Westerbeke 20BEG, 16BEG Service Manual

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~

WESTERBEKE

iC

¥'

*

·.

·*

*

SERVICE

25BEG(A)60Hz

20BEG(A)60HZANo

81

years

·.

8tNce

19'l1

·*

..

. · .

MANUAL

ANo20BEG(A)50Hz

16BEG(A)50H:Z

·~.

'*

..,

*

)!(..

MARINE

SINGLE

W70GA

PUBLICATION N0.048088

GENERATORS

and

MARINE

REVISION·3 APRIL 2018

THREE

PHASE

ENGINE

,

"""""""""""

§PC

WESTERBEKE CORPORATION• MYLES STANDISH INDUSTRIAL PARK

150

JOHN

FAX 1-508-884-9688 • WEBSITE: WWlilf. WESTERBEKE.COM .

.

HANCOCK

ROAD•

TAUNTON

MA

02780-7319

•TEL.

1·508-823-7677 ·

AwARNING

Exhaust colorless unconsciousness exposure

•Dizziness

•Nausea

"•Headache

•

IF GET seek until

gasses

gas.

can

Weakness

YOU

OR

ANYONE

OUT

INTO medical it

has

been

contain

Carbon

Monoxide

and

death.

Carbon

Symptoms

include:

and

Sleepiness • Inability

ELSE

EXPERIENCE

THE

FRESH

AIR

IMMEDIATELY.

attention.

Shut

inspected

down

and

A

WARNING

•

•Muscular

•Vomiting

WESTERBEKE

bulkhead

WESTERBEKE CARBON living/sleeping

T~ey

obtainable

WARNING'

Generators

Produce

CARBON

Gemvalars

MONOXIDE.

Required

Regular

Maintenance

f!!S!/.WESTERBEKE

Engines &

Monoxide,

is

poisonous

of

Throbbing

to

ANY

fhe

unit

repaired.

DECAL

and

near

also

MONOXIDE

are

inexpensive

at

your

an

odorless

and

can

carbon

in

Temples

Monoxide

Twitching

Think

Coherently

OF

THESE

ff

symptoms

and

do

not

is

provided

should

your

engine

recommends

DETECTORS

quarters

of

and

local

marine

and

cause

SYMPTOMS,

persist,

restart

by

be

fixed

to

a

or

generator.

installing in

the

youi

vessel.

easily

store.

CALIFORNIA

PROPOSITION

Marine

exhaust

are·

known

to

cause

and

diesel

and

some

to

the

cancer,

other

reproductive

and

of

State

65

WARNING

gasoline

its

constituents

of

&alifornia

birth

defects,

harm.

engine

TABLE

Parts

Identification Engine Troubleshooting Testing Control Alarms/Switches Instrument

Engine Generator Engine

Engine Lubricating Cooling Fuel Exhaust

Carburetor Carburetor Carburetor Carburetor

Testing

Data

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

for

Overhaul

Panels

Panel

Alarms/Breakers

Disassembly

Timing Belt ........................................................

Cylinder Head/Valves .........................................

Valve Seat ...........................................................

ValveNalve GuideNalve Spring .......................

Camshaft .............................................................

Cylinder Block/Piston ........................................

Piston/Piston Ring .............................................. 20

Connecting Rods ............................................ : ...

Crankshaft ..........................................................

Assembly

System

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

Manifold/Heat

(#039454) (#052563) (#052563)Exploded Troubleshooting

Engine Tachometer

Timing Starter Mando BE

25 25

W·70GA

W·70GA W·70GA Service Angular Torque

Adjustments

the

lgnitor

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

Belt.

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

Motor Alternator

Generator

Voltage Regulator Adjustments ..........................

Internal Wiring Schenatic ................................... 74

BE Troubleshooting ........................................... 76

AC Connections .................................................

Shore Power Transfer Switch .............................

and and

With Two Relays ................................................ 86

Remote Instrument Panel ...................................

Remote Start Panel ............................................. 89

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

20

Generator

20

Wiring

Engine Wiring

Transmission Standards/Limits Nut/Bolt

Specifications Standard Sealants Metric Index

Torque

and

Conversion

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

OF

CONTENTS

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

Guide

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

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

(Generator)

(Engine)

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

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

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

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

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

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

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

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

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

Exchanger

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

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

View

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

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

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

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

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

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

Specifications

Diagrams

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

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

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

Diagram

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

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

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

Tightening

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

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

Specifications

Lubricants

Data

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

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

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

2 3

.4

6 7

7 A

8 8 9

9 A

10

15 16 17 18

19

21

22 23

31

35

37

38 .39 .42

.43

.43B

.44

.47

48

49

51

65 72 73

77 79 80

82 88 90

91 93 94 96 97

98 99

.100

101

Engines & Generators

1

25KW

AND

20KW

BEG

GENERATOR

PARTS

IDENTIFICATION

EXHAUSTTEMPERATURE

LED

LIGHTS

.

SWITCH.

AIR

RIGHT

INTAKE

FLAME

SIDE

ARRESTOR

LUBE

OIL

ATER

TEMPERATURE

'OIL

PRESSURE

DRAIN

HOSE

SWITCH

BELT

GUARD

LEFT

FRESH

FUEL

SIDE

WATER

LIFT

PUMP

COOLANT

FIU

70"

EXHAUST

ELBOW

1

EXCHANGER

AIR

BLEED

PETCOCK

lwlWESTERBEKE

l Engine$ & Generators

2

W·

70GA

PARTS

IDENTIFICATION

FLAME

RAW

WATER

VACUUM

ARRESTER/AIR

PUMP

ADVANCE

UNIT

FRONT

Oil

SUMP

FILTER

COOLANT

FILLER

PRESSURE

CAP

DC

ALTERNATOR

EXHAUST WATER

INJECTED

EXHAUST

VCONNECTION

STARTER

SOLENOID

.a---

TRANSMISSION COOLER

LEFT

SIDE

ELBOW

REAR

FUEL. FILTER

ZINC

20A

CIRCUIT

BREAKER

TRANSMISSION.

COOLANT PRESSURE

CAP

DISTRIBUTER

PCVVALVE

INLET FILTER

,CARBURETOR

FRONT

RAW

WATER

PUMP

SHIFT

LEVER

REAR

Engines & Generators

2a

RIGHT

SIDE

ENGINE

DATA

DESCRIPTION

The

engine is a "Square" type with a total displacement

2184cc.

driven overhead cam

The

COMBUSTION BORE X STROKE TOTAL COMPRESSION COMPRESSION

It

is a watercooled, four cylinder engine with a belt-

(OHC).

main

specifications

CHAMBER

DISPLACEMENT

RATIO PRESSURE

are

TYPE

as

follows:

Multi-sphere

86mm x 94mm

2184cc

8.6

11.5

kg/cm2-

CYLINDER.BLOCK

The cylinder block construction

the block and cylinder liners are cast as one piece. The

cylinder walls The cylinder block sections to reduce noise. There are five main bering journals for crankshaft support. ,1

CYLINDER

This WES'IERBEKE engine is an overhead cam (OHC), cross-flow design. The rocker independently to This makes it possible to remove the cylinder head without disassembling the rocker arm assembly (and vice-versa) resulting in improved serviceability. The intake and exhaust ports

are

(cross-flow) and the intake ports incoming fueUair mixture.

CRANK

The piston is a tapered type with a recessed combustion

surface, specifically designed for the engine. The piston pin is offset Imm to the thrust side (direction durillg combustion stroke) to decrease knocking noise.

On the crankshaft,

thicker to improve the effectiveness reducing the conventional eight weights to

As

a result,

response.

bearing

are

double honed for a

is

deep-skirted with chambered cross

HEAD

the

head,

located

on

opposite sides

MECHANISM

the

outside of the balance. weight is made

the

inertial weight is reduced, improving epgine

End play

at the No.3

of

the

main

is

an integral design where

fine,

precision surface.

arm

assembly bolts

rather than using

of

the

cylinder head

are

designed to swirl the

of

a single,weight,

crankshaftis restricted

bearing journal.

MEASURING

Exhaust

·exhaust

. the

·of water

systems normally produce resistance to the

gases,

causing

back-pressure.

kept within a certain limit.

generator is

To

test exhaust pressure,

PSI tube.to the test part

ChCck

~e

into

service.

reached its nomial operating temperature, and at the point

where

it

(for

SOHz

Back-pressure

A

water

plastic

tube

tube with a

Back-pressure

put

exhaust

Measure

is about

column

ui

to

applications)

should not exceed

can

along a l/4".NPf

should nof exceed

the

water

Check

back

into

connect

on

the exhaust elbow

back-pressure

the

back-pressure

reach

its

rated

or

1800

be

made

yardstick

pipe

fitting._.

column.

Back-pressure

the

back-pressure before

service.

either

a water

as

before the generator is put

after the

load at

rpm

by taping

lll!d.

either

(for

60Hz

1.5

psi

(0.11

one

end of a

fittin~

the other end of

. · • . · ·

27in

(69cm)

type

270

rpm

the

head bolts.

lateral

pressure

four.

~y a ~t

flow

of

must

be

column

or

shown.

engine

has

1500

rpm

appli'i.ations).

kg/cm

J.

clear

the

VALVE

of

The valve mechanism employs the overhead camshaft

(OFIC). prevent carbon damage and irregular.

The valve spring is inner and outer springs. It is necessary to set the shorter pitched side toward cylinder head at the

The end play

of

the camshaft and cylinder head are determined by the

flange The adjustment

tension spring.

INTAKE

Both intake and exhaust manifolds·are consisting of

cylinders.

COOLING

A

centrifugal

block, driven by employed to provided by a belt driven raw water pump and a heat exchanger.

LUBRICATION

A crescent type oil pump is

to

feed

spin

FUEL

The carburetor

fuel

:function

A mechanical belt driven governor connected the

of

the

output ands torque.

·Nm:

.ENGWGENERATOR

·

'·

EXHAUST

•

Engines & Generators

3

MECHANISM

The rocker arm is offset against the exhaust stem to

of

the double coil type with unequal pitch

time

of

installation.

of

the camshaft cannot

on the cam.

of

the belt

AND·EXHAUST

of

an independent branch,

is

SYSTEM

be

adjusted. Positioning

carried out by the tensioner and

of

aluminum,

pipe

for each pair

SYSTEM

water pump is incorporated in the cylinder

the

timing

belt

A wax type thennostat is

ensure

proper temperature control. Cooling is

SYSTEM

driven

oil under pressure. The oil fiher

-on

type.

SYSTEM

is

a down-draft, one stage, single barrel and the

pump

is

an

electromagnetic type,

through the

carburetor controls

For

"additional

BACK

reciprocating

the

engine rotational speed, power

tnjormati0n,

SPECIFICATIONS

PRESSURE

directly

motion

refer

NiEASURiNG

P-5SURE

by

the

crankshaft

is.:ijill-tlow

It

performs the pumping

of

a plunger.

to

the.

in'.this

11f21"ual

PSI GAUGE

/·

,,

EXHAUST

and a

throttle arm

·

.BACK

TROUBLESHOOTING

GUIDE

The following engine troubleshooting guide may determining

Insufficient

Excessive

Difficult

Abnormal

Poor

if

Power

Oil

Starting

Combustion

Id.ling

a complete or partial overhaul is necessary.

Consumption

Insufficient

Compression

Seized Weak Burned Cracked Sticking,

ring Cracked

Malfunction Malfunction

Oil

Worn ring

Worn

Oil

Bad Worn

Oil

Malfunction Components

Burned Worn Burned

Malfunction Malfunction

Malfunction

Components

Sticking Weak Carbon

combustion

Malfunction Malfunction

Malfunction

Components

Poor

Failure

Malfunction

Compression

leakage

valve

stem

or

broken

cylinder

or

distorted

damaged,

or

worn

of

Fuel

of

Ignition

Working

leakage

Up

or

sticking

groove

piston

or

cylinder

Down

valve

seal

valve

stem

of

Engine-related

valve

piston,

piston

cylinder

of

Fuel

of

Electrical

of

or

burned

or

broken

accumulated

chamber

of

Fuel

of

Ignition

of

valve-to-valve

of

cylinder

of

Fuel

valve head

or

piston

or

head

Engine-related

valve

Engine-related

seat

head

be

helpful in

from

valve

spring

gasket

cylinder

worn

System

ring

guide

ring,

or

gasket

System

spring

in

System

contact

gasket

System

seat

head

piston

or

piston

cylinder

Note:

The

Engine

Troubleshooting

Engine

Noise

Engine

Misfires

Engine

Backfires

Cooling and

Data

are

in

Engine

Lubrication

those

sections

Crankshaft parts

Excessive Main Excessive Excessive

clearance Connecting

damaged

Piston

Worn Worn Seized Damaged Bent

Malfunction Valve

Malfunction Broken Excessive

stem Insufficient

Others

Malfunction Malfunction Malfunction

Poor Incorrect Dirty Cracked Faulty Spark High

Valve

Spark wrong.

Incorrect Engine Dirty

Cracked

High

Choke

or

· main

bearing

crankshaft connecting

rod

piston

Connecting

or

timing

valve

clearance

and

guide

lubrication

quality

timing.

flame

arrester.

distributor ignition plugs

exhaust

clearances

plug

wires

timing.

is

flooded.

flame

arrester.

distributor

exhaust

is

stuck

of

this

manual.

bearing

oil

clearance

seized

or

heat

end

play

rod

bearing

seized

parts

or

piston

ring Rod

of

Ignition

System

of

HLA

*

spring

between

of

rocker

of

water

pump

of

alternator

of

timing

fuel.

wires.

are

worn.

back-pressure.

closed.

belt

cap.

are

incorrect.

are

connected

cap.

bearing

tensioner

damaged

oil

or

heat

valve

arm

bearing

Malfunction System

of

Ignition

*

Tapet period after operating

4

noise

may occur if

of

time.

Tapet

the

engine.

noise

the

should

engine

is

not operated for a

stop

within 10 minutes

TROUBLESHOOTING

Engine

Overheats

Low

Oil

Starting

Pressure

Battery

Coolant system.

Faulty

raw

Belts

are

Raw

water

Faulty

thermostat.

Heat

exchanger

Collapsed

Low

oil

Faulty

oil

Wrong

Faulty

gauge Wrong Relief

valve

Faulty

oil

Faulty

engine

Loose Faulty

battery

Connections or

faulty.

Faulty

alternator.

No

excitation

GUIDE

loss.

Pressure

water

pump

loose

or

pump

is

hose.

level.

pressure

SAE

type

oil

filter.

is

stuck.

pump.

bearings.

alternator

voltage

to

the

to

the

broken.

worn.

oil

drive

test

impeller.

clogged.

sender

in

the

engine.

belt

regulator.

alternator

regulator

cooling

are

loose

High

Oil

Pressure

Blue

Exhaust

Discharge

Black

Discharge

from

exhaust

from

Smoke

the

Engine

smoke

the

Engine

Faulty

sender

Dirty

oil

or

engine.

Relief

valve

Lube

oil

is

High

lube Crankcase Valves

are

incorrectly. Piston

rings

Dirty

flame

Faulty

carburetor.

Idle

mixture Accelerator Valves

are

adjusted. Lube

oil

is

Piston

rings

or

gauge

wrong

SAE

is

stuck.

diluted.

oil

level.

breather

worn

or

adjusted

are

worn

arrester.

jet

too

diaphragm

worn

or

incorrectly

diluted.

are

worn

type

hose

or

rich.

leaking.

or

oil

in

the

is

clogged.

unseated.

Engines & Generators

5

TESTING

HOW

TO

DETERMINE

Cause

Generally, is power output, decreased compression fuel is sometimes caused by problems by

cause or causes inspection and maintenance.

is

caused by worn cylinders or piston rings, symptoms will

of

Low

Compression

the time at

determined by various conditions such

and oil consumption. The lowered

not necessarily

..

The decrease in compression pressure

many

factors. It

on

a good means of monitoring engine internal

occur:

1

Low

2

Increased

3

Increased

4 Hard engine starting

5 Noisy

These symptoms often appear together. can

result also from carburetor performance They are caused also by defective electrical devices such the

battery, alternator or

judge the optimum engine overhaul time by

compression pressure caused by worn cylinders and pistons plus

increased oil consumption. Satisfactory combustion obtained only under sufficient compression pressure. engine lacks compression pressure, incomplete combustion of fuel

will take place even

operating properly. overhaul, it is important pressure regularly. At the same time, the engine speed at which the measurement of compression should be checked because the compression pressure varies with

engine rpm. The engine rpm can

front

end

of

the crankshaft.

ENGINE

which

due

to trouble with the worn

is,

therefore, necessary

the basis of data produced

engine

power

fuel

OVERHAUL

an

engine should

pressure,

engine

plugs or

consumption

fueVcarburetor

Oil analysis

output

as

engine

oil consumption

engine

operation

Symptoms

starter.

Therefore it

if

other parts of

To

determine the period of engine

to

measure the

engine

be

PERIOD

be

overhauled

lowered engine

and increased

power output

itself, but

is

caused

to

determine a

by

periodic

on

a seasonal basis

wear.

the

following

2

or

worn plugs.

is

desirable to

the

lowered

the

engine

compression

pressure

is

measured

When

and

If

an

are

made at the

FOR

is

4

as

is

OVERHAUL

NOTE:

Make

certain properly symptoms that overhaul (cylinder

Before

clearances gasket

adjusted.

preparing

to

and test

DISASSEMBLY

NOTE:

Before

defects

for

cleaning.

•

• Carefully inspect each parts after

•

• Be

• Use

which

All

disassembled parts should be carefully arranged in the order of reassembly. Mark or label the parts needed

to

proper directions and positions.

If

the disassembly procedure

parts

to

be

in a

way without its performance.

Do disassembly.

deformation, and other problems. Carefully

checking

any

not

remove or disassemble parts that require

Careful

parts

clean.

the special care intrusion of dust and dirt.

the

engines

An incorrect

might,

incorrectly,

misfire,

for

an

engine

the

correct

the

engine.

disassembly and

cannot

insure proper mating and reassembly in the

disassembled, the parts should be disassembled

that will allow them

change in the engine's external

check

gaskets,

is

not

specified.

not to damage the disassembled parts.

proper tools.

to

keep the

valve

suggest

white

smoke,

overhaul,

specification,

cleaning,

be

found after

is

complex requiring

to

be efficiently reassembled

packings

Replace

Apply

oil when

fuel

system

clearances are

clearance

noise,

install a

carefully

disassembly

removal

and

oil

with

parts

can

an

engine

etc).

adjust

the

new

appearance

for

seals,

even

new

ones

necessary.

free

cause

valve

cover

check

and

as

many

no

damage,

if

defective.

Keep

Take

from

the

or

the

When the decrease

repair

limit, the engine must be overhauled.

The engine requires overhaul when oil consumption is high, blow-by evident, and compression below.

Engine compression slwuld

400 rpm. Cylinder

28.0

psi (20Kglcm

of

compression pressure reaches the

valves

be

198.l psi

compression

2

).

should

(14

not

are

vary

at

Kglcm

minimum or

2

at

)

more than

Engines &

Generators

6

GENERATOR

CONTROL

PANELS

DESCRIPTION

The generator mounted control.panel ON

switch

(black), a START switch(white)

switch

(red).

The

ON

switch provides power to the start circuit. This

switch by-passes the protective oil pressure

oil

until the The START switch energizes the start solenoid/starter which

cranks switch

The switch

The panel also has two

• A 15

•An 8 amp

any

REMOTE

An optional remote start/stop panel

controlling the generator from a remote location. This panel has the same

previously described. Also included which glows once the engine/generator rpm's. The purpose of the release the START switch. It engine/generator

pressure reaches 5 -

the

engine. This

is

depressed and held at the same

STOP

switch will

must

be depressed until the stop sequence

amp

slow bluw

fuse protects

optional

remote

START/STOP

s.witch

turn

off the engine/generator.

fuses

fu.se

protects

the

start/stop or instrument

PANEL

ON, START, and STOP functions

LED

is

running.

to protect the

engine

is

equipped

and

shutdown

10

psi.

will

not operate

time.

DC

the

start

operating

(OPTIONAL)

is

available

is

a green

has

is

to

alert the operator

is

also

an

indication that the

with

a STOP

unless

is

circuit:

circuit.

circuit panel.

8AMP

for

LED

reached

an

switch

the on

This

complete.

and

FUSE

light 600

to

REMOTE

An

includes a DC switches.

REMOTE

The remote instrument panel

installed an

located

installed in the thermostat is

adjacent

on

each wiring

The blue wire is

for between removed.

DIAGRAM

NOTE:

installers standards

INSTRUMENT

optional

charging

remote

water

voltmeter,

temperature

INSTRUMENT

on

the engine block, a water

oil

pressure

the threads of both senders. Electrical connections

sender

harness).

the water temperature

When

gauge

on

the

engine.

to

the oil pressure switch.

are

tied

is

for

terminal board connections

Refer

to

the

in

this

manual.

installing

responsibility

33

CFR

part I

PANEL

instrument

operating

PANEL

sender.

The

water

housing

off next

the oil pressure sender and

REMOTE

the

optional

to

comply

83.

(OPTIONAL}

panel

is

available

gauge,

oil

pressure

hourmeter,

INSTALLATION

has

two

sending units

temperature

Plugged ports for

temperature sender

and the oil pressure sender

Use

sealing

to

the senders location (

sender.

If

there

T-1

and

INSTRUMENT

remote

panels,

with

the

U.S.

which

gauge,

and

each

the

is

a jumper

T-2,

Coast

start/stop

to

be

sender

are

is

compound

for

in

the

tan wire

it

should

WIRING

it

is

the

Guard

and

be

7

GENERATOR

SAFETY

The engine switches. Should a shutdown

SHUTDOWN·

is

prote~ted

SWITCHES

by

three

occur,

ALARMS

automatic shutdown

do

not attempt

without finding and correcting the cause. Refer

ing Engine

TROUBLESHOOTING

The following switches:

High

An exhaust temperature switch

elbow. the DC voltage sensor indicate quate supply This switch resets at approximately

HIGH

starts,

runs

an.d

then

section

is

a description

Exhaust

Temperature

Normally closed, this switch

(shutting

an

excessive exhaust temperature

of

raw

opens

at 260-270°F

SWitch

off the

water

causes high exhaust temperatures).

225°F

EXHAUST

shuts

down

of

this manual.

of

these automatic

is

located

engine)

(127-132°C).

(107°C).

on

will

open

should the switch's

in

the

the exhaust

and interrupt

This

TEMPERATURE SWITCH

MOUNTED EXHAUST

AT

THE

ELBOW

AND

to

restart

to

the

head-

ENGINE

shutdown

(an

inade-

switch

SHUTDOWN

Low

Oil

Pressure

A

low

oil

pressure

engine's oil

switch's sensor monitors engine's

interrupting the

MOUNTED NEXT

TO

oil

TO

THE

SWITCHES

Switch

shutdown

gallery. pressure

THE

Ofl

Normally

fall

DC

voltage

ENGfNE

FfLTER

LOW

Engine

Circuit

The

generator's engine manual draw

or electrical

wiring

or

event the generator

breaker interrupts the and

repair the source of

fault,

reset the breaker

Breaker

reset circuit breaker

overload

engine

wiring

will

DC

switch

is

located

open

in

a static

the

engine's

to

5-10

thereby

OIL

is

protected

(20

anywhere

will

cause

shut

down

circuit.

the

problem. After repairing

and

restart the

oil

pressure.

psi,

this

switch

shutting off

PRESSURE

by

an

amps

DC).

in

the instrument panel

the

breaker

because

If

this should

generator.

off

the

state,

this

Should the

will

open

the

engine.

$WITCH

engine

mounted

Excessive current

to

trip.

In this

the

opened occur,

check

the

High

Water

Temperature

A high water temperature switch

housing. Normally closed, this coolant's operating temperature reach approximately (99°C), shutting off the

will

open

engine.

LOCATED HOUSfNG GOVERNOR

and

interrupt

AT

UNDER

SWitch

is

located

switch,

the

DC

This switch

HIGH

resets

WATER

TEMPERATURE

THE

THERMOSTAT

THE

at

the thermostat

shouid the

voltage

at

thereby

195°F

·SWITCH

fresh

water

210°F

(107°C).

High

RPM

Shutdown

An overspeed switch

generators engine

~ngine's

correcting the tarily

speed reaches

depressing

DIAGRAMS

NOTE:

To

by-pass

shutdown, Do

not leave

protection will

problem,

in

lift

TS

the

by

the

this

the

and

switch

be

lost.

Switch

in

the

grounding

2175

this

stop

switch. Refer

manual.

~·

.

overspeed

connect

in

this

OVERSPEED BOARD

DC

circuit

shuts

off

out the ignition

rpm(approx.imately).

switch

can

be

reset by

to

the

WIRING

-·

when

troubleshooting

it onto and

configuration

with

as

TERMINAL

the system

After

momen-

T4.

overspeed

if

the

a

7a

GASOLINE

NOTE:

Be certain to install the instrument panel in a location

that

is

accessible and where the gauges can be continually

monitored by the helmsman.

ENGINE

DESCRIPTION

The marine gasoline engine is equipped with an [optional] key start instrument panel. This panel connects to the engine wiring harness thru a

Included separately is an alarm buzzer with a 4 pin plug-in harness. This alarm buzzer will sound when the ignition key is turned on and should silence when the engine has started and the oil pressure rises sible for installing this alarm buzzer in a will be audible to the operator with the engine running.

15

foot plug-in harness.

apove 5 psi. The installer is respon-

dry location where it

INSTRUMENT

The

following is a description of the panel components.

Tachometer

and measures the engines total elapsed time in hours and

1110

hours. Refer to TACHOMETER for calibration.

Key

switch

-Turned

switch energizes the panel. {Illuminates the gauges and

activates the start button.]

Prestart

that is energized by the key switch. Pressing this button activates the fuel lift pump.

Start

ton, when pressed, energizes the starter which cranks the engine.

Oil

pounds per square inch. The alarm buzzer will sound a

pulsating signal

alarm oil comes to pressure.

Voltage

amoup.t the battery is being charges 13V to 14V].

Water

engine coolant.

[99°C],

Button

Pressure

will

briefly sound when the engine is first started

Gauge,

Temperature

the alarm buzzer will sound a continuous signal.

PANEL

-Registers revolutions

to

the 2 o'clock position (on], the

-A "push-to-start" rubber booted pushbutton

-Identical to the prestart button, the start but-

Gauge

-Measures the engines oil pressure

if

the oil pressure falls below 10 psi. This

-Measures the voltage in the

Gauge

If

the coolant temperature reaches 210°F

per

minute

DC

-Indicates the temperature

of

the engine

circuit [the

key

in

as

of

the

-~

~~~~~~~~~~~~

~

·

ENGINE

The mounted manual reset circuit breaker (20 amps DC). Excessive current draw the instrument panel wiring or engine wiring will cause the breaker to trip. because the open breaker disconnects the fuel supply. this should occur, check and repair the source After repairing the fault, reset the breaker and restart the engine.

LOW

Allow oil pressure alam1 switch is located off the engine's oil gallery. This switch's sensor monitors the engine's oil pressure. (0.4 - 0.7

CIRCUIT

DC

harness on the engine is protected

OIL

PRESSURE

Should

kg/cn).2),

BREAKER

In this event most engines will

the

engine's oil pressure fall to 5 -10 psi

this switch will activate a pulsating alaim.

ENGINE

or

electrical overload anywhere in

ALARM

SWITCH

ALARMS

by,

an engine-

shut

of

the problem.

down

If

NOTE:

The water temperature gauge will register the last reading when the engine is shut down. The true temperature will register when the power

AND

CIRCUIT

BREAKER

is

turned back on.

~

COOLANT

A coolant temperature switch is located housing. This switch coolant's operating temperature reaches approximately \ 210°F (99°C). .

TEMPERATURE

will activate a continuous

SWITCH

on

the them1ostat

al

aim

if

the

Engines & Generators

. 8

\

-~

·

GENERATOR

DISASSEMBLY

.

LABEl.

THE

TERMfNAL

GENERATOR

Disconnect the

wiring harness at the generator

battery cable connections

Separate disconnect

NOTE:

Label

Drain the engine

Carefully support from

the engine. See

this

manual.

Additional generator infonnation will

GENERATOR

NOTE:

of

the

generator

Remove the

AC

wiring

and

unplug

and

the

exhaust hose at

the

~I

_supply

any

lines,

oil

and the

and

section of

MPU

to prevent damaging the MPU.

the

and

return

hoses

or

coolant

then

unbOlt

SPECIAL

this

manual.

before disassembly

control

engine

water

lines.

cables

from

the

TOOIS -

the

engine's

panel.

Disconnect

ground

injected

as

you

the

elbow

separate

engine.

·generator

GENERATOR

be

found

FOR SEE

DC

cables.

and

backend

in

the

MAIN

THE

FOLLOWING

the

them.

in

ENGINE

DISASSEMBLY

PAGE

MARINE

GENERATOR

[TYPICAL]

_Engines & Genera.tors

9

-

WHEN

REMOVING

THE

MOUNTING

LOCK

THE

WITH A RING

BREAK

TOOL

HBW HURTH

TRANSMISSION

BOLTS.--"""'-..!,!.;-"

FLYWHEEL

GEAR

ENGINE

DISASSEMBLY

\

INSPECT

THE

PLATE

FOii

BROKEN

SPRINGS

""-ftm

FLYWHEEL

DAMPER'

WEAR

ANO

..

DAMPER

;_BOLTS

Pl.ATE

PROPULSION

Switch

off

from the engine and

Drain

or pump out all

from

the

Unplug transmission Detach the

the instrumental

the

engine.

NOTE:

Label

• Clean

•

Do

not remove

disassembly.

•

When

•

Perform

Keep

necessary.

from intrusion of dust

•

Parts

which

parts must

its

component,

reproduced

•

Pay

parts

necessary. to

• Carefully check each faulty tell

accurately

ENGINE

the

batteries

engirie

and

fluid

and

oil cooler

any

lines,

or

wash the

disconnecting

disassembly in a

disassembled

Take

must

be

restored

they

were

be

set

so

at

assembly.

attention

for their

you

to

positions

aid

condition

how

it

during

tape

engine

or

special

removed aside

marks

acted

and

disconnect

over

the terminals.

the

engine

hoses.

panel

wiring

the

transmission

hoses

and

hoses

or

engine

exterior.

disassemble

sensor

proper

parts

in

care

and

dirt.

to

their

at

separately

that

the

same

on

assemblies,

or

assembly.

part

or

during

removal

or

what

removal

the battery

oil

and

drain

harness.

oil cooler

unbolt

the transmission

cables

as

you

MAIN

the

parts

wires,

label

order

order.

Apply

to

keep

the

l'eSpectiVe

disassembly.

in

groups,

combination

directions.

component

or

cleaning.

was

abnonnal

cleaning.

Put

cables

the coolant

Drain the

hoses.

separat~

them.

ENGINE

that require

and

tape

the

using

proper

oil

when

fuel

system

components

This

each

or

components

on

for

from

means

that

marlced

set

can

and

marks,

any

sign of

The part will

a~out

it

· · · ·

. .

-~

from

PART$

:ilo

ends.

tools.

·

parts

all

for

be

if

more

Transmission

If

the

transmission

inspected.

replace the linkage

the

..

Flush out

and

transmission

For transmisdon service transmis.9ion

WFSTERBEKE

your

transmission

- . .

is not

and

cQOlant

hoses.

the propeller

and

change

manual. service

--

being

rebuilt,

it should

pressure

shaft.

To.rebuild

dealer or an authorized ·

test

the·

Inspect'and

the

and

lubricate

coupling.

transmission

niaintenance; refer to your

a transmission, contact

centir.

-~

DISASSEMBLY

NOTE:

Mount the engine

1. Remove the engine

2.

Remove the engine heat exchanger. one

end of

each

removed.

3. Remove the engine back plate. . .

4.

Remove the Label

the

wires

5. Remove the engine mounted

adapter mounting cover.

Th.e

drive clockwise breakdown.

6.

Remove the coolant recirculating pump.

cool.ANT

breakdown.

7. Remove the manifold.

direction.

RECIRCULATING

on

a suitable stand or work

oil

hose

connections.

hose connected

start

motor, drive belt and the alternator.

and

cables.

to

raw

plate, and drive from the front

is

removed

air

intake silencer and the intake

See

by

RAW

turning

WATER

PUMP

be

oil cooler

the gear shift

Clt:mn

and

fluid.

-

If

possible,

the

part being

water puinp,

in a counter

PUMP

See

for

parts

visually

and repaint

bench.

leave

for

parts

Engines & Generators

'9a

ENGINE

DISASSEMBLY

8. Remove the thermostat assembly. Leave temperature sender in

9.

Remove the crankSbaft pulley. crankshaft pulley from rotating, insert two

the

gap

at the rear end of the crankshaft.

Remove loosen

Using a the crankshaft

Remove the

the six bolts that secure the drive

the

timing pulley lock

6rnm

deflector.

hex

wrench,

pulley.

place.

bolt.

remove the six

·

To

prevent

the

bolts

into

plate

and

bolts

holding

TIMING

BELT

COVER (UPPER)

NOTE:

All assembled parts should be carefully arranged

order

of

reassembly.

insure proper reassembly.

REMOVE

.

11. Remove the timing belt covers, upper and lower.

12. Loosen the timing belt tensioner lock belt and

13. Remove the bolts to remove the timing belt tensioner

THE

TIMING COVER (LOWER)

remove the spring.

and

remove the timing belt.

Mark

or

TIMING

BELT·

BELT

GASKET

label the parts as needed

ASSEMBLY

TIMING

BELT

'

~,l

..

)WI

'"

~

/

:;

~»

If

l

.,

~

in

to

~.·.·~~···~·

~

~~IDLER.

TENSIONER LOCKBOLT

.

10.

Remove the following

Fuel pump/gasket The carburetor and

and insulator Spark plugs Dipstick The

distributor assembly/High tension The exhaust manifold Oil filter

and

p~

and

governor

oil pressure switch

with the

assemblies.

gasket

leads

NOTE:

Mark the

viewed from the front - belt end

For

INSPECTION

in

this

manual.

1

TENSIONER'

le

LOCK

14.

Remove the camshaft pulley. Remove by inserting a T-wrench

. from turning.

·~

nonnal

BOLT

TIMING PULLEY

and

ASSEMBLY,

.

BELT

rotation

or

of

similar

the belt (clockwise as

the engine) on the belt.

refer

to

tool

TIMING

to

the

pulley

prevent it

BELT

Engines & Generators

10

FRONT

HOUSING

ASSY

ENGINE

DISASSEMBLY

/INSPECTION

4.

Screw

in

the

pulley

.puller,

taper

ring

together.

NOTE:

While

screwing

peripheral

5.

Remove

6.

Remove

7.

Disassemble

of

the the

the

spacer with the plastic

timing

belt pulley.

woodruf

the

spacer from the

and

remove

·

in the pulley,

key.

hit

pulley

the

spacer

the

whole

hammer.

puller.

and

1.

2.

·

3.

Remove and

nuts.

Remove

the

front

housing

the inlet manifold.

the cylinder head

assembly

cover.

by

removing

the

bOlis

REMOVE

1.

:

2.

THE

Loosen increments, in

Inspect

the

diagram.

the

backward

END

PLAY:

MAXIMUM:

MEASURING

END

ROCKER

rocker shaft assembly

not all at once. Use

SHAFT

ASSEMBLY

the

bolts

in

sequence

several

indicated

. 5

2

using a magnet

0.08 • 0.16mm

0.20mm

6 10

end play by movirig the camshaft forward

base

(0.003 • 0.0061n)

(0.008in)

and

1

dial

gauge.

PLAY.

and

REMOVE

1.

Remove

2. Using a plastic spacer on the

3.

Attach a pulley puller on the washer or pipe into contact of

DIMENSION DIAMETER: LENGTH:

THE

TIMING

the lock bolt and lock

hammer,

front

the

puller.

DF

WASHER

24mm

(0.945in)

!5mm

(0.5~in)

,r,·

f.._r.::.~~-

~·./

,--..,..,,..,_,._

(

side

;\

/

BELT

strike

of

OR

PIPE:

-

~

....

PULLEY·"'

washer.

the

whole

the

pulley.

spacer.

with

the

TIMING

BELT

·PULLEY

peripheral of

Bring a suitable end

of

the

center bolt

INLET MANIFOLD

the

NOTE:

camshaft

REMOVE

Engines & Generators

11

If

the

end

play

and/or cylinder

THE

CYLINDER

exceeds specifications,

head.

HEAD

ASSEMBLY

CYLINDER

AND

GASKET

replace

the

AS A UNIT

HEAD

;

ENGINE

DISASSEMBLY

/INSPECTION

6

1. Loosen the cylinder head bolts in several increments to

remove, following the numerical sequence indicated

above.

REMOVE

1. Remove the bolts and remove the oil strainer.

Oil

PAN

CLEAN

OUT

AND

OIL

INSPECTFOR

AND

TUBE

RUST.

THE

OIL

THE

OIL

PAN

WITH

KEROSENE.

DETERIORATION

REPAINT

IF

NECESSARY.

PAN,

10

GASKET

AND

BAFFLE

PLATE

INSPECT LARGE

1.

Use a magnet base and a dial indicator.

STANDARD: LIMIT:

NOTE:

2. Inspect the oil clearance rod large end.

a. Remove the connecting rod cap nuts and remove the

b. Clean any oil

c.

THE

END

PLAY

OF

THE

CONNECTING

END

0.110 -0.262mm

0.30mm

(0.012in)

Replace if

cap and bearing.

Using a piece

direction over the oil port.

d.

Install the cap and bearing and tighten the nuts to the

specified torque.

TORQUE:

. . I

REMOVING

the

off

of

the crank pin.

660 -700

/

THE

CONNECTING ROD

CAPS

(0.004 -0.010in)

measured value exceeds

on

the bearing

the crank pin and bearing surfaces.

plasti-gauge, set it

Do

not set the plasti-gauge

-

Kgcm

~

the

of

the connecting

in

the longitudinal

ROD

limit.

REMOVE

THE

OIL

)

OIL

PUMP

STRAINER

,OIL

PUMP

I

e. Remove the

Inspect the oil clearance value with the standard value.

STANDARD MAXIMUM

f.

Remove the plasti-gauge.

MEASURING

OIL

CLEARANCE

THE

LARGE

cap

and beilririg arid reacfthe

VALUE:

0.027mm

LIMIT:

0.1Dmm

-

THE

OF

END

BEARING

:

I

by

comparing he measured

(0.001in)

(0.004in)

A~

plasti-::-gau~

REFER

TO

THIS

PUMP

THE

SECTION

MANUAL

OF

THE

FOR

A

LUBRICATION OF BREAKDOWN OIL

Engines & Generators

12

ENGINE

g.

If

the oil clearance exceeds the limit, replace the

bearing set with a

If

the replaced bearing set exceeds

crank pin and use

oil clearance required.

CONNECTING AMOUNT D.25mm

0.5Dmm

0.75mm

OF (D.009in) {D.019in) (D.029in)

new

an

under-size bearing

ROD

BEARINGS-

UNDERSIZE

R

DIMENSION:

one and measure again.

the

UNDERSIZE

3mm

(U.S.):

R

DISASSEMBLY

limit, grind the

to

obtain the

nNSPECTION

UNDERSIZE D.25mm

0.5Dmm

0.75mm STANDARD

3. Inspect the bearing oil clearance

a.

b. Remove the cap and bearing to remove the crankshaft.

WIDTH

PARTS (0.009in) (0.019in) (0.029in)

Loosen the main bearing cap bolts, alternating between the two bolts

ata

time.

28.04 -28.09mm

28.12 • 28.17mm

28.20-28.25mm

27.94-

of

one cap, turning each bolt a

WIDTH

(1.106 (1.108·1.109in) {1.111·1.113in)

27.99mm

(1.1008·1.103in)

of

the crankshaft journal.

-1.107in)

few

turns

REMOVE

THE

PISTON

AND

CONNECTING

ROD

ASSEMBLIES

1. Remove the cap nut and remove the connecting rod cap bearing.

2.

Force the piston and connecting rod out (downward) by tapping gently with the handle

3. Force the remaining piston and connecting rod assemblies out in the same manner as mentioned

INSPECT

1. Check the end play by moving the crankshaft forward

2.

THE

CRANKSHAFT

backward as shown using a magnetic base and dial gauge to measure the amount.

STANDARD: LIMIT:

Adjust the end play at the center main bearing measured value exceeds the limit.

NOTE:

into

vary

0.08 • 0.282mm

0.30mm

(0.012in)

The undersize center main bearings

the

following three

in

width

as

shown in

of

a hammer.

END

PLAY.

(0.003 • 0.011in)

types.

The center

the

table.

above.

are

main

if

the

classified

bearings

and

LOOSENING THE

CAP

BOLTS

---'""I/~

c.

Remove any oil

surfaces.

d. Install the crankshaft and set the plasti-gauge in the

longitudinal direction

the plasti-gauge over the oil port. Install the cap and bearing and tighten the bolts.

from

the

of

Crank

journal and bearing

the crank journal. Do not set

Engines & Generators

13

ENGINE

DISASSEMBLY

/INSPECTION

e. Remove

comparing

STANDARD: LIMIT:

Replace allowable

If

exceeds undersize

CRANKSHAFT

CONNECTING AMOUNT

0.25mm

0.50mm

0.75mm

2.

Disassemble

a. Remove the piston rings

the

cap

and bearing. Check

the

measured value with

0.032 -0.049mm

O.OBmm

(0.003in)

the

bearing set if

limit,

and remeasure

the

oil clearance provided

the

limit,

grind the crank journal and

bearing

to obtain

JOURNAl.:S

R

DIMENSION:

ROD

BEARINGS -UNDER.SIZE

OF

UNDERSIZE: (0.009in) (0.019in)

(0.029in)

the

piston and connecting

(0.0012 -0.0019in)

the

by

the

from

ring installation tool (commercial product).

b. Remove the piston pin from

pin setting

If

the piston pin is tight in the piston, immerse the

piston in hot water

c. Disassemble

assembly in

tool.

or

use a hot plate.

the

remaining piston

the

manner mentioned above.

the

oil clearance

the

standard

oil

clearance exceeds

the

clearance.

the replaced bearing

oil clearance

3mm

R

(U.S.)

the

piston using a

the

piston using

and

required.

rod

assembly.

connecting

use

the

by

value.

the

set

the

piston

rod

3. Disassemble a. Compress the valve spring and remove

retainer using a valve spring lifter

b. Remove the valve spring and upper

the

cylinder head

assembly.

and

the

pivot.

and

lower valve

spring seats by loosening the valve spring compression.

c. Remove the

d. Remove the valve seal.

valve from the valve

guide.

e. Remove the remaining valve assemblies

the above procedure.

valve

by

repeating

,.,PRESS

PULL

OUT

PISTON

PIN.

Heat the piston to 122° -

CONNECTING

I

ROD

158° F (50c -70°

USING A HOT HEAT

C). ,

THE

PLATE

PISTON

TO

Engines & Generators

14

CYLINDER

HEAD I VALVES

INSPECTION I REPAIR

INSPECTION

Clean off

gasket Inspect

Measure

shown

the

fragments.

for

the

below

Distortion:

cylinder head and remove

damage,

cylinder head distortion in the

using a gauge

0.15mm

any

cracks, and leakage of

and

(0.0016

straight

in)

edge.

water

six

or

oil.

FEELER

directions

GAUGE

MANIFOLD

Use

the mounting straightedge in

DISTORTION

VALVE

1.

Inspect each valve for the

MOUNTING

same inspection procedure

surface, measuring

several

(GRINDING

AND

VALVE

resurface if necessary.

(1) Damage

(2)

Roughness or damage

(3)

Damage

2.

Check the valve head

if

necessary.

VALVE

HEAD

IN:

EX:

0.5

mm

1.0mm

or or

MARGIN

(0.020in)

(0.039in)

SURFACE

directions.

LIMIT):

GUIDE

bent stem

uneven

wear

margin

THICKNESS

MIN. MIN.

tf

for

distortion

0.20mm

following.

to

face

of

stem

thickness.

STEMTIP

the

manifold

with a

(0.008in)

Replace

tip

gauge

or

Replace

and

a

If

the cylinder head distortion exceeds specification,

cylinder head surface.

If

the cylinder head height is

replace

following. Replace

it.

HEIGHT:

91.95-92.05mm

GRINDING

NOTE:

• Sinking

• Damage

Camshaft

•

LIMIT:

0.20mm

Before grinding the cylinder head, first check the \

if

necessary.

of

valve seat

of

manifold contact suiface

oil

clearance and end play.

not

within

(3.62D-3.624in)

(0.008in

)

MAX

specification,

grind

the

MARGIN THICKNESST·t:::=.====.

J__

r=------">-...

3. Measure the valve stem

DIAMETER

LIMIT

MEASURING

STEM

VALVE

(STANDARD)

IN:

8.03D-8.045mm

EX:

8.025-8.040mm

IN:

7.98Dmm

EX:

7.975mm

VALVE

DIAMETER

GUIDE

l.D.

IN:

B.07-8.09mm

EX:

8.07-8.09mm

(0.3161-0.3167in)

(0.3159-0.3165in)

·

(0.3177-D.3185in)

(0.3177·D.3185in)

diameter.

Engines & Generators

15

VALVES

SEAT

INSPECTION I REPAIR

VALVE

l.Inspect the contact surface

SEAT

for the

following.

(1) Roughness

of

the

(2)Damage

2.

If

necessary, resurface the

valve

seat cutter and/or resurface

3.

Check the

CONTACT

VALVE

4.

Check that the

WIDTH:

IN & EX:

.seat

contact width.

1.4mm

(0.055in}!

SEAT

valve

,

seating

the valve fare.

'(1)

If

the seating position is

seat with a

(2)

If

the seating

60°

cutter

poSition

and a 30°

is

seat with a 25° (IN) cutter

5. Seat the valve to the valve seat

lapping:iiOmpound

VALVE

SEAT

valve

seat

the

valve

position

too

high,

cutter.

too

low,

and

a

with

ANGLES

seat

and

valve

face

with

an

80°

valve

face.

is at the center of

correct the

15°

(EX)

valve

cutter.

a

7.

Measure

· (1) Method No. 1

Subtract

the

. inner diameter of the

.

LIMIT

IN:

7.980mm

IN:

7.975mm

(2) Method

Measure

guide

·

CLEARANCE

IN:

'EX:

MAXIMUM:

(0.312in)

(D.314in)

.

VALVE

No.

:the

valve

with

the

0.025-0.0&0mm

0.0304J.O&Smm

MEASURING

valve stem to guide

outer diameter of

corresponding

.GUIDE.

2

stem

play at a point close to the valve

valve

lifted

slightly

(0.0010-0.0024in)

(D.0012'·

D.20mm

l

'

0.00261n)

(0.0079in)

clearance.

the

valve stem

valve

off

DIMENSION

from

guide .

·cLEARANCE

the

valve

seat.

L

the

6.

Check the sinking of the

Meas~re

protruding

length

valve

seat.

(dimension

valve stem.

Dimension

(1) can

(2) insert a spacer head

(3)

L:

46.5mm

(1.831in)

..

If

Lis

within 46.5-47.0mm (1.831-1.SSOin), it

be

used as

If

Lis

to

If

L is within 48.0mm (l.890in),

is.

·

within 47.0-48.0mm (l.850-l.890in),

between

the

spring

seat

adjust. ·

cylinder head. ·

L)

of

and

the

replace

each

cylinder

the

8.

If

the stem play exceeds specifications, replace the

valve guide and/or the valve.

16

~

VALVES I VALVE

GUIDE I VALVE

INSPECTION

I

REPAIR

SPRING

REPLACEMENT

1. Pull the valve seal off the valve guide using pliers.

2.

Remove the valve guide toward the side opposite the combustion chamber and

installer.

OF

THE

VALVE

by

GUIDE

using the valve guide remover

INSTAUING VALVE

GUIDES

3. Fit the clip onto the valve guide. Use the valve guide remover side opposite the combustion chamber until the clip just contacts the cylinder head. The height must valve spring seat

(dimension A).

NOTE:

valve on both sides as a replacement.

and

installer

be

19.1-19.6mm

Although the shapes

guides

are

to tap the valve guide in from the

to

the end

different,

of

the valve guide

(0.752--0.772in) from the

of

the valve guide

of

the

intakes

and exhaust

use

the

exhaust valve guide

ROCKER

1. Check for wear

2.

ARM

AND

ROCKER

or

damage to the contact surface

rocker

arm

shaft and the rocker

Check the oil clearance between the rocker arm and shaft.

replace

if

necessary.

.

OIL

CLEARANCE

STANDARD:

LIMIT:

ROCKER

l.D.:

O.D.:

0.016 -0.061mm

0.10mm

ARM

16.000

-16.027mm

15.966

-15.984mm

(0.004in)

(0.630 -0.631in)

ARM

arm.

{0.0006 -0.0024in)

(0.629 -0.6297in)

SHAFT

replace

ROCKER ASSEMBLY

if

ARM

of

the

necessary.

'

' .

' 1 •

I:

'CYLINDER

VALvE

SPRING

1. Inspect each valve spring for cracks or damage.

2. Check the free length and angle. Replace

FREE

LENGTH

OUTER:

INNER:

50.4mm

42.7mm

(1.9Bin)

(1.68in)

HEAD

EX

if

J

I

.,

_L

·----\

, I

IN

necessary .

.

VARIATION

·

PERPENDICULAR

~.MEASURE

t::(dtD.

FROM

ANGLE

OUTER: INNER:

1.Bmm

1.5mm

(0.07in)

(0.06in)

MAX MAX

17

CAMSHAFT

1.

Check

the

cam

for

wear

or

Replace

2.

Check

3.

Measure the

DIAMETER

CENTER FRONT

OUT-O~RDUND:

.ff

11~ces11ary.,

the

cam

lobe

wear of

two

points

as

FRONT

AND

REAR:

31.940-31.965mm THREE

31.91D-31.935mm

33.961--\M.OOOmm

8.115mm

INSPECTING

CAMSHAFT

JOURNALS:

OIL

SEAL

SLIDING

(D.002~)

THE

•

height at

the

journals in X

shown.

(1.2575-1.2585in) (1.2563-1.25731n)

SURFACE:

(1.338-1.339in)

~

MAX.

~y

damage.

the

two

points

u

t.

t

and Y directions

~

f(

1;-_·,

B r

CAMSHAFT

INSPECTION I REPAIR

as

shown.

6.

at

.

Measure

END

MAXIMUM:

7.

· (

18-26Nm (1.8-2.7

the

camshaft end exceeds the

Measure camshaft

(l)

(2) (3)

TIGHTENING

specification,

cylinder

PLAY:

Remove bearing

Set the camshaft onto Position plasti-gauge on

the axial direction.

4)

Place the camshaft caps position,

head.

0.118-G.16mm

0.20mm

(0.008in)

the

oil

clearance of the camshaft

caps.

any

oil, or dirt

surface.

and

tighten them

TORQUE:

M-KG,

play.

If

the

replace

the

camshaft

(0.003-0.00&in)

from

the journals

the

cylinder

top

of the journals in

and

rocker

.to

the

13-20

FT-LB)

end

play

and/or

and

head.

arm

shafts

specified

and

in

torque.

4.

~spect

the

fuel

cam

Replace

HEIGHT:

.

MINIMUM:

5. Check the camshaft front

camshaft one

RUNOUT:

if

necessary.

37.&mm

37.1

FRQNT

and

rear journals

0.03mm

(1.481in)

(1.452in)

JOURNAL

full

turn

(0.0012in)

CAMSHAFT

for

wear

..

CENTER

runout.

on

V-blocks

to

measure

or

damage.

JOURNAL

Replace

deflection

if

necessary.

and

rotate

(runout).

TESTING RUN·OUT

the

Set

the

(5)

Remove clearance at each

OIL

CLEARANCE

0.035-0.085mm

CENTER

THREE

0.0651-0.115mm

MAXIMUM:

(6)

If

the

cylinder

MEASURING

.

··WITH

PLASTIGAUGE

the

camshaft

FRONT

JOURNALS:

D.15mm

{0.0059in)

oil

clearance

head.

caps

and

ineasure

cap.

AND

REAR:

(0.0014-0.0033in) (0.002&-o.00451n)

exceeds

specification, replace

the

oil

the

Engines ~ Generators

18

DESCRIPTION

1.

Inspect repair or

2.

_block~

·

,____

the

entire cylinder block for

replace

(1)

Leakingdamage

(2) Cracks

(3) Scoring of wall

Measure

DISTORTION:

----

the

distortion

~e~ix

0.15mm

~

if

faulty.

of

the

~tions

as

(O.OO&in)

shown in

CYLINDER

INSPECTION I REPAIR

cracks

or

top

surface of

the

figure.

BLOCK I PISTON

damage,

cylinder

3.

If

the distortion

ex.ceed

or replacing the cylinder

GRINDING

4.

If

remove

5. Measure

the

LIMIT:

0.20

upper

part of the cylinder wall

the

ridge with a ridge reamer.

th~

cylinder

levels in each cylinder

specification, repair

block.

mm

(0.008in)

~

ho~

in directions X

as

shown.

shows

by

grinding,

uneven

and Y at

CYLINDER

CHECK ON

INSPECT OR OFF DEPOSITS

wear,

::-

BLOCK

FOR

TOP

FACE

FOR

COOLANT

SCALE

AND

.

STRAIGHT

three

WARPAGE

CRACKS,

LEAKS.

OIL

CLEAN

CARBON

EDGE

Cylinder

0.25

0.50

CYLINDERS

INSPECT

OR

·

RING

FOR

RIDGES

TRAVEL

Size

Standard

(0.01

O)

(0.020).

CRACKS,

AT

TOP

Bore

oversize oversize

SCORES,

OF

86.00Q-86.019

86.25Q-86.269

86.SOQ-86.519

mm

(in)

Bore

(3.3858-3.3866) (3.3957-3.3964) (3.4055-3.4063)

B

C-+-''--

CYLINDER

Engines &

q~neratw.s

19

PISTON-PISTON

RING

INSPECTION I REPAIR

PISTON

1. Inspect the outer circumferences of all pistons for seizure or scoring. Replace

2.

Measure the outer diameter of each piston at a right

angle

(90°)

to

the

piston

the oil ring land lower

STANDARD

0.25mm D.50mm

3. Check the piston

CLEARANCE:

MAXIMUM:

4.

If

piston or rebore the cylinders to

NOTE:

VALUE:

85.944 • 85.964mm

OVERSIZE: OVERSIZE:

18mm· (D.709in

the

clearance exceeds the maximum, replace the

If

the

86.194 -86.214mm

86.444 • 86.464mm

~~§§~~~'OF

to

0:036-0.075

0.15mm

(D.DD59in)

piston

also.

if

necessary.

pin, 18 mm (0.709

edge;

(3.3836 • 3.3844in)

(3.3935 -3.3942in) (3.4033 • 3.4041in)

cylinder clearance.

(D.D014-0.003Din)

fit

oversize pistons.

is

replaced,

replace

in)

PISTON

INSPECT SCORING, OVERHEATING EXCESSIVE

RING

the

piston

below

FOR

WEAR,

CRACKS,

AND

WIDENING

GROOVES

rings

5. inspect the piston rings for damage, abnormal breakage. Replace if necessary.

6.

Insert the piston ring into the cylinder by hand it

to

PISTON

the bottom

7.

Measure the ring end gap.

END

GAP SECOND: OIL

RING:

MAXIMUM:

I · 1

:

RING

·a

I I

I '

8.

Measure entire circumference using a

CLEARANCE

SECOND:

MAXIMUM:

NOTE:

Measure

circumference

of

the ring

TOP:

D.20-0.35mm

D.15·D.3Dmrri

D.20-0.7Dmm

1.Dmm

(0.039in)

~CYLINDER

the piston ring to ring

TOP:

D.03-D.07mm

D.15mm

(Q.DD6in)

the

ofthe

travel

(O.D08-0.014in)

(O.OD6-D.012in)

(D.008-0.028in)

.

(D.001-0.0031n)

clearance

ring,groove.

by using

cleai:ance

new

piston

(O.DD1-0.003in)

around

the

around

ring.

entire

wear,

or

and

push

piston.

INVERTED PISTON

the

PISTON;

CLEARANCE.

Engines & Generators

..

20

NOTE:

If

gaps.

New

that

often

replacing

rings

supersede

piston

are

packaged

the

rings

service

check

with

detailed

manual.

the

piston

ring

instructions

CON_NECTING

RODS

INSPECTION I REPAIR

CONNECTING

1. Check the side surfaces of of each connecting

Replace

2.

Check connecting specified limit, correct

CONNECTING

100mm

CONNECTING 1oomm

if

necessary.

the

connecting

rod

ROD

RODS

rod

aligner.

BENDING

TORSION

for

rod

If

with a press

LIMIT:

the

big

end

and the

cracking

for bending and torsion

bending or torsion exceeds

or

or replace.

0.04mm

(0.0016ln)

CHECKING ROD

TO_RSIO~

0.04mm

(0.0016in)

small

any

other

damage

using

for

every

CHECK

FOR

CHECK

BIG

CLEARANCE

CONNECTING

UMIT

for

every

end

a

the

BEND

END

..

OR

TWIST.

THRUST

3.

Check the clearance and

the

piston

a. Measure the inner diameter of

CLEARANCE

0.015mm -0.040mm

MEASURING PIN

OUTER

-between

pins.

BETWEEN

THE

SMALL

(0.0006 -0.0016in).

PISTON

DIAMETER

MEASURING BUSHING

the

END

CONNECTING

1Nt4ER

connecting

bearings.

AND

THE

PISTON

ROD

DIAMETER

rod bearings

PIN:

·

.L_

Check mel!ing:

the

connecting rod bearings for peeling,

Replace

if

faulty.

burning,

·

EB

or

Engines & Generators

21

CRANKSHAFT

1.

Check

the

journals and

hole clogging.

2. Set the crankshaft

3.

Check

the

if

necessary

RUNOUT:

4.

two points.

0.03mm

Measure each journal diameter

MAIN

JOURNAL

DIAMETER:

59.937 • 59.955mm MINIMUM:

OUT

OF

ROUND:

CRANK

JOURNAL

DIAMETER:

50.940 • 50.955mm MINIMUM: OUT

OF

ROUND:

on

V-blocks.

crankshaft runout

(0.0012in)

(2.3597 • 2.3604in)

59.89mm

50.89mm

(2.358in)

0.05mm

(2.0055 -2.0061in)

(2.004in)

0.05mm

pins

for

at

MAX.

(0.0020in)

DISASSEMBLY

damage,

the

center journal.

TESTING RUN·OUT

in

X and Y

scoring, or

Replace

directions

oil

at

/INSPECTION

REAR

HOUSING ASSEMBLY SLIDING

OIL

SURFACE

S.

If

the

journals

UNDERSIZE

0.50

MM

MAIN

JOURNAL

0.25 Undersize

0.50 Undersize

0.75 Undersize

CRANK

0.25

Undersize

0.25

Undersize

0.25

Undersize

SEAL

~Ii

diameter is less than the

to

match undersize

BEARING:

(0.020

Bearing

No.1,2,4,5

JOURNAL

·

Bearing

IN),

0.75mm

DIAMETER

Size

No.3

Size

0.25mm

DIAMETER

CR~NKfl_INS

MAIN

JOURNALS

minimum,

bearings.

(0.010in)

(0.0301n)

UNDERSIZE

Jaumal

59.693 • 59.711

59.687.

59.705

59.443.

59.461

59.437 • 59.455

59.193.

59.211

59.187.

59.205

UNDERSIZE

Journal

50.690.

50.705

50.440-

40.455

50.190.

50.205(1.9760·1.9766)

OIL

PUMP

ASSEMBLY

SLIDING

. ;

grind the

MM(IN)

Diameter

(2.3501 • 2.3508) (2.3499.

(2.3404. (2.3400 • 2.3407)

(2.3304. (2.3302.

MM

(IN)

Diameter

(1.9957 • 1.9963) (1.9858 . 1.9864)

BODY

OIL

SURFACE

2.3506)

2.3410)

2.3311)

2.3309)

SEAL

@>Y

x

22

ALWAYS WH_EN

GRINDING

CHAMFER

THE

POINTS

JOUFJ!J(lLS

MARKED

AND

PINS

Take

•

Be bolts

•

During

are correct pistons,

•

Apply Insure rotate excessive

•

If

reference

•

Use

•

Tighten

specified

•

Use gaskets.

the

following precautions:

careful

not

to

mix

bolts and

are

used

on

various

assembly,

being

assembled in their proper

direction in relation to

piston

rings,

lubricating oil to moving parts that

moving

or

slide

and

tension.

there

are

mating

them correctly for

new

gaskets,

the bolts

torques using a reliable

liquid sealants when required on

Refrain

from

engine

recheck clearances

the

bearings

parts,

are

not subject

marks

lockwashers,

and

nuts

using tape

and

when

scribed

assembly.

on important

nuts.

Metric

assemblies.

and

order

engine

bearing

during

assembled

to

binding

during

o-rings,

etc.

torque

nuts,

sealants.

ENGINE

and

S.A.E.

insure

that

parts

and

facing

in

block,

such

caps.

assembly.

on

the

engine,

or

disassembly,

parts

of

engine

wrench.

bolts

and

ASSEMBLY

Be

aware

occur during

• Insufficient Lubrication. Heavily

reciprocating parts, lightly oil head ers,

the

as,

to

except These the

high-tack

•Reversed orientation.

washers,

•Mechanical damage.

torque

torque.

arm

shaft fasteners. The

The

latter-rocker shaft fasteners-should be

in

very

out.

Gaskets, damaged great

of

these common problems that

assembly.

those that penetrate into

fasteners should be sealed

equivalent.

Most

and

all thermostats are

Run

sequences

Exceptions

small increments, working

during

care.

and

in

are

especially

assembly,

three

torque-to-yield bolts

former

head

with

gaskets,

asymmetrical.

fasteners

steps-112,

are

gaskets,

they

should be positioned

oil

sliding

bolts

the

water

Pennatex

many

down

torqued

from

might

can

and

other jacket.

No.

bolt

in

approved

213,

and

rocker

as

indicated.

brought

the center

also

fasten-

2 or

1/1

down

bolts

be

with

INSTALL

1.

2.

3.

4.

THE

Align

the

oil hole in

opposite Apply

piston

Set Press

in

the F

a coat of engine oil

and

OIL

the

piston pin setting tool in

the

upper part of the installer

the

piston

PISTONS

mark

to

HOLE

pin.

AND

the

large end of

on the

to

the small end of each

CONNECTING

the

piston.

the circumference of

FMARK

position

with a press

RODS

connecting

as

shown.

to

rod

each

rod.

force

CAUTION:

• Insert the piston pin the

piston. -

•

The

piston pin should

guide

meets the bottom of the block.

•

The

pressing force is 5 -

3300

lb).

If

the piston pin cannot be pressed in

range,

replace the piston pin

•

After

pressing in the

torque

of the connecting

5.

After pressing the piston pin in, connecting must

rod upward

swing downward

from

the direction of

go

in until

15kN

or

piston

pin, inspect

rod.

and

release

freely.

the

lower

(500 -1500

!he

connecting

the

swing

the

it.

The

connecting rod

the F mark

end

of

the

kg,

1100

within

rod.

oscillation

large

end

on

this

of the

Engines & Generators

23

ENGINE

ASSEMBLY

Follow these steps to install the three-piece the piston.

1.

Apply

a liberal coat of engine oil

during installation.

to

the parts

2. Install the expander.

3.

Install the upper rail.

(a)

Insert one edge between the groove and the spacer, applying a

(b) Then press the rail with the other

firm

pressure with one

4. Install the lower rail in the same way

NOTE:

Be

careful about and after installation certain

they

turn smoothly

of

the

direction

the

in

upper

both

of

the

and

lower

directions.

oil

ring on

thumb.

as

the upper.

spacer opening,

rails,

make

TOP

2ND

4.

Apply a liberal coat piston circumference and rings.

5. Clean

NOTE:

the

bearing mating surfaces of the connecting and caps and install the upper and lower bearings certain to align he oil holes. Coat the surfaces engine oil and insert each piston the cylinder block by using a piston insertion

The

pistons must

front

of

the

cylinder

of

engine oil to the cylinder

and

connecting rod into

be

inserted

so

that

the F marks

block.

RINl,1

RING

SECTION

$ECTION

walls,

rods

being

with

tool.

face

SPACER

END

_G~PS

SPACEfl

Use this method to install the second and top rings.

1. install

2.

3. Position the opening

RINGS

MUST MOUNTED THE THEP(STONS

SO

R-MARKS

the

second ring to the piston

one,

using a piston ring insertion tool (commercially

available). Apply

a liberal coat

BE-------

THAT

FACE

CROWN

(UP)

of

engine oil during installation.

of

each ring

first,

as

shown.

ENDS

then the top

CRANKSHAFT

1.

Install the crankshaft checking the oil clearances bearings and check the end play.

NOTE:

The

block side

ASSEMBLY

shape

of

the

center main bearing

is

different from that

CENTER

MAIN

ON

THE

CYLINDER

SIDE

in

the cylinder block, after

of

the crankshaft

of

the

other

BEARING

BLOCK

.

on

main

and

the

bearings.

main

cylinder

Engines & Generators

24

ENGINE

2.

Remove and bearing.

3. Coat each bearing and bearing surface with clean engine

oil and

4.

Gently set

5.

Install

numbers

specified

TORQUE:

any

foreign

install

the

main

and

torque.

61-65ft·lb

material

the bearings.

crankshaft

bearing

arrows

caps

and

(8.4-9.0m-kg)

and

i!!

position.

iri

tighten

82-llBNm

oil from

accoidance

the

bolts

,

the

to

journal

With

the

ASSEMBLY

·

INSTALLING

1.

Coat oil

2.

Install the tubular body

mating sealant does not get

3. Coat

· installing the oil seal, be careful Tighten

M·10

M-B

MB

THE

the

0-ring

pump

body

and

apply

surface

the

lip of the oil

the

27-3811-lb

14-19ft·lb

bolts

(3.8-5.3111-kg)

(1.9-2.&m-kg)

OIL

PUMP

with

grease

and

then

install it

assembly.

dowel

pins ih place in the oil

a continuous bead of sealant

of

the

oil

pump.

Talre

care that

into

the oil

holes.

seal

with

fresh

engine oil.

not

to

damage

to

the

specified torque.

52Nm

25Nm

into

pump

around

the

·

PUMP

BODY

When

the

.

the

O·RING

lip.

6. Align

7~

Tighten specified

.

TORQUE

the

connecting rod

the

connecting rod

torque.

48.51ft·lb

(&.&-7

caps

.Om-kg)

with

cap

nuts

65-69Nm

the

to

match

the

mark.

INSTALLING

1.

Press

NOTE:

Coat

suifac~s

a

presSing

THE

REAR

the

oil seal into the rear

the

rear

with

fresh

engine

tooL

cover

C0\8

and

the

oii then

cover.

oil

seal,

press

contact

into

place

M10"

with

lw:llltEST'ERBEKE

~hies

& Generators

··25·

ENBlNE

2.

Insert

the

tubular dowel pin

install the

TORQUE:

3. Trim the rear cover gasket to the appropriate size

protrudes over the oil

rear

cover

61-87in-lb

(1.0-10.0m-kg)

,,

(\

::i\

. --

on

the

·cylinder

7-10Nm

pan contacting

~

;:-

'

I

/)

-

block,

sUrface.

ASSEMBLY

and

if

it

1.

Bolt the oil

TORQUE:

INSTALL

Installation

·Ii

Remove oil

pan and cylinder block with a cloth before coating

surfaces with sealant

• Apply sealant all

(2-4

• Overlap the entire surface.

• Coat the sealant the oil pan, but

INSTALL

6!1-100in-lb

Finish tightening after applying

TORQUE

&9-104in-lb

THE

Notes:

mm

bead).

THE

TO:

61-781n-lb

strainer

in

place.

(80-120cm-kg)

OIL

PAN

WITH

and

dust

from the

around

sealant

to ensure that

on

either the

not

all.

BAFFLE

PLATE

(80-11Dcm-kg)

the

oil

sealant.

(7.0-10.Dcm-kg)

8-12Nm

THE

BAFFLE

mating

surfaces

the inner

TORQUE TORQUE

8-10Nm

pan

edge

you

have

block,

the

TO:

bolts within

7-10Nm

:

OIL

STRAINER

PLATE

of the

of the.bolt

covered

baffle

plate

30

minutes

'oil

the

holes

the

or

INSTALL

1. Install the

2. Insert the valves into the

3. Install the lower

4.

NOTE:

that the valve

INSTALLING

THE

CJLINDER

valve

springs

Use

and

and upper

the valve spring lifter

install the

After

retainers.

installing

and

S[Jring

VALVE

HEAD

..

seals

by

using the

valve

guides.

valve

spring seats, inner and

valve

spring

seats.

and

pivot

the

valve

springs,

se~

!h:!!Jnselves.

SPRINGS

. v c

..

S.

Clean

any

oil and

cylinder block.

6. Position a nfil!! cylinder head gasket

crlin~

CYLINDER

59-64ft-lb

NOTE:

orde.r

·

treat~d

head on

HEAD

(8.2-8.Bkg-m)

Tighten

shown.

Remember

plain

washers.

BOLTS~

B2-88Nm

the

cylinder head bolts

. .

ei

I . .

from

block.

to

use

, r '

the

newly

dust

the.

COLDTORQUE:

top

valve

seat

the

valve

tap the

vtilve

c.

:i-i-.:::

surface of the

and

install

gradually

styled

pusher.

outer

springs

end

f

the

in

the

surface

valve

so

/'W'IWESTEllBEKE

) Engines & Generators

26

ENGINE

ASSEMBLY

INSTALL

1.

2.

3.

NOTE:

dowel

THE

After

cleaning

amount of engine oil. Coat

the

shaded

Bond

Seal

runs

out

of

After

cleaning the camshaft,

When

setting the

in

an

DOWEL

CAMSHAFT

the

camshaft,

areas

with a thin

No.

4 or

equivalent).

the

shaded

area.

camshcift

upward

position.

coat

with

layer of sealant

Make

gently

set it in place.

in

place,

a sufficient

sure

no

sealant

keep

the,

camshaft

(Three

Assembly

• When assembling, coat

• The rocker arms (intake

• Rocker

Notes:

not interchangeable.

arms

No. 1 and

and

No. 4 are

the same.

6

Apply

a liberal coat of engine

and

rotating parts.

the

rocker

arm

Install

BOLT

TORQUE:

A

CAUTION:

shaft

assembly

in

the

same

13-20ft-lb

order.

and rocker shaft

(1.8-2.7m-kg)

When

the

Is

tightened,

liberally

and

exhaust-front

No. 3 are

oil

to

18-26Nm

rocker

arm

it

must

with

engine

and

the

same

and

4 8

the

camshaft journals

assembly.

aad

rocker

be

done

evenly

oil.

rear)

No.

are

2

and

ASSEMBLE

Assemble as

shown.

NOTE:

center camshaft cap) face

NOTE:

THE

the

rocker arms and

Be

sure that

Use

the installation

ROCKER

the

rocker

SHAFT

camshaft

arm

each

other.

bolts

for

bearing caps

shcift

oil holes

alignment.

(in

the

INSTALL

1.

2.

3.

4.

5.

6.

THE

CRANKSHAFT

Turn

the

crankshaft

Prevent the crankshaft from bolts at

Place·a thin coat of engine the

the

rear of the

crankshaft. I

Install the

Align

the Install the tapered ring

LOCK

dowel

the notch of

mark on the

BOLT

TORQUE:

oil

so

the

dowel

crankshaft.

oil

pin on

the

crankshaft

pump

body.

and

116-12311-lb

TIMING

moving

crankshaft.

tighten

(16-17m-kg)

by inserting

on

the

timing belt

the

BELT

hole

front.end of

PULLEY

faces

upward.

~

p~y

lock bolt

157-167Nm

two

with

Engines & Generators

-27. .

ENGINE

ALIGN

MATCHING

THE

PULLEY

ON

THE

1.

Install the camshaft pulley washer and lock bolt. Prevent

the pulley from turning and tighten the lockbolt to the specified torque.

TORQUE:

35-48ft·lb

(4.8·6.6m-kg)

47-65Nm

//

WITH

FRONT

.

ASSEMBLY

MARK 1 ON

THE

NOTCH

HOUSING.

1.

Loosen the timing belt tensioner lock bolt spring

2.

Turn

revolutions clockwise and then align the pulley

''TOP"

TORQUE:

TENSIONER LOCK

BOLT

tension

to

the belt.

the crankshaft timing belt pulley

mark and tighten the tensioner lock bolt

specified torque. ·

27-38ft-lb

(3.8-5.3m~kg}

39·52Nm

two

and

apply

complete

at

the

) '

Z.

Install the timing belt tensioner and tensioner spring.

3. Install the timing belt.

TORQUE:

4. Position the tensioner all the

27·38ft·lb

(3.8·5.3m-kg)

37·52Nm

way

to

the intake side, and

temporarily secure it by tightening the lock bolt.

INSTALLING

B

THE

TIMING

Be

sure the timing belt is installed the correct

direction as indicated Be

sure no looseness is evident at the belt

tension side.

B

Be

sure no grease

belt swface.

BELT

on

the timing belt.

or

dirt is on the timing

TIGHTENING TENSIONER

.

If

re-using

the

INSTALL

1.

the same crankshaft pulley and the camshaft belt tension

THE

Set the gasket in place and assemble the lower belt

cover.

TORQUE:

~.

'~j}~

belt,

measure the belt tension

pulley.

is

.not

within specified range.

MATCHING

DEFLECTION 9 •

TIMING

BELT

COVERS

Tighten the bolts to the specified torque.

61-87in·lb

(70-10Dcm-k)

7-10Nm

THE

LOCK

BOLT

between

repeat

steps

if

MARK

10MM

(10Kg)

BELTITENSION

timing

Engines

28

& Generators

ENGINE

ASSEMBLY

2.

Install

the

lower

and

covers.

TORQUE:

Install indicator plate crankshaft pulley

NOTE:

61·87in·lb

the

crankshaft pulley

with

and

Make

certain

(70-100cm-kg)

the top

tighten

t?

crankshaft from rotating.

BOLT

TORQUE:

104·148in·lb

upper

timing

--1\l.l!--7

by

aligning

mark,

the

use

the

plain washers

(1.2·1.7m-kg)

EACH

belt gaskets

7-10Nm

TIMING COVERS

the top of the

left one or

six

bolts.

12·17Nm

TIMING

MARK

BELT

two

to

prevent

IS

on

2"

timing

the

.

"FROM

the

TO

ROCKER

COVER

FUEL

FILTER

SEE

ELECTRIC

IN

THIS

MANUAL

ENGINE

ADJUSTMENTS

5. Install

6.

7. Install

.

the

oil cooler

Install

the

exhaust

and

tighten

the exhaust manifold

TORQUE:

16-2111-lb

the

intake

TORQUE:

14·1911-lb

ARM'-....-""~.i§l'Vf

.

CHOKE..:r

""'Ill\

UNDER

and

manifold,

(2.2·2.9m·kg)

manifold

(1.9·2.&m·kg)

oil

filter.

set

22·28Nm

and

19·25Nm

the

new

to

the

proper

carburetor .

gasket in place

torque.

,CARBURETOR

FILTER

SCREEN

.-

4.

Install the oil pressure the

threads.

TORQUE:

104·156in·lb

TIGHTEN

..

BY

HANO

CRANKSHAFT'.

PULL~

switch

using sealing

(1.2·1.Bm·kg)

"-.......

SEALING

APPLY

12·18Nm

GASKET

CLEAN

INTAKE

MAN~f

CARBURETOR REFER

SECTION

'

8. Adjust the valve cleaiance

(See ENGINE ADJUSTMENTS)

9. Install seal

cap

tape

on

OIL

#39454

TO

THE

CARBURETOR

IN

THiS

the

sealing

and install

.

MANUAL

cap.

the

·.

Applying a coat

seal

cap

into

the

of sealant to

cylinder

head.

~

APPLY

SEALANT

the

Engines_ & Generators

29

ENGINE

ASSEMBLY

INSTALL

1. Set the gasket

2. Install the inlet manifold.

THE

WATER

in

place and install the water pump

assembly. Tighten the water

TORQUE:

14-19fl-lb

(1.9-2.6m-kg)

3.

WATER

PUMP-

INSTALL

1. Apply a thin coat

THE

FRONT

seal front housing front housing.

PUMP

pump

19-25Nm

HOUSING

of

engine oil

and

press the

bolts.

ASSEMBLY

to

the

camshaft oil

oil

seal into the

INSTALL

1. Install the thermostat housing and·thermostat.

2. Install the fuel lift pump.

5. Install the distributor. Lubricate the

THE

REMAINING

drive gear with engine oil and install Match the distributor housing and drive gear mating marks. Install the distributor in the front housing with the marks facing straight up. Loosely tighten the distributor installing bolt.

ENGINE

COMPONENTS

0-ring and the

it

on

the distributor.

2. Set the front housing gasket the oil seal with fresh engine oil

FRONT

housing using a

TORQUE:

HOUSING

14-19fl-lb

new

gasket.

(1.9-2.6kg-cm)

FRONT

HOUSING

in

place on the engine. Coat

and

install the front

19-25Nm

6. Install the spark plugs high-tension leads.

SPARK

PLUG

TORQUE:

SPARK

PLUG

GAP:

NOTE:

Loctite Anti-Seize applied

the

spark plugs will

of

the

spark plugs

7. Install the alternator bracket.

TORQUE:

8. Install the alternator.

FLANGE

9. Mount the heat exchanger and install the coolant hoses.

NOTE:

Refer

this

manual.

10. Install the starter motor.

11. Install the remaining hoses and carefully attach the wiring harness to the pre-marked terminals.

easier.

25-3fl-in

BOLTTORQUE:

to

HEAT EXCHANGER

and

11-17fl-lb

:t0.0002in

retard

(3.8-5.3m-Kg)

(0.8-0.05mm)

corrosion,

13-2Dfl-lb

connect the

(1.5-2.3m-kg)

to

the

threaded

making

38-53Nm

(1.9-3.1

m-kg)

SERVICE

15-23Nm

portion

future

19-31

Nm

in

removal

of

Engines & Generators

30

DESCRIPTION

The lubricating oil

pump.

oil

pump, oil filter then returns

When the oil pressure exceeds

pushes

open

the oil

sump,

range.

The which

and

OIL

system

engine

drives

various

to

the

relief

keeping

FLOW

is

a pressure feeding system

oil

is

drawn

the

oil, under pressure, through

lubricating

oil

sump

to

valve

in

the

oil pressure within its specified

DIAGRAM

LUBRICATING

from

the

oil

sump

points

in

the

engine. The

repeat the continuous

the

specified pressure,

the

oil

pump

and

returns

using

by

the

cycle.

the

oil

to

an

SYSTEM

LOW

OIL

PRESSURE

The

specified

+

0.1

kg/cm

worn

bearings. For additional information

readings,

OIL

PRESSURE

The

generator

Should

minimum, damage

A

CAUTION:

pliers,

switch. Snap-On, switch

safe

see

2

).

the

minimum

A

gradual

ENGINE

oil

loss of oil

TROUBLESHOOTING

SWITCH/SENDER

is

fitted with

the engine's oil pressure

the

switch will shut

by

interrupting the

Oil

Pressure

11ise

grips

or

Use

the

correct

Proto,

New

will

cause

pipe

oil

an

DC

wrenches

socket Britain leaks

pressure

oil pressure shutdown

drop

the

voltage

Switch • Oo

and

and/or

pressure

below

engine

to

on

which

others.

5P1itch

is

4.3 + 1.4 usually

on

low

the safe

down

to

the ignition

not

use

the

oil

pressure

is

available

Damage

failure.

psi

(0.3

indicates

oil pressure

chart.

switch.

prevent

coil.

lock

from

to

the

LUBRICATION

OIL

LEAKAGE:

OIL

PRESSURE

DROP:

TROUBLESHOOTING

Loose Faulty

Damaged Loose cover Damaged head Faulty Loose Loose

Oil

Insufficient Worn Worn weak Clogged Excessive be.tween.main

drain

seat

oil

bolt,

gasket.

oil

oil or

leak

and/or Plunger

spring

plug.

at

oil

pan

cylinder

pump

body

or

oil

pan

front

housing

filter.

damaged

oil

damaged.oil

(inside

oil

strainer

lubrication

pearing

and

head

cover.

bolt,

bolt.

gasket

oil

pressure

oil

clearance

and

cylinder

or

switch.

pump

gear

pump)

or

connecting

block.

head

cylinder

rod.

NORMALLY

+

EARLY

MODEL

ENGINES

TESTING

To install warming and

OIL

Note:

pressure up

an oil pressure as low as depending on the load placed on the generator.

OIL

PRESSURE

test

the

oil pressure,

a mechanical oil pressure

up

the engine, set

read the oil pressure

PRESSURE

A newly started (cold) engine may have an oil

BE1WEEN

to

70

or

remove

43

80

the

oil pressure sender, then

gauge

in

it's

the

engine speed at

gauge.

AND

59

PSI

1294 -392

psi. A warmed engine can have

40 psi. Oil pressure will vary

KPAJ

place.

CLOSED

After

1800

rpm

Engines & Generators

31

LUBRICATING

SYSTEM

ENGINE

Use a heavy duty engine oil with an API classification SL, or SM. Change the engine oil and filter after an initial 50 interval as specified in the section are used. An engine Westerbeke Corporation does not approve

use must be performed using conventional oil. intervals must SCHEDULE synthetic oils are used.

NOTE:

statements regarding

CHANGING

The engine oil should be warm. Remove the oil drain hose from its attachment bracket and lower it into a container and allow the oil hose and is properly secured in its holder after all been drained.

OIL

hours

of

break-in operation. Then follow the oil change

of

this manual and not

oil viscosity

in

all conditions

of

synthetic oils.

The

information

THE

to

pump

of

MAINTENANCE

be

extended

of

SAE

lSW-40 is

and

If

synthetic oils are use, engine break-in

be

as listed in the

section

of

this manual and not

above

synthetic

ENGINE

drain, or attach a pump to the end

the old oil out. Make sure the oil drain hose

OIL

recommended

all seasons.

MAINTENANCE

supersedes all previous

oil.

SCHEDULE

if

synthetic oils

or

disapprove the

Oil change

be

extended

of

the old oil has

for

the drain

SJ,

this

if

A

WARNING:

contaminants. and

nails

thoroughly discard used

clothing

oil

properly.

REPLACING

When removing the punch a hole in the upper and lower portion to drain the oil into a container before removing it. This helps to

lessen spillage.

helpful in removing the old oil

and a plastic bag around the filter when unscrewing any oil

aiat's

removed to.make sure that the rubber sealing gasket comes off with the sealed against the oil filter adapter, gently remove it. When installing the new oil filter element, wipe the filter gasket's

sealing

,,c;urfacie

cojlt'

thin

the oil filter; Screw the filter onto the threaded oil filter stub, and tighten the filter firmly by hand.

NOTE:

are

of

Use

genuine

not

recommended.

Used

engine

oil

Avoid

or

rags

prolonged using

soap

containing

contains

skin

and

contact.

water.

used

oil.

harmful

Clean

Launder

Discard

skin

or

·

THE

OIL

FILTER

used

oil filter, you may find it helpful

of

the old filter

An

automotive filter wrench should be

filter.

Place some paper towels

it

to catch

in the filter. Inspect the old oil filter as

old

oil filter.

on

plean engine oil to the rubber sealing gasket on

If

this rubber sealing gasket remains

the oil filter adapter free

WESTERBEKE

oil

filters.

of

it

is

oil and apply a

Generic filters

to

Always observe the old oil as it is removed. A yellow/gray emulsion indicates the presence this condition is rare, it does require prompt attention to prevent serious damage. Call a competent mechanic is present in be the result

engine and/or a siphoning through the raw water cooling circuit into

the

oil. Raw water present in the oil can

of

a fault in the exhaust system attached to the

the

exhaust, filling into the engine.

OIL

of

water in the oil. Although

SUMP

DRAIN

HOSE'/

.

if

water

:+-Smm

REFILLING

Add fresh oil through the valve cover. After refilling the oil, run the engine for a few.moments while checking the engine's oil pressure. oil filter or from the oil drain system, and then stop the engine. Then check the quantity stick. Fill to, but not over, the FULL mark on the dipstick

(11116)

SOCKET

FILTER

THE

Make

TIGHTEN

OIL

SUMP

sure there is no leakage around the new

of

oil with the lube oil dip-

OIL

PRESSURE

BY

SEALING

APPLY

HAND

GASKET

CLEAN

OIL

SWITCH

Engines & Generators

32

LUBRICATION

SYSTEM

REMOVAL OF

OIL

1.

2.

3.

4.

Removing

Insert a baffle

INSPECTION

PAN/OIL

Disconnect the Drain

the Remove Install

the

in

the reverse order of removal.

Oil

flat-tipped

plate

to

AND

PUMPS

negative

engine oil

parts

battery cable.

into

a suitable

in

the

numbered sequence

Pan

screwdriver between the

separate.

INSTALLATION

container.

shown.

oil

pan

and

__

@@

the

OIL

DRAIN

A

CAUTION:

the

stiffener

Oil

Strainer

Insert the oil strainer with a

TIGHTENING 8-12Nm (80-120

After

must

be

TORQUE:

CM-KG,

the

secured

sealant

within

new

69-104

has

gasket.

IN-LB)

been

30

minutes.

applied,

r-..

FASTENING

BOLT

1

',

Stiffener

After

removal

the

bolts.

Insert a flat-tipped screwdriver between the and

cylinder

of

the oil

pan,

block

to

separate.

I

l

GASKET~

I

~

remove the

'

I

·~

INSPECTION

Check

for

the

following problems. Repair or replace

if

necessary.

1.

Cracks,

2.

Damaged

·

INSTALLING

1.

2.

3.

deformation, damage (at bolt locations).

drain plug threads.

THE

BAFFLE

Use a rag contact

Apply

(thickness

face Install

to remove

surface.

sealant continuously only to

2-4

mm

inside the bolt holes with the

the

stiffener.

PLATE

any

dirt or grease

(0.08-0.16

oil

strainer and

baffle·

from

the

stiffener

in),

rimming

ends

over

&tiffener

the

face the

lapped.

sur-

1.

Remove

2.

Apply (thickness surface inside the bolt holes

3. Install the oil

·

TIGHTENING 7-12Nm (70-120

A

the

any

dirt or grease

sealant continuously

2-4

mm

pan.

TORQUE:

CM-KG,

CAUTION:

pan

must

After

be

secured

from

the

only

to

the

(0.08-0.16 in),

with

the

61-104

IN-LB)

the

sealant

within

has

30

minutes.

contact

oil pan

rimming

ends

been

surface.

the

over-lapped.

applied,

33

MAKE

CERTAIN

PAN

MOUNTING

HAVE

BEEN

THE

OIL

BOLTS

BRUSHED

CLEAN

OIL

PUMP

NUMBERS OF

DISASSEMBLY

7.

OIL

SEAL

5.

SNAP

OIL

PUMP

1.

Check or

2.

Inspect for wear or damage to

INSPECTION

for

distortion or

cover.

3. Inspect for weak or broken

PLUNGER

4.

Measure the

INNER MAXIMUM:

FREE

~OTOR

0.18mm

MEASURING CLEARANCE

5.

Measure the side clearance.

SIDE

CLEARANCE

INDICATED

RING

LENGTH:

tip

clearance.

TOOTH

TIP

(0.007in)

TIP

MAXIMUM:

ORDER

damage

the

plunger

STANDARD

ANO

VALUE

OUTER

0.1Dmm

LUBRICATION

~/~

2.COVER

3.

OUTER

ROTOR

4.

INNER

ROTOR

to

the

pump

body

plunger.

spring.

46.4mm

ROTOR

CLEARANCE

(0.004in)

SYSTEM

MEASURING CLEARANCE

6.

Measure

OUTER

MAXIMUM:

7.

Repair

8.

Inspect replace

a. b.

NOTE:.

end

INSTALLING

1.

Apply

the

2.

Apply a coat surface,

3.

Coat careful

4.

Install

USE

PERMATEX SEALANT SHADOW

the

ROTOR

TO

0.20mm

or replace if

for

damage

it

Remove

tool Press with

the

to

pry

in

the

an

outer diameter of

Press

of

the

pump

INSTALLING

OIL

a thin coat of

position shown

indicated

NOTE:

Be

careful not

the

oil

seal

not

to

the

oil

ON

AREAS

BODY

body

clearance.

PUMP

BODY

(0.008in)

necessary.

or

oil

seal

it

out.

new

oil

the oil seal

body.

SEAL

PUMP

grease

below.

of sealant

by

shading.

lip

with

damage

pump.

CLEARANCE

wear

to

the

oil

seal.

If

necessary,

by

using

a screwdriver or similar

seal

by

using

a pipe

or

round

rod

45mm

(l.77in).

in

until

it

is

flush

with

the front

rtf=-=~===='!'.:===i~

THE

to

the

0-ring

and

install it at

to

the

oil

pump

installation

to

let

sealaniget into

engine

the

lip.

oil

and install the

the

,_,,,_.,.,,.......,/

COAT GREASE

oil

hole.

seal.

0-RING

Be

WITH

.MEASURING

SIDE

CLEARANCE

34

COOLING

SYSTEM

COOLING

COOLANT

WATER

PUMP

TROUBLESHOOTING

LEAKAGE:

CORROSION

OVERHEATING

Failed

Heat Leakage heater Leakage switch Malfunction pump)

Damaged cover

Loose Damaged Cracked

Impurities

Water Thermostat Blockage Water

ln$uffici~rit

Radiator

Exchanger

from

hoses

from

of

or

loose

or

gasket

cylinder

in

coolant

passage

malfunction

in

heat

pump

malfunction

coolant

cap

malfunction

coolant water

temperature

water

thermostat

head

block

clogged

exchanger

hoses

seal

bolt

gasket

or

(water

~

_.--PIPE

SEAL

5. Use a pipe to remove the water seal.

INSPECTION

• Inspect the there 'is any damage to the timing belt grooves.

•

Check

• Check the shaft/bearing it should rotate easily without

any abnormal noise.

• Inspect for wear in areas where the impeller contacts the

seal. Replace the seal

pump

pulley and replace it with a new

the water pump body for cranking.

if

needed.

one

if

ASSEMBLY

REPLACE

NEWO-RING

WITH

A

DISASSEMBLY

1. Remove the water

removing

2. With the

shown

the

pump

'to

remove the pulley.

3. Set the pulley on a support block and press the impeller

off using a press and the shaft.

4. Press the

press with the iron the press.

shaft

pump

from the engine as a unit

belts.

on a bench, use a bearing puller

an

iron rod between the press and

and bearing assembly off using the

rod

set

between the assembly and

by

as

1. Install the water seal by tappmg as shown above.

NOTE:

Make

certain

the

seal

is

not

to

damage

the

cracked.

seal.

Take

2. Coat the seal with coolant.

NOTE:

Replace

3. Use a press Press with the pipe on the outer race

place.

the

shaft

and

bearing as

~o

push the shaft and bearing assembly into

as

assembly.

of

the bearing. After assembly, make certain the bearing turns smoothly.

PRESS

_

__,,_i

4.

Push the pump

5.

Press the impeller in

pull~y

into place using a press.

so

that

it

is flush with the end

the shaft.

care

iwt

of

Engines & Seneratars

g,5

If•

'

RAW

WATER

NOTE:

Since

from individually purchased parts would

price

of a new

pump be

Before disassembling the by rotating the drive have excessive

PUMP

completely rebuilding a damaged or worn pump

pump,

Westerbeke

purchased.

shaft.

play, a major

recommends that a new

raw

water

pump,

If

it

is

rough,

overhaul

may

Disassembly

The

pump,

as

removed attachment nipples threaded into its inlet The nipples with the tioning

1.

Loosen the set screw the lose

2.

Remove the four impeller cover cover

NOTE:

recommended,

the gasket well lubricated until

If

reusable.

3. Pull out the impeller screwdrivers.

4. Remove the cam

5. Remove the bearing and assembly

may

pump

if

removed.

water

the

key.

and

Replacement

it:S

allowed

seal

disassembly.

pump

its

assembly.

to

from

be left

in

place or

with

pulley

from

gasket.

of

the impeller cover gasket is

however,

to

dry,

the

with

screw

housing,

This

be inspected.

the

engine,

removed

Note

the

port location

an

allen

the

shaft,

screws,

if you

are

going

the pump

gasket will shrink and not be

long-nose

and

cam.

releasing

will

allow

COOLING

almost match the

inspect the

frozen,

be

needed.

will

have

and

outlet ports.

if

wrench

and

taking

the

to

is

pliers

or a pair of

the

the bearing and seal

pump

or seems

hose

they

interfere

and

posi-

remove

care not to

impeller

reuse

it,

keep

reassembled.

shaft, bearing

SYSTEM

6. Inspect

to

7.

8.

NOTE:

It

to

press

the

all

erosion.

A

CAUTION:

ken

off

blockage

found

Use

the illustration

pump.

a.

Apply a small

surface

b.

When

amount cam housing.

c.

Apply inner

d.

Apply a thin

gasket.

When

the

nipples

hose the

nipple

the

attach

may

be

necessary

bearing and seal assembly from the

parts

and

H

the

impeller,

in

the

cooling

in

the

heat

to

amount of petroleum jelly

and

to

the

positioning the

of Permatex

screw

head;

a light

film

surface

of the housing

coating of

pump

is

assembled,

into

the

thread.

hoses

Assemble

and

to

use

replace

any

they

of

those

the

must

circuit.

exchanger.

assist

in

reassembling

impeller

remove

of

pump

the belt

cam

#1

on

silicon

lubricant

housing;

shaft

in

the

any

reposition

the

a drift and arbor press

showing

vanes

have

be

foand

They

at

reassembly.

the

housing,

inner

excess

or

petroleum

for

the

impeller.

to

the

use

pump

to

IMPELLER

COVER

wear

been

to

often

the

to

cam

surface

from

impeller

and

Teflon

the

shaft.

or

bro-

prevent

can

be

raw

water

the

seat's

use a small

and

the

impeller

jelly

to

the

cover

tighten

the

sealant

engine

and

on

Engines & Generators

·'

36

RAW

WATER

PUMP

FUEL

GASOLINE

A

CAUTION:

rating

at

89

ta

your

engine

warranty.

The

use

of adversely and

AC/Amperage

A

CAUTION:

considered

levels

of

fuels

containing

warranty.

GASOLINE/WATER

A primary fuel filter of the water separating type must installed between the

and

water be carried to the

Most installers include a the generator installation package the problems that contaminants in the

These gasoline filters must through") bowls have drain impurities.

other contaminants from the

to

Only

at

higher.

and

fuels

with

affect

ther

Fuels

acceptable

Ethanol

meet

are

fuel

U.S.

valves

use

unleaded

Leaded

must

not

an

Octane

performance

output

of

the

containing

for

use.

not

acceptable

Ethanol

higher

SEPARATOR

fuel

tank

system

on

type of filter/water separator with

have

Coast Guard requirements. The

to

use

fuel

fuels

will

be

used

and

rating

lower

of

the

AC

generator.

up

to

Fuels

containing

for

than

AND

and

the engine

fuel

the engine.

as

they

fuel

metal

bowls

when·

checking for water

with

an

cause

can

than

drive

10"/o

Ethanol

use,

and

10"/o

can

FILTER

to

before

are

well

can cause. ·

(not "see-

Octane

harm

void

89

engine

higher

the

void

remove

they

aware

the

SYSTEM

can

.

are use

the

be

can

of

metal

and

GASDENSER

The

gasdenser around between

denser

ENGINE

Periodically leakage.

MA/Nl'ENACE

Changing

1.

Shut off

2.

Unscrew housing

3.

Remove

4.

Replace the

to tighten run

consists

the

raw

the

raw

cools

the

FUEL

check

Change

the

fuel

the retainer

and

the sealing "O"

housing.

cross

thread.

1/4 -112

the

engine

water

fuel

FILTER

the

SCHEDULE.

Filter

supply.

allow

replace

Thread

of a

portion

intake

line

and

intake

and

the

to

the

prevent

fuel

filter

vapor

connections

element

after

Element

ring

that holds

bowl

to

come

the

filter element and clean ring

and reassemble

the

retainer ring

When

retainer contacts the "O"

turnes

by

hand.

to

inspect

for

leaks.

of

the

fuel

insulated.

raw

water

lock.

and

the

away

on

Open

line

It

is

pump.

the

filter

first

50

filter

from

the

carefully

the fuel

that

located

bowl

hours.

bowl

housing.

the

bowl

so

ring,

supply

is

coiled

The

to

bowl.

as

gas-

for

See

the

to

not

and

GASOLINE/WATER SEPERATOR

FUEL

Periodically check and

make

are tight and secure.

pump's mounting

the mounting bolt to ensure proper pump operation. The engine mounted

A

connections Make

fuel

&:

FILTER

LIFT

PUMP

the

sure that

WARNING:

no

The

bolts

fuel

Fuel

is a fire

sure

proper

ventilation

system

components.

fuel

connections

leakeage

DC

ground connection at one of

should be clean

lift

pump

leakage

hazard

and

is

present

is

at

should

exists

the

to

and out of the

and

maintenance

fuel

whenever

that the

well secured

pump

be

corrected.

servicing

pump

:fittings

the

by

free.

or

its

Engines & Gtmerators

A

WARNING:

Use

r;xtreme

care

Fuel

ta

prevent

is

present

in

the

spillage.

----.0-RING

housing

HOUSING

and

lines.

37

EXHAUST

MANIFOLD

I

HEAT

EXCHANGER

EXHAUST

The exhaust manifold,

cylinder head, should be inspected before reassembly.

1.

Remove the exhaust manifold. Clean Replace

2.

Remove the exhaust nipples, elbows manifold.

3. Remove water connectors from and the end plates. and arrangement of each for proper alignment.

4.

Examine all parts

replace

5.

Flush out the

rinse thoroughly

4. Use a pipe cleaner to clear the passage that connects

coolant recovery

5. Flush out

MANIFOLD

which

elbows

and

inspect for cracks and defects.

as

needed.

Be

sure to note the proper location

for

defects, corrosion and wear and

as

needed.

the

coolant

manifolds

interior with a liquid cleaner

with

fresh

tank

tubing.

recovery

was

disassembled from the

from the lower surface

and

plugs from

the ends of the manifold

water.

tank

and

its

connecting

ASSEMBLY

1.

If

the manifold

intact,

it can be

reverse order of

Do

not reuse the

If

the manifold

below:

a.

Loosely attach manifold using sealant on

b.

Gradually tighten each fitting

alignment of steps.

BOLT

TORQUE

Reinstall the exhaust connections manifold using

Check the manifold pressure cap. pulling

certain the upper

any doubt, replace

it

and

was

removed

replaced

removal.

has

these

all

12·17

Loctite

make

on the cylinder head in the

gaskets;

been disassembled,

the

elbows to the cylinder head and

new

gaskets.

the

parts. This should be done in

ft-lb

(1.6 • 2.4m-kg)16 • 24

Anti-Seize on the threads.

sure

it closes

and

lower seals are in good condition.

the

cap.

as

install

an

assembly and left

new

ones.

follow

Do

not use

to

make

and

Open

when

any

sure of proper

plugs into the

the valve by

released. Make

the

gasket

Nm

of

the

and

the

tube.

steps

three

the

HEAT

EXCHANGER

The heat exchanger should be inspected and serviced an engine overhaul.

1.

Disconnect the hoses and remove the hose fittings, petcock, drain plugs and end fittings and gaskets.

2.

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

3. Clean out any zinc debris and raw water passages.

4. When reassembling, install

Apply some lubricant to petcocks and fittings

Install a new zinc anode.

5.

NOTE:

The threads

and

do not

require

it

may

insulate the zinc exchanger. zinc.

6.

Repaint the assembled heat exchanger with Westerbeke heat resistant spray enamel.

housing

zinc

exchanger.

and

new

the

as

you

install them.

of

the

zinc

sealant.

preventing

Sealant

from

anode. Also, remove the

pressure test the coolant

gaskets and 0-rings.

new

gaskets and to the

anodes

the

metal

electrolysis action

-~J,

~~~

GASKET

~i)-oiE--cooLANT

7.

Reconnect all hoses, replacing them

8.

If

Refill the system with coolant

9.

Pressure test system and check for leaks.

as

detailed above.

if

are

pipe

should not

of

the

DRAIN

as

needed.

during

at all

threads

be

heat

on

used

the

as

E_ngines

38

& Generators

CARBURETOR

BEG

#039454

INCOMING

.

FROM

PUMP

FUEL

SEE

ELECTRIC

IN

mis

MANUAL

ENGINE

ADJUSTMENTS

FµEl

LIFT.

..

.

CHOKE,..;r

UNDER

IDLE

MIXTURE

CARBURETOR

The carburetor cleanable metal screen

The electric choke uses a opens

the remains generator los:d

on

Air

ScreenJFlame

The air screen/flame arrester

releasing the hold-down

operation,

of

in

screen

Carburetor

Clean

this

then

clean

the

screen

there

are

Idle

Mixture

Adjustment is performed

the

jet slowly

turns.

Note:

An

induce down.

is

choke automatically

running. Some

is

started,

the

generator.

every

a water soluble

Filter

filter element

and inspect

if

necessary.

no

leaks.

Jet

in

idle mixture jet

a sooty exhaust

'

a single

air

is

on

(The

Arrester

100

Screen

every

until

it

JET

barrel,

.intake

12-volt

hunting

choke,

choke

can

clamp.

hours

from

cleaner

after

the

250

Tighten

with

seats,

then

adjusted

discharge

down-draft

filter/spark

heating

once

the

will

and

is

factory

easily

Clean

then

such

first operating

the

plug

the

generator operating.

back

too

at

type arrester.

element which

engine starts

occur

when

is

running without a

set).

be removed

after

the

on.

Clean

as

GUNK.

50

hours

hours.

and

make

it

out

far off its seat

engine

start-up and

ROCKER . PVC ARM

· •

with a

and

the

by

first 50 hours

the

air

of operation,

Replace

certain

Screw

1-1/2

to

2

can

shut-

CARBURETOR

Two

(2)

copper

accelerator

One

(1)

throttle

shaft

One

(1)

idle

mixture

One

(1)

choke

lever

One

(1)

rotary

throttle

One

(1}

fuel

(1)

accelerator

(1}

main

(1)

manifold

(1)

needl~

(1)

aluminum

00

COPPER

ACCELERATOR

PUMP

GASKETS

.

ifflH

THROTTLE

VALVE

SPRING.

o-

0-RING

cawo

CHOKE

LEVER

filter

body

valve

SHAFT

SPRING

SCREEN

V~VE

;~:

11

··•

COVER

CARBURETOR ALTER

l~AKE

MAN~'(~::.

One One

One

One One

~·

ROTARY

THROTILE

SHAfTVALVE

II

--·---

FUa

Fl~lER

ELEMENT

·•·

• •

. •·

•

MAIN

BOOY

GASKET

REBUILDING

Use

the following step by instructions to clean and rebuild the

model

THE

03945

REBUILDING

pump

valve

spring.

screw

0-ring.

spring.

shaft

valve.

element.

pump

diaphramfgasket.

gasket.

and

seat

gasket.

gaskets.

(two

pieces

KIT

-

:.ALUMINUM

O

f--

MANIFOLD

ACCELERATOR DIAPllRAM/GASKET

CARBURETOR

step

carburetor.

SEAT

VALVE

GASKET

PUMP

to

the

set).

Engines & Generators

39

DISASSEMBLY

1.

Loosen arrester hose throttle

2.

Remove

3. Disconnect

4.

the

flame

arrester

..

Disconnect the electric

attached

to

the

control linkage.

the

two

nuts

manifold

cotter

and

the

from

lift

the

vacuum

the electric

disconnect the electric

~e

electric choke

Remove

their

from

the

washers.

the

carburetor.

SPRING---J>-~a..

assembly.

two

choke

Disc!)Jlilect

clamp

manifold,

holding carburetor

hose

choke

assembly

the

CARBURETOR

and

choke

the

fuel

the

carburetor

from

at

one

to

too

control

retaining

electric

L-cHOKE

@

remove

end.

control

wire,

supply

the

manifold.

Remove

lever

choke

the

flame

the

vacuum

line,

to

the

lever

rod

screws

assembly

SCREW

the

rod

BEG

and

the

and

from

and

RETAINING

#039454

COVER

6.

In the carburetor

retaining pin in the

pivot bracket

catch the needle valve

.retaining hook under the

·it

aside.

7.

Remove

8.

Shake the float moving

the

old cover

inside the

top

the

If

and

you

float,

cover,

opposite

remove

that

gasket. can hear

replace

DIAPHRAGM

'SPRING

gently

punch

out

the

direction

the

hangs from the float

float~s

of

float.

Make sure you

pivot

any

sand-like

the

ann

split

and

it.

float

side

place

particles

of

CHOKE

CONTROL

ASSEMBLY

THROffiE

CAM

5.

Remove

LEVER

SCREW·

the four carburetor's top cover straight carburetor's base.

accelerator housing body.

Remove the

Inspect

COVER ANO

the

SCREWS

.

WASHERS

"1

diaphram

cover

Take

cover

cover,

_and

·1

screws

up

off

the

four

to

the

accelerator

replace

and

their

washers.

and

away

screws

side

of the carburetor's

diaphram

it

if

cracked or

CARBURETOR

ELECTRIC ASSEMBLY

I

Lift

from

the

holding the

and

spring.

porous.

TOP

CHOKE

the

COVER

FLOAT PIN

FLOAT HOOK

RETAINING

9.

Remove wrench. removed. new

10.

Plaee a

cqver.,

NEEDLE

SEAT

RETAINING

.

the needle valve's seat

Make

..

sure

that

at.

this

time.

Screw

gasket..

new

carburetor cover

Do

not

use.

any

VALVE~

~ff/

the

gasket

seats

in

the

gas}(et sealer

CARBURETOR

with a 10

aluminum

new

seat

on

this

COVER

millimeter

gasket

along

the

carburetor gasket.

GASKET

·•

TO~

COVER

is

with a

top

40

ALUMINUM~

GASKET

.

11.

Gently Replace

valve's retaining the

vertically.

DISTANCE

FLOAT

place

the

wire

hook.

housing

--FROM

RETAINING

the

needle

float

and

retaining

Now

mating

MATING

CARBURETOR

valve

in

the

float

retaining

loop

hooks

onto

check

the

float

surface

with

the

SURFACE~

4.76mm

needle

valve

so

that

the

float's

level

distance

housing held

(3/16i.n)

seat.

needle

from

BEG

#039454

15.

Reconnect and

replace

and

their

control

lever

insert

the.cotter

the

electric

the

two

washers.

rod

pin.

choke

assembly

choke

assembly

~e-attach

to

the

Re-attach

electric

the

choke

the

electric

to

retaining

assembly

vacuum

the

carburetor

choke

hose.

screws

to

and

COPPER

14.

WASHER

Place

the carburetor

carburetor tighten

shown.

screws

base.

Replace

the

four

cover

Snug

down

each.

can

strip :r in

top

screws

cover

the

four

in

screw.

straight

down

washers

the

indicated

Over

tightening.'these

the--

and

on

the

hand

order

as

16.

CHOKE

RETAINING

SCREW

Replace

throttle

shaft

remove

filter

element.

\.

t)'

Eu.r:m1c

TO ROD

Now

the

carburetor

on

the

carburetor

gasket

along

and

tighten

Reconnect line,

the

vacuum

replace

the

flame

the idle

valve

the

fuel

. ·

VSPRING

.

ctioKE

CONTROL

on

the

with a gasket

the

carburetor

the

throttle

flame

arrester

mixture

and the

filter

element

CHOKE

LEVER

..

LEVER

is

rebuilt.

are

properly

intake

control

hose,

arrester

clamp.

screws

0-ring,

the

rqtary

rotary

shaft

valve

spring.

plug

and

replace

~CHOKE

f)

Make

tightened

manifold

and

on

sealant.

to

the

linkage,

the

electric

the

using a new

manifold.

carburetor

SCREW

sure

all

and

Replace

the

choke

RETAiNING

.

the replace

manifold

the

two

fuel

supply

wire.

and

the

fuel

VACUUM

HOSE

screws

the

nuts

tighten

41

CARBURETOR

The

c.arburetot cleanable choke is the

ON

Air

Screen/Flame

The air

.

rel~iti.g:·the

of operation, every screen

in

Fuel

Filter

To

ensure proper approved filter/water seperator between

qua:lity

good

is

a:

single

metal

screen

all:

operated.bf a

switch

is

12-volt

depressed.

Arrester

screen/flame

.a

water soluble cleaner

the

fuel

arrester

hold-down

100

operation;

supply

and

properly

barrel,

intake

clamp.

hours

and

down-draft

filter/spark

choke solenoid

can

easily

Clean

from

then

such

there

must

(10

microns or

the

engine.

maintained.

#052563/BEGA

type

with

a

arrester.

be

removed

after

the

on

Clean

as

GUNK.

be

a Coast Guam

This

activated

by

first

50

the

less)

installed

filter

must

The

air

when

hours

be

of

MODELS

20/25KW

~.

·

...

FUEL

SHuT·Off.

SOLENOID

1'.HROlllE

'U~KAGE

".KEEP

LINKAGE

LUBRICATED

·.\..

.

WELL

(GRAPHITE)

-;--

REBUILDING

Use

the instructions the

model

THE

following

to

clean

052563

step

carburetor.

CARBURETOR

by.step

and

rebuild

42

CARBURETOR

APPLY

LOCTITE

#052563/BEGA

TO

THE

SCREW

THREADS

MODELS

20/25KW

I

#052313

CAPSCREW

CARBURETOR

KIT

#052700

NEE.OLE/SEAT

FLOAT

AXLE

FLOAT

AXLE·

FLOAT

CHAMBER VENTURI THROTTLE

IDLE

NEEDLE

MOUNTING

REBUILDING

ASSEMBLY

RETAINER

GASKET

O·RING

SHAFT

SEAL

GASKET

VENTURI 0-RING

43

CARBURETOR

#052563/BEGA

MODELS

20/25KW

DISASSEMBLY

3.

Remove solenoid plunger screws carburetor at solenoids bracket.

4. Holding

attach the plate and

S. Examine

return spring condition.

6.

Remove from

7. Remove the

assembly consists of the Note the in

9. Remove the

housing to the lower floating chamber gasket off

9. Lift the

the

10.

Carefully

housing with

11.

Hold the throttle plate closed. correct installation. Remove remove the plate. lower replace

12.

Remove the

13. Remove the

lower housing.

Cleaning

Thoroughly clean

solvent. Blow and

parts for wear or

intale screen/flame arrester

the

circlip

to

that secure

and

lift

the

same disconnecting the

the

choke

plate to

withdraw

the

choke

the

fuel

shut-off

the lower

the

seat

float

body.

and

upper housing

housing.

needle

needle,

spring

housing.

four

floating

as

chamber

remove

its

Examine

needed.

throttle idle

axle

sealing 0-ring.

inspection

all

dry

metal

passages

damage.

screws

and

Withdraw

mixture

and

the

closed,

the shaft for

and

the

metal

choke choke assembly

remove

the

choke

Re-use

solenoid

seat

needle,

securing

and

seperate

retainer

axle

venturi

the

shaft

seal

the

parts

with

Replace

and

REBUILDING

that

secures

shaft.

solenoid

off

spring

choke

shaft

wear

or

assembly.

and

the

lower

from

out

Note

the

for

with

idle

in

and

blow

compressed

blow

the

Remove

assembly

the

carburetor

from

the

two

shaft.

Remove

from

the

wear

and

replace

and

the

Note this

spring,

assembly

the

upper carburetor

the

two.

housing.

the

lower

the

lower

of the lower

its

orientation for

plate's screws

throttle shaft

wear.

Re-use or

brass

mixture

a carburetor cleaning

out all internal

as

needed.

dry.

choke

the

two

to

the

and

the

choke

screws

that

the

~ousing.

the

choke

as

needed.

metering

and

Lift

housing.

retainer.

jet

air.

Clean

housing.

position

the

body

and

from

Inspect

the

jet

and

the

lower

lift

all

air

INSTRUCTIONS

RESASSEMBLY

1.

Assemble and

2.

Carefully slide flat

shaft,

of the

· lightky (plate screws.

3.

Apply threads Back out

4. Install the

5.

Install retainer.

6.

Holding needle and Tighten

7.

Holding the assembly

seat. this Adjust on

8. Carefully install

the the the not extend

casting.

9. Correctly position

lower housing onto screws.

10.

Instalk Place spring facing

applying

11.

Attach Engage solenoids and choke shaft/plate

12.

Install fittting

13. Apply a small amount of Loctite

the lower

Re-install

Connect harness Check that there and

that

the throttle shaft

press

into

the

lower

the

throttle

surface

facing

out.

Apply a small

the

securing

plate are

Loctite

and

thread

one

metering

the

float

the

and

seat

assembly

securely.

the

The

float

lower housing bracket to

the

float

the

float

bracket.

venturi

into

half

moon

venturi

into

more

the

lower.

the

choke

the

choke

Loctite

the

choke

the

mounting

the

fuel

and

fuel

shut-off solenoid

housing

on

the

electric

and

reconnect

the

choke

amount of

screws.

the throttle

closed)

to

one

it

into

tum,

jet

assembly

lower throttle

boss

with a sealing

axle

in

place

so

the

float

should be

as

needed

the

0-ring

the

lower

opening

the

lower

than

the

and

carefully lower

Install

shaft

plate

out,

Secure

to

the

solenoid

choke

return spring

supply

tighten

and

tighten

intake

choke

the

are

no

soleboid

seal

body.

shaft

Install

Make

to

center it

side

of

the

and

righten

with

housing

facing

down,

using closes flush

by

body

in

the body.

3/16

inch

float and

tighten

with

onto

the

in

thread

and

bracket.

moves

elbow

position

and

securely.

manifold

solenoid

fuel

leaks

functions

into

the

throttle

Loctite

sure

the

body

and

the

idle

lower

securely.

the

axle

and

Thread

washer

the the

with within bending

to

the

venturi

lining

lower

The above

chamber

the

fiat

shaft

place

with

ends.

linkage

into

Ensure

freely.

to

the

correctly.

to

thread

usingnew

to

supply

when

the

brass

housing

the

lower

housing,

plate

to

the

thread

beveled sides of

bore.

Tap

the

tighten

the

mixture

body

axle

needle the

+ or -

body

venturi

the

surface

with Tighten

the

needle

the

its

to

properly.

screws

until it

and

the

axle

the

needle

into

the

retainer,

against

mating

surface

1/32

the

adjustment

and

insert

up

the

knob

and

fully

should

the

lower

gasket

onto

upper housing

four securing

facing

poppet

the

two

securely.

to

the choke

hole

in

the

chojke

and

inner

threads

it into its boss

mounting

conmnection

the

carburetor.

the

engine

the

end

plate

two

seats.

with

body.

invert

the

inch.

with

seat

body

the

out.,

and

screws

shaft.

the

plunger

seat

on

gasket.

in

is

test

of

tab

of

the

run

Engines & Generators

43a

CARBURETOR

TROUBLESHOOTING

THIS MODEL

.

Pn:llJ~

Hard

Flooded

Poor at

Generator

..

Starting

Performance

Speed.

TROUBLESHOOTING

WESTERBEKE

-~!>!Jable_Ca~~-

1.

Faulty

2.

Fuel.

3.

Fuel

4.

Faulty

1.

Carburetor open

2.

Float

3.

Roat or

securing

4.

Choke

at

1.

Main

2.

Carburetor

3.

Fuel

4.

Air

choke.

lift

idle

or

in chamber

stuck.

jet

filter

intake

BEG

pump.

jet

adjustment.

float

needle

damaged.

carburetor

gasket

screws

clogged.

inlet

filter clogged. filter

screen

..

leaking.

damaged

are

clogged.

CHART

AND

BEGA

valve

loose.

dirty.

APPLIES

TO

BOTH

CARBURETORS

VerlficationJRe•dy

1.

Check

choke

adjustment

Check

choke

cam

for

2.

Check

fuel

supply

and

3.

Replace

fuel

lift

pump.

4.

Adjust

idle

jet.

1.

Clean

or

replace

the

2.

Repair

or

replace

float.

3.

Replace

gasket

and/or

4.

Repair.

1.

Remove

and

clean.

2.

Remove

and

clean.

3.

Remove

and

clean.·

4.

Remove

and

clean.

and

smooth

correct

needle

tighten

operation.

radius.

type.

valve.

screws.

Engines & Generators

43b

ENGINE

ADJUSTMENTS

SPARK

The spark plugs should be cleaned and regapped after the first thereafter and replaced as needed.

SPARK

NOTE:

the of

PLUGS

50 hour break-in period, then inspected every 250 hours

A

WARNING:

the

engine

removing

PLUG

GAP:

PLUG

TORQUE:

Loctite Anti-Seize applied

spark plugs will

the

spark plugs

Do

is

hot.

them.

0.028 • 0.033 10-15

retard

easier.

not

remove

Allow

IN.

LB·FT

corrosion,

the

engine

(0.

75 -0.85

(1.5-2.31

to

the

spark

plugs

to

cool

MM).

KG·M).

the

threaded portion

making future

while

before

removal

INSPECTING THE

SPARK

PLUGS

CHECK

FOR

~BUILD

~

t

GAP

UP

AND

CARBON

f

.

HIGH

TENSION

CORDS

(IGNITION

WIRES)

of

BURNING

DRIVE

The drive belt must belt tension can cause rapid wear

The 25 and

BELT

ADJUSTMENT

be

properly tensioned. Excessive drive

of

the belt and reduce the service life the presence ing in high operating temperatures.

drives the governor and alternator and the other drives the raw water pump. belts is as follows:

1.

Remove the belt guard. To

2.

mounting bolts. To

loosen the two raw water pump mounting bolts.

3. With the belt(s) loose, inspect for wear, cracks and frayed edges, and replace

4.

To governor bolts.

To

pump drive belt, slide the raw required, then retighten its mounting bolts.

5.

The drive belts are properly adjusted no less than 3/8 inch (12mm) as the belt is depressed with the thumb at the midpoint between the two pulleys the belt.

NOTE:

for proper belt operation.

of

the fresh water pump's bearing. A slack belt

of

oil

on

~e

belt can cause belt slipping, result-

20

BEG

generators have two drive belts, one

The

tension adjustment procedure for both

adjust the governor drive belt, loosen the two governor

adjust the raw water pump/fresh water pump drive belt,

if

necessary.

loosen

or

tighten the governor drive belt, slide the

in

or

out

as

required, then retighten its mounting

loosen

or

tighten the raw water pump/fresh water

Maintain a 22

carried

on

board .

water pump

(lOmm) and no more than 1/2 inch

on

lb

pressure

to

Spare

belts should always

in

or

out as

if

it

can be deflected

the longest span

the

belt's outer face

of

be

or

Check the ignition wires every 500 operating hours as engine compartment

Check the resistance

becau~.

seperated or the wires from the spark plugs, grasp and twist the moulded cap,

th~n

THE

RESISTANCE

heat

can deteriorate the wires.

of

each wire.

the

wire

connection inside the cap may become

the

insulator

pull the cap off the spark plug.

VALUE

IS

410

may

OHM

Do

be

damaged.

PER

INCH

not pull on the wire

OF

When

WIRE.

CHECKING

RESISTANCE

removing

Engines & Generators

44

A

WARNING:

drive

belt's

6.

Operate the generator for about 5 minutes, then shut down the generator and recheck the belt(s) tension.

7.

Replace the belt guard.

Never

tension

attempt

while

the

to

check

engine

or

is

in

operation.

adjust

a

ENGINE

ADJUSTMENTS

VALVE

NOTE:

engines valves (see TORQUING THE BOLTS),

1.

2.jPosition the No. 1 piston

CLEARANCE

Re-torque the cylinder head bolts before adjusting the

Remove

/compression stroke. Adjust

·

for exhaust valve for cylinder and adjust the remaining

the

cylinder

#3

EXHAUST

ADJUSTMENT

CYUNDER

rocker.

cover

and

gasket.

at

Top

Dead Center (TDC)

the

Intake and Exhaust valves

#1

and the Intake valve for cylinder

#3.

Rotate the crankshaft

valves.

#1

INTAKE

#2

#4

EXHAUST

INTAKE

HEAD

#2

and the

of

360

it's

#4

I

IGNITION

1. front

INTAKE

2.

3.

TIMING

Attach

a timing light to the # 1 spark plug

crankshaft timing groove

scale

embossed

Each

timing mark represents

Start

the

operating Using

the timing light, align the timing

on

CRANKSHAFT' PULLEY

engine and

temperature.

the engine's front

warm

crankshaft pulley with the proper timing ignition cover. distributor

TIMING

25KW 20KW

timing scale embossed

Do this by loosening and slowly rotating

body.

Refer

to

SPECIFICATIONS:

20°

BTDC

AT

1800

12°

BTDC

AT

1

BOO

RPM RPM

and

the

2°.

the engine to

on

the

the timing

±5°. ±

5°

and

mark

timing

mark

cover.

/

its

normal

groove

in

mark

on

engine's

front

the

specifications:

the

on

the

front

3. Replace the rocker cover

ROCKER

COVER

4.

Adjust

all

5.

Tighten the lock

TORQUE:

160 ·

TORQUE:

values

210

2.9-5.1

to

0.012

nut.

KG·CM.

and

the

rocker cover

LB·FT

(0.4-0.7

(0.30mm)

with

OCK

KG·M).

the

NUT

gasket.

engine

hot.

ELECTRIC

The opens running.

started, no-load

The

the

choke rotating counterclockwise set

at temperature.

CHOKE

electric choke

the

choke automatically when

Some hunting may occur

when

the choke.is

on

it.

choke

is

adjusted with

(CARBURTOR

uses a 12

volt heating element

when

on,

and when the generator

the

engine off

by loosening the three cover-securing

the cover clockwise

to

RICH the choke.

the

factory for

an

to

LEAN

average of70°F

the choke may need re-adjustment at engine

#039454)

the

engine

the generator

and

cooled.

the

choke

the

choke

(21°C)

which

starts

screws

and

is

initially

room

commissioning for the ambient temperature of the area engine

is

on

the

underside of

SEE

CARBURETOR

operating

in.

The choke reference

the

choke

co~~r.

mark

is

located

and

is

first

has

Adjust

and

the

Engines & Generators

45

ENGINE

ADJUSTMENT

ENGINE

SPEED

(HERTZ)

ADJUSTMENT

Governor

The belt-driven, mechanically operated governor

the

engine's rpm under

detennines the hertz and

'

Governor

Operate the generator temperature before adjusting

NOTE:

adjust before

There are three adjusting points

tion).

1.

2. Hunting/Regulation Adjustment.

3.

Adjustments

If

the governor

the

linkage at no-load

proceeding

Increase/Decrease

sets

the no-load speed of

the governor

hold the throttle just slightly ball joint

position (when the engine linkage moves properly lubricated. Use graphite lube Disconnect the ball joint inside

engine speed between no-load adjust this eye bolt to hub.

adjusted as

If

move adjustment).

Bumper

a no-load surge

into

at

the linkage anns

of

the joint.

The

increase/decrease speed bolt

well.

the governor

the

spring

Screw

the

governor so far that it increases

various

to

is

with

Speed

and

the throttle lever should be adjusted

freely

surges

away

Adjustment.

ONLY.

voltage

bring

the

severely

to

the

adjustment.

Adjustment.

the

and that

and

draw

under

from

NEVER

load

conditions.

output of

the

unit up

governor.

out

obtain a

on

engine.

closed;

and

is

not running).

the

apply

the

load,

the

This

to

of

adjustment,

safe

the

governor (see

This

The linkage

about the width of'the

towards

ball joint connectors

for

graphite lube

If

the

and

full-load is too

spring closer to the

may

adjust

lever

hub

screw

tum

the

generator.

operating

output

the

M~e

this

variation

this

(check

is

used to

bumper

the

maintains

Engine

manually

voltage

illustra-

adjusting

between

closed

sure

purpose.

to

in

need to

eye bolt

speed

screw

no-load

speed

J:>olt to

.

this

are

'

the

great,

lever

be

to

remove

speed.

Governor

1.

2.

3.

.

4. Periodically adjµst the

TORQUING

After the initial break-in cylinder head bolts should be

Tighten shown. loosen one head bolt one-half between next head bolt stud) securely.

Maintenance

Periodically lubricate the

the

governor

lubricant or equivalent.

NOTE:

proper governor/throttle

Governor

NOTE:

Change To

change the

the

governor. Then place a container under the governor

andremove the drain plug. Note the governor

illustration below. Allow alien head "Oil Fill Lever" plug

the

governor. Add oil slcwly into the governor till

starts

flowing.

plug.

BELTS ADJUSTMENT).

stretchirig action.

ann

and throttle

Free

movement

oil capacity - 3

Do

not ovelf'ill

the governor oil

oil~

to

flow from this opening. Allow

Replace the alien

will. to some

THE

CnlNDER

the cylinder head bolts

Make

sure

the engine

55 - 59 lb-ft (8.2 -

in

the sequence.

linkage

of

this

operation.

the

every

remove fill plug

governor

degree,

arm attaching points at

lever.

linkage

ounces

governor.

250

all

the

oil from

head

plug

belt

Since

belts

affect

HEAD

period

(approximately

re-torqued.

according

is

cold

tum

and

8.8

Kg-m).

Tighten

Use a graphite

ann

is

l

OW~30

hours

of

from

the top

to

drain.

the

rear

oil

and

the

tension stretch

the

govenor's

BOLTS

to

the

when

this

then

tighten

Then

the

RS

important/or

synthetic oil.

operation.

of

Remove

of

it

to

stop

fill

(see

DRIVE

slightly,

50

is

proceed

(rocker cover

this

hours),

· sequence

done,

it

to

and

the

-

the

4

LINKAGE

HUNTING REGULATION

.

ADJUSTMENT

INCREASE/DECREASE SPEED

ADJUSTMENT

ARM

fo

OIL

PRAIN

IS

UNDER

Engines & Generators

46

ENGINE

ADJUSTMENTS

TESTING

1.

2.

3.

4.

5.

ENGINE

Make sure

Warm

up

After

the

to

reduce the exhaust

Remove

COMPRESSION

the

battery

is

the

engine

to

operating temperature.

engine is

all

spark

warm,

pipe

plugs.

fully charged.

tum it off for about

temperature.

Disconnect the primary wire connector coil. ·

6.

Connect a compression gauge

to

the

hole.

7. With

8.

the

throttle set

at

400

rpm,

crank

Check whether the gauge reads within

COMPRESSION DIFFERENCE

PRESSURE:

BETWEEN

CYLINDERS:

198.1

PSI

(14Kg/cm')

29

PSI

(2.0Kg/cm').

9. Check each cylinder.

10.

Refit the primary

wire

connector securely

coil.

10

from

the

No. l spark

the

engine.

the

limits.

AT

400

to

the

minutes

ignition

plug

RPM.

ignition

DISTRIBUTOR

CAP

INSPECTION

Check the following points, Replace

1.

Carbon or carbon deposits.

2.

Burnt or corroded terminals.

3.

Worn

distributor center contact.

CENTER CONTACT

DISTRIBUTOR

if

necessary.

Reference the illustration place the tip

the

gap.

of

a metal

This will indicate a serviceable

below.

screw

Using AWG#l6

driver near

c

B

IGNITER.

Momentarily place a screwdriver.

near this

llATTERY

point~

;

TESTING

wire,

connect the igniter through a

the

middle

of

the

igniter.

Ground the metal

back

Gap: 10mrrl (0.40in)

Engines & Generators

THE

IGNITER

pick-up of

side

of

the igniter.

47

12

the

igniter. Each time this

IGNITER

Do

not

C

as

If

the

left

VDC battery

is

done,

~~~~·AIR

mix

up

the

that

would

damage

distributor

shorted,

the

as

shown.

Momentarily

a spark should jump

wire

connections

the

igniter.

is

operated

igniter

and

with

coil

GAP

· Gap: 0.8mm (0.0027in)

to

terminals B and

tire

will

external

overheat.

resister

TACHOMETER/HOUR

The

tachometer/hour mentpanels common ground. other

volts alternator on

the

The tachometer

from

tachometer input

the

alternator

volts The

a

fault

meter.

Hour

Check for tenninals.

1.

Voltage

2.

Voltage

nections

terminal

Tachometer

. Check for

tenninal

1.

Voltage

tion

2.

AC output

3. Check for gropnd.

4. Check electrical connections minal

Tachometer

1. Check fqr

2.

3. Check

contains

the

tachometer.

charging

back of the

circuit

one

of the

diodes

producing battery

DC.

following

in either of

meter

are

Inoperative

the

proper

present - meter

not

present -trace for to

verify

Inoperative

the

proper

and

(-)

present - attempt

access

hole.

voltage not present -

voltage.

AC

to

alternator connection.

Sticking

proper

terminal Check for

terminal

alternator

and

good

and

that

alternator is

pivot

Tachometer

a.

With a band-held pulley

retaining

.

front

crankshaft

METER

meter

used

two

separate electrical circuits

One

circuit

operates

The hour

voltage

instrument.

operates

in

the

alternator

terminal

fault.

terminal

{-)

alternator.

while

procedures the

two

circuits

DC

voltage

is

(Jump

the

operation.)

AC

voltage

with

No results,

voltage

at

AC

voltage

terminal. ground

bolt.

to

defective

( +)

12

adjusting

check

tach

connection

well

Inaccurate

tach

on

the

nut or

with

pulley

rpm

nieter

the

in

propulsion engine

the

hour meter

circuit

operates

supplied

on

the

charging

follow

between

volts

repair

f!:om

grounded

a strobe-type at

to

the.

AC

voltage

and

supplied

engine

is

voltage

when

in

a tachometer/hour

( +)

- repair

and

(-)

electrical

DC

to

meter ( +)

between

engine

terminal

between "tachs

front

tachometer input

running. .

meter through calibra-

or replace

for

proper alternator DC

on

tachometer input ter-

between

to

of the crankshaft

idle.

TACHOMETER

NOTE:

Current

dial

to

instru-

with

a

and

the

on

12

(

+)

terminal

6-8

volts,

fed

to

the

running,

troubleshooting

and

alternator to

engine

tach,

13.0-14.8

(-)

or

replace.

con-

..

meter.

inp"

meter

block at

read

and

.

(-)

the

set

calibrating

TACHOMETER

NOTE:

In

the

tachometer engine's installations.

1.

Warm

Remove

cloth and place a piece of

pulley

2.

Start and

3.

Aim confirm

tachometer using instrumentreading is

showing.

bring the instrumen(

4.

Set the tachometer to the has

speed

r

model

the

tachometer

screw

is

a

new

installation

may

rpm.

This

up

the

any

specks

to

facilitate

idle

the light of

the

engine

reading.

the

instrument

Then

been

factory

screws

!~

:ji

!

:i

l!i

=

0

;;

-

.L..

i

tachometers

to

then

used forfine

CHECK

engine to

the

have

(New

not

always

calibration

normal

on

use

of a

engine.

the

tachometet onto

speed.

Adjust

cciarse

to

the

use

the

to

adjusted

been

use a coarse

the

crankshqft

pulley

tuning.

CALillRATION

Installation)

having

new

instrument panels,

be

correctly

should

operating

the

crankshaft pulley with a

suitable

photoelectric

Check

the

tachometer in the

adjustment

closest

fine

calibration

the

exact

idle

speed (the,engine idle

and

the

locked

in

calibrated

be

checked

temperature. .

reflecting

type

the

reflecting

the

instrument panel

to

calibrate the

RP.M.

that the photo

adjustment

reading

idle

screws

place).

as

'

adjustment

rpms.

The

+)TERMINAL

to

in

all

new

clean

tape

on

the

tachometer.

tape

·panel

the

photo

speed

and

high

: . =

the

to

by

tach

to

tach.

b. Using

the tachometer then

bring it

tach,

Check

Adjust

the

CALlBRATION

using

to

the

rpm reading

tach

as

a 2mm

RPM

needed.

(5164).

indicated

opening,

at

idle

fine

Zero the

by

the

and at

adjust

the tachometer strobe

or

high

throttle.

and

hand

.Engines &

?enerators

48

TIMING

.

183e~~JlQMfl~TALLATIQN_

NOTE:

The

timing

"/jeit

generator

in

the

b@t • · · ·

BELT

can.be

inspected/replaced

RUBBER

EXPOSED

. , .

with

the

.·

.

UPPER

TIMING

BELT

COVER

.

MARK

THE

IS

BELT

TO

FORWARD

TO

PREVENT

INSTALLATION

BE

RE·USEll_.

OF INCORRECT f/JELT

DISASSEMBLY

1.

Remove tensioner

2.

Remove

ROTATION

IF

THE

·~

r_

the

tensioner

lock bolt.

the

timing

spring

belt.

after

loosening

CRANKSHAFT

,

PUU,~.

the

·

3.

Replace

TIMING

Check

the

rotation

NOTE:

Do necessary, scratching

TIMING

Inspect

damage.

NOTE:

sary,

the

Do

use a rag

the belt

BELT

TENSIONER

timing

belt

and

abnormal

not

clean

use

a soft

it.

I

BELT

PULLEY

pulley

Replace

not

if

clean

to

wipe

if

any

tensioner

noise.

the

tensioner

rag

to

teeth

for

necessary.

the

pulley

it

clean.

of the

above

AND

IDLER

and

idler pulley

Replat:e

with

wipe

it

clean,

AND

CAMSHAFT

wear,

deformation,

with

cleaning

conditions

PUu.EY

if

necessary.

cleaning

and

_,

TIMING

'.TENSIONER

fluids.

exist

for

smooth

fluids.

If

avoid

BELT

PULLEY

or

other

If

neces-

CAMSHAFT

PULLEY

NOTE:

Do

not

allow

oil

or

water

to

contaminate

belt.

Do

not

twist,

tum

inside

out,

or bend

TIMING

1.

2. Check

BELT

Replace

moisture

for

Replace

INSPECTION

the

timing belt

on

it.

damage,

if

necessary.

wear,

if

there

peeling,

is

any

oil,

cracks,

the

timing

the

belt.

grease,

and

·

or

hardening.

TIMING

Inspect the

if

/w/WESTERBEKE

l

Englf!_f!S

~

~rators

49

BELT

necessary.

COVER

timing

belt

covers

{LOWER

for

AND

damage

UPPER)

or

cracks.

Replace

INSPECTION/INSTALLATION

INSTALLATION

1.

Align the timing mark c;amshaft

2.

Remove compression

MATING

3. Install the timing belt tensioner

4. Position the timing belt tensioner all

intake side, and temporarily secure it by tightening the lock bolt.

pulley with

all the spark plugs.

when

MARK

-

on

the

marks.

rotating

the

timing belt pulley and

This

is

to

prevent

the

timing

belt.

and

spring.

the

way

to

TIMING

the

BELT

DIRECTIOir\.

ARROW

IF BELT, DIRECTION ARROW -FORWARD

5.

Install the timing belt on the crankshaft pulley and the camshaft pulley from viewed retained.

6. Loosen

applies

7.

Turn

will apply equal tension to each side of the

..

· . -

I i i

RE-USING

THE

INSTALL

the crankshaft twice

TIMING

IT

IN

THE

OF

THE

APPLIED

ROTATION.

the

from the front of the engine)

·

the

tensioner lock bolt so that

'tension.

tension side (the right

so

that tension is

the

tensioner spring

in

the

direction of rotation.

timing

side

as

This

belt.

TENSIONER'

LOCK

BOLT

Engines_&

50

Generators

-

BATIERY

STARTER

MOTOR

START

SWITCH

CONTROL

SWITCH

FIGURE

1.

STARTER

TROUBLESHOOTING

To independently test the starter it it

from

the

engine. However, before doing this, should be made and not with the engine, battery, the other possible problem sources have been eliminated, then remove and test the starter. Comparison

with the Troubleshooting chart lem within the starter determine the repair or repairs needed serviceability.

Battery

Realistic testing, fully charged battery capable of supplying the current needs

of

the

starting system. Step ing system turer's instructions.

Wiring

Visual Inspection

Visually cuit for damage includes all ground connections. nections nents.

and

to

ensure that the problem

to

specific components. This

Test

as

well

as

is

to

test the battery. Follow the battery manufac-

Switches

inspect all wiring and switches in the starting

and

loose or corroded connections.

as

required. Replace damaged wiring or compo-

is

necessary

wiring

will

aid

to

successful operation, requires a

one

in troubleshooting the start-

Clean

to

remove

checks

is

with the starter

or switches. When

of

test results

in isolating the prob-

will

restore

the

starter

cir-

This

and tighten the con-

WIRING

to

CIRCUIT

Continuity Check

Disconnect the field lead terminal and insulate it carefully Set

the

transmission in neutral. voltage at the solenoid S terminal held

in the

START terminal, the control circuit and locate the point of voltage

rect

Starter

If

tion remov.e

Starter

With can indicate the need for component testing after the starter

·assembled. described in the

also overhaul. Comparison of test results with the shooting chart will indicate what corrective action, required.

use the voltmeter and

it,

as

necessary.

Removal

the

battery, wiring

and

the engine

the starter

No-Load

the

starter removed

reveal damage that

Repair

UNIT

used

to

test units

on

the starter

to

prevent accidental contact.

Use

a voltmeter

while

position.

and

is

for

If

voltage the

switches

known to

further testing.

are

be

wiring diagram

functioning

Test

frQm

the

engine,

can

be corrected

and

component test procedures

REPAIR

for

section.

normal operation after repair

from

the solenoid M

to

check

the

start switch

is

not present at

to

loss

in

satisfactory condi-

properly,

the no-load test

by

repair or it

are

The

no-load test

Trouble-

if

is

the trace and

may

is

or

any,

for

S

cor-

dis-

is

Engines & Generators

51

STARTER

MOTOR

Test Hook-Up (Figure 2)

Connect the starter illustration using suitable instruments, battery cables and connecting wiring. Do the following:

1.

Secure the starter in a suitable test stand to check

operation.

2.

Use

a momentary contact, pushbutton switch in the test circuit for a quick release are

encountered.

3.

Make

all connections or disconnections with the switch

open

and the carbon pile load turned

4.

If

sparking or current

noted

when making the connections, the starter sole-

noid

switch contacts

for

the

no-load test

if

very high current surges

flow

in the battery circuit is

may

be frozen shut (refer to

as

shown in the

off.

its

TROUBLESHOOTING).

5.

As

the last step in making the test connection, ground the negative battery cable securely ground on the

6.

The

carbon pile load is used voltage for comparison with specifications. It may not be necessary in

nate the need

Test Procedure

A

CAUTION:

opening

The

strong

personal

Into

the

starter

for

Keep

in

the

D.E.

shifting

Injury

.or

cranking

frame.

all

cases but should

interpolation of test data.

flngers

(drive

end}

action

of

damage

position

as and

to a clean metal

to

adjust the operating

be

used

and

tools

away

housing

the

spins.

while

solenoid

drive

pinion

·

could

to

elimi-

from

testing.

moves

the

cause

NOTE:

During

the

starter for

cycles,

allow

erwise

overheating

1. Momentarily close the a.

b.

c.

2.

Close the switch and observe carbon pile load 24-volt starter). Observe and record the ammeter and rpm readings. Release the switch.

3. Compare the ammeter

under the readings are outside the

TROUBLESHOOTING

causes. is operating normally.

the

no-load

cycles

the

starter

If

there is a high current operate (zero rpm), release the switch immediately. Internal mechanical damage is indicated. Discontinue the test and refer to

If

there is ate (zero open circuit is indicated. Discontinue the test and refer

If

there is a current release the switch the no-load test.

no

rpm),

to

TROUBLESHOOTING.

SPECIFICATIONS

If

the readings are within the limits, the starter

test,

of

30

seconds

to

cool

and

damage

switch.

current

release

and

to obtain a

and

close

the

switch

and

maximum.

for

at

least two

to

the

starter

flow

and the starter fails to

Between

minutes,

may

result.

TROUBLESHOOTING.

flow

and

the starter fails

the

switch immediately. An

flow

and

the starter operates,

proceed with the next step of

·

the

voltmeter. Adjust the

10

volt reading

·

rpm readings to those listed

at the end

limits

shown, refer

to determine the most likely

(20

of

this section.

volts on a

to

operate

oth-

to

oper-

If

BATIERY

CARBON

PILE

:

FIGURE

2.

STARTER

CLAMP

AMMETER

NO·LDAD

TEST

ON

HOOK·UP

VOLTMETER

BAT

s

M

..

52

STARTER

MOTOR

Troubleshooting

If

the

results

of the

no-load

to

the

following

Normal

Current Failure

current.

Failure

Low

speed

Low

speed

High

*

Refer

current

flow

to

speed

to

TROUBLESHOOTING

PROBLEM

and

speed.

with

test

operate

with

operate

with

high

current.

with

normal

with

high

the

UNrr

REPAIR

circuit

switch

very

low

high

current.

(or

low)

current.

section

test

are

outside the limits, refer

chart for the

open.

or

no

current.

for required

Starter

a.

Solenoid

Open

a.

b.

Open

c.

Open between

d.

Broken

a.

Frozen

train.

b.

Direct

a.

Excessive reduction loose

b.

Shorted

c.

Grounded

a.

High by dirty

b.

Causes

with

a.

Shorted

disassembly,

proba-

PROBABLE

OK.

switcl'l

solenoid field armature

internal

poor

commutator.

very

inspection,

wiring.

circuit.

coil(s)

commutator

brush

spring_ts)

bearing

or

ground

in

friction

unit,

pole

shoe,

armature.

armature

electrical

connections,

listed

under

low

or

fields.

hie cause apply specifically apply

CAUSE

contacts

bent

test,

stuck

or

high

bars.

or

other

damage

terminals

in

bearing(s)

armature

bent

drive

or

fields. resistance

defective

Failure

no

current.

and

if

necessary,

worn

or

shaft.

and

its

remedy.

to

operation under

closed.

insulation

brushes. to

drive

fields.

or

gear

shaft

or

-

caused

leads

or

to

operate

'

repair

to

the

no-load

a.

Recheck including

starter sluggish.

Test

a.

assembly:. Inspect

a.

b.

Inspect

c.

Inspect

d.

Inspect

a.

ln~ect

an

b.

Inspect bly, brush

a.

lnsrct an

b.

Inspect Inspect

c.

assembly

Inspect

a.

tions

b.

Remedies

with

a.

Inspect

or

replacement

The

problems

test and

other

circumstances.

listed

in

the chart

do

not necessarily

VERIFICATION/REMEDY*

battery,

battery

operation

and,

if

necessary,

and

test

and

test

armature.

brushes bearings,

and

test

solenoid

assembly,

installations

bearing,

gear

reduction

and

test

and

test

and

internal

and

armature

listed

very

low

and

test

instructions.

switches

cable

on

solenoid frame

and

parts.

frame

armature,

armature. frame

armature.

wiring,

under

or

field

and

loss.

engine

is

replace

assembly.

and

field

brush

springs.

armature,

for

no

drive

and

field

armature

shorts.

drive

gears.

and

field

electrical

commutator.

Failure

current.

and

frame

wiring,

Check

slow

solenoid

assembly.

assem-

shaft,

coil

to

assembly.

if

or

shaft

and

connec-

operate

STARTER

NOTE:

If

it

part

available, a

torque specified. ers

Always

is

necessary

numbers

wrench

unless

REPAIR

insta/,l

or

use

only

Torques

otherwise

Introduction

(Figure

Figure

parts lowing

3)

3

shows

and

assemblies.

components

Solenoid

Clutch

Drive

Brush

Holder Annature Frame

and

assembly

fasteners at their original

to

replace

equivalent.

afastener

to

tighten

specified

fasteners,

lfthe

of

equal,

fasteners

are

for

specified.

the

starter broken

Do

not attempt

which are serviced

(1)

assembly

(2)

(3)

(13)

Field

assembly

(19)

use

only

correct

part number

size

and

when a torque

dry,

unlubricated

down

into

to

disassemble

as

assemblies:

locations.

the

correct

is

strength.

value

fasten-

its component

the

fol-

Engines & Generato'!.

not

Use

is

This section provides instructions for complete

of

the starter

is

not due

only

is extent from the starter

assembled

affected

to

ensure that all parts can

inspected.

In

this

These

assemblies. Illustrations

· operations. starter, refer back

To

begin,

starter assembly.

as

would

be

for

an

overhaul,

required, the starter

necessary

parts.

section

groups

to

for

such

are

To

make

ensure

Use

to

gain

as

subassemblies

limited repair unless

Total

disassembly

the starter

then disassembled into

see

the

parts

to

Figure

a mark

completely

proper

alignment

a colored

the

case

and

repair affecting specific

may

be

access

to

or

be

thoroughly cleaned

is

broken

accompany

relationship of the

3.

pencil

or marker that

all parts.

53

for overhaul.

disassembled

these

parts.

groups

need

they

is

recommended

down

by

main

individual

the

text

down

one

of

all

its

components

disassembly

If

the starter

only

Parts

removed

not

be

contain

the

however,

and

groups.

parts

to

show

specific

complete

side

of

the

will

show

parts

to

the

dis-

at

and

'on

STARTER

MOTOR

SOLENOID ASSEMBLY

1.

CLUTCH DRIVE

2.

ASSEMBLY BRUSH HOLDER 2

3.

ASSEMBLY

BRUSH (GROUNDED)

4.

BRUSH (INSULATED)

5.

6. D.E. HOUSING

BUSHING BRUSH SPRING

7.

8. D.E. ARMATURE

BEARING

9. C.E. ARMATURE

BEARING CENTER SUPPORT

10.

BEARING SHIFT LEVER

11.

12. PINION STOP

13. ARMATURE TWO

C.E. FRAME

14.

DRIVE SHAFT

15.

ARMATURE SUPPORT

16.

BRACKET DRIVE SHAFT 36. DRIVE HOUSING BOLT (LONG)

17.

SUPPORT DRIVE HOUSING (SHORTER

18.

FRAME & FIELD

19.

ASSEMBLY C.E. FRAME 0-RING

20.

21.

SHIFT LEVER SCREW SHIFT LEVER WASHER

22.

SHIFT LEVER NUT

23.

SOLENOID SCREW

25.

26.

PLATE (IF USED)

DRIVE HOUSING PLUG

27.

28. DOWEL PIN

INSULATED BRUSH SCREW

29.

30.

WASHER (FIBER)

WASHER (THIN;

31.

32.

33. FRAME

34.

35. STOP RING

37. DRIVE HOUSING BOLT

39.

41.

42.

MAY

WASHER (THICK)

SEAL

BUSHING PLUG (IF USED)

GROUNDED BRUSH SCREW THRU

BOLT

BRUSH PLATE SCREW

ONE

BE USED)

.

ON

SOME MODELS)

18

34

OR

FIGURE

. Engines & Generators .

3.

STARTER

ASSEMBLY

54

STARTER

MOTOR

General

(Figure

Remove

1.

2.

3.

4.

Disassembly

4)

or

Disconnect:

The

motor lead

group

(A)

nut

on

the solenoid tenninal.

a.

Remove the nut

lead and reinstall the

Thro

bolts

Brush

plate

C.E.

frame (14)

Important:

a.

In

the following step, use care not

dowel pin

· brush holder group drive group assembly should be (0.079 in.) cured or manufactured

on

the frame, field

from the solenoid assembly (1). Reinstall the

on

the solenoid, slip off the motor

nut.

(41).

screws

(42).

and

0-ring

(28)

installed between the frame, field and

(A)

(B). This dowel pin

and

must be saved

lost,

it must be replaced with a 2 mm

dia. x 10

mm (0.394 in.) long pin pro-

locally.

and

brush holder

(20).

to

lose the small

and the gear reduction and

is

required for

If

the dowel pin

5. Frame, field and brush holder and frame seal (33).

a.

The armature assembly (13) frame, field and brush holder group

by

retained

6. Armature

a.

Do not remove the bearings from the armature

assembly unless replacement

CI.EANING,

7.

Solenoid

8.

Solenoid

a. Pivot the inside end of the solenoid assembly (1) out

of

engagement with the shift lever reduction solenoid

the gear reduction and drive group (B).

assembly

(13}

INSPECTION

screws

(25).

assembly

(1).

and

drive group (B) and withdraw the

assembly.

25

group

(A),

dowel pin

may

come off with the

(A)

or may be

with bearings (8 and 9).

is

required (refer

AND

REPAIR).

in

the gear

(28)

to

14

41

1. SOLENOID ASSEMBLY

8.

D.E. ARMATURE BEARING

9.

C.E. ARMATURE BEARING

13. ARMATURE ASSEMBLY

14. C.E. FRAME.

20. C.E. FRAME 0-RING

25. SOLENOID SCREW

28. DOWEL

33. FRAME SEAL

. 41. THRU BOLT

42. BRUSH, PLATE SCREW

.

A. FRAME, FIELD & BRUSH HOLDER GROUP B. GEAR REDUCTION & DRIVE

GROUP

FIGURE

4.

ELECTRICAL

9

GROUP

;

'.

55

Disassembly

(Figure

Remove

1.

Insulated

a.

2.

Frame

3.

Grounded

4.

Brushes a.

5.

Brush a.

NOTE:

ponents

tested

of

5)

or

disconnect:

brush

Move

the

es

(4

and

bly

(19) slightly

and

remove

and field

brush

( 4 and

Grasp

the

needle

the

brush ( 4 or

springs

Grasp

the brush end of needle nose the

brush socket on

and

remove

At

this

can

as specified

REPAIR.

Frame,

5)]

nose pliers, twist

be

screws

brush

holder

away

the

screws

assembly

screws

5),

if

brush

5)

(7),

if

pliers,

the

stage

inspected,

in

Field

(29).

from

to

reach

(39).

replacement

end of

and

withdraw

replacement

twist

the

spring.

of

disassembly,

CLEANING,

and

Brush

assembly

the

frame

aero~

{29).

(19).

is

each

brush

the

spring

is

each

brush

the

spring

brush

holder assembly

and

if

required,

STARTER

Holder

(3)

and

with

required.

spring (7) end

the brush. ·

required.

spring

end

al.l

INSPECTION AND

Group

[with the brush-

field

assem-

a screwdriver

with

away

from

(7)

with

away

from

(3)

electrical.

com-

independently

MOTOR

4

39.

·

3.

BRUSH HOLDER ASSEMBLY

4. BRUSH (GROUNDED)

5.

BRUSH (INSULATED)

·

7. BRUSH SPRING

'.

FIGURE

5.

FRAME,

7.'

FIELD

AND

19

19. FRAME ASSEMBLY

29.

INSULATED BRUSH SCREW .

39. GROUNDED BRUSH' SCREW

BRUSH

HOLDER

11

& FIELD

GROUP

.

Disassembly (Figure

Remove

1.

Housing

2.

:=pportbracket{16). a.

3.

Washers

a.

4.

Drive a.

5.

Shift lever nut Remove

6. clutch then

a.

of

Gear

6)

or

disconnect:

bolts

The

washers

ture support bracket or to

group

(C)

removed. In either her of each of these

(30 through

Save

the washers; they

position and number at

housing

Pry

out the drive housing plug using a large screw-

driver.

the shift lever

group

(C)

separate

Do

not remove the bushing plug

(6)

from the drive housing

is

required (refer

REPAIR).

Reduction

(36

and

37).

(30

through

as

the

armature support bracket is

32).

plug

(27)

(23),

washer

from

them.

to

and

32) the

case,

note the position and

washers.

are

to

assembly.

and

plate

(22)

(11)

and

the drive shaft

the

drive

housing

(18)

CLEANING,

Drive

Group

may

stick

to

the

arma-

drive shaft and clutch

num-

be installed in the

(26).

and

screw

(21).

(18)

(34)

or the bushing

unless

replacement

INSPECTION AND

same

and

together,

~1-·

·30

· •

31

32

6.

D.E. HOUSING

11. SHIFTLEVER

16. ARMATURE SUPPORT BRACKET

;

18.

DRIVE HOUSING

! 21.

SHIFT LEVER SCREW SHIFT LEVER WASHER

22.

23.

26.

27.

~o.

.

31.

LEVER

SHIFT PLATE (IF USED) DRIVE HOUSING PLUG WASHER {FIBER) WASHER

TWO

MAY BE USED)

•

FIGURE

21

BUSHING

NUT

{THIN; ONE

6.

GEAR

32. WASHER. (THiCK)

34. BUSHING PLUG {IF USED)

36. DRIVE HOUSING BOLT

(LONG)

'37.

DRIVE HOUSING BOLT {SHORTER DRIVE

OR

C.

REDUCTION

SHAFT & CLUTCH

GROUP

AND

DRIVE

ON

SOME MODELS}

GROUP

Engines &

56

Generators

STARTER

MOTOR

Disassembly

of

(Figures 7 and

Disassembly required unless it

or

one follows:

Remove

1.

Stop

a.

b.

c.

d. Inspect the

e.

2.

Clutch

3. Drive shaft

a. Do not

of

the

more

parts of

or

disconnect:

rings

(35)

Position the bench with

Using

an

8),

Figure clutch drive (35).

Using

care

stop

rings

the

end of

may

have cycles. stop are burrs away

Slide the Discard the New

(15)

ING,

Such

and

found,

only - not the base

metal

parts

drive

remove

unless replacement

INSPECTION

Drive

Shaft

8)

drive

shaft

is

necessary

the

group

and

pinion stop

drive

shaft

the

internal gear

open

tube

slightly larger

drive

the pinion

assembly

not

to

scratch the drive shaft

out

of the shaft groove

the

shaft.

edges

of the shaft

been

formed

burrs

may

clutch

drive

use

a suitable

filings.

pinion

stop

old

pinion stop

must

be

used

assembly

support

(2)

(17)

the bearing

and

Clutch

and

clutch

to

clean,

separately.

and

stop

(2)

until it

through

make

assembly

file

metal.

(12)

off

at

from

drive shaft

is

required,

AND

REPAIR).

Group

group

is

not

inspect or replace

Then

proceed

(12).

clutch

group

on the work

end

down.

than

the

shaft (see

(12)

toward

clears

the

(15),

and

slide them off

groove

for

burrs that

repeated cranking

removal

(2)

to

carefully remove the

the

(12)

assembly.

drive shaft

(10)

of the pinion

difficult.

Thoroughly clean

drive shaft

and

stop rings

(15).

from

the

drive shaft

(refer

to

the

stop

rings

pry

If

burrs

(15).

(35).

·

CLEAN-

as

the ·

2. CLUTCH DRIVE

ASSEMBLY

10. CENTER SUPPORT BEARING

12. PINION STOP

i.

FIGURE

' 14.2

(0.56 IN.) DIA

MM

7.

DRIVE

SHAFT

-B

10

15. DRlYE SHAFT

17. DRIVE SHAFT

SUPPORT

35. STOP RINGS

AND

CLUTCH

GROUP

22MM

(0.87 IN.) DIA

(2

PCS)

Engines &

57

DRIVE SHAFT (15)

FIGURE

Gen~ratol'$

8.

REMOVING

OPEN TUBE

PINION

STOP

STARTER

MOTOR

CLEANING,

INSPECTION,

TESTING

AND

REPAIR

Cleaning

NOTE:

Do

not clean or solving solvents. Solvents will dissolve grease packed drive assembly and

may

immerse

damage

starter parts

the

armature or field coil

in

grease

in

dis-

the

insulation. Clean:

1.

All starter parts with a soft cloth prior to testing.

Inspection (Figure

Inspection in the following steps refers to visual inspection of bility. Electrical tests for certain assemblies are described in

COMPONENT ELECTRICAL Inspect:

1.

2.

3.

4.

5.

3)

the starter parts and assemblies to determine their servicea-

TESTING.

All parts Replace parts or assemblies which are cracked, bent or otherwise damaged.

Threaded parts for stripped, crossed or otherwise damaged threads. Replace parts with thread damage that cannot Replace any hardware items that have damaged threads.

The solenoid assembly (1) for a cut or torn boot. boot is damaged, replace the solenoid assembly.

The clutch drive assembly (2) for the following Replace the clutch drive assembly

a. Pinion gear turns roughly or turns in both directions.

b. Pinion gear teeth broken or showing evidence

c. The brush holder assembly (3) for the following.

Replace the brush holder a. Loose riveted joints. b. Cracked

for

cracks, distortion other structural damage.

be

cleaned up using a suitable tap or die.

step wear.

Deep scoring

or

other damage to the shift lever collar.

if

damaged:

or

broken insulation.

if

damaged:

If

the

..

of

6. Brushes (4 and 5) for excessive wear. is

12

or

to

REPAIR

mm

other dam-

a. The minimum allowable brush length

(0.472 in.). Replace excessively worn brushes in sets.

7. The D.E. housing bushing (6) for scoring

age. Replace a damaged bushing (refer

PROCEDURES).

8. Ball bearings (8, 9 and 10)

a. Hold the armature (13) or drive shaft (15) and slowly

rotate the outer bearing race by hand.

b.

Check that the bearing turns freely without binding or the feel

c. Replace damaged bearings (refer to

of

flat spots.

as

follows:

REPAIR

PROCEDURES).

9.

Armature assembly (13) for the following:

a.

Gear teeth that are broken, or that show evidence of step wear or root interference.

b. Rough commutator surface. Polish with a No.

grit polishing cloth metal dust from between the commutator bars. commutator surface cannot be repaired in this man-

ner, replace the armature assembly.

commutator in a lathe.

c. Worn commutator. Replace the armature assembly

the commutator OD is less than 35

if

the undercut depth at any point is less than 0.2 mm

(0.008 in.). Do not undercut the insulation.

10. Drive shaft (15) for the following. Replace the drive shaft

if

damaged:

a.

Scored

or

damaged shaft where

bushing (6).

b. Internal gear with teeth broken

of

step wear.

c. Damaged spline. The clutch drive assembly must

slide smoothly and easily over the full length

'spline.

if

necessary. Thoroughly clean

Do

not turn the

mm

(1.378 in.) or

it

turns in the

or

showing evidence

of

400

If

the

if

58

STARTER

MOTOR

Component

Electrical

(Figures 9 and

Perfonn bly (1), armature bly

1.

2.

3. Check frame

the

following electrical tests

(19)

to

determine

Using

a suitable

solenoid a.

b.

Check grounds

(test

a. Rotate the

b. Check the

c.

d. Replace

opens as

a.

b.

c.

assembly (1)

Check the hold-in ance

between

the

solenoid mately 0.95 matelyl.75

An

extremely break or fault

resistance winding replacement of

the

armature

using

lamp

must

such

as a hacksaw short circuit that area.

ohmmeter. armature

Check for where

the A poor arcing or

show

evidence of

using a test

follows:

Check that

the

field

the

connection points for the insulated brushes

the field coil Check that

between

nects

to

Replace grounds

Testing

10)

assembly

their

ohmmeter,

resistance

windings

the

case.

ohms

high

in

the

reading

circuit.

the

(13)

suitable

be

110

armature

is

present,

armature

There

shaft

and

opens armature

connection

burning

armatures

and

field

lamp

there

terminal

straps.

there

the

frame

the

solenoid.

frame

and

or

opens.

on

the

solenoid

(13)

and

frame

and

field

assem-

serviceability.

check the

for

continu,ity

of the solenoid pull-in

in

series

motor terminal

The resistance

for

12-volt starters

for

24-volt starters.

resistance reading indicates a

winding

indicates a short or ground

Either condition

solenoid

as

follows

test equipment

volts

or

in

a growler

blade against

the steel

for grounds

shall be

any

point

by

visually inspecting the points

conductors join

often will be indicated

of the commutator.

which are shorted, grounded or

opens.

assembly

(llO

volts

is

continuity (no

that connects

is

no

continuity

and

the field terminal that

field assemblies that

windings

as

follows:

by

measuring the resist-

(see

Figure

should

be

and

approxi-

continuity. A very

is

cause for

assembly.

for

shorts,

and

instruments

less).

holding

the

strip

using

no

continuity between

on

the

(19)

max.)

to

a steel

armature.

will vibrate in

a test

commutator.

the

commutator.

for

grounds or

ohmmeter,

opens)

the

solenoid,

(no

grounds)

have

of

and

9)

approxi-

opens

lamp

by

between

assem-

the

and

low

in

the

or

strip

If

a

the

signs

or

and

on

con-

or

of

FIGURE

10.

BATIERY

TERMINAL

9.

SOLENOID

FRAME

MOTOR

TERMINAL

TERMINALS

AND

FIELD

ASSEMBLY

59

STARTER

MOTOR

Repair (Figures 3 and

1.

Procedures

11)

If

necessary, replace the bearings (8 and

the annature (13) as follows:

NOTE:

Ball bearings which armature removal

must

procedure causes

be

replaced

are

removed

with

new

interna,l

damage

bearings.

Remove or disconnect:

a. C.E. and/or D.E. bearings

of

the armature (13) using a suitable bearing puller.

(8

and/or 9) from the shaft ·

Install or Connect:

b. New C.E. and/or D.E. bearings

armature assembly (13) using a tube that bears on the bearing's inner race only. Press on the bearing until the inner race bottoms out against the shoulder on the armature shaft.

2.

If

necessary, replace the center support bearing (10,

Figure 3)

NOTE:

drive

removal

on

the drive shaft (15) as follows:

Ball bearings which

shaft must

be

replaced

procedure causes internal

(8

are

removed from

with

new

damage

bearings.

9,

Figure 3) on

from

the

bearings.

and/or 9) to the

to

The

the

bearings.

to

the

The

Remove or disconnect:

a. The center support bearing (10) from

(15) using a locally fabricated tool Figure

11.

the

as

shown in

Install or Connect:

b. The center support bearing (10) from

(15) using a locally fabricated tool (Figure 11). With the drive shaft in a suitable support fixture, place the tool bolt ends through the access holes end

of

the drive shaft and squarely press the bearing

of

the surface on the center shaft.

off

If

necessary, replace the bushing (6, Figure 3) in the

3. drive housing (18)

a. From inside the drive housing (18), drive out the

plug (34) nants

of

plug. Clean away any metal shavings. Using a suitable open tube, press out

b. c. Using a suitable open tube, press the

(6) into the drive housing (18) until the end bushing is flush with the inside

d. Install a new plug (34),

Stake housing material over the plug equally spaced.

as

follows:

if

present. Use a file to clean away rem-

the old stake to allow installation

if

used, to the drive housing.

the

new

of

the housing.

at

drive shaft

in

the wide

of

a new

bushing

of

the

three places,

(6).

SIDE

(1

3/8 IN.)

3·2

VIEW

MM

TOP

VIEW

MATERIALS NEEDED·

OF

FLAT

• PIECE THICK,

• THREE 6 MM OR 3/16 IN. BOLTS OF EQUAL LENGTH, LONG ENOUGH TO EXTEND BELOW THE IT. TO USE NUTS INSTEAD OF TAPPED HOLES, USE

LONGER BOLTS TO COMPENSATE FOR NUT THICKNESS.

1.

2. INSTALL

AND 55 MM (OR 2 1/4 IN.) SQUARE OR ROUND.

LOCATE THREE HOLES EQUALLY AROUND A

(1.26 IN.) CIRCLE

HOLES

OF INSTALLED BOLTS SHOULD PASS THROUGH

ACCESS HOLES

METAL STOCK ABOUT

FLAT

STOCK WHEN INSTALLED THROUGH

ON

FLAT STOCK. DRILL AND TAP

AS

NEEDED

SOL

TO

TS

IN

FLAT STOCK AND TIGHTEN. ENDS

IN

END

AT

LEAST

MATCH BOLT THREADS.

OF DRIVE SHAFT WITHOUT BINDING.

5MM

(OR 3/16 IN.)

35

MM

PRESS

CENTER

SUPPORT

BEARING

FIGURE

11.

TOOL

FOR

REMOVING

Engines & Generators

CENTER

60

SUPPORT

BEARING

STARTER

MOTOR

ASSEMBLY

Lubrication

1.

The armature bearings support bearing add lubricant to these bearings. Lubricate the following just before or during assembly (avoid excessive grease):

a. D.E. housing bushing (6) (in drive housing). b. The pivot hole and working surface on the ends

c.

Drive (Figures 7 and

1.

If

face with the internal gear end down and assemble the drive shaft and clutch group as follows:

Important:

a.

Install

1.

The drive shaft support (17) to the drive shaft (15), seat- ing the bearing

2.

The clutch drive assembly (2) to the drive shaft (15).

3.

A new pinion stop (12) onto the drive shaft (15), the end with the recess for the stop rings (35) up.

a. Install the stop rings (35) in the groove in the drive

b. Pick up and support the assembly under the pinion

c.

Assembly (Figure

Important:

If

install them

REPAIR

assembly.

During

the shift lever (11). The internal gear, shaft and spline

(15).

Shaft

and

Assembly

(8

and 9, Figure 3) and drive shaft

(10) are permanently lubricated. Do not

on

the drive shaft

Clutch

Group

12)

disassembled, position the drive shaft on the work sur-

If

the center support bearing (10) is being replaced,

install it

PROCEDURES,

assembly.

or

shaft

stop that will slide over the shaft between the pinion gear and the stop, can support (see Figure

Make sure the stop rings (35) (in the drive shaft groove) are fully seated in the pinion stop recess and

stake the upper edge stop ring (35) at four places, equally spaced. allow staked metal to contact the drive shaft

on

Connect:

(15).

(12).

of

Gear

the drive shaft (15) as specified in

step 2, before proceeding with

(10) in the support.

A metal block, with a U-shaped cutout

be

clamped in a vise to provide

12).

of

the pinion stop (12) over the

Reduction

and

Drive

Group

6)

the D.E. bushing (6) and plug (34) are being replaced,

in

the drive housing (18) as specified in

PROCEDURES,

step 3, before proceeding with

of

REPAIR

Do

not

(15).

1. Lubricate the D.E. housing bushing, shift lever, and drive shaft as described under

LUBRICATION DURING

ASSEMBLY.

Install

or

Connect:

2. The arms on the shift lever (11) with the shift collar on the drive shaft and clutch group

3. The assembled shift lever clutch group (C) into the drive housing holes in the drive shaft support in the drive housing.

a.

Make sure that the drive shaft support is fully seated in the drive housing and that the drive shaft bearing (10, Figure 7) remains fully seated in the drive shaft support.

4.

Shift lever screw (21), washer (22) and nut (23).

(C).

(11)

and the drive shaft and

(18), aligning the

(17, Figure 7) with those

Tighten:

a.

Nut to 4.5

5. The plate (26), to the drive housing

6. Washers (30 through 32) in the same number and posi-

tions as noted at disassembly.

7. The armature support bracket (16) to the drive housing

(18), aligning the mark made prior to disassembly with

that on the drive housing.

8. Drive housing bolts (36 and 37).

FIGURE

Nm

(40 lb-in.).

if

used, and the drive housing plug (27)

(18).

38

12.

APPROX.

MM

(1

1/2 IN.)

PINION

STOP

METAL

BLOCK

9 MM (3/16 IN.)

14.2 (0.56 IN.)

SUPPORT

BLOCK

APPROX.

MM

Engines & Generators

61

Assembly (Figures

./nstall

1.

of

Frame,

5,

13

SPRING POST

FIGURE

or

Connect:

Brush springs (7),

a. Start each brush spring onto the post on the brush

holder assembly (3) as shown in Figure 13, enough to hold the inside end

and

13.

Field

14)

BRUSH

if

removed.

and

Brush

SPRING

Holder

BRUSH

ASSEMBLY

BRUSH

.SOCKET

ON

POST

of

the spring from

turning.

b.

Grasp the free end pliers and twist clockwise over the top socket.

c.

Push the spring fully onto the post and release the free end to engage the notch

of

the spring with needle nose

in

the brush socket.

STARTER

Group

MOTOR

NOTE:

handling.

the clips

HOLDER

just

of

the brush

2. Brushes ( 4 and 5), if removed.

The

brush leads may

Do

not over-flex

may

break

off.

a.

See Figure 14 for the proper installed position brushes. Make sure the insulated brushes (5) go into the brush sockets that are mounted

b.

To install each brush, grasp the free

spring with needle nose pliers, twist clockwise to clear the brush socket and insert the brush partly into the brush socket.

c. Gradually release the spring so that its end contacts

the side (not end) will hold the brushes retracted until after the brush holder is installed over the armature commutator.

3. Grounded brush screws (39).

a.

Position the terminals

behind the terminal tabs on the brush holder (3) (see

Figure 13).

b.

Insert the brush screws (39) through tabs on the brush holder and thread them into the brush lead terminals.

Tighten:

c.

Grounded brush screws to 1.5

be

damaged

the

leads near the clip welds or

of

the brush holder assembly (3)

on

the insulation.

of

the brush (see Figure 13). This

of

the grounded brush leads

by

Nm

(13 lb-in.).

excessive

end

of

the

terminal

of

all

the brush

GROUNDED

BRUSH

FIGURE

14.

INSULATED BRUSH

SPRINGS

AND

BRUSHES

ON

BRUSH

HOLDER

SPRING

POST

Engines & Generators

62

STARTER

MOTOR

4.

The

frame and field assembly

assembly.

a.

Position the brush bolder

installed brushes) over and

field assembly

b. Attach the terminals of

the

conductors in the

the insulated brush

the

(19).

the

frame

screws

(19)

to

the brush bolder

assembly

tenninal end

insulated brush leads

(3) (with

of

and

field assembly with

(29).

Tighten:

c.

The insulated brush screws

Starter

(Figures

Support the gear reduction and drive group (B) with pinion gear end

Assembly

4and15)

down

and proceed

to

1.5 Nm {13 lb-in.).

as

follows:

Important:

If

the

armature them on the armature DURES, step 1 before proceeding

Install or

bearings

Connect:

(8 and 9)

{13)

are

being replaced. install

as

specified in REPAIR PROCE-

with

assembly.

1. Solenoid assembly (1).

a.

Pivot the plunger engagement with the shift lever in the gear reduction

and drive

b. Position the solenoid

install the solenoid

group

of

the solenoid assembly into

(B).

assembly

mounting

mounting flange

screws (25). ·

Tighten:

c.

Solenoid

Sc:rews

to

2:8

Nm

(25

lb-in.).

2. Frame seal (33).

3. The armature assembly (13)

the gear reduction

and drive

a. Make sure the gear teeth

bearing

ing recess.

(8) on the armature shaft fully into the hous-

4. Frame, field and brush holder

a.

Place

the dowel pin

support bracket group

(B). .

b.

Position the armature assembly dowel pin (28) and the

sembly, group

(B).

c. Twist the brush springs (7, Figure

brushes contact the commutator and release the brush springs the brushes.

5.

0-ring (20).

of

the

frame, field

and

seat in the gear reduction and drive

(4 and 5, Figure 5), slide the brushes in to

with

bearings

group

(B).

are

aligned, then seat the

group

(28)

in

the

the gear reduction and drive

and

brush holder group over

(13), align the hole for the

marks

made prior

on

the

to

(8

(A).

hole in the

5)

away from the

armature (13),

contact the ends of

the frame

to

the

and

9)

into

armature

to

disas-

Important:

a.

The 0-ring tion of the age, install

steps.

b. Install the 0-ring on the

er group field frame that installed. This theO-ring.

c.

Carefully roll the 0-ring position up

Allow the 0-ring to remain in this position until

C.E. frame

6. C.E. frame

a. Align the

field sembly.

b. Start the

bly,

ness

7. Brush plate

a.

Use a scribe or similar tool in

the brush holder assembly (3, Figure

screw boles in the

'lighten:

b. Brush plate screws

8.

Thru bolts (41).

a.

Install the thru bolts and tighten

not close the frame and field assembly where the

b...

Roll the 0-ring (20) back position between the field

c.

Align the timing ribs on

. {14) with the timing spots

assembly Refer

the motor but will

'lighten:

d. Thru bolts

9.

The motor lead Figure 5).

a. Remove the

install the motor lead terminal

can

easily be

C.E.

frame (14).

the

0-ring

(A)

so

that it is against the shoulder

will abut the

is the normal installed position

onto

the major

is

partially installed.

{14)

marks

on the

assembly

leaving a

of the 0-ring (20).

assembly.

to Figure

{19,

Figure

C.E.

frame onto the frame and field assemgap

just slightly

screw

{42).

C.E.

to

gap

between the

(A)

to

assure proper brush alignment.

15.

otily match

{41)

to

8.5

on

the frame and field assembly

nut

from the

damaged

To

prevent such dam-

as

described in the following

frame,

field and brush

C.E.

.~mt

of

its

O.D.

C.E.

frame

5)

made

larger

to

align

frame

(14).

2.8

Nm

(25

C.E.

down

C.E.

frame

the

edge of the

on

the

Marks are located in 2 places on

one

Nm

{75

tenninal

.Tighten:

b. The nut

11

on

Nm

(100 lb-in.).

the

terminal of the solenoid assembly

during installa-

frame when

normal installed

of

the fielq

and

prior to disas-

the tapped

lb-in.).

them

frame and the

into its installed

and

frame

way.

lb-in.).

on

and

reinstall the

frame.

frame

than the thick-

5)

with the

by hand but do

0-ring (20)

the frame

C.E.

and field

the solenoid,

bold-

on

the

for

and

holes

and

frame

(19,

nut.

the

goes.

to

63

STARTER

MOTOR

STARTER

Testing

After repair or overhaul,

fied

BLESHOOTING

After

reinstall it using the following torques

trical connections

A

is

trical

may

tery

skin

lighten:

STARTER

All

INSTALLATION

After

Repair

in

the

Starter

repair,

overhaul, testing

CAUTION:

disconnected

connections result. terminal,

No-Load

section.

to

the

Make

at

If

a

tool

the

or

Overhaul

the

starter

Test

starter.

sure

the

battery

to

the

starter.

is

shorted

tool

will

or

the

heat

bum.

a.

Solenoid battery (B) terminal nut

b. Solenoid

(16

lb-in.).

switch

(S)

tenninal nut

SPECIFICATIONS

12

Volt

models

have

VOLTS

10

these No-Load

can

found

replacement of the starter,

negative

when

at

be tested

in

the

TROU-

when

making the elec-

battery

making

Otherwise,

the·solenoid

enough

to

cause

to

18

Nm

to

1.8 Nm

Test

Specifications:

as

speci-

·

the

cable

elec-

,

injury

bat-

a

(13 lb-ft);

AMPS

Minjmum

125 190

.

FIGURE

Maximum

15.

ALIGNING

TIMING

Minimum

3000

C.E. FRAME

TIMING MARKS

FRAME AND FIELD ASSEMBLY

MARKS

RPM

Maximum

5600

All

24

Volt

models

Starter Solenoid current consumption:

RATED

have

VOLTS

20

VOLTAGE

12 24

these No-Load

Test

Specifications:

AMPS

52-59

100-125

Minimum

75

PULL

AMPS

IN

WINDING

VOLTS

10 20

Maximum

90

·OHMS

0.17 -0.19

0.16-

0.20

Minimum

3600

AMPS

12-14 12-14

HOLD

VOLTS

RPM

IN

WINDING

10 20

Maximum

5400

OHMS

0.76-0.81

1.15

-1.65

64

·wESTERBEKE

51 A MANDO

ALTERNATOR

JUMPERS

DISASSEMBLY

AND

TESTING

A

WARNING:

hot.

Do

not

touch

A

WARNING

certain away

A

DC applications. isolate before made

that

from

sheaves

WARNING

and

AC

circuits

DC

and

ped0t1Bing

without

A

failed

until

Before

everyone

and

Maltimeters

are

Always

disconnect

AC

converters

DC

proper

knowledge

altemator

the

altemator

starting

is

clear

belts

ofter

mixed

testing.

the

of

moving

during

and

DC

shore

and

shut

No

AC

of

can

become

has

cooled

engine,

parts!

test

procedures.

Circuits

together

power

down

tests

should

AC

circuits.

very

down.

make

Keep

in

marine

cords,

generators

be

REGULATOIH---11--l-l!Hl-l!l---ti&tM

COVER

SENSING TERMINALS

GROUND

TERMINAL

TESTING

1. Connect the positive voltmeter lead terminal

terminal E on the alternator.

2. Wiggle voltmeter. The meter should indicate the approximate battery voltage, and should not obtained, output circuit for loose damaged wiring.

NOTE:

alternator system

for tightness

clamps belt for excessive for proper belt

E

JUMPER

THE

the

Prior to

and battery temiinals. Inspect

8

OUTPUT

Band

connect the negative lead to the ground

engine wiring harness while observing the

or

if

the reading varies, check the alternator

any

alternator

wiring

for

and

cleanliness,

wear

and

tension.

.,,,......-•

CIRCUIT

to

the output

vary.

If

no reading is

or

dirty connections

testing,

defects.

particularly battery cable

replace

inspect

Check

all connections

the

alternator drive

if

necessary.

the

(!APACITOR

'Or

entire

Also adjust

REFER

TO WIRING WIRING

TESTING

1. Connect the positive (+>"voltmeter lead to the excitation

2. Tum the ignition switch to the on position and note

3.

4.

THE DIAGRAMS HARNESS

terminal the ground terminal E on the alternator.

voltmeter reading. The reading should be volts (see illustration). If

the rotor field circuit probably is shorted Disassemble the alternator and test the rotor

described under

COMPONENTS

If

the field circuit probably is open. Remove the regulator and inspect it for worn brushes Replace the brushes

long. tion, disassemble the alternator and test the rotor, outlined under

COMPONENTS

FOR

THE

CONNECTIONS

THE

Ron

reading

If

the brushes and slip rings are in good

ABOVE

EXCITATION

the alternator and the negative(-) lead

is between .75

CLEAN

in

this section.

is between 6.0

CLEAN

in

CIRCUIT

and

1.1 volts, the

or

AND TEST

if

they are less than l/4in.

AND TEST

this section.

ALTERNATOR

and

7.0 volts, the rotor

or

dirty slip rings.

ALTERNATOR

1.3

to

2.5

grounded.

as

(6

c~ndi

mm)

as

to

the

65

MANDO

ALTERNATOR

SERVICE

TESTING

THE

EXCITER

5.

If

no reading is obtained, an

alternator-excitation lead the regulator. Disconnect the lead from Connect the positive voltmeter lead to the excitation lead and the negative voltmeter E.

If

the voltmeter now indicates an approximate. battery voltage, the voltage regulator is defective and must be replaced. circuit for loose or

TEST

Perfonn this test operating correctly, using a

NOTE:

voltage reading with a battery chargeror allow the engine to run a sufficient length reading.

1. Connect the positive(+) voltmeter lead to the positive _battery

the negative terminal.

2. Start the engine and run it at fast idle until the engine

reaches its normal operating temperature. Adjust the engine speed to 1500 - 2000 voltmeter for

be

3.

If

alternator ground lead connection. good, the voltage regulator is faulty and must replaced. attempting to remove the alternator.

4.

If

a. Stop

b.

If

VOLTAGE

The

battery

of

time

tenninal and the

between 13.7 and 14.7 volts.

the

reading is high, check for a loose

the reading is low:

the connections. Remove the Phillips cover screw from the regulator cover (see illustration).

LEAD

open

or

in the excitation circuit

lead to ground terminal

no voltage is indicated, check the excitation

dirty connections

REGULATOR

to

detennine

must

in this test.

to folly charge the battery before taking a

'

the

highest reading.

Be

sure

to

engine and remove the alternator wiring

if

the voltage regulator is

0 - 20 volt

be folly clzarged to obtain a proper

If

necessary, clzarge the battery

negative(-)

rpm

disconnect the battery cables before

·

-$-

exists in the

exc

tenninal

or

damaged wiring.

DC

voltmeter.

voltmeter lead to

and observe the

The

reading should

or

dirty

If

the connection

be

c. Remove the nut from the output terminal and the

nut from the sensing terminal, and remove Jumper

(A).

d.

Remove another nut from the sensing terminal, and the

nut

from the excitation terminal.

of

R.

e. Remove the regulator cover. f. Temporarily re-install Jumper (A) and all associated

nuts. Leave Jumper (B) installed.

g. Remove the plastic plug from the side

regulator.

h.

Connect a jumper between the top brush lead and the ground.

REGULATOR--1.1-..1.. COVER

SENSING

TERMINAL

GROUND

CONNECT JUMPER

\

WIRE

\

of

JUMPER

BRUSHES

the

OUTPUT

TERMINAL

B

I

i. Repeat steps

is

NOTE:

Do

j.

If

a voltmeter reading

now obtained, the voltage regulator is faulty and

must

be

14.5 volts, inspect the brushes and slip rings for wear, dirt or damage. are good, the alternator is fault internally. Disassemble the alternator and test the components, as

outlined in this section.

1and2.

not

let the voltage exceed

of

replaced.

If

the voltmeter reading

If

16

volts.

14.5 volts

the brushes and slip rings

or

above is

is

below

Engines & Generators

66

.

MANDO

REMOVE

1.

2. Disconnect the wiring leads.

3. Loosen the screws. Holding the alternator, rotate it

4. Remove the screws and washers and remove the alternator.

REGULATOR.

ALTERNATOR

Disconnect the negative(-) battery ground cable.

toward the engine and lift the belt off the pulley.

ALTERNATOR

TERMINAL NUTS

APACITOR

OUTPUT TERMINAL

SERVICE

10.

Place an oversized V-belt around the pulley and fasten the pulley

11.

Use a 7/8 in. box wrench pulley nut.

12.

Remove the pulley nut, lockwasher, pulley, spacer.

A

more

winding

in

a vise.

PULLEY

CAUTION:

than

1/16

could

AND

DO

in.

result

to

loosen and remove the

FAN

COMPONENTS

NOT

insert

(1.6

mm}.

from

deeper

screwdriver

Damage

to

penetration.

fan,

bf;Jdes

the

stator

and

DISASSEMBLE

1. Remove the terminal nuts to remove the jumper (see

illustration).

2. Remove the remaining terminal nuts.

3. Remove the capacitor.

4. Remove the Phillips screw from the regulator cover.

ALTERNATOR

5. Remove the brush/regulator-assembly cover.

6. Remove the nut from the terminal.

7. Remove

8. Remove

9. Remove

brush/regulator assembly.

the

jumper.

the

terminal insulators.

the

two Phillips screws and remove the

NOTE:

Score the stator, and the front and rear housings

the unit

13. Remove the four through-bolts and carefully

SCREW

14. Carefully push the rotor assembly out

may

be reassembled correctly.

front housing away from the rear housing using two screwdrivers.

DRIVER

of

housing and rear housing.

pry

REAR

the front

so

the

HOUSING

NOTE:

If

the bearing

bearing must be installed.

15.

After removing the three bearing locking screws, care fully press the front bearing out against the inner race of the bearing.

67

is

removed from the housing, a new

of

the housing. Press

MANDO

BEARING

DRIVER

16.

Remove the rectifier assembly by removing the Phillips screw

and

lifting out the assembly.

ALTERNATOR

BEARING SCREWS

LOCKING

SERVICE

2. Inspect and test the diode-trio assembly: a. Using a commercial diode tester, a 12-volt DC test

or

lamp each light stud.

b. Reverse the tester leads and repeat the resistance

checks.

c. A very low resistance should

direction and a very high resistance should be indicated

d.

If

any diode appears to be defective, replace the complete assembly. Do not attempt to replace an individual diode.

3. Test the diode-rectifier bridge a.

Using a commercial diode tester, check for continuity from each ouput terminal.

an ohmmeter, check the resistance between

of

the t4ree diode terminals and the indicator

light stud

DIODE

TRIO

ASSEMBLY

be

indicated in one

in

the other direction

if

the diodes are normal.

as

follows:

of

three terminals to the

RECTIFIER

CLEAN

1. Inspect

AND

TEST

ALTERNATOR

and

test the brush/regulator assembly. The

brush

set

may be reused

mm)

or

(6 cracked

Test

a test a good brush/regulator assembly,

longer. The brushes must not

or

grpoved.

for

continuity between 1 and 2, and 3 and 4 using

lamp

or

an ohmmeter. These checks will indicate

if

necessary.

TESTING

BRUSH

REMOVAL

COMPONENTS

if

the brushes are 1/4 in.

assembly; replace

ASSEMBLY

be

oil soaked,

the

complete

GROUND TERMINAL

b. Reverse ·the tester leads and repeat Step a. c. Continuity should exist in only one direction and

all diodes should check alike.

d. Perform the same continuity checks between the

three terminals and strap ground terminal. This should show continuity in only one direction

through the diodes and all diodes should check alike.

e.

If

any diode appears to be defective, replace the

rectifier assembly.

Engines & Generators

68

RECTIFIER DIODES

MANDO

4;

Clean and inspect the front and rear housings: a.

Inspect the rear housing for cracks casting, stripped threads Replace the housing

b.

Inspect damaged threads in the adjusting ear, round correct slightly damaged threads using a tap. Replace the housing,

c.

If

solvent and dry with compressed air.

5.

Clean

ROTE:

since

a.

The cloth containing a moderate amount solvent. use pressurized solvent

b.

Check or exists

NOTE:

replace the

6. Inspect grooves minor a badly

the

front housing for cracks, stripped or·

bore

in

the mounting foot.

the housings are to

and

inspect the rotor shaft bearings:

Do not

it is serviced

rough

use a solvent

as a unit

bearings should

Do

not immerse a bearing in solvent.

the

bearings for obvious damage, looseness

rotation. Replace a bearing

as

to

its condition.

If

the

rear

entire

the

belt

pulley for rough

or

keyway, and for cracks

burrs

and correct minor surface damage; replace

worn

or

damaged pulley.

or

a damaged bearing bore.

if

any

of

these conditions exist.

if

necessary.

be

reused, clean

on

the

rear

with

the

rotor.

be

wiped clean with a lint-free

or

air.

rotor

bearing

needs

rotor.

or

badly worn belt

or

ALTERNATOR

or

breaks in the

or

an

out-of-

If

possible,

them

in

rotor bearing

of

commercial

or

if

any doubt

replacement,

breaks. Remove

EAR

HOUSING

SERVICE

LAMINATIONS

b.

Check the resistance from each lead (1, 2, and 3) to

the laminations (4). There should

if

the insulation is good.

c. Inspect the stator windings for signs

A discolored winding should be replaced.

d.

If

a winding shows a high resistance

circuit between any two

or

terminals windings and the laminations, the stator must replaced.

8.

Check

the rotor assembly as follows:

ROTE:

If

replace

a.

b.

c. Minor burning

d.

e.

9.

the

Visually inspect for physical defects such as dam-

aged shaft threads, worn

burned

Measure the winding resistance across the slip (A). Place the ohmmeter leads on the edges slip rings, correct winding resistance 27° C) is

be

can wipe the slip rings clean after polishing, removing

all grit and dust. Check for a grounded slip ring or rotor winding

measuring the resistance from each slip ring to rotor body be

indicated in both cases for a good rotor.

If

the

cannot

Use a commercial capacitor checker to test the capacitor for capacity, shorts, leakage, and series resistance .

indicates poor insulation between

slip

rings

need

entire

rotor.

or

pitted slip rings

not

on the brush contact surfaces. The

4.1to4.7 or

removed using a crocus cloth. Thoroughly

or

pole finger (B).

windings

be

are

corrected, replace the rotor assembly.

of

to

be

or

ohms.

pitting

of

defective or physical damage

be

no continuity

of

or

the three winding

replaced,

damaged bearing areas,

or

at

the slip ring surfaces

you

scuffed pole fingers.

70 - 80° F

An

open circuit

discoloration.

an open

the

be

must

rings

of

the

(21

-

· by

the

should

7.

Test

the

stator

a.

Using

continuity between

lo~

A

observed.

windings as follows:

an

ohmmeter or test lamp, check for

ohm

reading

all three leads (1, 2, and 3).

or

lit test lamp should

be

Engines & Generators

69

.--~--~--------~p

.--.--------a B

r---'1''-+-'l'--eiH-<1-~----;i.ol.2

'<>-llO--+n

0-~-4-n

INTERNAL

CIRCUIT

WIRIRG

EXC

s

MANDO

ALTERNATOR

SERVICE

2.

Place the rotor (pulley end up) press, on two steel blocks.

3. Press the front housing and bearing assembly down onto the rotor shaft. Press against the bearing's inner race only, using a sleeve driver. the rotor leads clear the steel blocks.

SLEEVE

DRIVER

ROTOR

on

the

bed

of

Take

care to insure that

FRONT

HOUSING

BEARING

an

arbor

ASSEMBLY

AND

ASSEMBLE

1. Carefully press the front bearing into the front housing, pushing against the bearing's outer race using a bearing driver.

TORQUE:

BEARING DRIVER

ALTERNATOR

Lock

~e

25 -

35

lb-ifl

BEARING. OUTER RACE

FRONT

bearing in place with screws.

(2.8 -4.0

Nm)

BEARING

ASSEMBLY

BEARING SCREWS

FRONT

LOCKING

BEARING

INSTAWNG

4. Install the rectifier assembly into

5. Insert the Phillips screw and tighten it.

RECTIFIER ASSEMBLY

6.

Assemble the front and rear housings as follows: a. Put the stator winding in the front housing with

b.

c. Slip the rear housing into place over the rotor shaft.

d. Install the four bolts and tighten them.

THE

FRONT

stator leads away from the front housing and the

notches in the stator laminations aligned with the

four through-bolt holes in the housing.

Align the scribe marks you front and rear housings during disassembly.

Align the mounting holes

through the holes

TORQUE:

NOTE:

will not be tapped.

35 • 65

If

HOUSING

at

lb-ft

(4.0 -7.3

the front housing is

ON

and

the top of

Nm)

THE

ROTOR

ASSEMBLY

the

rear housing.

made

in the stator,

put the stator leads the

rear housing.

new,

the through-bolt

the

and

ASSEMBLING

THE

BEARINGS

70

MANDO

ALTERNATOR

SERVICE

7. Install the spacer and the lockwasher and nut onto the shaft. Tum the nut a few turns.

8.

Place an oversized V-belt around the pulley and fasten the pulley in a vise.

INSTALLING

9. Use a torque wrench to the tighten the nut.

TORQUE:

10. Carefully install the brush/regulator assembly on the

rear housing with the two mounting screws.

11.

Illstall the small terminal insulators.

12. Install the large terminal insulator.

13. Install the jumper.

14.

Install the nut on the terminal.

15. Install the

16.

Install the Phillips screw for the brush/regulator assembly cover.

TORQUE:

17. Install the capacitor.

18.

Install the terminal nuts.

19. Install the jumper.

20. Install the last terminal nut.

35 -50

25 -35

THE

lb-ft

bru~h/regulator

lb-ft

PULLEY

(4.7 -6.8

(2.8 -5.1

fan.

Then push the pulley,

AND

THE

FAN

Nm)

assembly cover.

Nm)

NUT

INSTALL

1. Install the alternator, screws and washers.

2. Connect the wiring leads.

3.

4. Adjust the alternator belt's tension (see DRIVE BELT

Battery Maximum Cot

Reg. Ambient Ground

ALTERNATOR

Put the belt pump pulleys.

ADJUSTMENT

MANDO

Voltage

in

Speed

Set

on

ALTERNATOR

Speed

Voltage Temp.

the alternator, crankshaft and coolant

under ENGINE

ADJUSTMENTS').

SPECIFICATIONS

12

Volt

13500

RPM

Max.

2000

RPM

(at

Max.

14.7

1500

Volts

RPM

(at

exc.) L2)

-2oac -10o·c

Negative

Engines & Generators

71

THE

SINGLE

BE

AND

GENERATOR

THREE

PHASE

DESCRIPTION

'Ibis

generator

which

requires

duce

AC

are

stator erator.

The

be

induced rotation. voltage field.

This through age

which

in

the

auxiliary

supplied

voltage

generator

the lator

senses the exciter stator generator

is a four-pole,

only

the driving force of

output The copper

responsible

magnetic

into

Diodes

to

DC

creates

the

windings

is

supplied

to

a voltage

to further excite the exciter stator

to

AC

is

furnishing

for

field

the

and

supply

an

electromagnetic

of the main

to a load.

windings

regulator.

produce a rated

voltage

winding

brushless,

and

the self-exciting

produced

exciter rotor

in

the excitenotor rectify this

it to the

An

of

the

main

The

output

and

according

to

mainatin a constant voltage

laminated

causes

windings

field

stator,

AC

voltage

stator

regulator

AC

output.

adjusts

to

amperage

self-excited

the

engine

iron

feature

an

AC

windings

of the rotating

which

inducing

and

produces a

windings,

The

DC

generator

to

pro-

in the exciter

of this

gen-

voltage

during

rotates

an

AC

volt-

is

produced

is, in turn,

DC

enabling

voltage

excitation

load

regu-

to

the

output.

DRIVE

to

CIRCUIT

A circuit breaker generators.

generator breaker generator

NOTE:

add-on WESTER.BEKE

·

HUB

BREAKER

is

This

circuit

power

in

can

be

manually

to

ensure

This

circuit

kit for

earlier

dealer.

installed

breaker

case of

no

power

breaker

model

on

all

will

an

electrical

shut

off

is

coming

is

available

generations;

WESTERBEKE

automatically

overload.

when

servicing

into

the

as a WESTERBEKE

contact

disconnect

The

circuit

the

boat

your

DIODE

ASSEMBLY.

CIRCUIT PART

25

BEG/60Hz -43794

20

BEG/50Hz -42696

20

BEG/60Hz -42696

16

BEG/50Hz -42718

GENERATOR

HOUSING

BREAKER

NUMBERS

72

VOLTAGE

REGULATOR

ADJUSTMENTS

Description

The

voltage

regulator optimum complete· conditions that could be detrimental

AC

alternator performance. It

protection circuitry

is

an

advanced

to

guard

design

which

is

equipped

against operating

to

the

AC

alternator.

ensures··

with

Volts

This potentiometer is used

engine operating speed the output voltage should be held at

±1 %

from

a no-load condition

from

and ations

Prior

mers (using a mini phillips

clockwise stops.

Turn the

(Maximum) in

With with age The

lize. Increase the voltage

tion,

power factor 1.0 - 0.8

up

to

-6%.

to

starting the engine, turn the

(Minimum) direction until

AMP

and HERTZ

the

same

the

alternator running at

VOLT

adjust at minimum, it is possible that output

will

oscillate. Slowly rotate

v.oltage

output

only

the green LED will

to

adjust output

to a full

with

screwdriver)

trimmers

manner.

no-load,

the

of

the alternator will increase and stabi-

to

the desired

stay

lit

voltage.

rated

engine

VOLT

and

fully

you

feel

completely clockwise

at

normal

VOLT

adjust clockwise.

value.

At proper

generator output

drive

speed

STAB

in a counter

them

speed,

In

this

vari-

trim-

hit their

and

volt-

situa-

Stability

This potentiometer permits variation of

response pensation and obtain a minimum

voltage output. In

running at no-load and the output must Turn

starts terclockwise until the voltage a

order

the

to

volt.

to

generator load changes

to

adjust the regulator

STAB

adjust slowly clockwise until.the voltage

fluctuate. At

this

point rotate the

stability

is

~

Amp

Iii

Slab

=

Voll

the

regulator's

so

as

to

limit overcom-

recovery

stable within 1

time

the

alternator must

be

monitored.

STAB

to

the normal

adjust coun-

()r

2 tenths of

i

VOLTAGE

REGULATOR

DIAGRAM

be

Amp-Hertz

These

two

adjustments protection circuits in the by

the illumination

1.

Delay~

2.

Low

Both systems have adjusted using the respective circuits are able voltage to safeguard the exciter overheating.

The overload protection temporary overloading of motor start-up or other similar lator also tor operation

with the generator.

Setting

In

order

must

1. Load the alternator

the engine hertz

2. Rotate the AMP adjustment counterclockwise

its put should come

3. Slowly rotate the AMP adjustment clockwise output voltage increases age output

yellow

4. Return and the alternator Should this not happen, repeat the

NOTE:

remove

Setting

NOTE:

jumper strap

two setting,

i.

To

lower (54 hertz

2.

Rotate the Hertz adjustment counterclockwise the alternator's

. the same time the red

3. Increase The put

With

tion

overload protection

speed protection

has

a third

to

the

Overload

to

set the AMP

be

loaded to its full

by

on

50 hertz

stop.

Wait

of

the alternator

at

LED to

nominal

When

changing

the

60

hertz jumper bar

the

Underspeed

If

the

unit is

is

60 Hertz terminals.

the

alternator

adjust

the

engine speed

on

the

red "LED" light

will

return

the

above

nomially.

are

used

voltage

of

a colored

(red

LED).

an

intervention

potentiometer.

to

cause

an

adequate

system

the

generator

LED

(green),

indicate correct

Protection

overload

output

to

its

rating,

10.10%

about

on.

the start of

light should

units).

15-20

should

speed,

voltage

from

(54

to

the

come

60

Hertz

seconds

the

will rise

Protection

operating

in

place

underspeed

60 hertz

AC

engine

to

nonnal.

adjustments

on In

oider

should

at

units,

output

"LED"

speed

will

al

the

be

(low

90%

voltage

to

go

made,

in

conjunction

regulator that

LED

lights.

(yellow

windings

has a delay

load

operation

drop

approximately

adjustment.

hertz

from

regulator

45

LED).

threshold

reduction

during

surge

that

glows

protection,

rating.

then

decrease

on

60 hertz

after

and the

on.

yellow

LED

to

its nonnal

adjustment.

to

50

the

60

Hertz

to

adjust

running

frequency)

of

its

normal

hertz

on

starts

light

comes

its

nonnal

out

and

the

regulator

and

demands.

of

hertz

regulator

ensure

board

the

at

50

speed

which

Each

prevent

which

during

the

which

yellow

97%

At

will

no-load.

protection

hertz

to

decrease

on.

AC

with

the

two

are

indicated

can

be

of

the

two

in

exciter

their

permits

times

such

The

regu-

genera-

regulator

alternator

the

speed

units,

45

until

it hits

the

AC

out-

LED light

until

the

of the volt-

this point the

turn

off

value.

operation,

board.

that

the

between

the

underspeed

circuit,

running

speed

units.

slowly

until

and at

(frequency).

voltage

out-

should

func-

as

of

73

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

INTERNAL

WIRING

SINGLE

SCHEMATICS

PHASE

L-

EXCITER

+

_________

STATOR

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

I I

I

EXCITER

ROTOR

I

I I I I I I I

I I

I c I I I I

I I I

L-----r------~---J

REGULATOR

ROTOR

I I

FIELD

a I

bl

J

I

I I.

BLUE

RED

1-------1

I

STATOR

I I

~~~DINGSr-_-l_•_•_•_h

RED

YEUOW

r

RED

I

_:

FUSE

6.3

AMP

NOTE:

may

be

on

the

RED

®

This

fuse

located

regulator.

W2

®

U1

GREEN

AC TERMINAL BLOCK

V1

BLACK

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

I

.

EXCITER

I

I.

I I I I I

L-

:r

0

-'

UJ

>-

~-+~I

.-----1

STATOR

. I a

---------.l

THREE

6

WIRE

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

I I

:

ExCITER

1

ROTOR

I

I c

I I

ROTOR

: · 1

I

bl

FIELD

PHASE

RECONNECTABLE

POZI RESISTER

L-----r----------

'

REGULATOR

BLUE

U2 •

V2

W2

"'

~

al

,------.

I

BLACK

I

I I

I

GREEN

I

RED

I

I I

I

_____

I

AUX WINDINGS

fa

0:

STATOR

NOTE:

may

on

I

J

0

w

a:

FUSE

6.3AMP

This

be

located

the

regulator.

BLACK

GREEN

RED

fuse

l'5

!!:!

"'

•UI

AC

VI

TERMINAL BLOCK

WI

YELLOW

74

INTERNAL

3

PHASE

WIRING

TWELVE

WIRE

RECONNECTABLE

SCHEMATICS

r-------,

I

EXCITER

I I I I

I + I

I b :

STATOR

r - - - + - - - - - - -

EXCITER ROTOR.

- I I b I

_

__.

I I

t I

I

ROTOR

I I

FIELD

a'

c

DIODES

POZI RESISTER

-,

L---+-------.J

I..

-----

.....

REGULATOR

BLUE

YaLOW

I

AUX WINDINGS

2 !

: 3 :

: 4 :

: 5 :

: 6 :

7

r9•8•'1:

._

,

FUSE

6.3

AMP

NOTE:.

may

be

on

the

This

fuse

located

regulator.

NOTE:

IF

WIRING

- JUMPER MUST THE

FOR

REG!JLATOR.

L1

L2

5

L3

9

10 + 11

"SERIES

480V/60 380V/50

50 HZ.,

BE

0

2+3

0

6+7

0

Hz. Hz.

AC

VOLTAGE

THE

60

REMOVED

HZ.

FROM

N

.2_•.•.rn

Y"

CONNECTIONS

L1

1+3

L2

5+7

L3

"PARALLEL

208V·120V/60

I I

2+4

0

6+8

Y"

Hz.

N

0

L3

8+9

0 Q

10+11

"SERIES DELTA" -

240V/60 220V/50

Hz. Hz.

_L

75

BE

TROUBLESHOOTING/3

NOTE:

BE

PERFORMED

AC

GENERATOR

WITH

TROUBLESHOOTING

ENGINE

OPERATING

PHASE

MUST

AT

60

.

HER1Z

No

AC

Residual 15 -20

Low

AC

60-100

High

AC

150

VAC

Unstable AC

voltage

·

60

-100

PROBLEM

voltage

volts

AC.

voltage

VAC.

output

or

h_ig_her.

voltage

drop

volts

output

voltage

AC.

at

produced

output

at

output.

under

load

no

load.

at

no

load

1.

Short

or

main

stator

2.

Shorted

on

exciter

3.

Four

or

open

diodes

1.

Blown 6 AMP auxiliary

2.

FauJ!y

voltage

1.

Open

or

exciter

rotor 1 to 3 diodes.

2.

Open

or

rotor

winding.

1.

Faulty

voltage

1.

STB

pod

needs

al!i.ustment.

1.

Diode(s) breaking applied

PROBABLE

open

in

the

winding.

pozi-resistor

rotor.

more

shorted

on

exciter

buse

fuse

circuit

feed

re_gulator.

shorted shorted

(inductive)

regulator.

on

regulator

on

exciter

down

diodes exciter

when

1-3

or

rotor.

to

AVR.

rotor

load

diodes.

in

is

CAUSE

4.

Short

stator

5.

Short

.

field

3.

Shorted stator-auxiliary

3.

Faulty

2.

Faulty

or

open

winding.

or

open

winding.

or

open

voltage

in

exciter

in

rotating

main

winding.

regulator.

BE

GENERATOR

EXCITER EXCITER

ROTATING MAIN

AUXILLARY

EXCITER EXCITER

ROTATING MAIN AUXILLARY

STATOR

ROTOR

FIELD

STATOR

WINDING

STATOR. ROTOR

FIELD

STATOR

WINDING

SINGLE

_a

- b

b-c

:1

- 2

3-4

THREE

_a-

b-c

PHASE

b

RESISTANCE

VALUES

20 & 25

.18.06

0.68

0.68 0.72

1.75

0.05

1.19

20,

25, & 32

1820

0.7

2.01

0.06

0.98

BE

(each

(IN

BE

winding)

OHMS)

32

BE

18.20

0.72

2.01

0.05

0.98

, lwlWESTERBEKE

) Engines & Generators

76

GENERATOR

AC

VOLTAGE

NOTE:

erly positioned when changing the AC output configuration of

the

AC

tenninal block, use terminal ends for

accept multi strand copper wire

the

from or

white with a green strip. It connects between the neutral

stud and the generator frame.

CONNECTIONS

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

terminal block. For making connections to the AC

114

inch studs that will

sized for the amperage rating

hot lead connection. The frame ground wire

120/240V

0

60Hz

0

120V60Hz

0 0

AC

is

white

VOLTAGE

CONNECTIONS

Generator

I. Frequency

1800

rpm=

2.

To change generator freguency, follow the

Configure the AC terminal block for the

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

NOTE:

The installations ground

source

230V

,,

circuit.

in

50Hz

0

the

Frequency

is

a direct result

60 hertz; 1500 rmp =

white/green

where

This

vessel.

ground

the

AC

will prevent

115V

of

engine/generator speed:

50

hertz.

wire

may

be

circuit

has

a separate neutral and

.the

unit

from

50Hz

0

steP.s

below:

d~sired

removed

voltage

in

those

being a ground

is

L1

L2

CIRCUIT BREAKER

N

L1

I (

I I

1-------1

N

L1

A

JUMPER REQUIRED BETWEEN

CONNECTIONS.

IS

LOAD

L1

2

~

N

ILLUSTRATION

120/240V -60Hz

CONNECTIONS.

SHOWS

CIRCUIT BREAKER

77

AC

TERMINAL

BLOCK

ILLUSTRATION

230V-50Hz

CONNECTIONS.

SHOWS

DESCRIPTION

The

regulator

to

6)

and

connection

of

the

and

#0

on

NOTE:

the

regulator

is

their

generator.

#2

on

the

voltage

Series

Delta

board

equipped

and

The

AC

regulator

requires

between

.GENERATOR

with

seven

numbered

brass

jumpers.

jumpers

sensing

terminal

board.

the

terminal·B

for

the 3 phase

leads

connect

block

installation

The

illustrations

and

connection

and

between

of

10.

AC

VOLTAGE

terminals

show

configuration

#I

#2

and

a jumper

on

(0

CONNECTIONS

170 • 270V

80·160 v

CASEGND

L - L L-

N -120 L • L -190 L-

N -110

0

W2

U1

L1

BE

CONNECTIONS

208

VAC VAC VAC VAC

U2

V1

L2

THREE

3,U 1J 3,f 1,f

PHASE

FOR

50 60 50

60

V2

W1

BOTH

Hz Hz Hz

Ht

-1-N-OND

(SIX

WIRE)

60 & 50

HERTZ

L • L •

450

L-

N -

265VAC1.f l • L-380 L - N

~

230

D

VAC

VAC VAC

3,f 3,f

1J

3

PHASE

60Hz 60Hz 50Hz 50Hz

VOLTAGE

REGULATOR

SERIES

l - L -

L2,

L3·N

L - L -

L2,

l3-N

D

240

-120 230

-110

DELTA

VAC

VAC VAC

2jJ

11

3,B'

1.ft

60Hz 60Hz 50Hz 50Hz

BE

THREE

PHASE

{IWELVE

78

WIRE)

A.-

SERIES

repositioning

lead

from

generator

J.

Jumper

wire.

DELTA-Note

neutral

ho~sing.

using

of the

to

#1

O

AWG

the

ground

SHORE

POWER

TRANSFER

SWITCH

SHORE

Generator

~

If

cuit, this must be Switch. OFF of shore power

POWER

t =

I

'------~

I

I /,,,,.--, L-----(-<D

r-----\@

I ,

I

I I

the installer connects shore power

Set the transfer switch shown

CONNECTIONS

NOTE: Diagram shows

wire.120·

Volt system. For a

use

dotted

®'~

@;_1

__

;

done

lines

for

by

connections

the

other

means

(60

three-wire

hot

leg.

to

of

the

HERR)

foi' a

two-

system

Ship-to-Shore

the

vessel's

Shore Power Transfer

in

the

position. This switch prevents simultaneous connection

to

generator output

32008 32009

Amps/ 32010

Ampa/

Switch

Pole)

PN (40Amps/Pole)

PN (80

PN

(125

PN32133 (200Ampa/Pole)

AC

diagrams

to

cir-

(3

the

Pole)

120

VOLT/60

HZ

THREE

Notice the repositioning of terminal block

Generator

~

'----t-+---..,'®

tS2

. Shore

Switching

to

the generator case.

NOTE: Diagram shows wire,

120-Volt

with

three-wire,

/.,....-,,

I

;;~

i

Z

S1

N'

~oW':'

·.;/

Ground

(GRN)

.

Shore

\

z+--+------=~

Power

WIRE

the

white

connet.tions

system

from

120-Vojt

to

Generator

CONFIGURATION

wire

ground

load

on

the

for a two-

the

generator.

boat

system.

Ship-to·

Shore

32008

32010

32133

Switch

Pole)

PN (4DAmpS/

l21

L1 N Ships Load PN

:~~~·Volt

}It

Equipment

rs'ti~!~~'

PN (125Amps/Pote)

(200Amps/Pole)

Power

(3

Pol&)

A

CAUTION:

utility

share

at

the

same covered bilijy

ta

power time.

under

make

Damage

and

This

the

warranty;

sure

all

ta

the

generator

type

of

generator

ii is the

AC

connections

generator

output

installer's

are

can

result

are

cannl!Cfed

damage

respansi·

correct.

if

is not

A

CAUTION:

betore

switching

vice-versa

with

heavy

cause

damage

generator.

Heavy

share

because

AC

loads

ta

the

motor

power

voltage

an

the

exciter

leads

ta

generator surges vessel

cin:uil

should

be

power

Induced

being

by

operated

components

shut

off

or

switching

may

in

the

(

79

WESTERBEKE

25KW

AND

20KW

BEG

GENERATOR

SPECIFICATIONS

Engine

Type

Governor Combustion

Bore

&

Stroke

Piston

Displacement

;Firing

Order

Direction

of

Rotation

Compression Dimensions

Weight

25KW

20KW

Iodination

Compression (Limit

of

difference

between

cylinders)

Valve

liming

Vatve

Seat

Angle

Valve

Clearance

(engine

wann)

Engine

Timing

25KW

20KW

ENGINE

Ctiamber

,

Ratio

TUNE-UP

Pressure

SPECIFICATIONS

Gasoline,

four-cycle,

fresh

water-cooled,

overhead

mechanism

Hoof,

flyball

Multi-sphere

3.38 x 3.70

133.26

cubic 1-3-4-2 Clockwise,

8.6:1 Height

42.2

Wldlh:

22.4

Length:

• 282

968

lbs

(439.5

940

lbs

(426.7

Continuous Temporary

type.

inches

when

inches

Inches

kgs)

26"

30°

tour-cylinder,

Vertical,

5%

speed

(86.0 x 94.0

(2184

cubic

viewed

from

(1071.9mm)

(568.9mm) (716.3mm)

·

SPECIFICATIONS

163.Spsi

(11.Skglcnt)

28.0

psi

{2.0

Intake

Opens

Intake

Closes

Exhaust

Opens

Exhaust

Closes

Intake

45"

Exhaust45" Intake

0.012

Exhaust

0.012

20"

BTDC BTDC

at

12°

kg/cm2})

2°

53°

inches

1800 1800

BTDC

ABDC

57°

BBDC

-2°

ATDC

(0.3

incites

rpm ± .5° rpm ± .5°

at

(0.3

210

mm)

in-line

regulation.

mm).

centimeters)

the

front

;<

rpm

General

Distributor

Spark

Plug

Carburetor

Spark

Plug

Dwell

General

Fuel

Consumption

25KW

2DKW

fuel

Lift

Pump

Fuel

Riter

(on

engine)

Air

Cleaner

(flame

arrester)

Air

Row

(engine

combustion)

General

~.

Operating Fresh Raw

at

Water

Raw

Water

1800

System

(coolant)

!emperature

rpm

Capacity

Thread

(STD

Type)

Sap

.

Pump

Row,

IGNITION

Battery

Distributor Ignition

Solid

ignitor.

Size

14mm X 1.25 Down

uses

.030

63°

FUEL

Conventional pump.

Unleaded

rating

3.0

2.5

Electromagnetic-Lift capacity 6

Replaceable Replaceable

Me1al

69.5

COOLING

Fresh controlled

.130

·

Centrifugal Positive

belt

6.7

7.3

SYSTEM

ignition

with

coif

an~

state

type

pitch

draft

type,

approved

inches

(0.8

at

1800

rpm.

SYSTEM

carburetor

gasoline

of

89

or

better.

U.S.

SPH SPH

(11.3

(9.4

U.S.

cartridge-screw

at

fuel

screen

type

cfm

(1.9

cmm)

SYSTEM

water-cooled

with

-150°

~

~55

type,

displacement,

driven.

gpm

(25.3

qts

(6.9

liters)

12V

negative

Ignition

spark

with

signal

single flame

mm)

(ElO

LPH)

pump

-

cleanable.

block,

heat

ei<changer.

-

66°

metal

lpm)

ground.

module

and

plugs.

generator

barrel.

arrester

type

with

electric

Maximum).

at

fuH

output

at

fuH

output

feet

o~l

.8

meters)

inlet

thermoslatically-

C)

impeller,

belt-driven

rubber

Impeller,

lgnitor.

and

fuel

Octane

(wet)

lwlWESTERBEKE

l Engine$ & Generators

---··-·

. . -

80

(continued)

WESTERBEKE

25KW

AND

20KW

BEG

GENERATOR

SPECIFICATIONS

General

OH

Filter

Sump

Gapacity

(not

including

filter)

Operating

on

hot)

Grade

Battery

Capacity

Charging Charging

Pressure

Cranking

(engine

Oil

Starting Battery Starter

DC DC

Current

AC

General-Single

Voltage -Single

Voltage Frequency

Rating

211KW·6Dllz

161lW

22.5KVI.

20KW·50Hz

Phase

Regulation

(Volts

AG)

·50Hz 60

Hz

LUBRICATION

Pressure

fed

Full

flow,

paper

4.0

U.S.

qts

plus

filter/cooler

55-75

psi

(3.8 -5.2

API

Westerbeke 20BEG, 16BEG Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual