rinal
boards
and
rectifiers
may
become
corroded,
and
insulation
surfaces
may
start
conducting
if
salts,
dust,
engine
exhaust,
carbon.,
etc.
are
alloWed
to
build
up.
Clogged
ventilation
openings
may
cause
excessive
heating
and
reduce
life
of
windings.
•
For
unusually
severe
conditions,
thin
rust-inhibiting
petroleum
based
coatings
should
be
sprayed
or
brushed
over
all
surfaces
to
reduce
rusting
and
corrosion.
•
In
addition
to
periodic
cleaning,
the
generator
should
be
inspected
for
tightness
of
all
connections,
evidence
of
overheated
te:m:rinals
and
loose
or
damaged
wires.
•
The
drive
discs
on
single
bearing
generator's
should
be
checked
periodically
if
possible
for
tightness
of
screws
and
for
any
evidence
of
incipient
cracking
failure.
Discs
should
not
be
allowed
to
become
rusty
because
rust
may
accelerate
cracking,
The
bolts
which
fasten
the
drive
disc
to
the
generator
shaft
must
be
hardened
steel
SAE
grade
8,
identified
by
6
radial
marks,
one
at
each
of
the 6 comers
of
the
head.
•
The
rear
armature
bearing
is
lubricated
and
sealed;
no
maintenance
is
required,
However,
if
the
bearing
becomes
noisy
or
rough-sounding,
have
it
replaced.
•
Examine
the
bearing
at
periodic
intervals.
No
side
movement
of
the
shaft
should
be
detected
when
force
is
applied.
If
side
motion
is
detectable,
inspect
the
bearing
and
shaft
for
wear.
Repair
must
be
made
quickly
or
major
components
will
rub
and
cause
major
damage
to
the
generator.
Carbon
Monoxide
Detector-------.
VilESTERBEKE
recommends
mounting a carbon
monoxide
detector
in
the
vessel's
living
quarters.
Carbon
monoxide,
even
in
small
amounts, is
deadly.
The
presence
of
carbon
monoxide
indicates
an
exhaust
leak
from
the
engine
or
generator
or
from
the
exhaust
elbow!
exhaust
hose,
or
that
fumes
from a nearby
vessel
are
entering
your
boat.
If
carbon
monoxide
is
present,
ventilate
the
area
with
clean
air
and
correct
the
problem
inunediately!
Engines & Generators
68
Page 70
ELECTRONIC
REGULATION
SR7·2G
AVR
ADJUSTABLE
THRESHOLD
~F~~~~S~~fj~~~Wr
5
AMP
FUSE
OVERLOAD
PROTECTION
t::.::l
INTERVENTION
CI.) 0
0
"'A
I"C\
a:~
ADJUSTABLPTHRESHOLO
I
m~ ~ ~
sa
S8
7
OF
UNDERSPEED
/
iHrlZ
.
G);~
PROTECT/ON
INTERVENTION
Stab·
®§:....,.,l"'Tl!""rrn~nr-T'I'..,.....
volt
®!5
SA
----rCONNECT
FOR
60Hz
6----<REMOVE
fOR
50Hz
5
~
TID
DESCRIPTION
The voltage regulator
(AVR)
ensures optimum
AC
generator
perfonnance. This advanced design
AVR
is equipped
with
circuitry protection
to
guard against operating conditions that
could be detlimental
to
the AC generator. The following
infonnation details the voltage regulators adjustments and
connections. These procedures should be perfonned by a
qualified technician.
TERMINAL
CONNECTIONS
#1. Excitation
field
DC negative.
#2. Exciter
field
jumper
to
3
if
the
regulator
AC
supply
between
5 and 3A is less than 160
VAC.
#3.
Exciter
field
DC positive.
#3A. Supply voltage
to
regulator
CAC).
#4.
Sensing voltage.
#5.
Supply voltage
to
regulator
CAC).
#6. Jumper
to
SA
for 60
HZ
operation.
#7.
Not
used.
#SB.
N0t
used.
#SC. Sensing voltage.
POSSIBLE
CONNECTIONS
Exciter Field: The exciter field negative should be
connected
to
tenninal1 of the electronic regulator (nonnally
dark blue or black), while the positive (nonnally red or
yellow) should be connected
to
terminal 3. ,
Supply: There are
two
possibilities.
1.
The supply coincides
with
the sensing. In
this
case the
SR7/2 supply should be copnected
to
tenninals 3 and 5
(in case of
three:..phase
generators, tenninal 5 is normally
connected with the star point). Tenninals
3
and
4 should
be
cOlmected
to each other in such a way that the supply
is
also
sensing. Tins connection in necessary
when
the
generator does not have auxiliary winding for supplying
the
regulator.
2.
The supply
and
sensing separate.
TillS
is the case of a
generator equipped with auxiliary winding for regulator
supply.
Supply
is
always
connected
to
terminals
3
and
5
of
the
regulator.
o
4A
4
3A
31--.
2 .
EXCITER
FIELD
1/----'
In both of these cases, the
SR717
supply
can
vary
from
80
to
270
VAC.
But it should be noted that terminals 2
and
3
should be bridged
fQr
supply with voltage between
80
and
160
VAC,
while the same terminals should be left
open
if the
voltage
is
between
160
and
270
VAC.
Sensing: Sensing should be connected
to
terminals 4
and
5
and
can
vary
from
80
to
350
VAC.
The sensing is single
phase only
and
therefore
is
nonnally connected
to
one
alternator phase.
Operation
at
60
Hz: When operating
at
60
Hz,
terminals
SA
and
6 should be connected
to
each other
in
order
to
keep
the
low
frequency protection correctly regulated.
A
WARNING:
Be
aware
that
high
voltages
may
be
present.
Take
all
necessary
precaationms
to
sale
guard
against
electrical
hazards.
FUNCTIONS
OF
THE
REGULATOR
POTENTIOMETERS
Volt:
Witll
this
potentiometer, it is possible
to
adjust
the
voltage generated
by
the alternator
in
a very simple
way.
If
the
screw
is turned clockwise, the voltage increases, if the
screw is turned counterclockwise
it
decreases.
Stab: Tlns potentiometer optimizes altemator perfomlance.
If
tumed clockwise,
the
stability decreases
and
the
response
time decreases but the voltage tends
to
be less
stable.
If
turned counterclockwise, the response time increases
and
the
voltage tends
to
be more stable.
In order
to
adjust
tlllS
potentiometer correctly,
we
advise
using the following method.
1. Tile generator must be working, starting
[TOm
zero
load
and
the potentiometer must
be
at
maximum
stability
(turned
fully
counterclockwise).
2.
Slightly tum clockwise until the light generated
by
the
filament lamp oscillates, at
this
point,
turn
the
potentiometer slowly counterclockwise
until
the light
stabilizes.
Engines & Generators
69
Page 71
ELECTRONIC
REGULATION
SR7-2G
AVR
Hertz:
With
this
potentiometer, which
is
nonnally
pre-calibrated then sealed
by
the manufacturer, it
is
possible
to
adjust
the
low
frequency protection intervention.
To
recalibrate
this
protection,
you
must take the generator
to
a'
normal
zero
load condition, tum
the
potentiometer
clockwise until
the
limit position is reached, then decrease
the
nominal
speed
by
10
%.
'I11en
tum
the potentiometer
counterclockwise
and
measure
the
voltage value until it has
decreased
by 5 volts.
When
the
speed
decreases
by more
than
lQ%
of the nominal
value,
the
voltage
also
decreases proportionally, blocking
generator overheating. Even
if
we
advise calibrating
this
protection
at
10%
of the nominal value, it is obviously
possible
to
calibrate
the
threshold
at
other
values.
Amp:
With
this
potentiometer,
it
is
possible
to
adjust the
intervention level of
the
overload protection.
This
protection
system
has
an
intervention
delay,
which pennits a temporary
overload, necessary
when
starting
motors
or similar
applications
..
To
modify
this protection,
you
must overload the generator
by
15%
of
the
normal
load,
tum the potentiometer
to
minimum (counterclockwise) and wait about twenty seconds.
During
this
period of
time
the voltage value decreases. In this
condition
and
while turning the potentiometer clockwise,
fix
the generator voltage value
at
10%
less
than
the
nominal
one.
At
this
point,
while
the
initial overload is being removed, the
voltage increases
to
the nominal
value.
Fuse: The electronic regulator
is
equipped
with a fuse,
which
protects
the
alternator
from
overheating in cases of regulator
malfunction. The fuse
(250V-5A,
quick acting, F
type)
can
be
replaced
easily.
INTERNAL
WIRING
DIAGRAM
12
WIRE
RECONNECTABLE
WITH
SR7
M
2G
AVR
TO
AG
SENSE
CONNECTIONS
REFER
TO
THE
COMPLETE
WIRING
DIAGRAM
#52951
IN
THIS
MANUAL.
AVR
0
M
"
CJ
III
.,
..
:;;
..
..
..,
'"
...
'"
-
0
Jl8
'I
n.
8LU
BtU
arur_
"FElJl
TO
PANEl
FUSE
l~--
-,
ICSTATOR
I
1 r
" I
I
12.::================t::::::j======:::,11
.10-
"9
EXCITER
A
----
----I
I
I
I
I
+ I
I
I
,
,
I,
----
______
.1
fF~e::=~~~~~~1FUSE
Amp·
Hertz
Slab
voll·
d I
,
-,
I
I
. I
8":=~;;;=+=:+===:
'7
6·
1---
_.____
•
!5
:~==~~~p~O~~=+=+::::::~====~~3
.......
lOut
I
J
HEll
RED
lER~IHAl
BLOCK
,onN(CIiOlIS
SNOWN
ARE
CONFIGiRW
FOR
lO-WY,r
11nlln~
VAC
TERMINAL
BUlCK
EXCITER
r"-"l
•
8LU
m :
!"-"1
I
I
ROTOR
COMPONENT
RESISTANCE
VALUES
IN
OHMS
(AT
86°F)
STATOR
(each
winding)
__
·_O.041
AUXllIARY.
____
0.9
EXCITER
STATOR._11.3
EXCITER
ROTOR
___ . O.
72
(each
pair)
ROTOR
2.7
NOTE:
EXCITER
DC
VOLTAGE I AUXILIARY
VOLTAGE
NO
LOAD
7.0
VDC
215
VAG
o
VOLTAGE
RfGUI.ATOIl
~
______________________
ijlUE.
FULL
LOAD
14.0
VDC
222
VAC
YEllOW
Engines & Generators
70
Page 72
EXCITER
ROTOR
TROUBLESHOOTING
LOW
VOLTAGE·
EXCITER
ROTOR
AND
ROTATING
FIELD
Position
the
exciter rotor/rotating field so the transient
suppressor
is
visible
at
the
12
O'Clock position.
TESTING
THE
ROTATING
FIELD
WINDINGS
Place
the
ohm meter probes on the
two
large red wires (+)
and
(-).
These
are
the
connecting wires for
the
rotating field
windings.
These
wires
do
not need
to
be lifted off their connections
unless,
when
testing, there
is
an
ohm valve discrepancy or a
continuity
to
ground (the rotor shaft).
If
this
occurs, lift
these
two
flarge
:field
wires off
the
diode
plates, isolate them,
and
repeat
the
above
test.
NOTE:
When
removing
these
wires,
be careful noao
drop
the
screws
or
washers
into
the
rotor.
(+)
(RED)
TESTING
THE
EXCITER
ROTOR
WINDINGS
These windings are tested in pairs: A
to
0,0
to
C,
and C to
A
as shown on the drawing.
B
c
EXCITER
ROTOR
WINDINGS
VIEW
OF
ROTOR
FROM
THE
BEARING
END
12
a-CLOCK
PosmON
Disconnect these three wires from
the
diode bridge plates
taking care not
to
drop any screws or washers.
With
the
wires clear
from
the bridge plates. test each pair
with an ohm meter, A
to
B, 0 to
C,
and C to
A.
No
continuity should be found between the rotor
and
any
of
these three winding
pairs.
TESTING
THE
DIODES
Diodes
can
be checked with
an
ohmmeter.
Disconnect the
wire
of
the
particular diode
and
test
its
resistance in both
directions.
A perfectly functioning diode will
show a very
, high resistance in one direction and a
very
low
resistance
in
the
opposite direction. A faulty diode
will
show
either a
very
low
resistance, or
an
infinite resistance in both directions.
Should
the
whole bridge be replaced, remember
to
tighten
the screws with a suitable wrench
and
strictly comply
with
the polarities and internal wiring diagrams
in
thi~
manual
.
. :
DIODE
Engines & Generators
71
Page 73
TWELVE
LEAD
WINDING/TERMINAL
BOARD
CONNECTIONS
(SERIES
WYE)
SERIES
STAR
10':11
0
1
2-3
0
5
1 l
N
5
6-1
0
9
N
SO
Hz
L-L
400
volts
SO
Hz
L-N
230
volta
60
Hz
L-L
480
volts
60
Hz
L-N
277
volts
PARALLEL
DELTA
L
L
9 11
L3
SO
Hz
L-L
115
volts
60
HzL-L
138
volts
DOUBLE
DB.TA
3-wire
L
8-11
2-3
6-9
o 0
1
10
7 4
L1
N
L2
50
Hz
L-L
230
volts
50
Hz
L-N
115
volts
60
Hz
10L
240
volts
60
Hz
10N
120
volts
L
L
o
o
AND
(NOMINAL)
VOLTAGES
(PARALLEL
WVE)
PARAllEL
STAR
113
l
l
10.12
2-4
6-8
1-3
5·7
L2
L3
N
50
Hz
L-L
200
volts
SO
Hz
L-N
) IS
volts
60
Hz
L·L
240
volts
60
Hz
L-N
138
volts
10-12
2-4
---(.""'-----'(10.')
5 7
NU
L2
SO
Hz
L-L
230
volts
SO
Hz
L-N
115
volts
60
Hz
L-L
271
volts
60
Hz
L-N
138
volts
(Refer
to
Note
#
I)
L
0
o
lote ttl Single phase amperage
load.
The
phase CUl1Ymt must
nQt
exceed the
nominal
value.
Iote
##2
l1u'f!e
phase zig-zag connection.
The
rated power must
be
multiplied
by
0.866.
''''''IWEBIERBEICE
I Engines &
GeneratOl'll
72
SERIES
DELTA
L
N7
6
5
10-11
2-
(5
EH
0
0
1-12
5-4
9-8
L2 L3
so
Hz
L-L
230
volts
SO
Hz L-N
115
volta
60
Hz
L-L
277
volts
60
Hz
L-N
138
volts
(Refer to Note # 1)
L~
THREE
PHASE
'~2
DB·ZAB
'11
N
.~
_L
~3~
10,
.. 6 5
L
.9
8.10
o
1
L1
La
N
50
Hz
L-L
346
volts
50
Hz
L-N
200
volts
60
Hz
L-L
415
volts
60
Hz
L-N 240
volts
(Refer
to
Note
#2)
DOUBLE
1\
1\
2.~~~A~o
{4
32
""N
8-11
o
()
1
10
~3
5-12
6·9
o
7 4
N
Ll
50
Hz
L-N
230 volts
60 Hz L-N 240 volts
o
L
0
Page 74
CHANGING
HERTZ
AND
VOLTAGE
A
CAUTION:
As
a
precaution
against
an
unintentional
start,
shut
OFF
the
20
Amp
DC
breaker
on
the
control
panel.
1.
Refer
to
the
previous
page
that illustrates
the
various
AC
voltage output configurations
for
both
the
60
Hertz
and
50 Hertz
applications.
Select the configuration
for
the
HertzJVoltage
required.
2.
Reconfigure
the
6/12
AC
connections
on
the
teoninal
board
carefully
following
the
illustration. Reference
below
the
voltage
sensing
diagram
and
it's connections to
the
AC
terminal
block.
There
arethree
line
connections
when
needed
and a neutral.
These connections
MUST
correspond
to
and
be connected
to
the
line
(L) connec-
tions
on
the
AC
terminal board
and
the
neutral connection
as
well
to
it's corresponding connection.
AUTOMATIC
VOLTAGE
REGULATOR
NOTE:
Failure
to
properly connect these voltage sense
connections can result
in
an AC output voltage fault shut
down
either
from
low
or
high
AC
voltage or incorrect AC
voltage displayed
on
the
LCD
display.
3. There
are
three
line
connections. When
an
L3
is
not
present
on
the
AC
terminal
block,
insulate
and
tie off
the
L3
connection
from
the
Voltage
Sensing
Board.
4. Inside
the
control
box,
locate
the
ECU
and
position
the
HertzlFrequency
dip
switch
in
the
correct position
for
the
HertzIFrequency
desired.
5.
Verify
all
connections
are
correct and tum off
any
AC
panel
breakers.
6. Start
the
generator
and
monitor
the
AC
output
voltage
at
the
generator's
terminal
board. Une
to
line,
line
to
neutral.
Adjust
the
voltage regulator board
as
needed
to
obtain
the
correct
voltage.
Check
the
generator hertz/frequency
with
your
hertz
meter.
7.
Tum
on
the
AC
panel
breakers
and
load unit
and
monitor
the
operation.
OFF
WHEN
CHANGING
THE
GENERATORS~
FREQUENCY
(50/60
HZ)
SWITCH
#1
~
ON
THE
CONTROL
PANEL
feU
BOARD
MUST
BE
SWITCHED:
ON
FOR
50
HZ
AND
OFF
FOR
60
HZ
N , l
o
L'
DIP
SWITCH
ECU
SWITCHES
Engines & Generators
73
VOLTAGE
SENSING
BOARD
N
CONNECT
FOR
60Hz
REMOVE
FOR
50Hz
Page 75
AC
OUTPUT
CONFIGURATIONS
VOLTAGE
SENSING
BOARD
CONNECTIONS
[ill
[IT]
lTIl
[E
NOTE:
,
0
2+3
0
5
6+7
'0
9
lOt"
-SERIES
WYE"
480V'SO
Hz
380V
150
Hz
o
o
AVA
I I
I I
~
o
-PARAl.I.EL
WYE-
208V/60
Hz
(90VfSO
Hz
ECU
REOUIRED
TO
BE
R£-PROGRAMED
WHEN
CHANGING
ANY
or
THE
fOLLOWING
SETTINGS
I.
CHANGING
AC
WIRING
BETWEEN
WYE
AND
DELTA
CONfiGURATION.
2.
CHANGING
AC
WIRING
BETWEEN
2-WIRE
I-PH
AND
3-WIRE
I-PH
3.
CHANGING
BACKEHD
BETWEEN I -PHASE
AND
J-PHASL
[ill
0
4+1
6+9
[!]
0
"10
8t
II
0
0
[E
"OOUBl.E
DEL
TA-
(3-WlRE
SPUT
SINGLE PHASE!
120-240V/60
H,
IIO-220V/50
HI
-seRIES
DELTA-
240V/50
Hz
220V
150
Hz
"PARALLEL
OELTA-
120V/GO
H2
IIOV/50
Hz
-OOU8LE
DEl.TA"
!2-WlRE SINGLE PHASEI
240V/60
HI
220V/50
HI
EDE
1-PHASE / 3-PHASE
PIN
53328
REV
B
INTERNAL
WIRING
SCHEMATIC
EXCITER
ROTOR/ROTATING
FIELD
EXCITER
ROTDR
WINDINGS
ISOLATION
DIODE
PLATES
GHEEN
RED
+
r------------
I
I
EXCITER
RDTOR
I
WINDINGS
I
(
rII"F!--+
I
I
I
TRANSIENT
---j
I
I
I
I
I
I
..
,
FIElp
I
DIODE
I---..J.-.,--
I.
,
I '
I
--
I
L
_______________________
J
Engines & Generators
74
Page 76
GENERATOR
WIRING
SCHEMATICS
1--
---
- - j
: A
EXCITER
STATOR
:
r-
---~-
: I B :
I I
EXCITER
I
I
I·
I
IYELlll?l
I
ROTOR
I
I
+ I I
I I
I
I~
..
.-~
I
I~
..
.-~
BLUE
- I
I
L
DIODES
THREE
PAIRS
I
'-
-
i
I~
~Amp·
:a
Hertz·
~
StalJ-
in
voll--
\;
c..
_ _-.1
. I
-;n
~ri
::
..
E
VOLTAGE
REGULATOR'-
120/240V -60
HZ
® ®
L1
L2
:
~f-"--1
AC
CiRCUIT
ll---f--I
BREAKER
r
I
L1
L2
N
L1
'
CONDENSER
I
I
I
I
I
I
I
I
I
I
SUP~ESSO~
-.1
f---'----'
100
Ko
I I
AUXILIARY
6
AC
TERMINAL
BLOCK
.
.BLACK
GREEN
BLUE
SINGLE
PHASE
INTERNAL
WIRING
SCHEMATIC
;
115V
50Hz.-
230V
50Hz
120V
60Hz -240V
60Hz
YELLOW
120V -60HZ
230V·50HZ
@ ®
L1
L1
® ®
'-t-'-t--'
. I
I
-
--'
A
JUMPER
IS
REQUIRED
FOR
120V -60HZ
N
L1
Engines.& Generators
75
L1
N
115V·50HZ
® ®
I
I
-
--'
Ll N
Page 77
MECC
ALTE
GENERATOR
ASSEMBLY
OF
THE
GENERATOR
TO
THE
ENGINE
1.
Position
the
rotor
assembly
onto the
flywheel
aligning the
holes
in
the
drive
discs
with
the
holes
in
the
flywheel.
Install
the
M8
x 1,25 x 25mm bolts
(blue
loctite
on
threads)
and
torque
to
21
Nm
(16
ft-Ib). Install a threaded
rod
M12 x
1.75
x 90mm
long
into the threaded
end
of
the
rotor
shaft.
1
M10 X 1.25 X 25MM
2.
With
the
aid of a sling or fabricated lifting
eye,
support
the
stator housing assembly
and
carefully guide it over
the
rotor
assembly
until
the
rear bearing contacts
the
bearing
boss
in
the
rear
support.
3.
Place a large washer of at least
80rnm
in
diameter
with
a
center hole of
15mm
onto
the
threaded rod followed
by
a
12mm
x
1.75
nut.
Center
the
rear bearing
in
the
bearing
boss
of
the
support
plate.
Tighten
the
nut
until
the
bear-
ing
seats
fully
into
the
boss. Secure
the
stator housing
assembly
to
the
bell
housing
using
the
four
MIO
x
35mm
screws.
Torque
to
35
Nm
(25
ft-Ib).
remove
the
nut.
washer and threaded
rod.
BEARING
SUPPORT
BRACKET
4.
Rotate
the
generator
by
hand
two
full
revolutions
to
ensure
the
generator rotates
freely.
Reinstall
the
rear
vent
cover.
5.
Secure
the
generator
to
its rear isolators.
Route
the
generator.
wiring
into
the
control
box
and
mount
the
control box
to
the
generator.
Reconnect
all
wire
connections.
test
run.
/W'IWESTERBEKE
f Engines & Generators
76
Page 78
MECC
ALTE
GENERATOR
MAINTENANCE/PARTS
BREAKDOWN
INSPECTION/CLEANING
Periodically
inspect
the
rotor carrier
bearing.
Replace
this
bearing
at
10,000
hours
ofnonnal operation or
sooner
if
wear
is
evident.
Inspect
and
clean
the
control
box
interior,
look
for
loose,
broken.
or burned
wires
and
terminals.
Use
low
air
pressure
(25
psi
max.)
to
remove
dirt
and
dust
from
components.
REAR
VENT
COVER
PARTS
BREAKDOWN
DISASSEMBLY
Should it
become
necessary
to
disassemble
the
stator/rotor
assembly
from
the
engine,
use
the
following
as a guide.
1.
Properly
supportllift
the
rear of
the
engine
to
allow
the
generator
to
be
unbolted
from
the
rear support
isolators.
2.
Mark.
then
disconnect
the
electricalleds that
exit
the
generator
from
their connections
in
the
control
box.
,Be
sure
to
properly
mark
the
connection points
the
generator
leds
connect
to.
Make
an
illustration
if
needed whether
the
generator is
to
be
reinstalled or a replacement
is
to
be
installed.
This
is
to
ensure proper reconnection of
electricalleds.
Unbolt
the
control
box
and
lift'it off
the
generator.
3.
Remove
the
rear
vent
cover.
Support
the
generator
with
11\
sling
or
fabricated
lifting
eye.
Using a 17mm
socket
wrench
remove
the
four bolts
that
attach
the
generator
stator
housing
assembly
to
the
flywheel
housing.
carefully
work
the
stator
assembly
off
the
rear
beruing
and
off
and
ove(
the
rotor
assembly.
Remove
all
dirt,
oil.
grease
and
dust build
up
from
the
external surface of
the
generator.
Build-up
reduces
heat
dissipation
and
causes
the
AC generator end
to
operate
at
a
higher
temperature.
This results in a
loss
of
efficiency
and
reduces
service
life.
4.
Support
the
rotor
assembly
with a sling
and
using
a
17mm
box
wrench,
unbolt
the
rotor
assembly
from
the
flywheel.
DISC
EngInes & Generators
77
Page 79
BE
TROUBLESHOOTING
NOTE:
AC
GENERATOR TROUBLESHOOTING
MUST
BE
PERFORMED WITH
IRE
ENGINE OPERATIN
AT
60
HZ.
FAULT
PROBABLE
CAUSE
NO
AC
VOLTAGE
OUTPUT
AT
NO
LOAD.
1.
Short
or
open
in
the
4.
Open
in
exciter
main
stator
winding.
stator
winding.
2.
Shorted
pozi-resistor
5.
Open
in
rotating
on
exciter
rotor.
field
winding.
3.
Four
or
more
shorted
or
open
diodes
on
exciter
rotor.
RESIDUAL
VOLTAGE
PRODUCED
AT
1.
Blown 6 AMP
fuse
3.
Shorted
or
open
main
NO
LOAD
15 -20
VOLTS
AC.
auxiliary
circuit
feed
to
AVR.
stator
auxiliary
winding.
2.
Faulty
voltage
regulator
LOW
AC
VOLTAGE
OUTPUT
AT
1.
Reset
voltage
potentiometer.
4.
Short
in
rotating
field
winding.
NO
LOAD
60 -100
VAC.
rotor
winding.
2.
Open
or
shorted
diodes
in.
exciter
rotor 1 to 3 diodes.
5.
Short
in
exciter
stator.
3.
Faulty
voltage
regulator
HIGH
AC
OUTPUT
VOLTAGE
1.
Reset
voltage
potentiometer.
150
VAC
OR
HIGHER.
UNSTABLE
VOLTAGE
OUTPUT.
1.
STB
pod
on
regulator
2.
Faulty
voltage
regulator.
needs
adjustment.
AC
VOLTAGE
DROP
UNDER
LOAD
1.
Diode(s)
on
exciter
rotor
60
-100
VOLTS
AC.
breaking
down
when
load
is
applied
(inductive)
1-3
diodes.
Engines & Generators
78
.
Page 80
DECIMAL
TO
METRIC
EQUIVALENT
CHART
Fractions
of
Decimal
(in.) Metric
(mm)
Fractions
of
Decimal
(in.)
Metric
(mm)
an
inch
an
inch
1/64
0.015625 0.39688 33/64
0.515625
13.09687
1/32 0.03125 0.79375 17/32 0.53125
13.49375
3164
0.046875
1.19062
35/64 0.546875
13.89062
1/16
0.0625
1.58750
9/16
0.5625
14.28750
5/64
0.078125
1.98437
37/64
0.578125
14.68437
3/32
0.09375
2.38125
19/32
0.59375
15.08125
7/64
0.109375
2.77812
39/64
0.609375
15.47812
1/8
0.125
3.175
5/8
0.625
15.87500
9/64
0.140625 3.57187
41/64
0.640625
16.27187
5/32
0.15625
3.96875
21/32 0.65625
16.66875
11/64
0.171875
4.36562
43/64
0.671875
17.06562
'.
3116
0.1875 4.76250
11/16
0.6875
17.46250
13/64
0.203125
5.15937 45/64 0.703125
17.85937
7/32
0.21875 5.55625 23/32
0.71875
18.25625
15/64
0.234375 5.95312
47/64
0.734375
18.65312
1f4
0.250 6.35000
3/4 0.750
19.05000
17/64 0.265625 6.74687
49/64
0.765625
·19.44687
9/32
0.28125 7.14375
25/32 0.78125 19.84375
19/64
0.296875 7.54062
51/64
0.796875
20.24062
5/16
0.3125 7.93750
13116
0.8125
20.63750
21/64
0.328125 8.33437
53164 0.828125
21.03437
11/32
0.34375 8.73125
27/32
0.84375
21.43125
23/64
0.359375
9.12812
55/64
0.859375
21.82812
3/8
0.375
9.52500
7/8 0.875 22.22500
25i64
0.390625
9.92187 57/64
0.890625
22.62187
13/32
0.40625 10.31875
29/32
0.90625 23.01875
27/64
0.421875
10.71562
59/64 0.921875 23.41562
7/16
0.4375
11.11250
15/16
0.9375
23.81250
29/64
0.453125
11.50937
61/64 0.953125 24.20937
15/32
0.46875
11.90625 31/32
0.96875
24.60625
31/64
0.484375
12.30312
63164 0.984375
25.00312
1/2
0.500
12.70000
1
1.00
25.40000
Engines & Generators
79
Page 81
STANDARD
AND
METRIC
CONVERSION
'DATA
LENGTH-DISTANCE
Inches
(in) x 25.4 = Millimeters
(mm) x .0394:::
Inches
Feet
(ft) x .305
:::
Meters
(m) x 3.281
:::
Feet
Miles
x
1.609
::
Kilometers
(km)
x
.0621
=
Miles
DISTANCE
EQUIVALENTS
1
Degree
of
Latitude::::
60
Nm
::::
111.120
km
1
Minute
of
Latitude:: 1 Nm = 1.852
km
VOLUME
Cubic
Inches
(in!) x 16.387 = Cubic
Centimeters
x
.061
=in
3
Imperial
Pints
(IMP
pt)
x
.568
:::
Liters
(L) x 1.76
=
IMP
pt
Imperial
Quarts
(IMP
Qt)
x
1.137
::::
Liters
(L)
x.88
'"
IMP
Qt
Imperial
Gallons
(IMP
gal)
x
4.546
:::
Liters
(L) x .22:::
IMP
gal
Imperial
Quarts
(IMP
qt)
x
1.201
..
US
Quarts
(US
qt) x .833
:::
IMP
qt
Imperial
Gallons
(IMP
gal) x 1.201
..
US
Gallons
(US
gal) x .833
..
IMP
gal
Fluid
Ounces
x
29.573
;;;
Milliliters
x
.034
::
Ounces
US
Pints
(US
pt)
x
.473::
Litcrs(l) x 2.113:::
Pints
US
Quarts
(US
qt) x .946:::
Liters
(L)
x
1.057 = Quarts
US
Gallons
(US
gal) x 3.785 = Liters
(L)
x
.264
;"
Gallons
MASS-WEIGHT
Ounces
(02)
)(
28.35
:::
Grams
(g)
x .035,.
Ounces
Pounds
(lb)
x
.454
'"
Kilograms
(kg) x 2.205
=
Pounds
PRESSURE
Pounds
Per
Sq
In
(psi)
x
6.895
=
Kilopascals
(kPa)
x
.145:::
psi
Inch.es
of
Mercury
(Hg)
x
.4912
..
psi x 2.036 = Hg
Inches
of
Mercury
(Hg) x 3.377 = Kllopascals
(kPa) x .2961 = Hg
Inches
of
Water
(H20)
x
.07355
=
Inches
of
Mercury
x
13.783
=
H20
Inches
of
Water
(H20)
x
.03613 = psi
x
27.684
=
HaD
Inches
of
Water
(H20)
x
.248
=
Kilopascals
(kPa)
x
4.026
:::
H20
TORQUE
Pounds-Force
Inches
(in-Ib) x .113
'"
Newton
Meters
(Nm) x 8.85
=in-Ib
Pounds-Force
Feet
(ft-Ib) x 1.356 = Newton
Meters
(Nm) x .738
'"
ft-Ib
VELOCITY
Miles
Per
Hour
(MPH) x 1.609
==
Kilometers
Per
Hour
(KPH) x .621
==
MPH
POWER
Horsepower
(Hp)
x
.745
=
Kilowatts
(Kw) x 1.34 = MPH
FUEL
CONSUMPTION
Miles
Per
Hour
IMP
(MPG)
x
.354 = Kilometers
Per
Liter
(Km/L)
Kilometers
Per
Liter
(Km/L) x 2.352
::
IMP
MPG
Miles
Per
Gallons
US
(MPG)
x
.425
==
Kilometers
Per
Liter
(Km/L)
Kilometers
Per
Liter
(Km/L)
x 2.352 =
US
MPG
TEMPERATURE
.
Degree
Fahrenheit
(OF) = (OC
X
1.8) + 32
Degree
Celsius
(GG)
,;,
(OF·
32) x .56
LIQUID
WEIGHTS
O1esel
Oil
:: 1 US
gallon = 7.13
Ibs
'Fresh
Water:: 1 US
galion
= a.33
Ibs
Gasoline,;, 1 US
gallon
==
6.1
Ibs
Salt
Water
==
1
US
gallon::
8.56
Ibs
Engines & Ge(lerators
80
Page 82
STANDARD
HARDWARE
BOLT
HEAD
MARKINGS
Bolt
strength
classes
are
embossed
on
the
head
of
each
bolt.
Metric
bolt
class
numbers
identify
bolts
by
their
strength
with
10.9
the
strongest.
NOTES:
1.
Use
the
torque
values
listed
below
when
specific
torque
values
are
not
available.
2.
These
torques
are
based
on
clean,
dry
threads.
Reduce
torque
by
10%
when
engine
oil
is
used.
3.
Reduce
torques
by
30%
or
more,
when
threading
capscrews
into
aluminum.
STANDARD
BOLT & NUT
TORQUE
SPECIFICATIONS
METRIC
BOLT & NUT
TORQUE
SPECIFICATIONS
SAE
Grade
5
SAE
Grade
6·7
SAE
Grade
8
Capsrew
Body
Size
Torque
Torque
Torque
Boll
Grade
4.6
Grade
4.8
Grade
8.8 -9.8
Grade
10.9
(inches) • (Thread)
FI·Lb(Nm)
FI-Lb
(Nm)
FI-Lb(Nm)
Dia.
Wrench
Size
FI-Lb
(Nm)
Ft·Lb
(Nm)
FI·Lb
(Nm)
FI·Lb
(Nm)
1/4
-
20
8
(11)
10
(14)
12
(16)
-2B
10
(14)
14
(19)
;.~
M3
5.5mm
0.3
(0.5)
0.5
(0.7)
1
(1.3)
1.5
(2)
5/16
-lB
17
(23)
19
(26)
24
(33)
-24
19
(26)
27
(37)
M4
7mm
0.8
(1.1)
1
(1.5)
2
(3)
3
(4.5)
M5
Bmm
1.5
(2.5
2
(3)
4.5
(6)
6.5
(9)
318
-16
31
(42)
34
(46)
44
(60)
-24
35
(47)
49
(66)
MB
10mm
3
(4)
4
(5.5)
7.5
(10)
11
(15)
M9
13mm
7
(9.5)
10
(13)
lB
(25)
35
(26)
7/16
-14
49
(66)
55
(75)
70
(95)
Ml0
16mm
14
(19)
18
(25)
37
(50)
55
(75)
-
20
55
(75)
7B
(106)
1/2
-13
75(102)
85
(115)
105
(142)
-
20
B5
(115)
120
(163)
M12
18mm
26
(35)
33
(45)
63
(85)
97
(130)
M14
21
mm
37
(50)
55
(75)
103
(140)
151
(205)
M16
24mm
59
(BO)
85
(115)
159
(215)
232
(315)
9/16
-12
110
(149)
120
(163)
155
(210)
-lB
120
(163)
170
(231)
M18
27mm
81
(110)
118
(160)
225
(305)
321
(435)
5/8-11
150
(203)
167
(226)
210
(285)
M20
30mm
l1B
(160)
166
(225)
321
(435)
457
(620)
-18
170
(231)
240
(325)
M22
33mm
159
(215)
225
(305)
435
(590)
620
(840)
314
-10
270
(366)
280
(380)
375
(50B)
-16
295
(400)
42(f(569)
M24
36mm
203
(275)
288
(390)
553
(750)
789
(1070)
7/8
- 9
395
(536)
440
(597)
605
(820)
-14
435
(590)
675
(915)
M27
41
mm
295
(400)
417
(565)
811
(1100)
1154
(1565)
M30
46mm
402
(545)
568
(770)
1103
(1495)
1571
(2130)
1- B
590
(800)
660
(895)
910
(1234)
-14
660
(895)
990
(1342)
M33
51
mm
546
(740)
774
(1050)
1500
(2035)
2139
(2900)
M36
55mm
700
(950)
992
(1345)
1925
(2610)
2744
(3720)
SEALANTS
&
LUBRICANTS
GASKETS/SEALANTS
Oil
based
PERMATEX
#2
and
it's
HIGH
TACK
equivalent
are
excellent
all
purpose
sealers.
They
are
effective
in
just
about
any
joint
in
contact
with
coolant,
raw
water,
oil
or
fuel.
A
light
coating
of
OIL
or
L1aUID
TEFLON
can
be
used
on
rubber
gaskets
and
O-rings.
LOCTITE
hydraulic
red
sealant
should
be
used
on
oil
adapter
hoses
and
the
oil
filter
assembly.
Coat
both
surfaces
of
the
oil
pan
gasket
with
high
temp
RED
SILICONE
sealer.
When
installing
gaskets
that
seal
around
water
(coolant)
passages,
coat
both
sides
with
WHITE
SILICONE
grease
..
High·copper
ADHESIVE
SPRAYS
are
useful
for
holding
gaskets
in
position
dur-
ing
assembly.
Specialized
gasket
sealers
such
as
HYLOMAR
work
well
in
applications
requir-
ing
non-hardening
properties.
HYLOMAR
is
particlarly
effective
on
copper
cylinder-head
gaskets
as
it
resists
fuel,
oil
and
water.
Use
L1aUID
TEFLON
for
sealing
pipe
plugs
and
fillings
that
connect
coolant
passages.
Do
not
use
tape
sealants!
BOLTS & FASTENERS/ASSEMBLIES
Lightly
oil
head
bolts
and
other
fasteners
as
you
assemble
them.
Bolts
and
plugs
that
penetrate
the
water
jacket
should
be
sealed
with
PERMATEX
#2
or
HIGH
TACK.
When
assembling
the
flywheel,
coat
the
bolt
threads
with
LOCTITE
blue.
Anti-seize
compounds
and
thread
locking
adhesives
such
as
LOCTITE
protect
threaded
components
yet
allows
them
to
came
apart
when
necessary.
LOCTITE
offers
levels
of
locking
according
to
the
job.
LITHIUM
based
grease
is
waterproof,
ideal
for
water
pump
bearings
and
stuff-
ing
boxes.
Heavily
oil
all
sliding
and
reciprocating
components
when
assembling.
Always
use
clean
engine
oil!
'",..,/WESTERBEKE
I
~ngines
& Generators
81
Page 83
METRIC
CONVERSIONS
INCHES TO MILLIMETERS
MILLIMETERS TO INCHES
Inches
mm
Inches
mm
mm
Inches
mm
I
Inches
1
25.40
15
381.00 1
0.0394
15
0.5906
2
50.80
20
508.00
2
0.0787
20 0.7874
3
76.20
25
635.00
3
0.1181 25 0.9843
4 101.60
30
762.00
4 0.1575 30 1.1811
5
127.00
35
889.00
5
0.1969
35 1.3780
10
254.00
40
1016.00
10
0.3937 40 1.5748
-~
10
MILLIMETERS
= 1
CENTIMETER,
100
CENTIMETERS
= 1
METER",
39.37
INCHES
(~.3
FEET)
INCHES TO METERS
METERS
TO INCHES
Inches
Meters
Inches
Meters
Meters
Inches
Meters
Inches
1
0.0254
7 0.1778
0.1
3.937 0.7 27.559
2
0.0508
8 0.2032 0.2
7.874 0.8 31.496
3
0.0762 9 0.2286 0.3
11.811 0.9 35.433
4
0.1016 10
0.2540
0.4
15.748
1.0
39.370
5
0.1270
11
0.2794 0.5 19.685
1.1
43.307
6 0.1524 12 0.3048 0.6 23.622
1.2 47.244
TO
CONVERT
METERS
TO
CENTIMETERS,
MOVE
DECIMAL
POINT
TWO
PLACES
TO
THE
RIGHT
YARDS TO METERS
METERS
TO
YARDS
Yards
Meters
I
Yards
Meters
Meters
Yards
Meters
Yards
1 0.91440
6
5.48640 1 1.09361
6
6.56168
2
1.82880
7
6.40080 2 2.18723 7 7.65529
3 2.74320
8
7.31520
3
3.28084
8 8.74891
4
3.65760
9
8.22960
4
4.37445
9
9.84252
-~
4.57200
10
9.14400
5
5.46807 10 10.93614
MOVE
DECIMAL
POINT
FOR
HIGHER
VALUES
e.g.
6,000
METERS = 6,561.68
YARDS
POUNDS TO KILOGRAMS KILOGRAMS TO POUNDS
Ib kg Ib
kg kg Ib
kg
Ib
1
0.454
6
2.722 1
2.205
6
13.228
2
0.907 7
3.175 2
4.409 7
15.432
3 1.361
8
3.629 3 6.614
8 17.637
4 1.814
9
4.082 4 8.818
9 19.842
5 2.268
10
4.536
5
11.023
10
22.046
GALLONS
TO LITERS
LITERS
TO
GALLONS
Gallons
Liters
Gallons
Lit
Gallons
Liters
Gallons
1 3.79
10
37.86 1 0.26
60
15.66
2 7.57
20
75.71 2 0.53
90
23.77
3
11.36
30 113.57
5
1.32 120 31.32
4
15.14
40 151.42 10 2.64
150
39.62
5
18.93
50 189.28 20 5.28
180
47.54
PINTS TO LITERS
LITERS TO PINTS
Pints
Liters
Pints
Liters Liters
Pints
Liters
Pints
1
0.47 6
2.84
1
2.11
6
12.68
2 0.95 7
3.31
2 4.23
7 14.79
3
1.42
8
3.79
3
6.34
8
16.91
4 1.89 9 4.26 4 8.45
9
19.02
5 2.37
10
4.73
5
10.57 10 21.13
TEMPERATURE
32
40
50
60
70 75
85
95
105
140 175
212
OF
I I I I I
I
I
I
I I I I
I I I I I I
I
I I I
I I
0 5 10
15
20
25
30
35
40
60
80 100
ac
Engines & Generators
82
Page 84
INDEX
Alternators .
.............................
52
Removing Injectors
......................
37
Disassembly
...........................
55
Spray Pattern
..........................
37
Exploded View
.........................
58
Testing Engine Compression
...............
39
Troubleshooting
........................
52
Testing Oil Pressure
.....................
39
Assembly Instructions
.......................
7
Valve Clearance
........................
38
Assembly Procedures
.......................
6
Engine Troubleshooting
.....................
3
Decimal to Metric Chart
....................
79
Engine Tuning Operation
....................
7
Disassembly Procedures
.....................
5
Gasket Information
.........................
6
Disassembly / Assembly
.....................
8
Generator Information
....................
68
Balancer Shaft
.........................
14
Assembly to Engine .
.....................
76
Bearing Case Cover
.....................
17
BE
Troubleshooting .
.....................
78
Camshaft
..............................
14
Changing Hertz
and
Voltage .
..............
73
Crank Gear .
...........................
15
Disassembly
...........................
77
Crankshaft
............................
18
Electronic Regulation
....................
69
Crankshaft
Oil
Slinger
..................
.13
Exciter
Rotor
Troubleshooting
..............
71
Cylinder Head
..........................
9
Internal Wiring Diagram .
.................
70
Cylinder Head Cover
.....................
8
Internal Wiring Schematics .
...............
74
Drive Pulley
...........................
12
Maintenance
...........................
68
Flywheel .
.............................
17
Mecc Alta Generator .
....................
76
Gear Case
............................
.13
Parts Breakdown .
.......................
77
Governor Springs/Control Panel
............
11
Testing the Diodes .
......................
71
Idler Gear
.............................
13
Twelve Lead Winding
Injection Pipes
..........................
8
Terminal Board Connections .
..............
72
Injection Pump
.........................
10 Hardware Torques
.........................
81
Main Bearing Case Assembly
..............
19 Metric Conversion Data
....................
80
Nozzle Heat Seal
.........................
9
Raw Water Pump
........................
.45
Nozzle Holder/Glow Plug
..................
8
Sealants and Lubricants
.....................
81
Oil Pan/Strainer .
.......................
15
Serial Number Location
.....................
1
Oil Pump
.............................
14 Service Data/Standards and Limits
............
61
Piston Rings/Connecting Rods
.............
16 Servicing
...............................
21
Pistons
...............................
15
Aligning the Camshaft
....................
26
Rocker Arm/Push
Rod
.....................
9 Aligning Crankshaft
.....................
29
Tappets .
..............................
10
Aligning/Push
Rod
.....................
.24
Thermostat Assembly
....................
20
Balancer Shaft Oil Clearance
..............
25
Valves .
...............................
10
Balancer Shaft Side Clearance
.............
25
Water Pump Assembly
....................
20
Cam Height .
...........................
27
Engine Adjustments
......................
36
Camshaft Alignment
.....................
26
Air
Intake Silencer
.....................
.40
Camshaft Oil Clearance
..................
27
Belt Tension
...........................
36
Camshaft Side Clearance
.................
25
Fuel Injectors
..........................
36
Clearance-Valve Stem/Guide
...............
21
Glow Plugs
............................
36
Connecting
Rod
Alignment
................
28
Injector Testing
........................
.37
Crankshaft Side Clearance
................
29
Magnetic Pick-Up Coil
..................
.40
Correcting the Cylinder .
..................
33
Engines & Generators
83
Page 85
INDEX
CrankpinlCrankpin Bearing Oil Clearance
....
30
Crankshaft Alignment
....................
29
Crankshaft Bearing lIReplacing
............
31
Crankshaft Sleeve Wear .
.................
.32
Cylinder Wear .
........................
.33
Idler Gear Bushing
......................
26
Idler Gear Side Clearance
................
25
Oil Clearance/Camshaft Journal
............
27
Oil ClearanceCrankshaft Journal/Crankshaft
Bewing
2
....
.32
Oil ClearanceCrankshaft Journal/Crankshaft Bearing 1
.....
30
Oil Clearance
Idler Gear Bushing/Idler Gear
Shaft
.........
26
Oil Clearance-Rocker Arm/Shaft
............
23
Oil Pump Specifications
..................
33
Piston Pin Bore
J.D. . ....................
27
Piston Ring Clearance
..................
.28
Piston Ring Gap
........................
28
Push
Rod
Alignment
....................
.24
Replacing Crankshaft Bearing 1
............
31
Replacing Crankshaft Sleeve
...............
32
Replacing Small End Bushing
..............
28
Replacing Valve Guide
..................
.21
Rotor Lube Clearance/Oil Pump
............
33
Small
End
Bushing/Oil Clearance
...........
27
Spring Valve
..........................
.23
Timing Gear Backlash
....................
24
Valve Guide
............................
21
Valve Lapping
..........................
23
Valve
Recessing
.........................
21
Valve Seating
..........................
22
Valve Spring
..........................
.23
Special Tools
.............................
59
Specifications
...........................
.43
Spring Valve
.............................
23
Starter
Motor
..........................
.46
Bench Testing .
........................
.48
Exploded View
.........................
51
Service
...............................
47
Troubleshooting
.......................
.46
Testing for Overhaul
........................
2
Tools-Special
............................
59
Torque Specifications
......................
67
Troubleshooting
...........................
3
Wiring Diagram
..........................
34
Wiring Diagram (24 Volt)
...................
34
Engines & Generators
84
Page 86
Page 87
Engines & Generators
#1128-DWIWM-IO/08
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