~
.....
SERVICE
MANUAL
5.0KW
BCG-60Hz',
4.2
KW
BCG-50Hz
5.0KW
BCGA-60Hz , 4.2KW
BCGA-50Hz
7.0KW
BCGC-60Hz
'5.9KW
BCGC-50Hz
7.0KW
BCGD-60Hz , 5.9KW
BCGD-50Hz
GASOLINE
GENERl{
R~
:
Single
Phase'
,
NO. 052020
FIRST EDITION
MARCH 2005
~r~
rWESTERBEKE
member
J
WESTERBEKE
CORPORATION·
150
JOHN
HANCOCK
ROAD
~'lTr
•
MYLES
STANDISH
INDUSTRIAL
PARK • TAUNTON
MA
02780
~~~~
~~B
SITE:
WWW.WE~~ERBEKE.COM
Gasoline with an ETHANOL content
higher than 10% (E10) is not allowed
and may void warranty.
Engines & Generators
A
WARNING
Exhaust
gasses
contain
Carbon
Monoxide.
an
odorless
and
colorless
gas.
Carbon
Monoxide
is
poisonous
and
can
cause
unconsciousness
and
death.
Symptoms
of
Carbon
Monoxide
exposure
can
include:
-Dizziness
-
Throbbing
in
Temples
-Nausea
-
Muscular
Twitching
-Headache
-
Vomiting
-
Weakness
and
Sleepiness
-Inability
to
Think
Coherently
IF
YOU
OR
ANYONE
ELSE
EXPERIENCE
ANY
OF
THESE
SYMPTOMS,
GET
OUT
INTO
THE
FRESH
AIR
IMMEDIATELY.
If
symptoms
persist,
seek
medical
attention.
Shut
down
the
unit
and
do
not
restart
until
it
has
been
inspected
and
repaired.
A
WARNING
DECAL
is
provided
by
WESTERBEKE
and
should
be
fixed
to
a
bulkhead
near
your
engine
or
generator.
WESTERBEKE
also
recommends
installing
CARBON
MONOXIDE
DETECTORS
in
the
living/sleeping
quarters
of
your
vessel.
They
are
inexpensive
and
easily
obtainable
at
your
local
marine
store.
CALIFORNIA
PROPOSITION
65
WARNING
Marine
diesel
and
gasoline
engine
exhaust
and
some
of
its
constituents
are
known
to
the
State
of
California
to
cause
cancer,
birth
defects,
and
other
reproductive
harm.
SAFETY
INSTRUCTIONS
INTRODUCTION
Read this safety manual carefully. Most accidents are
caused by failure to follow fundamental rules
and
precautions. Know when dangerous conditions exist
and
take the necessary precautions to protect yourself,
your
personnel,
and
your
machinery.
The following safety instructions are in compliance with
the American Boat
and
Yacht Council (ABYC) standards.
PREVENT
ELECTRIC
SHOCK
A
WARNING:
00
not
touch
AC
electrical
connections
while
engine
is
running,
or
when
connected
to
shore
power.
Lethal
voltage
is
present
at
these
connections!
•
Do
not operate this machinery without electrical
enclosures and covers in place.
• Shut off electrical power before accessing electrical
equipment.
• Use insulated mats whenever working
on
electrical
equipment.
• Make sure your clothing and skin are dry, not damp
(particularly shoes) when handling electrical equipment.
• Remove wristwatch and all jewelry when working on
electrical equipment.
•
Do
not connect utility shore power to vessels AC
circuits, except through a ship-to-shore double throw
transfer switch. Damage to vessels
AC
generator may
result
if
this procedure is not followed.
• Electrical shock results from handling a charged
capacitor. Discharge capacitor by shorting terminals
together.
PREVENT
BURNS -HOT
ENGINE
A
WARNING:
00
not
touch
hot
engine
parts
or
exhaust
system
components. A running
engine
gets
very
hot!
• Always check the engine coolant level at the coolant
recovery tank.
A
WARNING:
Steam
can
cause
injury
Dr
death!
• In case
of
an engine overheat, allow the engine to cool
before touching the engine
or
checking the coolant.
PREVENT
BURNS -FIRE
A
WARNING:
Fire
can
cause
injury
or
death!
• Prevent flash fires. Do not smoke
or
permit flames or
sparks to occur near the carburetor, fuel line, filter, fuel
pump, or other potential sources
of
spilled fuel or fuel
vapors.
Use a suitable container to catch all fuel when
removing the fuel line, carburetor, or fuel filters.
•
Do
not operate without a Coast Guard Approved flame
arrester. Backfire can cause severe injury
or
death.
•
Do
not operate with the air cleaner/silencer removed.
Backfire can cause severe injury or death.
• Do not smoke or permit flames or sparks to occur near
the fuel system. Keep the compartment and the
engine/generator clean and free
of
debris to minimize the
chances
of
fire. Wipe up all spilled fuel and engine oil.
•
Be
aware - diesel fuel will burn.
PREVENT
BURNS -EXPLOSION
A
WARNING:
Explosions
from
fuel
vapors
can
cause
injury
or
death!
• Follow re-fueling safety instructions. Keep the vessels
hatches closed when fueling.
Open and ventilate cabin
after fueling. Check below for fumes/vapor before
running the blower. Run the blower for four minutes
before starting your engine.
• All fuel vapors are highly explosive. Use extreme care
when handling and storing fuels. Store fuel in a
well-ventilated area away from spark-producing
equipment and out
of
the reach
of
children.
•
Do
not fill the fuel tank(s) while the engine is running.
• Shut off the fuel service valve at the engine when servicing
the fuel system. Take care in catching any fuel that might
spill.
DO
NOT
allow any smoking, open flames, or other
sources
of
fire
near the fuel system or engine when
servicing. Ensure proper ventilation exists when servicing
the fuel system.
• Do not alter
or
modify the fuel system.
•
Be
sure all fuel supplies have a positive shutoff valve.
•
Be
certain fuel line fittings are adequately tightened and
free
of
leaks.
• Make sure a fire extinguisher is installed nearby and is
properly maintained.
Be
familiar with its proper use.
Extinguishers rated ABC
by
the NFPA are appropriate
for all applications encountered in this environment.
Engines & Generators
SAFETY
INSTRUCTIONS
ACCIDENTAL
STARTING
A
WARNING:
Accidental
starting
can
cause
injury
or
death!
• Disconnect the battery cables before servicing the engine!
generator. Remove the negative lead first and reconnect
it last.
• Make certain all personnel are clear
of
the engine before
starting.
• Make certain all covers, guards, and hatches are
re-installed before starting the engine.
BATTERY
EXPLOSION
A
WARNING:
Battery
explosion
can
cause
injury
or
death!
•
Do
not smoke
or
allow
an
open flame near the battery
being serviced. Lead acid batteries emit hydrogen, a
highly explosive gas, which can
be
ignited
by
electrical
arcing
or
by
lit tobacco products. Shut off all electrical
equipment in the vicinity to prevent electrical arcing
during servicing.
• Never connect the negative
(-)
battery cable to the
positive
(+) connection terminal
of
the starter solenoid.
Do not test the battery condition by shorting the terminals
together.
Sparks could ignite battery gases or fuel vapors.
Ventilate any compartment containing batteries to prevent
accumulation
of
explosive gases. To avoid sparks, do not
disturb the battery charger connections while the battery
is
being charged.
• Avoid contacting the terminals with tools, etc.,
to
prevent
burns
or
sparks that could cause an explosion. Remove
wristwatch, rings, and any other jewelry before handling
the battery.
• Always tum the battery charger off before disconnecting
the battery connections. Remove the negative lead first
and reconnect it last when disconnecting the battery.
BATTERY
ACID
A
WARNING:
Sulfuric
acid
in
batteries
can
cause
severe
injury
or
death!
• When servicing the battery or checking the electrolyte
level, wear rubber gloves, a rubber apron, and eye
protection. Batteries contain sulfuric acid which is
destructive.
If
it comes in contact with your skin, wash it
off at once with water. Acid may splash on the skin or
into the eyes inadvertently when removing electrolyte
caps.
TOXIC
EXHAUST
GASES
A
WARNING:
Carbon
monoxide
(CO)
is a deadly
gas!
• Ensure that the exhaust system is adequate to expel gases
discharged from the engine. Check the exhaust system
regularly for leaks and make sure the exhaust
manifolds/water-injected elbow is securely attached.
•
Be
sure the unit and its surroundings are well ventilated.
Run blowers when running the generator set or engine.
•
Do
not run the generator set
or
engine unless the boat is
equipped with a functioning marine carbon monoxide
detector that complies with ABYCA-24. Consult your
boat builder or dealer for installation
of
approved
detectors.
•
For
additional information refer
to
ABYC T-22
(educational information on Carbon Monoxide).
A
WARNING:
Carbon
monoxide
(CO)
is
an
invisible
odorless
gas.
Inhalation
produces
flu-like
symptoms,
nausea
or
death!
•
Do
not use copper tubing in diesel exhaust systems. Diesel
fumes can rapidly destroy copper tubing in exhaust
systems. Exhaust sulfur causes rapid deterioration
of
copper tubing resulting in exhaust/water leakage.
•
Do
not install exhaust outlet where exhaust can
be
drawn
through portholes, vents,
or
air conditioners.
If
the engine
exhaust discharge outlet is near the waterline, water could
enter the exhaust discharge outlet and close or restrict the
flow
of
exhaust. Avoid overloading the craft.
• Although diesel engine exhaust gases are not as toxic as
exhaust fumes from gasoline engines, carbon monoxide
gas is present in diesel exhaust fumes.
Some
of
the
symptoms
or
signs
of
carbon monoxide inhalation or
poisoning are:
Vomiting Inability to think coherently
Dizziness
Headache
Nausea
Throbbing in temples
Muscular twitching
Weakness and sleepiness
AVOID
MOVING
PARTS
A
WARNING:
Rotating
parts
can
cause
injury
or
death!
•
Do
not service the engine while it is running.
If
a
situation arises in which it is absolutely necessary to
make operating adjustments, use extreme care to avoid
touching
movmg parts and hot exhaust system
components.
Engines & Generators
i i
SAFETY
INSTRUCTIONS
•
Do
not wear loose clothing
or
jewelry when servicing
equipment; tie back long hair and avoid wearing loose
jackets, shirts, sleeves, rings, necklaces or bracelets that
could
be
caught in moving parts.
• Make sure all attaching hardware is properly tightened.
Keep protective shields and guards in their respective
places at all times.
•
Do
not check fluid levels
or
the drive belts tension while
the engine is operating.
• Stay clear
of
the drive shaft and the transmission coupling
when the engine is running; hair and clothing can easily
be caught in these rotating parts.
HAZARDOUS
NOISE
A
WARNING:
High
noise
levels
can
cause
healing
loss!
• Never operate an engine without its muffler installed.
•
Do
not run an engine with the air intake (silencer)
removed.
• Do not run engines for long periods with their enclosures
open.
A
WARNING:
Do
not
wOlk
on
machinery
when
you
ale
mentally
or
physically
incapacitated
by
fatigue!
OPERATORS
MANUAL
Many
of
the preceding safety tips and warnings are repeated
in your Operators Manual along with other cautions and
notes to highlight critical information. Read your manual
carefully, maintain your equipment, and follow all safety
procedures.
GASOLINE
ENGINE
AND
GENERATOR
INSTALLATIONS
Preparations to install an engine should begin with a
thorough examination
of
the American Boat and Yacht
Council's (ABYC) standards. These standards are a
combination
of
sources including the USCG and the NFPA.
Sections
of
the ABYC standards
of
particular interest are:
H-2 Ventilation
P-l
Exhaust Systems
P-4
Inboard Engines
E-9 DC Electrical
Systems
All installations must comply with the Federal Code
of
Regulations (FCR).
ABYC,
NFPA
AND
USCG
PUBLICATIONS
FOR
INSTALLING
DIESEL
ENGINES
Read the following ABYC, NFPA and USCG publications
for safety codes and standards. Follow their
recommendations when installing your engine.
ABYC
(American Boat and Yacht Council)
"Safety Standards for Small Craft"
Order
from:
ABYC
3069 Solomon's Island Rd.
Edgewater,
MD
21037
NFPA
(National Fire Protection Association)
"Fire Protection Standard for Motor Craft"
Order
from:
NFPA
11
Tracy Drive
Avon Industrial
Park
Avon,
MA02322
USCG
(United States Coast Guard)
"USCG 33CFR183"
Order
from:
U.S. Government Printing Office
Washington, D.C. 20404
Engines & Generators
...
III
INSTALLATION
When installing WESTERBEKE engines and generators it is important that strict
attention be paid to the following information:
CODES
AND
REGULATIONS
Strict federal regulations, ABYC guidelines, and safety codes must be complied with
when installing engines and generators in a marine environment.
SIPHON-BREAK
For installations where the exhaust manifold/water injected exhaust elbow is close to
or
will be below the vessel's waterline, provisions must be made to install a siphon-
break in the raw water supply hose to the exhaust elbow. This hose must
be
looped a
minimum
of
20" above the vessel's waterline. Failure to use a siphon-break
when
the
exhaust
manifold injection
port
is
at
or
below the load waterline will result
in
raw water damage to
the
engine
and
possible flooding
of
the boat.
If
you have any doubt about the position
of
the water-injected exhaust elbow relative
to the vessel's waterline under the vessel's various operating conditions,
install a
siphon-break.
NOTE:
A siphon-break requires periodic inspection
and
cleaning to ensure proper
operation. Failure to properly maintain a siphon-break can result in catastrophic
engine damage. Consult the siphon-break manufacturer
for
proper maintenance.
EXHAUST
SYSTEM
The exhaust hose must
be
certified for marine use. The system must be designed to
prevent water from entering the exhaust under any sea conditions and at any angle
of
the vessels hull.
Engines & Generators
iv
AVAILABLE
FROM
YOUR
WESTERBEKE
DEALER
TABLE
OF
CONTENTS
Parts
Identi'fication
....................................................
2
Testing
for
Overhaul
...................................................
3
Troubleshooting
Chart ...............................................
.4
Generator/Engine
Disassembly
..................................
6
Engine
Assembly
.........................................................
7
Timing
Belt
Disassembly
............................................
8
Engine
Disassembly
(p.12-p.31)
................................
12
Service
Data/Standards
and
Limits
...
.......................
32
Engine
Hardware
Torques .......................................
33a
Special
Tools -Engine
..............................................
34
Exhaust
Manifoldmeat
Exchanger
...........................
35
Coolant
Circulating
Pump
........................................
36
Raw
Water
Pump
.......................................................
37
Carburetor
.................................................................
38
Distributor
.................................................................
39
Starter
Motor
........
....................................................
40
Wiring
Diagram
.......
..................................................
44
Wiring
Schematic
....................................................
.45
Remote
Panel
Wiring ...............................................
.46
Testing
Relays
..........................................................
.47
Testing
the
Igniter
...................................................
.48
Governor
System
Components
and
Operation
........
.49
Panel
Wiring
Schematic
...........................................
50
Electronic
Governor
Troubleshooting
......................
51
Electronic
Governor
(Models
Prior
to
June
2004)
........
52
Electronic
Governor
Troubleshooting
......................
54
Engine
Adjustments
..................................................
55
Battery
Charge
Controller
........................................
58
Specifications
7.0Kw
...............................................
59
Specifications
5.0Kw
...............................................
60
Generator
Information
..............................................
61
BC
Generator
Testing
and
Troubleshooting
.............
62
(p.62-p.72)
Governor
Wiring
Diagram
.........................................
73
Terminal
Board
Connections
....................................
74
Shore
Power
Transfer
switch
...................................
74
Special
Tools-Generator
...........................................
75
Bolt
and
Nut
Tightening
Method
..............................
76
Standard
Hardware
....
...............................................
77
Sealants
and
Lubricants
...........................................
77
Metric
Conversion
Charts
........................................
78
Index
..........................................................................
81
Engines & Generators
1
CONTROL
PANEL
FLAME
SCREEN
EXHAUST
SWITCH
COOLANT
FI
THERMOSTAT
REAR
FUEL
FILTER
AIR
BLEED
PETCOCK
FRONT
PARTS
IDENTIFICATION
EXHAUST
MANI
FUEL
FUEL
FILTER
LEFT
SIDE
Engines & Generators
2
FILL
DISTRIBUTOR
I
I
__
----
THROTTLE
CONTROL
\\~,-----
OIL
DRAIN
HOSE
FILTER
RAW
WATER
PUMP
RIGHT
SIDE
CHARGER
__
~"u
..
FUSE
AC
CIRCUIT
BREAKER
HEAT
EXCHANGER
ZINC
ANODE
,FLEXIBLE
ISOLATED
MOUNTS
TESTING
FOR
OVERHAUL
HOW
TO'DETERMINE
ENGINE
OVERHAUL
PERIOD
Cause
of
Low
Compression
Generally, the time at which an engine should be overhauled
is detennined by various conditions such as lowered engine
power output, decreased compression pressure, and increased
fuel and oil consumption. The lowered engine power output
is not necessarily due to trouble with the engine itself, but is
sometimes caused by improper oil, clogged filters
or
a faulty
carburetor.
The
decrease in compression pressure is caused by many factors. It is, therefore, necessary to determine a cause or causes
on the basis
of
data produced by periodic inspection and
maintenance.
Oil analysis on a seasonal basis is a good
means
of
monitoring engine internal wear. When caused by
worn cylinders or piston rings, the following symptoms will
occur:
1 Low engine power output
2 Increased fuel consumption
3 Increased oil consumption
4
Hard
engine starting
5 Noisy engine operation
These symptoms often appear together. Symptoms 2 and 4
can result also from improper fuel regulation
or
a faulty carburetor. They are caused also by defective electrical devices
such as the battery, starter
or
spark plugs. Therefore it is
desirable to judge the optimum engine overhaul time by the
lowered compression pressure caused by worn cylinders and
pistons plus increased oil consumption. Satisfactory combustion is obtained only under sufficient compression pressure.
If
an engine lacks compression pressure, incomplete combus-
tion
of
fuel will take place even
if
other parts
of
the engine
are operating properly. To
detennine the period
of
engine
overhaul, it is important to measure the engine compression
pressure regularly.
At
the same time, the engine speed at
which the measurement
of
compression pressure is made
should
be
checked because the compression pressure varies
with engine rpm. The engine rpm can
be
measured
at
the
front
end
of
the crankshaft.
NOTE:
To
test engine compression see
the
ENGINE
ADJUSTMENT section
of
this
manual.
OVERHAUL
CONDITIONS
Compression pressure tends to increase a little in a new
engine until piston rings and valve seats have been broken in.
Thereafter, it decreases gradually with the progress
of
wear
of
these parts.
When decrease
of
compression pressure reaches the repair
limit, the engine must be overhauled.
The engine requires overhaul when oil consumption is high,
blowby evident, and compression values are
at
minimum or
below.
Engine compression should
be
178
psi (1260
Kpa)
at
400
rpm.
Wzth
a limit 137 psi
(860
/(paY.
Pressure should not
differ by
more
than
14 psi
(100
Kpa)
between
cylinders.
See
ENGINE COMPRESSION in this
manual.
ENGINE
OVERHAUL
The following sections contain detailed information
relating to the major components and systems
of
the engine.
Included are disassembly and inspection instructions for the
guidance
of
suitable equipped and staffed marine engine service and rebuilding facilities. The necessary procedures
should be undertaken only by such facilities.
Additional detailed information and specifications are
provided in other sections
of
this manual, covering the
generator, alternator,
starter. motof"engineadjllstments,
cooling pumps, etc.
DISASSEMBLY
1. Before disassembly and cleaning, carefully check for
defects which cannot
be
found after disassembly and
cleaning.
2. Clean the engine exterior.
3. Perform disassembly
in a proper order using proper tools.
Keep disassembled parts in order. Apply oil when neces-
. sary. Take special care to keep the
fuel
system parts
fro~
.
intrusion
of
dust and dirt.
SERIAL
NUMBE~
LOCATION~~
~
The
engine
serial
FiII
in
the information
t~(,~Ob')..
~,,!umber
is
st~mped
below for reference.
~.'
3?
~
\,
mto
the
engme
block.
~~
f\ll
~~~
.
"\
~l
'~
~
',<
:
11
The
engine
mo'-:;d~el~i~:~~~~~~~~~~
number
ands~~al
number
are
printed
on a decal
on
the
engine
manifold.
The
generator
serial
number
is
stamped
on
the
top
of
the
generator
ILUL~~.LJ:~MIIIiI
specijilcations
are
on a decal
on
the
side
of
the
generator.
An
additional
decal
is
located
on
the
top
of
the
generator
Iiousing.
Engines & Generators
3
BeG'
GENERATOR
TROUBLESHOOTING
The
following
troubleshooting chart describes certain
problems
relating to engine
service,
the
probable causes of
these problems,
and
the recommendations
to
overcome
these
problems.
Problem
HARD
STARTING
OR
FAILURE
TO
START
SMOKY
EXHAUST
EXCESSIVE
OIL
CONSUMPTION
ENGINE
BACKFIRES,
MISFIRES
Probable
Cause
1.
High
exhaust
pressure.
2.
Timing
belt.
3.
AC
generator
overload.
4.
Check
valve
at
fuel
supply.
5.
Defective
starter.
6.
Faulty
fuel
regulator.
7.
Raw
water
in
cylinders.
WHITISH , PURPLE
OR
BLUE
SMOKE
1.
Excessive
engine
oil.
2.
Excessive
rise
of
oil
into
combustion
chamber.
a.
Poor
piston
contact.
b.
Seized
piston
ring.
c.
Excessive
piston-to-cylinder
clearance.
d.
Worn
valve
stem
and
valve
guide.
e.
Low
engine
oil
Viscosity.
f.
Excessive
oil
pressure.
g.
Piston
rings
are
worn
or
unseated.
3.
Insufficient
compression.
BLACKISH
OR
DARK
GRAY
1.
Poor
compression.
2.
Improper
valve
clearance.
3.
Insufficient
intake
air
(air
cleaner
clogged).
4.
Improper
fuel.
OIL
LEAKAGE
1.
Defective
oil
seals.
2.
Broken
gear
case
gasket.
3.
Loose
gear
case
attaching
bolts.
4.
Loose
drain
plug.
5.
Loose
oil
pipe
connector.
6.
Broken
rocker
cover
gasket.
7.
Loose
rocker
cover
attaching
bolts.
OIL
LEVEL
RISING
1.
Dead
cylinder.
2.
Displaced
or
twisted
connecting
rod.
3.
Worn
piston
ring.
1.
Incorrect
valve
clearances.
2.
Valves
are
out
of
adjustment.
This
chart
may
be
of
assistance
in
determining
the
need
for
an
engine
overhaul.
For back-end troubleshoting, refer
to
the
BC
GENERATOR
ELECTRICAL
TESTING
section
in
this
manual.
VerificationJRemedy
1.
Install a larger
diameter
exhaust.
2.
Inspect
timing
be~-replace.
3.
Remove
loads
before
starting.
4.
Repair
or
replace
..
5.
Repair
or
replace
starter.
6.
Replace
regulator.
7.
Failure
of
exhaust
system
or
syphon
break.
Clear
cylinders-
Engine
may
need
overhaul.
1.
Correct
oil
level.
2.
Engine
overhaul.
a.
Check
standam.
b.
Replace
or
clean.
c.
Replace
or
correct.
d.
Replace.
e.
Replace.
f.
Correct.
g.
Engine
overhaul.
3.
See
LOW
COMPRESSION;
HARD
STARTING.
1.
See
LOWCOMPRESSION.
2.
Valve
adjustment.
3.
Replace
air
cleaner.
4.
Replace
with
proper
fuel.
1.
Replace
oil
seals.
2.
Replace
gasket.
3.
Retighten
bolts.
4.
Retighten
plug.
5.
Retighten
oil
connections.
6.
Replace
gasket.
7.
Retighten
attaching
bolts.
1.
Check
compression.
2.
Replace
connecting
rod.
3.
Replace
ring.
1.
Adjust
valves
and
clearances.
2.
Adjust
valves
and
clearances.
I~/WESTERBEKE
I Engines & Generators
4
BCG
ENGINE
TROUBLESHOOTING
PROBLEM
PROBABLE
CAUSE
VERIFICATIO
N/REMEDY
ABNORMAL
SOUND
CRANKSHAFT
AND
MAIN
BEARING
OR
NOISE
1.
Badly
worn
bearing.
1.
Replace
bearing
and
grind
crankshaft.
2.
Badly
worn
crankshaft.
2.
Grind
crankshaft.
3.
Melted
bearing.
3.
Replace
bearing
and
check
lubrication
systern.
CONNECTING
ROD
AND
CONNECTING
ROD
BEARING
1.
Worn
connecting
rod
big
end
bearing.
1.
Replace
bearing.
2.
Worn
crankpin.
2.
Grind
crankshaft.
3.
Bent
connecting
rod.
3.
Correct
bend
or
replace.
PISTON,
PISTON
PIN,
AND
PISTON
RING
1.
Worn
cylinder.
1.
Rebore
cylinder
to
oversize
and
replace
piston.
2.
Worn
piston
pin.
2.
Replace
piston.
3.
Piston
seized.
3.
Replace
piston
and
rebore
cylinder.
4.
Piston
seized
and
ring
worn
or
damaged.
4.
Replace
piston
and
rings.
VALVE
MECHANISM
1.
Worn
camshaft.
1.
Replace.
2.
Excessive
valve
clearance.
2.
Adjust.
3.
Worn
timing
gear.
3.
Replace.
4.
Worn
fan
pulley
bearing.
4.
Replace.
LOW
COMPRESSION
MAIN
ENGINE
TROUBLES
1.
Incorrect
valve
clearance.
1.
Adjust
valve
clearance.
2.
Inadequate
contact
of
valve
seat.
2.
Lap
valve.
3.
Valve
slem
seized.
3.
Replace
valve
and
valve
guide.
4.
Broken
valve
spring.
4.
Replace
valve
spring.
5.
Compression
leaks
through
cylinder
head
gasket.
5.
Replace
gasket.
6.
Piston
ring
seized.
6.
Replace
piston
and
piston
ring.
7.
Worn
piston
ring
and
cylinder.
7.
Overhaul
engine.
S.
Worn
engine
bearings.
S.
Overhaul
engine.
EXCESSIVE
FUEL
CONSUMPTION
1.
Noisy
knocking.
1.
See
KNOCKING.
2.
Smoky
exhaust.
2.
See
SMOKY
EXHAUST.
3.
Moving
parts
nearly
seized
or
excessively
worn.
3.
Repair
or
replace.
4.
Poor
compression.
4.
See
LOW
COMPRESSION;
HARD
STARTING.
5.
Improper
valve
timing.
5.
Adjust.
6.
Improper
valve
clearance.
6.
Adjust.
INSUFFICIENT
INTAKE
AIR
1.
Air
intake
obstructed.
1.
Remove
obstruction.
NOZZLE
TROUBLES
1.
Seized
nozzle.
1.
Replace.
2.
Worn
nozzle.
2.
Replace.
KNOCKING
ENGINE
KNOCKS
WITHOUT
MUCH
SMOKE
1.
Main
engine
troubles.
a.Overheated
cylinder.
a.
See
OVERHEATING;
LOW
OUTPUT.
b.Carbon
deposits
in
cylinder.
b.
Clean.
KNOCKING
WITH
DARK
SMOKE
1.
Poor
compression.
1.
See
LOW
COMPRESSION;
HARD
STARTING.
LOW
OIL
PRESSURE
1.
Worn
Bearings.
1.
Engine
overhaul
replace
bearings.
2.
Relief
valve
malfunction.
2.
Overhaul
oil
pump.
3.
Clogged
oil
cooler/fdter.
3.
Repair
and
replace.
4.
Diesel
dilution
of
the
oil.
4.
Injection
pump
repair.
Engines & Generators
5
GENERATOR/ENGINE
DISASSEMBLY
DESCRIPTION
The engine component
of
the BC generator is not as bulky or
heavy as most engines (approx. 75 lbs) so it can be
disassembled and repaired on a sturdy work bench. make
certain however that the engine is securely fastened so
it
can
not topple
off
the bench and that the bench also is secure and
can not tip over.
Set the generator breakers and panel switches in the off
position. Disconnect the AC wiring connections at the
terminal block/circuit breaker and unplug the harness at the
control pane. Disconnect the battery cable connections and
the engine ground cables.
Close off the raw water seacock and disconnect the raw
water components. Separate the exhaust at the water injection
elbow and disconnect the fuel supply.
A
CAUTION:
Make
certain
the
fuel
lines
are
closed
off
and
drained.
Clean
up
all
fuel
and
oil
spills
and
properly
dispose
of
the
rags.
STARTER
MOTOR
HOUSING
TYPICAL
BC
GENERATOR
BACK-END
ASSEMBLY
Unfasten the generator from its mounting rails or the
mounting rails from the platform and remove the generator
from the boat.
Once the generator is securely mounted on the work bench,
drain the engine oil and coolant.
Remove the starter motor. Disconnect and remove the wiring
harness, be certain to tag
all the wiring -connections so you
can separate them.
Separate the generator back-end from the engine.
Once the
housing is removed, the remaining generator components can
be disassembled from the engine back-plate.
NOTE:
For servicing and testing
of
the back-end (generator),
refer to the GENERATOR section in this manual.
ASSEMBLY
BOLTS
GENERATOR
i:-REMOVE
USING
AN
BMM
(tt/t6')
SOCKET
~ifl!(r?
TO
DRAIN
THE
OIL
OR
PUMP
THE
WARMED
OIL
UP
THRU
THE
HOSE.
COOLANT
DRAIN
LOCATED
JUST
BELOW
THE
INTAKE
MANIFOLD
Engines & Generators
6
GENERATOR
BACK·END
SEE
SPECIAL
TOOLS
FOR
DISASSEMBLING
THE
GENERATOR
COMPONENTS
ENGINE
ASSEMBLY
GENERAL
INFORMATION
• Be careful not
to
mix
bolts and nuts. Metric and S.A.E.
bolts are used on various engine assemblies.
• During assembly,
recheck
clearances and insure that parts
are being assembled in their proper order and facing in the
correct direction in relation to the engine block, such as,
pistons, piston rings, bearings and bearing caps.
• Apply lubricating oil to
moving
parts during assembly.
Insure that moving parts,
when
assembled
on
the engine,
rotate
or slide and are
not
subject to binding or
excessive tension.
•
If
!!here
are mating
marks
scribed during disassembly,
reference them correctly for assembly.
• Use new gaskets, lockwashers, O-rings, packings and seals.
• Tighten the bolts and nuts
on
important parts
of
the engine
to specified torques using a reliable torque wrench.
• When required, use liquid sealants when required on nuts,
bolts and gaskets. Refrain
from
using tape sealants.
• Most gaskets and
many
bolt
washers are asymmetrical,
make certain they are positioned properly.
Torquing
Hardware
Prevent mechanical
damage
by
running fasteners down in
three
steps-1/2,
213,
and
111
torque. Exceptions are torque-to-
yield bolts and rocker
arm
shaft
fasteners.
The
former are
torqued as indicated.
The
latter-rocker shaft fasteners-should
be
brought down in very small increments, working from the
center bolts out. Gaskets, especially head gaskets, might be
damaged during assembly, they should be positioned with great
care.
See
TORQUE
SPECIFICATIONS thru out this manual.
Sealants
and
Lubricants
Oil based
PERMAlEX
#2
and
its HIGH TACK equivalent are
excellent all purpose sealers.
They
are effective in
just
about
any joint in contact with coolant, raw water, oil, or fuel. A light
coating
of
oil or LIQUID
TEFLON
can be used on rubber
gaskets and a-rings.
LOCTITE hydraulic red sealant should be used on oil adapter
hoses and the oil filter assembly.
Coat both surfaces
of
the oil
pan
gasket with high temp RED
SILICONE SEALER.
When installing gaskets that seal around water (coolant)
passages, coat both sides with
WHITE
SILICONE GREASE.
Do not use sealant when installing a new gasket.
HIGH-COPPER
ADHESNE
SPRAYS are useful for hold-
ing a gasket in position during assembly.
Specialized gasket sealers
such
as HYLOMAR work well in
applications requiring non-hardening properties.
HYL011AR
is particularly effective on
copper
cylinder-head gaskets and
resists fuel, oil , and water.
NOTE:
TAPE
SEAlANTS should be used
on
pipe
plugs
and
fitting that connect water coolant passages.
Bolts
and
Fasteners
Lightly oil head bolts and other fasteners
as
you assemble
them. Bolts and other plugs that penetrate the water jacket
should
be
sealed with PERMATEX #2 or HIGH TACK.
When assembling the flywheel, coat the bolt threads with
LOCTITE blue.
LITHIUM based grease is waterproof, ideal for water pump
bearings and stuffing boxes.
Antiseize compounds and thread locking adhesives such as
LOCTITE
protect threaded components yet allow them to
come
apart when necessary.
LOCKTITE
offers levels
of
locking according to the job.
Heavily oil all sliding and reciprocating components, always
use clean engine oil.
Engines &
Generators
7
TIMING
BELT
DISASSEMBLY
NUMBERS
INDICATE
THE
SUGGESTED
ORDER
OF
DISASSEMBLY
TORQUE
1 -9
Ft-Lbs
10-12Nm
1
TIMING
BELT
COVER
A
3
ACCESS
CDVER~
9
CAMSHAFT
SPROCKET
TORQUE
1 -9
FT-LBS
10-12Nm
\
\
12
CRANKSHAFT
BOLT
13
CRANKSHAFT
10
FLANGE
NUT
SPROCKET
TORQUE
36
-
40
FHBS
[50
-56
NmJ
TIMING
BELT
ADJUSTMENT,
INSPECTION
AND
REPLACEMENT
CAN
BE
PERFORMED
WITH
ENGINE
IN
THE
BOAT
TORQUE
98 -
105
Fr-LBS
135
-145
Nm
TIMING
BELT
COVER
C
INSTRUCTIONS
FOR
INSPECTING
AND
REPLACING
THE
TIMING
BELT
WESTERBEKE requires
as
normal maintenance, replacing
the timing belt after
1000 engine operating hours. The timing
belt should always
be
replaced during an engine overhaul.
The adjustments, inspection, and replacement procedures
may be performed without removing the generator from the
boat
THE
TIMING
BELT
PART
NUMBER
IS
#043036
Timing
Belt
Removal
1.
Tum
the crankshaft clockwise to align the timing mark on
the camshaft sprocket and timing belt rear cover.
NOTE:
Always tum the crankshaft clockwise.
TIMING
MARK
-=>~-/'
2. Remove the plug on the left smface
of
the cylinder block
and insert a rod with a diameter
of
0.31 in (8 mm) to lock
the counterbalance shaft.
NOTE:
Be
sure
to
use
an inserting
rod
with
a diameter
of
0.31
in
(8
mm).
(::::j.<,--....u..,~...,-
~----'-'2.6
In
[65
mm]
ROD
0.3110
[8
mm]
3, Loosen the timing belt tensioner
nut
4. Move the timing belt tensioner toward the water pump,
and temporarily tighten the nut to hold the tensioner in
that position.
Engines & Generators
CRANKSHAFT
SPROCKET
8
TIMING
BELT
DISASSEMBLY
5.
Remove
the
timing belt.
NOTE:
If
the
timing
belt
is
to
be
reused,
draw an arrow
on
the
belt
to
indicate the direction
of
rotation (clockwise).
Camshaft
Sprocket
Removal
1.
Remove
the
camshaft sprocket bolt without turning
the
camshaft.
SPROCKET
BOLT
Oil
Pump
Sprock~t
Flange
Nut
Removal
1.
Remove
the
plug
from
the
left side of the cylinder
block.
2.
Insert
an
0.31
in
(8
mm)
diameter round bar to lock
the
counterbalance shaft.
3.
Remove
the
oil pump sprocket
flange
nut.
OIL
PUMP
SPROCKET
Crankshaft
Bolt
Removal
1.
Lock
the
crankshaft
in
position.
NOTE:
Do
not turn
the
crankshaft.
2.
Remove
the
crankshaft
bolt.
Timing
Bell
Inspection
Replace
the
belt
if
any of
the
following conditions
exist:
•
HllI'dening
of
the back
rubber,
leaves
no
indent
when
pressed
with
fingernail
(back
side
is
glossy).
•
Cracks
on
rubber
back.
•
Cracks
or peeling of
canvas.
•
Cracks
on
tooth
bottom.
•
Cracks
on
belt.
•
Abnormal
wear of
belt
sides.
The sides are normal if
they
are
sharp
as
if
cut
by a knife.
•
Abnormal
wear
on
teeth.
•
Tooth
missing and
canvas
fiber
exposed.
HARDENING
~
'v.
~
F
00
PEELING
00
$
CRACKS
ON
UNDERSIZE
CRACKS
ON
TOP
Tensioner
Inspection
CRACKS
ON
EDGE
ROUNDED
EDGES
FLUFFY
STRANDS
TOOTH
MISSING
CANVAS
EXPOSED
1.
Replace
the
tensioner if
the
pulley
binds,
rattles or
is
noisy
when
turned.
Engines & Generators
9
ENGINE
TIMING
BELT
Flange
Installation
1.
Mount
the
flange
so
that its side shown
by
the heavy
arrow
in
the
illustration faces toward
the
sprocket.
R--rri~
-~
WASHER
Crankshaft
Bolt
Installation
1.
Lock
the
crankshaft.
NOTE:
Do not
tum
the crankshaft.
2. Tighten
the
crankshaft bolt
to
the specified torque.
Oil
Pump
Sprocket
Flange
Nut
Installation
1.
Insert
the
round
_bar
into the plug
hole
in the left side
of
the cylinder block
to
keep the counterbalance shaft from
turning.
2.
Install the
oil
pump sprocket.
Camshaft
Sprocket
Bolt
Installation
1.
Tighten the bolt to the specified
torque.
CAMSHAFT
BOLT
TORQUE
58 -72
Ft-Ibs
(80
-100
Nm)
SPROCKET
BOLT
Tensioner
Spring/Timing
Tensioner
Installation
1.
Install
the
tensioner spring and timing belt
tensioner.
2. Hook
the
tensioner spring onto
the
bend
of the timing belt
tensioner bracket
and
the stopper
pin
on
the cylinder
block.
3.
Move
the
timing
belt tensioner
as
close
as
possible
to
the
water
pump;
temporarily tighten
the
tensioner
nut.
Timing
Belt
Installation
1.
Align
the
triangular marking on the camshaft sprocket
with a marking on the timing belt rear
cover.
2.
Align
the
notch
in
the crankshaft sprocket flange
with
the
marking
on
the
front case.
3. Align
the
triangular marking on
the
oil
pump sprocket
with
the
marking
on
the front case,
and
then
insert a
2.56
in.
(65
mm.)
or
longer,
0.31
in
(8mm.) diameter round
bar
into
the plug hole
in
the left side of the cylinder block.
MARK
ON
TIMING
BELT
REAR
COVER
__
N'-P
NOTCH
IN
CRANKSHAFT
SPROCKET
MARK
ON
FRONT
CASE
Engines & Generators
10
ENGINE
TIMING
BELT
At this time, check that the moveable range
of
teeth on the
oil pump sprocket
is
according to specifications.
STANDARD
VALUE:
410 5 teeth
in
forward
direction.
1
to
2
teeth
in
reverse
direction.
4.
If
the movable range
of
the teeth
on
the oil pump sprocket
exceeds the specified range, correct as follows:
a.
Pull out the round bar from the plug hole in the left
side
of
the cylinder block.
h.
Turn
the oil pump sprocket one
tum
at
a time until the
round bar can again be inserted.
c.
Check that the movable range
of
the oil pump sprocket
is in the specified value.
5.
Set the timing belt over the crankshaft sprocket and then
over the oil pump sprocket
and
camshaft sprocket,
in
that
order.
NOTE:
Ensure
that
the
tension
side
of
the
timing belt
is
not
slack.
Keep
the
round
bar inserted until
the
timing
belt has
been
placed.
After
this
step,
be
sure
to
remove
the
round
bar.
6. Apply counterclockwise force to the camshaft sprocket
to
make the belt taut on the tension side, and make sure that
all timing marks are lined up.
CAMSHAFT
SPROCKET
TENSION
SIDE
7. Loosen the temperorarily tightened tensioner nut on the
water pump side 1 or 2 turns, and tension the belt making
use
of
the spring force.
8. Tum the crankshaft
clockwise by nine camshaft sprocket
teeth
(81°)
to
align the timing mark on the camshaft
sprocket with the tensioner set mark on the timing belt
rear cover.
A
CAUTION:
This
operation
is
performed
to
give
a
proper
tension
to
the
timing
belt,
so
do
not
tum
the
crankshaft
counterclockwise
and
push
the
belt
to
check
the
tension.
TENSIONER
SET
MARK
9. Make sure that the timing belt teeth are engaged with the
camshaft sprocket teeth along the portion
of
the sprocket
shown by the curved arrow in the illustration below. Then
tighten the tensioner nut.
lO.Pull the timing belt in the center
of
the tension side
toward the sealing gasket line for the belt cover, as illus-
trated. Make sure that the clearance between the back of
the belt and the sealing line is the standard value.
STANDARD
VALUE:
O.47in.
(12mm)
SEALING
GASKET
LINE
0.47
In
[12
mmJ
1l.PulI out the rod from the plug hole on the left surface
of
the cylinder block and apply the specified sealant. Then
tighten the plug to the specified torque.
Specified sealant value: 3M
AID
Part No. 8660 or
equivalent.
TIGHTENING
TORQUE:
11-16
ft.lbs.
(15-22
Nm)
Engines & Generators
11
ENGINE
DISASSEMBLY
Disconnect
and
drain
the
oil
hoses.
remove,
clean
and
inspect
the
oil gallery/filter
assembly,
replace the
filter.
Remove
the
thermostat assembly
and
clean
the
interior
chambers.
Inspect
the
seals
in
the
pressure
cap
when
reassembling. Replace the thermostat
and
gasket.
GASKET
APPLY
SEALANT
TO
GASKET
WHEN
INSTALLING
THERMOSTAT
Loosen
the
raw
water
pump,
remove
the
drive belt
and
then
remove
the
raw
water
pump.
RAWWATEfi
PUMP
FILTER
~
FUEL
FILTER
ASSEMBLY
Remove the
fuel
filter
assembly.
Drain and inspect
the
hoses.
Inspect
the
O-ring
and
replace
the
filter
element.
Remove
the
engines coolant
pump.
For servicing, refer
to
COOLANT
PUMP.
Detach
and
remove
the
ignition
wires,
the distributor
and
spark
plugs.
Refer to DISTRIBUTOR DISASSEMBLY
in
this
manual.
See
ENGINE ADJUSTMENTS for information on ignition
wires
and
spark plugs.
SPWFtU~·
•
..-v-
WESTERBEKE
Engines & Generators
12
\
4CYLINDER
HEAD
BOLTS.
TORQUE
43 -51
FT-LI3S
60-10Nm
'\
~~.
r.
-~
7RETAlNINGLOCK~
.~
8
VALVE
S:~RIN:~~
RETAIN/
~
9
VALVE
SPRING
SEAL
10
VALVE
SPRING
19VALVEGUIDE-
If
16
EXHAUST
VALVE----4
REMOVING
THE
CYLINDER
HEAD
FROM
THE
CYLINDER
BLOCK
Disassemble the cover bolts as shown above, taking care not
to lose the washer and insert. Remove the rocker cover and
rocker cover gasket.
Loosen each
of
the cylinder head bolts, a little at a time so
as
to
avoid the possibility
of
distorting the cylinder. Repeat
several times until the bolts are unfastened. Follow the
sequence shown in the diagram.
Remove the cylinder head and the cylinder head gasket.
15
CYLINDER
HEAD
INTAKE
VALVE
SEAT
Engines & Generators
13
NUMBERS
INDICATE
THE
SUGGESTED
ORDER
OF
DISASSEMBLY
8 6
CYLINDER
HEAD
BOLTS
LOOSENING
SEQUENCE
CYLINDER
HEAD
AND
VALVES
Use
pliers
to
remove the valve stem seals. Do
not
reuse
the
stem
seals.
CYLINDER
HEAD
INSPECTION
Before
cleaning
check the cylinder head for water
leaks,
cracks
and
other
possible damage.
Clean
by
completely
removing the oil, scaling, carbon
and
sealant After
flushing
the oil passage, blow
air
thru
to
ensure
that
no
portion
of the oil passage
is
clogged.
To
check
the
cylinder head bottom surface for
flatness
and
distortion,
as
indicated in the diagram, use a straight edge
and
a feeler
gauge.
If
distortion exceeds the limit correct
by
grinding.
CYLINDER
HEAD
FLATNESS
standard
O.02Oln
(0.05mm)
CYLINDER
HEAD
GRINDING
LIMIT
0.079In
(0.2mm)
Limit
0.079
(0.2mm)
Total
resurfacing
depth
of
cylinder
head
and
block
CYLINDER
HEAD
HEIGHT
(NEW)
4.287 -4.2951n
(108.9
-109.1mm)
A
CAUTION:
No
more
than
0.079In
(O.2mm)
of
stock
may
be
removed
from
the
cylinder
head
and
cylinder
block
mating
surfaces
in
total.
See
the
STANDARDS
AND
UMITS
CHART
for
cylinder
head
rework
dimensions of the valve seat hole.
VALVE
ASSEMBLY
INSPECTION
Valve
SteroNalve
Seat
If
the valve stem
is
bent
or
worn,
replace the
valve.
Check
contact between the valve
and
valve seat
by
applying a
thin
coat
of
Prussion Blue (or Redhead)
on
the valve seat contact
face,
then insert the valve into the valve guide and
press-fit
the valve
on
the valve
seat.
Do
not rotate the valve.
Check
if
the valve seat contact face contacts the center posi-
tion
0f the valve contact
face.
If
it
is
not correct
concentric,
correct the valve seat
If
the
margin
is
out
of
the
limit, replace
the
valve.
THICKNESS
OF
VALVE
HEAD
MARGIN
standard
Intake
0.0391n
(1.0mm)
Exhaust
0:051In
(1.3mm)
Limit
0.02010
(0.508mm)
0.031
In
(0.787mm)
CONTACT
WITH
VAlVE
SEAT
[to
be
at
center
of
sea
-
---r--
VALVE
HEAD
THICKNESS
[MARGIN]
.L
VAlVE
LENGTH:
Intake
3.6010
(100.6mm)
'Exhaust
3.96810
(100.8mm)
VALVE
SEAT
WIDTH
OF
CONTACT
standard
0.03510 -0.051
(0.9
-1.3mm)
Valve
Spring
VALVE
LENGTH
Measure the
free
height of
the
valve spring
and
replace
the
spring
if
it is out of limit
VALVE
SPRING
FREE
LENGTH
Standard
1.823In
{46.3mm)
____
Umlt
1.783ln
(45.3
mm)
MEASURING
VAlVE
SPRING
FREE
LENGTH
Also
check
the
spring
for
squareness
and
if
it exceeds
the
limit replace the spring.
VAlVE
SPRING
SQUARENESS
Standard
less
than
2°
Limit
4°
Refer
to
the StandardslLimits chart
for
additional
specifications
on
valves.
TESTING
SQUARENESS/ANGLE
Engines & Generators
14
CYLINDER
HEAD
AND
VALVES
Valve
Stem
and
Guides
MEASUR;NG
VALVE
STEM
DIAMETER
VALVE
STEM
SEAL
TO
VALVE
GUIDE
CLEARANCE
Standard
Intake
Exhaust
Limit
Intake
Exhaust
0.0008 -0.0020in
(0.7 -0.05mm)
0.020 -0.0033in
(0.50 -0.085mm)
0.00391n
(O.10mm)
O.0059in
(0.15mm)
VALVE
STEM
OUTER
DIAMETER
Standard
Intake
Exhaust
0.2585 -0.25911n
(6.565 -6.580mm)
0.2571 -0.2579in
(6.330 -6.550mm)
Valve
Seat
Reconditioning
Before correcting the valve seat, check
for
clearance
, between
the
valve guide and the valve. replace
the
valve
guide
if
necessary.
To
recondition, use a valve and seat cutter and a pilot or a
seat grinder, repair
so
that the seat width and seat angle are
the
specified configuration.
After correction, the valve and
the
valve seat should be
lapped with lapping compound.
INSTALLATION
Valve
Stem
Seal
VALVE
SEAT
CONTACT
WIDTH
.035 -.051
in
[0.9
-1.3
mml
Install
the
valve
spring seat,
then
using the valve
stem
seal
installer, install a new stem seal
to
the
valve guide.
Do
not use
the
old valve stem seal.
NOTE:
Use
the
installer tool
to
insert
the
stem
seal,
improper
installation
can
cause
oil
to
leak
into
the
cylinder.
VALVE
STEM
SEAL
INSTALLER
Valve
Springs
~
VALVE
STEM
SEAL
Install the valve spring
with
it's enamel coated side
toward
the
rocker arm
side.
ENAMel
COATED
SIDE
~~~~
~;---SPIRINIi
RETAINER
SEAT
Use
the valve spring compressor
to
compress
the
valve
::,::
:.
tho
v,"ve
s;;;omP"~'
remove
the
REMOVING
RETAINER
LOCKS
Cylinder
Head
Gasket
I J
VALVE
SPRING
f
COMPRESSOR
Clean the residue of gasket
and
oil
from
the gasket
mounting
surface
of
the cylinder block and the cylinder
head.
Place a
new
cylinder head gasket
on
the
cylinder block
facing its identification
mark
upward.
CYLINDER
HEAD
GASKET
Engines & Generators
15
CYLINDER
HEAD
AND
VALVES
Cylinder
Head
Bolts
Tighten the cylinder head bolts in the order shown in the diagram using a stepped-up tightening torque.
1.
Temporarily tighten the bolts in numerical order
to
14-
22ft-lbs (20 - 30 Nm).
2. Tighten the bolts again in numerical order to 29 - 36ft-Ibs
(40- 50Nm).
3. Tighten the bolts in numerical order to the specified
torque.
CYLINDER
HEAD
TORQUE
43
-51fHbs
(50-
70Nm)
Rocker
Cover
Install the rocker cover using a new gasket (slightly coat both
sides with clean oil). Gradually tighten the cover bolts to the
specified torque making certain the cover gasket is positioned
properly.
ROCKER
COVER
BOLT
TORQUE
(5mm
BOLT)
2.9·5.2
ft·lbs
(4
·7Nm)
ENGINE
FRONT
Engines & Generators
16
INTAKE
SIDE
EXHAUST
SIDE
CYLINDER
HEAD
BOLTS
TIGHTENING
SEQUENCE
CAMSHAFT
AND
ROCKER
ARMS
TORQUE
21 -25
FT-LBS
TORQUE
21 -25
Ft-Lbs
2! . 35
Nm
~
21-35Nm
----,
il
NUMBERS
INDICATE
THE
SUGGESTED
ORDER
OF
DISASSEMBLY
10
ROCKER
ARM
®
EXHAUST
1
ROCKER
ARM,
ROCKER
SHAFT
ASSEMBLY
12CAMSHAFT
®
OILSEAL
~
INSPECTING
THE
CAMSHAFT
1.
Visually inspection the camshaft for cracks and damage.
If
necessary, replace the camshaft.
NOTE:
lfthe
damage is slight, you
may
be able to correct the
camshaft with an oil soaked fine
emery
grindstone.
Take
special
care
to not damage
the
original cam/arm.
2. Inspect the camshaft journal and,
if
wearing exceeds the
limit, replace the camshaft.
CAMSHAFT
JOURNAL
DIAMETER
STANDARD
'.6118 -
1.61241n
(40.940 -40.955mm)
CHECK
CAM
LOBES
FOR
WEAR & DAMAGE
CHECK
JOURNAL
BEARINGS
FOR
WEAR
DAMAGE
Camshaft
NOTE:
lfthe
Journal is seized, also check the cylinder head!
3. Measure the cam height and,
if
it
is
less than the limit,
replace the camshaft.
CAMSHAFT
HEIGHT
Intake
#1
#2
#3
Exhaust
#1
#2
#3
C:C-~O'
HEIGHT
~.
STANDARD
1.38151n
(35.09mm)
1.38071n
(35.07mm)
1.38031n
(35.06mm)
1.38391n
(35.15mm)
1.38311n
(35.13mm)
1.38541n
(35~19mm)
14
CAMSHAFT
LIMIT
1
.36181n
(34.59mm)
1.3610in
(34.57mm)
1.3606in
(34.56mm)
1.3642in
(34.65mm)
1.3634in
(34.63mm)
1.3657in
(34.69mm)
MEASURING
CAMSHAFT
HEIGHT
4. Inspect the clearance between the camshaft journal and
the camshaft support bore as follows:
a. Measure the camshaft journal diameter and the
camshaft support bore.
h. Calculate the clearance and replace the camshaft
or
cylinder head
if
the clearance exceeds the limit.
BEARING
OIL
CLEARANCE
STANDARD
0.0018 -0.0033in
(.045·
0.085mm)
Engines & Generators
17
CAMSHAFT
AND
ROCKER
ARMS
Rocker
Arm
Check each component part
of
the rocker arm assembly and
carefully inspect the individual rockers where the arrows
indicate.
ROCKER
ARM
INSPECTION
Inspecting
Clearance
Rocker
Arm
And
Shaft
Check the clearance between the rocker arm and shaft and,
if
it
exce,eds the limit, replace the rocker arm or shaft.
ROCKER
ARM
CLEARANCE
(ROCKER
ARM
TO
SHAFT)
Standard
0.0005 -O.0017in
(D.012 -O.043mm)
Limit
0.004in
(O.1mm)
Rocker
Shaft
1. Inspect the rocker shaft where the rocker arms sit for
water and damage. Replace the shaft
if
worn.
2. Measure the shaft length and the shaft outer diameter
(O.D.).
If
the shaft fails to meet the standards, replace
the shaft.
ROCKER
SHAFT
LENGTH
Standard
9.134in
(232mm)
ROCKER
SHAFT
0.0.
Standard
16.985 • 16.988in
(0.6687 -0.6693mm)
~
~~II
Or]
J
OIL
HOLES
OIL
HOLES
INSTALLATION
1. Apply a coating
of
engine oil
to
the camshaft journals
and cams and insert the camshaft through the rear
of
the
cylinder head.
2.
Install the camshaft thrust plate as shown in the diagram
tighten the bolts
to
the specified torque.
THRUST
PLATE
BOLTTORQUE
7 -
91t-lbs
(10
-12Nm)
TORQUE
BOLT
3. Measure the end play
of
the camshaft by inserting a
feeler gauge in the gap between the rear
of
the thrust
plate and the new front camshaft journal.
VALVE
Standard
0.236 -0.0551
in
(0.06 -0.14mm)
Limit
0.1181n
(O.3mm)
4. Using the oil seal installer tool, install the front
oil
seal in
the cylinder
head,
5.
Install the rocker armlrockershaft assembly. Install the
rocker shaft so the portion shown in the diagram
is
located on the front.
BOLT
HOLE
FRONT
BOTTOM
VIEW
OIL
HOLE
6. Tighten the rocker arm shaft bolts (4 bolts) uniformly and
then to the specified torque.
ROCKER
ARM
SHAFT
BOLT
TORQUE
21 • 25ft·lbs
(29 -35
Nm)
Engines & Generators
18
PISTONS
AND
CONNECTING
RODS
ARROW
FRONT
MARK
-,
NUMBERS
INDICATE
THE
SUGGESTED
ORDER
OF
DISASSEMBLY
gOIL
RING
REMOVING
THE
CONNECTING
RODS/PISTONS
Tum the engine over and remove the connecting rod bearing
caps and the connecting rod bearings, note the markings on
the bearing cap and keep the disassembled parts (connecting
rod, rod cap, piston, etc. classified by cylinder.
If
the marks
are worn away be certain to remark them.
Disassemble
the
Pistons
Using the ring remover, remove the piston rings. While
removing the piston rings, note the order they are removed
and which side
of
the ring faces the piston crown.
11
PISTON
RING
\~~~
111
PISTON
RING
112
PISTON
RING
BOLT
STOPPER
NOTCH
Remove
the
Piston
Pins
CYLINDER
NUMBER
Insert the special tool, push the rod, and guide B into the
piston pin then set the piston and connecting rod assembly
on the pin setting base. Make certain that the front (arrow)
stamped on the piston top surface faces upwards. Using a
press, drive out the piston pin.
NOTE:
Keep
the
disassembled
piston,
piston pin and
connecting
rod
in
order
according
to
the
cylinder
number.
Engines & Generators
19
PISTONS
AND
CONNECTING
RODS
PISTON
PIN
INSPECTION
Reinsert the piston pin into the piston hole with your thumb
..
You
should feel a slight resistance,
if
the bore is misaligned·
the pin will click or bind as
it
enters. Try the pin from both
sides. Replace the piston
if
the pin can be too easily inserted
or if there is excessive play.
NOTE:
The
piston
pin
and
piston
are
replaced
as
an
assembly.
Measure the outside diameter
of
the piston pin.
PISTON
PIN
0.0.0.6300 -0.6302in
(16.001
-16.007mm)
Pistons
Check the piston surfaces for wear, seizure, cracks and
streaking.
If
any damage is evident, replace the piston.
Inspect the oil return hole in
the
oil ring groove and the oil
hole in the piston boss. Clean the piston
if
these are clogged.
Check the piston pin hole
for
signs
of
seizure
or
damage.
Replace the piston
if
damage
is
evident
Measure the piston
diameter at
90° (perpendicular)
to
the pin bore axis.
PISTON
0.0.2.5579 -2.55911n
(64.97 -65.00mm)
If
the piston diameter is less then the standard replace
the piston.
NOTE:
The
piston
and
piston pin
are
replaced
as
an
assembly.
Piston
Rings
Insert the piston ring into the cylinder bore placing it against
the top
of
the piston head and pressing it in. When it marks a
right angle, measure the piston ring gap with a feeler gauge.
When the gap
is
too large, replace the piston ring.
PISTON
RING
GROOVE
Standard
No.1
0.0480 • 0.04881n
(1.22
·1.24mm)
No
2
0.0476 -0.04841n
(1.21 • 1.23mm)
Oil
0.1108
-0.1116In
(2.815 -2.835mm)
PISTON
RING
END
GAP
No.1
No.2
Oil
PISTON
Standard
0.0059·
0.01181n
(0.15 -0.30mm)
0.0138·
0.01971n
(0.35 -0.50mm)
0.008·0.028In
(0.2 -0.7mm)
limit
0.81n
(0.0315mm)
0.8in
(0.0315mm)
1.Oin
(0.0394mm)
Check the piston ring for damage, wear, seizure and bends
replacing the rings
if anything unusual
is
noted. Always
replace the piston rings when installing a new piston.
RING
SIDE
CLEARANCE
FEELER
GAUGE
Check the clearance between the piston ring and the ring
groove,
if
it exceeds the limit, replace the rings, the piston
or
both.
PISTON
RING
SIDE
CLEARANCE
Standard
Limit
No.1
ring
No.2
ring
0.0012'
0.0028in
(0.03 -0.07mm)
0.00471n
(0.12mm)
0.0008·
0.0024in
(0.02·
0.06mm)
0.00391n
(0.10mm)
Connecting
Rod
Bearing
Visually check the surface
of
the bearing. Replace those
which are lopsided, streaked
or
seized. When streaks or
seizure are excessive, check the crankshaft.
If
damage is
discovered on the crankshaft, either replace
it
or reuse after
undersize machining.
If
the connecting rod bearing indicates
severe thermal damage, replace the bearing.
Measure the inner diameter
of
the connecting rod bearing
and the outer diameter
of
the crankshaft pin.
If
the gap (oil
clearance) exceeds the limit, replace the bearing, and,
if
necessary, the crankshaft...or undersize machine the crankshaft
and replace the bearings with an appropriate undersize type.
CONNECTING
ROD
BEARING
OIL
CLEARANCE
Standard
Limit
0.009 -0.00201n
(0.022 -0.052mm)
0.0041n
(0.1mm)
CONNECTING
ROO
__ .........
....
PISTON
RING
GAP
Engines & Generators
20
PISTONS
AND
CONNECTING
RODS
NOTE:
See
Crankshaft/Bearing
section
for measuring
the
oil
clearance
with
a Plastigauge.
Use a rod aligner to check the connecting rod for bend and
twist.
CONNECTING
ROD
BEND
LIMIT
D.DD4in
(D.OSmm)
CONNECTING
ROD
TWIST
LIMIT
D.004in
(0.1mm)
CONNECTING
ROD
BIG
END
TO
CRANKSHAFT
SIDE
CLEARANCE
Standard
0.0039 -D.DD9Sin
(0.10 -D.2Smm)
CONNECTING
ROD
CENTER
LENGTH
Standard
4.0138 -4.D178in
(101.9S
-1D2.0Smm)
ASSEMBLY
Piston
Connecting
Rod,
Piston
Using the special tool (pin setting base) assemble the
piston and connecting rod and press-in the piston pin. First,
install the piston pin into the special tool,
GUIDE
A
PUSH
ROD
Set up the piston and connecting rod on the piston pin setting
base. Make sure that the front marks are facing up. Apply
engine oil to the outer circumference
of
the piston pin and
insert the pin, Guide A and the push rod (assembled) into the
piston and connecting rod.
Using a press, load the push rod top end and press-fit the
piston pin in the connecting rod. The piston pin is press
fitted
in
the specified position by
press-fitt~ng
the Guide A
bottom end surface until it is seated on the bottom surface
of
the base.
If
the press-fitting load is out
of
the specification,
replace the pin (piston assembly) or connecting rod,
or
both.
PISTON
PIN
PRESS-FITTING
LOAD
1102 -33071bs
(SDDD
-15DONm)
Oil
Ring
Assemble the oil ring spacer into the piston ring groove.
Then, after assembling the upper side rail, assemble
the
lower side rail.
NOTE:
There
is
no
difference
between
the
upper and
lower
m
SIDE
RAIL
side
rails
or
the
spacers.
//https://manualmachine.com/-
~~.,....,.-
'---.J-1~
SPACER
The chart below identifies the color coding on new spacer
and side rails according to size.
SPACER
AND
SIDE
RAIL
CODING
SIZE
Color
Identification
S.lO.
D.DD98in
(O.2Smm)
Oversize
Two
Blue
LInes
D.D197in
(D.SDmm)
Oversize
One
Red
Line
O.029Sin
(0.7Smm)
Oversize
Two
red
lines
0.D394in
(1.DDmm)
Oversize
One
Yellow
Line
Install the three-piece oil ring in the piston. Then, make
certain the side rails move smoothly in both directions. The
side rail my be easily installed by pushing it in with your
finger after fitting the one end over the piston groove.
Do
not
use an expander ring on the oil ring.
END
OF
SIDE
RAil
Piston
Rings
Use a piston ring expander and install the piston rings with
the marker and size marks facing up toward the piston top.
Notice the difference in shapes between No.1 and No.2 ring.
f..---...,/-"
PISTON
RING
~~1I2PISTONRING
Engines & Generators
21
...
PISTONS
AND
CONNECTING
RODS
Installing
the
Piston
Assembly
Apply
an
ample
amount of
oil
to
the
outside
surfaces of
the
piston
and
the
piston
rings.
Position
the
piston
rings
and
oil
ring
(side
rail
spacer)
end
gaps
as
shown.
SlDERAIL
~
II
FRONT
+
~
/J
#2
SPACER
~
-;::::?
'-SIDE
RAIL
Insert
the
piston
and
connecting rod
assembly
into
the
cylinder,
working
from
the
arrow
mark
on
the
piston
top
toward
the
camshaft
spx;ocket
side.
FRONT
ARROW
MARK
Securely
pressing
the
piston ring with
the
ring
band,
insert
the
piston
and
connecting
rod
assembly
into
the
cylinder.
Keep
in
mind
that
the
piston ring
may
be
damaged
if
hit
too
strongly.
PISTON
RING
BAND
INSTALLER
Crankshaft/Bearing
Assembly
When
the
bearings
are
to
be
replaced, select
the
appropriate
bearings
for
assembly
according
to
the identification
marks
for
the
crankshaft
and
the
connecting
rod.
CRANKSHAFT
NO.3
NO.2
NO.'1
r----NO.1
ARM
CRANKSHAFT
PIN
DIAMETER
Identification
marks
(1)
1/\
(2)
G
(3)
C
Journal
Diameter
1.4171
-1.4173in
(35.995 -36.ooomm)
1.4167
-1.4171In
(35.985 -38.995mm)
1.4165 -1.4167in
(35.980 -35.985mm)
CONNECTING
ROD
BIG
END
INNER
DIAMETER
Identification
Marks
o
I
II
Big
End
Inner
Diameter
1.5354
-1.5356In
(39.000 -39.005mm)
1.5356
-1.5360in
(39.005 -39.015mm)
1.5360
·1.53~2In
(39.015'
39.020rnrn)
CONNECTING
ROD
BEARING
THICKNESS
Identification
Color
Brown
Blue
Bearing
Thickness
0.0586 • 0.0588in
(1.488
-1.493mm)
0.0588 -0.05901n
(1.493
-1.498mm)
0.0590 -0.0592in
(1.498
-1.503mm)
CONNECTING
ROD
BEARING
SELECTION
TABLE
Crankshaft
Pin
Identification
Marks
IDENTlFICATlO
MARK
(1)
1/\
(2)
B
(3)
[
CONNECTING
ROD
Connecting
Rod
Bearing
Identification
Marks
I
1I
m
I
]I
m
I
][
m
STOPPER'
NOTCH
Brown
Brown
Brown
Blue
Blue
Blue
IDENTIFICATION
COLOR
Engines & Generators
22
CYLINDER
NUMBER
PISTONS
AND
CONNECTING
RODS
Installing
the
Connecting
Rod
Bearing
Caps
Since the connecting
rod
cap bolts and nuts are torqued
using the plastic area tightening method, the bolts should be
examined before reuse.
If
the bolt threads are "necked
down".
the bolt should
be
replaced.
Necking can be checked by running a nut with fingers to the
full length
of
the bolt threads.
If
the nut does not run
smoothly, the bolt should be replaced.
Before installation
of
each nut, apply clean engine oil to the
thread portion and bearing surface
of
the nut.
Install each nut to the bolt
and
tighten it with your fingers.
Then tighten the nuts alternately to install the cap properly.
Tighten the nuts to the proper torque.
CAP
NUT
TIGHTENING
TORQUE
11+90·
turn
(15Nm
+90·
turn)
A
CAUTION:
If
the
cylinder
head
has
been
installed
before
installing
the
connecting
rod
cap
nut,
remove
the
spark
plugs.
Make a paint mark on
the
head
of
each
nul
Make a paint
mark on the bolt end at the position
90° to 100° from the
paint mark made
on
the nut in the direction
of
the tightening
nul
Give a 90° to 100°
tum
to the nut and make sure that the
paint mark on the nut and that
on
the bolt are in alignment.
If
the nut is turned less than 90°, proper fastening
perfonnance may not
be
expected. When tightening the nut,
rum it sufficiently.
If
the nut is overtightend (exceeding 100°), loosen-the nut
completely and then retighten
it
by repeating the tightening
procedure.
Engines & Generators
23
FRONT
CASE I COUNTERBALANCE
SHAFT
AND
OIL
PAN
TORQUE 6 -7
R-Lbs
'-1
11
FRONT
OIL
SEAl.
5
OIL
PUMP
COVER
CONFIGURAnON
OF
FRONT
CASE
GASKET
ENGINE
BLOCK
NUMBERS
INDICATE
THE
SUGGESTED
ORDER
OF
DISASSEMBLY
ASSEMBLY
"
----------------------------~---------~---;~--------~
OIL
PAN
REMOVAL
Remove
the
oil
drain
hose
assembly.
Remove
the oil
pan
bolts
and
then
use
the
special
tool
to
break
the
pan
seal.
IL
PAN
GASKET
TOOL
COUNTERBALANCE
SHAFT
REMOVAL
1.
Remove
the
plug
on
the
cylinder
block
and
insert
an
0.32in
(8mm)
rod
into
the
hole
to
lock
the
counterbalance
shaft.
2.
Remove
the
oil
pump
cover
and
gasket.
Discard
the
gasket
3.
Remove
the
oil
pump
driven
gear
tightening
flange
bolts
.
to
release
the
counterbalance
shaft.
4.
Remove
the
counterbalance
shaft.
Drive
it
from
the
front
FLANGE
BOLT
OIL
PUMP
DRIVEN
GEAR
Engines & Generators
.
24
FRONT
CASE I COUNTERBALANCE
SHAFT
AND
OIL
PUMP
4.
Using a special
tool
drive
the
counterbalance
shaft
front
bearing
from
the
cylinder
block.
EARING
REMOVER
TOOL
S.
Use
the
same
tool
and
drive
the
counterbalance shaft
rear
bearing
from
the
cylinder
block.
OIL
PUMP
ASSEMBLY·
INSPECTION
Fit
the
oil
pump
gear
into
the
cylinder
block.
then,
using
a
feeler
gauge,
check
the
clearance
with
the
body
at
the
points
indicated
in
the
diagram
below.
DRIVEN
GEAR
BODY
CLEARANCE
STANDARD
A.
0.0161 -O.0266ln
(0.410 -O.675mm)
B.
0.0051-
O.oo69ln
(0.130 -0.175mm)
DRIVE
GEAR
BODY
CLEARANCE
STANDARD
C.
0.0173 -0.02761n
(0.44 -0.70mm)
D.
0.0059 -O.OTIln
(o.150 -0.195mm)
DRIVEN
GEAR
SIDE
ClEARANCE
.0024 -0.00471n
(0.06 -0.12mm)
DRIVE
GEAR
SIDE
CLEARANCE
0.0027 -0.0051
In
(0.07 -0.13mm)
Using a straight
edge,
check
the
side
clearance
at
the
point
indicated
in
the
illustration
with a feeler
gauge.
There
should
be
no
uneven
wear
on
the
contact
surfaces
of
the
cylinder
block
or
on
the
pump
gear
side of
the
pump
~--DRIVE
GEAR
FRONT
CASE·
INSPECTION
Check
the
front
case
for
cracks
or other damage
also
inspect
the oil
holes.
If
the
oil
holes
are
clogged,
use
compressed air
or solvent
to
clean
them
out
CRANKSHAFT
FRONTOtL
SEAL
CRANKSHAFT
FRONT
OIL
SEAL • INSPECTION
Check the
oil
seal
for
wear
and
damage. Inspect
the
oil
seal
lip for
hardening.
If
there
any
signs
of
wear,
replace
the
seal.
COUNTERBALANCE
SHAFT
COUNTERBALANCE
SHAFT·
INSPECTION
Inspect the
oil
holes
for
clogging and clean
if
necessary.
Inspect
the
shaft journal
for
seizure.
damage
and
its
contact
with the
bearing.
Check
the
counterbalance shaft
oil
clearance.
Replace
the
counterbalance shaft
if
it
fails
to
meet
the
standards.
COUNTERBALANCE
SHAfT
STANDARDS
Front
Journal
Diameter
0.7869 -0.78741n
(19.987 -20.DOOmm)
Rear
Journal
Diameter
1.7317
-1.7322In
(43.984 -44.DDOmm)
Front
Journal
011
Clearance
0.0014·
0.00271n
(0.035 -0.068mm)
Rear
Journal
011
Clearance
0.0014 -0.00281n
(0.035 -0.071mm)
Engines & Generators
25
FRONT
CASE I COUNTERBALANCE
SHAFT
AND
OIL
PUMP
INSTALLATION
Counterbalance
Rear
Bearing
1.
Install
the
special
tool
guide pins (bearing Installer)
in
the
tapered
hole
of
the
cylinder block
as
shown.
~()r---.,
r
OILHOL
\
~
J
()r
~\
BEARING
2.
Mate
the
ratchet
ball
of
the
bearing
in
the
oil
hole
of
the
rear
bearing
and
install the bearing
in
the
bearing
installer.
3.
Apply
clean engine oil to the outer circumference of the
bearing
and
the bearing
hole
in the cylinder
block.
4.
Insert
the
installer
by
mating it with
the
guide
pins
and
press-in
the
bearing.
' J
~
GUIDE
PIN
____
"'.H'
~
a
::/
\
Counterbalance
Front
Bearing
1.
Apply
engine
oil
to the bearing outer circumference
and
the
bearing
hole
in
the cylinder block.
2.
Press-in
the front bearing using the installer
tool.
FRONT
BEARING
INSTAu.ATION
Crankshaft
Oil
Seal
1.
Front
Case
Assembly
Install
the
front
case
assembly
through
the
gasket
and
tighten
the
bolts
to
the
specified
torque.
FRONT
CASE
BOLTS
TORQUE
6 -7ft.lbs.
(8
-10
Nm)
There
are
two
different length front
case
bolts.
Make
certain
they
are
positioned
properly.
See the
diagram.
NOTE:
When
installing
the
front case
assembly,
apply
oil
to
the inner
circumference
of
the
oil seal
lip.
When
installing
the front
case
assembly
take
care
not
to
damage
the
oil
seal
lip
on
the
stepped
up
portion
of
the front end
of
the
crOJ'lbhajt.
A
A_~~\
B
Oil
Pump
Driven
Gear
A
BOLT
-18mm
(.71
in)
B
BOLT
-30mm
(1.18
In)
B
1.
Apply
an
ample
amount
of clean engine
oil
to
the
oil
pump
driven
gear
and
insert it so that
the
timing
mark
is
positioned
as
shown.
2. Using
the
same
hole
on
the
side of
the
cylinder
block,
reinsert
the
8mm
rod
to
lock the counterbalance
shaft.
Then
tighten
the
flange
bolt to the
specified
torque.
~~
J~\-\
-
~;/
~lr
~
~,I
0
n~~
SETTING
THE
DRIVEN
GEAR
TIMING
MARK
DRIVEN
GEAR
FlANGE
BOLT
TORQUE
25 -29ft.lbs.
(34
•
4ONm)
Engines & Generators
26
FRONT
CASE
lOlL
PUMP
AND
OIL
PAN
TIMING
MARKS
Oil
Pump
Cover
Gasket
Fit a new oil pump cover gasket into the groove in the oil
pump cover. The fiat side
of
the gasket
is
positioned against
the pump cover.
Oil
Pump
Seal
Press the seal into the oil pump cover flush with the surface
using the seal installer tool.
INSTALLING
THE
OIL
PUMP
SEAL
OIL
PUMP
ASSEMBLY
FRONT
CASE
CONFIGURATION
Oil
Pan
Remove the old gasket and sealant from the oil pan and
cylinder block with a scraper, wire brush, solvent, etc. Make
certain all residue is removed.
GASKET
Engines & Generators
27
CRANKSHAFT
I
BEARINGS
AND
OIL
SEAL
NUMBERS
INDICATE
THE
SUGGESTED
ORDER
OF
DISASSEMBLY
CYLINDER
BLOCK
8
CRANKSHAFT
BEARING
(UPPER)
INSPECT
THE
JOURNALS
FOR
UNEVEN
WEAR.
CHECK
FOR
CRACKS,
BENDS,
AND
CLOGGED
OIL
HOLES.
9
CRANKSHAFT
TORQUE
98
-
105
FT-LBS-----~
[135 - 145
Nmj
MAIN
BEARING
BOLT
TORQUE
36 -
40
FT-LBS
[50-56Nm]
'="'
__
----.
THRUST
BEARING
~
~
TORQUE
98 -
105
FT-LBS
[135 -145
Nm]
~
_____
-6f'BEARING
CAP
BOLT
CRANKSHAFT
INSPECTION
1.
Check
the
journals and pins
for
damage,
seizure and
cracks.
Check
the
journals'contact surface
for
uneven
wear
and
replace if badly damaged.
2.
Measure
the
outside diameter of the journal
and
the
inside
diameter of the main bearing. If the clearance
(oil
clearance) exceeds the limit, replace
the
main
bearing
and
also
the
crankshaft, if necessary. Otherwise, fabricate
an
undersized crankshaft and replace
the
main
bearing with
an
undersized
one.
Standard
limit
0.0008·
0.0018in
(0.021 -0.D45mm)
.004in
(O.1mm)
3.
When
grinding the crankshaft
to
under-size,
take
note of
the
"R" dimensions
of
the
fillets
of
the
journal and pin
area.
MEASURING
POSITION
MEASURING
THE
CRANKSHAFT
0.0.
AND
BEARING
1.0.
Q-w
Engines & Generators
28
MEASURING
DIRECTION
CRANKSHAFT,
BEARING
AND
OIL
SEAL
R •
0.059
IN
{1.5MM]
R .
0.059
IN
{1.5MM]
MEASURE
THE
CRANKSHAFT
OIL
CLEARANCE
The crankshaft oil measured by using a plastic gauge
as follows:
1. The oil and grease and
other foreign matters form the
crankshaft joumal and bearing inner surface.
2. Install the crankshaft.
3. Cut the plastic gauge to the same length as the width
of
the bearing and place it on the journal in parrallel with its
axis.
4. Gently place the main bearing cap over
it
and tighten the
bolts to the specified torque.
S. Remove the bolts and gently remove the
main
bearing
cap. Measure the width
of
the smashed plastic gauge
(at its widest section) by using the scale printed on the
plastic gauge.
MAIN
BEARING
BOLT
TORDUE
36 -
40
FT-LBS
[50-56Nm]
~
PlASTlGAUGE'
SCALE
INSPECTING
THE
CRANKSHAFT
REAR
OIL
SEAL
1. Inspect the oil clearance lip for wear
or
damage. Check
the rubber portion for deterioration and hardening.
Replace the seal
if
at
all suspect.
2. Check the oil case for cracks and damage.
If
here is
damage, replace the case.
CRANKSHAFT
BEARINGS
SPECIFICATIONS
Upper
and
Lower
When the bearings are to be replaced, select the correct ones
and install them in positions according to the identification
marks stamped on the crankshaft and the top surface of the
cylinder block.
CRANKSHAFT
JOURNAL
DIAMETER
Identification
Marks
1
2
3
Journal
Diameter
1.5746
-1.5748
in
(39.994 -40.000mm)
1.5743
-1.5746
In
(39.988 -39.994mm)
1.5741-1.5743
in
(39.982 -39.988mm)
CAMSHAFT
JOURNAL
CRANKSHAFT
BEARING
THICKNESS
Identification
Colors
brown·
blue
yellow
green
o
Bearing
Thickness
0.0783·0.0784
in
(1.988
-1.991mm)
0.0784 -0.0785
In
(1.991 -1.994mm)
0.0785 -0.0786
in
(1.994 -1.997mm)
0.0786 -0.0787
in
(1.997 -2.000mm)
0.0787 -0.0789
in
(2.000 -2.003mm)
o
"'~N"I""'"
CYLINDER
BLOCK
dodd
zzzz
CYLINDER
BLOCK
BEARING
DIAMETER
Identification
Marks
o
I
n:
Bearing
Inner
Diameter
'1.7323 -1.7325
in
(44.000 -44.o06mml
1.7325
-1.7328
in
(44.006 -44.012mm
1.7328
-1.7330
in
(44.012 -44.018mm
BEARING
IDENTIFICATION
MARKS
CRANKSHAFT
BEARING
SELECTION
CHART
Crankshaft
Journal
Crankshaft
Bearing
Cylinder
Block
Bearing
Identification
Marks
Identification
Marks
Identification
Marks
1
brown
0
I
blue
]I
2
0
blue
I
yellow
]I
3
blue
0
yellow
I
green
]I
Engines & Generators
29
CRANKSHAFTI
BEARING
AND
OIL
SEAL
CRANKSHAFT
BEARINGS
INSTALLING
THE
THRUST
BEARINGS
1.
Apply
a coat
of
oil
to
the
thrust beating
and
install
so
that
the
oil
groove
faces
outward
as
illustrated.
2.
Install
the
bearing cap paying careful attention
to
the
cap
number
and
the
arrow mark.
Apply
oil
to
the bolt
threads.
3.
TIghten
the
bearing cap
to
the
specified
torque.
BEARING
CAP
BOLT
TORQUE
36 -40
ft-Ibs
(SO -5SNm)
MEASURING
END
PLAY
Push
the
crankshaft to
the
rear.
Then,
insert a
feeler
gauge
in
the
gap
between
the
crankshaft journal side
surface
and
the
thrust bearing
end
surface
to
measure
the
end
play.
CRANKSHAFT
END
PLAY:
0.0020 -0.0009in
(0.05 -0.02Smm)
CRANKSHAFT
CRANKSHAFT
REAR
OIL
SEAL
1.
Apply
engine
oil
to
the
rear cover
and
to
the
oil
seal.
2.
Press
the
oil
seal
into
the
seal
case
using
the
special
tool.
3.
OIL
SEAL
CASE
NOTE:
Make
certain
the
lips
of
the
oil seal
are
not turned
up.
OIL
CASE
BOLT
TORQUE:
7 - 9
Ft-Ibs
(10
-12Nm)
Engines & Generators
30
CYLINDER
BLOCK
INSPECTION
AND
PISTON
CLEARANCE
NUMBERS
INDICATE
THE
SUGGESTED
ORDER
OF
DISASSEMBLY
CYLINDER
BLOCK
1
OllU'EH
PlUG
1/4'~
2
DOWEl----.o
•
6STUDS8X5D-7T/
.
8
KNOCK
BUSHINGS
6 X
9~
CYLINDER
BLOCK
INSPECTION
1.
Before inspecting, clean the cylinder block to ensure that
the water and oil holes are not plugged.
If
clogged, clear
with compressed
air.
2.
Check for cracks and damage. Use a flaw detecting compound
as
needed. Replace the block
if
defective.
3. Inspect the mating surface.
Using a straight edge and
feeler gauge measure the flatness
of
the top surface.
Grind
or
replace
if
the limit is exceeded.
FLATNESS
STANDARD
VALUE:
0.0020
in
(0.05
mm)
LIMIT:
0.DD4
in
(0.1
mm)
4. Inspect the cylinder bore. Using a cylinder gauge, mea-
sure the bore at six places (as shown in the diagram).
Calculate the difference between the max. and min.
val-
ues.
If
worn
or
damaged, rebore
or
replace the cylinder.
CYLINDRICITY
STANDARD
VALUE:
0.0004
in
(0.01
mm)
or
less
CYLINDER
BORE:
2.5591 -2.5602
in
(65.00 -65.03
mm)
0.47
IN
[12rnrn)
DOWN
UPPER
CENTER
MEASURING
lOWER
DIRECTION
MEASURING
POSITION
CHECKING
THE
PISTON
CLEARANCE
Calculate the difference between the minimum cylinder bore
in the thrust directitm and the piston outer diameter shown in
. the illustration.
If
the difference exceeds the specified range,
replace the piston or cylinder block,
or
rebore the cylinder.
PISTON
TO
CYLINDER
CLEARANCE
STANDARD:
0.0008 -0.0016
In
(0.0 -0.04
0101)
BORING
THE
CYLINDER
1. Select
an
oversize piston based on the cylinder with the
maximum bore and maximum damage depth.
2.
Using the outer diameter (at the specified measurement
point)
of
the selected oversize piston, calculate
the
boring .
dimension.
Boring
dimension
=
(Piston
D.O.) + (piston
clearance) -(honing
margin:
0.0008i"
(0.02mm))
OVERSIZE
PISTON
OUTSIDE
DIAMETER
AND
CYLINDER
(INNER
DIAMETER
FINISH
DIMENSION
(REF))
Size
Mark
Piston
Dia.
Cylinder
loner
Dia.
0.250.S.
25
2.5677 -2.568910
2.5693 -2.56971n
(65.22 -65.25mm)
(65.26·
65.27mm)
0.500.S.
50
2.5776 -2.5787in
2.5791
·2.5795in
(65.47 -65.50mm)
(65.51 -65.52mm)
0.750.S.
75
2.5874 -2.58861n
2.5890 • 2.5894in
(65.72 -65.75mm)
(65.76 -65.77mm)
1.000.S.
100
2.5972 -2.59841n
2.5988 -2.5992in
(65.97 -66.o0m)
(66.01 -66.02mm)
3. Bore the cylinder
to
obtain the calculated dimensions.
4. Hone to finish the cylinder inner diameter.
S.
Check again for cylindricity and piston clearance .
Engines & Generators
31
SERVICE
DATA / STANDARDS
AND
LIMITS
~
BCG
ENGINE/GENERATOR
Component
Specified
Value I Standard
Repair
limit
inches(mm) inches(mm)
FRONTCAS~COUNTERBAlANCESHAFT
Oil
Pump
Side
Clearance
Driven
Gear.
.........................
0.0024-0.0047
(0.06-0.12)
Drive
Gear
............................
0.0027-0.0051
(0.07-0.13)
Counterbalance
Shaft
Front
Journal
Diameter
·
...............................
0.7869-0.7874
(19.987-20.000)
Counterbalance
Shaft
Rear
Journal
Diameter
·
...............................
1.7317-1.7322
(43.984-44.000)
Counterbalance
Shaft
Front
Journal
Oil
Clearance
·
...............................
0.0014 -0.0027
(0.035 -0.068)
Counterbalance
Shaft
Rear
Journal
Oil
Clearance
·
...............................
0.0014 -0.0028
(0.035 -0.071)
CYLINDER
BLOCK
Cylinder
Bore
2.5591-2.5602
(65.00-65.03)
Out-of-Roundness
and
Taper
of
Cylinder
Bore
0.0004
(less
than
0.05)
Gasket
Surface
Flatness
0.0020
(less
than
0.05)
CYLINDER
HEAD
0.0039
(0.1)
Flatness
of
Gasket
Surface
... 0 ..
0019
(Less
than
0.05)
............
0.0079
(0.2)
Overall
Height..
...................
.4.287-4.295
(108.9-109.1)
Cylinder
Head
oversize
rework
dimension
of
valve
seat
hole
Intake
0.3
0.S
......
1.2323 -1.2333
(31.300 -3.325)
Intake
0.60.S
.....
1.2441
-1.2451
(31.600 -31.625)
Exhaust
0.3
0.S
....
1.1535 -1.1544
(29.300 -29.321)
Exhaust
0.6
0.S
....
1.1653 -1.1662
(29.600 -29.621)
Cylinder
Head
rework
of
valve
guide
hole
(both
intake
and
exhaust)
0.05
O.S
..................
0.4744 -0.4751
(12.050
-12.068)
0.25
0.S
..................
0.4823 -0.4830
(12.250
-12.268)
0.50
O.S
..................
0.4921 -0.4928
(12.500 -12.518)
Intake
Valve
Seat
Angle ........................
.45°
Exhaust
Valve
Seat
Angle
......................
30°
Intake
Valve
Seat
Width
..................
0.079
(2.0)
........................
0.004
(0.1)
Exhaust
Valve
Seat
Width
...............
0.079
(~.O)
........................
0.004
(0.1)
Valve
Clearance
........................................
.
Exhaust...
...................................
0.D12
(0.30)
Intake
..................................... : ...
0.008
(0.20)
Valve
Head
Thickness
(margin)
(Intake)
.........................................
039
(1.0)
...........................
020
(.5)
(Exhaust)
......................................
051
(1.3)
.............................
031
(8)
Valve
Length
(Intake)
.....................................
3.960
(100.6)
(Exhaust)
..................................
3.968
(100.8)
Valve
Stern
0.0.
Intake
.......................
:0.2585 -0.2591
(6.565 -6.580)
Exhaust
......................
O.2571 -0.2579
(6.530 -6.550)
Stem
to
Guide
Clearance
Intake
.........................
0.0008 -0.0020
(0.02 -0.05)
......
0.0039
(0.10)
Exhaust
...................
0.0020 -0.0033
(0.0050 -0.0085)
..
0.0059
(0.15)
Valve
Guide
Length
(Intake)
.........................................
1.73
(44)
(Exhaust)
...................................
1.949
(49.5)
Component
VAlVES
Specified
Value I Standard
inches(mm)
Valve
Guide
Service
Size
0.05,
0.25,
0.50
oversize
Valve
Seat
Width
of
Seat
Contact..
.............................
035-
.051
(0.9-1.3)
Valve
Seat
Angle
..............................
300/44°/65°
Repair
Limit
inches(mm)
Valve
Seat
Sink
............................................................................
0.008
(0.2)
Valve
Spring
Free
Length
................
1.823
(46.3)
......................
1.783
(45.3)
Valve
Spring
Load/lnstaUed
Height
Ibs.lin
(N/mm)
..........................
.46/1.48
(210137.7)
Squareness
.....................................
.Iess
than
2°
.............................
.40
TIMING
BELT
...................................................
.47
(12)
ROCKER
ARM
Camshaft
Heig
ht
No.1
(lntake)
..........................
1.3815
(35.09)
..................
1.3618
(34.59)
No.2
(Intake)
..........................
1.3807
(35.07)
..................
1.3610
(34.57)
No.3
(Intake)
..........................
1.3803
(35.06)
..................
1.3606
(34.56)
No.1
(Exhaust)
.......................
1.3839
(35.15)
..................
1.3642
(34.65)
No.2
(ExhalJst)
.......................
1.3831
(35.13)
..................
1.3634
(34.63)
NO.3
(Exhaust)
......................
1.3854
(35.190)
................
1.3657
(34.69)
Camshaft
Journal
Diameter
..........................
1.6118-1.6124(40.940-40.955)
Bearing
Oil
Clearance
..........
0.0018-0.0033
(.45-0.085)
End
Play
....................................
0024-.0055
(.06-.14)
.................
118
(.03)
Rocker
Shaft
Length
........................
9.134
(232)
Rocker
Arm
Shaft
Outer
Diameter
.......
0.6687 -0.6692
(16.985 -16.998)
Clearance
...................
0.0005 -0.0017
(0.012 -0.043)
......
0.004
(0.1)
PISTON
AND
CONNECTING
ROD
Piston
Outer
Diameter
......
2.5579-2.5591
(64.97-65.00)
Piston
to
Cylinder
Clearance
..................................
0.0008 -0.0016
(0.02 -0.04)
Piston
Ring
Grove
Width
No.1
.............................
0.0480 -0.0488
(1.22 -1.24)
No.2
.............................
0.0476 -0.0484
(1.21 -1.23)
Oil
..............................
0.1108 -0.1116
(2.815 -2.835
Piston
Service
Size
...............
0.25,
0.50,
0.75,
1.00
OS
Piston
Ring
End
Gap
No.1
.............................
0.0059 -0.0118
(0.15 -0.30)
........
0.0315
(0.8)
No.2
.............................
0.0138 -0.0197
(0.35 -0.50)
........
0.0315
(0.8)
011
....................................
0.008 -0.028
(0.2 -0.7)
............
0.0394
(1.0)
Piston
Side
Clearance
No.1
.............................
0.0012 -0.0028
(0.03 -0.07)
......
0.0047
(0.12)
No.2
.............................
0.0008 -0.0024
(0.02 -0.06)
......
0.0039
(0.10)
Piston
Pin
0.0
..............
0.6300 -0.6302
(16.001
-16.007)
Piston
Pin
Press-in
Load
Ibs(N)
...................................
1102 -3307
(5000 -15000)
End
Play
............................
0.0059 -0.0118
(0.15 -0.28)
Engines & Generators
32
SERVICE
DATA / STANDARDS
AND
LIMITS • BeG
ENGINE/GENERATOR!
Component
Specified
Value I Standard
Repair
limit
inches(mm)
inches(mm)
PISTON
AND
CONNECTING
ROD
Piston
Pin
Press-in
temperature
. .
.....
",.,
...
,.,
... , ...
"""",
.. " ...
ordinary
temperature
Connecting
Rod
Center
length
................. " ...........
.4.01384,0178
(101.95
-102,05)
Parallelism
between
Big
End
and
Small
End
.. " .. " ... " ............... " ..
""
............
0.004
(0,05)
Connecting
Rod
Twist...."
................
0.004
(0.1)
Connecting
Rod
Big
End
to
Crankshaft
Side
Clearance
.................. " ..............
0.0039 -0.0098
(0.10 -0.25)
..........
0.16
(0.4)
Component
Specified
Value I Standard
Repair
Limit
inches(mm)
inches(mm)
CRANKSHAFT,
BEARING
Crankshaft
End
Play
..........
0.0020 -0.0098
(0,05 -0.25)
.................
.
Crankshaft
Journal
0.0,
..
1.5740
-1.5748
(39.98 -40.0)
Crankshaft
Pin
0,0,
........
1.4165
-1,4173
(35.98 -36,00)
Cylindericity
of
Journal
and
Pin
.....................................
Less
than
0.0002
(0.005)
Concentricity
of
Journal
and
Pin
, ,
.... " .. " ........................
.Less
than
0,0006
(0.015)
Oil
Clearance
of
Journal
,
........
""
...................
0.0008 -0.0018
(0.021 -0,045)
......
0.0039
(0.1)
Oil
Clearance
of
Pin
........
0.0009 -0,0020
(0.022 -0.052)
Undersize
rework
dimension
of
Journal
0.25
U.S
..................
1.5644 -1.5650
(39.735 -39.750)
0.50
U.S,
................. 1 ,5545 -1.5551
(39.485 -39,500)
0.75
U.S
... " ............
1.5447 -1.54539
(39.235 -39,250)
Undersize
rework
of
dimension
of
pin
0.25
U.S,
.................
1.4069 -1.4075
(35.735 -39.750)
0.50
U.S
.................. 1 ,3970 -1.3976
(35.485 -35.500)
0.75
U.S
....... " ......... 1 ,3872
-1.3878
(35.235 -35.250)
Engines & Generators
33
ENGINE
HARDWARE
TORQUES
Timing
Belt
Nm
ft.lbs.
Front
Case,
Counterbalance
Shaft
Nm
ft.lbs.
Crankshaft
bolt
135-145
98-105
Front
case
bolts
8-10
6-7
Timing
belt
cover
bolts
10-12
7-9
Oil
pump
cover
bolts
8-10
6-7
Camshaft
sprocket
bolts
80-100
58-72
Oil
pan
bolts
10-12
7-9
Oil
pump
sprocket
nuts
50-57
36-41
Oil
drain
plug
35-45
25-33
Timing
tensioner
nuts
22-30
16-22
Oil
screen
bolts
15-22
11-16
Timing
belt
rear
cover
bolts
10-12
7-9
Oil
pump
driven
gear
bolt
34-40
25-29
Rocker
Arms
and
Rocker
Shaft
Rear
cover
bolts
10-12
7-9
Rocker
cover
shaft
29-35
21-25
Piston
and
Connecting
Rod
Camshaft
thrust
plate
bolt
10-12
7-9
Connecting
rod
cap
nut
15 + 90'
turn
11 + 90·
turn
Rocker
arm
adjust
nut
8-10
6-7
Crankshaft,
Bearing
Cylinder
Head,
Valve
Oil
seal
case
bolts
10-12
7-9
Cylinder
head
bolt
(cold
engine)
60-70
43-51
Bearing
cap
bolts
50-55
36-40
Spark
plug
15.2
10.8
Cylinder
Block
Rocket
cover
12-13
9-10
Taper
plug
1/16
8-12
6-9
Miscellaneous
Taper
plug
1/8
15-22
11-16
Coolant
temperature
sender
12-18
9-13
Water
drain
plug
35-45
25-33
Coolant
temperature
switch
12-18
9-13
Taper
plug
1/4
NPT
35-45
25-33
Generator
mounts
34-47
23-34
Oil
pressure
switch
12-18
9-13
Exhaust
manifold
16-23 12-17
Oil
pressure
sender
12-18
9-13
Thermostat
housing
8-11
6-8
Water
Pump
Carburetor
to
manifold
16-23
12-17
Water
pump
8-10
6-7
Engines & Generators
33-a
CAMSHAFT
OIL
SEAL
INSTALLER
MD
999569
PISTON
PIN
SETTING
BASE
Used
to
pUll-out
and
press
in
the
piston
pin.
MD
999583
CRANKSHAFT
REAR
OIL
SEAL
INSTAllER
MD
998376
PUSH
ROD
AND
PIN
SET
GUIDE
Used
to
pUll-out
and
press
in
the
piston
pin.
MD
999584
PIN
For
supporting
the
sprocket
when
the
camshaft
sprocket
is
loosened
or
tightened.
MD
998715
END
YOKE
HOLDER
For
supporting
the
sprocket
when
the
camshaft
sprocket
is
loosened
or
tightened.
MD990767
VALVE
SPRING
COMPRESSOR
MD
999597
SPECIAL
TOOLS • ENGINE
NOTE:
These special tools are available from
your local Mitsubishi Automotive Dealer
VALVE
STEM
SEAL
INSTALLER
MD
998302
OIL
PAN
GASKET
CUrrER
For
removing
the
oil
pan
to
break
the
oil
pan
seal.
MD
998727
BEARING
REMOVER
For
pulling
out
the
front
and
rear
bearings
(counterbalance
shaft).
MD
999593
FRONT
BEARING
INSTALLER
(Counterbalance
shaft).
MD
999591
INSTALLER
FOR
THE
REAR
OIL
SEAL
(Counterbalance
shaft).
MD
999592
CRANKSHAFT
FRONT
OIL
SEAL
INSTALLER
MD
999570
OIL
PUMP
Oil
SEAL
INSTALLER
Engines & Generators
34
EXHAUST
MANIFOLD
I
HEAT
EXCHANGER
EXHAUST
MANIFOLD
The exhaust manifold, which was disassembled from the
cylinder head, should be inspected before reassembly.
1. Remove the exhaust elbow from
the manifold. Scrape off
and discard the old gasket. Inspect the exhaust elbow for
corrosion and damage, replace
if
necessary.
2.
If
the exhaust elbow passes inspection, remove the high
temperature sensor and clean and re-paint the elbow with
WESTERBEKE heat resistant enamel.
3. Carefully inspect the exhaust manifold, remove the hose
connections noting the location
of
each for proper
alignment at reassembly. Clean the exterior and interior
manifold.
If
the manifold can be reused, repaint with
WESTERBEKE heat resistant enamel.
ASSEMBLY
1.
If
the manifold was removed as an assembly and left
intact,
it
can
be
replaced on the cylinder head in the
reverse order
of
·rem<?val.
Install a new gasket.
MANIFOLD
MOUNTING
BOLTS
TORQUE
12
-17
ft-lb
(16 -23
Nrn)
2. Attach the hose connections to the manifold and the
exhaust elbow.
Once the engine has been re-installed and
running, carefully check these assemblies and hose
connections for leaks.
INSPECT
HOSES.
REPLACE
IF
SOFT
OR
WORN
ON
THE
ENDS
HEAT
EXCHANGER
The heat exchanger should be inspected and serviced during
an engine overhaul.
1. Disconnect the hoses and remove the hose fittings,
petcock, drain plugs and zinc anode. Also, remove the
end fittings and gaskets.
2. Inspect the tube (casing) for wear and dents,
if
at all
suspect replace the heat exchanger.
3. Clean out any zinc debris and pressure test the coolant
and raw water passages.
4~
When reassembling, install new gaskets and O-rings.
Apply some lubricant to the new gaskets and to the
petcocks and fittings as you install them.
5. Install a new zinc anode.
NOTE:
All
of
the
above
can
be
accomplished
by
sending
the
heat exchanger
to
a heat exchangerlradiator
service
shop.
They
will also service transmission and
engine
oil
coolers.
6. Repaint the assembled heat exchanger with
WESTERBEKE heat resistant spray enamel
HEAT
EXCHANGER
ASSEMBLY
Reinstall the heat exchanger. Tighten down the holdown
brackets and once the engine is running, check the heat
exchanger and hose connections for leaks.
Engines & Generators
35
COOLANT
CIRCULATING
PUMP
REMOVING
THE
COOLANT
PUMP
1.
Loosen the belt guards thumbscrews and remove the
engine's belt guard from its brackets at the front
of
the
engine.
2. Ease the belt tension by releasing the raw water pump and
remove the engine drive belt [on carburetor models it will
be necessary to remove the governor belt].
3.
Unscrew the five bolts that hold the pump to the engine
and remove the coolant pump and its gasket. Note that the
pulley is an integral part
of
the pump assembly.
INSPECTION
RAW
WATER
PUMP
PULLEY
Carefully check the pump body and impeller for cracks and
damage. Inspect the weep holes for
sign~
of
water leakage
and rust that would indicate a faulty seal. The pulley should
turn the shaft (and impeller) smoothly, without noise
or
sluggish rotation.
The pulley edges should be smooth and undamaged and the
locknut should be drawn up tight.
COOLANT
PUMP
PULLEY
FLANGE
REPAIR
If
the pump does not pass inspection, replace the entire pump
assembly which includes the pulley.
THREE
BOLTS
0.24 X 1.38
IN
(96X35
mm)
INSTALLATION
TWO
BOLTS'
0.24 X 0.71
IN
(6
X18
mm)
When reinstalling the pump use a new gasket. There are five
bolts in two sizes that fasten the pump in place, make certain
they are positioned properly. See the diagram above.
Use
sealant when assembling the new gasket.
CIRCULATING
PUMP
BOLT
TORQUE
6 -
7ft
-Ibs
(8
-10
Nm)
Engines & Generators
36
RAW
WATER
PUMP
l
PN.46120
13C1RClIP(EXTl'RNAL).~
",.
I
17'""",, " .
rQJ
15
D-RiNG
~
1
-'>
Ii':.
18
DUTBl
~~
9 I
·;::v. :....
BEARING
8
:
...
;:-:'.
:','
4
SCREW
WEAR
PLATE
---
PUMP
OVERHAUL
Disassembly
The pump when removed from the engine will have
the
hose
attachment nipple threaded into the inlet and outlet ports
of
the
pump along
with
a drive pulley attached
to
the shaft
of
the
pump.
Remove
these
attachments noting their positions
before starting
the
pump
disassembly.
1.
Remove
the
four cover plate
screws
#12,
cover
plate
#11
and
sealing
O-ring #10.
2.
Remove
the
im~lle~
#9 using a pair of pliers, grasping
the
~ub
and pulling
It
out of
the
pump
with
a twisting
motion.
3.
Remove
the
screw #4 and sealing washer #3 that hold
the
cam
in
place.
Remove
the
cam
#2
and
inner
wear
plate #8
behind
it
4.
Remove
dust plate #20 and circlip
#19.
5.
Support
the
pump
body on an arbor press
and
with
a drift,
press
the
shaft
and
bearing assembly out
the
pulley end of
the
pump.
6.
Remove
the
O-ring
from
the shaft.
7.
Support
the
outer bearing #18
and
push
the shaft out of
the
bearing.
8.
Remove
the
spacer #17
and
circlip #13.
LIGHTLY
GREASE
THE
PUMP
CHAMBER,
O-RING,
AND
IMPELLER
WITH
GLYCERIN.
Inspection
INSPECT
THE
a-RING
AND
IMPELLER.
REPLACE
IF
THEY
SHOW
SIGNS
OF
WEAR.
Inspect all parts
and
replace those
showing
wear
or
corrosion.
Reassembly
1.
Install a new
shaft
seal
#5
in
the
pump
body.
Apply
some
glycerin
to
the
lip of
the
seal.
2.
Install
the
circlip #13 on
the
shaft.
Support
the
outer
bearing #18 and push
the
shaft
into
the bearing
until
the
bearing contacts
circlip.
3.
Install spacer #
17
against
the
circlip.
Support
the
inner
bearing #16
and
push the shaft into
the
bearing
until
it
contacts
the
spacer.
4.
Apply
some
glycerin onto
the
O-ring
#6
and
install it
on
the
shaft approximately
1/8"
away
from
the
inner
bearing.
S.
SUp?ort
~e
pump
body
on
an
arbor
press.
With a twisting
motion,
mstall
the
shaft
and
bearing
assembly
into
the
shaft
seal
#5
until
the
inner bearing contacts
the
pump
body.
Then
with
the
push shaft
and
bearing,
assembly
into
the
pump
body
so
that
the
outer bearing just
clears
the
boss
for
circlip
#19.
6.
Install circlip
#19
and
push
the
shaft
and
bearing
assembly
so
the
outer bearing #18 contacts
the
circlip #19.
7. Install
the
dust plate
#20.
8.
Install wear plate #8,
cam
32
and
secure
it
in
place
with
washers
and
screw #4.
9.
Apply
some
glycerin
to
the
surface
of
the
impeller
housing,
impeller inner surface of
the
cover
plate
#11
and
O-ring
#10.
10.With
a twisting
motion,
install
the
impeller #9
into
the
pump.
Install
the
O-rinK # 10
and
secure
the
cover
plate
#11
with
the
four
screws
#12.
1l.Install
the
pulley
on
the
shaft
and
the
hose
nipples
back
into
the
pump.
Mount
the
pump
on
the
engine.
Check
pulley
alignment.
Attach
the
raw
water
hoses.
Engines & Generators
37
CARBURETOR
•
LOW
PROFILE
CARBURETOR
The carburetor
is
a single barrel, side-draft
type
with
a
cleanable
metal
screen
air
intake filter/spark
arrester.
Air
Screen
The
air
screen
can
easily
be
removed.
Clean after
the
first
50
hours
of
operation
and
every
100
hours
from
then
on.
Clean
the
air
screen
in a water
soluble cleaner
such
as
GUNK.
CHOKE
SOLENOID
The
choke
solenoid
is a 12
volt
DC
operated unit
that
func-
tions
to
close
the
choke
plate
in
the
carburetor when
the
ON
switch
is
depressed
during
engine
start-up.
AIR
ON
SWITCH
{CHOKE
ENERGIZED]
The
choke
solenoid
de-energizes
once
the engine
starts
and
the
ON
switch
is
released.
Some
unstable
running
may
be
present
when
the
engine
starts
cold
but should
smooth
out
as
the
engine
reaches
operating
temperature.
Confirm
Proper
Operation
Start
the
engine
and
allow
the
engine
to
warm
up.
Once
warm,
engage
the
ON
switch.
If
the
engine
chokes
and
stops,
the
choke
linkage
needs
to
be lengthened
to
hold
the
choke
open
slightly
more.
If
the
engine slows but continues
to
run,
the
adjustment
is
ok.
Linkage
Adjustment
Adjust
the
linkage
so
that
when
the
choke
solenoid
is
energized,
the
choke butterfiy/.lever
is
open
approximately
1/16".
Adjust
the
linkage
so
the
pin
hole
in
the linkage
is
approximately
1116"
beyond
the
fully
closed
choke lever
..
then
connect
the
choke
lever
to
the
linkage.
Refer
to
the
IDLE MEASURE ADJUSTMENT
at
the
top
of
this
page.
ADJUSTMENT:
THE
IDLE
MIXTURE
CAN
BE
ADJUSTED
BY
PRYING
OFF
THE
PLASnC
CAP.
TURN
THE
SCREW
ALL
THE
WAY
DOWN -THEN
BACK
THE
SCREW
OUT 3 112
TURNS.
ONCE
RUNNING,
ADJUST
NO
MORE
THAN
1/2
TURN
IN
EITHER
DIRECTION
WHEN
STABILIZING
THE
ENGINE
SPEED.
SPARK
ARRESTER
SILENCER
NOTE:
THE
CHOKE
MECHANISM
SHOULD
FLU7TER
WHEN
THE
ENGINE
IS
CRANKING.
THE
RETURN
SPRING
MUST
REST
AGAINST
THE
ACTUATORS
MOUNTING
BRACKET -NOT
IN
THE
HOLE
IN
THE
CASTING
BOSS.
Speed
Actuator
Adjustment
BUnERFLY/lEVER
,!!~~~AnACHMENT
The
speed
actuator
adjustment
should
be
the
only
device
in
control of
the
throttle's position.
The
throttle linkage's eye
bolts
must
be
2 5/S"
apart
(see
illustration. The
throttle
should
be
in
full
fuel
position
when
the
unit
is
shutdown.
OPEN
1/16"
Engines &-Generators
38
~
PIN
HOLE
SPEED
ACTUATOR:
THE
SPEED
ACTUATOR
SHOULD
MOVE
FREELY.
.
KEEP
THE
SOLENOID
DRY
AND
LUBRICATE
THE
LINKAGE
WITH
TEFLON
OR
GRAPHITE
LUBRICANT
ONLY.
1
CHECK
THE
DISmlBUTER
CAP
FOR
CRACKS,
WEAR
AND
EVIDENCE
OF
OR
BURNING.
IF
ANY
OF
THESE
CONDmONS
EXIST.
REPLACE
THE
DlSmlBUTER
CAP.
NUMBERS
INDICATE
THE
SUGGESTED
ORDER
OF
DISASSEMBLY
6
2
TESTING
THE
PICK
UP
COIL
STANDARD
RESISTANCE
VALUE;.420
;540 m
DISTRIBUTOR
3
COVER
PICK·UP
ASSEMBLY
VACUUM
CONTROL
1
WIRE
SET
Cheek that
when
a screwdriver
is
passed near the iron
core
of
the
pick-up assembly
the
needle of
the
tester deflects.
Adjust
the
point
'gap
of
the
pick-up
assembly
between
the
rotor
and
the
pick-Up.
STANDARD
GAP:
0.35mm
TO
O.40mm
INSPECTING
SPARK
PLUGS
Check
the
plugs
for
carbon
build-up
and
burning.
Check
the
plug
gap.
SPARK
PLUG
GAP:
0.028·0.031
in
(0.7
•
0.8
mm)
Engines & Generators
39
STARTER
MOTOR
NOTE:
To
oider
spare
parts,
contact
your
WESTERBEKE
dealer.
Q)
COVER
\
;/
~
o
RETAINER
/)
/'"
:----------------y
1
~ / ~
BUSHIN~
: WGEAR :
I I
I I
STATIONARY
GEAR
ASSEMBLY
~----------------:
~TW_
RETAINER
.
D.E.
HOUSING
/i
~
Ii
SCREW
/"
SCREW
STARTER
DISASSEMBLY
Disconnect
the
wires
and
remove
the
solenoid
from
the
motor.
Remove
the
thru
bolts
and
screws
from
the
back
of
the
motor
and
separate
the
frame.
This
will
provide
access
to
the
brush
holder
assembly
and
the
armature.
BRUSH
HOLDER
ASSEMBLY
C.E.
FRAME
(COVER)
Use
this
exploded
view
drawing
to
disassemble
and
reassemble
the
starter
motor.
The
following
pages
describe
the
testing
and
repair
of
the
starter
motor
assembly.
Engines & Generators
40
STARTER
MOTOR
DESCRIPTION
The starter can be roughly divided into the following sections:
• A motor section which generates a drive power.
•
An
overrunning clutch section which transmits an arma-
ture torque, preventing motor overrun after starting.
• A switch section (solenoid) which is operated when actuating the overrunning clutch through a lever and which
supplies load current to the motor.
The starter is a new type. small. light-weight and is called a
high-speed internal-reduction starter. The pinion shaft
is
separate from the motor shaft; the pinion slides only on the pinion shaft. A reduction gear is installed between the motor
shaft and a pinion shaft. The pinion sliding part
is
not
exposed outside the starter so that the pinion may slide
smoothly without becoming fouled with dust and grease. The
motor shaft
is
supported at both ends on ball bearings. The
lever mechanism. switch and overrunning clutch inner circuit
are identical to conventional ones.
ADJUSTMENT
AND
REPAIR
If any abnormality is found by the following tests. the starter
should be disassembled and repaired.
Pinion
Gap
Inspection
1.
-Connect a battery (12V) between the starter terminal S
and the starter body, and the pinion drive should rotate out
and stop.
A
CAUTION:
Never
apply
battery
voltage
for
over
10
seconds
continuously.
2.
Lightly push the pinion back and measure the return
stroke (called pinion gap).
3.
If
the pinion gap
is
not within the standard range, (0.5 to
2.0 rom), adjust it by increasing or decreasing the number
of
shims on the solenoid. The gap
is
decreased as the
number
of
shims increases.
PINION
GAP
No-Load
Test
1.
Connect the ammeter, voltmeter, and battery to the starter
as illustrated.
2. When the switch
is
closed, the pinion must protrude and
the starter must run smoothly (at 3000 rpm or more),
If
the current
or
starter speed is out
of
specification, disas-
semble the starter and repair
it.
e
.-------------1
BATTERY
A
CAUTION:
Use
thick
wires
as
much
as
possible
and
tighten
every
terminal
securely.
This
is a solenoid
shift-
type
starter
which
makss a rotating
sound
louder
than
that
of a direct-drive
type
starter..
When
detecting
starter
rotation
at
the
pinion
tip,
be
careful
not
to
come
in
contact
with
the
pinion
gear
when
It
protrudes.
SOLENOID
Perform the following tests.
If
any test result
is
not
satisfactory, replace the solenoid assembly.
1.
Inspect the solenoid for continuity between terminals
(+) and (-)
and
between terminals S and the body and
M and the body. There should
be
no continuity found
between terminals S and
M.
Continuity will be found
between terminals S and the body and terminal M and
the body.
MULTIMETER
NOTE:
Disconnect the wire from terminal
M.
2. Connect a battery to the solenoid's terminal S for (+)
and M for (-). Have a switch in the + lead and close
it.
The pinion drive should extend fully out.
A
CAUTION:
Do
not
apply
battery
current
for
more
than
10
seconds
when
tsstinu
the
solenoid.
Engines & Generators
41
STARTER
MOTOR
STARTER
INSPECTION
Solenoid
Inspect the solenoid for continuity between terminals S
and
M and between tenninals S and
body.
No continuity should
be found between
S and M. Continuity should be found
between
S and the body and M and the body.
CONTINUITY
CHECK
Inspecting
The
Armature
1. Check the armature with a growler tester.
If
it's
short
circuited, replace the armature. Also check for insulation
between the communicator and
its shaft.
If
poorly
insulated, replace
the
armature.
ARMATURE--H-~
ARMATURE
CHECK
2. Measure the commutator O.D. and the depth
of
undercut.
Repair or replace
it
if
the service limit is exceeded. Also
check the commutator outside surface for
dirtiness
and
roughness.
If
rough, polish the commutator with fine
crocus cloth.
Brush
and
Brush
Holder
Inspection
1.
Check the brushes.
If
worn out beyond the service limit,
replace the brushes.
Brush Height
Standard 17
mm
(0.669 in)
Limit 6
mm
(0.236 in)
BRUSHES
NEW
USED
2. Check the brush spring tension. A weak
or
defective
spring will cause excessive brush wear; replace the springs
if suspect.
-
BRUSH
HOLDER
ASSEMBLY~
uu""""-___"
3.
Check for insulation between the positive brush holder
and holder base.
If
poorly insulated, replace the holder
assembly. Also check the brush holders for proper staking.
Commutar
O.D.
Standard
Standard: 38.7
mm
(1.523 in)
Service limit: -1.0
mm
(-0.039 in)
COMMUTATOR
0.0.
Engines & Generators
42
STARTER
MOTOR
Field
Coil
Inspection
1.
Check
for
insulation between one end (brush)
of
the
coil and yoke.
2.
Check for continuity between both ends (brushes)
of the coil
3. Check the poles and coil for tightness.
MUlTIMETER
FIELD
COIL
TEST
CONNECTOR
STARTER
ADJUSTMENT
AND
REASSEMBLY
A
CAUTION:
Before
installing,
thoroughly
clean
the
starter
flange
and
mounting
surfaces,
remove
a/l oil,
'old
paint,
and
rust.
Starter
perfonnance
largely
depends
on
the
quality
of
the
wiring.
Use
wire
of suffi-
cient
size
and
grade
between
the
battery
and
starter
and
fully
tighten
to
the
tenninal.
Reassemble the starter assembly
in
the reverse order
of
disassembly, making sure
of
the following:
1.
Pinion
shaft end play adjustment. Set the end play (thrust
gap) to between
0.5 to 2 mm by inserting an adjusting
washer between the center bracket and the reduction gear.
a. Fit the pinion shaft, reduction gear washer and snap
ring
to
the center bracket.
h. Measure end play by moving the pinion shaft
in
the
axial direction. If the end play exceeds
0.5 mm,
increase the number
of
adjusting washers inserted.
2.
Greasing.
Whenever the starter has been overhauled,
apply grease to the following parts:
a.
Armature shaft gear and reduction gear.
h.
All bearings.
c. Bearing shaft washers and snap rings.
d. Bearing sleeves.
e.
Pinion.
f. Sliding portion
of
lever.
A
CAUTION:
Never
smear
the
starter fitting
surface,
terminals,
brushes,
or
commutator
with
grease.
3. After reassembly, check
by
conducting a no-load test
again.
GEAR
WASHER
SNAP
RING
PINION
SHAFT
END
PLAY
Engines & Generators
43
FUEL
PUMP
-·l
==,=;~Pl
GENERATOR
WIRING
DIAGRAM
r
FUEL
i
.. i ...
,.
SOLENOID
'1
CHOKE
SOLENOID
----.----.------~
G
'"'16
GRA
EXHAUST TEMPERATURE
SWITCH
(N/C)
IGNITI~Nf\
COIL
lJ
DISTRIBUTOR
4114
RED/VIO
#12
YEll
RED
OlL
PRESS
,
)i\SWiTCH
'IwO)
'-Il·
InI--
,I
~
WATER TEMPERATURE
II
SWITCH
IN/C)
AUX.
OIL
PRESS
SWITCH
IN/C)
---+-+-------r--4~-
-#
12
RED
#1
G RED/WHT
BATTERY
12
VDC
#-
12
8LK
ON
SWITCH
REMOVE
(CUT OUT)
RES I STOR
R 6
ON.
OVERS
PHD
BOARi)
FOR
OPERATION
AT
1500
RPM
(50Hz)
,-----------~----------~--_+--+0~~~
START/STOP
o
OVERspnD
BOARD
12
II
I
III
L-t-t----_
't
IBARBER
COcE"AN
I
CONTROl I ER
*'16
ORG
i
16
WHT
t
16
BLK
#16 RED/VIQ
tl6
elK
----"#Ts
RE'"'.D"I"V
I"'D:---'
f---'l.-----.----~~-~-!-~
_R_ED
___
•
THESE
TWO
'lfIRES
ARE
POLAR
lIED.
OflSERVE
WIRE
TERMINAL
NUMBtRS.
OR
CHECK
WIRE
WITH
VOM
I
ATTACH
RED
LEAD
OF
YOM
TO
RED
WIRE
FROM
CONTROLLER.
!f16
WHT
0
*'
I G BlK
2
ATTACH
BLACK
LEAD
OF
YOM
TO
EACH
PURPLE
WIRE
iNDIVIDUAllY
OBSERVE
POLAR I TV
Engines & Generators
44
SWITCH
METER
~
I
12
VDC
GENERATOR
WIRING
SCHEMATIC
).j
___________
BA_T_T_ER_V_D~~>-:-W-'
T_C_"
_____
..::-jAI~I:;
II'
~I~II--
------~o----------~
t
J-
STARTER
)~----------.----
>-----!
'}.t
1 20
AMP
II
I ( I C I
RCU
I T
~
t I
BREAKER
2/A~P
KI
F.W.
RECTIFIER
rUSE
30A
~l"r
\
;:>-----1
J--
GENERA
TOR
STARTER SOLENOID
BATTERY
CHARGER
I
BARBER
COLMAN
I
ELECTRON!C
GOVERNOR
K2
HOUR
METER
~----------~If-----------------------------'----------~-+~
CO
I L
IL
_____
_
l f'll---4
1
0----------<n
~
DISTRIBUTOR
®30A
~SE
l
n
~
~
; ;
ru
~IL--+
___
~
~'"
-~
1/
FUEL
PUMP
FUEL
SOL
o,----------{~
ACTUALT""O'--,
----1~
~~~~~
0q~1~~
________________
~
OVERSPEED
Y r
'-=-
en
+
"'
,
D.
K2-RUN
RELAY
DS~.
s~
__
~
____
8~~6
~85
__________
___
L-
________
J.;(il"'--
__
~
di'__.j
CHOKE
SOL
ON
START
SWITCH SWITCH
KI-START
RELAY
l
~-'
~--~"_-,
____
--jf--
__
-j-
_____
~
_____
~86~
,8~5
__________
___
r-:""L _
,,_"
,
oJ,----<I--Io-"!"""
-
,..
CKf2~
-,
I
I
I
I
I
I
I
I
I
I
I
I
I
~4
-,
L!_I
STOP
SW
CKT
I
EXTHtMUpS
T L
SW
ITCH
OIL
PRESS.
SW I TC
H
WATER
Sm~H\----?-
REMOTE
CONIIECTOR
SHORTING
PLUG
JUMPER
PINS 2
TO
5
EnginesJt
Generators
45
12
AUX
OIL
PRESS. SWITCH
1
11
elK
'3
NOTES'
TAIL
WIRE
iI6AWG(IOSOEG C
60QV-AlPHMf
1858/19-MIL-W-16878D
TYPE
B)
UNLESS
Sf>EClrIED
OTHERWISE,
2
WARNING -RELAYS
KI,
K2
HAVE
INTERNAL
O!ODES
ACROSS
THEIR
COilS,
POLARITY
AS
INDICATED
MUST
BE
MAINTAINED
TO
AVOID
OA'-4AGE
TO
THE
RELAYS
RED
W
I-
REMOTE
PANEL
WIRING
SCHEMATIC
#043912
REMOTE
PANEL
RED
C
KT
1
L-------+---l{'.
ON
SW
WHITE
WHITE
Engines & Generators
46
#14
WHT/RED
#14
VEl/RED
#14
WHT
#14
RED/VIO
VIEWED
FROM
MATING
END
TESTING
RELAYS
GENERAL
All DC voltage measurements are made
to
the engine battery
negative ground point unless specified otherwise. In making
test measurements, make sure
that a good ground for the
meter
is
established, preferably the point where the negative
battery is connected to the engine. Battery positive voltage is
indicated
as
B+
and
should measure
no
less
than
11.5 volts.
AC voltage measurements
should
be made with a true
RMS AC meter to insure measurement accuracy.
ENG
INE.
GRO U NO
-",""i-hJ!i'(
I
rn:.
...
eil
GROUND
AND
8(+)
CONNECTIONS
RELAYS
o
The relays used in the control system have coils which are
polarized by the fact that they have internal free wheeling
suppression diodes across them. Relay coil terminal 86 must
be maintained (+), terminal
85(-).
The relay coil is rated 12V
DC, and the coil resistance is typically 85 ohms. With
B+
on
terminal 86, direct grounding
of
terminal 85
is
permissible
for testing purposes.
RELAYS
ARE
MOUNTED
TO
THE
FLOOR
OF
THE
CONTROL
PANEL
RELAYS
FOR
WIRING
CONNECTIONS,
REFER
TO
THE
WIRING
,
DIAGRAM
..
~~
~'l~
Engines & Generators
47
TAP
THE
GROUND
CONNECTION
TO
THE
TERMINAL.
RELAY
SHOULD
____ ~ "CLICK"
ON.
TO
B(+)
TESTING
THE
RELAY
TERMINALS
TESTING
COIL
RESISTANCE
TESTING
THE
IGNITER
DESCRIPTION
Unplug
the
two
connector's
at
the
distributor
plug.
Take
care
to
note
the
two
separate
connections
as
they
must
be
reconnected
in
the
exact
same
position.
Place
your
ohmmeter
leads
on
the
terminals
SG
and C shown
below
and
read
the
meter.
Then
reverse
the
ohmmeter
leads
and
again
read
the
meter.
In
one
direction
the
ohm
reading
will
be
100
ohms
less.
In
the
other
direction
there
should
be
no
ohm
reading.
Any
value
above
100
ohms
indicates a faulty
igniter.
Any
ohm
value
found
with
the
meter
connections
in
either
direction,
the
igniter
is
faulty.
SWITCH THE OHMMETER LEADS
BACK
AND
FORTH BETWEEN
TERMINALS
SG
AND.Q AND
READ THE VALUES.
Engines & Generators
48
GOVERNOR
SYSTEM
COMPONENTS
and
OPERATION
DESCRIPTION
The Electronic Governor consists
of
three components, the
CONTROLLER,
a pc board installed in the control panel. A
MAGNETIC
PICK·UP
(MPU) installed in the bellhousing over
the engine flywheel and the linear
ACTUATOR
mounted on the
engine and attached by linkage to the injection pump
throttle control.
SYSTEM
OPERATION
On start up system DC voltage is supplied to the controller to
use for actuator operation. When the starter is energized and
the engine cranks, the magnetic pick-up
(MPU) that is
positioned over the engines flywheel ring gear sends a low
AC signal
to
the controller (1.5 - 2.5 AC volts).
The controller interprets this
as
engine cranking speed and
sends a DC voltage
to
the actuator to operate the carburetor's
throttle ann. The position
of
the throttle
by
the actuator has
been previously determined by the speed adjustment on the
speed controller. The engine carries up to a set speed
determined by the AC voltage sent
by
the MPU.
The speed controller maintains this signal no load to full load
by varying the DC voltage
to
the actuator providing more or
less
tlu'ottle depending on the generator load.
Gain
Adjustment
The gain can be adjusted using a small screwdriver.
Adjustment should be between
30% and 40% as
is
required
to dampen speed oscillation under load.
An
adjustment
of
more than 40% can cause the unit to race (speed up) when
the load is removed or go into a hunting mode.
50
\
.,
'(S);
- -
.,.
...
GAIN
ADJUSTMENT
, \
o ,,0
0
Speed
Controller
The speed controller has a green LED indicating power
to
the controller, a plus and minus speed adjustment (buttons)
and a gain adjustment. The green LED blinks when the
power
is
tumed on and after it receives a signal from the
magnetic
pick-Up, it blinks at a faster rate.
GAIN
ELECTRONIC
SPEED
CONTROLLER
MAGNETIC
PICK-UP
[MPU]
INSTALLATION
The
MPU
is installed
in
the threaded opening on the side
of
the flywheel bellhousing. This positions the MPU over
the teeth
of
the flywheel ring gear.
Viewing through this opening, manually rotate the engine
crankshaft so as to position the flat
of
one
of
the ring
gear's teeth directly under the opening. Thread the
MPU
into the opening until it gently contacts the flat
of
this
tooth (Thread is
3/8" x 24). Back the MPU out
of
the
opening one
tum
and then lock it in this position with the
jam
nut. This will position the end
of
the MPU
approximately 0.030 inches away from the flats
of
the ring
gear teeth.
To ensure the
MPU
is positioned correctly, slowly rotate
the crankshaft by
3600 by hand
to
assure there is no
physical contact between the
MPU
and the ring gear teeth.
If
contact is felt between the
MPU
and the flywheel teeth,
the MPU may
be
damaged. Remove the MPU and inspect
it. Replace
if
necessary and repeat the above
installation procedure.
;=::,.=:=====
D.D30in
NOTE:
If
replacing the Magnetic Pick-Up (MPU) it
MUST
be replaced without cutting
and
splicing into the existing
wiring cable. Doing
so
will cause a erratiC
AC
signal to
the controller.
GOVERNOR
CIRCUIT
VOLTAGES
Monitoring the voltages found
in
the electronic governor's
circuit will be helpful in determining where in the circuit
the operating fault lies and with which component.
The circuit voltages listed with the circuit
"wiring
schematic" are the approximate voltages found in the
governor circuit with the unit running at idle and at
normal
1800rpm.
The electronic governor's circuit voltages can all
be
read
and monitored from the connections on the
12
position
terminal strip as illustrated.
Engines & Generators
49
PANEL
COMPONENT,S/WIRING
ELECTRONIC
SPEED
CONTROllER
PN
046945
.
/:
NOTE:
For
wiring
connection
:/'
refer
to
the
diagram
below.,
#16
BLACI<NVHITf
#16
WHITE
ONIC
SPEED
ELECTR
CONTRO
#16
VIOLfT/WHITE
(+)
fER
P.
,,-
#16
VIOLET
(-)
\
!.'l
#16
BLACK
(DC
-J
.
'"
:"
8l
~
HOURMETER
.7 6
OVERS
PEED
PC
.BOARD
PN
046732
MAGNETIC
PICK-UP
(MPU)
PN
046874
[~t:,~c,~~~~p
WIRING
SCHEMATIC
...--,--,.1-.......
.
NOMINAL
VOLTAGES
at
IDLE
and
1800
RPM
iH-}-
OVERSPEED
PC
.
BOARD
PH
046490
\
I@I
(illi
@j~i~
/
.
9.
8
\
NOTE:~E
WIRE
A
RE
POLARITY
SENSATIVE.
OBSERVE
WIRE
TERM
INAL
NUMBERS
Engines & Generators
50
TERMINALS
#7
~#6
#9'~
#8
#10 ~ #11
IDLE
1.5 -2.5
VAG
5.0 -5.5
DC
6.5·7.0
DC
#16 ~ #16
12.2
DC
RED
BLACK
1800
RPM
TERMINALS
#7~#6
4·7
AC
#9
~
#8
5.5·6.5
DC
#10 ~ #11
6.0 • 6.5
DC
.
#16
-+
#16
13.2
DG
RED
BLACK
ELECTRONIC
GOVERNOR
TROUBLESHOOTING
PROBLEM
TEST/CHECK
CORRECTION
Unit
starts,
then
overspeeds
1.
Check
DC
voltage
between
terminal
1.
Charge
starting
battery.
Start
unit,
troubleshoot
and
shuts
down.
#12
and + connection
on
hourmeter
battery,
charge
circuit.
when
ON
switch
is
depressed.
NOTE:
When
troubleshooting,
manually
operate
the
throttle
to
prevent
an
overspeed
or
disconnect
the
throttle
from
the
actuator
and
operate
manually.
2.
Check
the
AC
signal
from
the
MPU
2.
Check
the
MPU
resistance
value
and
positioning.
while
cranking,
voltage
should
be
Adjust
and
replace
as
needed.
1.5 -2.5
VAC.
3.
Check
the
actuator.
3.
Check
the
resistance
value.
Apply
12VDC
across
leds.
Should
fully
retract.
Replace
as
needed.
4.
Check
the
controller.
4.
Manually
control
unit.
Start
and
check
DC
voltage
between
#9
and
#8,
between
#11
and
#10.
Replace
controller
or
as
board
as
needed.
Unit
starts,
runs
at
idle.
1. I ncorrect
speed
adjustments
..
1.
Check
and
adjust
speed
adjustment.
NOTE:
Less
than
one
volt
DC
2.
Faulty
governor
controller
..
2.
Check
DC
voltages
from
controller
to
OIS
board
found
between
terminals
#9
and
and
O/S
board
to
actuator.
#8
and
high
DC
voltage-t 0 volts
or
higher
between
terminals
#11
and
#10
indicated a faulty
controller.
Actuator
hunts
during
operation.
1.
Improper
controller
adjustment.
1.
Lessen
GAIN
adjustment.
NOTE:
Check
carburetor
adjustments
before
proceeding.
2.
Linkage
or
rod
end
bearings
are
2.
Lubricate
and
replace
as
needed.
sticking
or
binding.
3.
Inadequate
DC
supply
voltage.
3.
Manually
stabilize
the
unit.
Check
the
DC
voltage
to
the
controller.
Correct
as
needed.
4.
MPU
positioned
marginally
4.
Check
the
MPU
signal.
Adjust
positioning
too
far
away
from
the
flywheel
as
needed.
teeth,
giving
an
erratic
AC
input
signal
to
the
controller.
Engines & Generators
51
THE
ELECTRONIC
GOVERNOR
GENERATOR
MODELS
UP
TO
JUNE
2004
DESCRIPTION
A generators engine must run at a constant speed to enable
the generator to produce the stable AC power (hertz)
required.
The Electronic Governor consists
of
three components, the
CONTROLLER,
a pc board installed
in
the control panel. A
MAGNETIC
PICK·UP
(MPU) installed in the bellhousing over
the engine flywheel and the linear
ACTUATOR.mounted
on the
engine and attached
by
Linkage
to the injection pump
throttle control.
The
Electronic Governor regulates the engine speed by
sensing the engine's RPM with the magnetic pick-up at the
flywheel. The governor's controller continuously monitors
the engines speed and
if
there is any discrepancy, the
controller signals the actuator and the actuator adjusts the
engine to the desired speed electronically.
CONTROLLER
ADJUSTMENT
The
controller has two adjustments: the
SPEED
adjustment
is
used
to increase
or
decrease the the engine's speed to the
desired hertz. The
GAIN
adjustment affects the reaction
time
of
the actuator to the generator load changes.
NOTE:
A high gain adjustment can induce
an
oscillating
of
the actuator producing a hunting mode. In such cases,
lessen the gain adjustment.
CALIBRATION
1. With no power to the governor (engine not running),
adjust the
GAIN
potentiometer to 9:00 o'clock.
2. Start the engine and adjust the speed by turning the
speed pod clockwise to desired speed.
NOTE:
Controllers are factory adjusted to minimum
RPM. However,
for
safety, one should be capable
of
disabling the engine
if
an overspeed should exist.
3.
At
no load, turn the
GAIN
potentiometer clockwise
until the engine begins to
hunt
If
the engine does
not
hunt, physically upset the actuator linkage.
4.
Tum
the
GAIN
potentiometer counterclockwise until
engine runs stable.
NOTE:
Controllers are available in
12
and
24 VDC
models. The operating voltage range is +
or
- 20%.
If
the voltage varies
wove
or
below this range, the
controller
will
not
operate
and
the engine will run in
the idle mode until proper
DC
voltage is supplied to
the controller.
ELECTRONIC
GOVERNOR
ADJUSTMENTS
The
controller has two adjustment pods.
You
need a mini
screwdriver
to adjust these.
One
is speed and one is gain.
These
are noted on the drawing
of
the controller.
Sum
the engine. The speed should be in the low idle range
600-700 rpm.
If
the engine speed is higher than this idle
range, shut the engine down. Check the linkage between
the actuator and throttle arm. The throttle arm stop should
be about touching the open idle stop screw boss. Adjust the
linkage to position the throttle lever. Restart the engine and
using the speed adjustment buttons bring the engine speed
to
1800 rpm (60Hz), 1500 rpm (50Hz). Momentarily push
the actuator linkage towards the actuator and release. The
actuator should quickly regain proper speed.
If
there is any
hunting, adjust the gain towards zero
(0) until this hunting
is removed.
When the gain is adjusted, you may need to re-adjust the
speed at no load, shut the generator down.
Start the generator.
Check speed (hertz) set at
50Hz/60Hz.
Load the generator.
If
the governor is slow to react and maintain 50Hz/60Hz,
adjust the gain clockwise. Again you may need to adjust
the speed at no load.
You
will find the governor will maintain set engine RPM
± 0.5
Hz
right up to the full rated amperage output for the
generator.
Engines & Generators
52
THE
ELECTRONIC
GOVERNOR
MAGNETIC
PICK-UP
[MPU]
INSTALLATION
The
MPU
is
installed
in
the threaded opening
on
the side
of
the
flywheel
bellhousing.
This
positions the
MPU
over
the teeth
of
the
flywheel
ring
gear.
Viewing through this opening, manually rotate
the
engine
crankshaft
so
as
to
position the
flat
of one of the ring
gear's teeth directly under the
opening.
Thread the
~U
into the opening until it gently contacts
the
flat
of this
tooth (Thread is 3/8" x 24). Back
the
MPU
out of the
opening one turn and then lock it in
this
position
with
the
jam
nut.
This will position the
end
of
the
MPU
.
approximately
0.030 inches
away
from
the
fiats
of
the nng
gear teeth.
To
ensure the
MPU
is
positioned correctly, slowly rotate
the crankshaft
by
360
0
by hand
to
assure there
is
no
phy~ical
contact between the
MPU
and
the
ring gear teeth.
If
contact
is
felt between
the
MPU
and
the
flywheel
teeth,
the
MPU may be damaged.
Remove
the
MPU
and inspect
it
Replace
if
necessary and repeat
the
above
installation procedure.
NOTE:
When replacing tlie Magnetic Pick-Up (MPU) it
MUST
be replaced without cutting and splicing into the
existing wiring cable. Doing
so
will cause a erratic A C
signal
to
the controller.
:=:====
O.030in
--
GOVERNOR
CIRCUIT
VOLTAGES
Below
are
the
voltages
normally
found
in
the
governor
circuit
when
the
system
is
functioning
normally.
These
voltages
are
an
approximate
and
should
be
of
help
in
troubleshooting a system that
is
not
functioning
correGtly.
DC
Voltage
into Controller
Bat
+
to
Bat -(battery
charging
voltage
13.5
-14.5
VDC)
(Terminal
block
#1
and
#2)
DC Voltage to Actuator
ACT
to
ACT
(5.5 -6.5
VDC)
(Terminal
block
#5
and
#6)
AC
Voltage from
MPU
into Controller
MPU
to
MPU
(2.5 - 7.0
VAC)
(Terminal
block
#3
and
#4)
This
voltage
spread
is
the result of the
distance
the
MPU
is
positioned
from
the
fiat
of the
flywheel
ring
gear
tooth.
The
closer to the tooth, the higher the
AC
signal.
The
further
away,
the lower
the
AC
signal.
Engines & Generators
53
Problem
System
appears
dead.
(No
actuator
movement)
Engine
runs,
but
at
idle
speed
Actuator
lever
goes
to
full
extension
when
the
preheat
switch
is
depressed
and
stays
extended.
ELECTRONIC
GOVERNOR
TROUBLESHOOTING
Test/Check
1.
Check
the
battery
voltage
at
the
controller
terminal
block
with
the
Preheat/On
switch
depressed.
2.
Inspect
the
linkage
for
binding
or
sticking.
3. If
there
is
no
signal
or a weak
signal
from
the
MPU,
measure
the
AC
voltage
between
the
white
and
black/white
wire
leads
from
the
MPU
on
the
controller
terminal
block.
While
cranking
the
engine
or
with
the
engine
running
at
idle,
voltage
should
be
1.5-2.5
VAC.
NOTE:
The
AC
input
impedance
of
meter
must
be
5000
ohms/volts
or
greater.
NOTE:
When
making
this
test
on
diesel
units,
disable
the
preheat
solenoid
by
disconnecting
the
"s"
terminal
connection
so
as
not
to
damage
the
glow
plugs.
4.
Check
the
actuator
with
the
preheat/on
switch
depressed.
This
provides
DC
voltage
to
the
controller.
Measure
the
DC
voltage
between
the
actuator
connections
on
the
controller
block
and
the
black
DC
(-)
power
connection
on
the
controller
terminal
block.
Both
connections
should
have
battery
voltage
+0.00
or
-0.75
VDC.
a.
Purple
lead
to
Black
DC
(-).
b.
Purple
lead/purple/white
lead
to
Black
DC
(0).
NOTE:
Continue
this
test
(ONLY)
if
the
battery
voltage
is
not
present.
c.
The
following
checks
are
performed
between
the
connections
at
the
actuator
and
the
Black
DC
(-)
connection
on
the
controller
terminal
block.
This
is
to
determine
if
there
is a break
in
the
line
between
the
controllers
terminal
block
connection
and
the
actuator
connections
or
the
actuator
leads
themselves.
1)
Low
voltage
(1.0-2.0
VDC)
at
either
actuator
connections.
2)
Battery
voltage
at
both
actuator
connections.
3)
Battery
voltage
at
one
actuator
connection
but
not
at
the
second.
1.
Check
the
controlier
by
removing
the
two.
purple
leads
one
at a time
that
come
from
the
actuator
off
the
controlier
terminal
block.
Lift
one
actuator
lead
and
depress
the
preheat/on
switch.
Reconnect
and
do
the
same
with
the
second.
NOTE:
Ear/y
controllers
had
two
solid
purple
leads
for
the
actuator
connections.
Later
model
controllers
have
one
solid
purple
and a purple/white
stripe
for
the
actuator
connection.
The
purple/white
lead
is
designated
(+)
and
is
specific
only
in
gasoline
DC
circuits.
a.
Actuator
goes
to
full
extension
(Diesel),.
Does
not
retract
(Gasoline).
b.
Actuator
does
not
extend
(Diesel).
Correct
1.
Inspect
the
DC
circuit
back
to
the
starting
battery.
2.
Free
up
the
linkage
and
clean
and
lubricate
the
linkage.
3.
Check
for
damage
to
or
improper
adjustment
of
magnetic
pick-up.
Replace
or
re-adjust.
4.
Low
voltage
(1.0-2.0
VDC)
at
either
actuator
connections.
b.
Replace
the
controller
if
battery
voltage
is
not
present
at
both
the
Purple
leads.
1)
Broken
actuator
lead,
repair.
2)
Broken
actuator
lead,
repair
or
replace
actuator.
3)
Check
actuator
winding
for
open.
Replace
actuator.
1.
Check
for a shorted
actuator
lead.
Replace
the
controller
because
it
should
not
cause
the
actuator
lever
to
go
to
full
fuel
when
the
engine
is
not
running.
a.
Check
for
shorted
actuator
load.
b.
Replace
controller.
Actuator
hunts
during
operation.
1.
Linkage
or
rod
end
bearings
are
sticking
or
binding.
1.
Lubricate
or
replace.
2.
Improper
governor
adjustment.
3.
Inadequate
power
supply
voltage.
a.
Connect a DC
voltmeter
to
Red
(+)
and
Black
(-)
leads
at
the
controller
terminal
block.
b.
Disconnect
both
leads
coming
from
actuator
from
controller
terminal
block.
c.
Connect
one
lead
from
the
actuator
to
the
Red
(+)
on
the
terminal
block
and
the
other
actuator
lead
to
the
Black
(-)on
the
terminal
block.
d.
Momentarily
depress
the
preheat/on
switch.
The
actuator
should
extend
fully
and
stay
extended
(diesel)
and
retract
(gasoline)
as
long
as
the
switch
is
depressed.
2.
Re-adjust
the
calibration.
3.
If
actuator
doesn't
fully
extend
(diesels)
or
retract
(gasoline)then
check
the
actuator
leads.
If
the
voltage
is
less
than
specified,
check
for
loose
or
poor
connections
in
the
DC
circuit
back
to
the
battery,
check
the
K2
relay
and
its
connections.
Measure
the
DC
voltage
across
the
Red
(+)
and
Black
(-)
leads
while
perfOrming
this
test.
DC
voltage
must
be
greater
than
80% 0 the
DC
voltage
measured
across
the
battery
supply.
24
VDC @ 80% = 19.2
VDC
12
VDC @ 80% = 9.6
VDC
NOTE:
Reconnect
the
actuator
leads
properly
after
completing
this
test.
e.
MPU
pOSitioned
marginally
too
far
away
from
flywheel
e.
Check
the
position
of
the
MPU.
teeth
giving
erratic
AC
input
to
controller.
If
problems
continue
to
perSist,
contact
your
WESTERBEKE
dealer
for
additional
assistance.
Engines & Generators
54
ENGINE
ADJUSTMENTS
ENGINE
COMPRESSION
TEST
1.
To
check the engine's compression pressure, warm
up
the
engine then shut it
down.
2.
Remove the
three
spark plug
caps
and
remove
the
three
spark plugs.
3. Install a compression adapter
and
gauge
in the spark
plug
hole.
4.
Close
the
raw
water seacock.
5. Crank the engine
with
the start motor and
unplug
the
ignition
coil
and
allow
the compression gauge
to
reach a
maximum reading and record.
6.
Measure
the
compression pressure
for
all
the
cylinders.
Ensure that compression pressure differential
for
each
cylinder
is
within
the
specified
unit.
COMPRESSION
PRESSURE
189PSI
(1260
Kpa)
at
400
RPM
Compression
Pressure
should
not
differ
by
more
than
14
psi
(100Kpa)
7.
If a
cylinder's
compression
or
pressure
differential
is
below the limit,
add
a small amount of engine oil through
the
spark plug
hole
and repeat steps 4 and
5.
a)
If additional oil causes
an
increase of pressure, the
piston
ring
and/or cylinder
wall
may
be
worn
or
damaged.
b)
If additional
oil
does not increase compression
pressure, suspect poor valve contact, valve
seizure,
or
valve
wear.
8. Reinstall three
plugs
and ignition
wires.
9.
Open the raw water seacock.
COMPRESSION
GAUGE
TESTING
ENGINE
~
~COMPRESSION
~
ADAPTER
NOTE:
Do
not
guess
the
conditions
of
other cylinders
from
a
result
of
testing
one
cylinder.
Be
sure
to
measure
the
compression pressure for each
cylinder.
Look for cylinders
with
dramatically (at least 20%) lower compression
than
the
average
of
the
other cylinders.
If
the
weak cylinder
is
flanked
by
healthy
cylinders,
the
problem
is
either valve or
head-
gasket
related.
very
low
compression
in
an
adjacent cylinder
indicates gasket
failure.
Abnormally high
readings
on
all
cylinders indicate heavy carbon accumulations, a condition
that might
be
accompanied by high pressure and
noise.
TESTING
OIL
PRESSURE
To
test oil pressure, remove the hex
head
plug
from
the oil
gallery
and
install a mechanical oil pressure
gauge
in
its
place.
After warming
up
the
engine,
set
the
engine
speed at
1800
rpm
and read the oil pressure
gauge.
OIL
PRESSURE
BETWEEN
30
AND
40
PSI
AT
1800/1500
RPM
NOTE:
A newly staned, cold engine may
have
an
oil pressure
reading
up
to
70
or
80
psi.
A warmed engine
can
have
an
oil
pressure
reading
as
low
as
30 psi.
Oil
pressure will vary
depending
upon
the
load placed
on
the
generator.
OIL
GALLERY
HIGH
TENSION
CORDS
(IGNITION
WIRES)
Check
the
ignition
wires
every
500 operating hours
as
engine
compartment heat can deteriorate the
wires.
Check
the
resistance of each
wire.
Do
not
pull
on
the
wire
because the wire connection inside
the
cap
may
become
separated or the insulator
may
be
damaged.
When removing
the
wires
from the spark
plug,
grasp
and
twist the moulded
cap,
then
pull the
cap~ff
the spark
plug.
THE
RESISTANCE
VALUE
IS
410
OHM
PER
INCH
OF
WIRE.
TESTING
RESISTANCE
Engines & Generators
55
ENGINE
ADJUSTMENTS
TORQUING
THE
CYLINDER
HEAD
BOLTS
After
the
initial
breal<-in
period (approximately
50
hours),
the
cylinder head bolts should
be
re-torqued.
Tighten the
cylinde:r
head bolts according
to
the
sequence
shown. Make sure the engine
is
cold
when
this
is
done,
and
loosen one head bolt one-half tum
and
then
tighten it
between
43 -51
Ib-ft (60 - 70
Nm).
Then
proceed
to
the
next
head bolt
in
the
sequence. Tighten
the
RS
(rocker
cover
stud)
securely.
FRONTOF~
ENGINE
..........-...
6
IGNITION
TIMING
4 2
1.
Attach a timing light
to
the
#1
spark plug and
mark
the
front timing pointer
to
indicate
15°.
Locate the
timing
mark
on
the crankshaft pulley
and
mark
it
with
white
chalk
or a crayon.
2. Start the engine and warm it
up
to
its normal operating
temperature. Make sure the generator
is
operating without
a loadoni(.
3. Using the timing light, align the timing mark
in
the
front
crankshaft pulley
so
it
is
just slightly before the
fIrst
tim-
ing pointer.
Do
this
by
loosening and slowly rotating
the
distributor
body.
Use
the
following timing specifIcations:
Timing
Specifications:
15" ± .5°
BTDC
at
1800
rpm
(no
load
on
generator)
IGNITION
TIMING
7
VALVE
CLEARANCE
ADJUSTMENT
NOTE:
Retorque
the
cylinder head bolts
before
adjusting
the
engine's
valves
(see
TORQUING
THE
CYliNDER
HEAD
BOLTS).
1.
Remove
the
rocker cover and gasket.
2.
Rotate
the
crankshaft in the normal direction of rotation,
placing
the
No.1 piston at the top
of
its compression
stroke
with
the exhaust and intake valves completely
closed. Adjust the intake and exhaust valves for No.1
cylinder,
the
exhaust valve for
No.2
cylinder,
and
the
intake valve for NO.3 cylinder (see chart).
3.
Rotate
the
crankshaft
180
0
in
its normal direction of
rotation. Locate the piston
in
No.1
cylinder at
the
top
of
its exhaust stroke. Adjust the intake valve for
No.2
cylinder and the exhaust valve for
No.3
cylinder
(see
chart).
CYLINDER
#
CRANK
ANGLE
1 2 3
When
No. 1 piston
is
set
at
top
of
IN
•
•
compression
stroke
•
•
EX
When
No. 1 piston
is
positioned
IN
•
at
top
of
exhaust
stroke
EX
•
4
..
Replace the rocker cover along with a new rocker cover
gasket..
Rocker
cover
torque:
2.9-5.1
Ib-ft
(4
-7
Nm)
VALVE
CLEARANCE
Valve
Clearance:
INTAKE
.008
inches
(O.20mm)
EXHAUST
:012
inches
(O.30mm)
Engines & Generators
56
ENGINE
ADJUSTMENTS
SPARK
PLUGS
The
spark
plugs
should
be
cleaned
and
regapped after
the
fIrst
50
hour
break-in
period,
then
inspected every 250
hours
thereafter
and
replaced
as
needed.
A
WARNING:
Do
not
remove
the
spark
plugs
while
the
engine
is
hot.
Allow
the
engine
to
cool
before
removing
them.
Spark
plug
gap:
0.031
+/~
0.0002
in.
(0.8
-0.05
mm).
Spark
plug
torque:
10
-15Ib-H
(1.5
-
2.31
kg-m).
NOTE:
£octite Anti-Seize applied
to
the
threaded portion
of
the
spark plugs will
retard
corrosion,
making future removal
of
the
spark plugs
easier.
GAP
INSPECT
FOR
WEAR & CARBON
INSPECTING
THE
SPARK
PLUGS
CHOKE
SOLENOID
INSPECT
FOR
DAMAGE
CHECK
FOR
DETERIORATION
AND
DAMAGE
The choke solenoid
is a 12
volt DC 9perated unit
that
func-
tions
to
close
the
choke
plate
in
the carburetor
when
the
ON
switch is depressed
during
engine start-up.
The choke solenoid de-energises once the engine
starts
and
.the
ON
switch
is
released.
Spme unstable running
may
be
present
when
the
engine
starts cold but' should
smooth
out
as
the
engine
reaches
operating
temperature.
Keep
this
solenoid
dry
and
periodically lubricate
the
linkage
between
the
solenoid
and
the
choke
lever.
~---CHOKE
SOLENOID
DRIVE
BELT
ADJUSTMENT
The
drive belt must
be
properly
tensioned.
Excessive
drive
belt
tension
can
cause
rapid
wear
of
the
belt
and
reduce
the
service
life of
the
fresh
water
pump's
bearing.
A slack
belt
or
the
presence
of oil
on
the
belt
can
cause
belt
slipping,
resulting
in
high
operating temperatures.
The
BCGB
generator
has
two
drive
belts.
one
drives
the
governor
and
alternator
and
the
other
drives
the
raw
water
pump.
The tension adjustment procedure
for
both
belts
is
as
follows:
1.
Remove
the
belt
guard.
2.
To
adjust
the
governor
drive
belt.
loosen
the
two
governor
mounting
bolts.
To
adjust
the
raw water pump/fresh
water
pump
drive
belt,
loosen
the
two
raw
water
pump
mounting
bolts.
3.
With
the
belt(s) loose,
inspect
for
wear.
cracks
and
frayed
edges,
and
replace if
necessary.
4.
To
loosen
or
tighten
the
governor
drive
belt,
slide
the
governor
in
or out
as
required,
then
retighten
its
mounting
bolts.
To
loosen
or tighten
the
raw
water
pump/fresh
water
pump
drive
belt. slide
the
raw
water
pump
in
or
out
as
required,
then
retighten
its
mounting
bolts.
5.
The
drive
belts
are
properly
adjusted if it
can
be
deflected
no
less
than
3/8 inch
(IOmm)
and
no
more
than
112
inch
(l2mm)
as
the
belt
is
depressed
with
the
thumb
at
the
midpoint between
the
two
pulleys
on
the
longest
span
of
the
belt
NOTE:
Maintain a
22
lb
pressure
to
the
belt's outer face
for proper belt operation.
Spare
belts
should
always
be
carried
on
board.
6.
Operate the generator for about 5
minutes,
then
shut
down
the
generator
and
recheck the
beJt(s)
tension.
7.
Replace
the
belt
guard.
RAW
WATER
PUMP
BRACKET
Engines & Generators
57
BATTERY
CHARGE
CONTROLLER
THE
CHARGING
SYSTEM
Westerbeke's
low
profile
generators
are
equipped
with
a
battery
charge
controller that
is
powered
from
a separate
winding
in
the
generator.
The battery charger controller
is
an
encapsulated, solid-state unit that supplies a
DC
charging
voltage
to
the
generator's starting battery
while
the
generator
is
operating.
Charging Voltage: 13.1 - 13.4 volts
DC
Charging Anlperage: 0 - 17- amps DC
NOTE:
The
battery
charging
circuit
is
totally
separate from
the
AC output
of
the
generator.
The
generator
output
affects
the
circuits
output,
but not
the
reverse.
A separate
group
of stator
windings
supplies
AC
voltage
to
a
bridge
rectifier
which
converts
the
AC
current
to
supply
the
charging
unit.
The unit senses
the
needs
of
the
starting
battery
and
supplies a DC
charge
when
one
is
needed.
If
you
suspect that
the
unit
is
faulty
(if
the
battery'S
charge
is
low),
check
the
charging
circuit
and
it's components(see
TESTING
THE
BATTERY
CHARGER).
Check
all
connections
for
cleanliness
and
tightness
including
the
ground before
replacing
the
I.C.
charger.
NOTE:
When
the
generator
is
first
started,
the
charger
will
produce a low
chargillg
rate.
This
charging
rate
will
rise
as
the
generator
is
operated.
Fuse
Protection
A
30
amp
fuse
protects
the
windings
from a failure
of
the
bridge
rectifier
or
the
battery charger caused
by a high
amperage
or
a short circuit.
VOLTAGE
ADJUSTMENT
POD
TURN
RIGHT
TO
INCREASE
OR
LEFT
TO
DECREASE
(+
OR -2VDC)
OUTPUT
VOLTAGE
SHOULD
BE
13.1
TO
13.4
VDC
Testing
the
Battery
Charger
To
test the battery
charger,
put a multimeter
between
the
positive (+)
and
negative
(")
leads.
to
the
battery.
It
should
indicate
13.1 V to
13.4V
with
the
engine
running.
If
only
the
battery
voltage
is
indicated, check that
the
battery charger
terminal connections
are
tight.
With
the
unit
running,
test
between
the
(+)
and
(-)
on
the
battery
charger
(as
illustrated)
for
13.
IV
to
13.4V.
If
no
charge
is
indicated,
replace
the
charger.
Use
of a dedicated
and
isolated starting
battery
is
strongly
recommended.
FUSE -INTEGRAL
CONTROLLER
WINDING:
NO
TIME
DELAY---------.
Pn#43634
30A
250V
MDA-30
B~IDGE
(+)
(-)
GROUND
Bew
FUSE·
INTEGRAL
CONTROLLER
WINDING:
NO
TIME
DELAY
Pn#43634
30A
250V
MDA-30~
DC
(+)
CHARGE
.
(0)
ICHARG"~
n
BRIDGE
~
V1
RECTIFIER
!
V2==IEl
CONTROL
BOX
GROUND
~.i'.....
30
AMP
FUSE
q;·~I~(&)·"::··
..
~
~.
..:.,
NOTE:
ON
SOME
MODELS
THE
BATTERY
CHARGE
CONTROLLER
IS
MOUNTED
AT
THIS
END
OF
THE
CONTROL
BOX.
NEGATIVE
TEST
PROBE
Engines & Generators
58
7.0
KW
BCGC/BCGD
GENERATOR
SPECIFICATIONS
ENGINE
SPECIFICATIONS
Engine
Type
Bore & Stroke
Total
Displacement
Bearings
Compression
Chamber
Compression
Ratio
Hp@1800J1500
rpm
Rring
Order
Aspiration
Direction
of
Rotation
Inclination
Dry
weight
Governor
Fuel
Pump
Fuel
Distributor
Spark
Plugs
Ignition
Coil
Flame
Arrester
Carburetor
Fuel
Consumption
(Full
Load)
3-cylinder,
4-cycle, , overhead
camshaft
w/counterbalance
shaft,
water
cooled
gasoline
engine
2.56 x 2.61
inches
(65.0 x 66.3
rnm)
40.3
cubic
inches
(0.66
liters)
Four
main
bearings
Semi-spherical
9.8:1
8.0/6.5
1-3-2
Naturally
aspirated
Counterclockwise
viewed
from
the
back
end
25°
continuous,
all
directions
3071bs
(139.3
Kgs)
Electronic
FUEL
SYSTEM
Open
flow,
self
bleeding
Unleaded
89
octane
or
liigher
gasoline
Breakerless
distributor
14mm
12
volt
Metal
screen
type
Single
draft
type
.8
GPH@
1800
rpm
ELECTRICAL
SYSTEM
Start
Motor
12-Volt
reduction
gear
with
solenoid
Starting
Battery
12-Volt,
(-)
negative
ground
Battery
Capacity
105
Cold
Cranking
Amps
(CCA)(min))
Battery
Charging
Integral
electric,
17
amps
General
Fresh
Water
Pump
Raw
Water
Pump
Raw
Water
Flow,
Cooling
Water
Capacity
Operating
Temperature
Fresh
water-cooled
block
through
raw
water-
cooled
heat
exchanger
circuit
Centrifugal
type,
metal
impeller,
bell-driven.
Positive
displacement,
rubber
impeller,
belt-driven.
4.9
US
gpm
at
1800
rpm
(approx.
measure
before
discharging
into
exhaust
elbow).
3
qts
(2.8
liters).
150°
-170° F (65
_77°
C)
LUBRICATION
SYSTEM
General
Oil
Filter
Oil
Capacity
Operating
Oil
Pressure
Oil
Grade
Forced
lubrication
by
gear
pump.
Full
flow,
paper
element
spin-on
disposals.
2.5
qts.
(2.4
liters).
40 -60
psi
(2.8 -4.2
kg/cm').
API
Specification
SJ
class
AC
GENERATOR
(Single
Phase)
Single
Phase
Ratings:
7.0KW
5.9KW
Brushless,
four-pole
capaCitor,
regulated.
1800
rpm/60Hz,
1500
rpm!50Hz
120
volts,
58.3
amps,
60Hz
single
phase, 4 wire,
10.
power
factor
230
volts,
25.6
amps,
50Hz
single
phase, 4 wire,
10.
power
factor
TUNE-UP
SPECIFICATIONS
Spark
plug
Gap
0.031
±.002
inches
(O.B ± O.05mm)
Spark
Plug
Torque
10.8 -15.2
Ib-ft
Cylinder
Head
Torque
60-70
Nm
(43-51
ft-Ibs)
Bolt
Torque
See
TORQUING
THE
CYUNDER
HEAD
Engines & Generators
59
5.0
KW
BCG\BCGA
GENERATOR
SPECIFICATIONS
ENGINE
SPECIFICATIONS
Engine
Type
Bore & Stroke
Total
Displacement
Bearings
Combustion
Chamber
Compression
Ratio
Hp@180011500
rpm
Rring
Order
Aspiration
Direction
of
Rotation
Inclination
Dry
Weight
Governor
Fuel
Pump
Fuel
Distributor
Spark
Plugs
Ignition
Coil
Rame
Arrester
Carburetor
Fuel
Consumption
(Full
Load)
3
cylinder, 4 cycle,
overhead
camshaft
w/counterbalance
shaft,
water
cooled
gasoline
engine
2.56 x 2.61
inches
(65.0 x 66.3
mm)
40.3
cubic
inches
(.66Uter)
Four
main
bearings
Semi-spherical
9.8-1
8.0/6.5
1-3-2
Naturally
aspirated
Counterclockwise
viewed
from
the
back
end
25°
continuous,
all
directions
307
Ibs
(139.3
Kg)
Electronic
FUEL
SYSTEM
Electric
fuel
pump
Unleaded
89
octane
or
higher
gasoline
8reakerless
distributor
14mm
12
volt
Metal
screen
type
Single
draft
type
.8
GPH @ 1800
rpm
ELECTRICAL
SYSTEM
Start
Motor
12
volt
reduction
gear
with
solenoid
Starling
Battery
12
volt
negative
ground
Battery
Capacity
105
Cold
Cranking
Amps(CCA)(min)
Battery
Charg i ng
Integral
electric,
17
amps
General
Fresh
Water
Pump
Raw
Water
Pump
Fresh
water-cooled
block
through
raw
water-
cooled
heat
exchanger
circuit
Centrifugal
type,
metal
impeller,
belt-driven
Positive
displacement,
rubber
impeller,
belt
driven.
Raw
Water
Flow
4.9
gpm
at
1800
rpm
(measured
before
discharge
into
exhaust
elbow)
Approx.
Cooling
Water
Capacity 3 qts
(2.8
liters)
Operating
Temperature
150
0
-
1700 F
(65
0
- n°
C)
LUBRICATING
SYSTEM
Type
Oil
Riter
Oil
Capacity
Oil
Grade
Operating
Oil
Pressure
Forced
lubrication
by
gear
pump
Fuel.
flow,
paper
element,
spin-on
disposals
.2.5
qts.
(2.4
liters)
API
Specification
SJ
class
40 -60
psi
(2.8 -4.2
kg/em')
AC
GENERATOR
(SINGLE
PHASE)
Type
Ratings
5.DKW
4.2KW
Brushless,
four
pole
capacitor,regulated.
1800
rpm/60Hz,
1500
rpm/50Hz
120
volts,
41.6
amps,
60
Hz
Single
phase, 4 wire,
1.0
power
factor
230
volts,
18.2
amps,
50
Hz,
single
phase,
4
wire,
1.0
power
factor
TUNE-UP
SPECIFICATIONS
Spark
PI
ug
Gap
0.031
±.002
inches
(0.8±0.05
mm)
Spark
Plug
Torque
10.8
-15.2Ib-ft
Cylinder
Head
Torque
60 -70
Nm
43 -511t-lbs
Bolt
Torque
See
TORQUING
THE
CYLINDER
HEAD
Engines & Generators
60
GENERATOR
INFORMATION
USE
OF
ELECTRIC
MOTORS
The power required
to
start
an
electric motor
is
considerably
more
than
is
required to keep it running after it is
started.
Some
motors require
much
more current
to
start them
than
others. Split-phase
(AC)
motors require
more
current
to
start,
under similar circumstances,
than
other types. They
are
com-
monly
used
on
easy-starting loads, such
as
washing
machines, or where
loads
are applied after
the
motor
is
started, such
as
small power
tools.
Because they require 5
to
7 times
as
much current
to
start
as
to
run, their use should be
avoided, whenever possible, if
the
electric motor is
to
be
dri-
ven
by a small generator. Capacitor
and
repulsion-induction
motors
require
from 2 to
4 times
as
much current
to
start
as
to
run.
The current required
to
start
any
motor varies with
the
load connected
to
it.
An
electric motor connected
to
an
air
compressor,
for
example, will require more current
than
a
motor
to
which
no
load
is
connected.
In
general,
the
current
required
to
strut
115-
Volt
motors
connected
to
medium
starting
loads
will
be
approximately
ac;
follows:
MOTOR
SIZE
AMPS
FOR
AMPS
FOR
(HP)
RUNNING
STARTING
(AMPERES)
(AMPERES)
1/6
3.2
6.4
to
22.4*
114
4.6
9.2
to
32,2*
1/3
5,2
10.4
to
72,8
*
1/2
7.2
14.4
to
29.2*
3/4
10,2
20.4
to
40.8*
1
13
26
to
52
*NOTE:
In
the
above
table
the
maximum
Amps
for Starting
is
more
for
some
small motors
than
for larger
ones.
The
reason
for this is
that
the
hardest starting types (split-phase)
are
not
made
in
larger
sizes.
Because
the
heavy
surge
of current needed for starting
motors
is
required for
only
an
instant,
the
generator will not
be damaged if
it
can bring the motor
up
to
speed in a
few
seconds.
If
difficulty is experienced
in
starting motors, tum
off all other electrical loads
and,
if possible, reduce
the
load
on
the
electric
motor.
Required
Operating
Speed
Run
the
generator
first
with
no
load applied, then at half
the
generator's capacity,
and
finally loaded
to
its full capacity
as
indicted
on
the
generator's data plate. The output voltage
should
be
checked periodically
to
ensure proper operation of
the
generating plant
and
the
appliances
it
supplies.
If
an
AC
voltmeter or ampmeter
is
not installed
to
monitor voltage and
load, check it with a portable meter
and
amp
probe.
Generator
Frequency
Adjustment
Frequency is a direct result of engine/generator
speed,
as
indi-
cated
by
the following:
o When
the
generator is run at 1800
RPM,
the
AC
voltage
output frequency
is
60
Hertz.
Therefore,
to
change
the
generator's
frequency,
the
generator's
drive engine's speed must be changed
.along
with a reconfig-
uring of the
AC
output connections at
the
generator.
Generator
Maintenance
D Maintaining reasonable cleanliness
is
important.
COlmections
of terminal boards
and
rectifiers
may
become
corroded,
and
insulation surfaces
may
start conducting if
salts,
dust,
engine exhaust, carbon,
etc.
are
allowed
to
build
up.
Clogged ventilation openings
may
cause exces-
sive heating and reduced life of windings.
o For unusually severe conditions, thin rust-inhibiting
petroleum-base coatings, should be sprayed
or
brushed
over all surfaces
to
reduce rusting
and
corrosion.
D In addition
to
periodic cleaning,
the
generator should
be
inspected for tightness of
all
connections, evidence of
overheated terminals
and
loose or damaged
wires.
o The drive discs on single bearing generators should be
checked periodically if possible for tightness of screws
and
for
any
evidence of incipient cracking failure.
Discs
should
not be allowed
to
become rusty because rust
may
accelerate cracking. The bolts which fasten
the
drive
disc
to
the
generator shaft must
be
hardened steel
SAE
grade
8,
identified by 6 radial marks, one at each of
the
6 comers of
the
head.
o The rear armature bearing
is
lubricaled
and
sealed;
no
maintenance
is
required. However, if
the
bearing becomes
noisy or rough-sounding, have it replaced.
o Examine bearing
at
periodic intervals.
No
side
movement
of shaft should be detected when force
is
applied.
If
side
motion
is
detectable, inspect the bearing
and
shaft
for
wear.
Repair must be
made
quickly or major components
will rub
and
cause major damage
to
generator.
Carbon Monoxide Detector
WESTERBEKE recommends mounting a carbon
monoxide detector in
the
vesssel's living quarters. Carbon
Monoxide, even in small amounts,
is
deadly. '
The
presence of carbon monoxide indicates
an
exhaust leak
from
the
engine or generator or from
the
exhaust elbow/
exhaust hose, or that fumes
from a nearby
vessel
are
entering your boat.
If
carbon monoxide
is
present, ventilate
the
area with
clean
air
and
correct the problem immediately!
Engines & Generators
61
BC
GENERATORS
5.0n.O
KW
DESCRIPTION
The
BC
generator
is
a brushless, self-excited generator
which
requires
only
the
driving
force
of
the
engine
to
produce
an
AC
output.
The stator
houses
two
sets
of windings;
the
main
stator
windings
and
the
exciter windings. When
the
generator
is
started,
residual magnetism
in
the
four
rotating
poles
induces a voltage
in
the stator
which
then
generates
an
even
larger
voltage
in
the
exciter windings.
This
mutual build
up
of
voltage
in
the
four
rotating
poles
and
in
the
exciter
wind-
ings
quickly
reaches
the saturation point of
the
capacitor(s)
and
a regulated
energy
field
is
then
maintained
in
the
stator.
At
the
same
time,
this
regulated
field
produces a
steady
volt-
age
in
the
stator
windings
which
can
then
be
drawn
off
the
generator's
AC
terminals
to
operate
AC
equipment.
The
generator
is
a single-phase, reconnectable
120
volt
AC
two-wire
or
115
volt
AC
two-wire
or
230
volt
AC
two-wire,
at
50
hertz.
Winding Connections:
The
single-phase
synchronous
generator
has
4 stator
leads
and
can
be
configured
to
120
volt
output.
Bearings:
The
bearings
are
sealed
type
and
permanently
greased requiring
no
maintenance during their
working
life
(approx.
30,000
hours).
PRELIMINARY
CHECKING
Before electrical testing, check
for
proper
engine
speed/hertz
adjustment.
Low
engine
speed
will
cause
low
AC
voltage
output,
high
engine
speed-high
AC
output.
Refer
to
WESTERBEKE'S operators
manual
or service
man-
ual
for
engine
speed/hertz adjustment or
for
other possible
engine
related
problems.
Before
testing,
get a clear explanation of
the
problem
that
exists,
be
certain
it
relates
to
generator components.
A
WARNING:
AC
and
DC
circuits
often
share
tlie
same
distributor
panel.
Be
certain
to
unplug
AC
power
cords
and
shut
down
DC/AC
inverters.
Simply
switching
off circuit
breakers
will
not
do
the
job
since
It will still
leave
hot
wires
on
the
supply
side
of
the
panel.
INTRODUCTION
TO
TROUBLESHOOTING
The
following
test procedures can be
used
to
troubleshoot
WESTERBEKE'S 4
POLE
DUAL EXCITER CIRCUIT
BRUSHLESS GENERATORS. Due
to
the
simplicity of
the
generator,
troubleshooting
is
relatively
easy.
Field testing
and
repairing
can
be
accomplished
with
basis
tools
and
repair parts
which
should include
the
following:
A quality multimeter (multitester) capable of
reading
less
than
one
ohm
and
with a specific
diode testing
function.
Basic electrical tools including cutters,
soldering
iron,
wire
strapper/crimper,
terminal
connectors,
etc.
Repair parts
such
as
diodes,
fuses,
bridge
rectifier,
etc.
A
CAUTION:
(ON
SOLDERING)
When
soldering,
use a large
enough
soldering
iron
to
get
the
job
done
quickly.
Excessive
heat
will
damage
the
diodes.
Also
make
certain
nD
soldering
splashes
Dnto
the
windings
as
It will
melt
the
insulation.
ROTATING
FIELD/AUXILIARY
WINDINGS
WINDINGS
WINDINGS
Two
sets
of
windings
are
found
in
the
rotor
assembly.
An
AC
voltage
is
produced in
two
groups
of
windings
as
the
rotor
turns at
its
rated
rpm.
This
AC
voltage
passes
through
each
of
the
two
diodes
mounted
on
the
isolated
fixture
just
before
the
rotor carrier bearing. The
AC
sine
wave
is
changed
to
DC
and
this
DC
voltage
is
passed through
the
two
groups
of
rotating
field
windings producing a
DC
field
around
these
windings.
This
field
affects
the
AC
winding
of
the
two
main
stator
groups
inducing
an
AC
voltage in these
windings
that
is
available
at
the
AC
terminal block connections.
Engines & Generators
62
BC
GENERATORS
TROUBLESHOOTING
CHART
MECC
ALTE
(REFER
TO
THE
WIRING
SCHEMATIC
BELOW)
A,B,C,&D
refer
to
the
components
of
the
INTERNAL
WIRING
DIAGRAM
and
their
test
procedures
in
the
following
pages.
WINDING
RESISTANCE
VALUES
(OHMS)
5.0KW
7.0KW
NOTE:
This
fault finding chatt
is
compiled
assuming
the
engine
is
operating at
the
correct
speedlhertz.
MAIN
STATOR:
#1
TO
#3
0.4
0.2
FAULT
No
AC
Output
Residual
Voltage
4-6
VAC
(Hot
N)
at
No-Load
High
AC
Output
at
No-Load
CAUSE
TEST/CORRECTION
Shorted
stator
B
Open
stator
B
Shorted
diode
(two)
A
Faulty
capacitor
(two)
Open
exciter
Shorted
exciter
Engine
speed
(hertz)
is
too
low
Electrical
connections
are
faulty
C
B
B
Adjust·
Inspect
wiring
connections
I
ncorrect
voltage
tap
C
on
capacitor
Incorrect
capacitor
C
Incorrect
hertz
tap
on
capacitor
C
Engine
speed
(hertz)
too
high.
Adjust'
#4
TO
#6
0.4
0.2
ROTOR:
(Each
pair)
4.0
2.0
EXCITER:
(Each
winding)
3.9
2.5
CHARGE
WINDING:
0.08
0.08
INTERNAL
WIRING
SCHEMATIC
r - - - - - - - - -
BRIDGE·
- - - - - - - - - - - -
.,
•
FUSE
•
: D I
:
r:
I
r - . - - - - • , I I r
CHARGER,
I • ,
D;O_DEfrJ·
~-b-
---------
--
~-
---,
----0
-"~~U~J
I I I
Low
AC
Output
Faulty
rotor
winding
A :
A:
I
60-160V
Faulty
diode
A I
-,
8
1
--------
DioDe
':
:
Faulty
capacitor
B :
tEl
'b
:
Faulty
diode
A : : I :
Voltage
Drop
Under
Load
(or
at
No-Load)
No
Battery
Charge
Low
Battery
Charge
High
Voltage
Output
when
Load
is
applied
Unstable
Voltage
Noisy
Operation
~~p~1~l:;:t(~ertz)
A~jUst.
~
_______
j r . i -i --
-'iF
-n
JO
- 0 - - •
--1
:
50Hz
60Hz
7760Hz
50H~2
Faulty
Bridge
rectifier
0 : b
,0
b b .
00
0 0 i
Faulty
integral
controller
0 :
J..
..
A..
.i..
4.:
Blown
fuse
B L..-fl-----l L_-U-_..l,
Faulty
wiring
B L
__
~~A~I~~
______
c~~~~.~
_1
Engine
speed
(hertz)
is
too
high
Electrical
connections
are
faulty,
loose
Faulty
support
bearing
Generator
rotor
connection
to
engine
is
loose
Adjust*
Inspect
wiring
connections
Inspect
rear
bearing"
Check
rotor
security**
A -
ROTOR
WINDINGS
B -
STATOR
WINDINGS
C -
CAPACITOR
WINDING
D·
BATTERY
CHARGE
WINDING
*
Refer
to
the
GENERATORS
OPERATOR
MANUAL
••
Refer
to
the
GENERATORS
SERVICE
MANUAL
Engines & Generators
63
TESTING
THE
Be
ROTOR
(MECC
ALTE
MODEL)
THE
MfCC
ALTtE
MODEL
GENERATOR
IS
IDENTIFIED
BY
ITS
LOUVERED
.
BACK
COVER
THAT
IS
FASTENED
BY
FOUR
HEX
SCREWS
Testing
the
Mecc
Aite generator can
be
accomplished
with-
out removing the bearing support bracket.
Simply
tum
the
armature
to
allow access for
the
testing
as
shown.
TESTING
THE
WINDINGS
THROUGH
THE
DIODES
Rotate
the
armature
into
position
to
access a
diode.
To
make
a quick test of
the
windings,
assume
the
diode
to
be
OK
and
test
the
connection at each end of
the
diode.
Tum
the
arma-
ture
and
test
the
other
side.
WINDING
ROTATING
FIELD/AUXILIARY
WINDING
RESISTANCE
VALUE
4.0
OHM
TESTING
THE
ROTOR
FIELD
WINDINGS
Unsolder
the
winding connection
from
the
diode
and
care-
fully
remove
the
diode
from
its
isolated
heat
sink
using a thin
walled,
deep
well
7116"
(llmm) socket.
With
the
diode
removed, both leads for
the
first
group
of
rotating field/auxiliary windings
will
be isolated
with
no
interference
from
a possibly
faulty
diode.
Check
the
resistance value of
the
rotating
windings
by
placing an ohmmeter's probes across
the
two
exposed
leads.
GOO
POWER
I
a
.
DW~'A
~\Y*
~\
WINDlNGS'--
CONTINUITY
TEST
Check that
no
continuity exists between either of
the
winding
leads
&I1d
the
generator shaft.
If
continuity
is
found,
there
is
a
short
in
the windings.
Repeat these tests on the second set
of
windings on the
opposite side.
TESTING
FOR
CONTINUITY
(TEST
BOTH
LEADS)
Engines & Generators
64
BC
GENERATORS
TROUBLESHOOTING
CHART
COLISEUM
MODEL
(REFER
TO
THE
WIRING
SCHEMATIC)
FAULT
CAUSE
TEST
NO
AC
VOLTAGE
OUTPUT
1.
Shorted
stator
1.
W1 & W2
2.
Open
stator
3.
Rotor
diode
open/shorted
2.
W1 & W2
3.01
& 02
RESIDUAL
VOLTAGE
3·4
VAC
1.
Faulty
capacitor
LINE
TO N AT
NO
LOAD
2.
Open
exciter
winding
3.
Shorted
exciter
4.
Engine
speed
low
5.
Electrical
connection
HIGH
AC
OUTPUT
1.
Engine
speed
too
high
AT
NO
LOAD
2.
Capacitor
connection
LOW
AC
OUTPUT
60·100
VAC
VOLTAGE
DROP
UNDER
LOAD
HIGH
VOLTAGE
OUTPUT
(NO
LOAD/LOADEDj
UNSTABLE
OUTPUT
1.
Faulty
rotor
winding
2.
Faulty
diode
(shorted)
3.
Faulty
capacitor
4.
Faulty
exciter
windings
1.
Faulty
diode
2.Engine
speed
low
3.
Faulty
capaCitor
1.
Engine
speed
1.
Electrical
connection
2.
Engine
speed
1.
C1
2.
EW1 -EW2
3.
EW1 • EW2
4.
Adjust
5.
Inspect
1.
Adjust
2.
Correct
1.RW
2.01
or
02
3.
Check
rating
4.
Check
windings
1.
01
or
02
2.
Check/adjust
3
Check
rating
1.
Check/adjust
1.CJ1eck
2.
Check/adjust
GENERATOR
WINDING
SCHEMATIC
NOTES:
For 60Hz operation: Connect capacitors
to
E31-E41 and to
Ell-E21.
For 50Hz operation: Connect capacitors
to
E31-E42
and
Ell-E22.
EW1-Exciter
Windings
1
EW2-Exciter
Windings
2
BCW-Battery
charging
windings
RW-Rotor
Winding
""C:1JCl
Ell
E21
E22
"I--~"_
....
EWl
RW
W1
W1·Stator
Winding
1
W2·Stator
Winding
2
C·Capacitor
D1/D2·Diodes
...---------T11
r------T31
tfl--_
....
---'"
......
---T41
02
rnr1lC1JL.V-1------~~~
~~E42
V2
Engines & Generators
65
POTENTIAL
Be
PROBLEMS
Diodes
1.
An open diode
will
cause the loss of
any
rotating
field.
2.
A shorted diode will weaken the rotating
field.
Field
Windings
1.
An open
field
winding
will
cause the loss of the rotating
field.
2. A shorted
field
winding
will
cause a weak rotating
field.
3. Test each diode individually. A resistance value should
be
found through
the
diode
in
one direction
and,
with
the
meter probes reversed,
show
no
ohm value.
RESIDUAL
VOLTAGE
TEST
(unit
operating
at
rated
hertz)
Exciter circuit capacitor disconnected
from
exciter
windings
MAIN
STATOR
RESIDUAL
VOLTAGE
(Live
to
neutral)
3·4VAC
EXCITER
WINDING
GROUP
EWI
EW2
E31·E42
Ell
toE22
S-6VAC
5·6VAC
NOTE:
The presence
of
correct residual voltage is an
indication the winding is
O.K.
(main stator
or
exciter
windings).
WINDING
RESISTANCE
VALUES
(OHMS)
5.0KW
7.0KW
EXCITER
WINDINGS:
EW1
(E11 & E22)
3.4
2.2
EW2
(E31 & E42)
3.4
2.2
BATTERY
CHARGING:
BCW
0.5
0.5
STATOR
WINDINGS:
W1
(T11 & T22)
0.6
0.9
W2
(T31 & T42)
0.6
0.9
ROTOR
WINDINGS:
RW
1.7
2.2
TESTING
THE
BC
ROTOR
COLISEUM
MODEL
COLISEUM
MODEL
"COVER
PLATE
SCREWS
.~
COVER
PULLING
BOLTS
~
DIODE
POWER
ID
REMOVE
THE
COVER
PLATE
1.
Remove
the
four
cover plate
screws.
TESTING
FOR A WINDING
SHORTED
'
DCV~.A
TO
GROUND
If
ACV~+t
f
IDA
COM
y.n.A
2.
Insert
two
8mm x 35mm-1.25
pitch
bolts
into
the
two
left
and
right
vacant
holes
as
shown.
CONTINUITY
TEST
©
3.
Tighten
these
two
bolts
in
sequence.
This
will
pull
the
cover
plate off
the
generator,
exposing the rotor
assembly
with
the
bearing
in
place.
With
the
diode still removed
from
the isolated
plate,
test
the
continuity between
the
winding/diode connection
and
the
4.
When
re-installing, place a
small
amount of petroleum
jelly
on
the
rotor
bearing
"0"
ring
located in
the
cover
boss.
Position
the
cover
onto
the
bearing
and
thread
the
allen
head
screws
back
into
place
finger
tight).
Tighten
the
screws
in a cris-cross manner
drawing
the
end
cover
onto
the
bearing.
When
fully
on,
tighten
the
screws
securely.
Use
a thin
walled,
deep
well
7/16" (llmm) socket
and
. e
remove
the
diodes
from
the isolated
plate.
With
the
winding~
generator
case.
TESTING
THE
ROTOR
FIELD
WINDINGS
k
connection still attached
to
the
diode
test
between
the
con-
"-..
nection and'the metal of the rotor shaft as shown above, I
~-
.........
check
both
sides.
I"..
..
"
GENERATOR
CASE
/
II
I
ROTOR
WINDING
RESISTANCE
5.0
KW
3.9
TO
4.0
OHM
7.0
KW
2.1
TO
2,2
OHM
RW
TESTING
ROTATING
FIELD
FOR
SHORT
TO
GROUND
POWER
mJ~IOA
mA
DCV.
'~.
.'
ACV
*
~
,]I--
__
H--...I
02
TESTING
THE
DIODES
Refer
to
the
following pages.
Engines & Generators
66
TESTING
THE
DIODES/CONTROL
PANEL
TESTING
THE
DIODES·
ALL
MODELS
Carefully
unsolder
the
winding
connection
to
the
diode
and
remove
the
diode
using a thin
walled,
deep
well
7/16"
(llnun) socket
and a box
wrench
as
needed.
Test
the
diode
as
shown
with
ohmmeter
leads
at
both
ends,
then
reverse
the
positions.
ISOLATOR
POST
(RED)
CONTROL
BOX I CONTROL
PANEL
COMPONENTS
BRIDGE
UNBUNDLE
THESE
WIRES
TO
ACCESS
THE
WINDING
FOR
TESTING.
ON
SWITCH---lI4oI
A
low
resistance should be found
with
the
leads
in
one
direc-
tion
and
infinite
resistance (blocking)
in
the
other
direction.
DIODES:
1.4 • 1.5
OHMS
(APPROX.)
USING
A 260
FLUKE
76
METER.
NOTE:
Different meter models
may
show different ohm
values, but should read
the
same for both
diodes.
DIODES
RATING
1600
VOLTS
26
AMPS
The
diode's rating
is
far in excess of
the
circuit's
requirements. Most likely a diode
failure
will
result
from
a generator overspeed or
load
surge.
ELECTRONIC
GOVERNOR
Engines & Generators
67
W1
Be
GENERATORS
TROUBLESHOOTING
NO
AC
VOLTAGE
OUTPUT
EXCITING
THE
GENERATOR
To
quickly
detennine a short
or
an
open
in
the
main
stator
winding,
excite
the
generator
with
12
VDC
using
one
exciter
winding
group
to
accomplish
this.
The
AC
voltage
that
the
generator
will
produce
measured
between
the
line
and
neutral
during
excitation
will
be
very
low.
NORMAL
AC
VOLTAGE
DURING
12
VDC
EXCITATION:
12
-16
VOLTS
AC
111
131
50Hz
•
Cl
Ellr.iJ21
E31
E22
DUEL
EXCITER
EW'
(COLISEUM)
DUAL
EXCITEIII
(MECC
AlTE)
60Hz
7 8
9
9
7
8
•
•
••
•••
EW2
50Hz
~
1:1~
2--0
~C~
~~
3--0
1:4~
T41
t42
121
5.-....0
t22
6--<)
MAIN
STATOR
MAIN
STATOR
EXCITING
PROCEDURE
Locate
one
of
the
exciter
winding
groups
in
the
generator.
Unplug
all
connections
from
both
capacitors. Connect
12
VDC
across
the
winding
using the
winding
end
connection.
For
example:
Winding
group
EWI between connection
Ell
and
E22.
Winding
group C between
#50Hz
and
#9.
12
VOlTDC+
Engines & Generators
68
60Hz
•
Be
GENERATORS
TROUBLESHOOTING
REACTION
DURING
EXCITATION
No
Continuity
between
Isolated
Stator
Windings
and
Ground
(Unit
running-12VDC
applied
to
winding)
1. A very
low
AC
outout
and
loading of
the
drive engine
and
a growling
noise
from
the
generator
end.
This
indicates a shorted stator winding
to
ground
or
the
stator windings
are
shorted
to
each
other.
Isolate
the
winding
groups
and
verify a short
to
ground.
No
continuity should be found between
the
two
isolated
stator
winding
groups.
W1
6 5
II
I
I
I
I
I
I
I
411
l:
I
2.
No
reaction
from
the
generator or
drive
engine.
No
AC
output.
This
is
an
indication of
an
open
in
one
of the
main
stator
winding
groups. Isolate the
winding
groups
and
verify
an
open
winding.
'--------T21
---~E
YGROUND
W1
No
Continuity
between
Isolated
Stator
Winding
Groups
.--------T11
....----,;--T31
......
---141
'------
42
'-------121
'------~-
122
nn
65
432
1
, J
!!
J
TEST
EACH
OF
THE
WINDING
LEADS
INDIVIDUALLY
AS
SHOWN
THERE
SHOULD
BE
NO
CONTINUITY
BETWEEN
LEADS
Engines & Generators
69
TEST
EACH
WINDING
TO
CASE
GROUND
Be
GENERATORS
TROUBLESHOOTING
TESTING
THE
EXCITER
WINDINGS
AC
voltage
can be
measured
across
the
capacitor electrical
connections
while
the
generator
is
operating.
This
voltage
may
be
as
high
as
350
to
400
volts
AC.
This
AC
voltage
build-up
is
accomplished
as
the
exciter
winding
for
each capacitor charges the capacitor
and
the
capacitor discharges back
into
the
winding.
This
flow
of
saturating
AC
in
the exciter
winding
produces a
phase-
imbalance
type
of
filed
that affects
the
auxiliary
windings
of
the
rotor.
The
AC
voltage
reading
is
taken between the
two
electrical
connections
on
each separate capacitor with
the
generator
operating at
its
correct
no
load
speed.
EXCITER
WINDING
INTEGRITY
(RESIDUAL
AC
VOLTAGE)
The
condition of each exciter winding can be determined
by
the
residual
AC
voltage each exciter winding should be
producing
with
the
generator running
at
proper
no
load
speed.
To
do
this:
Unplug
all
connections
from
the
capacitor.
Locate
the
electrical connection
for
each winding
end.
Place your
AC
volt
meter
connects
across
these
two
connections. Start
the
generator
and
observe
the
residual
AC
voltage produced
by
the
winding.
Check
the
other exciter
winding
in
the
same
way.
Residual
AC
voltage lower
than
listed below
will
indicate a
faulty
winding.
RESIDUAL
AG
VOLTAGES
(Each
exciter
winding)
5.0
KW
E11 • E22
AND
E31
• E42_
5·6
VAG
#50 • #9
AND
#50 • #9_
7 • 9
VAG
7.0KW
E11 • E22
AND
E31 • E4L_
5·6
VAG
#50 • #9
AND
#50 • #9
_ 7 • 9
VAC
THERE
SHOULD
BE
NO
CONTINUITY
BETWEEN
LEADS
50HZ
AND
#9
TO
CASE
GROUNDS
/'
./
MEASURING
VOLTAGE
/~
GENERATOR
RUNNING"
MECCALTE
MODEL
50Hz
60Hz
9
.
~
COLISEUM
MODEL
CAPACITOR
C1
E11r'.
E
E~21
•
~E22
EWl
CAPACITOR
MEASURE
THE
RESISTANCE
VALUE
OF
THE
EXCITER
WINDINGS
BETWEEN
THE
·7
....
TESTING
WINDING
LEADS
MAIN
STATOR
WINDING
RESISTANCE
LESS
THAN
ONE
OHM
FOR
EACH
WINDING
GROUP
FOR
NO
CONTINUITY
END
LEADS
OF
EACH
WINDING
TO
METAL
CASE
EngInes & Generators
70
MAIN
STATOR
RESIDUAL
VOLTAGE
LINE
TO
NEUTRAL
4-6
AC
VOLTS
(THIS
INDICATES
GOOD
STATOR
WINDINGS)
Be
GENERATORS
TROUBLESHOOTING
TESTING
CONTINUITY
Quick
field
check
(no
capacitance
scale
on
meter).
Connect a digital
ohm
meter
or
analog
ohm
meter
(high
scale)
to
the
capacitor
terminals.
The
meter
will
register
and
arbitrary
ohm
value
for
the
material
in
the
capacitor.
the
meter's battery
will
then
start
to
charge
the
capacitor
and
the
ohm
value
will
increase.
If
the
meter
does
not
react
as
above,
the
capacitor
is
faulty.
The
method
above
indicates a
presumably
good
capacitor,
but
does
not
verify
it's microfared rating
as
would
be
necessary
when
troubleshooting a capacitor
whose
MF
rating
has
dropped
causing a
low
AC
voltage
output.
In
such
cases,
the
capacitors
rating
MUST
be
verified
accurately.
A
WARNING:
Capacitors
must
be
discharged
before
handling
as
they
store
electricity
and
can
pack a poten-
tially
lethal
charge
even
when
disconnected
from
their
power
source.
i\
DISCHARGING
THE
CAPACITOR
CAPACITOR
RATINGS
AND
PART
NUMBERS
25MFD
35MFD
55MFD
Pn#046875
Pn#049627
Pn#048816
60MFD
Pn#048018
Engines & Generators
71
Be
GENERATOR
COMPONENTS
COLISEUM
MODEL
DIODE
ASSEMBLY
MECC
ALTE
MODEL
Engines & Generators
72
GENERATOR
FUEL
PUMP
Gi-~~
..
-.~-
..
WIRING
=-S116~'K
L-
____
til
=
tr'~~
-D
yoo
~
DISTRIBUTOR
EXHAUST
SWITCH
-:'
.
'14
REO/VIQ
+.
,.
.~
0"
."
R
16
GRit
J
0
TEMPERATURE
IN/C)
COIL
-,,0
YIOI!!.~+
11&
VIOIWH)
!
14
fiEDIV
10
'12
VEl/REO
WATER
~
AUX,
;;
SWITCH
~
'16
CiX1)
~OV[
ON
OVERS
OPERATION
I
CUT
PHD
AT
DUll
BOARD
1500
RES!
RPM
FOR
STOR
{50Hll
• +
"
'--
,;
R
~--i
VIO
\fr
If-
~O~
0
-c::Jo
~D~
OV['SPEED
~~~r~
-r
.--
$[~-
L
j-----
r---
--
-b
~J.(';
'IC"U~
[
c
BOARD
6
MrUA1Q~
0
12
I
1
BARBER
CONTRmLER
--.~---
c
'"
I!~
COLE:,.
A
'-THrSE
TlIO WIR[S
POLAR
llED.
WIRE
TERMINAL
Oft
CHECK
I.
ATTACH
2.
AHACH
OSSE
RilE
DIAGRAM
CHOKE
SOLENOID
[-1
--
D
SOLENOID
-----C
FUEL
1~
e!OIL
u
SWITCH
'OIL
I"
OBSCRV(
WIRE
RI::O
IlLACK
POL
PRESS
SWITCH
(NIDI
If
n
.nr
DF
TEMPERATURE
IN/C)
PRESS
IN/Ct
R
116
REO/WHT
116
ORG
tl6
"HT
116
BlK
tis
REO/VIC
~
"
'"
~
.
888®©
~
IGBe'Q8
tGfee©©
VOM
or
or
VOM
VOM
#16
TO
RED
To
EAel1
ME
NUIo48ERS.
WITH
LEAD
LEAD
fiR
I
T'I'
116
R[O
WIR(
Y
~
~
:
"16
PURPLE
#46876
--
__
.
'"
/;
/j
BlK
e
>
0
w
*
T
1
RED/VIO
-,
FRoM
CONTI1QllER.
WIRE
D--SA
TTERY
,------' ---
--~Z1
30
rUSE
----
AMP
J
12
-0
®
/1
-
STARTER
N
~
'16
I--
"
,
~
-jll
REO/VIO
[ =
.-----
"",
'"
,,,'
®
0
w
*
Q
~
~
.
~
1---.1
-=
I
~0
CMT
E
I"
~KT2
iI'
OMT
118
SlK
1
I(~
"2
IlLK
~
BATTERY
CHARGeR
DC
BREAKER
SA
ON
SWITCH
~
N
·
"eu;t------
~~
l~
; ® •
'['ill"'"
20A
CIRCUIT
FUSE
SWITCH
I
START/STOP
0
HOUR
METER
(~)I
--
INDIVIDUALLY
--
vec
AC
G(H
.
Engines & Generators
73
MECC
ALTE
5.0
BCG
7.0
BCGD
4
L1
120V/60Hz
COLISEUM
5.0
BCGA
7.0
BCGC
Generalor
CIRCUIT
BREAKER
L1
AC
TERMINAL
BOARD
CONNECTIONS
ISOLATED
POST
(NEUTRAL)
N
21
41
1
5
=-
L1
240V
60Hz
11
=-
L1
L2
4
ISOLATED
POST
(N.EUTRAL)
2
N
31
ISOLATED
POST
(NEUTRAL)
N
1 6
230Vj50Hz
N
L1
ISOLATED
POST
ISOLATED
POST
4 1 3 6
115V/50Hz
ISOLATED
POST
ISOLATED
POST
~
11
='----.-
___
S_IN---,GLE
LINE
120
VOLT
SYSTEM
SHORE
POWER
TRANSFER
SWITCH
''-~L
il!:
z·
/
.....
--.~.\
~
k1--,-+-"
If
the installer connects shore power
to
the
vessel's
AC
cir-
cuit,
this
must
be
done
by
means
of
the
Shore Power Transfer
Switch.
Set
the
transfer switch shown in the diagrams
to
the
OFF
position.
This switch prevents simultaneous connection
of
shore
power
to
generator output.
,--",,/
~
I/-·-'k'+~
-+~~_~lJ
Ship's
Load
1£ ' ....
_"'/
~~~40.vott
i
Ground
I.,
eqUIpment.
Z
(GRN)
~
~
Shore
PO\.\lsr
120
VOLT/50
HERTZ
TWO
WIRE
CONFIGURATION
Generator
~
I
NOTE:
Diagram
shows
connections
for a two
..
wire.
120-Volt
system
from
the
generator.
with
three
...
wlre,120-Voll
boat
system.
,---+---'<-\<:ll
/
,-_
....
Ship·
to·
Shore
Switch
(3
Pole)
PN
32008
(40
Amps/Pole)
~
:;
..
Z
Jumper
Z
II:
r4'
<of
'.,I
/_-...
......
2
\
~
.I:+\ -------'f-----, ID
I
'--",,/
"
..J
PN
32009
(80
Ampsl
Pole)
PN
32010
(125
Amps/
Pole)
PN
32133
(200
Ampsl
Pole)
/--~'-
ID
~l
I
&+\
---i_N-:-:e-c-:U1..;;,ral'--...N
Ships
Load
~
Ground
Ii,
E'luipmenl
Z (GRN)
A
CAUTION:
Damage
to
the
generator
can
result
if
utility
shore
power
and
generator
output
are
connected
at
the
same
time.
This
type
of
generator
damage
is
not
covered
under
the
warranty;
it
is
the
installers
responsi-
bility
to
make
sure
all
AC
connections
are
correct.
230
VOLT/50
HERTZ
TWO
WIRE
CONFIGURATION
z
w
W
II:
c:I
Generator
r
GENERATOR
GROUND
w
...
~
Ship-to
..
ShOre
Switch
PH
32008
PN
32009
PH
32010
PH
32133
/'--,
I I
1
~L1
,---+-----1.-(3
2 I
, "/
......
_""
/'-
.......
,
SHIP'S
LOAD
;;17'-.)
(WHTI
~~~~:o-VOIt
~
~
WESTERBEKE
Shore
Power
Engines & Generators
~----~5
~N
(NEUTRAL)'
7 ® "
, /
~--'
74
--::-
SHORE
GROUND
_
SHIP'S
-
GROUND
SPECIAL
TOOLS -GENERATOR
FIELD
FABRICATED
TOOLS
These
drawings provide a means
by
which
simple tools
can
be
made
to
assist
in
the removal
of
the generator end from
the
engine
and
in
the replacement of
the
generator
end on the
engine.
A
local
machine
shop
should
be
able
to
fabricate
these tools
at
a
modest
price,
but
first
check
with
your
local
WES1ERBEKE
dealer to
see
if these tools
are
on
hand
for
loan.
Housing
Puller
Tool
This
tool
allows the bearing
in
the generator housing
to
be
gently
pushed straight off the housing without any twisting.
If
a
nut
of
the
same specifications
as
that of the tapped hole
in
the
pilot
tool
were
to
be
welded
on
the end
of
the eye bolt,
this
tool
would
be
able
to
pull the bearing
back
into place without
any
twisting.
Please refer
to
these drawings before the genera-
tor
end
is
removed.
HOUSING
PULLER
TOOL
(FIELD
FABRICATED)
1/2-13
UNC
Store-bought
eye
bolt
with
tapered
tip.
,
4"
I
(101.6
mm)--I
11
450
I
~
•
.-.1
ap~r
( \
'\
'®
r----I--+--,~
1
Z"
J&
0
,/
----
Weld
a
1/2-13
UNC
Hex
Nut
to
one
side
of
this
center
hole.
1/2"
(12.7
mm)
Cia.
Drill
Typ.
4
holes
Material:
Cold-roiled
Steel
Lifting
Eye
Tool
This tool allows a mechanic
to
safely remove the generator
end from the engine
by
attaching this Generator End Lifting
Eye
to
the
four screw holes located under the control panel.
To
use this Lifting Eye, remove the generator's control panel
and
screw
the
Lifting Eye
to
the
generator
end.
Disk
Alignment
Tool
4
HOLES
1/4"
(6mm)
Center
lifting
eye
on
baseplate
and
weld
securely.
>
1bis tool allows a mechanic
to
safely remove
and
install the
generator drive disks
by
aligning the disks with the Drive Plate
Guide Pin. The Pin screws
into
the flywheel and acts
as
a
guide. Also the pin helps to support some
of
the
rotor
and
the
drive plate's weight while removing or replacing these parts.
s
Material: One M8 bolt
with
the hex head machined off and a
screwdriver slot cut
in
the machined
end.
Pilot
Tool
Screwed into the end of the rotor shaft, this tool can be
used to pull the stator assembly away from the engine
without damaging the stator windings. This tool can be
used at reassembly.
ROUND
TIP
('::'=f§).z~L
.......
____
.....!-1
---
~
I
12"
15.5
mm
Drill
\4-(-----(304
8
mm)------,·
1-1/4"
(31.75
mm)
Deep
.
M18 x 1.5
Pitch
(Approx.)
Tap
1"
(25.4
mm)
Deep
PROPER
USE
OF
HOUSING
PULLER
Material:
Aluminum
Engines & Generators
75
ANGULAR
NUT
AND
BOLT
TIGHTENING
METHOD
1.
Carefully
wash
the
nuts
and
bolts
to
remove
all
oil
and
grease.
2.
Apply a coat
of molybdenum
disulfide
grease
to
the
tlu'eads
and
setting
faces
of
the
nuts
and
bolts.
3.
Tighten
the
nuts
and
bolts
to
the
specified
torque
(snug
torque)
with a torque
wrench.
CENTER
liNE
4.
Draw a line
(A-B)
across the center of
each
bolt.
S.
Draw
another
line
(C-D)
on
the
face
of
each
of
the
parts
to
be
clamped.
This line should be
an
extension of
the
line
(A-B).
COINCIDING
LINE
G
6.
Draw
another
line
(F-G)
on
the
face
of
each
of
the
parts
to
be
clamped.
This
line
will
be
in
the
direction
of
the
specified
angle
(Q)
across
the
center
(E) of
llle
nut
or
bolt.
7.
Use
a socket
wrench
to
tighten
each
nut
or
bolt
to
the
point
where
the
line
(A-B)
is
aligned
willl
the
line
(F-G).
Example:
Specified
Angle
and
Tightening
Rotation
A
30
0
1112
of a
turn
B
60°
116
of a
turn
C
90
0
1/4
of a
turn
D
180
0
112
of a
turn
E
360
0
One
full
turn
Engines & Generators
76
STANDARD
HARDWARE
BOLT
HEAD
MARKINGS
Metric
bolt
class
numbers
identify
bolts
by
their
strength
with
10.9
the
strongest.
NOTES:
1.
Use
the
torque
values
listed
below
when
specific
torque
values
are
not
available.
2.
These
torques
are
based
on
clean,
dry
threads.
Reduce
torque
by
10%
when
engine
oil
is
used.
3.
Reduce
torques
by
30%
or
more,
when
threading
capscrews
into
aluminum.
STANDARD
BOLT & NUT
TORQUE
SPECIFICATIONS
METRIC
BOLT & NUT
TORQUE
SPECIFICATIONS
SAE
Grade
5
SAE
Grade
6-7
SAEGrade
8
Capsrew
Body
Size
Torque
Torque
Torque
Boll
Grade
4.6
Grade
4.8
Grade
8.8 -9.8
Grade
10.9
(Inches) -(Thread)
FI-Lb
(Nm)
Ft-Lb
(Nm)
A·Lb
(Nm)
Ola.
Wrench
Size
FI-Lb
(Nm)
Ft-Lb
(Nm)
Ft-Lb
(Nm)
Ft·Lb
(Nm)
114 -20
8
(11)
10
(14)
12
(16)
-
28
10
(14)
14
(19)
M3
5.5mm
0.3
(0.5)
0.5
(0.7)
1
(1.3)
1.5
(2)
5/16
-18
17
(23)
19
(26)
24
(33)
-24
19
(26)
27
(37)
M4
7mm
0.8(1.1)
1
(1.5)
2
(3)
3
(4.5)
M5
8mm
1.5
(2.5
2
(3)
4.5
(6)
6.5
(9)
318
-16
31
(42)
34
(46)
44
(60)
-24
35
(47)
49
(66)
M8
10mm
3
(4)
4
(5.5)
7.5
(10)
11
(15)
M9
13mm
7
(9.5)
10
(13)
18
(25)
35
(26)
7/16-14
49
(66)
55
(75)
70
(95)
M10
16mm
14
(19)
18
(25)
37
(50)
55
(75)
-
20
55
(75)
78
(106)
1/2
-13
75
(102)
85
(115)
105
(142)
-20
85
(115)
120
(163)
M12
18mm
26
(35)
33
(45)
63
(85)
97
(130)
M14
21
mm
37
(50)
55
(75)
103
(140)
151
(205)
M16
24mm
59
(80)
85(115)
159
(215)
232
(315)
9/16
-12
110
(149)
120
(163)
155
(210)
-18
120
(163)
170
(231)
M18
27mm
81
(110)
118
(160)
225
(305)
321
(435)
5/8-11
150
(203)
167
(226)
210
(285)
M20
30mm
118
(160)
166
(225)
321
(435)
457
(620)
-18
170
(231)
240
(325)
M22
33mm
159(215)
225
(305)
435
(590)
620
(840)
314
-10
270
(366)
280
(380)
375
(508)
-16
295
(400)
426"(569)
M24
36mm
203
(275)
288
(390)
553
(750)
789
(1070)
7/8
- 9
395
(536)
440
(597)
605
(820)
-14
435
(590)
675
(915)
M27
41
mm
295
(400)
417
(565)
811
(1100)
1154
(1565)
M30
46mm
402
(545)
568
(770)
1103
(1495)
1571
(2130)
1 - 8
590
(800)
660
(895)
910
(1234)
-14
660
(895)
990
(1342)
M33
51
mm
546
(740)
774
(1050)
1500
(2035)
2139
(2900)
M36
55mm
700
(950)
992
(1345)
1925
(2610)
2744
(3720)
SEALANTS
&
LUBRICANTS
GASKETS/SEALANTS
Oil
based
PERMATEX
#2
and
it's
HIGH
TACK
equivalent
are
excellent
all
purpose
sealers.
They
are
effective
in
just
about
any
joint
in
contact
with
coolan~
raw
water,
oil
or
fuel.
A
light
coating
of
OIL
or
LIQUID
TEFLON
can
be
used
on
rubber
gaskets
and
O-rings.
LOCTITE
hydraulic
red
sealant
should
be
used
on
oil
adapter
hoses
and
the
oil
filter
assembly.
Coat
both
surfaces
of
the
oil
pan
gasket
with
high
temp
RED
SILICONE
sealer.
When
installing
gaskets
that
seal
around
water
(coolant)
passages,
coat
both
sides
with
WHITE
SILICONE
grease.
High-copper
ADHESIVE
SPRAYS
are
useful
for
holding
gaskets
in
position
dur-
ing
assembly.
Specialized
gasket
sealers
such
as
HYLOMAR
work
well
in
applications
requir-
ing
non-hardening
properties.
HYLOMAR
is
particlarly
effective
on
copper
cylinder-head
gaskets
as
it
resists
fuel,
oil
and
water.
Use
LIQUID
TEFLON
for
sealing
pipe
plugs
and
fillings
that
connect
coolant
passages.
Do
not
use
tape
sealants!
BOLTS & FASTENERS/ASSEMBLIES
Lightly
oil
head
bolts
and
other
fasteners
as
you
assemble
them.
Bolts
and
plugs
that
penetrate
the
water
jacket
should
be
sealed
with
PERMATEX
#2
or
HIGH
TACK.
When
assembling
the
flywheel,
coat
the
bolt
threads
with
LOCTITE
blue.
Anti-seize
compounds
and
thread
locking
adhesives
such
as
LOCTITE
protect
threaded
components
yet
allows
them
to
came
apart
when
necessary.
LOCTITE
offers
levels
of
locking
according
to
the
job.
LITHIUM
based
grease
is
waterproof,
ideal
for
water
pump
bearings
and
stuff-
ing
boxes.
Heavily
oil
all
sliding
and
reciprocating
components
when
assembling.
Always
use
clean
engine
oil!
Engines & Generators
77
STANDARD
AND
METRIC
CONVERSION
DATA
LENGTH-DISTANCE
Inches
(in)
x
25.4
=
Millimeters
(mm)
x
.0394
=
Inches
Feet
(tt)
x
.305
=
Meters
(m)
x
3.281
=
Feet
Miles
x
1.609
=
Kilometers
(km)
x
.0621
=
Miles
VOLUME
Cubic I nches
(inS)
x
16.387
=
Cubic
Centimeters
x
.061
=in
3
Imperial
Pints
(IMP
pt)
x
.568
=
Liters
(L)
x
1.76
=
IMP
pt
Imperial
Quarts
(IMP
qt)
x
1.137
=
Liters
(L)
x.88
=
IMP
qt
Imperial
Gallons
(IMP
gal)
x
4.546
=
Liters
(L)
x
.22
=
IMP
gal
Imperial
Quarts
(IMP
qt)
x
1.201
=
US
Quarts
(US
qt)
x
.833
=
IMP
qt
Imperial
Gallons
(IMP
gal)
x
1.201
=
US
Gallons
(US
gal)
x
.833
=
IMP
gal
Fluid
Ounces
x
29.573
=
Milliliters
x
.034
=
Ounces
US
Pints
(US
pt)
x
.473
=
Liters(L)
x
2.113
=
Pints
US
Quarts
(US
qt)
x
.946
=
Liters
(L)
x
1.057
=
Quarts
US
Gallons
(US
gal)
x
3.785
=
Liters
(L)
x
.264
=
Gallons
MASS-WEIGHT
Ounces
(oz)
x
28.35
=
Grams
(g)
x
.035
=
Ounces
Pounds
(Ib)
x
.454
=
Kilograms
(kg)
x
2.205
=
Pounds
PRESSURE
Pounds
Per
Sq
In
(psi)
x
6.895
=
Kilopascals
(kPa)
x
.145
=
p.si
Inches
of
Mercury
(Hg)
x
.4912
=
psi
x
2.036
=
Hg
Inches
of
Mercury
(Hg)
x
3.377
=
Kliopascals
(kPa)
x
.2961
=
Hg
Inches
of
Water
(H20)
x
.07355
=
Inches
of
Mercury
x
13.783
=
H20
Inches
of
Water
(H20)
x
.03613
=
psi
x
27.684
=
H20
Inches
of
Water
(H20)
x
.248
=
Kliopascals
(kPa)
x
4.026
=
H20
TORQUE
Pounds-Force
Inches
(in-Ib)
x
.113
=
Newton
Meters
(Nm)
x
8.85
=in-Ib
Pounds-Force
Feet
(ft-Ib)
x
1.356
=
Newton
Meters
(Nm)
x
.738
=
ft-Ib
VELOCITY
Miles
Per
Hour
(MPH)
x
1.609
=
Kilometers
Per
Hour
(KPH)
x
.621
=
MPH
POWER
Horsepower
(Hp)
x
.745
=
Kilowatts
(Kw)
x
1.34
=
MPH
FUEL
CONSUMPTION
Miles
Per
Hour
IMP
(MPG)
x
.354
=
Kilometers
Per
Liter
(Km/L)
Kilometers
Per
Liter
(Km/L)
x
2.352
=
IMP
MPG
Miles
Per
Gallons
US
(MPG)
x
.425
=
Kilometers
Per
Liter
(Km/L)
Kilometers
Per
Liter
(Km/L)
x
2.352
=
US
MPG
TEMPERATURE
Degree
Fahrenheit
(OF)
=
(OC
X
1.8) + 32
Degree
Celsius
(OC) = (OF
-
32)
x
.56
Engines & Generators
78
DECIMAL
TO
METRIC
EQUIVALENT
CHART
Fractions of
Decimal (in.)
Metric (mm)
Fractions of
Decimal (in.)
Metric (mm)
an inch
an inch
1/64 0.015625
0.39688
33/64
0.515625
13.09687
1/32
0.03125 0.79375
17/32
0.53125
13.49375
3/64 0.046875 1.19062
35/64
0.546875
13.89062
1/16
0.0625
1.58750 9/16
0.5625
14.28750
5/64
0.078125
1.98437
37/64 0.578125
14.68437
3/32
0.09375 2.38125
19/32
0.59375
15.08125
7/64
0.109375 2.77812
39/64
0.609375
15.47812
1/8
0.125
3.175
5/8
0.625
15.87500
9/64 0.140625 3.57187
41/64
0.640625
16.27187
5/32
0.15625 3.96875
21/32 0.65625
16.66875
11/64 0.171875 4.36562
43/64 0.671875
17.06562
3/16 0.1875 4.76250
11/16 0.6875
17.46250
13/64 0.203125 5.15937
45/64
0.703125
17.85937
7/32
0.21875 5.55625
23/32
0.71875 18.25625
15/64 0.234375 5.95312 47/64
0.734375
18.65312
1/4 0.250
6.35000
3/4 0.750
19.05000
17/64 0.265625 6.74687
49/64 0.765625
19.44687
9/32
0.28125 7.14375
25/32
0.78125 19.84375
19/64 0.296875
7.54062
51/64 0.796875
20.24062
5/16 0.3125 7.93750
13/16 0.8125
20.63750
21/64
0.328125
8.33437
53/64 0.828125
21.03437
11/32 0.34375
8.73125
27/32
0.84375
21.43125
23/64 0.359375 9.12812
55164 0.859375
21.82812
3/8
0.375
9.52500
7/8 0.875
22.22500
25/64 0.390625
9.92187
57/64
0.890625
22.62187
13/32
0.40625
10.31875
29/32
0.90625 23.01875
27/64 0.421875
10.71562
59/64
0.921875
23.41562
7/16 0.4375
11.11250
15/16
0.9375
23.81250
29/64 0.453125
11.50937
61/64 0.953125 24.20937
15/32 0.46875
11.90625
31/32 0.96875
24.60625
31/64
0.484375
12.30312
63/64
0.984375 25.00312
1/2 0.500 12.70000
1 1.00
25.40000
Engines & Generators
79
ENGLISH
TO
METRIC
CONVERSION
CHART
Multiply
Temperature
By
. I b
To
Qet
eqUiva ent
num
er 0 :
Degree Fahrenti'eit
CF)
(OF-32) + 1.8
Deqree Celsius
DC)
Multiply_ Acceleration
By
To qet equivalent number of:
FooVsecond2(ftlsec~
0.3048
Meterlsecond2(m/s
2
)
Inch/second2(in.lsec
2
)
0.0254
Meterlsecond2 (m/s
2
)
Multiply
Toraue
By
To
Qet
eauivalent number
of:
Pound-inch lIb·in.) 0.11298
Newton-meters (N·m)
Pound·foot llb·ttl
1.3558
Newton-meters (N·m)
Multiply
Power
By
To
get
eauivalent number
of:
Horsepower (hp)
0.746
Kilowatts
{kW}
.-
Multiply
Pressure
or
Stress
By
To oet eauivalent number
of:
Inches of water (in. H
0)
0.2491
Kilopascals (kPa)
Pounds/square
in.
(lb/in.
2
)
6.895
Kiloj:lascals (kPa)'
Multiply
Eneray
or
Work
By
To aet eauivalent number
of:
British Thermal Unit (Btu)
1055
Joules (J)
Foot-pound (ft·lb)
1.3558
Joules (J)
kilowatt-hour (kW·hr)
3,600,000.
or
Joules
(J = one
W/s)
.3.6.X
10
6
Multiply
Light
By
To get equivalent number
of:
Foot candle (fc)
1.0764
Lumens/meter2(lm/m2)
Multiplv
Fuel
Performance
By
To oet eauivalent number
of:
Miles/qal (mile/qa!)
0.4251
Kilometers/liter
(km/Ll
Gallons/mile (oal/mile)
2.3527
Liter/kilometer (Llkm)
Mult!RJy Veloeitv
By
To aet equivalent number
of:
Miles/hour (mile/hr)
1.6093
Kilometers/hour' (km/hr)
Multiolv
Length
By
To
Qet
eauivalent number of:
Inch (in.)
25.4
Millimeters
(mm)
Foot (ft)
0.3048
Meters
(m)
Yard (vd)
0.9144
Meters
(m)
Mile (mile)
1.609
Kilometers (km)
Multiply
Area
Bv
To oet eauivalent number of:
I nch
2
(in.
2)
6452
Millimeters2(mm~
Inch2(in.
2
)
6.45
Centimeters2(em
2
)
Foof2(fF)
0.0929 Meters
2(m2
)
Yard2{yd")
0.8361 Meters
2
{m")
Multiolv
Volume
By
To oet eauivalent number of:
Inch3(in.3)
16387
Millimeters~mm3)
Inch
3
(in.
3
)
16.387
Centimeters3(
em
l
)
Inch3{in.
3
)
0.0164
Liters
(l)
Quart (at)
0.9464 Liters (Ll
·Gallon (oal)
:5.785
Liters (Ll
Yard
3
{vd
3
)
0.7646
Meters3(m
l
)
Multiply
Mass
Bv
To
oet equivalent number of:
Pound (Ib)
0.4536
KiloQrams
(ko)
Too_(ton)
...
907
•.
1B
Kiloarams
(kq)
Ton
(ton\
0.907
Tonne (t)
Multiply
Force
By
To
gel
~guivalent
number of:
KiloQram
(kq\
9.807
Newtons
(N)
Ounce (oz)
0.2780
Newtons
(N)
Pound (Ib)
4.448
Newtons{tJl
Engines & Generators
80
INDEX
BCGIBCGA Specifications
......................
60
Oil Pump, Front Case, and Oil Pan
................
24
BCGCIBCGD Specifications
.....................
59
Oil Seal
.....................................
29
Angular Nut and Bolt Method
....................
76
Parts identification
..............................
2
Assembly
- Engine
............................
12
Piston Clearance
..............................31
Battery Charge Controller
......................
.58
Pistons
......................................
19
BC Generators
- Description
.....................
61
Pump - Coolant
..............................
.36
Bearings
....................................
28
Raw Water Pump
.............................
.37
Camshaft
....................................
28 Relays - Testing
.............................
.47
Camshaft and Rocker Arms
......................
17
Remote Panel Wiring Schematic
.................
.46
Capacitors Testing
.............................
69
Rocker Arms
.................................
17
Carburetor
...................................
38
Safety Instructions
..............................
1
Choke Solenoid
...............................
57 Schematic Windings
(Coliseum)
...................
65
Compression Test
.............................
55
Sealants and Lubricants
.........................
77
Connecting Rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19 Service Standards and Limits
.....................
32
Control Box Components
.......................
67 Shore Power Transfer Switch
.....................
74
Coolant Circulation
Pump
......................
.36 Spark Plugs
..................................
57
Counterbalance Shaft . . . . . . . . . . . . . . . . . .
........
.24 Special Tools - Engine
..........................
34
Crankshaft, Bearing, and
Oil Seal
.................
29 Special Tools - Generator
.......................
75
Cylinder Block Inspection
.......................
31
Specifications - 5.0 BCGIBCGA
..................
59
Cylinder Head and Valves
.......................
13
Specifications - 7.0 BCGCIBCGD
.................
59
DecimallMetric Chart
..........................
79
Standard Hardware
............................
77
Diodes - Testing
..............................
67
Standards and Limits
...........................
32
Distributor
...................................
39
Starter Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
Electronic Governor
......................
.49,52,53
Torquing the Cylinder Head Bolts
.................
56
Engine Adjustments
............................
57
Terminal Board Connections
.....................
74
Engine Assembly
..............................
12
Testing Diodes
................................
67
Engine Assembly
- General Data
.................
6,7 Testing Engine Compression
.....................
55
Engine Troubleshooting
.........................
.4 Testing for Overhaul
...........................
.3
Exciter Windings Testing
........................
70
Testing Oil Pressure
..........................
.55
Exciting the Generator
..........................
68
Testing Relays
...............................
.47
Exhaust Manifold
............................
.35
Testing the BC
Ro~or
(Coliseum)
..................
66
Front Case
...................................
24 Testing the BC Rotor
(Mecc
Aile)
.................
64
Generators - Maintenance
.......................
61
Testing the Igniter
............................
.48
Generator Components
.........................
72
Testing Windings
..............................
70
Generator Information
..........................
61
Timing Belt
...................................
8
Generator Troubleshooting
......................
69
Torques - Hardware
...........................
33a
Generator Wiring Diagram
......................44
Troubleshooting - Engine
.......................
.4
Generator Wiring Schematic
....................
.45
Troubleshooting - Generator
.....................
69
Governor Troubleshooting
.......................
54
Troubleshooting Chart
(Coliseum)
.................
65
Hardware Torques
............................
33a Troubleshooting Chart Governor
..................
54
Heat Exchanger
..............................
.35 Troubleshooting Chart
(Mecc
Aile)
................
63
High Tension Cords
............................
55
Troubleshooting Governor
.......................
51
Ignition Wires
................................
55
Valve Clearance
...............................
56
Ignition Timing
...............................
56
Valves
......................................
13
Igniter Testing
..
. . . . . . . . . . . . . . . . . . . . .
........
.48 Winding Schematic
(Coliseum)
...................
65
Magnetic
Pick-Up
.............................
53 Wiring Diagram
...............................
73
Maintenance
- Generator
........................
61
Wiring Diagram - Generator
....................
.44
Manifold - Exhaust
............................
35
Wiring Schematic - Generator . . . . . . . . . . . . . . .
....
.45
Metric Conversion Chart
........................
80
Wiring Schematic - Remote Panel
................
.46
Metric/Standard Formulas
.......................
78
Wiring Schematic
(Mecc
Alfe)
..................
63
Oil Pump
.. , .................................
24
Engines & Generators
81
Engines & Generators
WMDW6071120
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