Westerbeke 71 B-FOUR, 71 C-FOUR, 20.0KW BEDA, 16.0KW BEDA, 20.0KW BED Service Manual

SERVICE

MA

UAL

71

B·FOUR

/71

DIESEL

and

6.0KW·50Hz

DIESEL

TORS

SINGLE

AND

THREE

PHASE

PUBU

CATlON N

O.

43317

2ND

EDITION

I MARCH

2010

CALIFORNIA

PROPOSITION

Diesel engine exhaust and of

its

constituents are known

the State

of

California cancer, birth defects, and other reproductive harm.

A

65

WARNING

to

cause

WARNING

some

to

Exhaust orless unconsciousness exposure

-Dizziness

gasses

gas.

can

contain

Carbon

and

Include:

-Nausea

-Headache

-

WfIlIkness

IF

YOU

SET

OUT seek until

and

OR

ANYONE

INTO

medical

It

has

been

Sleepiness

THE

attention.

Inspected

Carbon

Monoxide

death.

ELSE

EXPERIENCE

FRESH

AIR

Shut

and

Monoxide,

is

poisonous

Symptoms

-

Throbbing

-

Muscular

-

Vomiting

-Inability

IMMEDIATELY. " symptoms down

repaired.

ANY

the

an

and

of

Carbon

in

Twitching

to

Think

OF

unit

and

odorless

can

cause

Monoxide

Temples

Coherently

THESE

SYMPTOMS,

do

not

and

restart

col-

persist,

SAFETY

INSTRUCTIONS

INTRODUCTION

Read

this

safety manual

caused

by

failure

tions.

Know

when

necessary

and

The

precautions

your

machinery.

foUowing

safety

the American Boat and

PREVENT

A

while

power.

•

Do enclosures and covers in place.

• Shut equipment.

• Use insulated mats whenever working on electrical equipment.

• Make sure your clothing and skin are dry, not damp (particularly shoes) when handling electrical equipment.

• Remove wristwatch and all jewelry when working on

electrical equipment.

•

Do

circuits, except through a ship-to-shore double throw transfer switch. Damage to vessel's result

• Electrical shock results from handling a charged capacitor. Discharge capacitor by shorting terminals together.

PREVENT

A

exhaust

very

• Always check the engine coolant level at the coolant recovery tank.

A

•

In

before touching the engine

ELECTRIC

WARNING:

engine

is

Lethal

voltage

not operate this machinery without electrical

off

electrical power before accessing electrical

not connect utility shore power to vessel's

if

this procedure is not followed.

BURNS -HOT

WARNING:

system

hot!

WARNING:

case

of

an engine overheat, allow the engine

carefuUy.

to

foUow

fundamental rules and

dangerous

to

protect yourself, your personnel,

instructions

Yacht

Most

accidents

conditions exist and

are

in

compliance

Council (ABYC)

SHOCK

Do

not

touch

AC

elBCtrlcal

IUnning

Of

when

l

is

present

connected

at

these

AC

ENGINE

Do

not

touch

hot

engine

components. A IUnnlng

Steam

can

cause

injury

or

checking the coolant.

are precautoke

with

standards.

CDIIIIBCIIons

to

shore

connections!

AC

generator may

parts

Of

engine

gets

Of

death!

to

cool

the

PREVENT

A

• Prevent flash fires. sparks to occur near the carburetor, fuel line, filter, fuel pump, vapors. removing the fuel line, carburetor,

•

Do arrester removed. Backfire can cause severe injury or death.

•

Do Backfire can cause severe injury

•

Do fuel system. Keep the compartment and the engine/generator clean and free fire. Wipe up all spilled fuel and engine oil.

• Be aware - diesel fuel will burn.

PREVENT

A

Injury

• Follow re-fueling safety instructions. Keep the vessel's hatches closed when fueling. Open and ventilate cabin

after fueling. Check below for fumes/vapor before ning the blower. Run the blower for four minutes before starting your engine.

• All fuel vapors are highly explosive. Use extreme care when

handling and storing fuels. Store fuel in a well-ventilated area away from spark-producing equipment and out reach

•

Do

• Shut off the fuel service valve at the engine when servicing the fuel system. Take care spill. sources ing. Ensure proper ventilation exists when servicing the fuel system.

•

Do

• Be sure all fuel supplies have a positive shutoff valve.

• Be certain fuel line fittings are adequately tightened and free

• Make sure a fire extinguisher is installed nearby and is properly maintained.

Extinguishers rated for all applications encountered in this environment.

BURNS -FIRE

WARNING:

or

Use a suitable container

not operate with a Coast Guard Approved flame

not operate with the air cleaner/silencer removed.

not smoke

Fire

can

cause

Do

not smoke

other potential sources

or

permit flames

of

debris

to

Injury

Of

death!

or

permit flames or

of

spilled fuel

to

catch all fuel when

or

fuel filters.

or

death.

or

sparks to occur near the

minimize the chances

or

fuel

BURNS -EXPLOSION

WARNING:

Of

death!

of

not fill the fuel tank(s) while the engine is running.

DO

of

not alter

of

leaks.

Explosions

children.

NOT

allow any smoking, open flames,

fire

near the fuel system or engine when servic-

or

modify the fuel system.

ABC

from

fuel

vapors

in

catching any fuel that might

Be

familiar with its proper use.

by

the NFPA are appropriate

can

cause

run-

or

of

the

other

i

SAFETY

INSTRUCTIONS

ACCIDENTAL

A

WARNING:

01

death!

• Disconnect the battery cables before servicing the engine! generator. it last.

• Make certain starting.

• Make certain installed before starting the engine.

BATTERY

A

WARNING:

01

death!

•

Do

not smoke or allow being serviced. Lead acid batteries emit hydrogen, a highly explosive arcing equipment in ing

servicing.

• Never connect tive

(+) connection terminal of

test the battery condition by shorting the terminals together. Ventilate accumulation of explosive gases. disturb the battery charger connections while the battery being charged.

•

Avoid burns wristwatch, rings, and any other jewelry before handling the

battery.

•

Always the

battery connections. Remove the negative lead

and reconnect it last when disconnecting the

BATTERY

A

WARNING:

severe

STARTING

Accidental

Remove the negative lead first and reconnect

all

personnel are clear of the engine before

all

covers, guards,

starting

and

can

cause

hatches

Injury

are

re-

EXPLOSION

Battery

or

by

lit tobacco products. Shut off all electrical

the

Sparks could ignite battery gases or

any

compartment containing batteries

contacting the terminals with tools, etc.,

or

sparks that could cause

turn the battery charger off before disconnecting

gas,

which can

vicinity

negative

explosion

an

open

to

can

cause

flame

near the battery

be

ignited

prevent electrical arcing

(-)

battery cable

the

starter solenoid.

To

avoid sparks,

an

explosion. Remove

Injury

by

electrical

to

the posi-

fuel

to

battery.

to

ACID

Injury

Sulfuric

01

death!

acid

In

battelles

can

cause

dur-

Do

not

vapors.

prevent

do

not

prevent

first

is

TOXIC

• Ensure that the exhaust system is adequate

• Be sure the unit and its surroundings

• In addition to routine inspection of the exhaust

• For additional information refer to

•

• Although diesel engine exhaust gases are not

EXHAUST

A

WARNING:

discharged from the engine. Check the exhaust system regularly for leaks and make are

securely attached and no warping exists. attention exhaust pipe

install a carbon monoxide detector. Consult your boat builder or dealer for installation

tional information

A

odorless

nausea

Do fumes tems. tubing resulting in exhaust/water leakage.

Do through portholes, vents, or exhaust discharge outlet enter the exhaust discharge outlet and flow

exhaust fumes gas toms or signs of carbon monoxide inhalation are:

Vomiting Dizziness Throbbing in temples Muscular twitching Intense headache Weakness

to

WARNING:

gas.

01

death!

not use copper tubing in diesel exhaust

can

Exhaust sulfur causes rapid deterioration of copper

not install exhaust outlet where exhaust can

of exhaust.

is

present in diesel exhaust fumes. Some of the

GASES

carbon

the manifold, water injection

nipple.

Inhalation

rapidly

from

and sleepiness

monoxide

on

Carbon Monoxide).

ca,

bon

monoxide

ploduces

destroy

Avoid

copper

is

overloading the craft.

gasoline engines, carbon monoxide

(CO)

sure

the exhaust manifolds

of

approved detectors.

ABYC

(CO)

Du-lIke

tubing

air conditioners.

near the waterline, water could

Is a deadly

to

expel

Pay

elbow,

are

well ventilated.

T-22

Is

an

Inlllsible

symptoms,

systems.

in exhaust

If

close

or

restrict the

as

or

gas!

gases

close

and

system,

(educa-

Diesel

sys-

be

drawn

the engine

toxic

as

symp-

poisoning

•

When

servicing the battery or checking the electrolyte level, wear rubber gloves, a rubber apron, and eye protection.

Batteries contain sulfuric acid which is destructive. it comes in contact with your with

water.

Acid may splash

inadvertently

when

removing electrolyte

skin,

wash

on

the skin or into

it off at caps.

If

once

the

eyes

Engines & Generators

ii

AVOID

• Do not service the engine while it

MOVING

A

WARNING:

01

death!

arises in which it ing adjustments, use extreme care ing parts and hot exhaust system components.

PARTS

Rotating

parts

can

cause

is

running.

is

absolutely necessary to make operat-

to

avoid touching mov-

Injury

If

a situation

SAFETY

•

Do

not wear loose clothing equipment; avoid wearing loose jackets, shirts, sleeves, rings, necklaces or bracelets that could

moving parts.

• Make sure all attaching hardware is properly tightened.

Keep protective shields and guards

places

at

all times.

•

Do

not check fluid levels

the engine is operating.

• Stay clear when the engine is running; hair and clothing can easily be caught in these rotating parts.

HAZARDOUS

A

of

the drive shaft and the transmission coupling

NOISE

WARNING:

High

loss!

• Never operate an engine without its muffler installed.

•

Do

not run an engine with the air intake (silencer)

removed.

•

Do

not run engines for long periods with their enclosures

open.

A

WARNING:

mentally

or

Do

not

physically

or

jewelry when servicing

be

in

their respective

or

the drive belt's tension while

noise

legis

can

cause

wotk

on

machinery

Incapacitated

by

fatigue!

caught in

hearing

when

you

INSTRUCTIONS

ABYC, INSTALLING

Read the following ABYC, NFPA and for safety codes and standards. Follow their recommendations when installing your UNIVERSAL engine

ABYC "Safety Standards for Small Craft"

Order ABYC

15 East 26th Street

New York, NFPA

"Fire Protection Standard for Motor Craft" Order From:

NFPA

1 Batterymarch Park P.O. Quincy,

USCG "USCG 33CFR183"

Order From:

U.S.

Washington, D.C. 20404

alB

NFPA

AND

DIESEL

(American Boat and Yacht Council)

From:

NY

10010

(National Fire Protection Association)

Box 9101

MA

02269-9101

(United States Coast Guard)

Government

Printing

USCG

PUBLICATIONS

ENGINES

Office

USCG

FOR

publications

OPERATORS

Many

of

in

your Operators Manual along with other cautions and

notes

to carefully, maintain your equipment, and follow procedures.

ENGINE

Preparations to install an engine should begin with a thorough examination (ABYC) standards. These standards are a combination sources including the

Sections

B-2 P-l P-4 Inboard engines E-9

All installations must comply with the Federal Code Regulations (FCR).

MANUAL

the preceding safety tips and warnings are repeated

highlight critical information. Read your manual

all safety

INSTALLATIONS

of

the American Boat and Yacht Council's

of

USCG

and the NFPA.

of

the ABYC standards

Ventilation

Exhaust systems

DC

Electrical systems

of

particular interest are:

of

iii

INSTALLATION

When installing WESTERBEKE engines and generators it is important that strict attention be paid to the following information:

CODES

Strict federal regulations, ABYC guidelines, and safety codes must be complied with when installing engines and generators

AND

REGULATIONS

in a marine environment.

SIPHON-BREAK

For installations where the exhaust manifold/water injected exhaust elbow is below the vessel's waterline, provisions must be made to install a siphon-break in the raw

of

water supply hose to the exhaust elbow. This hose must be looped a minimum above the vessel's waterline. Failure to use a siphon-break when the exhaust

manifold injection damage to the engine

EXHAUST

The exhaust hose must be certified for marine use. The system must be designed to prevent water from entering the exhaust under any sea conditions and at any angle of

the vessels hull.

'A

detailed

engines

port

and

SYSTEM

40

page

and

generators,

is

at

or below the load waterline will result in raw water

possible flooding

Marine

Installation

is

available

Engines & Generators

of

Manual

from

the boat.

covering

your

WESTERBEKE

gasoline

dealer.

and

18"

diesel,

Introduction Testing Engine Engine Engine Engine Exhaust Heat

Exchanger

Fuel

Injection

Fuel

Lift

Fuel

Injectors .................................................. -..........

Glow

Plugs ................................................................

Engine Coolant Lubricating Oil

Pressure

Oil

Pressure

Raw

Water Starter Tachometer

Alternator

...............................................................

for

Overhaul Troubleshooting Disassembly Inspection

Reassembly

Manifold

.....

..............................................

.............................................

...............

.....................................

....................................................

...................................................

.....................................................

........................................................

Pump

.................................................

Pump

.........................................................

Adjustments

Circulating

Oil

Switch

..................................................

Pump

........................................

Pump

...............................................

..................................................

..............................................................

Pump

......................................................

Motor

...........................................................

..............................................................

Testing

....................................................

TABLE

OF

. 2

3

.4

8

.

13

23

. 29 . 29

30

.

31

32

34

35

37

.38

39 39

.40 .41

. 45

.46

CONTENTS

DC

Wiring

DC

Wiring

Generator

BE

Generator Generator Voltage Internal BE

Troubleshooting

Electronic Electronic Shore DC

Wiring

DC

Wiring Generator Service

Torque Engine Standard Metric

Index

Diagram Schematic Information

............................................................

AC

Voltage

Regulator

Wiring

Schematics

Governor Governor

Power

Transfer Diagram Schematic Specifications

Data/Tolerances

Specifications Specifications

Hardware

Conversions

..........................................................................

(engine)

....................................

(engine)

................................

..............................................

Connections .........................

Adjustments

...................................................

..............................

......................................

.................................................

Troubleshooting

Switch

...................................

(generator)

......................

................................

............................

.........................................

&

Limits

............................

...............................................

Torques

.....................................

..................................................

.48 .49

50

.

51 52

. 54

55 56

.

57

58

59

60

61

. 62

64 68 69

70

71

72

Engines & Generators

1

INTRODUCTION

PRODUCT

Product software (tech data, parts lists, manuals, brochures and catalogs) provided from sources other than WESTERBEKE are not within

WESTERBEKE CANNOT CONTENT

WARRANTIES OR REPRESENTATIONS

THERETO, COMPlETENESS BE

UABLE FOR INCURRED OF

THE FURNISHING OR USE OF SUCH SOFTWARE.

WESTERBEKE customers should also keep in mind the time span between printings software and the unavoidable existence WESTERBEKE manuals. Product software provided with WESTERBEKE products, whether from WESTERBEKE

or other suppliers, must not and cannot be relied upon exclusively as the definitive authority product. It not only makes good sense but is imperative that appropriate representatives

supplier in question be consulted to determine the accuracy

and currentness

the customer.

NOTES,

As this manual takes you through the disassembly, inspection

and assembly procedure

information will be highlighted by

and WARNINGS. An explanation follows:

NOTE:

SOFTWARE

WESTERBEKE'S control.

BE

RESPONSIBLE FOR THE

OF SUCH SOFTWARE, MAKES NO

WITH RESPECT

INCLUDING ACCURACY, TIMELINESS OR

THEREOF AND WILL IN NO EVENT

ANY

TYPE OF DAMAGE

IN CONNECTION WITH

of

WESTERBEKE product

ofWESTERBEKE

of

the product software being consulted by

CAUTIONS

An operating procedure essential

AND

WARNINGS

of

your engine/generator, critical

NOTES, CAUTIONS,

OR

ARISING OUT

of

earlier

on

the respective

to

note.

INJURY

or

the

CUSTOMER

IDENTIFICATION

/..-v-IWES

CARD

I

ERBEKE

I .

Customer Identification WESTERBEKE

MAIN

STREET

HOMETOWN, Model71C

Expires 4/4/98

The

WESTERBEKE serial number is an alphanumeric number that can assist in determining the date manufacture first character indicates the decade (A=1960s, B=1970s, C=1980s, in the decade, and the fourth and fifth number represents the month

SERIAL

The engine and generator serial numbers and model numbers

are located on a decal

The engine serial number can also

engine block serial number is stamped into the generator housing flat surface on the left side

An

the engine model and serial number.

0=1990s), the second character represents the year

of

manufacture.

NUMBER

identification plate on the engine manifold also displays

OWNER

USA

Ser. #UOOOO-D702

of

your WESTERBEKE engine/generator. The

LOCATION

on

the generator housing.

be

found stamped into the

just

above the injection pump. The generator

on

of

the generator

..

the

A

CAUTION:

obselVt1d, your

engine/generator.

A

WARNING:

followed,

ORDERING

Whenever replacement parts are needed, always provide the generator model number, engine serial number, and generator serial number as they appear name-plate located on the generator end. You must provide us with this information so your engine/generator. description and part number for each part needed (see the separately furnished WESTERBEKE packaged parts because parts are frequently not made to the same specifications as original equipment.

Procedures,

can

result

Procedures,

can

result

PARTS

which

if

not

strictly

in

the

damage

in

personal

on

we

In

addition, include a complete part

Parts List). Also insist upon

or

destruct/on

whIch

if

not

properly

injury

or

loss

of

the silver and black

may properly identify

will

fit

or

of

life.

generic

GENERATOR 10

DECAL

ENGINE SERIAL NUMBER

The following sections contain detailed information relating to the proper operation characteristics components and systems disassembly, inspection and reassembly instructions for the

guidance service and rebuilding facilities. The necessary procedures should be undertaken only by such facilities.

Additional detailed information and specifications are provided in other sections

generator, alternator, starter motor, engine adjustments,

cooling pumps, etc.

of

suitable equipped and staffed marine engine

of

the engine. Included are

of

this manual, covering the

of

the major

Engines & Generators

2

TESTING

FOR

OVERHAUL

HOW

TO

DETERMINE

Cause

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 with the engine itself, but is sometimes caused by injector nozzle wear judge by a decrease in compression pressure. The decrease in compression pressure is caused by many factors. therefore, necessary to determine a cause or causes on the basis maintenance. Oil analysis on a seasonal basis is a good means by worn cylinders will occur:

These symptoms often appear together. Symptoms (2) and

(4) can result also from excessive fuel injection, improper

injection timing, and wear 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 plus increased oil consumption. In diesel engines,

satisfactory combustion is obtained only under sufficient compression pressure.

pressure, incomplete combustion

if determine the period

measure the engine compression pressure regularly.

same time, the engine speed at which the measurement compression pressure is made should be checked because the compression pressure varies with engine rpm. The engine rpm

NOTE:

ENGINE ADJUSTMENT section

blowby evident, and compression valves are at minimum or

of

Low

Compression

of

diesel engines, is not necessarily due to trouble

or

injection pump wear. It is most reasonable to

of

data produced by periodic inspection and

of

monitoring engine internal wear. When caused

1 Low engine power

2 Increased fuel consumption

3 Increased oil consumption

4

Hard

5 Noisy engine operation

other parts

can be measured at the front end

OVERHAUL

Compression pressure tends to increase a little engine until piston rings and valve seats have been broken in. Thereafter, it decreases gradually with the progress of

these parts.

When decrease limit, the engine must be overhauled.

The engine requires overhaul when oil consumption is high,

below.

427

psi

of

the engine are operating properly.

To

test engine compression see the

CONDITIONS

of

Engine compression should be

at

200 rpm.

ENGINE

or

piston rings, the following symptoms

engine

of

If

an engine lacks compression

of

engine overhaul, it is important to

compressiOll pressure reaches the repair

OVERHAUL

output

starting

plugs and nozzles. They are

by

worn cylinders and pistons

of

fuel will take place even

of

this manual.

30

PERIOD

To

the crankshaft.

in

a new

kg/cm2,

It

At

of

is,

the

of

wear

Precautions

When servicing an engine, keep precautions.

for

Disassembly

and

Reassembly

in

mind the following

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.

or

4. Do not remove disassembly.

5. Perform disassembly

Keep disassembled parts

sary. Take special care to keep the fuel system parts from

intrusion

of

disassemble the parts that require no

in

a proper order using proper tools.

in

order. Apply oil when neces-

dust and dirt.

Reassembly

1. Clean or wash the parts. Apply oil on surfaces where

needed

2. Carefully check gaskets, packings and oil seals even

3. Be sure to install components

4. After completion

ENGINE

The following ENGINE TROUBLESHOOTING section may be engine overhaul.

SERVICE

The engine block predecessor, the 71B-FOUR, with variations in service data

(tolerances, limits and torques). In this service manual or 71 C designates this service data and a small will identify the artwork. Components that are common to both engines such as the Raw Water Pump will have no designation.

The 71B-FOUR engine powers the The 7lC-FOUR engine powers the

NOTE:

identified, see

or

specified.

if

checking is not specified. Replace with new ones

if

defective.

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.

of

reassembly, recheck for any abnormalities. the engine sufficiently for a test run.

Prepare for starting the engine, and idle

TROUBLESHOOTING

of

assistance in determining the need for planning and

MANUAL

of

the

7lC-FOUR

Make certain the engine model has been correctly

SERIAL NUMBER LOCATION.

differs from it's

71 B

718

or

71C

20.0KW BED generator.

20.0KW BEDA generator.

Engines & Generators

3

The

following

troubleshooting table describes certain problems relating these problems, these problems.

to

engine service,

and

the

recommendations

ENGINE

the

probable causes of

to

overcome

TROUBLESHOOTING

Note:

The

engine s electrical system

ampere

mounted

manual

on

the

reset same

circuit

bracket.

breaker.

is

protected

The

preheat solenoid

by a 20-

is

PROBLEM

HARD

STARTING

LOW

CRANKING

1.

Engine

oil

2.

Run-down

3.

Worn

battery.

4.

Battery

terminals

5.

Defective

6.Defective

DEFECTIVE

1.

Air

2.

Clogged

3.

Low

4.

Inadequate

5.

Injection

6.

Injection

MAIN

1.

Low

2.

Burnt

3.

Faulty

4.

Incorrect

5.

Governor

starter.

main

INJECTION

trapped

fuel

injection

pump too

ENGINE

compression.

a.

Incorrect

b.

Inadequate

c.

Valve

d.

Broken

e.

Compression

f.

Piston

g.

Worn

glow

governor

PROBABLE SPEED

viscosity

stem

spring

too

battery.

loosely

drive

section.

SYSTEM

in

fuel

passage.

filter.

pressure.

spray.

delivering

early.

TROUBLES

valve

clearance. contact seized.

valve

spring.

leaks

ring

seized.

piston

ring

plug.

plug

operation.

lever

out

fo

CAUSE

high.

connected.

insufficient

of

valve

seat.

through

and

cylinder.

position.

POSITION

fuel.

cylinder

head

gasket.

1.

Replace

2.

Recharge

3.

Replace

4.

Clean

5.

Repair

6.

Check

1.

Bleed

2.

Clean

3.

Adjust

4.

Clean

5.

Repair

6.

Adjust

a. b.

c. d. e.

f.

g.

2.

Replace

3.

Correct

4.

Set

5.

Correct

VERIFICATION/REMEDY

engine

oil

with

less

viscous

battery.

terminals

clutch

air

or

injection

or

injection

Adjust

Lap Replace Replace Replace Replace Overhaul

lever

or

replace

from

replace

or

replace

valve

valve.

glow

lead

wire

to

starting

spring

and

correct

starter.

for

disengagement.

fuel

system.

filter.

pressure.

nozzle.

injection

pump.

timing.

clearance.

valve

and

valve

spring.

gasket.

piston

and

piston engine. plug.

connection.

position.

cables.

guide.

oil.

ring.

LOW

OUTPUT

LOW

COMPRESSION

INJECTION

1.

2.

3.

INSUFFICIENT

1.

2.

3.

INSUFFICIENT

1.

SYSTEM

Incorrect Insufficient Low

injection

Air

trapped

Clogged

filter.

Contaminated

Clogged

air

injection

injection.

pressure.

FUEL

in

fuel

INTAKE

cleaner.

OUT

OF

timing.

system.

tank.

AIR

ADJUSTMENT

Engines & Generators

4

See

1.

2.

3.

1.

2.

3.

1.

HARD

Adjust Repair Check

Check Clean

or

Clean

tank.

Clean

or

STARTING

injection

timing.

or

replace

injection

and

nozzle

retighten

replace

filter.

air

pump.

and

adjust

connector.

cleaner.

pressure.

(continued)

ENGINE

TROUBLESHOOTING

PROBLEM

LOW

OUTPUT

EXCESSIVE CONSUMPTION

(cDnt.)

OIL

OVERHEATING

1.

Low

coolant

2.

Loose

V-belt.

3.

Incorrect

4.

Low

OIL

1.

Defective

2.

Broken

3.

Loose

4.

Loose

5.

Loose

6.

Broken

7.

Loose

OIL

1.

Incorrectly

2.

Displaced

3.

Worn

4.

Worn

OIL

.

1.

Defective

2.

Worn

injection

engine

LEAKAGE

oil

gear gear drain oil

pipe

rocker

LEVEL

RISING

or piston piston

LEVEL

FALLING

stem

valve

PROBABLE

level.

timing.

oil

level.

seals. case

gasket.

case

attaching

plug.

connector. cover

gasket.

cover

attaching

positioned

twisted ring. or

and

piston

connecting

cylinder.

seal.

valve

guide.

CAUSE

bolts.

ring

rod.

gaps.

VERIFICATION/REMEDY

1.

Add

coolant.

2.

Adjust

or

3.

Adjust injection

6.

Add

engine

1.

Replace

oil

2.

Replace

gasket.

3.

Retighten

4.

Retighten

5.

Retighten

6.

Replace

gasket.

7.

Retighten

1.

Correct

ring

2.

Replace

connecting

3.

Replace

ring.

4.

Replace

piston

1.

Replace

stem

4.

Replace a valve

replace

V-belt.

timing.

oil.

seals.

bolts. plug. oil

connections.

attaching

gap

positions.

and

seal.

and

bolts.

rod.

rebore

valve

cylinder.

guide.

EXCESSIVE CONSUMPTION

SMOKY

FUEL

EXHAUST

ENGINE

1.

2.

3.

4.

5.

6.

INSUFFICIENT

1.

NOZZLE

1.

2.

IMPROPER

WHITISH

1.

2.

Noisy Smoky Moving Poor Improper Improper

Air

intake

Seized Worn

FUEL

LEAKS

Excessive Excessive

a.

Poor

b.

Seized

c.

Excessive

BODY

TROUBLES

knocking.

exhaust.

parts

compression.

valve valve

INTAKE

obstructed.

TROUBLES

nozzle.

FUEL

OR

PURPLISH

engine rise

piston

nearly

seized

or

excessively

timing. clearance.

AIR

oil.

of

oil

into

combustion

contact.

ring

..

piston-to-cylinder

worn.

chamber.

clearance.

1.

See

2.

See

SMOKY

3.

Repair

4.

See

5.

Adjust.

6.

Adjust.

1.

Remove

1.

Replace.

2.

Replace.

Replace

Find

fuel

1.

Correct

a. b.

c.

KNOCKING.

EXHAUST.

or

replace.

LOW

COMPRESSION;

obstruction.

with

proper

leaks.

oil

level.

Check.

Replace

or

clean.

Replace

or

correct.

fuel.

HARD

STARTING.

(continued)

Engines & Generators

5

ENGINE

TROUBLESHOOTING

PROBLEM

SMOKY

EXHAUST

ABNORMAL OR

NOISE

(cont.)

SOUND

WHITISH

3.

4.

BLACKISH

1.

2.

3.

CRANKSHAFT

1.

2.

3.

CONNECTING

1.

2.

3.

OR

d.

Worn

valve

e.

Low

engine

f.

Excessive Injection Insufficient

Engine

Insufficient Improper

Badly Badly Melted

Worn Worn Bent

OR

body

a.

Poor

b.

Improper

worn worn

bearing.

connecting crankpin.

connecting

timing

compression.

fuel.

PURPLISH

compression.

DARK

troubles.

intake

AND

bearing. crankshaft.

ROD

PROBABLE

stem

oil

is

valve

CAUSE

(cont.)

and

viscosity.

pressure.

too

late.

GRAYISH

clearance.

air

(air

cleaner

MAIN

BEARING

AND

CONNECTING

rod

big

end

rod.

valve

bearing.

guide.

clogged).

ROD

BEARING

d. e.

f.

3.

Adjust.

4.

See

a. b.

2.

Clean

3.

Replace

1.

Replace

2.

Grind

3.

Replace

1.

Replace

2.

Grind

3.

Correct

VERIFICATION/REMEDY

Replace. Replace. Correct.

LOW

COMPRESSION;

See

LOW

COMPRESSION;

Adjust.

air

cleaner.

with

proper

bearing

and

crankshaft.

bearing

and

bearing.

crankshaft.

bend

or

replace.

fuel.

grind

check

HARD

crankshaft.

lubrication

STARTING.

HARD

STARTING.

system.

ROUGH

OPERATION

PISTON,

1.

2.

3.

4.

VALVE

1.

2.

3.

4.

INJECTION

1.

2.

3.

4.

GOVERNING

1.

2.

PISTON

Worn

cylinder.

Worn

piston

Piston

seized.

Piston

seized

MECHANISM

Worn

camshaft.

Excessive Worn Worn

Uneven

Control

Worn

Inadequate

Governor

Fatigued

valve

timing

fan

pulley

PUMP

injection. rack

delivery

SYSTEM

lever

governor

PIN,

AND

PISTON

pin.

and

ring

wom

clearance.

gear.

bearing.

SYSTEM

malfunctioning.

valve.

injection

nozzle

malfunctioning.

spring.

RING

or

damaged.

spray.

1.

Rebore

cylinder

2.

Replace

3.

Replace

4.

Replace

1.

Replace.

2.

Adjust.

3.

Replace.

4.

Replace.

1.

Adjust

injection

2.

Disassemble,

3.

Replace.

4.

Replace

1.

Check

governor

2.

Replace.

piston. piston

and

piston

and

check

injection

to

oversize

rebore rings.

or

replace

and

nozzle.

shaft

correct

and

replace

cylinder.

parts.

injection

correct

piston.

pump.

operation.

(continued)

Engines & Generators

6

ENGINE

TROUBLESHOOTING

PROBLEM

KNOCKING

INTERMITTENT

EXHAUST

SOUND

ENGINE

1.

a.

h.

2.

3.

4.

KNOCKING

1.

2.

3.

1.

2.

3.

KNOCKS

Main

engine Overheated Carbon

deposits

Too

early

Too

high

Improper

Poor

compression.

Injection

a.

Worn

h.

Pinion

c.

Broken

d.

Worn

Improper

a.

Poor

h.

Poor

c.

After-injection

d.

Nozzle

Fuel

filter

Fuel

pipe

Water

mixed

PROBABLE

WITHOUT

troubles.

cylinder.

in

injection

WITH

pump

pressure.

fuel.

DARK

malfunctioning.

plunger.

is

not

in

delivery

nozzle. spray. chattering.

needle

clogged. sucks

air.

in

fuel

CAUSE

cylinder.

timing.

SMOKE

mesh

valve

seat.

drip.

valve

seized.

MUCH

with

control

spring.

SMOKE

rack.

a.

See

h.

Clean.

2.

Correct.

3.

Correct.

4.

Replace

1.

See

a.

h.

c.

d.

a.

h.

c.

d.

1.

Clean

2.

Retighten

3.

Replace

VERIFICATION/REMEDY

OVERHEATING;

with

proper

LOW

COMPRESSION;

Replace. Correct. Replace. Replace.

Clean

or

replace

Repair

or

replace

Repair

or

replace

Replace.

or

replace.

pipe

fuel.

jOints

LOW

fuel.

nozzle.

nozzle. nozzle.

or

replace

OUTPUT.

HARD

STARTING.

pipe.

OVERHEATING

LOW

OIL

PRESSURE

1.

V-belt

2.

Damaged

3.

Lack

4.

Low

5.

Knocking.

6.

Moving

7.

Defective

1.

Worn

2.

Relief

3.

Clogged

4.

Diesel

slackening

water

of

coolant.

oil

level

or

parts

seized

thermostat.

Bearings. valve

malfunction.

oil

cooler.

dilution

or

pump.

poor

of

the

slippery

oil

quality.

or

damaged.

oil.

with

oil.

1.

Adjust,

2.

Replace.

3.

Add.

4.

Add

5.

See

6.

Replace.

7.

Replace.

1.

Engine

2.

Overhaul

3.

Repair.

4.

Injection

replace

or

change.

KNOCKING.

overhaul

oil

pump.

pump

.replace

repair.

clean.

bearings.

Engines & Generators

7

ENGINE

GENERATOR

Disconnect the at the control panel and remove the speed sensor from the bellhousing. Carefully support and then unbolt the generator back end from the engine.

For generator maintenance and service, refer to the

GENERATOR SECTION

\

AC

wiring, unplug the

of

DC

this manual.

wiring harness

DISASSEMBLY

3. Remove engine heat exchanger and engine cooler. end

sible, leave one the part being

4. Remove starter motor.

S.

Remove engine bellhousing.

6. Remove transmission damper plate. . FROM THE

7.

Remove flywheel.

of

removed.'

If

pos-

each hose connection attached to

ONE

BOLT DEVIATES

6(],

S-.€T

UP

S'

."

PROPULSION

Unplug the instrument panel wiring harness. Drain the transmission fluid and the transmission oil cooler hoses, Detach the oil cooler hoses and unbolt the transmission from the engine.

For transmission service and maintenance refer to your transmission owners manual.

To rebuild a transmission contact your WESTERBEKE dealer

or

With the transmission or generator separated from the engine, begin the following step by step procedure disassembly.

ENGINE

Take the following precautions:

•.

Clean the exterior of

dirt and oil.

• Be careful not to damage the disassembled parts.

• Mount the engine on suitable engine stand for disassembly.

ENGINE

your local marine transmission shop.

DISASSEMBLY

of

the engine

of

any deposits

~

of

engine

WHEN REMOVING THE

MOUNTING

LOCK

THE FLYWHEEL

TOOL

GEAR

WITH A RING

BREAK

BOLTS --____

I4...~-IJ

STARTER/SOLENOID

f·

.

{PROPULSION

ENGINE

1. Drain the engine oil and coolant from the engine

and heat exchangers.

2. Remove engine wiring harness terminal connections to insure proper reattachment.

in

its entirety. Label

C

o

~~:

~~

iBIO~

DAMPER PLATE

\

~·t~

00

,

DAMPER

,BOLTS

PLATE

GENERATOR

9. Unbolt elbows in

its entirety.

10. Remove the engine alternator and

11. Remove the engine mounted fuel filter and fuelline to injection pump. (Note the arrangement ers

on

Engines & Generators

8

at

banjo bolts

head and remove the exhaust manifold

raw

water pump.

of

sealing wash-

at

fuel filter and injection pump.)

12.

Remove

Leave

13.

Remove

14.

Remove

15.

Remove

injection pump to the injectors. Leave the two upper line clamps

NOTE:

injection

foreign material.

16.

Remove

17.

Remove

and from the fuel injection pump. (Note the washer arrangement on fuel return line banjo bolts. Cap all the openings on the fuel return line, injectors and injection pump.)

a.

b. Remove the glow plugs.

18. Remove the crankcase breather hose and rocker

arm cover.

the thennostat housing and the thennostat.

temperature sending unit in place.

the coolant circulating pump. the air intake silencer.

all the high pressure injector lines from the

in

place.

Cap

the ends

pump

the intake manifold. the fuel return line from the top

Remove washers from the cylinder head.

of

the lines

and

at

the injectors to prevent entry

the fuel injectors, dust seals and sealing

and

the connections

.

""",....

of

\ \

', . ....:J.--l

~i

\ \

.;

the injectors

ROCKER COVER

of

at

ARM

the

"

ROCKER

\

ASSEMBLY

a. Remove the rocker arm assembly.

b.

Remove the valve stem caps so as not to lose them when removing the cylinder head. top

which

c. Remove the

which valve

it

belongs.

d.

Lift the cylinder head off the engine .

ARM,

valve

push

'J

,

it

belongs.

rods.

Label

each

Label

rod

each cap as

as

to

\

r

19. Remove the cylinder head.

NOTE:

Loosen the cylinder head bolts equally

in

the'

order shown in

,.'

i I

!

14;1

10

1.6

~he

dia~r~

:"

23;7

INTAKE

and

MANIFOLD:

jASSEMBLyL

gradually

,.

.

;.

i /

i13

9

I

14

.J

8

/12

1

i

20.

RelIlove the

I

Engines & Generators

9

,

,~~

~~.

~ter~assembl~

@I@..

21.

Remove the injection pump, Scribe the mating marks

pump hody flange and the timing gear case

on the

before removing.

EXTRACTOR

TOOL

*49

SE

01157

INJECTION PUMP

a. Remove

b.

Loosen the two injection pump hold down nuts. Do

the

cover

and

the

lock

nuts.

not remove entirely. The hold down nut on the engine

of

side

universal

c. Remove

the pump can be loosened

socket

and

extension

the

nut

and

lockwasher

by

with

from

using a

ratchet.

the

injection

114"

pump shaft,

REMOVING CRANKSHAFT

PULLEY

NOTE:

Remove the pulley bolt with the aid

mm

socket

and

draw

38

22. Remove the

timing

the pulley

gear

off

the front crankshaft,

cover.

of

a

23. Remove the injection pump gear and the oil baffle plate,

24.

Remove the central

25.

With a suitable

idler

gear and idler gear spindle,

puller

remove the crankshaft gear

and key.

26.

Remove the

camshaft

gear using a suitable puller.

,

INJECTION

.

GEAR

AND

PUMP BAFFLE

PLATE'

'"

THE

NOTE:

Take care

timing

gear

d.

Place the keyway on the injection pump shaft in the pulley bolt before attempting

not

to drop the

case.

nut

12:00 position with the aid

and

the washer into

of

the front crankshaft

to

remove the

injection pump.

e. With the use

of

extractor #49 SE

01

157 apply sufficient pressure to loosen the pump from the keyed gear. The loose hold down nuts will prevent the

pump.

from falling from the engine.

EXTRACTOR

NOTE:

If

injection

HOLES

an extractor is

pump

shaft loosely

not

available, replace the nut on the

and

with a nylon drift

and

hammer gently tap the injection pump shaft to dislodge it

from the keyed drive gear.

'

f. Once loosened. remove the hold down nuts and

washers and carefully withdraw the pump from the

drive

gear

and

injection

engine so

pump

drive key inside

as

to

avoid

the

losing

timing

the

case.

TIMING

GEAR

COVER

@~

IDLER

SPINDLE~

~>::.

\8.»

TIMING

GEARS·

PUMP

71

B

GEAR

, I

,

ENGINE

'DISASSEMBLY

'J

~

REMOVING

THE

llOLER

TIMING

~EARS

INJECTION

PUMP

GEAR

'INJECTION

27. Thrn the engine

28. Loosen the set screw,

29. Remove the pushrod tappets attempting to

30. Remove the block. Discard

over

camshaft

are

remove

timing

gear

the

old

/

\.'.~

REMOVING

and remove the oil pan.

then

remove the oil pump assembly.

carefully. Insure that all the

seated into the engine block prior to

the

camshaft from the block.

~~

from the front of the engine

gasket.

!

OIL

PAN:

••

.. : ....

0

. "

,Jfi!J

..

~~

'~~

THE

OIL

PAN.

'..~

G

Engines & Generators

11

.~

~

. -

REMOVING

THE

TIMING

..

GEAR

-

-...

CASE

.,'

ENGINE

DISASSEMBLY

31. Remove the rear oil seal.

32. Remove the connecting rod bearing caps.

33. Remove the piston the top of the cylinder block.

34. Remove the main bearing caps.

NOTE:

Mark the bearing caps

35. Remove the crankshaft.

CRANKSHAFT

\

ASSEMBLY

.

and

connecting rod assemblies from

to

insure

properr~~sembly.

38. Disassemble the piston assembly.

a. Using the piston ring remover, remove the

piston rings. b. Remove the wrist pin snap rings. 'c.

Using a nylon drift, drive the wrist pin from the piston

and rod.

\

PISTON

I;IST~N

RING:

"

~~

I,

i

I

REMOVING VALVES

36. Remove each valve from the cylinder head Use disassembly. Arrange or label valves them in the cylinder and the guide from which they

were removed.

37. Disassemble the rocker arm

THE

an

appropriate valve spring compressor

assembly.

so

as

assembly.

to

aid:

in

to replace

1'-

[lARGE

END

'._-

.'.--~\

/

L

PISTON

d. Protecting your eyes with safety glasses, disengage

and withdraw the snap rings. Although mechanics

I

generally press out (and sometimes hammer out)

(

I

pistons pins, these practices should be discouraged. Instead, take the time to heat the pistons, either with a heat gun or on a hot plate. Pins will almost fall out.

e.

While the piston is still warm, check for bore integrity. Insert the pin from each side.

at the center, the bore might

misaligned, the

\ far boss.

\

NOTE:

The number

1\

correspond to the cylinder number. Sometimes these numbers are scrambled

l them. Stamp the correct numbers on the pads provided

l,tO

prevent confusion, deface the originals.

I

or

missing,

stamped

ASSEMBLY

will click or bind as it enters the

on the rod shank and cap should

and

\

"\

. \

\

be

tapered;

the mechanic

If

the pin binds

if

the bore is

must

supply

and,

Engines & Generators

12

ENGINE

INSPECTION

CYLINDER

1. Visual Inspection.

or any other damage and,

2.

Distortion Inspection. Measure the cylinder head

surface distortion gauge. Take 6 measuring positions as shown in the diagram.

IT

the distortion exceeds permissible limit, replace the cylinder head. (The must

Cylinder

71

ani

FEELER

HEAD

Check

if

necessary, repair or replace it.

with

a straight edge and the thickness

head

has

no

be replaced,

Head

C Positions: 1, 2 0.10

GAUGE

not

renewed.)

Distortion

3,4,5,

~

Limit

6 0.25

the cylinder head for cracks

allowance for planing and

mm

(0.004 in)

mm

(0.010 in)

a Use a new welch washer. h. Insert the welch

cylinder

i

WELCH

is toward the

c.

After installation, completely fixed

WASHER"'-..

washer

check

in

place.

REMOVING

I

INSERT

so that its convex surface

head gasket.

to see

if

the insert is

THE.

2·

!-~~~-&::"""~-e~~~~~~~~5

6

1.

3.

Insert Inspection.

insert and,

4.

Insert Replacement. To remove the insert, place a

suitable with a hammer. To install, set the insert in position and insert the welch washer into the insert guide hole. Secure the welch washer

if

detected, replace it.

drift into the injection nozzle hole, then tap the drift

by

tapping the raised center

Check

for cracks

of

the welch washer.

or

damage on the

12mm(.08

VALVE

NOTE:

1.

respectively for intake

contact width intake and exhaust sides.

pennissible

Mllve

71

in)

SEAT

Valve seat inserts

Valve Seat Angle. Valve seat angle is

of

the

limit, replace

margin

ani

limit

C 1.35

and

valve

mm

cannot

If

(0.053 in)

be fitted to this engine.

exhaust sides. The standard

seat

is 2.0

the

valve margin is less than the

the

valve.

45°

and

mm

(0.08 in) for both

30°

Engines & Generators

13

"I

3{7

mm

(1.25

EXHAUST

in)

ENGINE

INSPECTION

2.

Dimension

stem,

if

it

L.

Check the protruding length of the valve

exceeds the specification, correct it as follows:

Dimension L Standard

71

Bn1

C 48.0

a.

When

0.0202 in) from the standard, it is possible to use both the

valve and the cylinder head.

/

DIMENSION

b.

When

(0.20 - 0.059 in) from the standard, adjust the

dimension L to the standard by adding some washers

(inner diameter 12.8 mm

(1.535

cylinder head. When

c.

mm,

0.059 in) from the standards, install the valve with

new

a

d.

When

(0

- 0.0202 from the standard, replace the valve.

e. When dimension L becomes to large

(0.020 - 0.059 in) from the standard, replace the valve and adjust the dimension L some washers between the lower spring seat and the cylinder head.

f. When dimension L becomes to large (more than 1.5

mm

(0.059 in) from the standard, replace both the

valve

and

,

l

..

mm

(1.890 in)

dimension L becomes large 0 - 0.5

I

L

dimension L becomes to large 0.5 - 1.5 mm

mm

(0.504 in ), outer diameter 39

in)

between the lower spring seat and the

dimension L becomes to large ( more than 1.5

one, and recheck dimension L. dimension L becomes

the cylinder head.

1Q

large 0 - 0.5 mm

to

the-

I

,

0.5 - 1.5

standard by adding

'LOWER

SPRING SEAT

mm

(0-

111m

g. Check for

applying a the valve seat the valve guide

seat.

NOTE:

Do not rotate

h. Check

center position position is not

valve seat.

2.

Stem Wear Inspection.

diameter is less than

Stem diameter

71B

contact

if

the

limit

Intake

thin

contact

the

valve

centered,

the

coat

and

of

Exhaust

71C

Intake

Exhaust

between the valve and valve seat by

of

Prussion Blue (or Redlead)

face, then insert the valve into

press fit the valve on the valve

on

valve!

CONTACT

seat

contact face contacts the

the

valve contact face.

repair the valve and the

If

the valve stem is bent or its

limit, replace the valve.

8.884

mm

8.864

mm

7.880

mm

7.867

mm

..

(0.350 in) (0.349 in) (0.3102 in) (0.3097 in)

FACE

If

the contact

\.

\

!

WASHER

Engines & Generators

14

i

CHECKiNG

VALVE

STEM

WEAR

....

ENGINE

INSPECTION

VALVE

1.

valve spring

Valve

71 B

71C

2.

spring

Squareness

71

SPRING

Free Length Check. Measure

and

if

free

length is less than

Spring

Limit

Inner

spring

Outer spring Inner

spring

Outer spring

Squareness Check. Check the

and,

if

it

is

more than the limit, replace

Limit

Bn1

C

42

mm

43.6

52.9

1.25

1.37

the

free

the

(1.654 in)

mm

(2.083 in)

mm

(1.

717

mm

(1.717 in)

squareness

mm

(0.049 in)

mm

(0.054 in)

length of

limit,

replace

in)

of

the

spring.

the

valve

it.

VALVE

1. Inspecting

Set a dial gauge with a magnet and check between is

Clearance

2.

press out side, using using the

GUIDE

clearance

the

valve stem and the valve

more than the limit, replace the valve or

Limit

0.127

Valve guide replacement.

the

valve guide towards the combustion

the

valve guide installer (49 0636

the

valve guide installer, press in

cylinder head until the valve guide height reaches

between valve and guide.

the

guide.

valve

mm

(0.005 in)

To

remove

the

valve

indicated scale on the valve guide installer.

clearance

If

the

clearance

guide.

the

valve

chamber

165A).

guide

guide,

Again

into

the

3.

Fitting Pressure Check. Check

pressure than

NOTE:

spring several times.

with

a valve spring tester

the

limit, replace the spring.

Measure the fitting pressure after compressing the

71

Bn1

C

Spring

Inner

Fitting

Pressure

VALVE

SPRING

TESTER

Length

Limit

37.8 1013

~SJ

,>",

mm (1.49 in)

kg

TESTING

the

and,

if

Fitting Pressure

Spring

(22.7Ib)

THE

SPRING

valve

the

40.3

spring

pressure

Outer

nun

14.5

kg

FIniNG

fitting

is

less

Spring

(1.59 in)

(32.0

lb)

PRESSURE

NOTE:

Be sure to press in the chamber on the valve chamber side.

protruding portion Protrusion

71

Bn1C

After

of

Standard

16.5mm(0.650in)

HEIGHT THE

SPRING

16.5

mm

guide

the

pressure

the

ABOVE

SEAT

(0.65 in)

valve

end

valve

guide so that the inside

faces

to the combustion

fit, check the length

guide.

of

the

VALVE

GUIDE

INSTALLER

SPECIMEN SPRING

VALVE

Engines & Generators

15

ENGINE

INSPECTION

ROCKER

1.

Visual Inspection. Check each component part

rocker arm assembly for cracks or other damage. Check the oil passages if

necessary, repair or replace it.

ARM

of

the rocker arm and shaft are clogging and,

RETAINING

RING.......

~-JAMNUT

BRACKET

___

~

,

1~

TAPER

-®~

l@i

2.

Inspecting clearance between rocker arm and shaft. Check the clearance between the rocker arm and shaft and, it exceeds the limit, replace the rocker arm bushing or shaft.

Clearance Standard

71

an1C

3.

Rocker Arm Bushing Replacement Using a suitable

mandrel and press, press out the bushing. Aligning the oil passages the rocker arm. After the rocker arm bushing has been replaced, ream the bushing bore with a reamer so that the clearance between the bushing and shaft becomes equal to the standard clearance.

0.016 - 0.061 (0.0006 - 0.0024 in)

0.07mm (0.003 in)

limit -

of

the rocker arm bushing, press the bushing into

\"

SCALLOP

if

"AT

SPRING

WASHER

RECESS

if

TAPPET

1.

Visual inspection.

other damage and, abnormal wear with the cam, and the tappet.

2.

Inspecting Clearance Between Tappet and Tappet

Bore.

Check the clearance between the tappet and tappet bore and, tappet or cylinder block.

Clearance Limit

71an1C

of

if

the clearance

0.10

TAPPET CLEARANCE

CYLINDER

1.

Visual Inspection.

and damage. to see that oil or cooling water passages

.

if

clogged, remove with compressed air or a wire probe.

BLOCK

If

necessary, repair or replace it entirely Check

REMOVE LOCATING DOWELS

Check

if

damaged

the portion

if

anyone

is

mm

(0.004 in)

Check

BEFORE

INSPECTING

the tappet for cracks and

replace the tappet. Check for

of

the tappets that contact

is abnormally worn, replace

greater than the limit, replace the

..

the cylinder block for cracks

ar" not clogged and,

REPLACING THE

BUSHING

,

REAMING

THE

BUSHING

BORE

-,

Wi

2.

Distortion Inspection. Check the gasket face distortion

of

the cylinder block

replace it.

Distortion limit:

71

ani

C

Engines & Generators

16

:w

~Pi

and

(1)

(2)

(3) (4)

.

DISTORTION

~

"$

if

it

exceeds the limit, repair or

0.10

mm

(0.004 in)

0.25

mm

(0.010 in)

INSPECTION

".J

~:I--4

2

ENGINE

INSPECTION

CYLINDER

1.

Wear Inspection. Measure the liner bore at three

positions

gauge in exceeds the limit, replace the liner.

Cylinder

71

Bn1

2.

Cylinder Liner Replacement. Hydraulic press or

similar device is needed.

a. Attach the cylinder liner puller and installer

rim

b. Check for scratches on the cylinder block side and,

remove engine oil.

c.

To bore and the liner exterior, then set the liner on the cylinder block. installer, press the liner into the cylinder block.

NOTE:

the

liner,

(2,200 - 6,600

LINER

of

upper, middle and lower portions with a cylinder

X-X

and Y-Y directions as shown.

Liner

Bore

C 88.925 - 88.950

Wear

Limit 0.20

X--I+--

of

the cylinder liner, then press out the liner.

them

by using extremely fine emery paper with

install the liner, apply engine oil on the cylinder block

Using the cylinder liner puller and

Press the liner

in

mm

Y

---J+-X

'-'

.....

y

straight.

(3.5010 - 3.5020 in)

mm

-/

X - X IS THE THRUST DIRECTION

When

keep the pressure within a

[b).

If

(0.008 in)

press

range

of

wearing

CYLINDER

to

the lower

fitting

1-3

tons

LINER

if

any,

PISTON

1.

groove

AND

PISTON

RING

Visual Inspection Check the sliding surface and ring

of

the piston for wear, scratches

or

any other damage.

a. Inspecting the clearance between the piston and the

cylinder liner.

b. Check the clearance between the piston and the cylinder

liner by measuring the cylinder bore and the piston diameter and, the cylinder liner

PISTON

c.

To

measure the piston above from the piston bottom at right angle to the piston pin.

Piston

and

71B 71C

Standard Piston

71 B 88.880 ± 0.013 71C

if

the clearance exceeds the limit, replace

or

piston.

LINER

<1lameter,

Cylinder Clearance

0.044 - 0.70

0.054 - 0.080

mm

Diameter

88.872 - 88.898

_-;:::;::=::::::;;;-_..--SUB

MEASURING

measure

18

mm

(0.0017 - 0.0028 in)

(0.0021 - 0.0031 in)

mm

(3.4989 ± 0.0005

mm

(3.499 - 3.500 in)

COMBUSTION

CHAMBER

(0.7

(71C)

in)

GAUGE

Measure the liner protrusion and correct it

Protrusion Limits

71 B 0.101 - 0.000 71 C 0.659 - 0.790

mm

(0.0040 - 0.0000 in)

mm

(0.026 -

PROTRUDING

LENGTH

if

necessary.

0.031

in)

3.

Piston Ring

breaks, seizure replace the ring. and the ring groove and, ring.

Clearance limit

71Bn1C

Engines & Generators

17

Inspection

and

wear

Check

0.30

mm

TAKE

MEASURE

.18

mm

(0.7 in)

Check

the piston ring for

and,

if

any

of

these conditions exist,

the clearance between the piston ring

if

it exceeds the limit, replace the

UP

(0.012 in)

ENGINE

INSPECTION

OIL

HOLE

:

CLEARANCE

(0.012 -0.039

0.0005 -0.0015

in)

mm

~SMALL

OIL

HOLE

PISTON

LARGEEND--

~BEARINGS

~

BEARING

CONNECTING

1. Visual Inspection. Check the

or other damage and,

2. Bend Inspection. Using a connecting rod

the the limit, repair it with a press or replace

Bend

71B/71C

INSTALL

NEW BEARING BOLTS

bend

and twist

Limit

CAP

ROD

of

0.05

per

100

if

necessary, replace

the

connecting

mm

(0.002 in)

mm

(3.9 in)

connecting

rod

END

rod

it.

and,

if exceeding

it.

BUSHING

for

aligner,

cracks

check

PISTON

BUSHING~,

4.

Small end bushing replacement. Using a

press out the bushing. Align the oil passages of connecting rod bushing bushing

the

specified clearance between the small end bushing

the piston

REMOVING SMALL

,BUSHING

END

~~~=~!=~r~~~

and

the small end bushing; press in the

to

the

connecting

has

been replaced, ream the bushing

pin.

THE

'/'

/

rod

bore. After a small end

PRESS

MANDREL---------.

PRESSING THE

('BUSHING

OIL

HOLES

----IIl

{7

NOTE:

When reaming the bushing, correctly insert the reamer in the bushing. In the bushing the cutting direction. different positions

surface, the reaming should always be made in

Make

at

all times.

order

to prevent unevenness on

certain the reamer is stopped

NEW

the

bore

,IN

press,

to

obtain

.. 1

and

at

OIL

HOLES,

3.

InspeCting clearance between the piston pin and

small end bushing. Check the

piston

and

the small end bushing

limit,

replace

the

piston pin or small

Clearance

71 B Standard: 0.012 - 0.031 mm (0.0005- 0.0015 in)

Limit: 0.05mm (0.002 in)

71C

Standard: 0.014 - 0.041 mm

Limit: 0.05

mm

clearance

(0.002

and,

bushing.

in)

between

if it exceeds the

(0.0006

- 0.0016 in)

5.

connecting rod side play with the exceeds the limit, replace the connecting rod and crankshaft.

the

Engines & Generators

Side Play Limit

71B/71C

18

Inspecting

connecting

0.40mm

(0.016 in)

rod side play. Check the

<ljal

gauge

and,

if

it

CONNECTING SIDE

PLAY

ROD

TEST

5.

Inspecting

ring into the bottom

end

ring

Piston

Ring

71Bn1C

. Be sure to position

surface

of

piston

gap and,

End

1.5

the cylinder liner.

ENGINE

ring end gap. Position the piston

of

the cylinder liner. Measure the piston

if

it

exceeds the limit, replace the ring.

Gap

Limit

mm

(0.59J.in)

the

piston ring below the ring sliding

INSPECTION

CRANKSHAFT

1.

Visual Inspection.

other damage. crankshaft and perform a dle flame over the crankshaft cracks.

PERFORMING A COLOR

If

cracking

If

any cracks are

Check

the crankshaft for cracks or

is

suspected, thoroughly clean the

color

test on the shaft, or run a can-

and

look for oil seepage from

detec~,

repl~ce

the crankshaft.

TEST

6.

Inspecting connecting rod bearing. Check the

connecting rod bearing for peeling and thermal damage. is severe, replace the bearing.

7.

Inspecting connecting rod bearing clearance.

Using the plastigauge, measure the oil clearance

if

connecting rod bearing and, the connecting rod bearing.

\

Con~ecting

! 71 B Standard: 0.012 - 0.031

Rod

Bearing Clearance

Limit:

0.05

71 C Standard: 0.036 - 0.076

Limit:

Undersize Bearing:

0.10

0.254

0.508

0.762

it exceeds the limit, replace

mm

(0.0005 -

mm

(0.002 in)

mm

(0.0014 - 0.0030 in)

mm

(0.004 in)

mm

(0.010 in)

mm

(0.020 in)

mm

(0.030 in)

of

the

0.0012

If

in)

it

CRANKSHAFT

Check for clogging with compressed

2.

Runout inspection.

it exceeds the limit, replace

Runout Limit

71Bn1C

........

air

0.05

of

oil passages and,

or

wire.

Check

the

crankshaft.

mm

(0.01020 in)

if

clogged, remove

the crankShaft runout and,

CRANKSHAFT

RUNOUT

..INSPECTION

GAUGE

3.

Inspecting crank pin

shaft on both ends using V-blocks. Measure the diameter

each crank pin and crankshaft ter is less nal to size for the next undersize bearing.

than the limit, refinish the crank pin and main jour-

and

journal. Support the crank-

main

journal and,

if

the diame-

71B

Crank

standard diameter

57.112 - 57.125

mm

(2.2485 - 2.2491 in)

Main journal standard diameter

69.812 - 69.825

mm

(2.7485 - 2.7491 in)

Wear

limit

0.05mm in)

(0.002

Wear

limit

0.05mm

(0.002 in)

if

of

CONNECTING

Connecting

71

B 7.8 - 8.0

.

71

C 6.9 -

Rod

ROD

BEARING

Cap

Tightening Torque

m-kg

7.5

m-kg

CLEARANCE

(56 - 58 ft-lb)

(50 - 54 ft-lb)

Crank

Main journal standard diameter

Engines & Generators

19

71C

standard diameter

53.0 - 53.013

(2.0866 - 2.0861 in)

65.0 - 65.013

mm

(2.5591 - 2.5596 in)

Wear

limit

0.05mm

(0.0020

Wear

limit

0.05mm

(0.0020

in)

ENGINE

8,

For

the

measurement on both main journal, measure them at vertical directions

b, When refinishing the crankshaft, it's

as

c,

Refer

crankshaft

-

~1-=-3.71~.~3.~gg~m~m~e!IJ==~~~~~~

I

(0.146·

0.157

R2 = 3.20 . 3.61

(0.126·0.142

Undersize

0.254

mm

0.508

mm

0.762

mm

Undersize

0.254

mm

0.508

mm

0.762

mm

on

shown in

to

the

In)

mm

.

in)

bearing

(0.01 (0.02 (0.03

bearing

(0.01 (0.02 (0.03

front and rear

the

diagram.

chart for refinishing

where

an undersize

in)

56.868 -56.871

in)

56.604

in)

56.350

in)

69.558 -69.571

in)

69.304 -69.317mm

in)

69.050-

71B

-

56.617

-

56.363

Main

69.063

the

places.

bearing

Crank

journal

crank

and

finish

dimensions

is

used.

diameter

mm

(2.2389 -2.2391

mm

(2.2285 -2.2312

mm

(2.2185 -2.2191

diameter

mm

(2.

7385 -2.

(2.7182

mm

(2.7185

and

horizontal

to

Rl

of

7391

-2.7291

-2.7191

INSPECTION

the

mm

the

Oil Clearance

71 B Standard:

71C

Main Bearing

71

in) in) in)

Bn1

CAMSHAFT

1. Visual Inspection. Check the camshaft for cracks damage.

Inspecting cam

2. is

less than the limit, replace the camshaft.

it

71Bn1C

0.059 - 0.090

0.12

Limit:

Standard: 0.040 - 0.091

Limit: 0.12

Cap

C lightening

If

necessary, replace the camshaft.

Cam height limit: 42.478

mm

torque:

height.

mm

(0.005 in)

mm

(0.005 in)

11.0

Measure

(0.0020 - 0.0040 in)

(0.0016 - 0.0036 in)

-11. 7 m-kg

the

(80

cam height

mm

(1.6724 in)

-

85

ft-lb)

and

and,

if

71C

Undersize

0.254

0.508

0.762 Undersize

0.254

0.508

0.762

4. Inspecting crankshaft end play. Check of

the

replace Crankshaft end

the

rear end of

the

axial direction.

Crankshaft

71Bn1C

5. Inspecting main bearing. Check the for

peeling, seizure or fusion

the

bearing.

6.

Inspecting main bearing clearance.

plastigauge, measure limit, replace

bearing

mm

(0.01

in)

mm

(0.02

in)

mm

(0.03

in)

bearing

mm(O.Ol mm mm

crankshaft

the

End

in)

64.733 -64.746

in) in)

and,

if

is

crankshaft

Play

the

main

64.479 -64.492

64.225 -64.238

measured

bearing.

(0.02 (0.03

thrustwasher with 0.178

play

the

End

Standard: 0.14 -

play limit: 0.40

the

Crankpin~

52.

733 -52.

52.479 -52.492.

52.225 ~ 52.238

the end play exceeds

oil clearance

Main

by

and

moving

0.39

mm

(0.0157 in)

and,

if

746

mm

(2.0761 -2.0766

mm

(2.0661 ~ 2.0666

mm

(2.0561 -2.0566

jour1llll

mm

(2.5485 -2.5491

mm

(2.5385 ~ 2.5391

min

(2.5285 -2.5291

mm

(0.007

setting a dial

the

mm (0.0055 -

main

necessary,

and,

if

diameter

Using

the

end

play

the

limit,

in)

oversize.

gauge

on

crankshaft in

0.0153

bearing

replace

the

it exceeds

the

in)' in)

!It))

in) in) in)'

in)

INTAKE

AND

EXHAUST

CAM

~H"G~IW

!

3. Inspecting

journal

and,

camshaft.

No.1 No.2 No.3 No.4

Front

Center

Rear

camshaft

if

wearing exceeds the limit, replace

71

B Diameter

51.910 -51.940

51.660 -51.690

51.410 -51.440

51.160 -51.190

71

C Diameter

52.06 -

(2.0497 -

51.81

(2.0398 -2.0409

51.31 -51.34

(2.0201 -2.0212

journal. Check

of

Journal

mm

(2.0437 -2.0449

mm

(2.0339 -2.0351

mm

(2.0240 -2.0252

mm

(2.0142 -2.0154

of

Journal

52.09

mm

2.0508

in)

-51.84

mm

in)

mm

in)

the

camshaft

in) in) in) in)

Wear

0.008mm

(0.0003

the

Wear

Limit

0.008mm

(0.0003

Limit

in)

1'WV"wesiERBEICE

I

Engines

& Generators

20

ENGINE

4.

Inspecting camshaft oil clearance. Check the

clearance of the camshaft

the

cylinder block

clearance is more than

cylinder block.

71

ani

C Oil clearance limit: 0.145 mm (0.0057 in)

5.

Inspecting camshaft runout. Check the camshaft

runout

and,

if

it exceeds the limit, replace the camshaft.

71

ani

C Runout limit: 0.08

6.

Camshaft front bearing replacement. Mount

camshaft assembly in a vise equipped with copper or aluminum plate, then remove the bolt, lock plate, cam

thrust plate, bearing outer face and

R,

Using a press, press out the bearing.

b,

Check the removed parts for wear or other damage and

replace the parts c, Install the bearing onto the camshaft d,

Assemble the thrust plate and camshaft gear onto

camshaft.

71 a

Tightening

71 C

Tightening

7.

Inspecting camshaft end play. Measure

of the camshaft with is

more

than

the limit, replace the thrust plate.

71

ani

C

End

by

and

camshaft journal

the

limit, replace

as

necessary.

torque: torque:

6.4 -9.5

6.2

the

thickness gauge

play limit:

measuring

mm

key.

m-kg

-

7.0

m-kg

0.3

mm

the

camshaft bore in

diameter.

the

camshaft or

(0.003

in)

with

a press.

(46 -69

ft-Ib)

(45 -51

ft-lb)

the

and

if the end play

(0.012

in)

If

oil

the oil

the

gear,

the

end play

INSPECTION

CHECKING CLEARANCE

BETWEEN BUSHING

AND

GEARS

1. Visual Inspection Check each gear tooth for

other damage.

2.

Inspecting

of

the idler gear and,

plate or idler gear.

71

a

Standard

71C

Standard

71

ani

IDLER

GEAR

end

play

if

end play: end play:

C Tightening torque:

~,

')

SPINDLE

of

idler

it exceeds

0.15 -0.30

O.~O'"

0.030

2.3 -3.2

FQE~:~:;~;~

).

THE

1.\\\\

\\'K\\\<\I~\,(\\'I.'

gear. Check

the'

limit, replace

mm

(0.0059 -0.0118

mm

(0.0079

m-kg

I~

cracks

the

end play

the

-0.0118

(16.6 -23.1

THRUST

or

thrust

in)

ft-Ib)

,

PLATE

TESTING END

IDLER

GEAR

AND

IDLER

1.

Visual inspection. Check the damage

inner surface and,

if

oil passage for clogging and, with compressed

2.

Inspecting clearance between bushing and spin-

dle. Check the clearance between

the

spindle and,

or spindle.

Clearance

71

ani

of the idler gear and

necessary, replace the idler gear or spindle. Check

air or wire. '

if

it exceeds the limit, replace

C

Standard:

Limit:

GEAR

if

necessary, clean

0.034 -0.084

0.15

mm

CAMSHAFT'

PLAY

SPINDLE

on

the

spindle sliding surface

the

idler gear bushing and

the

mm

(0.0013 -0.0033

(0.006

in)

bushing

passage

idler gear

the

in)

CHECKING IDLER

END

NOTE: THE 71C

TWO IDLER GEARS;;;"... /

3.

Inspecting

, backlash between each gear and,

replace the gears.

NOTE:

the idler gear and clearance between the idler gear bushing

and

71an1C

~

GEAR

PLAY

Before inspecting the backlash, check

spindle.

):

USES

_

~

~"(.

backlash

Standard: 0.10 - 0.17

Backlash

limit: 0.30

between gears. Check the

if

it exceeds the limit,

mm

(0.012 in)

the

end play

(0.004 -0.007in)

of

'

....

'walERBEICE

I Engines & Generators

21

ENGINE

PUSH

ROD

1.

Visual Inspection. Check the push rod for damage on

both ends.

2.

Bend Inspection. Check the push rod for bend and,

it exceeds the limit, replace it. Place the push rod on a flat surface and measure the clearance between the center push rod and the flat surface. Replace the push rod wear limit is exceeded.

71

B171C

.

TESTING

PUSH

If

it is severe, replace it.

Bend

limit: 0.19

THE

ROD

mm

(0.0075 in)

PUSH

RODS

if

of

the

INSPECTION

REAR

OIL

1.

Inspecting oil seal.

other damage and,

if

the

2.

Oil seal replacement.

existing seal worn or frayed, their grooves and thoroughly clean the half-housings.

a. With half-housing

seal recess uppermost, settle one inch (25 mm) seal wick at each that each end (0.010/0.020 in) two-piece housing.

b. Press the remainder

starting from the

c.

Using a suitable place in

SEAL

both

Check

if

necessary, replace it.

held

end

of

the

beyond

center

round

half-housings.

REAR

OIL

the oil seal lip for wear or

Upon

inspection, finding the

pick

the old seal halves out

in

a soft-jawed vise and the

into

the groove. Make certain

seal

projects 0.25/0.51 the joining faces

of

the seal wick into the groove

and

working outwards.

bar, roll and press the seal into

SEAL

of

MAIN

mm

the

CAP

of

the

BOLT

of

TIMING

GEAR

COVER

1. Inspecting timing gear cover. Check the timing gear

cover and oil seal for any damage. cover or oil seal.

2.

Oil seal replacement. To remove the oil seal, use the

oil seal puller and installer and pull out the oil seal. apply the engine oil on the outer periphery of the oil seal, then press in the oil seal with oil seal puller and installer.

OIL

SEAL

PULLER

AND

INSTALLER

',.

~

----IIV~--~--l~~III~I--

TIMING

GEAR

OIL

~

Dll

SEAL

If

necessary, replace the

OIL

SEAL

TIMING

GEAR

REPLACEMENT

OIL

SEAL

6.35·7.62 (0.250 • 0.300

INSET

MM

IN)

To

install,

COVER

o

3.

To

refit the assembly: Thoroughly clean the butt joint

between the half-housings.

a. Lightly coat the

compound similar adhesive/sealant. wick seals with

b. Oil the crankshaft

half-housings in engine block bearing cap face finger tight only.

c.

Tighten the clamping bolts to a temporary torque

0.55 - 0.83 kg m

d. Tighten the bolts

1.66

kgfm

e.

Finally, tighten the clamping bolts to a torque

kgf m

(12

butt

Lubricate

graphite

position

and

locate

(4

in

(121b ft).

lb ft).

joint

faces with a liquid gasket

to

Dow

Corning Silastic 732 RTV

the exposed diameter

grease.

at

the

oil return groove. Place the

against the gasket and the

all the bolts into the block and

- 6

lb

ft).

the block and cap to a torque

LOWER HOUSING

SEAL

HOUSING

CLAMP

of

BOLT

of

1.66

SEAL

BOLT

the

Engines & Generators

22

ENGINE

REASSEMBLY

Take the following precautions:

• Be careful bo.lts

• During assembly, recheck clearances and insure that parts are co.rrect pisto.ns,

• Apply lubricating Insure that ro.tate excessive

•

If

there are mating marks scribed during disassembly,

reference them

•

Use

• Tighten

specified

• Use liquid sealants when required

gaskets. Refrain

Be

aware

no.t

to.

mix

are used

being assembled

o.r

new

o.n

vario.us

directio.n

pisto.n

slide and are

the

in

rings, bearings and bearing caps.

o.il

mo.ving

tensio.n.

co.rrectly

gaskets, lockwashers,

bo.lts

and nuts

to.rques

of

using a reliable

fro.m

these common problems that can

bo.lts

and

nuts.

Metric and S.A.E.

engine assemblies.

in

their

pro.per

o.rder

relatio.n

parts, when assembled

to.

the engine

to.

mo.ving

no.t

using tape sealants.

parts during assembly.

subject

to.

binding

fo.r

assembly.

o.-rings,

o.n

impo.rtant

to.rque

o.n

nuts,

etc.

parts

and facing in the

blo.ck,

such

as,

o.n

the engine,

o.r

o.f

engine

wrench.

bo.lts

and

to.

occur during assembly.

Insufficient Lubrication. Heavily

reciprocating parts, lightly except

tho.se

that penetrate fasteners high-tack equivalent.

sho.uld

be sealed with Permatex

Reversed orientation.

and all

thermo.stats

o.il into.

Mo.st

are asymmetrical.

Mechanical damage. Run fasteners

to.rque

sequences and in three steps-ll2, 2/3, and III Exceptio.ns fasteners. The latter-rocker shaft fasteners-sho.uld

small increments, especially head gaskets, might assembly, they

are

to.rque-to.-yield

fo.rmer

wo.rking

sho.uld

are

to.rqued

fro.m

be

po.sitio.ned

o.il

sliding and

head

bo.lts

and

o.ther

the water jacket. These

No.. 2 o.r

gaskets, many

bo.lts

and

as

indicated. The

be

the center

alSo.

be

damaged during·

with great care.

do.wn

ro.cker

bro.ught

bo.lts

bo.lt

in

appro.ved

arm shaft

do.wn

o.ut.

fasteners,

the

washers,

to.rque.

in

very

Gaskets,

ENGINE

1.

spring lifter arm and pivo.t, assemble the valve, seat, upper spring seat

NOTE:

valve only.

2. brackets and

rocker shaft is identified by a pin protruding

a larger

rocker

which prevents the shaft o.il

dJJ

~

3. rings.

sho.wn thro.ugh circlips can respective the

ASSEMBLY

Install the valves

o.il

deflecto.r,

The oil deflector should be installed on the intake

Assemble the

o.il

ho.le

arms.

This pin fits a

to.

the rocker arms and valves.

ROCKER

.EV

ASSEMBLY

Assemble the connecting rod, piston and piston

Arrange the pisto.n and the

and,

using the

the

pisto.n be

fitted. Fit the

gro.o.ves.

pisto.n

with the inscriptio.n mark

in

cylinder head. Using

inner valve spring,

and

taper sleeve in this

rocker

between the supply

arm shaft, rocker shaft

arms.

No.te

slo.t

in the

fro.m

turning and cutting

ARM

\

.J

'.

pisto.n

and

co.nnecting rod until the

Install the

I'

112

'ROCKER SHAFT/ .

SUPPORT

pin installer, insert the pisto.n

pisto.n

o.uter

valve

o.rder.

that the

ho.les

serving

#1

ro.cker

ROCKER

co.nnecting

circ1ips

rings

to.

o.n

ring upward.

fro.nt

fro.m

~.

.'

rod as

to.

ring

the

valve

lo.wer

spring

spring,

end

o.f

the

to.p

and

#1

and #2

shaft

suppo.rt

o.ff

the lube

TJ.

••

/.

TA.PERPINHQLE

-ll-:;;",,,.:i1

()'

pisto.n

their

groo.ves

,\

SCALLOP

o.n

FRONT

FRONT IS

INDICATED

. A BOSS ON THE

BOTTOM NEAR THE OIL HOLE

___

OF

........

PISTON

BY

-

:

CHECK GAPS RINGS WITH DETAILED

. THAT OFTEN SUPERSEDE

THE SERVICE MANUAL.

Engines & Generators

23

_1ST

_2ND

mRD'OILRING

THE PISTON RING

WITH CARE.

ARE

NEW

PACKAGED

INSTRUCTIONS

______

PISTON

RINGS/

MARK

ENGINE

4.

Install the crankshaft.

NOTE:

Do

not apply oil to the backsides

bearing shells.

a. Fit the main bearings on the cylinder block and the

bearing caps respectively. Check that the oil ways align

perfectly with those in the block.

h. Fit the thrustwashers to the cylinder block so that the

oil grooves on thrustwashers face to crankshaft side.

c. Position the crankshaft to the cylinder block, being

careful not to drop the thrustwashers as the crankshaft settles into place.

FITTING BEARING

THE

CAPS

of

the main

REASSEMBLY

PLACE A HEAVY GENTLY PRESS

FORCE

THE THE ENTIRE BE COATED WITH

HAMMER

DOWN

OF

YOUR HAND.

SURFACE SHOULD

FRESH

r \ r

INSTALLING

PISTON

AND

WITH

LUBE

AND

CONNECTING

OIL

ROD

ASSEMBLY

'\

d. Fit the thrustwasher to the main bearing cap so that the

oil grooves Then install the main bearing cap to the cylinder block with arrow mark crankshaft pulley side.

Main Bearing Cap Tightening Torque

71

Bn1

C 11.0 -

FITTING THRUST WASHERS

5.

oil seal lip .

6.

THE

Install the rear oil seal. Apply engine oil to the

Install the piston and connecting rod assembly.

a. Place the piston rings so that the ring ends are

properly spaced around the circumference

as

shown

h.

Using a ring compressor, in the position as is shown.

c. Install the caps to the connecting rods, ensuring that

the identification numbers on the cap and connecting rod are matched.

Cap Tightening Torque (install new connecting rod bolts)

71

B 8.2 - 9.0

71C

on

thrustwasher face to crankshaft side.

of

the main bearing cap facing the

11.

7

m-kg

(80 - 85 ft-lb)

on

the previous page.

fit

the piston into the cylinder

m-kg

6.9 - 7.5

m-kg

(59 -65

(50 - 54 ft-lb)

ft-lb)

of

the piston

7.

Install the idler gear spindle. Align the oil passages

the idler gear spindle

8.

Install the

on the cylinder block, then match the surfaces gear case end and that trudes from the mating surface,

knife. .

9.

Installation

a. Insert the tappet into the cylinder block. h. Insert the camshaft into the cylinder block. c. Install the camshaft thrust plate.

Thrust Plate Tightening Torque

71

Bn1C

and

cylinder block.

timing

INSTALLING

1.6 -

gear case. Attach the straight edge

of

the cylinder block.

of

the

crankshaft.

2.4

m-kg

cut

THE

(11.6

of

the timing

If

the gasket pro-

away the excess with a

TAPPETS

-17.4

ft-lb)

of

Engines & Generators

24

ENGINE

REASSEMBLY

10. Install each gear. While aligning the timing mark each gear, install the following gears on each position.

a. Timing gear

b. Camshaft gear c. Idler gear d. Injection pump drive gear

. e. Install the idler gear thrust plate, then tighten the nuts.

Tightening Torque

71an1C

f. Tighten the camshaft gear attaching bolts.

Tightening Torque

71

ani

C 6.4 - 9.5 m-kg (45 -

(71C

uses two idler gears)

2.3 - 3.2 m-kg (16.6 -23.1ft-lb)

51

ft-lb)

718

~

••

NOTE: THE 71C USES

i TWO IDLER GEARS

INJECTION

DRIVE

IDLER GEAR

PUMP

GEAR

of

h. Install the oil deflector

11. Install the timing

a. Install the bearing

gear cover.

b. Install the injection

timing gear cover.

c.

Install the timing cover attaching nuts pulley has been installed temporarily to center the seal.

Timing Gear Cover

71

an1C

12. Install the crankshaft pulley. Then temporarily tighten the pulley attaching bolt.

Mount the oil pump. Apply the sealing agent on set

13. screw thread and tighten screw.

14.

Position the new

a. Position the gasket

(B) and

b. Apply a silicon sealing agent on the mating surfaces

the gasket and that between the cylinder block and the timing gear case.

Tightening

1.6 -

(C).

on

gear

housing

pump

gear

cover

and

2.4

m-kg

oil

pan

ends

the crankshaft.

cover.

cover on the timing

drive gear cover on the

and tighten the timing gear

bolts after the crankshaft

Torque

(11.6

-17.4

ft-lb)

gasket set.

(A) on the gaskets

of

g.

Mount the injection pump on the gear case, then

tighten the pump drive gear attaching nuts.

15.

Install the oil pan.

Tightening Torque

71

ani

C

16.

Attach the backing plate.

Tightening Torque

71

ani

C 3.3 - 4.8

Engines & Generators

25

1.

60 -

2.30

m-kg

(12 -

(23.9 - 34.7 ft-lb)

17

ft-lb)

ENGINE

17.

Install the

of

the crankshaft.

end

18.

Install the

bolts. Torque the bolts. Bend the tabwasher to lock the

bolts in place.

Tightening Torque

,71Bn1C

flywheel.

tabwasher

15.5-16.3

(112 -

118ft-lh)

TABWASHER

FLYWHEEL

-_-+-_

BOLT

PATTERN

Install the flywheel onto the rear

plate and the flywheel

mkg

REASSEMBLY

25. Tighten

cylinder head bolts evenly in the sequence shown.

Tightening Torque

71

B 11.8 - 12.5

71

C 11.0

20

19

18

rl

-

13

the

-11.7

14

10

9 5

cylinder

m-kg m-kg

head

(85 - 90 ft-lh) (80 -

6 2

4

3 7

bolts.

85

ft-lh)

12

11,

Q

FRONT'

Tighten the

15

16

17

19. Tighten the

front

crankshaft pulley bolt.

Tightening Torque

71

Bn1

C 35 -

20. Install the

i and 4

if

they were removed earlier during disassembly.

Position the gasket

40

m-kg

(253 - 289 ft-lh)

two

tubular

on

cylinder block. Do not use any liquid

dowels adjacent to cylinders

seal or cement.

21. Position the

22. Insert the pushrod. Check

cylinder

head.

if

the push rod is securely

set in the tappet concavity.

~

INCORRECT

CORRECT-~1iN1

TAPPET

CAM

LOBE

23. Position the valve cap

CAM

LOBE

on

the top

of

the

valve stem.

24. Install the rocker arm assembly onto the cylinder head. Remember that the end of the rocker shaft

having the pin occupying the slot in toward the front (pulley) end

of

the engine.

#1

rocker support points

WHEN

NO 4 CYLINDER

4 4 3 2

4

EXHAUST

4

INTAKE

WHEN

I

3

EXHAUST

I

3

NO 1 CYLINDER

IS

AT

TOP

I

2

EXHAUST

INTAKE

DEAD

CENTER

2

INTAKE 1 INTAKE

11

EXH~UST

I

2 1 1

IS

AT

TOP

DEAD

CENTER

26. Adjust valve clearance. Adjust the valve clearance.

Set No, 1 cylinder to compression stroke and

No.2

intake cylinders ... and

IDC

(top dead clearance)

and

adjust the valve clearance on No. 1

No.1

and

of

No.3

the

exhaust

cylinders.

a. Tum the crankshaft once, setting the

piston at and No.4 intake cylinders

IDC

(compression) and adjust the

...

and the No.2 and No.4

No.4

cylinder

No.3

exhaust cylinders.

h. Adjust each valve's clearance by inserting a 0.012 in

(0.03 mm) feeler gauge between the rocker arm and

the valve stem.

J1llve

Clearance

71Bn1C

27.

Install

0.30

the

mm

cylinder

(.12 in) cold

head cover.

Torque

71Bn1C

NOTE:

After the engine

readjust the valve clearances with a warm engine, see

0.3 - 0.4

m-kg

(2

- 3 ft-lh)

has

been reassembled,

ENGINE ADJUS'IMENTS.

Engines & Generators

26

ENGINE

28.

Install the thermostat and thermostat housing.

a. Inspect the thermostat housing and the housing

Apply some sealant

b. Install the temperature switch and sendor and

nect their

c.

Install a

wires.

new can become a spare). When installing the stat and gasket, apply a thin coat of sealant sides of the gasket.

d.

The thermostat can placing it in a pan temperature of the water should open noticeably (with travel

1/4 in -

is

THERMOSTAT HOUSING'

THERMOSTAT

~

WATER SENDER

29.

Install the coolant pump assembly.

Tightening Torque

71B/71C

A complete breakdown

PUMP in this manual.

30.

Adjust the injection timing.

See INJECTION TIMING.

31.

Mount the oil filter bracket and install a

112

in)

boiling.

71C

TEMP

...........

"-

"

1.6-2.3

ASSEMBLY is covered on another page

When installing the

to

engine oil

32.

Mount the

Tightening Torque

71 B/71 C

33.

Install the intake manifold.

Tightening Torque

71B/71C

34.

Mount the fuel filter assembly.

the rubber gasket. Tighten

front

4.6 -6.8

1.6-2.4

to

the

gasket

when

reassembling.

thermostat and gasket (the

old

new

be

checked

of

cold water and then raising

and

be

fully

\...:;;~:::--'-"~

m-kg

of

the

for

proper operation

to

a boil. The thermostat

on

the

opened

(12

COOlANT

when

AIR

-17ft-lb)

BLEED

order of

the water

new

filter apply a

engine mounting bracket.

m-kg

(33 -49

m-kg

(11.6

thin

coat of clean

by

hand.

ft-lb)

-I7.4ft-lb)

gasket.

recon-

thermostat

thermo-

to

both

the

PETCOCK

filter.

REASSEMBLY

by

35.

Install the fuel injection nozzles. Install

overflow same order

Injection Nozzle Hold Down

71

Injector Tightening Torque

71C

See FUEL INJECTORS

36.

anti-seize compound

Glow Plug Tightening Torque

71B/71C

To

37. vent hose.

Rocker

71 B/71 C 0.25 - 0.40

38. fuel filter and the line

sealing washers.

39. the injection pump

line clamp.

TorqueAttaching Nuts

71B/71C

40.

41.

42. cooler on the flywheel bellhousing.

The

Refer to HEAT EXCHANGER.

pipe.

Use new sealing washers throughout, in the

as

were the old washers.

B 1.6 - 2.4

6.0 -

Install the

test the glow plugs, see

Mount the rocker arm cover and crankcase

Arm

Connect the fuel line

Connect the high pressure injector lines from

m-kg

7.0

m-kg

glow

1.0

-1.5

Cover Tightening Torque

2.5 -3.0

Install the bellhousing. Install the air intake silencer.

Mount the engine heat exchanger and engine oil

heat exchanger should be serviced

718

Nuts

Torque

(11.6

-17.4

ft-lb)

(43

-

51

ft-lb)

plugs

and connectors.

on

the threads.

m-kg

(7.2

-IO.8ft-lb)

GLOW

m-kg

to

injectors. Reinstall the

m-kg

PLUGS

(1.8 - 2.9 ft-lb)

to

the

engine mounted

the injection pump. Use

(18 - 22ft-lb)

at

MANIFOLD

ASSEMBLY

the

fuel

Use

new

engine overhaul.

'''''WEBJERBEICE

I Engines & Generators

27

ENGINE

43.

Install the alternator and drive belt.

A

CAUTION:

the

polarity

from

thB

and

wiring

a. Install the alternator support bolt through the alternator

leg (underside) into the engine casting.

b.

Swing the alternator into position on the adjusting

bracket and fasten. Lightly tighten. c. Adjust belt tension. d.

Tighten both bolts and recheck belt tension.

Torque Values

71

ani

C Support bolt

Adjusting bracket bolt

NOTE:

Make alternator ers

as

needed,

See

ALTERNATOR for

Connect

be

revelSlld, a powerful

battery

into

the

alternator,

harness.

certain

the

belts

and engine pulleys.

to

align

the

alternator.

testing.

aiternator

PfDptlr/y.

current

would

damaging

20

- 24

Nm

(15 -

18

12

-14

Nm

(9 -10 ft-Ibs)

are

perfectly aligned with the

If

not,

insert or

remove

Should

the

ft-Ibs)

REASSEMBLY

50.

Install

flow

diodes

spac-

COOling

51.

fill with ATF Dextron

NOTE:

Drive

pressure tested

mission oil cooler hoses should also the

TYPICAL TRANSMISSION

OIL

50. Generator. Mount the generator back end assembly

with it's control panel. Reconnect nect all AC connections.

system.

Marine Engine. Reinstall the marine transmission and

Some transmissions, such as

require

text

on

COOLERS

new

hose connections and clamps

ill.

the

oil coolers.

and

HEAT EXCHANGERS.

Oil

coolers should be cleaned,

repainted at engine

oe inspected. Refer

all

DC

Borg

Warner

overhaul.

~

wiring and recon-

"'1111

~,..

Velvet

The

~

for

trans-

to

44.

Install the raw water pump and drive belt.

Insure it is in proper alignment with the crankshaft pulley. Check tension.

Refer

to

RAW

WATER

45.

Install the oil and water sender and switch.

46.

Install the starter motor.

47.

Install the breaker panel and the

preheat solenoid.

48.

Reinstall the engine electrical harness.

49.

Mount the complete exhaust manifold and the

expansion tank

Torque Mounting Bolts

2.7-

3.3 m-kg

See

EXHAUST MANIFOW for service and

PUMP

to

the cylinder head.

(20

- 24 ft-lb)

inspection.

A

CAUTION:

to

WESTERBEKES

Fill the engine cooling system with antifreeze mixture and the engine oil sump with lube oil

The engine should be test run under load prior to reinstalling. At

this time readjust the valve clearances on the hot engine.

Check

wiring

all

AC

and

schematics

(A.P.1.

DC

and

wiring

diagrams.

spec.

CF

connections

or

CG-4).

'

....

IWESJERBEICE

i Engines & Generators

28

EXHAUST

MANIFOLD I HEAT

EXCHANGER

EXHAUST

The exhaust manifold, which was disassembled from the cylinder head, should be inspected before reassembly.

1. Remove the exhaust elbows from the lower surface the manifold. Clean and inspect for cracks and defects.

Replace as needed.

2. Remove the exhaust nipples, elbows and plugs from

the manifold.

3. Remove water connectors from the ends

and the end plates (71B). tion and arrangement

4. Examine all parts for defects, corrosion and wear and

replace as needed.

5. Flush out the manifolds interior with a liquid cleaner and

rinse thoroughly with fresh water. Use a pipe cleaner to clear the passage that connects the

6.

coolant recovery tank tubing.

7. Flush out the coolant recovery tank and it's

connecting tube.

MANIFOLD

of

....".,"'...............

of

the manifold

Be

sure to note the proper loca-

each for proper alignment.

EXHAUST

TO

COOLANT

MANIFOLD

RECOVERY

REPLACE

of

TANK

GASKET

Check the manifold pressure cap. it and make sure it closes upper and lower seals are replace the cap.

HEAT

EXCHANGER

The heat exchanger should be inspected and serviced during

an engine overhaul.

1. Disconnect the hoses petcock, drain plugs fittings and gaskets.

2. Inspect the tube (casing) for wear and dents, suspect replace the heat exchanger.

3. Clean out any zinc debris and pressure test the coolant and raw water passages .

4. When reassembling, install new gaskets and Apply some lubricant petcocks and fittings as

5. Install a new zinc anode.

when in

and

to

Open the valve by pulling

released. Make certain the

good

condition.

remove the hose fittings,

zinc anode. Also, remove the end

the new gaskets and to the

you

install them.

If

any doubt,

if

at all

O-rings.

CLEAN

AND

THE

MANIFOLD

ASSEMBLY

1.

If

the manifold was ·removed as an assembly and left intact, it can be replaced reverse order new ones and torque the bolts or nuts to the proper specification (1O-12lb-ft).

If

the manifold has been disassembled, follow the

2. steps below.

a. Loosely attach the elbows to the cylinder head and

the manifold using new gaskets.

gasket sealant.

h. Gradually tighten each fitting to make sure

alignment steps. Torque to 10-12 lb-ft.

c. Reassemble the manifold end plates (71B), and the

connectors

gaskets and coat the gasket surfaces with a suitable gasket cement such as High Tack. Torque the nuts

to 8-10 lb-ft.

d.

Reinstall the exhaust connections and plugs into the manifold using Locktite-Anti-Seize on the threads.

of

removal.

of

all the parts. This should be done in three

on

the cylinder head in the

Do

not reuse the gaskets; install

Do

not use any

the manifold. Be sure to use new

REPAINT

of

proper

NOTE:

All

o/the

above can heat exchanger to a also service transmission

6. Repaint the assembled heat exchanger with Westerbeke

heat resistant spray enamel.

HEAT

EXCHANGER

718

AFTER

5. Reconnect all hoses, replacing them as needed.

6. Refill the system with coolant as detailed above.

7. Pressure test system

COMPLETED

be

accomplished

heat

exchanger service shop. They will

and engine oil coolers.

by

ENGlN£lSSEMBLY

and

check for leaks.

sending the

REPLACE

HOSE

Engines & Generators

29

FUEL

INJECTION

PUMP

SPEED

The fuel injection pump is the most important component

the diesel engine and, therefore, calls for the utmost caution

in handling.

Speed (hertz) and timing are the only adjustments the service dealer can perform on the injection pump. Other types adjustments or repairs must be performed by a qualified injection service shop.

Early

When servicing the injection pump, the service shop must be advised The service shop will have to remove and replace the

governor spring with a propulsion spring. Once the injector

pump is set up to propulsion specifications, the generator

governor spring is reinstalled in the injection pump and the pump remounted on the engine. Then set the throttle for proper engine no-load speed (hertz).

For the disassembling, inspecting, reassembling and internal adjusting the pump be taken to a qualified injection service shop authorized to service Diesel KiKi injection equipment.

The only adjustment the servicing mechanic should make to the injection pump is the adjustment for engine idle speed.

1. Checking Idle Speed.

Normal

71 B 600 - 700 71 C 580 - 630

2.

NOTE:

or

ADJUSTMENT

Models

if

a. Warm up the engine.

h. Remove any specks on the crankshaft pulley with a

clean cloth and place a piece tape on the pulley to facilitate use

type tachometer. c. Start and idle the engine. d. Aim the light

to confirm the engine speed. e. Adjust the idle speed

the specified value.

Idle Speed

To

adjust the engine idle speed, loosen the lock nut the idle adjustment bolt and tum the bolt clockwise to increase idle speed and counterclockwise to reduce.

Should engine

readings as shown

strobe type tachometer

without

the pump is to be used in a generator application.

of

the injection pump, it is recommended that

(PROPULSION

Electronic

of

the tachometer onto the reflecting tape

if

the engine speed is not within

RPM RPM

RPM

be in question, verify tachometer

at

the instrument panel with a mechanical

at

the engine crankshaft.

ENGINE)

Governing

of

suitable reflecting

of

a photo-electric

of

3. Inspecting and adjusting the injection pump timing.

a. Remove the air intake/silencer assembly.

h. Remove the 4 high pressure injector lines that connect

between the injection pump and injectors.

c. Remove the bolt and gasket installed on the distributor

of

head

d. Remove the valve rocker cover.

e. Rotate the crankshaft in normal direction

(use front crankshaft pulley nut) and place at

NOTE:

rocking (one opening, the

f. Remove the snap ring circlip from the end

rocker shaft washer.

g.

Loosen the rocker arm adjusting bolt so as to allow the

arm to be removed from the push rod and slide it off

the rocker shaft.

h. Press down on

that the valve

remove the cap, keepers and valve springs from the No.1 valve.

NOTE:

not to drop keepers

i.

Position a dial indicator gauge on the valve stem and with the front crankshaft pulley nut, rock the crankshaft counter-clockwise and clockwise to locate exact TDC of the dial indicator gauge to the valve stem. (The gauge should be able movement.)

the injection pump.

of

rotation

No.1

IDC

of

its compression stroke.

To

verify, the rocker

at

Insure the valve

the compression stroke for No.1 piston and then zero

arms

of

No.4

cylinder should be

other

closing).

of

the

cylinder No.1 along with the retaining

the

valve and spring assembly and note

is

hitting the top

moves

down

push

to

measure up to .300 inch

~~

__

;...

of

No.1 piston. Then

freely in its guide. Take care

rod hole.

of

valve

~~==~l=5.21

(0.205

mm

t

j.

Tum the crankshaft until the indicator shows the valve drip to be at .264 inch. This is 30 degrees

k. Install the measuring device (Diesel Kit #57828 -

3520) in the head. (Refer to step c.) Insure that the feeler needle the measuring device is in contact with the plunger inside

bolt

hole

of

the injection pump distributor

of

the pump. Zero the measuring device scale.

BIDC.

piston

BTDC

in)

of

ADJUSTING

IDLE

SPEED

Engines & Generators

30

FUEL

INJECTION

PUMP/FUEL

LIFT

PUMP

4. Turn the crankshaft in the direction until the No.1 piston is at

indicator on the valve stem. a.

The measuring device indicator needle should move

1.00

mm

from the zero setting.

Beginning

71

an1C

NOTE:

to be more

must be adjusted to correct the movement.

S.

Adjusting the injection pump.

of

Static Injection

Cam lift 1.00

If

the measuring device show movement

or

less than specified above, the injection pump

IDe

of

normal rotation

by referencing the

mm

(0.0394 in)

at

the plunger

a. Disconnect the fuel supply and return line connections

from the pump.

h. Disconnect the support bracket at the back

injection pump as filter adapter.

c. Loosen the two injection pump hold down nuts that

secure the injection pump to the engine.

d. Rotate the injection pump either towards the engine

away from the engine to adjust the measuring device indicator to show

Secure the pump by tightening the two

e.

hold down nuts.

f. Remove the measuring device and replace the bolt

and gasket and reattach all fuel lines using new sealing washer.

6. Installing injection pump. Install the injection

noting the following points:

a. Tighten the lock nut

the specified torque.

Tightening Torque - Injection Pump

71

ani

C 4.0 - 7.4

h. After the injection pump has been installed, loosen the

overflow valve, and bleed the priming pump.

it

attaches to the lube oil

1.0

mm

of

movement.

pump in the reverse order

of

injection pump drive gear to

m-kg

(29 - 51 ft-lb)

air by operating the

of

removal,

the

or

FUEL

LIFT

PUMP

The

Fuel Lift Install a new filter as illustrated and clean the ground wire end terminal.

MAGNET

pump

(Early

should

____

Models)

be

I~'-+~"\

cleaned and repainted.

FUEL

LIFT

PUMP

GROUND

Troubleshooting

This lift pump operates heat is depressed. pump should produce a in the pump is operating. there is 12 volts properly grounded.

at

1. Test the pump

illustrated. Fuel delivery more every 15 seconds.

FUEL

LIFT

Simulate

the

pump

by

connecting

PUMP

during

the start sequence when pre-

a start and depress preheat, the

clicking

sound indicating the piston

If

no

clicking is heard, check that

connection and that the pump is

a battery and fuel line as

must

be

225 cc (0.5 pints) or

TESTING

THE

FUEL

PUMP

CYLINDER

INJECTION

PUMP

r

SUCTION

HEAD

APPRDX.

500

NOTE:

Later model use a solid state This lift pump can also shown above.

FUEL

Engines & Generators

31

mm

LIFT

WESTERBEKE

fuel

lift

pump

be

adapted

PUMP

engines

that requires no maintenance.

to replace the

and

generators

pump

FUEL

INJECTORS

REMOVING

1.

Disconnect the high pressure lines from the injectors and loosen the lines at their attachment to the injection pump and move them out bending the lines.

2. Remove the fuel return line in its entirety from the top the injectors. Take care not to lose the two sealing washers and banjo bolt that attaches the fuel return line to each injector.

3.

71 B Remove the two nuts and washers that hold the

injector on the cylinder head.

THE

INJECTORS.

of

the way

of

the injectors. Avoid

71 C Unscrew the injector from the cylinder head.

NOTE:

Clean the area around the base

it

out

of

lifting debris from falling down into the injector hole. will not lift out easily like, work the injector side to side with the aid adjustable

4.

The injector seats in the cylinder head on a copper sealing washer. This washer should be removed with the injector and replaced with a new washer when the injector is reinstalled.

INJECTION

1.

Using the nozzle tester, check the spray pattern and injection starting pressure adjust or replace the nozzle. When using nozzle tester, take the following precautions:

A

CAUTION:

such

velocity

of

fingers

bloodstream,

a.

If

it. At the same time, clean or replace the

h. 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 tempurature

of

e. Operate the hand lever

bleed the lever at intervals ing the injection starting pressure.

the cylinder

or

open end wrench to free it

TESTING

The

that

and

hands,

it

may

the diesel fuel

20" C (68

0

air in the nozzle line, then move the hand

head

and

is

held

of

nozzle and,

spray

injected

it

may

penetrate

destroying

cause

blood

of

the nozzle tester is stained, replace

F)

of

one stroke per second while read-

of

the injector prior to

to help prevent any rust

If

the injector

in by carbon build up

of

and

then lift it out.

if

it exceeds the limit,

from

the

nozzle

deeply

Into

tissue.

If

it

enters

poisoning

nozzle tester several times to

•.

an

the

filter.

or

is

skin

the

or

of

the

Start to Injection

71

B/71 C 135 -

71

B

If

the injection starting pressure within the limit, loosen the cap nut holder, insert flat screwdriver through the bolt hole the cap nut, then turn the pressure adjusting screw to set

the injection starting pressure to 200 kglcm2 (2.844

Ib/in2). Then, gradually decrease the pressure until the

injection starting pressure is 135 kglcm2

After the injection starting pressure has been adjusted,

hold the pressure adjusting screw with flat screwdriver, then tighten the cap nut. Then check the injection starting pressure again

Cap

Nut

Tightening Torque - Injector

71

B 4- 5

The injection starting pressure for the adjusted by increasing or decreasing the thickness adjusting shim.

The shim has (0.0020 in), from 1.0 As

0.05 kglcm2 (71.1 Ib/in the shim, grip the retaining nut in a vise and remove the body with a wrench. Tighten the retaining nut to the

specified torque.

m-kg

20 different thickness for every 0.05

mm

(0.0020 in) is increased, approximately 5.0

140

kg/cm2 (1920 - 1990

of

the nozzle

on

the nozzle

if

it does not change.

(8.82 -11.021b)

71 B INJECTION PRESSURE

71

C injectors

mm

(0.0393 in) to 1.95

2

of

injection pressure. When replacing

)

mm

!

ADJUSTING

SHIM

~

j

lblin2J

is

(1920 Ib/in2).

SCREW

is

of

the

mm

(0.0768 in).

SHIM

THICKNESS

O.1mm

O.2mm O.3mm O.5mm

not

of

ADJUSTMENT

INJECTION

NOZZLE

Engines & Generators

32

71 C INJECTION PRESSURE

ADJUSTMENT

FUEL

INJECTORS

INSPECTING

1.

Operate the hand lever one stroke per second to check rectly in its axial direction. A nozzle is defective injects fuel in an oblique direction or in several separate strips. Also, a spray in the fonn defect. These defects may sometimes be caused by clogging cleaned before reassembly. (Care should be taken not to expose ones skin to this spray and cause infection.) .

NORMAL

2.

Apply the pressure by operating the hand lever, and check the drips from the nozzle tip. on the bottom, it is considered defective and should be replaced. A very small amount remain on the tip

SPRAY

with dust and, therefore, all parts should be carefully

I

!

II:

I~I

'1':"\

If

PATTERN

of

the nozzle tester at intervals

if

the fuel is injected cor-

of

particles indicates a

as

it may penetrate the skin

,~,

\~

FAULTY

ANGLE

of

115

kglcm2 (16351b/in2) to nozzle

it drips or has a large accumulation

of

fuel may sometimes

of

the nozzle; however, this does not

\\,'

FAULTY

DIRECTION

if

of

it

fuel

of

ASSEMBLING

Assemble in the reverse lowing points:

1.

To assemble the nozzle and nozzle holder, first assemble the pressure adjusting nut. Mount the nozzle position, then mount

2. After the nozzle check the injection starting pressure and spray condition.

Nozzle

Nut

Tightening Torque

71Bn1C

Cap

Nut

Tightening Torque

71 B 4 - 5 m-kg (29 -

@

___

:;---;::

~

-WASHER

order

nut

the

and

nozzle

8

-10

m-kg

NUT

INJECTOR LINE

of

disassembly, noting the fol-

side, and temporarily tighten the

and

set the needle valve to proper

nozzle

nut.

holder have been assembled,

(58 -72ft-lb)

36

ft-lb)

BANJO

BOLT-i

RETURN

GASKETS

.....

~

NUT-~

BODY

SCREW~

NOZZLE UPPER

SEAT

SPRING

CD

~

mm-lrr

CORRECT

W

DISASSEMBLING

1.

Clamp the nozzle holder in a vise, then remove the cap nut.

2. Remove the pressure adjusting screw, then pull out the upper seat, spring and the push rod.

3. Clamp the nozzle holder in a vise, remove the nozzle nut then pull the nozzle out.

4. Clean the disassembled parts with clean diesel fuel, then remove the carbon adhering on the nozzle.

NOTE:

Do

not

S.

After cleaning, check to see down into the valve seat by its own weight when setting the nozzle body upright position and inserting needle valve.

6. Check that surfaces and sliding surfaces valve and,

NOZZLE

~

"",0-'"

AFTER

DRIP

AND

INSPECTING

use

a metal tool

there is no flaw or other damage on mating

if

present, replace the nozzle assembly.

BODY

M

TEST

to

remove

if

the needle valve comes

of

•

WRONG

the

carbon.

nozzle body and needle

TORQUE WRENCH

"""'''-'''-~

~~

---t.IOZZLE NUT

71C

INJECTOR

INSTALLING

Install the nozzle and

of

order

1.

2.

Tightening Torque

71

Tightening Torque

71C

removal, noting

When installing the

use a new copper washer.

71 B TIghten the

the specified torque. nuts; do not tighten

B 1.6 - 2.4

(27mm)

nozzle

m-kg

6.0-7.0m-kg(43-51ft-lb)

BRUSH

ROD

NOZZLE

BODY

NUT

nozzle

holder assembly in the reverse

the

following points:

nozzle

one

and nozzle holder assembly,

and

nozzle holder assembly to

Switch

back and forth between the

completely with the other loose.

(11.6 -17.4 ft-lb)

CONNECTOR

71 B INJECTOR

Engines & Generators

33

GLOW

PLUGS

DESCRIPTION

The glow plugs are wired through the preheat soleniod. When PREHEAT is pressed at the control panel this solenoid should "click"

on

and the glow plug should begin to get hot.

INSPECTION

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

burn erosion;

if

it has eroded too much, replace the plug.

TESTING

An accurate

Touch one prod to the glow plug's wire connection, and the other to the body glow method can be used with the plug You

can also use

(8

to

A

'0

,he

'lISting

way

to test glow plugs is with an ohmmeter.

of

plug will have a

an

ammeter to test the power drain

9 amps per plug).

WARNING:

'ouch.

'hII

BII

plugs

TIuIss

t:IIlflful

the glow plug,

1.0-

to 1.5-ohm resistance. This

glow

plugs

no'

'0

in

or out

bum

as

shown. A good

of

will

becomll

,our

t1ngllfS

the engine.

VII"

whlln

ho'

Re-install the plugs in the engine and test them again. The plugs should get very hot (at the terminal end) within 20 to 25

seconds. short circuit. When reinstalling the glow plugs, use anti-seize compound on the threads.

A

than

If

the plugs don't heat

WARNING:

30

stlt:Dnds

Do

no'

(J.O - 1.5 m-kg

kllllfJ a glow

Tightening

up

quickly, check for a

plug

on

TERMINAL

torque:

THE

END

(7·

iljt-lb)

GLOWPWG

OHMMETER

for

TEST·

mom

TIP

Engines

34

&

Generators

ENGINE

ADJUSTMENTS

VALVE

1.

2. Pull off the

3.

Valves are adjusted with the piston in the cylinder being adjusted at stroke.

NOTE:

CLEARANCE

Warm the engine to normal operating temperature.

ADJUSTMENT

air breather pipe from the rocker cover, and

take off the rocker cover bolts and the rocker cover to expose the rocker shaft and valve assembly.

Remove the glow plugs from each of the cylinders to

by

enable the engine to be easily rotated each cylinder for valve adjustment.

TDC

(top dead clearance)

Retorque the cylinder head bolts before adjusting the

engine

s valves.

4. Loosen the head bolts in the reverse order

CYLINDER

19

HEAD

hand to position

of

its compression

of

tightening.

BOLT

PATTERN

15

16

7. Tum the crankshaft once, setting the piston cylinder at TDC (compression) and adjust to the following values:

Intake Exhaust -

8. Adjust each valve's clearance by inserting a

No.3

and

No.4

cylinders

No.2

and

No.4

cylinders

(0.03 mm) feeler gauge between the rocker arm and the valve stem. Make sure to adjust all valves when the engine is cold.

of

0.012 in

.

VALVE

No.4

CLEARANCE

13

• 5

5.

Tighten the head bolts in the order shown.

Cylinder

71 B 11.8 - 12.5 71 C

6. Set the piston

Intake Exhaust -

WHEN

4

EXH~IJST

Head

Bolt

Tightening Torque m-kg

11.0

-11.7

m-kg

of

No. 1 cylinder and check the valve clearance at each position indicated. Adjust,

NO 4 CYLINDER

4 4 3 2

if

the clearance is incorrect.

- No. 1 and No.1

and

IS

I 12

4

INTAKE 3 INTAKE

No.2

No.3

,VALVE

AT

TOP

EX~AUST

4'

(85 - 89 ft-lb)

(80 - 85 ft-lb)

to

cylinders

ADJUSTMENT

DEAD

CENTER

12

FRONT'

TDC (compression)

SEQUENCE

17

9. Install the cylinder head cover.

,

Head

Cover

Bolt

Torq~e

.71

Bn1

C 0.3 - 0.45

ENGINE

Check the compression pressure. 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 dramatically (at least of more than 42.7 psi

Compression

71Bn1C

Compression

71

COMPRESSION

the others. Compression pressure should not differ by

Pressure

30.0

Pressure

Bn1C

27.0

..

m-kg

(2

- 3 ft-lb)

To

do this warm the engine,

20%)

lower compression than the average

(3.0 kg/cm2) at 200

Standard

2

kglcm

kg/cm2 (3841hlinl)

(4271b/in2)

Limit

rpm.

at

200 rpm

2

INTAKE 1 INTAKE

3

EX~AUST

3 2 1 1

.

WHEN

NO 1 CYLINDER

11

EXH~USTI

IS

AT

TOP

DEAD

CENTER

MEASURING COMPRESSION

.

Engines & Generators

35

ENGINE

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. cylinder is still low, apply a small amount of oil into the

to

cylinder comes up - the rings are faulty.

Abnonnally high readings on all cylinders indicates heavy carbon accumulations, a condition that might

accompanied by high pressures and noise.

NOTE:

the injection service loss in

injector faults.

When re-installing the glow plugs use anti-seize compound.

seal the rings and repeat the test.

In

case

of

severe vibrations and detonation

injectors checked and overhauled by an authorized fuel

center.

Poor fuel quality, contaminates and

of

positive fuel pressure to the injection pump will result

If

be

If

the

compression

noise,

have

ADJUSTMENTS

ADJUSTMENT -71

Make the necessary adjustment by turning the idle adjustment bolt on the fuel injection pump.

1.

Loosen injection pump.

2.

Tum

the standard range.

3. Tighten the locknut.

4. Race the engine several times to ensure the at the standard range.

ADJUSTING

the

the idle adjustment bolt until the idling speed

SCREW

Bn1

locknut on the idle adjustment bolt

LOCKNUT

C

idle

IDLE

ADJUSTMENT

on

the

is

speed is

at

BOLT

SETTING

1.

2.

3. Idle the engine.

4.

Jd/eSpeed

71 71 C 580 - 630 rpm

THE

IDLE

SPEED

Warm the engine to nonnal operating temperature. Stick a piece

pulley.

Use the light the reflecting tape and check the valve shown by the tachometer.

B 600 -

of

suitable reflecting tape on the crankshaft

of

a photoelectric strobe type tachometer on

700

rpm

ADJUSTMENT -20KW

Note:

Speed adjustment

by the electronic governor see

for speed

and

gain adjustments.

of

the generator (hertz)

~,THROTTlE

SCREW

is

ELECTRONIC GOVERNOR

~WIRE

STOP

controlled

LOCKED

Engines & Generators

36

COOLANT

CIRCULATING

PUMP

DISASSEMBLY

1. Remove the press.

2. Remove the bearing shaft from the impeller and bearing housing by using a support block and press.

3. Remove the snap ring with snap ring pliers and press out the water pump shaft

PUlllP

pulley boss by using a support and

from the bearings.

INSPECTION

Inspect the shaft, bearings and impeller. Look for cracks and damage. Check the housing gasket and inspect the rear seals

an,d

small end gaskets.

Replace any parts that show wear.

'\

APPLYATHINCOATOFOIL

,

TO

SPRING LOADED SEAL

NOTE:

Do

not

allow suifaces spring-loaded seal.

3. After the water

of

the ceramic ring

pump shaft

pump

rotates smoothly. '

oil

or

grease to contaminate the

or

the graphite (small end)

has

been assembled, check

if

of

the

ASSEMBLY

Assemble the water pump disassembly, using the following procedure:

1. Fill lithium grease (lithium base NLGI following positions.

• Ball bearings

• Approximately

• Space between the ball bearing and water baffle plate.

2. Apply a

of proper aperture mandrel.

thin coat

the water seal and press the larger end into the

of

(49 0636 145)

in

the reverse order

1/3

space between both ball bearings

of

engine oil to the press fit surface

the pump using a tubular

of

No.2)

into the

(COOLANT

'-.~·------\WATER

PUMP

BODY

PUMP

\

Engines

I

37

I

.~(3enerators

\-

STRAINER

INSPECTION

1.

Visually parts. special care or by

check

the

Check the sliding surface of

and

excessive

rubbing

streaks.

them

/1

COVER

DRIVE

GEAR,

__

2.

Clearance between pump body above

clearance

Clearance Limit

71an1C

When

the

clearance exceeds the limit, replace

.".

shaft'inner

rotor,

~

0.1

pump

disassembled parts

replace the cover

(Minor

with

steps

a compound

I

and

with

a dial gauge

mm

(0.0039 in)

body and

drive

LUBRICATING

and

replace

pump

cover.

if

the

surface

streaks

may

on

a surface plate.)

shaft.

Measure

and

magnet

gear.

faulty

with

has

steps

be

repaired

\

ROTOR

ASSEMBLY

LUBRICATING

OIL

PUMP

the

base.

the

pump

drive

OIL

PUMP

4.

Clearance between outer rotor and pump clearance between feeler gauge. rotor or pump

Clearance

0.3

5.

Clearance between rotor and pump float body straight edge with a feeler gauge. the outer rotor and pump

Clearance

Limit

mm

(0.12 in)

OUTER

of the rotors. Place a straight edge across

and measure

limit, replace the drive

Limit

the

outer rotor and pump body

If

the clearance exceeds the limit,

body.

the

clearance between the rotor

gear,

drive shaft, inner

body.

0.15

mm

(0.006 in).,

body.

cover.

If

the

clearance

,STfIAIGIHT

Check

with

replace

Check

the

pump

and exceeds rotor,

EDGE

CHECKING

END

FLOAT

\~

the

a the

end

3.

\

Clearance between inner rotor and outer clearance between the lobes of the rotors with a feeler

gauge.

If

the

clearance exceeds

both rotors.

Clearance Limit

71an1C

0.3

mm

~~~"'"

~~~~!/.;f1TALLY

,i

the

(0.012 in)

INNER

o

I

limit, replace

ROTOR

MARKS

,DIAL

rotor.

GAUGE

Check

the

Engines & Generators

\

'38

6.

Free Jength of plunger spring. worn plunger and fatigued spring.

Spring free Limit

71

ani

C 40

mm

(1.61 in)

(~~i(D

1\

MEASU~ING

\

LENGTH

7. Assembly. Assemble in the reverse order of

NOTE:

the

tally marks

Cover Tightening Torque

71

ani

FREE

When

installing

C 0.8

I.W

the

rotors into

on

the rotors

-1.2

i

40

mm

(1.61

in)

the

body,

are

positioned toward the

m-kg

(5.8 - 8.7 ft-lb)

'

disassembly.

be

sure

that

cover.

OIL

PRESSURE

OIL

PRESSURE

When performing an engine overhaul, replace the oil pressure switch and the oil pressure sender. When installing the new parts apply a teflon sealant to the threaded ends being careful not to close off the oil hole in the sender.

Oil Pressure

71 ani C 1.2 - 1.8

A

CAUTION:

ers,

vise switch. Snap-On, swItch

Use

will

SWITCH/SENDER

Sender

grips

Proto,

cause

Oil

or

the

and

Switch

Pressure

pipe

wrenches

correct

New

Britain

oil

leaks

m-kg

socket

Torque

(9

- 13 ft-lb)

SWitch -00

on

the

which

and

others.

and/or

switch

not

use

oil

pressure

Is

avaIlable

Damage

faIlure.

SWITCH/OIL

lock

pli-

from

to

the

PRESSURE

OIL

PRESSURE

To test the oil pressure, remove the oil pressure sender, then install a mechanical oil pressure gauge in it's place. After warmer read the oil pressure gauge.

. Oil Pressure

71 ani C 3.8

LOW

A gradual loss bearing failure. For additional information on low oil pressure

readings, see the ENGINE

up

the engine; set the engine speed at 2400

1

OIL

PRESSURE

of

oil pressure usually indicates a specific

kg/cm

(54 lblin1)

TROUBLESHOOTING chart.

or

more

at

rpm

3600

and

rpm

CURRENT AND

EARLY

ENGINES

GENERATORS

MODEL

+

Engines & Generators

39

RAW

WATER

PUMP

\

Disassembly

L

The pump, as removed from the engine, will have hose attachment nipples threaded into its inlet and outlet port. They may be left in place the pump disassembly. Note the port location and positioning if

1.

2. Remove the 4 cover plate screws, cover plate,

NOTE:

recommended; gasket well lubricated until allowed

3. Pull out the impeller with long nose pliers or pry out with

4. Remove the two screws that hold the bearing assembly,

NOTE:

press

OVERHAUL

or

removed

removed.

Loosen the set screw with an allen wrench and remove the water pump pulley from the shaft

and cover gasket.

Replacement

of

the cover plate gasket

however,

if

you

the

to

dry,

the

gasket will shrink and not

a pair

of

screwdrivers.

this will release the shaft, bearing and seal assembly. Removing the retaining rings will allow the bearings and seals to be disassembled for inspection.

It may

be

necessary

the

bearing and seal assembly from

to

use

if

they interfere with

is

are

going

to

reuse

pump

is

reassembled.

be

reusable.

a drift and arbor press

the

shaft.

it,

keep

If

the

it's

to

6. Inspect all parts and replace those showing wear or erosion.

7.

Use the illustration water pump.

a. apply a small

inner race and

b.

When positioning the cam amount cam screw threads, remove any excess from the impeller housing.

c. Apply a light

inner surface

S. When the

hose nipples. Assemble the pump to the engine and attach the hoses and belt.

of

pump

below

to assist in reassembling the raw

amount

to

Perm

film

of

is

of

petroleum jelly to"the seal's

the

impeller shaft at reassembly.

in

the housing use a small

ate x #1

the

assembled reposition and tighten the

on

the inner

of

silicone

housing for the impeller.

COVER

I

jGASKET

,.-

.-'.

~

cam

or

petroleum jelly to the

surface and

I

LUBRICATE

SHAFT

AT

ASSEMBLY

,

RAW

WATER

PUMP

\718-

71C

'

IRAW

I

,WATER,

PUMP

'.

:

Engines & Generators

40,

71

STARTER

DESCRIPTION

The starter can be roughly divided into the following sections:

• A motor section which generates a drive power.

•

An

overrunning clutch section which transmits an arma-

ture torque, preventing motor overrun after starting.

• A switch section (solenoid) which is operated when actuating the overrunning clutch through a lever and which supplies load current to the motor.

The starter is a new type, small, light-weight and is called a

high-speed internal-reduction starter. The pinion shaft is separate from the motor shaft; the pinion slides only on the pinion shaft. A reduction gear is installed between the motor shaft and a pinion shaft. The pinion sliding part is not exposed outside the starter so that the pinion may slide smoothly without becoming fouled with dust and grease. The

at

motor shaft is supported lever mechanism, switch and overrunning clutch inner circuit are identical to conventional ones.

ADJUSTMENT

If

any abnormality is found by the following tests, the starter

should be disassembled and repaired.

Pinion

1.

2.

3.

Gap

Connect a battery (12V) between the starter terminal S and the starter body, and the pinion drive should rotate out

and stop.

A

CAUTION:

seconds

Lightly push the pinion back and measure the return stroke (called pinion gap).

If

the pinion gap is not within the standard range, (0.5 to

2.0 rom), adjust it by increasing or decreasing the number of

shims on the solenoid. The gap is decreased as the

number

AND

Inspection

Never

continuously.

of

shims increases.

both ends

REPAIR

apply

battery

on

ball bearings. The

voltage

for

over

10

MOTOR

No-Load

1. Connect the ammeter, voltmeter, and battery to the starter

2. When the switch is closed, the pinion must protrude and

....---------------.,1

A

tighten type that starter in

SOLENOID

Perform the following tests. satisfactory, replace the solenoid assembly.

1. Inspect the solenoid for continuity between terminals

Test

as illustrated.

the starter must run smoothly (at the currellt semble the· starter and repair it.

or

starter speed is out

.

".

'

..

\

I

3000 rpm

of

or

more).

specification, disas-

\

e

1

!BATTERY

CAUTION:

starter

of a

contact

(+) and (-) and between terminals S and the body and

M and the body. There should be no continuity found between terminals between terminals S and the body and terminal M and the body.

Use

every

terminal

which

direct-drive

rotation

with

at

the

thick

wires

as1much

securely.

makes a rotating

type

the

pinion

S and M. Continuity will be found

This

sound

starter. gear

If

When

tip, be

careful

when

any test result is not

1----..,

as

possible

is a

solenoid

louder

detecting

not

it

protrudes.

than

to

and

shift-

come

If

O.5::Z.0mm

\

PINION

GAP

..

NOTE:

Disconnect the wire from terminal

2.

Connect a battery to the solenoid's terminal S for (+)

and M for (-). Have a switch

The pinion drive should extend fully out.

A

CAUTION:

than

10

seconds

Engines & Generators

\

41

\ .

f

MULTIMETER

~~.-

Do

not

when

.

apply

testing

M.

in

the + lead and close it.

battery

the

solenoid.

current

for

more

71

I

AnRACTION

3.

iHOLDING

TEST

:BATTERY.

Holding test. With a battery connected to the solenoid ter-

minal S (+) and to the starter body, manually pinion

fully,

The

pinion must remain at that position even

when released from holding with your hand.

TEST

,Q2~~~

~·\COl.NEC:TOR

STARTER

pullout

the

OFF

MOTOR

4. Return test:.

With

a battery connected to the solenoid terminal M (-) pinion fully. when released from holding by hand.

and

to

the starter body, manually pull out the

The

pinion

must

return to its original position

';BATIERY

I

RETURN

TEST

\

STARTER

I

..

1. Disconnect the wire from the solenoid terminal M (-).

2. Loosen the two screws fastening the solenoid. Remove the solenoid assembly.

3. Remove the two long through bolts and two screws fastening the brush holder. Remove the rear bracket.

4. With the brushes pulled away from the armature, remove the yoke and brush holder assembly. Then pull the armature out.

5. Remove the cover, pry the snap ring out, and remove the washer.

Unscrew the bolts and remove the center bracket. At the

6. same time, the washers for adjustment will come

DISASSEMBLY

the

pinion shaft end play

off.··

ilNSPECT

I

STARTER'

MOTOR

718

71C'

IS~~PRING~~~

FOR

WEAR & CHIPPING

_

~_--

,~~~CTFOR

. .

\

lEVERSPRI~-><ii-

jr-----

\

.

PLAY

&

NOISE

7. Pull out the reduction gear lever and lever spring from the front bracket.

8.

On the pinion side, pry the snap ring out, and pull out the

pinion and pinion shaft.

of

9. At each end

a bearing puller. It is impossible to replace the ball bearing press-fitted in the front bracket. off, replace the front bracket assembly.

')AUJ"'SIING' i

I I

I

J:ARMATURE

I

the armature, remove the ball bearing with

If

that bearing has worn

BRUSH

SHIMS

j.'

BRUS

..

HES

~~

. .

t

k~LDER

ASSEMBLY

'.

!

/.),

~

r:::--

:./

li,~

Engines. & Generators

142

I

STARTER

MOTOR

STARTER

INSPECTION

Solenoid

Inspect the solenoid for continuity between tenninals M and between tenninals S be found between between S and the body and M and the

CONTINUITY

Inspecting

1. Check the armature with a growler tester. If it's short circuited, replace the armature. Also check

between the communicator and its shaft.

insulated, replace the armature.

Sand

The

Armature

and

body. No continuity should

M. Continuity should

body.

CHECK

If

be

found

for

insulation

poorly

Sand

Brush

1. Check the brushes.

. Brush Height

Standard Limii 6 mm

and

Brush

replace the brushes .

17

mm

(0.236 in)

BRUSHES

2. Check the brush spring spring will cause excessive if

suspect. .

Holder

If

worn

(0.669 in)

Inspection

out

beyond the service limit,

NEW

tension.

A weak or defective

brush

USED

wear; replace the springs

ARMATURE

CHECK

2. Measure the commutator O.D. and the depth of undercut. Repair or replace it

check the commutator outside surface for dirtiness and roughness. crocus cloth.

If

if

the service limit is exceeqed. Also

rough, polish the commutator with

Commutar

IN.~;ft,

$ervice limit: -1.0

Standard: 38.7

O.D.

fine

Standard

mm

(1.523 in)

mm

(-0.039 in)

BRUSH

HOLDER

.

ASSEMBLY

I

3. Check for insulation and holder base.

assembly. Also check the

~

C>Q~~"""'"

If

poorly

between

the

insulated,

brush

holders for proper staking.

~~r7"'"

positive brush holder

replace the holder

Engines & Generators

43

il

Field

Coil

Inspection

.'

1. Check for insulation between one end (brush) coil and yoke.

2. Check for continuity between both ends (brushes) of

the coil

3. Check the poles and coil for tightness.

,

MULTIMETER

FIELD

COIL

\

I

TEST

STARTER

of

the

MOTOR

2. Greasing. Whenever the starter has been overhauled,

A

3. After reassembly, check

apply grease to the following parts:

a.

Armature shaft gear and reduction gear.

h.

All bearings. c. Bearing shaft washers and snap rings. d.

Bearing sleeves.

e.

Pinion.

f. Sliding portion

CAUTION:

terminals,

again.

\WASHER.

brushes,

flever

of

lever.

smear

the

or

commutator

by

.

GEAR

starter

with

conducting a no-load test

fitting

grease.

surface,

STARTER

A

starter 'old

depends cient and

Reassemble the starter assembly in the reverse order disassembly, making sure

1. Pinion shaft end play adjustment. Set the end play (thrust

gap) to between washer between the center bracket and the reduction gear.

a.

h. Measure end play by moving the pinion shaft in the

ADJUSTMENT

CAUTION:

paint.

size

fully

Fit the pinion shaft, reduction gear washer and snap ring to the center bracket.

axial direction.

increase the number

flange

and

on

the

and

tighten

Before

and

mounting

rust.

quality

grade

to

0.5 to 2

AND

REASSEMBLY

installing,

Starter

of

between

the

terminal.

of

If

the end play exceeds 0.5 mm,

of

thoroughly

surfaces,

performance

the

wiring.

the

battery

the following:

mm

by inserting an adjusting

adjusting washers inserted.

remove

largely

Use

wire

and

clean

the

all

oil,

of suffi·

starter

of

\

SNAP

RING

I

--....,I~--;:O.5

i

PINION

mm

MAX

SHAFT

END

PLAY

+

.

Engines & Generators

144

TACHOMETER

TACHOMETER/HOURMETER

The tachometerlhourmeter used in propulsion engine instrument panels contains two separate electrical circuits with a

common ground. other the tachometer. The hourmeter circuit operates on volts alternator charging voltage supplied to the (+) terminal on the back

The tachometer circuit operates on AC voltage 6-8 volts, fed from one tachometer input terminal while the engine is running, and the alternator producing battery charging voltage 13.0-14.8

volts

The following are procedures to follow when troubleshooting

a fault in either

of

DC.

Hourmeter

Check for the proper DC voltage between (+) and terminals.

a. Voltage present - meter is defective - repair or replace.

b. Voltage not present - trace

nections for fault. (Jump terminal to verify the operation.)

Tachometer

Check for the proper

terminal and

a. Voltage present - attempt adjusting meter through cali-

bration access hole. No results, repair or replace meter.

b. AC voltage not present - check for proper alternator

DC output voltage.

c. Check for AC voltage at tach terminal on alternator to

ground.

One circuit operates the hourmeter and the

12

of

the instrument.

the diodes in the alternator and supplied to the

of

the two circuits in a tachometerlhourmeter.

Inoperative

(-)

(+) and (-) electrical con-

12

volts DC to meter (+)

Inoperative

AC

voltage between tachometer input

(-)

terminal with the engine running.

Tachometer

Inaccurate

a. With a hand-held tach on the front of the crankshaft

pulley retaining front crankshaft pulley rpm. Set the engine with a hand or strobe tach

b. Adjust the

driver through the tachometer. Zero the tach and bring it by the strobe at high speed

needed.)

NOTE:

Current model tachometers use a coarse adjustment dial to set the tachometer calibrating screw is then used for fine tuning.

COARSE ADJUSTMENT

nut

or

with a strobe-type tach, read the

at

1S00-1800 rpm.

tachometer

the

or

2S00-3000 rpm). (Adjust the tach as

with a small Phillips type screw-

calibration access hole in the rear

to

hand

tach. (Verify the rpm at idle and

to

the crankshaft pulley

~0IZ'l..,--(+)

rpms.

TACHOMETER

(AC

of

the rpm set

The

TERMINAL

VOLTAGE)

INPUT

d. Check electrical connections from tachometer input

terminal to alternator connection.

Tachometer

a. Check for

minal and (-) terminal.

b. Check for good ground connection between meter (-)

terminal and alternator.

c.

Check that alternator is well grounded to engine block at alternator pivot bolt.

Sticking

properAC

voltage between "tach inp." ter-

EARLY

MODEL

EARLY

TACHOMETER

MODEL

TACHOMETER

.

CALIBRATION

(-)

GROUND

,TERMINAL

TACHOMETER

(AC

VOLTAGE)

INPUT

Engines & Generators

45

DESCRIPTION

The charging system consists regulator, an engine

cuit breaker and a battery with connecting cables. Because the use

of

integrated circuits (IC's) the electronic voltage reg-

is

ulator back

f14

BROWN·=~=:~-_

114

PURPLE==#i~iiiii®

to

Fuel

Solenoid

IFuel

Lift

Pump

very compact and is mounted internally or on the

of

the alternator.

;;;:"~

ALTERNATOR

of

an

alternator with a voltage

DC wiring harness, a mounted

114

GREY==~=5:~",=-

114

B~L~UE~~~.~~~

114

PINK·

DC

cir- ,

of

......

TESTING

1.

Start the

2. After a tery voltage set

The voltage should be increasing toward 14 volts. your

3. Turn to step 5 on the next page.

Gt'f'~=

few

on

DC

alternator

1t4

BROWN

to

Tachometer

Engin~

minutes

at

volts.

of

the battery terminals using a multi-meter

is working.

MULTI

running measure the starting bat-

If

it is,

METER

51

AMP

ALTERNATOR

(GENERATOR)

TROUBLESHOOTING

A

WARNING:

hot.

Do

not

This troubleshooting section is to determine exists with the charging circuit determined that the alternator or voltage regulator is bad, it is best to have a qualified technician check it out.

The alternator charging circuit charges the starting battery

and the service battery. An isolator with a diode, a solenoid, or a battery selector switch is usually mounted in the to isolate the batteries so the service battery

along with the service battery.

starting battery but not the service battery, the problem is in

the service battery charging circuit and not with the alterna-

tor.

Testing

A

that

sheaves

NOTE:

the

WARNING:

everyone

and

Multimeters and DC Circuits

A

failed

touch

until

Alternator

Before

is clear of

belts

during

alternator

the

alternator

or

If

starting

moving

test

can

become

has

cooled

if

with the alternator.

is

the alternator

the

engIne

parts!

Keep

procedures.

\\...~~~~~~=

ItO

RED

11+

OUTPUT

to

Starter

TESTING

BATTERY·ALTERNATOR

(ENGINE

very down.

a problem

If

it

is

4.

If

the starting battery voltage remains around 12 volts after the engine is started and run for a few minutes, a problem exists with the alternator

A.

Turn

tions. Insure that the battery terminals and the engine

ground connections are tight

A

circuit

not discharged

is

charging the

make

certain

away

from

charging

switch

B. If a battery selector switch is

insure that it is

C.

Turn

engine.

D. Check the battery voltage.

condition the reading should

Motor

THE

STARTING

RUNNINP)

GROUND

or

the charging circuit.

otT

the engine. Inspect all wiring and connec-

and

clean.

CAUTION:

Circuit,

when

on the ignition switch,

To

avoid

never

shut

the

engine

Is

on

the correct setting.

damage

off

the

to

the

engine

mnning!

in

the charging circuit,

but

do

not

If

your battery is in good

be

12

to 13 volts.

aml

MULnMETER

G

coM

battery

start

the

DC and A

cations.

Always disconnect shore power

C circuits

are

often mixed together

and AC converters and shut down generators forming DC proper

testing.

knowledge

of

No

AC

tests should

circuits.

cords, be

made

in

marine

isolate

before

DC

per-

without

appli-

TESTING

(IGNITION

Engines & Generators

46

THE

ALTERNATOR

VOLTAGE

ON -ENGINE

OFF)

_GROUND

STARTING

BATTERY

ALTERNATOR

TESTING

e. Now check the voltage between the alternator output

If

tenninal (B+) and ground. voltage at the alternator should be the same as the tery, or

if

an isolator is in the circuit the alternator volt-

age will be zero.

between the alternator and the battery. Check all the

connections

cuit.

TESTING

BATTERY-ALTERNATOR

f.

Start the engine again. Check the voltage between the

alternator output and ground. The voltage reading for a properly operating alternator

should tor is over- or under-charging, have it repaired at a reli- able service shop.

THE

(ENGINE

be

If

not, a problem exists in the circuit

-look

for

STARTING

RUNNING)

between13.5 and 14.5 volts.

the circuit is good, the

an

opening in the charging cir-

~::::.--'

If

your alterna-

bat-

.

GROUND

ENGINE

Alternator

5. Check the voltage should have a voltage between engine is running. battery charging circuit. Troubleshoot the service battery charging circuit by checking the wiring and connections, the solenoid, isolator, battery switch and the battery itself.

MULTI

is

Working

METER

(KID

0

COM

of

the service battery. This battery

13

and

14

volts when

If

not, there is a problem in the service

SERVICE BATIERY

TESTING BATTERY

THE

SERVICE

(ENGINE

RUNNING)

the

NOTE:

Before removing,the alternator for

meter

to

ensure

that

12

volts DC excitation

EXC terminal if

at

the

B output

If

12

volts

wiring looking for

the

terminal.

are

not present at

and poor connections.

repair;

use a volt-

is

present at

test

showed only battery voltage

the

EXC terminal, trace

the

•

A

CAUTION:

charging

Megger).

ALTERNATOR

When rebuilding the engine. The alternator and inspected. The housing can be wiped off with a solvent and the alternator tenninal studs should wire brush. Make certain those studs are tight. Also 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. send it to a service shop for testing and overhaul.

When

circuit

do

not

You

can

damage

INSPECTION

perfonning

use a high

the

tests

on

the

voltage

altemator

If

the alternator is at all suspect,

tester

diodes.

~hould

be

cleaned with a

altemator

(i.e.

be cleaned

Engines & Generators

PROPULSION

WIRING

DIAGRAM

ENGINE

#039144

"0

It

D

tlof

,,111:

r~'

I I

'~

_..I'

0 (

MOO£UJ

,.------

,:~:

I~

I

+.rLcfl

~"'="

MIW!l.

NOTE

,:

An

on-off switch

should be installed in this

circuit to disconnect the

starter from the battery in

an emergency and when leaving the boat. Twelve volt diesel engine starters typically draw amps when cranking. A switch with a continuous rating

of

VDC will normally serve this junction, but a switch must never be used to

"make" the starter circuit.

200 to 300

175 amps

at

12

"

!

_________

"

o

;;

"W].

_

L..

___

"'"""~':":""

________

:"'_=_:"'_'::-

___

,

+

AUI

..

C

8uun

'::-_:;_':':""_;:;J ____

-,

,

I

I I

I

CAPTAIN

PANEL

ADMIRAL

PANEL

r--

I

L

___________

.11

IU

'/1

U •

....

L.:::==:j'~lIt·~lt·

L1

==::====::====::=~

Engines & Generators

48

__

l

___

__

,

I I I

I

PROPULSION

WIRING

SCHEMATIC

ENGINE

#039144

+

II

~-------4I~'-I~-----'~M~-------------+

.A'

• n

n.

nAn

YOC

14L.

r-'

I I

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.--+-+--+----

c '

[J

ALARM

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UFT

FUlL

........

~·V

0.'.

SEIDEl

'FACIIOMETEI

. .

'UN'

..

'_I:I

'.!.IE!!

-----,

-

ADMIRAL PANEL

II

Wll

•• M IIPI'

OPTIONAL

.i,'''

',

...

..,cIY

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TO

ALTERNAIORS®

..

,

WT'~t;!J'T"OUD

•

,wn_,

CAPTAIN PANEL

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114

T.

8

@

UN I yfRSAL

PRESIOIIIE

72

AMP

PROPULS ION

51

AMP

All

ALI

'

....

'WESJERBEKE

I

Engines & Generators

'49

GENERATOR

INFORMATION

USE

OF

ELECTRIC

The power required

more

than

is

required

Some

motors require

others.

Split-phase

under

similar circumstances, than other types. They are com-

monly

used on easy-starting loads, such machines, started, 7

times avoided, ven motors to load compressor, motor

In

to

*NOTE:

more

for

maJe

Because motors be

seconds.

off on

Required

Run generator's capacity,

.

indicted

should

the voltmeter and

or where loads are applied after the motor

such

as

much

whenever possible, if the electric motor is to be dri-

by

a small generator. Capacitor and repulsion-induction require from 2

.run.

The current required

connected

for

to

which

general,

the

current

medium

starting

MOTOR

SIZE

(HP)

1/6 1/4

1/3

112

3/4

1

In

the

for

some small motors

this

is

that the hardest starting types (split-phase)

in

larger

the heavy surge of current needed for starting

is required for only

damaged

all

the

if it can bring the motor up

If

difficulty is experienced in starting motors, tum other electrical loads and, if possible, reduce the load electric

Operating

the

generator first with

on the generator's data plate. The output voltage

be checked periodically

generating plant and the appliances it supplies.

or ampere meter is not installed

load,

check it with a portable meter and amp probe.

MOTORS

to

start an electric motor

to

keep it running after

much

more current

(AC)

motors require more current

small power tools. Because they require 5 to

current

to

start

as

to

run, their

to

4 times

to

it. An electric motor connected

example, will require more current than a no

load

is

required

loads

will

AMPS

(AMPERES)

above

table

as

much current

to

start any motor varies with

connected.

to

start

115-

be

approximately

FOR

RUNNING

3.2

4.6

5.2

7.2

10.2 13

the

maximum Amps for Starting is

than

for larger

is

it

to

start them than

as

washing

Volt

motors as

AMPS STARTING

(AMPERES)

6.4

9.2

10.4

14.4

20.4

ones.

sizes.

an

instant, the generator will not

to

speed in a few

motor.

Speed

no

load applied, then at half the

and

finally loaded to its full capacity as

to

ensure proper operation

to

monitor voltage

considerably is started.

to

start,

is

use

should be

to

start as

to

an air

connected

follows:

FOR·

to

22.4*

to

32.2*

to

72.8

*

to

29.2*

to

40.8*

26

to

52

The reason

are

If

an AC

the-,

not

of

Generator

Frequency is a direct result indicated

o When the generator is run

output frequency is

o When the generator is run at 1500 RPM, the

output frequency is

Therefore, tor's drive engine's speed must be changed. A reconfiguration of

the AC output connections at the generator is also neces-

Frequency

by

the following:

to

change the generator's frequency, the genera-

Adjustment

of

engine/generator speed, as

at

1800 RPM, the

60 Hertz.

50

Hertz.

AC

voltage

sary.

Generator

o Maintaining reasonable cleanliness

Connections corroded, and insulation surfaces may start conducting salts, dust, engine exhaust, carbon, build sive heating and reduced life

Pf1aintenance

is

important.

of

terminal boards

up.

Qogged ventilation openings may cause exces-

and

rectifiers may become

etc.

are allowed to

of

windings.

if

o For unusually severe conditions, thin rust-inhibiting petro-

leum-base coatings, should be sprayed or brushed over all surfaces to reduce rusting and corrosion. suggested are Daubert Chemical and Ashland "Tectyle 506"

or

equivalent.

'TYpical

Co.

"Non-Rust AC-410"

materials

o In addition to periodic cleaning, the generator should be

inspected for (a) tightness of

overheated terminals and (c) loose

o The drive discs on' single bearing generators should

checked periodically and for any evidence 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

8,

identified by 6 radial marks, one

ners

of

the head.

o The rear armature bearing

maintenance is required. However, if the bearing becomes noisy or rough-sounding, have it replaced.

of

all connections, (b) evidence

or

damaged wires.

if

possible for tightness

of

incipient cracking failure. Discs

at

is

lubricated and sealed; no

each

of

screws

SAE

of

the 6 cor-

be

grade

o Examine bearing at periodic intervals. No side movement

of

shaft should motion is detectable, bearings are wearing or wear on shaft

of Repair must be made quickly or major components will rub

and cause major damage

be

detected when force is applied.

bearing socket outside bearing has occurred .

to

generator.

if

side

NOTE:

When

the

vessel

in

which

the

generator is installed

conIIlins that vide

paneL

A C equipment

the

generator's

one

120 volt A C hot leg for

This

will

AC

ensure

of

120 volts

Qnly,

terminal block be configured

the

vessel's distribution

good

motor starting response

generator.

it

is

recommended

to

pro-

from

the

I "'IIY'IWESTERBEKE

I

Eng;n~l!&

50

Generators

THE

SINGLE

BE

AND

GENERATOR

THREE

PHASE

DESCRIPTION

This generator

tor which requires only duce

AC stator are responsible erator. The magnetic be

induced rotation. Diodes located in the exciter rotor rectify age

to

D<;

. This creates

the windings

which

is auxiliary windings to

a voltage regulator. The regulator produces a DC voltage

to

further excite the exciter stator windings, enabling the gen-

erator

to senses AC voltage output and adjusts DC excitation exciter stator winding according ator

is

furnishing.

3

is

a four-pole, brushless, self-excited genera-

the

driving force of the engine

output. The copper

into

the

related excitor rotor windings during

and

supply

an

electromagnetic field which rotates through

of

the main stator, inducing

supplied

produce a rated AC output. The voltage regulator

to

a load. An AC voltage is produced

of

To

INTERNAL

PHASE

TWELVE

and

laminated iron

for

the self-exciting feature

field

produced causes

it

to

the windings

the

main stator and

maintain a constant voltage output.

WIRING

WIRE

of

to

amperage load the gener-

SCHEMATIC

RECONNECT

in

the

of

an

AC voltage

this

the rotating field.

an

AC voltage

is,

in tum, supplied

ABLE

r--------,

I I

EXCITER r - - - + - - - - - - - ,

I A

lIB

I

I I I ROTOR . I

I

!

I 1 I b I

I I : 2 I

J L

L.

+1

1.

_____

:1

___

al~1

: i -1* 4

+

_______

...1

3:

..J

to

exciter

this

volt-

to

the

pro-

gen-

in

to

the

CIRCUIT

A circuit breaker tors. This circuit breaker will automatically disconnect generator power breaker can be manually shut off when servicing the generator

NOTE:

add-on kit for earlier model generators; contact ERBEKE dealer.

BREAKER

is

installed on

in

case

of

an

electrical overload. The circuit

to

ensure that

This circuit breaker is available

no

power

is

coming into the boat.

all

WESTERBEKE genera-

as

a WESTERBEKE

your

WEST-

.-.-----,

1 C I

:

STATOR

r-I-:

--'2~--r!-~--:

!

'-1:r-_

r-+-i~4:-----i:I-----:·S

c:::;:

~5;;;:::::

r--+:---..---j----.... 4

~~~6

~_"I

r..

I

3

__..:1-----:

==::;:

~====:::

7 1

8

,

1'2

11

1~

.

Pc

.

7 Tennlnal

~

BkIck

~

CIRCUIT PART

NUMBERS

20

KW -60

[16

KW -50

25

KW

.;.

[20

KW -50

32

KW

-

[25

KW -50

BREAKER

Hz

NO.

Hz

NO.

68

Hz

NO.

Hz

NO.

68

Hz

NO.

Hz

NO.

42701

42718)

42702

427111

42703 T 0

BI

REGULATOR

FUSE

6.3 AMP

Engines & Generators

51

A EXCITOR

1. Exciter Stator Wmdings

B.ROTOR

1. Auxiliary Wmdings a.b.c.

2. Diodes

3. Main Rotor Windings

4.

Pori Resistor

C.

MAIN

STATOR

1.

Auxiliary Windings

2. - 7 Main Stator Windings

3. Auxiliary Windings (AC to Regulator)

D.

AC TERMINAL BOARD

E.

REGUlATOR

DESCRIPTION

. The regulator

to

6)

and connection of

the

and

#0

on

NOTE:

the

regulator

is

equipped

their

and

generator.

#2

the

Series

The sensing leads connect between

on

the

AC

voltage regulator board.

Delta

board

with

brass

jumpers for

terminal

requires

between

GENERATOR

seven numbered terminals (0

jumpers. The illustrations show

the

3 phase configuration

block and connection

the

installation

terminal B and

of

a jumper

10.

AC

#1

#2

and

on

VOLTAGE

CONNECTIONS

BLK

CASE GND

AVR

U1

l-I-+--NtGND

V1

170·270

3

PHASE

PARAU.EL

VOLTAGE

WYE

V

(STAR)

180

·160

REGULATOR

V

SERIES

WYE

~

(iU).

BlK

CASE

(STAR)

!j

}-i-----J

AVR

GND

......

l1

U1

l1

BE

THREE

l2

V1

l2

PHASE

(SIX

SERIES

L3

l-I--I---NtGND

l3

WIRE)

DELTA

GRN

GND

L-L -208 L-N L-L -190 t-N

-120

-110

VAC

VAC VAC VAC

30 10 30 10

50 60 50 60

Hz Hz Hz

Hz

BE

THREE

~.

L-L -450 L-N -265 L-L -380 L-N

Engines & Generators

VAC VAC VAC

-230

VAC

PHASE

(TWElVE

30 10 30 10

52

60

Hz

60

Hz

50

Hz

50

Hz

WIRE)

N

L-L-

L2,

L3-N -120

L-L-

L2,

L3-N -110

A.

SERIES repositioning lead

from

ator

housing.

J.

Jumper Wire.

240

VAC30 VAC

230

VAC30 VAC

DELTA:...

of

Note

the

neutral

using

'10

60

10

60

50

10

50

the

ground

to

gener-

AWG

Hz Hz Hz Hz

GENERATOR

AC

VOLTAGE

,NOTE: erly positioned when changing the of

the AC terminal block. For making connections to the

terminal block, use terminal ends for 1/4 inch studs that will

accept multi strand copper wire sized for the amperage rating

from the hot lead connection. The frame ground wire is white or white with a green strip. stud and the generator frame.

CONNECTIONS

The frame ground wire (white/green) must be prop·

AC

output configuration

It

connects between the neutral

BE

SINGLE

PHASE

Ae

VOLTAGE

AC

CONNECTIONS·

Generator

1.

Frequency is a direct result

1800 rpm =

2.

To

Configure the

frequency as shown above. Ensure that the case ground wire is connected to the correct terminal block neutral

ground stud.

NOTE:

installations where

ground

source

Frequency

of

engine/generator speed:

60

hertz; 1500 rmp =

change generator frequency, follow the steps below:

AC

terminal block for the desired voltage

The

white/green ground

theAC

circuit

circuit.

in

This will prevent

the

vesseL

50

hertz.

wire

may be removed

has

a separate neutral and

the

unit

from

being a growid

in

those

120/240

L1

L2

V -

60

Hz

o 0

il

I I

100

I I I I

L--

I

••

--l

L1

120

o 0

V·

60

Hz

A

JUMPER

230V-50Hz

115

o 0 o 0

L1

100

IS

REQUIRED

FOR

120V -60

Hz

---H--DIODES/LEDS

V·

50

Oil

I I

I I I I

~

__

--l

REGULATOR.

Hz

i

20

KW

BED

SHOWN

CIRCUIT

BREAKER

120V • 240V • 60Hz

Engines & Generators

53

.

VOLTAGE

REGULATOR

ADJUSTMENTS

Description

The voltage regulator is an advanced design which ensures optimum AC alternator performance. complete protection circuitry to guard against operating conditions that could be detrimental to the AC alternator.

This potentiometer is used to adjust output voltage. At proper engine operating speed the output voltage should be held at ±1

% from a no-load condition to a full rated generator output and from power factor ations

up

to

-6%.

Prior to starting the engine, turn the VOLT and STAB trimmers (using a mini phillips screwdriver) fully clockwise (Minimum) direction until you feel them hit their stops.

Tum the (Maximum)

With the alternator running with age will oscillate. The voltage output

lize. Increase the voltage to the desired

tion, only the green LED will stay lit.

AMP and HERTZ trimmers completely clockwise

in

the same manner.

VOLT adjust at minimum, it is possible that output volt-

1.0 - 0.8 with engine drive speed vari-

at no-load, at normal speed, and

Slowly rotate the VOLT adjust clockwise.

of

the alternator will increase and stabi-

It

is equipped with

ina

counter

~alue.

In

this situa-

stability

This potentiometer permits variation

response to generator load changes so pensation and obtain a minimum recovery time to the normal

voltage output.

In

order to adjust the regulator stability the alternator must be

running

Tum the STAB adjust slowly clockwise until the voltage starts terclockwise until the voltage is stable within 1 or 2 tenths

a volt.

.!

~

a~

no-load and the output must

to

fluctuate.

green

yeHow

Hertz

AmI!

Stab

Volt

At

this point rotate the STAB adjust coun-

'-

L

of

the regulator's

as

to

limit overcom- .

be

monitored.

of

.

Amp-Hertz

These two adjustments are used

protection circuits in the voltage regulator that are indicated

by the illumination

1. Delayed overload protection

2. Low speed protection (red LED). Both systems have an intervention threshold which can

adjusted using the respective potentiometer. Each

are

circuits

voltage to safeguard the excitor windings and prevent their

overheating. The

temporary overloading motor start-up ulator also has a third LED (green), that ator operation to indicate correct operation with the generator. . .

Setting

In

order to set the

must

1. Load the alternator

the engine by 10.10% (54 Hertz hertz

2. Rotate the

its stop. Wait about 15-20 seconds after which the put should come on

3. Slowly rotate the

output voltage increases to approximately voltage the yellow LED light should come on.

4. Return

and the alternator voltage will.rise to its normal value. Should this not happen, repeat the adjustment.

NOTE:

remove

Setting

NOTE:

jumper strap

two

setting, the alternator should

1. To adjust the underspeed (low frequency) protection circuit, lower the engine speed

(54 hertz on 60 hertz units, 45 hertz

2. Rotate the Hertz adjustment counterclockwise slowly until

the alternator's

the

3.

Increase the engine speed to its normal speed (frequency).

The

put will return to normal.

With the above adjustments made, the regulator should function normally.

able to cause an adequate reduction in excitor

overload protection system has a delay which permits

the

be

loaded to its full output rating. .

on

of

the alternator should drop and the yellow LED light

output· at the start

to

When changing from

the

60

the

If

the unit is operating

60

Hertz terminals.

same

red "LED" light will

of

a colored LED lights.

of

or

other similar load surge demands.

Overload

AMP

overload protection, the alternator

to

50 hertz units).

AMP adjustment counterclockwise until it hits

..

AMP

nominal speed, the yellow

hertz jumper

Underspeed.

is

in place on the regulator board between the

In

AC

output voltage starts

time the red

in

conjunction with the two

(yellOW

the generator during times

LED).

glows

of

the regulator

be

of

the

two

such

The

reg-

during gener-

Protection

its rating, then decrease the speed

on

60

hertz units, 45

AC

adjustment

of

60

bar

cl~kwise

the adjustment.

LED

hertz

to

50

from the regulator board.

97%

will turn

hertz

until the

of

the

At

this point

operation,

off

Protection

at

60

Hertz ensure that the

order to adjust the underspeed

be

at

90%

"LED"

go

running

light

out and the

at

no-load.

of

its normal running speed

on

50

hertz units.

to

decrease and at

comes

on

.

AC

voltage out-

out-

as

of

VOLTAGE

REGULATOR

DIAGRAM

Engines & Generators

54

r------------,

EXCITER STATOR

r-----~----------,

I I I I I I

I

EXCITER

I I I

I

ROTOR

INTERNAL

WIRING

SINGLE

I

ROTOR

FIELD

I~:

SCHEMATICS

PHASE

RED

I

1-------1

I I

I

STATOR,

RED

I

RED

l.._

:::

g

..J

W'

>-

_

________

W

::>

-'

CD

o

~

~~:

i

Hertz

Amp

~

stab

.

~

Voll

c..

r------------,

II

I I I I I I

l..

_____

REGULATOR

i'M

~------~---J

J

. :

~

THREE

6

WIRE

EXCITER

~

-----i -

I I I I I

I I I

I I ROTOR I I I

--

-------

AUX

RED

BLUE

YELLOW

PHASE

RECONNECT

ABLE

~

U2

_.

~B~lACK~t-I

V2-'(G~RETNENrfI1""".r-1

RED

r----'

I STATOR I

••••

RED

®

W2

®

U1

GREEN

r-1

_2BLACK~

_~~~EE~N

___

____

V1

BLACK

'UI

.1VI

! I j

I I I I J

I I I

l.._~

________

l.._

_

%

o

-'

~"

red

w

-'

Q

>-

m

~

green

yellow,,-

Hertz

Amp

Slab

Volt

.....

___

~

J

REGULATOR

Et(]~

__________

Engines & Generators

! M

TlREiEiDi":",-rj

J

BWE

YEllOW

55

::::::~I-!-:

s

a;

_--.!R~ED~_--,WI

FUSE

6.3

AMP

NOTE:

BE

PERFORMED

BE

TROUBLESHOOTING

AC

GENERATOR

WITH ENGINE

TROUBLESHOOTING

OPERATING

MUST

AT

60 BER1Z.

No

AG

voltage

Flesidual

15 -20

Low 60

High 150

AG

-100

AG

VAG

volts

voltage

Unstable

AG

voltage

60

-100

FAULT

output

voltage

AG.

VAG.

output

or

higher.

voltage

drop

volts

AG.

at

produced

output

at

voltage

output.

under

load

no

load.

at

no

load

1.

Short main

2.

Shorted

on

exciter

3.

Four open

1.

Blown 6 AMP auxiliary

2.

Faulty

.

1.

Open exciter

2.

Open

rotor

1.

Faulty

1.

STB

pod

needs

1.

Diode(s) breaking applied

PROBABLE

or

open

in

the

stator

winding.

pozi-resistor

rotor.

or

more

diodes

circuit

voltage

or

shorted

on

buse

regulator.

exciter

fuse

feed

to

diodes

or

rotor 1 to 3 diodes.

or

shorted

exciter

winding.

voltage

regulator.

on

regulator

adjustment.

on

exciter

down

(inductive)

rotor

when

1-3

load

CAUSE

rotor.

AVR.

in

is

diodes.

4.

Short

stator

5.

Short

field

3.

Shorted stator

3.

Faulty

2.

Faulty

or

open

winding.

or

open

winding.

or

open

auxiliary

voltage

in

exciter

in

rotating

main

winding.

regulator.

r------------,

EXCITER

STATOR

r----

. ,

,

:

EXCITER

~,

Rm~

!

......

I--,--~

L

_____

.

REGULATOR

L_

~

__

---------~

§

....

>-

-1--

------

RmRFlELD

~

~-~----_---~

---'

.

BLUE

RED

YEllOW

....

---

I I

,

I J

AUX

J J

_____

RED

---1

STATOR.

RED

.J

J

fUSE

RED

®

wz

GREEN

BLACK

Engines & Generators

56

ELECTRONIC

GOVERNOR

ELECTRONIC

The system

1. Controller - Mounted inside the instrument panel box.

2. Sensor - Installed on the generator stator housing over the flywheel ring gear.

3. Actuator - Mounted at the front

attached with linkage to the throttle arm of'the injection pump.

Controller

1.

Speed. - This adjustment is used speed to the desired hertz.

2. Gain - This adjustment affects the reaction time actuator

NOTE:A

the actuator producing a hunting mode. In such cases, lessen the gain adjustment.

GOVERNING

is

composed

SYSTEM

of

three basic components:

of

the engine and

Adjustments

to

raise or lower engine

of

to

the generator/engine load changes.

high gain adjustment can induce an oscillating

the

of

Calibration

1. With no power to the governor (engine not running) adjust the GAIN potentiometer to

2. Start the engine and adjust the speed by turning the SPEED potentiometer clockwise to desired speed.

NOTE:

Controllers are factory adjusted to minimum

However, for safety, one should

if

engine

3. At

4. Tum the gain potentiometer counterclockwise until the

an overs

no the engine begins to hunt. physically upset the governor linkage.

engine runs stable.

peed

should exist.

load, tum the GAIN potentiometer clockwise until

If

9:00 o'clock.

rpm

be

capable

the engine does not hunt,

of

disabling the

•

SENSOR

PV

11039172

ELECTRONIC

GOVERNOR

TERMINAL

SPEEDm

GAIN

i\J

LINEAR

ACTUATOR

KEEP

ACTUATOR

LINKAGE

WELL

LUBRICATED

FLYWHEEL

HOUSING

TO

ELECTRONIC

CONTROLLER

Engines & Generators

57

LINEAR

ACTUATOR

(20

KW

SHOWN)

TROUBLESHOOTING

THE

ELECTRONIC

'GOVERNOR

System (Engine

Actuator is

depressed

Actuator engine

running.

Problem

appears

runs

at

fully

extends

and

hunts

dead

idle.)

when

stays

extended.

(oscillates)

PREHEAT

and

1.

,

Low

2.

Stuck

3.

No

signal

(Measure

engine

be

2.5

4.

Check check negative

a. b.

5.

Perform terminals DC

lead

(Preheat a.

b.

c.

1.

Check actuator Depress

a. b.

NOTE:

Release

the

purple

1.

Linkage binding.

Improper

2.

controller.

3.

Inadequate controller,

Connect a DC plus controller

Lift terminal

Connect C

plus

DC

Momentarily

The

3a.

Sensor away erratic

Probable

battery

linkage.

volts Actuator -depress

for

Purple Second

Low actuator

Battery connections.

Battery but

leads PREHEAT.

Actuator Actuator

connections.

and

both

negative.

actuator

from

voltage

or

weak

AC

voltage

is

running

or

greater.

battery

black

lead

to

purple

the

following

at

the

actuator

at

the

controller

depressed).

voltage

connection.

voltage

not

the

other.

controller.

from

the

fully

does

PREHEAT

lead.

between

adjustment

DC

power

complete

voltmeter

negative

terminal

purple

block. one

purple

terminal

and

depress should

pOSitioned

flywheel

signal

voltage

cause

at

signal

at

voltage

at

black.

to

(1.20-2.0

at

Lift

terminal

extends.

not

actuator

leads

block.

leads

marginally

controller.

from

sensor

idle.

Voltage

PREHEAT

between

terminal

black.

check

between

and

the

terminal

VDC)

both

actuator

one

actuator

one

of

the

block.

fully

extend

and

reconnect

and

of

GAIN

supply

to

the

following

across

at

the

from

the

lead

to

the

other

PREHEAT.

fully

extend.

teeth

giving

to

controller.

sensor.

while

should

block.

negative

block.

at

either

lead

pu

rple

and

throttle

on

tests:

the

to

the

too

far

and

1.

Check

wiring

2.

Lubricate,

3.

Check

for

housing.

Replace

4.

Replace

controller

leads.

a.

Broken

b.

Broken

c.

Replace

a.

Short

in

b.

Replace

1.

Lubricatelfree-up.

2.

Lessen

GAIN

It

actuator

3.

It

the

voltage connections, due

to

remote

connections.

DC

voltage

registering

12

VDC

System

24

VDC

System

NOTE:

Reconnect

3a.

Check

the

VerificationJR_edy

for

cause.

Check

battery

free

up

linkage

between

improperly

actuator

the

lead

controller.

does

position

installed

or

adjust.

if

battery

lead.

actuator.

to

actuator.

adjustment

not

fully

is

less

than

low

battery

panel

installation

on

the

-

9.6

VDC

-19.2

actuator

of

the

or

voltage

(Recalibrate

extend,

specified,

voltage,

meter

or

higher

VDC

or

higher

leads

properly

sensor.

state

controller

damaged

is

not

the

check

the

check

voltage

and

small

should

be:

after

of

charge.

and

throttle

sensor

in

present

at

Controller).

actuator

for

loose

drop

in

DC

wire

sizes

making

flywheel

both

leads.

or

poor

circuit

making

this

test.

arm.

Engines & Generators

58

SHORE

Generator

I

N

!

:

z

If

cuit, this must be done by means

Switch. Set the transfer switch shown

POWER

G1

'"G2

• '

t

1<--

I

I 1'

L-----t<D

r-----\~

I

CONNECTIONS

NOTE:

Diagram

wire.

120-Volt

dotted

--"

https://manualmachine.com/_

~

/

system.

lines

__

"_58

.....

shows

tor

connections

For

a

the

other

(60

three-wlr.

hot

for a two

leg.

I

~

~~~~="n~d

I

1S2

S1

N

Shore

"'Pow.,

the installer connects shore power to the vessel's

__

~

__

~

of

the Shore Power Transfer

in

POWER

HERR)

..

system

Shlp.to·Shoro

PH (40

PH (SOAmpo/PoIe,

PH (125

PH (200

the diagrams to the

Swttch(3PoIeI

3200a

AmpO/Polo,

32008 32010

Ampol

Polo'

3213S

Ampo/PoIe,

AC

cir-

OFF position. This switch prevents simultaneous connection

of

shore power to generator output.

TRANSFER

120

VOLT/60

SWITCH

HElm

Notice the repositioning terminal block to the generator case.

"'-----'l

l'

r'='_+---\-WCI)lth

! ~~,vp~~p,r

i

z

'---+-+----+~

.lS2 S',..

Shore PoWer

Switching

NOTE:

wlr

••

120-Volt

Ihr

"

....

-,

I &4-I--'==-

'i~

i

z

•

.,/

Ground

~(G~R~H~)-+----~I

T

N"

J

Shore

Power

THREE

Diagram

••

\

WIRE

CONFIGURATION

of

the white wire ground load on the

.howl

-wlr

connections

.,stem

from

••

120-Voll

to

Generator

for

a two-

the

118nerator.

boIIt

.,.tem.

Ship·

U}

LI PH

.-..

..

H Shlpo

Lood

:~~~-VOII

I'"

Equipment

Power

to.

Shoro

Switch

(3

PH

32008

(40Ampo/Polo)

ra'1,:~~~PoIO)

32010

(125

Ampol

PH

32133

(200Ampo/Polo)

Poiol

Polo'

A

CAUTION:

utility

shore

at

the

same covered bility

to

power time.

under

make

8amage

and

This

the

warranty;

sure

aI/

to

the

generator

type

of

generator

it

AC

connections

generator

output

is

the

installers

are

can

result

are

connected

damage

responsi-

correct.

is

if

not

A

CAUTION:

before

switching vice-versa with

heavy

cause

damage

generator.

Heavy

shore

because

AC

loads

to

the

motor

power

voltage

on

the

exciter

leads

to

generator surges vessel

circuit

should

be

power

Induced

being

by

operated

components

shut

off

or

SWitching

may

in

the

Engines & Generators

GENERATOR

WIRING

DIAGRAM

#039422

LIFT

PUMP

II"

PUR

[l<'---'"

SPEED ACTUATOR

Pu"

-----l----,

';v

""~

FUEL

i

..

'"

SOLENOID

GLOWPLUGS

~"

WATER

~

TEMP.

SENDER

~0

..-----'~

NOTE

"

.BAIIEB'l"

~~

"BAT~RY

2:

~14-

SWITCH

~

~--~--~-----JO~ill~~~~

I

;

STAR!ER

"

GROUND

~

,\..2

J

"Q~-..-

~

TO

BLOCI(

·".ED

-".ED

.,

....

'"

BLU

,.4

ARtf

~D

"OPUIVREa

~~

·s·

,010A

C.B •

'.12.£0

tj~~

'I~

pup

.....

ro/PUR

OIL

PRESsURE

"'ULU

OIL

PRESS."~

SENDER T

SW.

u~

EXHAUST

"'LT[RNATOR

~

.""L

D-~)

z

..

"

...

'"

...

-

~EMP.

SW.

0,\

51

...

NOTE

2:

An

on-off switch

should

be

installed in this circuit to disconnect the starter from the battery in an emergency and when leaving the boat. Twelve volt diesel engine starters typically draw amps when cranking. A switch with a continuous

rating"

of VDC will normally serve this [unction, but a switch must never

"make"

200

175'amps

be

used to

~he

starter circuit.

to

at

300

12

r

i

Ii!

L

_______________ ~ ______ J

·I

....

AN

.,

..

"<CORN

-----------

.~

'--I-

fi".,~Ji

~

G V

Engines & Generators

r:-uR

.,0

W,",T

----

m?i

jJjlf

lc:.1

---,

~T

::~

SWITCH I

1

STANDARD INSTRUMENT PANEL

I

60

+

12VDC

r

-1

BATTERY

: :

SWITCH

L

_,

+-

__________

. r

'

'20A

: .

ie.B.

, ,

L

_J

-1

STOP

iSWITCI:\

-,

GENERATOR

WIRING

SCHEMATIC

PREHEAT

SOL.

r-----

...

,

L..

____

J

START

SWITCH

r----j

O.P. SW. SW.

START

..;.r-1----I--

K

0

SOL.

L..

___

.... ' ___

..I

W.T.

#039422

STARTER

-i

M

)..----4

GLOWPLUGS

LIFTPUMP

P

FUEL

SOl...

REMOTE

______________________

, ____ --_____ ------

L +

_____________________________________

START/STOP

STOP SWITCH

'14

RED

-----••

1#10

BlACK I 4A

-------

,-----

, I

1#14

K

I.

PANEL

55A SURGE'

22A

,'

I

-----~

T.

'14GhEEN

,I

'22 I

BLACK

I

I I

____

l~~.LV!!i.!l!'_TO

'-----1-----------,

, :

PREHEAT SMnTCH

I

------1----------

REO

,

I

-'

__

START'

',;3A

RUN

A

RED

-

---

-----

TO

TBt-l

.IA

~REEN

~TB1-GND

T82-1

PURPLE

TO

T82-2

~55A

SURGE

22A

START

3A

RUN

RED

TOTBI-2

~,!l],

__ TOTBI-4

'

-------------------,

REMOTE

PANEL

REAR

V1eN

'-..'WESJERBEICE

I

Engines & Generators

'61

~

~¥~

SPECIFICATIONS

WESTERBEKE

20

KW

BEDA

GENERATOR

Engine

Type

Aspiration Governor Combustion Bore & Stroke Piston Firing Direction Maximum

(at Compression Dimensions

Weight Fuel

(approximate) InClination

Generator

Chamber

Displacement

Order

of

Rotation

Torque

1800

rpm)

Consumption

Power

Ratio

Take

SPECIFICATIONS

Diesel, water-cooled mechanism

Naturally Electronic Swirl

3.50 x 4.0 154 1-3-4-2 Clockwise,

1171b-ft

21:1 Height:

Width: Length:

943lbs

2.0

Continuous Temporary

off

30

four-cycle,

type

cubic

gph

Horsepower

Vertical,

(33

hp

aspirated.

Governing

inches

when

(16.18

kg-m)

28.50

inches

22.00

inches

45.79

inches

(431.7

kgs)

(7.57

Iph)

15°

200

(not

(maximum)

four-cylinder,

at

(88.9 x 101.6

(2.5

viewed

at

to

in-line 1800

liters)

from

(1163.3

full

rated

exceed

fresh

overhead

rpm

maximum).

mm)

the

front

(723.9mm)

(546.1

mm) mm)

output

20

min.)

valve

General Fuel Fuel

Injection

Fuel

Injection Nozzle Fuel

Filter (on

engine)

Air

cleaner

Air

Row

(engine

combustion)

General

Operating Fresh

Water

Raw

Water

Raw

Water

at

1800

rpm

System

capacity

(fresh

water)

Pump Timing

Temperature

Pump

Row,

FUEl

SYSTEM

Open

flow,

self

No.2

diesel

ZEXEL

Model

0°

TOC

(Top

Throttle

type

Spin-on

type,

Metal

screen

81.0

cfm

(2.29

COOLING

Fresh

controlled 170 Centrifugal

Positive belt

14.0 before

11.5

SYSTEM

water-cooled

with

-190°

F

type,

displacement,

driven.

gpm

(52.9

discharging

qts

(10.88

priming

oil

(cetane

VE

Distributor

Dead

full

type

cmm)

heat

(n

-

metal

Ipm)

liters)

- 1

rating

Center)

flow

block,

thermostatically-

exchanger.

88°

C) impeller, rubber

(measured

into

exhaust

bleed

of

45

belt-driven

impeller,

elbow);

point

or

higher)

Compression

(Limit

of

difference

cylinders)

Valve

Timing

valve

Seat

Angle

Valve

Clearance

(engine

cold)

Engine

Speed

Injector

Pressure

Engine

Timing

TUNE-UP

Pressure

between

SPECIFICATIONS

427

psi

(30

kglcm2)

at

200

(47.2

psi

{3.0

kg/cm'l)

Intake

Opens

17°

Intake

Closes

Exhaust Exhaust

Intake

45°

Exhaust Intake

0.012

Exhaust 1800

RPM

1500

RPM 1920 + 71-0 Static

timed -drop

0.205 ± .005

4]0

Opens Closes

300

inches

0.012 60

50

psi

BTOC

ABDC

51 ° BBDC 13°

ATDC

(0.3

inches

(0.3

Hertz Hertz

(135

+

valve

inches

BTDC

mm)

5-0

method

rpm

mm)

kglcffi2)

General Oil

Filter

Sump

capacity

(not

including

Operating (engine

hot)

Oil

Grade

filter)

Oil

Pressure

LUBRICATION

Pressure Full

flow,

6.5

U.S.

plus

50-60

API

Specification

SAE

SYSTEM

fed

system

paper

qts

(6.15

filter/cooler

psi

(3.5 -4.2

30,

lOW-3D,

element,

liters)

assembly

kglcffi2)

of

CF

or

15W-40

spin-on

CG-4,

type

Engines & Generators

.62

SPECIFICATIONS

WESTERBEKE

20

KW

BEDA

GENERATOR

Starting

Battery

Capacity

DC

Charging

Altemator Starter Starting

Aid

DC

No-Load

Current

DC

Cranking

Current

AC

General -Single

Voltage -Single

Voltage

regUlation: Frequency Rating

regulation:

(Volts

AC)

ELECTRICAL

12-Volt,

(-)

400 -600

51

Amp

rated,

12-Volt,

Reduction

Glow

plugs,

±

2%

of

250 -300

GENERATOR

Phase

(SINGLE

Brushless, lubricated Reconnectable

with

solid

120

or

120/240

230

Volts -50

±

2%

no

0.30

Hertz

20

KW -60

120

Volts

1201240

16

KW -50

230

Volts

SYSTEM

negative

ground

Cold

Cranking

belt-driven

Gear, 3 KW

sheathed

rated

Amps

(engine

four-pole,

single

bearing

single

state

voltage

Volts -60

Hertz

load

to

full

no

load

to

Hertz

(1800

166

Amps

Volts

166183

Hertz

(1500

72.7

Amps

(CCA)

type

cold)

PHASE)

revolving

field

design.

phase

for

1201240

regulator.

Hertz

load. full

load.

rpm)

Amps

rpm)

Sealed

volts

General

-3

20.0

16.0

Voltage

(60

Voltage

(50

Amperage

(60

Amperage (50

Air (60

Note: Engine

Requirements (60

Phase

KW -60

Hertz

KW -50

-3

Phase

Hertz)

-3

Phase

Hertz)

-3

Hertz)

-3

Hertz)

Requirements

Hertz

at

1800

Increase

Combustion

Hertz

at

1800

AC

GENERATOR

Brushless

Hertz

Phase

Sealed design. WYE,

regulator

Low High DELTA

High DELTA

Low

High

DELTA

High

DELTA

GENERATOR

Air

15%

425

for

81.0

air

RPM) supply

RPM)

six

lubricated

12

Lead

high

voltage

with

voltage

WYE

voltage

WYE

voltage

COOLING

cfm

(12.74

50

Hertz

cfm

(2.29

(3

Phase)

pole,

revolving

single

bearing

reconnectable

Delta.

protection

WYE

cmm)-

operation

1500

cmm)

field.

for

Solid

State

circuitry.

208 480 240

380

230

70

Amps

35

Amps

60

Amps

30.4

52.5

rpm

low

voltage

volts volts volts

volts

Volts

Amps Amps

voltage

Engines & Generators

63

SERVICE

DATA I TOLERANCES

20

KW

71

60Hz

Generator/16KW

I-FOUR

AND

LIMITS

50

Hz

71

C-FOUR

Generator

VALVE

Intake Valve Opens BTDC

Exhaust Valve Opens BBDC

Compression Pressure Standard

Limit Differences Between Cylinders

Valve Clearance (cold)

CYUNDER

Dimension L (Intake)

HW

and

Distortion Limit

(Exhaust)

Seat Angle (Intake)

Contact Seat Width ( Intake)

Valve

TIMING

ClosesABDC

ClosesATDC

Limit

Intake

Exhaust

VALVE

Margin

SEAT

Standard

Limit

Standard

Limit

(Exhaust)

Limit

17" 47"

0

51

0

13

2

)

200 rpm

2

)

200 rpm

30.0 kglcm2 (4271b/in

27.0

kglcm2

(3841b/in

3.0

kglcm2

(431b/in

0.3 (0.012)

mm(in)

0.10 (0.004) Positions 1 + 2

0.25 (0.010) Positions 3 + 6

48.0 (1.89)

49.55 (1.95)

48.05 (1.89)

49.55 (1.95) 45°

300

2.0 (0.079)

1.35 (0.053)

17"

47"

0

51

0

13

2

)

200 rpm

2

)

200 rpm

30.0 kglcm2 (427 Ib/in

27.0 kglcm2 (3841b/in

3.0 kglcm2 (431blin

0.3 (0.012)

mm(in)

0.10 (0.004) Positions 1 + 2

0.25 (0.010) Positions 3 + 6

48.0 (1.89)

49.55 (1.95)

48.05 (1.89)

49.55 (1.95) 45°

300

2.0 (0.079)

1.35 (0.053)

VALVE

Valve

GUIDE,

Stem to Guide Clearance (Intake) Standard

Main

Journal

Valve

VALVE

Main

Bearing Clearance Standard

Protrusion from Cylinder

Stem Diameter (Intake) Standard

Head Thickness (Intake) Standard

AND

VALVE

(Exhaust) Standard

Guide

Inner

Spring Diameter

Journal

Valve

Diameter Standard

(Exhaust) Standard

Head Diameter (Intake)

Valve

Seat Width (Intake)

Grinding Limit

SPRINGS

Limit

Wear

Limit

Wear

Limit

Head

Limit

Limit Limit

(Exhaust)

mm(in)

0.038 - 0.085 (0.001 - 0.003)

0.127 (0.005)

0.058

- 0.105 (0.002 - 0.004)

0.127 (0.005)

- 9.040 (0.355 - 0.356

9.018

69.812 - 69.825 (2.748 - 2.749)

0.05 (0.002) (2.718)

69.05

0.059 - 0.090 (0.002 - 0.004)

0.12 (0.005)

16.5 (0.650)

8.955 - 8.980 (0.353 - 0.354)

8.884 (0.350)

8.935 - 8.960 (0.352 - 0.353)

8.864 - (0.349)

1.7 (0.067)

1.0 (0.039)

1.5 (0.059)

1.0 (0.039)

- 40.6 (1.59 - 1.60)

40.4

35.87 - 36.13 (1.41 - 1.42)

36.8 (1.45)

31.7 (1.25)

mm(in)

0.038 - 0.085 (0.001 - 0.003)

0.127 (0.005)

0.058

- 0.105 (0.002 - 0.004)

0.127 (0.005)

9.018

- 9.040 (0.355 - 0.356

65.0

- 65.013 (2.5591 - 2.5596)

0.05 (0.002)

69.05

(2.718)

0.040 - 0.091 (0.0016 - 0.0036)

0.12 (0.005)

48.0 (1.890)

8.955 - 8.980 (0.353 - 0.354)

7.880 (0.3102)

8.955 - 8.980 (0.353 - 0.354)

7.867 (0.3097)

1.7 (0.067)

1.0 (0.039)

1.5 (0.059)

1.0 (0.039)

40.4 - 40.6 (1.59 - 1.60)

35.87 - 36.13 (1.41 - 1.42)

36.8 (1.45)

31.7 (1.25)

'-..'WESJERBEICE

I Engines & Generators

64

SERVICE

DATA I TOLERANCES

20

KW

71

60Hz

Generator/16KW

I-FOUR

AND

LIMITS

50

Hz

71

C-FOUR

Generator

VALVE

Free length

CONNECllNG

GUIDE,

Valve

Clearance between Piston Pin & Small Bore

Connecting Rod Side Clearance Standard

Crankpin Bearing Clearance Standard

Crank

VALVE

Spring Squareness Limit (Inner)

of

Valve

RODICONNECllNG

Pin Dia. Available Undersize Bearing

AND

VALVE

Valve Face Angle (Intake)

Rear Oil

Spring

Spring Constant (Inner) 2.02kglmm

Seal

Insert Limit

(Inner) Standard

(Outer) Standard

ROD

Length (Center to Center)

Maximum Allowable

Small Bore

Oil Clearance

0.254

0.508 (0.02)

SPRINGS

45°

(Exhaust)

(Outer)

Limit Limit

(Outer) 2.16kglmm (121lb/in)

30"

6.35 - 7.62 (0.250 - 0.300)

1.25

1.37

43.6 (1.717)

42.0 (1.654)

55.7 (2.193)

52.9

BEARING

173.Q12 -173.063

Twist

End End

Standard

Limit

Wear

Limit

(0.01)

0.762 (0.03)

0.05 per

28.012 -

0.012 -

0.05 (0.002)

0.239

0.4

0.012 -

0.05 (0.002)

56.868 -56.871

56.604 -56.617

56.350 -56.363

mm(in)

(0.049) (0.054)

(2.083)

(1131b/in)

mm(in)

100

28.033

0.031

- 0.330 (0.009 - 0.013)

(0.016)

0.031

(6.811

- 6.813)

(0.002 per 3.94)

(1.103 -

(0.0005 - 0.0015)

(0.0005 - 0.0012)

(2.2389 -2.2391) (2.2285 -2.2312) (2.2185 -2.2191)

1.104)

mm(in)

45°

30"

6.35 - 7.62 (0.250 - 0.300)

1.25

(0.049)

1.37

(0.054) (1.654)

42.0

42.0 (1.654)

43.6 (1.717)

2.02kglmm

2.16kglmm (121lb/in)

173.Q12 -173.063

0.05 per

28.012 - 28.033

0.014 - 0.041 (0.0006 - 0.0016)

0.05 (0.002)

0.239

0.4 (0.016)

0.012

0.05 (0.002)

64.746 -64.733

64.479 -64.492

64.225 -64.238

(1131blin)

mm(in)

(6.811

- 6.813)

100

(0.002 per 3.94)

(1.103 -1.104)

- 0.330 (0.009 - 0.013)

-

0.031

(0.0005 - 0.0012)

(2.5485 -2.5491) (2.5385 -2.5391) (2.5285 -2.5291)

CRANKSHAFT

Crankpin Diameter Standard

Main Journal Dia. Available Undersize Bearing

Available Oversize

Crankshaft

CYLINDER

BLOCK,

Limit

Liner Protrusion above Cylinder Block

AND

MAIN

Grinding Limit

Thrust

Crankshaft Run-Out

End

Play Standard

PISTON

of

Distortion

Wear Limit

AND

of

Cylinder Block

Cylinder Liner Diameter

of

Cylinder Liner

BEARING

Wear

Limit

0.254 (0.01)

0.508 (0.02)

0.762 (0.03)

Bearing

Limit

PISTON

'-..'WESJERBEICE

mm(in)

57.112 - 57.125

0.05 (0.002)

56.35

(2.218)

69.558 -69.571(2.7385 -2.7391)

69.304 -69.317

69.050 -69.063

0.178

(0.007)

0.05

(0.002)

0.140 - 0.390 (0.005 - 0.015) (0.016)

0.4

0.10

(0.004)

0.25

(0.010)

88.925 -

0.20

(0.008)

0.101 0 (0.004 -0)

(2.248

(2.7182 -2.7291)

(2.7185 -2.7191)

mm(in)

Positions 1 + 2 Positions 3 + 4

88.950

(3.501

- 2.249)

- 3.502)

I Engines & Generators

mm

(in)

53.0 - 53.013 (2.0866 - 2.0861)

0.05 (0.002)

56.35 (2.218)

52.733 -52.746

52.479 -52.492

52.225 -52.238

0.178 (0.007)

0.05 (0.002)

- 0.390 (0.005 - 0.015)

0.140

0.4 (0.016)

0.10 (0.004) Positions 1 + 2

0.25 (0.010) Positions 3 + 4

88.925 -

0.20 (0.008)

- 0.790 (0.026 - 0.031)

0.659

(2.0761 -2.0766) (2.0661 -2.0666) (2.0561 -2.0566)

mm(in)

88.950

(3.501

- 3.502)

65

SERVICE

DATA I TOLERANCES

20

KW

71

60Hz

Generator/16KW

B-FOUR

AND

LIMITS

50

Hz

71

C-FOUR

Generator

CYLINDER

Piston Diameter (Diameter measured at

Clearance Between Piston Ring & Ring Groove

bore

BLOCK,

axis and

PISTON

23m

(0.91

Piston

Ring

Piston

AND

in)

and

Groove

Ring

Thickness

Ring

Piston Pin

Piston

PISTON

9(f

up

from bottom)

Liner

Clearance

Width

End

gap

Diameter

Pin Hole Bore

OIL

Oil Pressure

Outer

Rotor

and

Body Clearance Standard

Clearance Between Lobes Standard

Rotor

End

Float Standard

Pump

Shaft

and

Body Clearance Standard

Free Length

of

Plunger Spring Limit

to

Top

Second

Oil

Top

Second

Oil

Top

Second

Oil

Limit

Top

Second

Oil

Limit

PUMP

Limit

mm

(in)

88.872 - 88.898( 3.499 - 3.5(0)

0.044 - 0.070 (0.0017 - 0.(028)

2.433 - 2.543 (0.096 - 0.1(0)

2.423 - 2.443 (0.095 - 0.096)

4.793 - 4.813 (0.1887 - 0.1895)

2.363 - 2.383 (0.093 - 0.094)

4.743 - 4.763 (0.187 - 0.188)

- 0.18 (0.002 -

0.05

0.04 - 0.08 (0.002 - 0.(03)

0.03

- 0.07 (0.001 -

0.3 (0.012)

0.350.55

1.5 (0.059)

27.994 - 28.000 (1.1021 - 1.1024)

27.996 - 28.008 (1.1022 - 1.1027)

0.14 - 0.25 (0.006 - 0.010) 0.14 - 0.25 (0.006 - 0.010)

0.3 (0.012) 0.3 (0.012)

0.04

0.250(0.01)

0.04 - 0.10 (0.002 -

0.15 - (0.006)

0.06

0.1 40

(0.014 - 0.022) (0.014 - 0.022)

(0.014 - 0.022)

more than 3.8

- 0.15 (0.002 - 0.006) 0.04 - 0.15 (0.002 - 0.006)

- 0.15 (0.002 - 0.006)

- (0.004)

(1.61)

0.(07)

0.(03)

Kg/cm2

0.(04)

88.880 ± 0.013 (3.4989 ± 0.(005)

0.054

2.433 - 2.543 (0.096 -

2.423 - 2.443 (0.095 - 0.096)

4.793 - 4.813 (0.1887 - 0.1895)

2.363 - 2.383 (0.093 - 0.094)

4.743 - 4.763 (0.187 - 0.188)

0.05

0.04 - 0.08 (0.002 -

0.03 - 0.07 (0.001 -

0.3 (0.012)

0.350.55

1.5 (0.059)

27.994 - 28.000 (1.1021 - 1.1024)

27.996 - 28.008 (1.1022 - 1.1027)

(54Ib/in2) at 3600

0.250(0.01)

0.04 - 0.10 (0.002 - 0.(04)

0.15

0.06

0.1 - (0.004) 40

mm

(in)

- 0.080 (0.0021 - 0.(031)

0.1(0)

- 0.18 (0.002 -

(0.014 - 0.022) (0.014 - 0.022) (0.014 - 0.022)

- (0.006)

- 0.15 (0.002 -

(1.61)

0.(07)

0.(03)

rpm

0.(06)

Oil Filter Relief Valve Opens

Oil Capacity

of

Classification

STARTER

Depth

of

Brush

Under

Cut

Height

Commutator

of

Brush

Spring

O. D. Standard

Pinion

Shaft

OIL

PUMP

the Oil

MOTOR

Standard

Pressure

End

at

Pan

Limit

Play

0.8 - 1.2

6.0 liters (6.3 US quarts) API,

270 c (80

-1 -27° c (30 -80

-18 -_1° c (0 -30°

0.5 (0.019)

0.2 (0.008)

17 (0.669)

6 (0.236) 3

38.7 (1.523)

-1.0 (-0.039)

0.5 (0.014)

Engines & Generators

CF,

Kg/cm2

0

(11

- 17lb/in2)

or CG-4

t), or over SAE 30

° t),

SAE

t)

SAE

mm

(in)

(43 Ib/in2)

66

20W-20

lOW

0.8 - 1.2 Kg/cm2

6.0 liters (6.3 US quarts) API,

CF,

or CG-4

27°c (80

-1 -27° c (30 -80

-18 -_1° c (0 -300

0

0.5 (0.019)

0.2 (0.008) 17 (0.669)

6 (0.236) 3 Kg/cm2 (43 Ib/in2)

38.7 (1.523)

-1.0 (-0.039)

0.5 (0.014)

f),

or

over SAE 30

mm

(11

° t),

t)

(in)

SAE

- 17Ib/in2)

SAE

20W-20

lOW

SERVICE

DATA I TOLERANCES

20

KW

71

60Hz

Generator/16KW

I-FOUR

AND

LIMITS·

50

Hz

71

C-FOUR

Generator

ROCKER

ARM

Oearance

Journal

Cam

Lobe Height (Exhaust) Standard

AND

ROCKER

Rocker

in Rocker

ARM

SHAFT

Bore in Rocker

Arm

Shaft Diameter

Arm

Standard

Arm

Limit

TAPPET

Outer

Diameter

Bore in Cylinder Block

in Cylinder Block Standard

Limit

CAMSHAFT

Camshaft Run-Out

Camshaft End.Play

Joumal

Wear Limit

Bore in Cylinder

on

Clearance Standard

Lobe Height (Intake) Standard

Standard

Diameter

of

Joumal

Limit

1.

2.

3.

4.

1.

2.

3.

4.

Limit

mm(in)

15.876 - 15.896 (0.625 - 0.626)

15.835 - 15.860 (0.623 - 0.624)

0.016

- 0.061 (0.0006 - 0.0024)

0.07 (0.003)

mm(in)

14.224 - 14.249 (0.560 - 0.561)

14.288 - 14.319 (0.563 - 0.564)

- 0.095 (0.002 - 0.004)

0.039

0.10 (0.004)

mm(in)

0.08 (0.003)

- 0.180 (0.001 - 0.007)

0.020

0.3 (0.012)

51.910

- 51.940 (2.044 - 2.045)

51.660

- 51.690 (2.034 - 2.035)

51.410 - 51.440 (2.024 - 2.025)

51.160

- 51.190 (2.014 - 2.015)

0.008 (0.0003)

- 52.030 (2.047 - 2.049)

52.000

51.750

- 51.780 (2.037 - 2.039)

51.500

51.250

0.06

- 51.530- (2.028 - 2.029)

- 51.280 (2.018 - 2.019)

- 0.12 (0.002 - 0.005)

0.145 (0.006)

42.580

(1.676)

42.478 (1.672)

42.580 (1.676)

42.478 (1.672)

mm(in)

15.876 - 15.896 (0.625 - 0.626)

15.835 - 15.860 (0.623 - 0.624)

- 0.061 (0.0006 - 0.0024)

0.016

0.07 (0.003)

mm(in)

14.224 - 14.249 (0.560 - 0.561)

14.288 - 14.319 (0.563 - 0.564)

- 0.095 (0.002 - 0.004)

0.039

0.1 (0.004)

mm(in)

0.08 (0.003)

- 0.180 (0.001 - 0.007)

0.020

0.3 (0.012)

Front 5i.06 - 52.09 (2.0497 - 2.0508) Center 51.81 - 51.84 (2.0398 - 2.0409) Rear 51.31 - 51.34 (2.0201 - 2.0212)

0.008 (0.0003)

- 52.030 (2.047 - 2.049)

52.000

51.750

- 51.780 (2.037 - 2.039)

51.500

- 51.530- (2.028 - 2.029)

- 51.280 (2.018 - 2.019)

51.250

0.06

- 0.12 (0.002 - 0.005)

0.145 (0.006)

42.580

(1.676)

42.478 (1.672)

42.580 (1.676)

42.478 (1.672)

TIMING

Backlash Between Gear Standard

Idle Gear

Idle gear Bushing Inside Diameter

Idle gear

Clearance Between Bushing

Spindle Diameter

End

and

GEAR

Limit

Play

Spindle

Standard

Limit

0.10 - 0.17 (0.004 - 0.007)

0.3 (0.012)

0.15

44.009

43.975

0.034 - 0.084 (0.001 - 0.003)

0.15 (0.006)

mm(in)

- 0.30 (0.0059 - 0.0118)

- 44.034 (1.733 - 1.734) (1.730 - 1.731)

'-..'WESiERBEICE

I Engines & Generators

67

mm(in)

0.10 - 0.17 (0.004 - 0.007)

0.3 (0.012)

0.20

- 0.030 (0.0079 - 0.0188)

44.009

43.975

0.034 - 0.084 (0.001 - 0.003)

0.15 (0.006)

- 44.034 (1.733 - 1.734) (1.730 - 1.731)

TORQUE

20

KW

SPECIFICATIONS

60Hz

Generator/16KW

50

Hz

Generator

Injection

Alternator

Camshaft

Connecting

Coolant

Temperature

Crankshaft

Cylinder

Idler

Injection Nozzle

Injection

Pump

Drive Gear

Injector

Oil

Rocker

Thermostat

71 B FOUR

COMPONENT

Bracket

BackPlate

Camshaft

Thrust

Coolant

Pump

Damper

Engine

Exhaust

Flywheel bolts 15.5 - 16.3 (112 -

Friction

Gear

pipe

Hold

Intake

Main

Oil

Pan

Pressure

Oil

Pressure

Oil

Rear

Arm

Rocker

Timing

Gear

Plate 1.6 - 2.4 (12 - 17)

Rod

Cap

Pump

Pulley 1.6 - 2.4 (12 - 17)

Sender

Switch 1.2 -

Pulley

Nut

Head

Bolts 11.8 - 12.5 (85 - 90)

Head

Cover

Plate 1.9 - 2.7 (14 - 20)

Mounts

Manifold

Gear

Glow Plug 1.0 - 1.5

Thrust

Bearing

Upper

Pump

Oil Seal

Plate

to

Body 6.0 - 8.0 (43 - 58) 8 - 10 (58 - 72)

Flare

Nut

Lock

Nut

Down Nuts 1.6 - 2.4 (11.6 - 17.4)

**Injectors

Manifold 1.6 - 2.4 (12 - 17)

Cap

Pan

Bolts 1.6 - 2.3 (12 - 17) 1.6 - 2.3 (12 - 17)

block

Sender

Switch

Cover 0.8 - 1.2 (5.8 - 8.7) 0.8 - 1.2 (5.8 - 8.7)

Pump

Pipe 0.8 - 1.2 (5.8 - 8.7) 0.8 - 1.2 (5.8 - 8.7)

Cap

Assembly

Arm

Cover

Housing 0.8 -

Thrust

Plate 1.9 - 2.6 (14 - 19)

Gear

Case 1.6 - 2.4 (12 - 17) 1.6 - 2.4 (12 - 17)

Gear

Cover

m-Kg

3.8 - 5.3 (27 -

3.3 - 4.8 (24 - 35)

6.4 - 9.5 (46 - 69)

8.2 - 9.0 (59 - 65) 6.9 - 7.5 (50 - 54)

1.6 - 2.4 (12 - 17) 1.6 - 2.4 (12 - 17)

1.2 - 1.8 (9 - 13)

35 - 40 (253 - 289)

0.3 - 0.45

3.2 - 4.7 (23 - 34) 3.2 - 4.7 (23 - 34)

2.7 - 3.3 (20 - 24) 2.7 - 3.3 (20 - 24)

6.4 - 9.5 (46 - 69) 6.4 - 9.5 (46 - 69)

2.2 - 3.2 (17 - 23) 2.3 - 3.2 (16.6 - 23.1)

2.5 - 3.0 (18 - 22) 2.5 - 3.0 (18 - 22)

4.0 - 7.0 (29 - 51)

11.0 - 11.7 (80 - 85) 11.0 - 11.7 (80 - 85)

1.2 -

1.2 - 1.8

1.5 - 2.0

11.0 -

0.25 - 0.40 (1.8 - 2.9) 0.25 - 0.40 (1.8 - 2.9

1.6 - 2.4 (12 - 17) **

The with a torque tightened

**

The with a

.

(ft-lb)

38)

1.8

(9 - 13) 1.2 - 1.8 (9 - 13)

(2

- 3)

118)

(7

- 11) 1.0 - 1.5

-

1.8

(9 - 13) (9

- 13) 1.2 - 1.8 (9 - 13)

(11

- 14)

11.7

(80 - 85) 11.0 - 11.7 (80 - 85)

1.1

(6 - 8)

71B-FOUR

71C-FOUR

torque

engine

value

of

evenly.

engine

value of6.0 - 7.0 m-Kg (43 -

•

71 C FOUR

m-Kg

3.8 - 5.3 (27 - 38)

3.3 - 4.8 (24 - 35)

6.2 -

7.0 (45 - 51)

1.6 - 2.4 (12 - 17)

1.2 - 1.8 (9 - 13)

35 - 40 (253 - 289)

11.0 - 11.7 (80 - 85)

0.3 - 0.45 (2 - 3)

1.9 - 2.7 (14 - 20)

15.5 - 16.3 (112 - 118)

4.0 - 7.0 (29 - 51)

6.0 - 7.0 (43 - 51)

1.6 - 2.4 (12 - 17)

1.6 - 2.3 (12 - 17)

1.2 - 1.8

1.5 - 2.0

0.8 -

1.1

1.9 - 2.6 (14 - 19)

1.6 - 2.4 (12 - 17)

uses

injectors that

1.6 - 2.4 m-Kg (11.6 - 17.4 ft-lb) per

injectors are screwed directly

(ft-lb)

(7 -11)

-

(9

- 13)

(11

(6 - 8)

- 14)

are

51

bolted

ft-lb).

to

into

the

head

bolt,

the

head

Engines & Generators

68

71

Bn1 C ENGINE

SPECIFICATIONS

Engine

Type

Aspiration Governor

Combustion Bore & Stroke Piston Firing Direction

Maximum (at

Compression

Dimensions

Weight Fuel

(approximate)

Inclination

Generator

Chamber

Displacement

Order

of

Rotation

Torque

1800

rpm)

Consumption

Power

ENGINE

Ratio

Take

SPECIFICATIONS

Diesel,

four-cycle,

water-cooled,

mechanism Naturally Electronic Swirl

3.50 x 4.0 154 1-3-4-2 Clockwise, 1181b-ft

21:1

Height:

Width:

Length: 652

1.4 allowing

Continuous

Temporary

Off

30

vertical

(71

aspirated

Governing

type

inches

cubic

inches

when

(16.31

26.9

inches

22.2

inches

39.5

inches

Ibs

(295.9

US

gph

(5.2

3600

rpm

14°

25°

Horsepower

three-cylinder,

in-line

Hp

at

3600

(88.9 x 101.6

(2.5

liters)

viewed

from

kg-m)

(684.2

mm)

(563.6

mm)

(1003.3

kgs)

Iph)

at

2500

full

throttle

(not

to

exceed

(maximum)

fresh

overhead

rpm

maximum).

mm)

the

front

mm)

rpm

with

in

forward

30

min.)

valve

the

gear

prop

General Fuel Fuel

Injection

Fuel

Injection

(spill

timing)

Nozzle

Fuel

Filter

Air

cleaner

Air

Flow

(engine

combustion)

General

Operating

Fresh

Water

Raw

Water

.Raw

Water

at

3600

rpm

System

Capacity

(fresh

water)

Pump

Timing

Temperature

Pump

Flow,

FUEL

SYSTEM

Open

flow,

self

No.2

diesel

Bosch

Model

0°

TDC

(Top

Throttle

type

Spin-on

type,

Metal

screen

160.4

cfm

(4.5

COOLING

Fresh

controlled 170 Centrifugal Positive

gear-driven. 10

before

11.5

SYSTEM

water-cooled

with

-190° F (77 -88°

displacement,

US

gpm discharging

qts

(10.88

bleeding

oil

(cetane

VE

Distributor

Dead

Center)

full

flow

type

cmm)

heat

type,

metal

(37.8Ipm)

liters)

-1

bleed

rating

of

at

3600

block,

thermostatically-

exchanger.

C)

impeller, rubber

(measured

into

exhaust

point

45

or

higher)

rpm

belt-driven

impeller,

elbow).

Compression (Limit

of

Difference

Between

Cylinders)

Valve

Timing

Valve

Seat

Angle

Engine

Speed

Valve

Clearance

(engine

cold)

Engine

Speed

Injector

Pressure

Engine

Timing

Starting

Battery

Capacity

DC

Charging

Alternator Starter Starting

Aid

DC

No-Load

Current DC

Cranking

Current

TUNE-UP

Pressure

ELECTRICAL

SPECIFICATIONS

427

psi

(30

kg/cm')

at

200

(47.2

psi

{3.0

kg/cm'})

Intake

Opens

17"

Intake

Closes

Exhaust Exhaust

Intake

45°

Exhaust 1800

rpm

1500

rpm

Intake

0.012

Exhaust Idle

speed:

Cruising 1920 + 71 Static

timed -drop

0.205 ± .005

47°

Opens Closes

30°

60

Hertz

50

Hertz

inches

0.012

speed:

-0

psi

in

BTDC

ABDC

51 ° BBDC

13°

ATDC

(0.3

mm)

inches

(0.3

750 -1000 2500 -3000

(135

+ 5 -0

valve

BTDC

method

SYSTEM

12-Volt,

(-)

negative

ground 400 -600 51 12-Volt, Glow

±

250 -300

Amp

2%

Cold rated, reduction

plugs,

of

rated

Amps

Cranking

belt

driven

gear,

sheathed

Amps

(engine

3

type

rpm

mm)

rpm

Amps

!WI

cold)

limit

kg/cm')

(CCA)

Standard

Gear

Ratio

Prop

Shaft

Rotation

Prop

Recommendations

for

this

Gear

Lubrication Sump

General Oil

Sump (not

Operating (engine

Oil

Capacity

Filter

Capacity

including

hot)

Grade

Fluid

Oil

Pressure

TRANSMISSION

Hurth -case servo-operated

2.7: Right 20D x 14P

propeller rated

throttle

ATF

0.79

LUBRICATION

Pressure Full

6.5

U.S.

filter)

plus

50 -60

API SAE

hardened

multiple

1

hand

-2

blade

should

rpm

type A Dextron

US

allow

(3600 + 000 -100)

in

forward

quarts

(0.75

SYSTEM

fed

system

flow,

paper

element,

qts

(6.15

filter/cooler

Specification

30,

psi

(3.5 -4.2

10W-30,

assembly

CF

15W-40

helical

or

20D x 12P

the

gear.

II

or

liters)

kg/cm')

or

disc

clutch

engine

III

spin-on

CG-4,

gears,

-3

to

at

full

type

with

blade reach open

it's

full

Engines & Generators

69

NOTE:

Grade

4 6mm Smm

10mm 10mm 12mm 12mm 12mm 13mm 14mm 14mm 16mm 16mm

Grade

6mm Smm 10mm 10mm 12mm 12mm 12mm

STANDARD

HARDWARE

TORQUES

Unless stated otherwise for a specific assembly, use the following torque values when tightening standard hardware.

Grade

7T,

8T

and

bolt bolt

6T

head/nut

head/nut bolt bolt bolt bolt bolt bolt bolt bolt bolt bolt

bolt bolt

bolt bolt bolt bolt bolt

head/nut head/nut head/nut head/nut head/nut head/nut head/nut head/nut head/nut head/nut

head/nut head/nut

head/nut head/nut head/nut head/nut head/nut

Pitch

1.25

1

1.5 (ISO)

1.5

1.75

1.5

1.5 2

1.5

2

1

1.25

1.5

(ISO)

1.5

1.75

Ib-II

2.9-5.1

7.2-11.6

13.7-22.4

13.0-21.7

25.3-39.S

21.7-36.2

32.5-50.6

36.2-57.9

34.0-55.7

54.2-79.6

51.4-76.7

4.3-6.5

10.S-15.9

21.7-32.5

19.5-30.4

36.2-57.9

36.2-50.6

34.7-49.2

kg-m

0.4-0.7

1.0-1.6

1.9-3.1

1.S-3.0

3.5-5.5

3.0-5.0

4.5-7.0

5.0-S.0

4.7-7.7

7.5-11.0

7.1-10.6

0.6-0.9

1.5-2.2

3.0-4.5

2.7-4.2

5.0-S.0

5.0-7.0

4.S-6.S

6mm

bolt

Smm

bolt

10mm

bolt

10mm

bolt

12mm

bolt

12mm

bolt

12mm

bolt

13mm

bolt

14mm

bolt

14mm

bolt

16mm

bolt

16mm

bolt

Grade 5 Cap

1/4

UNC

1/4

UNF

5116

UNC

5116

UNF

3/8

UNC

3/8

UNF

7/16

UNC

7/16

UNF

112

UNC

112

UNF

8.8 head/nut head/nut

head/nut head/nut head/nut head/nut head/nut head/nut head/nut head/nut head/nut head/nut

Screw

Pitch

1.25

1.75

1

1.5 (ISO)

1.5

2

1.5

2

Ib-II

5.S-S.7

14.5-21.7 2S.9-39.S

26.S-37.6

54.2-75.9

50.6-65.1

43.4-61.5

57.9-S6.S

72.3-10S.5

68.7-101.3

10S.5-166.4

101.3-159.1

9-11 11-13 1S-20 21-23 2S-33 30-35 44-49 50-55 68-73 73-S0

7.5-10.5

S.0-12.0

10.0-15.0

9.5-14.0

15.0-23.0

14.0-22.0

9.4-10.1

10.1-11.1

kg-m

0.S-1.2

2.0-3.0

4.0-5.5

3.7-5.2

7.0-9.0

6.0-S.5

1.2-1.5

1.5-1.S

2.5-2.S

2.9-3.2

3.7-4.6

4.1-4.S

6.1-6.S

6.9-7.6

PARTS

Taper Taper Taper Water

.

Oil Side Bearing

REQUIRING

screw screw screw

drain

pressure

SEALANT

112" 1/4" 1/8"

plug

switch

seal

cap

No.

1

BOLT

M6

M8 M10 M12 M14

Thread Thread Thread Thread Thread

Periphery

Contact

DIA.

GENERAL

SURFACES

(where

portion

(Gear

portion

(Cylinder

portion

(Cylinder

portion

(Cylinder

portion

(Cylinder

(Main

bearing

surface

with

SCREWS

BOLT

HEAD

4 7

0.3-0.5

1.0

-1.3

1.8 -2.5

0.8

-1.0

1.5

-2.2 2.5-3.5

3.0-4.2 5.0-7.0

3.0-4.2 5.5-7.5

5.0-7.0

8.0

-11.0 16.0-19.0

SEAlANTS

REQUIRING

to

mount

case)

block head block block

caps

cylinder

sealant

right

rear

right right

No. 1 and

block

SEALANT

coated

side,

surface)

side, side

surface)

No.5)

MARK

parts)

pump

rear

middle

9.5

cover)

portion)

1.0

10

-1.3

-12.0

SEALANT

Liquid

Teflon

Liquid

Teflon

Liquid

Teflon

Liquid

Teflon

Liquid

Teflon Permatex Permatex

#6B #6B

70

METRIC

CONVERSIONS

INCHES

Inches

1 25.40

2

3 76.20 4 101.60 5

10

Inches

1 0.0254 7

2

3 0.0762

4 0.1016

5 0.1270

6 0.1524

TO

Yards Meters Yards Meters Meters Yards Meters Yards

1

2 1.82880 7

3 2.74320 8

4

5

50.80

127.00

254.00

MILLIMETERS

Meters Inches Meters Meters Inches Meters Inches

0.0508 8

CONVERT

0.91440 6

3.65760 9

4.57200

MOVE

TO

MILLIMETERS MILLIMETERS

mm

INCHES

YARDS TO METERS METERS TO YARDS

DECIMAL

Inches

= 1

CENTIMETER,

TO

METERS

TO

POINT

15 20 25

30

35

40

METERS METERS

9 10 11 12

CENTIMETERS,

10

FOR

mm mm

381.00

508.00

635.00

762.00 4

889.00

1016.00

100

CENTIMETERS

0.1778

0.2032 0.2

0.2286

0.2540

0.2794

0.3048 0.6 23.622

MOVE

5.48640 1 1.09361

6.40080 2

7.31520

8.22960 4 4.37445

9.14400 5 5.46807

HIGHER

VALUES -e.g.

1 2 3 0.1181

5

10

= 1

0.1

0.3

0.4

0.5

DECIMAL

3

Inches

0.0394

0.0787

0.1575

0.1969

0.3937

METER

=

3.937

7.874

11.811

15.748

19.685 1.1

POINT

TWO

2.18723

3.28084

6,000

METERS = 6,561.68

39.37

TO

PLACES

TO

INCHES

mm

15 20 25 30 35 40

INCHES

(3.3

INCHES

0.7

0.8

0.9

1.0

1.2

TO

THE

6 7 7.65529

8

9

10

YARDS

Inches

0.5906

0.7874

0.9843

1.1811

1.3780

1.5748

FEET)

27.559

31.496

35.433

39.370

43.307

47.244

RIGHT

6.56168

8.74891

9.84252

10.93614

Ib

1 0.454 6 2.722 1 2.205 6 2 0.907 3 1.361 8 3.629 3 4 1.814 5 2.268

Gallons Liters Gallons Liters Liters Gallons Liters Gallons

1 3.79 2 7.57 3 11.36 4 15.14 5 18.93

Pints

1 2 0.95 7 3.31 2 4.23 7

3 1.42 8 4 5

POUNDS TO KILOGRAMS KILOGRAMS TO POUNDS

kg Ib

7

9

10

32

GALLONS

PINTS

Liters

0.47

1.89

2.37

40

50

TO LITERS

10 20 30 40 50

TO

LITERS

Pints

6

9

10

60

I I I I

kg kg Ib kg Ib

3.175 2

4.082 4

4.536

37.86 1

75.71 2

113.57 5 1.32

151.42

189.28

Liters Liters Pints Liters Pints

2.84 1 2.11

3.79

4.26 4

4.73

TEMPERATURE

70

75

5 11.023

10 20

3

5

85

95

4.409

6.614

8.818

LITERS

TO

0.26

0.53

2.64

5.28

LITERS TO PINTS

6.34

8.45

10.57

105

140

I I I I I I I I

7 15.432 8 9 19.842

10

GALLONS

60

90

120 150 180

6

8 9 19.02

10

175

212

13.228

17.637

22.046

15.66

23.77

31.32

39.62

47.54

12.68

14.79

16.91

21.13

of

I I I I I I I I I I I I

0

5

10 15

20

25

30

35

40

60

80

100

°C

Engines & Generators

71'

INDEX

AC Voltage Connections Alternator Inspection Alternator Testing Alternator Troubleshooting Block - Cylinder Camshaft Circuit Breaker - Generator Connecting Rod Coolant Circulating pump Crankshaft Crankshaft Bearing Assembly

Cylinder Block Cylinder Head Cylinder Head Bolt Pattern Cylinder Liner Electric Motors - Chart Electronic Governor Electronic Governor Troubleshooting Engine - Propulsion Schematic Engine Adjustments Engine Compression Engine Disassembly

Engine Inspection Engine Reassembly Engine Specifications Exhaust Manifold Frequency - Adjustment

Fuel Injection Pump Fuel Injectors Fuel Lift Pump Gears Generator Generator Disassembly Generator Wiring Diagram Generator Maintenance Generator Specifications Generator Information Generator Wiring Schematic

Glow Plugs

Heat Exchanger

Hour Meter Idler Gear Injection Pump Injectors - Fuel Intake Manifold Assembly L Dimension

................................

...............................

..........................

..............................

...........................

............................

...........................

..........................

BE

Single and Three Phase

.............................

...........................

.............................

............................

.............

..........................

............................

.................

......................

........................

.................

..................

...............

.....................

.......................

..............

......................

........................

......................

.........................

..................

......................

...............

.....................

....................

.....................

.................

~

...................

..........

.........

............

52, 53

047 046 046

16

20

51

18 .37 .19 .12

16 13

26, 35

.17

50 Pumps: 57 58

049

.36 .35

.13

23 69 29 Rocker Arm - Inspection

50, 53 Rocker Arm Removal

.30

.32 Three Phase Voltage Regulator

.31

.11,21

51

60,61

50 62

.50

55

.34

4, 5

11,21

.30 .32

.14

Maintenance - Generator Manifold - Exhaust

Manifold - Intake Assembly Metric Conversion Chart Oil Coolers - Transmission

Pressure

Oil Oil Pressure Sendor Oil Pressure Switch Oil Pump - Lubricating Oil Seal - Rear

Overhaul - Testing

Parts

Ordering Piston and Piston Ring Piston Assembly Propulsion Engine - Wiring Diagram

Coolant Circulating Fuel Lift Injection

Raw Water Push Rod Raw Water Pump

8

Oil Seal

Rear Regulator - Voltage Regulator - Voltage Adjustments

Schematics:

BE Three Phase (12 wire) BE Three Phase (6 wire) Generator (single phase)

8

29

27

Generator 6 Wire Reconnectable

Propulsion Engine

Remove Start/Stop Panel Three Phase 12 Wire Reconnectable

Screws

Sealants Sendor - Oil Pressure Serial Number Location Shore Power Transfer Switch Solenoid Specifications - Engines Specifications - Generators Speed Adjustment - generator

Speed Adjustment - Propulsion Engine

- Standards

.................................

........................

..............................

.......................

........................

....................

...........................

..........................

.... ' .........................

....................

.........................

.....................

..............................31

..............................

(Overhaul)

................................

Overhaul

............................

........................

......................

........................

......................

Start Motor

.....................

....................

................

....................

..................

..........

..................

.................

..............

....................

.............

.................

..................

............

..................

....................

................

....................

..................

................

.........

........

50 29

.27

71 28 39

.39

39

.38

22

3

2 .17 .12

048

.37

30

040

22

040

.22

54 54

16 12

52 52 52 55 55

049

61 51 70 70

39

.2

59

Al

69 62 57

.30

'

.....

'WESIERBEICE

I

Eng~nes

&

_Generators

72

INDEX

Spindle - Idler Gear

Starter Motor Starter Starter Motor -Adjustment and Repair Switch - Oil Pressure Tappet - Inspection Testing for Overhaul Thermostat Assembly Timing Gear Case Timing Cover Timing Gear

Tolerances

Motor - Solenoid

and

Camshaft Connecting Rod/Connecting Rod Bearing Crankshaft and Main Bearing Cylinder Block, Piston and Piston Cylinder Head and Valve Spring

Oil Rocker Starter Motor Tappet Timing Gear Valve Guide, Valve and Valve Valve Timing

..............................

Pump

Arm and Rocker Shaft

................................

........................

............................

...................

.......................

........................

......................

.........................

............................

Limits:

..............

............

.............................

..............

..........................

...........................

Spring

..........................

........

.....

21 .41 .41 .41

39 Troubleshooting: 16

27

11

22

.11

67

.....

65 65 Voltage Regulator Adjustments 65 Wiring Diagrams: 64 Generator 66 Propulsion Engine

67 66 67 67

64, 65

64

Torques:

Standard Hardware Westerbeke Components

Transmission - Oil Coolers

Alternator

3

BE

Generator Electronic Governor Engine

Valve Clearance Valve Guide

Valve Seat Valve Voltage Regulator

................................

...............................

Spring

............................

.......................

........................

............................

.............................

......................

..................

.....................

.........................

...............

......................

70 68 28

.40

...

56 58

26, 35

.15

13

15 54 54

60

.48

4

Engines & Generators

73

WESTERBEKE

WESTERBEKE AVON.

CORPORATION

MA

02322

- TEL: (508) 588-7700 - FAX: (508) 559-9323

-AVON

INDUSTRIAL

PARK

IWM-k

4/98

5C

Westerbeke 71 B-FOUR, 71 C-FOUR, 20.0KW BEDA, 16.0KW BEDA, 20.0KW BED Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual