Westerbeke 6.5 SBCG, 5.4 SBCG, 5.0 SBCG, 4.2 SBCG Service Manual

..

.

·

SERVICE·MANUAL

.

MARINE

.

~

6.5

,.

5.0

. . -

SBCG·&OHZ SBCG•&OHZ

GASOLINE

. . . . .

5.4

.

.·

4.2

GENERATORS

..

SBCG·50HZ.

SBCG-50HZ

'

..

· .

Single

. · ·

CALIFORNIA

PROPOSITION

WARNING

65

Exhaust gasoline

constituents}

the

cancer, reproductive

Exhaust

colorless unconsciousness exposure

•Dizziness

•Nausea

•Headache

•

IF GET :;eek

until

gas

engines

State

of

birth

gasses

gas.

can

Weakness

YOU

OR

ANYONE

OUT

INTO medical it

has

been

from

are

California

defects, harm.

contain

Carbon

include:

and

THE

attention.

diesel

and

(and

some

known

to

cause

and

A

WARNING

Carbon

Monoxide

and

death.

Sleepiness

ELSE

EXPERIENCE

FRESH

AIR

Shut

inspected

of

its

other

Monoxide,

is

poisonous

Symptoms

•

•Inability

IMMEDIATELY. down

and

repaired.

of

Throbbing

Muscular

Vomiting

to

ANY

the

unit

an

odorless

and

can

Carbon

Twitching

OF

in

Temples

Think

THESE

If

symptoms

and

do

Monoxide

Coherently

not

and

cause

SYMPTOMS,

persist,

restart

A

WARNING

·

should generator.

WESTERBEKE

MONOXIDE

quarters easily

DECAL

be

fixed

DETECTORS

of

your

obtainable

is

provided

to a bulkhead

also

recommends

in

vessel.

at

your

They

local

by

WESTERBEKE

near

your

installing

the

living/sleeping are

inexpensive

marine

engine

CARBON

store.

and or

and

Gasoline

with

an ETHANOL

content·

higher

than

and

10°/o (E10)

may

void

is

not

allowed

warranty.

~,~

rWESTERBEKE™

~

Engines

&

Generators

THIS

PAGE

INTENSIONALLY

LEFT

BLANK

SAFETY

INSTRUCTIONS

·INTRODUCTION

Read this caused

precautions.

take

personne4

The the

!PREVENT

A

while

power.

11

Ill Use insulated

II

PREVENT

A

exhaust hot/

1111

A

II

safety

manual

by

failure

Know

the

necessary

and your

foUowing

safety

American Boat and

ELECTRIC

WARNING:

engine

Is

Lethal

voltage

Do

not operate this machinery without electrical

enclosures Shut off electrical power before accessing electrical

equipment.

equipment. Make sure your clothing and skin are

(particularly Remove

electrical equipment.

and

mats

shoes)

wristwatch and all jewelry

BURNS -HOT

WARNING:

system

Monitor engine antifreeze coolant level at the plastic coolant recovery tank and periodically location when

In before touching

on

the water jacketed exhaust manifold, but

the engine is

WARNING:

case of

an

engine

carefully.

to

follow

fundamental

when

dangerous

precautions

to

protect

Most

accidents rules

conditions

yourself,

machinery.

instructions

Yacht

are

Council

in

compliance

(ABYC)

SHOCK

Do

not

touch

AC

electrical

running,

covers in place.

or

when

connected

Is

present

whenever working

when handling electrical equipment.

at

these

connections

connections!

on

electrical

dry,

not

when

working

ENGINE

Do

not

touch

hot

engine

parts

components. A running

COLD.

Steam

can

cause

overheat,

the

engine or checking the coolant.

allow

engine

at

Injury

or

the engine

the filler

are

and

exist and

your

with

standards.

to

shore

damp

on

or

gets

cap

death/

to

cool

very

only

PREVENT

A

II

Prevent sparks pump, vapors. removing the fuel line, carburetor, or

II

Do Backfire can cause severe injury or

II

Do the engine/generator clean and free of debris chances

11

Be

PREVENT

A

Injury

II

Follow hatches closed when fueling. Open and ventilate cabin

after fueling. Check below for fumes/vapor before running the before starting your engine.

11

All when ventilated area and out of the reach of children.

1111

Do

1111

Shut off the fuel system. spill. sources servicing. the

11

Do

II

Be sure all

II

Be certain fuel line free of leaks.

II

Make sure a

properly maintained. Be familiar with its proper Extinguishers rated for all applications encountered in this

BURNS -FIRE

WARNING:

flash to or other potential sources of spilled

Use a suitable container

not operate with the air cleaner/silencer

not smoke or pennit fuel

system.

aware-

Fire

can

cause

fires.

Do not smoke or pennit

occur near the carburetor,

flames

Keep

the compartment and

of

fire.

Wipe

up

all spilled

diesel fuel will bum.

injury

or

fuel

to

catch

fuel

death.

or sparks

fuel

BURNS -EXPLOSION

WARNING:

or

death!

re-fueling safety instructions.

fuel

handling

not

fill

DO

of

fuel

not alter or modify the fuel system.

Explosions

blower.

vapors

are

highly

and

away

the

fuel

tank(s) while the engine

the

fuel

service

Take

NOT

allow

fire

near

the

Ensure proper ventilation exists

system.

fuel

supplies

fire

extinguisher is installed nearby and

from

fuel

Run the blower

explosive.

storing

fuels.

from spark-producing equipment

valve

care in catching

any

smoking, open

fuel

system

have

fittings

are adequately tightened

ABC

by the

Use

Store

at

the

engine

or

a positive shutoff

NFPA

vapors

Keep

for

fuel

any

engine

are appropriate

environment.

death!

flames

line,

fuel

all

fuel

filters.

removed.

to

occur near the

to

minimize the

and engine

can

the vessel's

four

minutes

extreme

in a

is when

fuel

flames,

when

or

filter,

fuel

or

fuel

when

oil.

cause

care

well-

running.

servicing

that might

or other

servicing

valve.

and

is

use.

SAFETY

INSTRUCTIONS

ACCIDENTAL

A

WARNING:

or

death!

11

Thm

unit's engine.

•

Make starting.

•

Make

re-installed before starting

BATTERY

A

WARNING:

or

death!

•

Do

not being highly arcing equipment during

•

Never positive Do

not together. Ventilate accumulation of disturb is

being

11

Avoid bums wristwatch, the

battery.

•

Always the

battery connections.

and

reconnect it last

BATTERY

A

WARNING:

severe

•

When

level, protection. destructive. it off at once into

the

caps.

STARTING

Accidental

OFF

the

DC

battery

selector

certain

all

certain

all

EXPLOSION

Battery

smoke

or

serviced.

explosive or

servicing.

connect

test

the

contacting

or

Lead

by

lit

tobacco

in

the

( +) connection

the

battery condition

Sparks could ignite

any

compartment

battery charger connections

charged.

sparks

that could

rings,

tum

the

battery charger off before disconnecting

ACID

Sulfuric

Injury

or

death!

servicing wear

the

rubber

Batteries contain sulfuric

If

it

comes

with

eyes

inadvertently

starting

breaker

personnel

covers,

on the control panel or

switch

to

are

guards,

the

explosion

allow

an

open

acid

batteries

gas,

which can

products.

vicinity

explosive

the

to

prevent

negative(-) battery cable

terminal

contammg

gases.

terminals

cause

and

any

other jewelry before

Remove

when

servicing

acid

battery or checking

gloves,

a rubber

in

contact

water.

Acid

when

can

OFF before servicing

clear of

and

hatches

engine.

can

flame

near

~mi~

be

1gmted

Shut

electrical

of

the

by

shorting

batt~l!'

gases

To

avoid

with

tools,

an

explosion.

the

negative

the

in

batteries

apron,

acid

with

may

splash

removing electrolyte

cause

Injury

the

engine before

are

cause

injury

the

battery

hydrogen,

by

elec1?cal

o~

all

el~tncal

arcmg

to

the

s~er

solenoi~.

the

o~

fuel

battenes

while

the

your

sparks,

the

etc.,

Remo~e

lead

battery.

can

cause

electrolyte

and

eye

which

skin,

on

the

to

handling

tum

the

the.

~

termmals

vapors. prevent

do

not

battery

prevent

first

is

wash

skin

or

TOXIC

11

• Be sure

•

11

•

AVOID

11

EXHAUST

A

WARNING:

Ensure that discharged regularly for water-injected

the

Run blowers Do

not

run equipped detector that complies with boat builder or dealer for installation of detectors.

For additional information, refer (educational information

A

WARNING:

odorless nausea

gas.

or

death!

Do

not

use Diesel

fumes systems. copper tubing resulting

Do through portholes, exhaust discharge outlet

enter

flow

Although

exhaust

gas symptoms poisoning

Vomiting

Dizziness

Headache

Nausea

Exhaust sulfur causes rapid deterioration of

not

install exhaust outlet where exhaust

the

exhaust

of

exhaust.

fumes

is

present

MOVING

A

WARNING:

or

death!

Do

not

service situation arises in make

operating adjustments, touching components.

moving

GASES

Carbon

monoxide

the

exhaust system

from

the

engine. Check

leaks

and

make

sure

elbow

is

securely

unit

and

its surroundings

when

running

the

generator set or engine

with

a functioning marine carbon

Carbon

Inhalation

copper tubing in

can

rapidly

vents,

discharge

Avoid

diesel

engine exhaust

from

in

diesel

or

signs

of carbon

are:

the

ABYC

on

Carbon

monoxide

produces

diesel

destroy

in

exhaust/water

or air conditioners.

is

near outlet

overloading

gasoline

engines,

exhaust

monoxide

Inability Throbbing Muscular twitching Weakness

PARTS

Rotating

the

engine

which

parts

while

it

is

and

hot exhaust

can

absolutely use

(CO)

is

adequate

the

exhaust

attached.

are

ge[lerator

A-24.

to

ABYC

Monoxide).

(CO)

Ru·llke

exhaust

copper

the

waterline,

lQld

close

the

gases

are carbon

fumes.

to

think

in

and

cause

it

is

running.

extreme

Is

a

deadly

to

expel

exhaust

manifold/

well

ventilated.

set or

unless

the

monoxide

Consult

approved

TII-22

is

an

invisible

symptoms,

systems.

tubing

in

leakage.

can

If

the

water

or

restrict

craft.

not

as

monoxide

Some

of

the

inhalation

coherently

temples

sleepiness

Injury

If

necessary

care

to

system

gas!

gases

system

engine.

boat

your

exhaust

be

drawn engine

could

the

toxic

as

or

a

to

avoid

is

Engines & Generators

ii

II

Do

not

wear

loose

equipment;

jackets,

could

II

Make Keep places

m

Do

not

the

engine

1111

Do

not

the

exhaust generator death

HQAQQOQS

,A,,WIRNING:

tie

shirts,

be

caught

sure

all

attaching

protective

at

all

times.

check

fluid

is

operating.

allow·any

discharge

is

operating.

can

occur.

NOISE

back

sleeves,

in

shields

High.

lt(isl

II

Never

operate

ID

Do

not

flame

arrester

II

Do

not

open

(when

A

WARNING:

mentally

an

run

the

engine

removed.

run

engin~s

installed).

Do

or

phf5ically

SAFETY

clothing or jewelry

long

hair

and

rings,

necklaces or bracelets that

moving

levels

swimming

parts.

hardware and

guards in their respective

or

the

or activity around or near

opening

Carbon

for

Monoxide poisoning

.

noise

levels

engine without its muffler installed.

with

the

air intake (silencer)

for

long periods with their enclosures

not

work

on

machinery

incapacitated

when

servicing

avoid wearing

is

properly

drive belt's tension

the generator

can

cause

by

fatigue!

tightened.

while

hearing

when

you

lo'ose

or

INSTRUCTIONS

while

the

or

are

ABYC, INSTALLING

Read for safety codes and standards. Follow their tions-when

ABYC(American Boat and "Standards Craft"

Order

NFPA

AND

ENGINES

the following ABYC,

installing your engine.

and

Technical Information

from:

ABYC

613 Third Street, Suite

AJUiapolis, www.abycinc.org

NFPA - No.302 (National Fire Protection

"Pleasure and Commercial Motor Craft" .

from:

National Fire Protection Association Battery March Park Quincy,

USCG.(Untted States Coast Guard)

"regtllatedions are

Code of Regulations"

from:

U.S. Washington,

MD 21403

MA02269

Government Printing Office

D.C.

USCG

AND

NFPA

10

i.uider

titles CFR33

20404

PUBLICATIONS

FOR

GENERATORS

and

USCG

publications

recommenda-

Yacht Council)

Reports

for

Association)

and

CFR46

Small

of

the

OPERATORS

Many

of

in

your

notes

to carefully, procedures.

GASOLINE

Preparations begin

with a thorough

Yacht

Council's

a

combination

Sections H-2

Ventilatior).

·

H-24

Gasoline P-1

Installation for

P-4

Marine

E.UA.C

All

installations

Regulations

www.abycinc.org

MANUAL

the

preceding

Operators

highlight

maintain

ENGINE

to

install

(ABYC)

of

the

AB

for

Fuel'

of

Propulsion

Inboard

and

DC

Electrical must

(FCR).

critical information. Read

sources

safety

tips

and

warnings are repeated

Manual

Exhaust

along

with

other cautions

yorii-

manual

your

equipment, and follow

·

AND

GENERATOR

a gasoline engine or generator should

examination of the American Boat

standards.

lnc~uding

YC

standards

Boats

using

Systems

and

Auxiliary

Engines

Systems

comply

These

the USCG

of particular interest

Gasoline

Engines

and

Transmissions

on

Boats

with

the

Federal Code of

all

INSTALLATIONS

stlindards

and

safety

and

are

from

the

NFPA.

ar~:

...

Ill

When

installing WESTERBEKE

be

paid

attention

to

INSTALLATION

engines

the

following infonnation: ·

and generators it

is

important

that

strict

CODES

Strict

when

AND

REGULATIONS

federal reguiations, installing engines and

ABYC

guidelines, and safety

generators

in a marine environment·

cod~

must be complied

SIPHON·BREAK

For

installations

or

will be

break in minimum of

the

exhaust manifold

raw

water

If

you have

to

the vessel's waterline under the vessel's various operating conditions,

siphon-break.

NOTE:

A operation. engine

damage.·

EXHAUST

The

exhaust system's hose MUST

Exhaust

and

turns

and

turns.

MUST be

system

any

under

where

below

the vessel's waterline, provisions must

the

raw

water

20"

above

injection

damage

siphon-break

Failure

to

the

any

doubt about the

to

properly

requires

Con8ult

SYSTEM

Hose

is recommended. The

without

the

need

In

this

regard,

designed

sea

conditions and at

the

exhaust manifold/water injected exhaust elbow

be

made toiristal.l a siphon-

supply hose

the vessel's waterline.

engine and possible flooding

the

of additional fitting

a single

to

the exhaust

port

is

at or

position

periodic

of

inspection

maintain a siplwn-break

siphon~break

length

to

prevent the entry of watednto the exhaust system

any

be

certified

use

angle

of

manufacturer

of

elbow.

This hose must

Failure

below

the water-injected exhaust elbow relative

the

and

to

use

a siphon-break when

load

waterline

of

the

boat.

cleaning

can

to

result

for proper

for

marine

use.

Corrugated Marine

this type of

and

corrugated exhaust hose can

of

vessels

hose

clamps

heel.

allows for extreme bends

to

accomplish these bends

is

close

be

looped a

wiU

result in

instaU

ensure

proper

in

catastrophic

maintenance.

be

used.

with

to

a

AVAILABLE

YOUR

DEALER

SIPHON-BREAK

Loop·

The

FROM

WESTERBEKE

WITH

STAINLESS

A

detailed engines to

download

Marine

and

Installation

generators,

from

our

website

is

Manual

supplied

at

Engines & Generators

covering

with

each

unit. A pdf

www.westerbeke.com.

iv

gasoline

and

diesel,

is

available

·

CARBON

MONOXIDE

"CO"/

L~W·CO

GENERATORS

DESCRIPTION

Carbon is a colorless,

monoxide

gas

that

can

one

of

the

threat

that

must

Several

standards

parts

per

million

Regulator

EPA

ACGm

EPA

NIOSH OSHA

ACGm

NIOSH NIOSH

(IDLH)

1200

ppm

IMMEDIATELY

A

city

in California characterizes the effect

concentration

Parts

per

25

"CO" is a component

tasteless, odorless, lighter

kill

you

without

major

safety risks associated with

not

be

underestimated.

for

CO

have been published, expressed in

"pp~"

and

co

ppm

9

25

35

50

125

200

1200

Is

the

so-called

DANGEROUS

this

way:

Million

IDLH

TO

Responses

Permissible exposure level,

100

200

IMPORTANT

of

engine exhaust. It

.than

air poisonous

any

warning.

hours

of

conce~tratlon

LIFE

apparent No poisoning

Allowable Should

this level

time. A possible

headache

CO poisoning is

bo!lting.

exposure:

Exp~re

.

Hours·

8

1

8

0.5

0.0

•

AND

HEALTH.

of

CO

toxic symptoms.

for

long period.

for

several hours.

not

be

exposed above

for

any

~riod

mild

in

two

to

three

It

is a

no

of

fJ.'ontaJ.

hours.

INFORMATION

As

soon

as

CO leaves the exhaustoutlet,

to

dilution in the open

exhaust outlet,

In

a

clo~

or underneath a stem swim platform, potentially rise to the undiluted level exhaust system due gas.

Therefore, one should never rely on

~aust

Wesmrbek~

by

precise coupled with after emissions

engine

commonized across several engine models being for some and extra-adequate for others, different

The fuel system

air/fuel'ratio control is comprised components: purchased sub-assemblies, machined sensors, electronics and of CO reduction, any variability

these components can and will cause variability of output.

CO

concentration also varies with load. always, the worst case CO concentration load.

the.

space, such as the engine

to provide a margin

generators achieve

cOntrol

are

not the same for every model

is different Also,

CO

levels for different models.

air.

The closer a

higher the concentration of

to

a lack

of

fresh air

of

safety. reduction

contrOl

which accomplishes the

of

the engine's air/fuel

~tment

in

certa,in

others:

a special catalyst

fuel system

of

Because of

in

the

level

person

is

to

CO.

compartment

concentrations

emanating

thus

many

functioning

to

dilute

dilution

of

CO

.

because

components

producing

required

different

the

extreme·

Usually,

occurs

from

of

ration

at

is subject

the

will

the

exhaust

the

CO

each

adequate

precise

castings,

level

of

any

the

CO

but

not

maximum

are

Even

though

Westerbeke

reduce

normal

levels imately extremely

tant

it

99%,

to

install

is

always

tor

sounds,

You

can

detector

boat

leaving

help.

an

dangerous.

a CO detector

turned

do

not turn it

not

taste.

on,

tum

ports

exhaust leak

off

generators

of co in the

For this reason it

ne~

on

and

functioning properly.

off,

assuming

smell, or otherwise detect

all

engines

and

hatches open, and seek professional

are

engine-

of

untreated exhaust would be

the generator and

and

generators,

·

designed

exhaust by approx-

is

extremely impor-

it'

is a false

If

CO.

Leave the

evacuate

to

·

to

be sure

this

detec-

signal.

the

j...,..,.JWESTERSEKE

(Engines

y·

& Generators

CARBON

MONOXIDE

"CO"/

LOW-CO

GENERATORS

IMPORTANT

Catalyst performance will degrade over time. As the generator accumulates operating hours,

The

will increase. hours

of

engine

Verification seasonally Verification involves actual sampling appropriate

There are two locations where exhaust gas can be sampled. Dry, but hot, exhaust gas can plugged opening on the top elbow's cast. Measurements at this location may not be practical in all instances due to the high exhaust temperature, temperature limits temperatures involved The other location is the boat's exhaust outlet, which contains entrained cooling water (except

systems).

location and it is critical that the probe not ingest water.

Probe-type analyzers have an through the probe. As a result, they tend to ingest water when it is present. opening pointed in the direction out the tubing leading to the probe running continuously downhill. probe and the analyzer and be sure no water is being ingested. repaired

Only analyzers with probes should be used at this

of

the flow. Position the analyzer as high as possible with

Observe the usually translucent tubing between the

If

or

catalyst

operation.

of

satisfactory

or

each

CO

analyzer.

of

Be

sure to aim the probe downwards with the

any water is ingested into the analyzer, it must be

replaced and recalibrated.

must

CO

500

hours

(which

be

of

the water injected exhaust

the analyzer, safety concerns over

or

the possibility

air pump drawing a gas sample

CO

concentrations

be

replaced

levels

of

sampled at the 1/8NPT

of

the water flow and just

every

2,000

must

be

done

ever

occurs

first).

exhaust gas with an

of

high levels

dry stack exhaust

of

CO.

INFORMATION

Whenever taking the time to verify proper exhaust with a use the analyzer to from exhaust leaks. Pay close attention to the connection

the cylinder block to the sump plate, the sump plated to the water injected exhaust elbow casting and all subsequent downstream exhaust components and hoses and connection

points. Remember, exhaust gas that has not yet passed

through the catalyst is raw exhaust, untreated exhaust gas and is very high in

Analyzers usually require periodic calibration. Follow the instructions that come with the analyzer very carefully regarding calibration.

The following are manufacturers that offer Extech, TIF, Testo, TSI, Bacharach, Fluke, Monoxor, Fyrite, Zellwgwer Analytics, Industrial Scientific Corp, GFG, TPI, Teledyne and others. Westerbeke recommends analyzers with a probe connected, to the analyzer tubing. They are slightly more expensive than those with the sensor built into one end to sample the exhaust coming out

CO

analyzer, always take theopportunity to "sniff'

around the engine looking for

CO

content.

by

of

the analyzer, but they allow you

of

POSITION THE AND SECURELY

ADJUSTABLE

CLAMP

CO

levels from the

CO

analyzers:

a length

the boat's exhaust outlet.

TWO

TIGHTEN

of

transparent

THE

CLAMP

FLANGES

(AND

CO

of

OVER

GASKET)

CO

When measuring ambient upwind level at the exhaust will be influenced upwards by the ambient level.

For exhaust

CO

level by also measuring

of

the exhaust outlet, especially in marinas. the

changing

back

at the exhaust outlet be aware

the

exhaust

pressure,

catalyst

refer

to

the

CO

away from and

and

measuring

Table

of

Contents.

the

CO

the

INSTALI,.ING A NEW CATALYST

Engines & Generators

Vi

EMISSIONS

This genset meets the requirements Emissions Standards as stated on the nameplate.

California users unauthorized modifications or replacement air intake, or speed control system components that affect engine emissions are prohibited. Unauthorized modification, removal or replacement

Federal Emissions Compliance Period: The Federal

Emissions Compliance Period referred indicates the number has been shown to meet Federal Emissions requirements.

Catagory C=

Emissions

Engine

Engine Valve Engine Ignition Timing Engine Engine

Engine Emission Contol System

Catalyst Oxygen Sensor Back

of

this genset should be aware that

of

the engine label is prohibited. California genset users may use the table below

of

operating hours for which the engine

250 hrs, B=500 hrs,m A

Warranty

Fuel

Requirements

Adjustment

Lubricating

Adjustments

Pressure

Information

Oil Requirements

of

California's Exhaust

of

fuel, exhaust,

to

on the nameplate

=lOOO.hrs.

EMISSIONS

The California emissions control warranty statement is located in the same packet, factory.

The engine is certified to operate on unleaded gasoline. See

RECOMMENDATIONS.

See MAINTENANCE SCHEDULE. See See ECU.

The engine emission control system consists

manufacture. See See MAINTENANCE SCHEDULE. See MAINTENANCE SCHEDULE.

CONTROL

if

MAINTENANCE SCHEDULE. ENGINE OIL RECOMMENDATIONS.

MAINTENANCE SCHEDULE.

You and other manuals and information you receive with your genset. maintenance or service should seek assistance from an approved WESTERBEKE dealer.

locating information related to the California Air Resources

Board requirements for emissions control.

INFORMATION

information

should carefully review operator (Owner) Installation

If

you are unsure that the installation, use,

of

your genset is authorized, you

as

an aid in

TABLE

as

this manual when the genset is shipped from the

FUEL

of

engine design and precision

Engines & Generators

Vii

TABLE

OF

CONTENTS

ENGINE

BLEEDING

Wiring Diagram ........................................................ 14

ELECTRONIC

ELECTRICAL

TESTING

Serial Number ...................................................... 2

ENGINE

ON-BOARD

Instructions to

test

Compression Test ................................................. 9

Cylinder Head Bolt Sequence .............................. 9

Drive BeltAdjustments ......................................

Oil

Spark Plugs ......................................................... 10

Ignition Wires ..................................................... 1 0

Valve Clearance ..................................................

Measuring Exhaust Back Pressure .....................

Ignition Timing ...................................................

Ignition

Testing the Igniter ............................................. .12

Testing/Adjusting Pick-Up Coil.. ....................... 12

Relay Control Board ..............................................

Control Circuit (Panels) ......................................... 16

Electronic Control (ECU) ......................................

Fuel Injection .........................................................

-Throttle Body ........................................................

Map Sensor ............................................................

Stepper Motor ................................. ; ...................... 20

Fuel lnjector/Pressure ............................................ 20

Shutdown Switches ...............................................

Pick-Up Coil (MPU) ............................................. 22

Fuel Pump .............................................................. 22

Oxygen Sensors ..................................................... 23

Air Coolant, Heater Sensors ................................. 24

Ba;tery Charging Circuit ....................................... 25

FOR

OVERHAUL.

TROUBLESHOOTING

SOFTWARE

for

using

PC

System

Components

ADJUSTMENTS

Pressure ........................................................ 1 0

Coi1

....................................................... 12

THE

FUEL

SYSTEM

COMPONENT

TESTING

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

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

DIAGNOSTICS

Interface

AND

Software

TESTING

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

TESTING

VALUES

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

(Chart) ...................... 26

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

3-8

2

3

10

11 11 11

13

15

17

18 18

19 19

21

ENGINE AND

ENGINE

RAW STARTER DISTRIBUTOR

SERVICE

Nut/Bolt Tightening Methods ................................... 66

Special Tools-Engine ................................................ 67

BC BC

INTEGRAL

AC

SBEG SPECIAL SHORE REMOTE ENGINE-GENERATOR METRIC

DISASSEMBLY,

INSPECTION

ASSEMBLY

DESCRIPTION GENERAL

TIMING

INSPECTION

This

procedure

with

the

LOW

CO.

Oil Gallery, Distributor,

The.rmostat, Raw Water Pump ........................... 35

Cylinder Cylinder Head/Rocker

Camshaft/Rocker Arms .....................................

Piston/Connecting Rods .................................... .42

Front Case/Counterbalance Shaft

and

Oil Pan ......................................................... 47

Oil Pump/Front Case .......................................... 50

Crankshaft, Bearings/Oil Seal.. ..........................

Cylinder Block/Pistons ....................................... 54

Coolant

Exhaust Manifold/Heat Exchanger .................... 56

HARDWARE

WATER

DATA

GENERATORS TROUBLESHOOTING

Internal Wiring Schematic ..................................... 69

Exciting the Generator ...........................................

Testing Continuity ................................................. 72

Testing Capacitors ................................................. 73

·

E

xc1ter Testing BC

Components .................................................... 75

TERMINAL

WINDINGS

TOOLS-GENERATOR

POWER

CONVERSION

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

INFORMATION

BELT

DISASSEMBLY

AND

may

generator

in

Components ...................................... 33

HeadNalves

Pump

..................................................... 55

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

REPLACEMENT

be

performed

the

boat

......................................... 36

Cover ............................. 39

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

TORQUES , ...............................

PUMP

MOTOR

(Exploded View) ....................... 58

(Exploded View) .......................... 59

(Exploded View) ................................ 62

STANDARDS/LIMITS

(Chart) ............. 63

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

(Chart) ..............................

w·

d' 73

1n

1ngs .................................................. .

BC

Rotor ................................................... 74

CONTROLLER

CONNECTIONS

SCHEMATICS

(Charger) ......................... 76

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

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

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

TRANSFER

CONTROL

WIRING

SWIJCH

DIAGRAM

SPECIFICATIONS

(Charts) ................................ 8il

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

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

27 28

29-32

.40

51

57

68

-69

70

76

77

78

79 80

81

Engines

& Generators

1

TESTING

HOW

TO

DETERMINE

Cause

Generally, the time at which an engine should be overhauled is determined 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 tors. It is, therefore, necessary to determine a cause or causes on maintenance. means worn cylinders or piston rings, the following symptoms will occur:

These symptoms often appear together. Symptoms 2 and 4 can result also from improper fuel regulation buretor. They are caused also by defective electrical devices such as the battery, starter desirable to judge the optimum engine overhaul time lowered compression pressure caused by worn cylinders and pistons plus increased oil consumption. Satisfactory combustion is obtained only under sufficient compression pressure.

·If tion are operating properly. overhaul, it is important to measure the engine compression pressure regularly. which the measurement should with engine rpm. front end

NOTE:

ADJUSTMENT

of

Low

Compression

by

various conditions such as lowered engine

decrease in compression pressure is caused by many fac-

the basis

of

data produced by periodic inspection and

Oil analysis on a seasonal basis is a good

of

monitoring engine internal wear. When caused by

1 Low engine power output 2 Increased fuel consumption 3 Increased oil consumption 4

Hard

5 Noisy engine operation

an engine lacks compression pressure, incomplete combus-

of

fuel will take place even

be

checked because the compression pressure varies

The

of

the crankshaft. ·

To

test engine compression see the

section

ENGINE

OVERHAUL

engine starting

or

a faulty car-

or

spark plugs. Therefore it is

if

other parts

To

determine the period

At

the same time, the engine speed at

of

compression pressure is made

engine rpm can be measured at the

of

this manual.

of

ENGINE

PERIOD

by

the

the engine

engine

FOR

OVERHAUL

· on

ENGINE

The following sections contain detailed information relating to the major components and systems Included are disassembly and inspection instructions for the guidance vice and rebuilding facilities. The necessary procedures should be undertaken only by such facilities.

Additional detailed information and specifications are provided in other sections generator, alternator, cooling pumps, etc.

OVERHAUL

of

the engine.

of

suitable equipped and staffed marine engine ser-

of

this manual, covering the

starter: motor, engine adjustments,

DISASSEMBLY

1.

Before disassembly and cleaning, carefully check for defects which cannot be found after disassembly and cleaning.

2. Clean the engine exterior. Perform disassembly in a proper order using proper tools.

3.

Keep disassembled parts in order. Apply oil when neces-

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

intrusion

The

generator serial

number

the

generator

of

is stamped

top

of

the

nm.l.HTLY.

dust and dirt.

·

from ·

OVERHAUL

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

these parts.

When decrease limit, the engine must be overhauled.

The engine requires overhaul when oil consumption is high, blowby evident, and compression values are at minimum below. Engine compression should be 178 psi (1260Kpa)

400

rpm. With a limit 137 psi (860 Kpa). Pressure should not differ ENGINE

CONDITIONS

of

compression pressure reaches the repair

by

more than 14 psi ( 100 Kpa) between cylinders. See

ADJUSTMENTS in this manual.

of

wear

or

at

Engines ~ Generators

2

-~m>riflrrnltin••~

l'!d

on

the side

generator.

PC

INTERFACE

Prior to overhaul, it is advised to operate the unit with PC Interface Software connected to the ECU. This will help determine system operation and whether system components may need replacement during overhaul.

on

are

a decal

of

the

SOFTWARE

ENGINE

TROUBLESHOOTING

PROBLEM

Engine

Low

oil

High

oil

backfires.

overheats.

pressure.

Spark

1.

2.

Incorrect

3.

Dirty

4.

Cracked

5.

High Coolant

1.

system. Faulty

2.

3.

Belts

4.

Raw

5.

Faulty

1.

Low

Wrong

2.

3.

Wrong

Relief

4.

Faulty

5.

6.

Faulty

7.

Faulty Dirty

1.

engine. Relief

2.

PROBABLE

plug

wires

timing.

flame

arrester.

distributor

exhaust

back-pressure.

loss.

Pressure

raw

water

pump

are

loose

or

water

pump

thermostat.

oil

level.

SAE

type

oil

filter.

valve

is

stuck.

oil

pump.

engine

bearings.

oil

filter.

oil

or

wrong

valve

is

stuck;

CAUSE

are

connected

cap.

test

impeller.

broken.

worn.

oil

in

the

SAE

type

wrong.

cooling

engine.

oil

in

the

PROBLEM

No

DC

charge

starting

battery.

Blue

exhaust discharge engine.

Black

exhaust discharge engine.

Poor

Performance

at

generator

smoke

from

speed.

to

the

smoke

the

1.

Faulty AGM

2.

Faulty battery

3.

Faultybattery Faulty

4.

Faulty

5.

Lube

1.

High

2.

3.

4.

5.

1.

2.

3.

4.

5.

1.

2.

3.

lube Crankcase Valves

incorrectly. Piston

or

unseated.

Dirty Lube Valves

adjusted.

Piston Cankcase

Fuel

injector

Fuel

pump

replace. Throttle

Remove

PROBABLE

30

fuse.

connections

charging

bridge generator

oil

is

are rings

flame

oil

is

are

rings

body

and

amp

buss

Ref.

DC

control.

charging

rectifie.

charger

diluted.

oil

level.

breather

worn

or

are

worn

arrester. diluted. worn

or

are

worn

breather

not

functioning

clogged.

Jirter

clean.

CAUSE

fuse

or

30

wiring

diagram.

to

control.

windings.

hose

is

clogged.

adjusted

incorrectly

or

unseated.

hose

is

clogged.

properly.

Remove

streim

dirty.

amp

and

ENGINE

DIAGNOSTIC

This Diagnostic Software Kit is designed to aide the technician in monitoring the ECU

functions (Electronic Control Unit) functions.

The Diagnostic Software will run newer based operating systems. These must have a minimum of

128 megabytes the communication cable plugs into a serial connection adapter to convert from serial to

Bus). When using serial to port that the adapter is using MUST

configure the Diagnostic Software. The Westerbeke communications cable is unique to this

Diagnostic Software and must be used to the

ECU substituted. The Diagnostic Software is designed with ple screen, tabs and pull down menus to aide the user in the diagnostic process.

The Diagnostic Software is for monitoring only so none

SOFTWARE

will occur

of

the values can be changed.

TROUBLESHOOTING/SOFTWARE

KIT

#05541

CO

generator's operation and

on

of

RAM

(Random-Access Memory) and

USB (Universal Service

USB adapters, the communication

if

any other communications cable is

0

WINDOWS 98 and

be

known in order to

or

otherwise damage

multi-

ONLY.

It is read

or

an

DIAGNOSTICS

TEST

PROCEDURE

GASOLINE

DIAGNOSTIC SOFTWARE IS A VALUABLE TOOL SOLVING ENGINE PROBLEMS. REPLACE BASIC TROUBLESHOOTING SENSE. IN GATHERING VALUABLE INFORMATION.

DIAGNOSTIC

THE

FOLLOWING PROCEDURES WILL HELP

FOR

DATA SOFTWARE

(EC1

LOGGING

IT

USING

PC

INTERFACE

SHOULD NOT

OR

0)

COMMON

THE

IN

Engines & Generators

3

ON-BOARD

DIAGNOSTICS 1 PC

INTERFACE

SOFTWARE

After installing the PC Interface Diagnostics Software on your laptop, shut off the generators control box. Attach one end communication cable to one If

your laptop does not have a serial port, you must use adapter that goes from a serial port to a USB. Attach the other end connection on the communications cable lines up with the pin number 1 on

the number

communication cable is connected to both the

your laptop. Open the Interface Software and under communication select

comm port. Select the comm port that the cable is connected

to. word

RED

achieved. at the properly positioined on the the connector. Verify the computer Comm correct. Make sure the main

The

Conditions, Wideband States and Emissions Records Display.

ENGINE

This section monitors the running conditions

Coolant

Coolant temperature

Air

Air temperature is displayed in degrees C and degrees

Engine

Oil pressure is displayed in BAR and PSI.

Battery

Battery voltage at the ECU is displayed in V de.

of

the communication cable to the 10 pin

ECU. Reference the label on the ECU to identify pin

1.

Turn on the 20 amp DC breaker as soon as the

Under communication select start comm or crtl +S. The

communication under the menu bar should turn from

to

GREEN

If

it does not turn green, check the connections

PC and the ECU. Make sure that the connector

EClO interface is divided into four sections. Engine

CONDITIONS

Temperature

Oil

Pressure

Voltage

20 amp DC breaker on the

of

the Westerbeke

of

your laptops serial ports.

an

ECU. Make sure that the red wire on the

ECU and

if

the communication link

ECU

and that all the pins are in

DC

circuit breaker

02

Sensor Control, Engine Control

is

displayed in degrees C and degrees

is

properly

is

Port selected is

is

turned on.

of

the engine.

F.

Pulse

Width

Indicates the fuel injector pulse width.

Manifold

Indicates the pressure in the intake manifold in kPa.

WIDEBAND

This section monitors the operating conditions

wideband oxygen sensor.

WB

There are seven wide band sensor states.

1.

WB Time Stamp is the initialization state for the wide

2. WB

3. WB CL Start Comp is the beginning

4. WB Warmup is entered only

5. WB CL No Fault Checks occurs when the lambda closed

6. WB Closed Loop is closed loop lambda control with a

7. WB Open Loop state occurs

WB

There are three states for the Heater Status. Low Temperature, High Temperature, and Normal Temperature. The Normal Temperature is at 893mV.

Pressure

02

SENSOR

02

Sensor

band lambda sensor.

OL Delay occures during the post-crank enrichment period. This is an open loop fueling period. This state is present until the temperature.

fueling for the post-startup. The closed loop control targets a rich lambda set point. The lambda set point function a function

temperature is not above a certain threshold.

loop control is trying to control the fuel delivery to Stoich faults are performed.

target set point occurs.

is detected. The closed loop lambda control

02

Heater

States

of

engine coolant and this set point leans out as

of

time.

(Lambda= 1.000) but no checks for emissions

of

Status

CONTROL

of

the

WB02 heater comes up to its operation

of

closed-loop

is

if

the engine coolant

Stoich and emissions faults checks

if

an emission malfunction

is

disabled.

a

Engine

Engine runtime

Engine

Engine speed

60Hz operation= 1800 rpm and 50Hz operation= 1500

Hours

is

displayed in hours.

Speed

is

displayed in RPM.

Lambda

ExhaustAir/Fuel mixture.

abve and below Air/Fuel mxture.

Throttle

Indicates the position relative to the fully closed position.

1.000 continuously as the ECU adjusts the

Position

You

should see readings going

of

the throttle control unit in steps

rpm.

WB

02

Crossing

There are three states for Crossing Stoich. Initialize indicates

the initialization period for the sensor. Rich indicates a

Lambda lower than

than

1.000.

Running

Indicator will be turn

WB

This indicator reads the Wideband Heater status in milli-volts. The set point for this function

Closed

GREEN

02

Heater

Stoich

1.000. Lean indicates a Lambda higher

Loop

PI

Control

RED

when running Open Loop and will

when running closed loop.

Voltage

is

893mV.

4

ON-BOARD

ENGINE

This section monitors the control conditions

Emission

There are four Emission Conditions.

1.

2.

3.

4. Not Crossing Stoich - This condition will display

Heater Malfunction -This condition will display

heater condition displays Wideband

Engine

Along with the Genset is equipped with an LCD display to indicate shutdown. Refer to your Owners Manual for a description display. When the Genset is operational and everything is operating properly, this

There are ten Engine Shutdowns that are controlled by the ECU.

1.

2.

3.

4.

5.

6.

CONTROL

STATES

Conditions

Closed Loop Disabled - This condition will display

the Wideband

02

Sensor Control has been disabled

Normal Operation -This condition will display when

the engine is running and everything is operating prop-

erly.

Sensor Out Of Range - This condition will display

when the lambda is extemely rich (less than lean (greater than 4.6)

engine has been running too Rich than the allotted time period. A perfect Stoich reading in the display is

on

the Wideband

02

1.000.

Sensor.

..

02

Sensor has failed

it

is probably time to change the

Shutdowns

PC

Interface to display shutdowns, the

box

will display Normal Conditions.

Over-Crank Timeout - This will display

start button is pressed and the starter motor is cranking the engine but seconds.

High Engine Coolant Temperature - This will display

if

the temperature

Overspeed -This will display

exceeds 60Hz and 1800 rpm for 50Hz).

Underspeed - This will display

below

20%

and 1200rpm for 50Hz).

Speed Loss - This will display

signal due to a sensor failure

running due to some other malfunction not covered

under the

runs

out

may

be

High Exhaust Temperature - This will display

exhaust elbow overheats due to a lack charge.

it

does not start the engine in about six

of

the engine coolant exceeds 95•C.

20%

of

the desired set speed. (2160 rpm for

of

the desired set speed. ( 1440 rpm for 60Hz

ECU

shutdowns. Sometimes if

of

fuel this shutdown or Low

displayed.

Check

the

raw

water pump for

DIAGNOSTICS 1 PC

of

the genset.

if

0.8) or very

if

or

too lean for more

if

the

..

If

this

of

if

after the

if

the engine speed

if

the engine speed falls

if

there is a loss

or

the engine has stopped

Oil

of

flow

of

speed

the

Genset

Pressure

if

the

raw water dis-

if this failure

occurs.

the

INTERFACE

7.

Low Oil Pressure

falls below 8 psi.

8.

Oil

Pressure Sensor Shorted - This will display

is a short in the oil pressure sensor wire.

9. External Fault - This will display

connected to the auxiliary fault terminal such as a fire boy device has been triggered.

10. Low Battery Level

battery voltage is too low to crank the engine long enough to start.

Engine

There are five Engine States.

1.

2.

3.

4.

5.

Firmware

The Firmware Revision Number consists first part is the Revision Number, and the third part is the Major Revision Number.

NOTE:

the

Frequency

This box displays the position

Switch on the ECU. position dip switch block. Switch Number 1 is for selecting the desired engine speed. When the switch is in the

tion, the engine will run at

When the switch is in the

at

NOTE:

OFF and must to before

further

State

Idle- This is the state when the engine is turned off Crank - This is the state when the starter motor is

engaged and cranking the engine over for starting.

Run

- This is the state when the engine is running.

Shutdown - This is the state after the stop button has

been pressed and the engine is shutting down.

Idle

Wait

- This is a short period, approximately 3 sec-

onds, after the stop button has been pressed before the

start button can be pressed again. This allows the engine

to stop turning before attempting a restart.

Revision

Part Number, the second part is the Major

When

requesting service

complete

Firmware

Option

1800 rpm for 60Hz operation.

To

change

the

Main

be

switched

another,

there

operating

details.

SOFTWARE

-This

will display

on

Crank - This will display

Number

information,

Revision

On

the top

the

speed selection,

DC Circuit Breaker

OFF.

When

are

wiring changes that must

the

Genset.

Number.

of

the Frequency Option

of

the

1500 rpm for 50Hz operation.

OFF

position, the engine will run

switching

See

you

if

the oil pressure

if

the device

of

three parts. The

please

ECU

there is a four

the

engine

on

the

from

one

Owners

if

reference

ON posi-

must

be

panel box

frequency

be

performed

Manual

there

the

..

for

5

ON-BOARD

DIAGNOSTICS 1 PC

INTERFACE

SOFTWARE

Start off by collecting date from the time that the engine is started.

If

you have a genset that has the idle mode, start the

PC

interface communicating and data logging before you

If

start the engine. idle mode, start the PC Interface as soon as possible after the engine is running. minutes before trying to apply an AC load. Monitor and record AC volts and amps

After the engine is warmed up, start applying an AC load by

on

turning change for a couple Monitor and record load site. Continue to as AC load until the unit is at or near full power rating. AC voltage times the the unit is overloaded

After loading up the genset, begin to reduce the AC load. Let the unit run at each load site for a couple stabilize. Continue to reduce the AC load and monitor voltage and amperage until there is no AC load on genset. This will give a technician a baseline when the engine is running under a controlled load condition.

Finally, after running the controlled baseline test, this might sound strange,

particular scenario that will cause a problem for the unit. Sometimes awhile and when happens. Try repeating the scenario that the customer mentions. Always start least a couple get a starting point. Then continue to record data until the problem shows up.

If

you have a unit with no idle mode, and the unit shut down under some kind and save the file. the unit was to shut down under some kind have to manually

shutting data file to stop and save itself.

various devices.

of

you have an engine that does not have an

Let

the engine warm up for about 10 to

if

possible.

Let

the unit run at each load

of

minutes so that the unit is stable.

AC

volts and amps

Power is determined by multiplying the

AC

amperage. This will determine

or

not.

but

sometimes the customer might know a

we

hear customers say that the unit runs fine for

my

air conditioner shuts off something

by

recording date from the start up for a

of

minutes with no load on the generator to

of

fault, the date log will automatically stop

If

you have a unit with an idle mode, and

stop the data log to save it.

the

DC

circuit breaker, this will also cause the

if

possible at each

of

minutes to

of

what is going on

of

fault, you will

Or

in the case

15

if

of

Speed

Simple enough, this is the speed that the engine is running, the genset is set up to operate at to run at unit is set up for be

When a genset is governing properly, you should see read-

ings slightly above and below the desired speed. Even a well

tuned engine will vary a little. The point is you should see

readings above and below the desired speed. readings remain more than desired speed for a prolonged period problem, especially applied.

If

data box labeled Stepper trolled by a stepper motor. Usually the step count for the engine running with no steps range. A couple does not indicate a problem. However, the single digit numbers maybe that the thrrottle body assembly may be out calibration can only go to a positioin that it thinks is zero. calibratiort is off, the stepper cannot move the throttle closed

enough to slow the engine down. An engine that has this problem will run at the proper speed once some AC load has been added. However, when that load is dropped, the speed

will be too high, and in some cases may cause the engine to

over-speed and shut down.

If

is probably a totally different problem. Again, look at the

Stepper

would mean that the throttle is being opened to compensate

for loss

make sure that the fuel level is full in the fuel system and that

the fuel is good and the filters are clear. Bleed the fuel system

to remove any air. Check to make sure that the

screens are clean. Check to make sure that the spark plugs

have not fouled.

1800 rpm (belt driven units may be different).

50

Hz

operation then the engine speed will

1500 rpm.

if

this is noticed with no AC load

the speed is too high with no

AC

of

or

not functioning properly. The stepper motor

the engine speed is too low with no

Position. Is the speed low but steps are high? This

of

speed

but

the speed is not coming up. Check to

60

Hz, then the engine needs

If

you see speed

20

rom above

AC

Pos. (steps). The throttle is con-

load is typically in the 20-30

steps above or below this range

or

even showing a zero, the problem

or

below the

of

time, there could be a

load applied, check the

if

the step count is in

of

If

the

AC

load applied, there

air intake

If

the

WHAT

All on information applies whether you are looking at the data file after Interface. The data file can be opened in most spreadsheet software such as Microsoft Excel.

Some

explanatory and simple engine temp, air temp, oil pressure, and battery volts would be easy to figure out. Some familiar.

TO

DO

WITH

THE

DATA

of

the data that is being recorded is also being displayed

the PC Interface in the various boxes. The following

it

has been recorded

of

the data that is being collected is pretty much self

or

watching it live in the PC

to follow. For example, I think that

of

the other items may be less

If

t:pe

engine speed is okay when running with no AC load, but once underway with some AC load being aplied the speed drops and stays below the desired speed, first check the AC power by multiplying the total AC volts to get the kilowatts. what the unit is rated for, then it is overloaded., Shut off some

of

the devices until the speed returns to normal and check the power again. applied and the speed cannot maintain, follow the same suggestions from the previous paragraph.

If

there is only a small AC load

AC

amperage times the

If

this number is higher than

6

ON-BOARD

DIAGNOSTICS 1 PC

INTERFACE

SOFTWARE

Pressure manifold. At no-load the The wider the throttle plate is open, the closer it gets to atmosphere which is about running at no-load will see a full load it would be around 70 MAP default value that is in the code.

WB the heater temperature in the Wideband in all the units that do not have an idle mode, the set point is 893. In other units the set-point will vary but wll be displayed in this box.

WB the heater temperature in the Wideband 02 Sensor. heater is working properly, you will typically see values stay within

is, the colder the heater is. Typically a reading in the

area means that the heater is not working at all. is swinging dramatically above and below the set-point, the sensor is probably failing. The sensor should be replaced.

Lambda in a combustion chamber compared to the amount that should have been present in order to obtain combustion. Thus, when a mixture contains exactly the amount present the ratio will be one to one and lamba will equal

1,000.

amount

1,000.

of

Perfect combustion requires an air/fuel ratio

14.7:1 (by weight) under normal condtions. Thus a lean air/fuel ratio of, say, 16:1 would translate to a lambda value of

would indicate an air/fuel ratio

multiplying .97

In our applications

1

,000. Because constantly lamba fluctuating slightly above and below the 1,000 target.

Immediately after a startup it is typical to see a rich readings for lambda. This is part takes a couple control

If

heater value to make sure that the heater is working. Remember that it takes about three minutes after starting an engine for it to be totally in control. Physically remove the sensor and check it for corrosion and build up from the water being injected through the exhaust. Salt water deposited on the senor will be very damaging. evidence

(kPa)

- This is the pressure that exists in the intake kPa

will be lower than at full load.

100 kPa. Typically a genset

kPa

value around 30, while at

90 kPa.

and never moves then there is a problem with either the

sensor or the wiring to the

Heater

Current

fuel (a rich mixture), lamba will

1.088. (To calculate, divide 16 by 14.7.) A lamba

you see a problem in this area first check the Wideband

Set-point

Temp

20

millivolts

- Lambda represents the ratio

of

oxygen required to burn the amount

If

the mixture contains too much oxygen for the

of

fuel (a lean mixture), lamba will be greater then

If

a mixture contains too little oxygen for the amount

be

changing, ideally you should see the value

of

the air fuel mixture.

of

build up, replace the sensor.

-This

- This is the actual value in millivolts

of

the set-point. The higher the number

by

14.7).

we

want to see lambda reading around

of

the combustion involved this number will

of

the startup process and usually

minutes for sensors to warm up and take

If

the kPa is stuck at

MAP

sensor, as

is the set-point in millivolts

02

of

be

less than 1,000.

of

14.259:1 (derived by

70

is a

Sensor. Curently

If

the

4000

If

the value

the amount present

"prefect"

of

fuel

of

approximately

of

.97

of

deposits.

If

there is any

of

After checking the check the air intake screens and spark plugs to make sure they are clean and functioning properly. running too lean, check the fuel Jevels and the quality fuel. Water in the gas will cause the genset to run lean.

Lambda wideband oxygen sensor is contributing. is the maximum.

Wideband value controlling terms. Their reading at 1

Lambda controlling terms. Their

1

,000 enriching

NB

equipped with a narrowband oxygen sensor, this will value

Stepper stepper motor. The value displayed is in steps. being the closed position. Most units will run at the to engine.

Pulse The value will

Ip reading. There is not much to learn from this number.

Main

derived from a value in the fuel table, which is based on the

engine rpm and the

Air compensation based temperature. This value can be both positive and negative. This value is added compensation value.

Frequency

the

show this column but will display the Frequency

the Title area at the top

The

For most applications,

speed

PW

P, I & D

P & I

STT

- (Narrowband Short Term Trim)

of

its contribution. Max contribustion is 1%.

Pos

20 to 30 steps range. These values will vary from engine

Width-

Current

Fuel

Temp

and

ECU, whether it is 50 or

Generator

of

1500 rpm, while 60

of

1800 rpm.

senor and the genset is running too rich,

If

the genset is

Trim - Is the fueling trim precentage that the

In

most cases 15%

Term

- These values are the lambda job

is to keep the lambda

,000 by enriching

Term

or

enleaning the fueling.

(steps) - The throttle shaft is controlled by a

Is tlie fueling duration in milliseconds (ms).

be

lower at no'load than at full load.

- Is the electrical"value equivalent

Comp

(%)

MAP

Engine

on

or

Option -Tis

Frequency

or

enleaning the fueling.

- These values are the lambda value job

is to keep the lambda reading at

If

you genset is

zero

steps

no

load in

of

the Lambda

- Is the fueling compensation that is

pressure.

Temp

Comp

(%)

- Is the fueling

the air temperature and engine

subtracted from the main fuel

the value

of

the data log.

50

Hz

of

the speed selector on

60Hz.

Some interfaces may not

Option in

- Is a function operation is with an engine

Hz

operation is with an engine

of

engine speed.

be

of

the

Engines & Generators

7

ON-BOARD

DIAGNOSTICS 1 PC

INTERFACE

SOFTWARE

De-rated P P(Proportional) rated right after start-up for a short period of allows P value engine the

top

This

Speed speed governing process. These values changing and it them. should reason there is

probably

TO

Click Click File/Exit

Tenn

- This code provided

Term,

in the speed

the engine

which

is

cold.

on

will

be

P,

I & D Terms -These values reflect

The only thing I can

see

CLOSE

the X in

to

warm

up

with

could cause "hunting" or instability

On

some

older units there

the

EUC

that

can

manually de-rate the P

reflected in this

is

very hard

these values constantly changing.

are

all

zeroes in these columns than the engine

not

running.

THE

MONITOR

the top right hand comer of the

box.

to

say

get on

for

PID

control,

out

haviQ.g ~ aggressive

is

are

any information

the subject

tpe

to

be

de-

time.

This

when

also a trim pot

value.

the

engine

constantly

from

is

that

you

If

for

some

Window

the

on

or

Engines ~ Generators

8

ENGINE

ADJUSTMENTS

ENGINE

NOTE:

the simple connect starter

the a starter

1.

COMPRESSION

The

ECU

(Electronic

electrical

between

solenoid

starter

circuit

between

solenoid.

Start

the

operating

2.

Open

the

ECU.

solenoid

3.

Close

the

prevent unit's

exhaust exhaust expel

water cranking.

4.

Remove

remov~

5.

Thread

plug

-opening

gauge

TEST

activation

solenoid

engine

temperature.

DC

Connect

connections.

.raw

the

pressure

the

all

the

to

the

of

the starter motor

Control

Unit).

To

jumper arrangement

the

and

these

battery

tlte

with

and

B+

cable connection

spade

type

activation

a push button in this jumper

two

connections and activate the

allow it

to

warm up

Then shut it down.

breaker

on

the unit's control box

the

jumper arrangement

water seacock. This

raw

water pump from pumping water

system

during the test

will

be

present during

from

the

unit's exhaust system during engine

high

tension leds from the spark plugs

spark

plugs.

compression gauge adapter into

of cylinder

#1.

Connect the compression

adapter.

is

by-pass

can

be

is

to

as

no the

REFER DIAGRAM FOR

a function

the

ECU,

fabricated

on

connection

to

its

nonnal

to

orr

the

or

very

test

to

·

the

spark

TOmE.WIRING

IN

m1s

WIRE

CONECTIONS

of

a

to

the

on

to

make

disable

starter

i~to

the

little ·

help

and

MANUAL

.

6. Activate the starter motor using the push button electrical jumper arrangement for the

crank,

engine to the engine to

observing the compression

crank

until the gauge reaches a

starter.

reading wherefurther cranking does not produce a reading on the ·compression gauge. Stop cranking

record the

7. Remove the compression gauge

~sure.

and

adapter

spark plug opening and install it in the #2 cylinder plug

opening and repeat step -

8.

Proceed

cylinderS

STANDARD 178

Cylinder pressures should not differ

to the next cylinder and repeat step #6

have been tested and

COMPRESSION

PSI

(12.5

KG/CM

2

)

Ensure that compression cylinder

9. Reinstall three plugs and ignition wires. Open the, seacock.

NOTE:

compression comp'i'ession valve the

is

within the specified

A wet test can be performed

figures;

This

is the;fesult'idfwom cylinders/rings or

seats/valves or both. Place a

cylinder and the peiform the

..

6.

the~

pr¢s~

PRESSURE

.

press1,1re

AT

mot•e

differential for

unit.

on

will help determine

few

compression

400

than 14 psi

cylirz4ers

squirts

Allow

gauge.

from

RPM

on

,the

the

Allow

maximum

higher

and

the

#1

spark

until

all

recorded.

each

with

low

~(the

low·

worn

of

oil

into

test

on

that

.

cylinder.

a. A dramatic rise in recorded compression

value

would

indicate worn cylinder/rings.

b.

A minimal rise in recorded compression would indicate both cylinder/ring and valve

c.

No

appreciable rise in recorded compression

indicate valve/valve seat

wear.

value

wear.

would

.

CONNECTING THE

SOLENOID

STARTER.

Cylinder

Tighten

gram

1.

Temporarily

22ft-lbs

2.

Tighten (40-

3.

Tighten torque

CYLINDER

TO

THE

ON

THE

·Head

Bolts

the

cylinder

head

using a stepped-up

tighten

(20 -30 the

bolts

Nm).

again

50Nm).

the

bolts

in

..

HEAD

TORQUE

bolts

in

the

order

tightening

the

bolts

in

torque.

in

numerical order

43_-51ft·lbs

(60 • 70Nm)

to

shown

to

the

specified

29-

in

the

to

36ft-lbs

14-

dia-

.

·uSING

AN

ELECTRICAL

BY-PASS

THE

Rocker

TO

Cover

Install the rocker cover using a

sides

with

clean

oil). Gradually tighten

specified properly.

torque

making certain the cover gasket

ROCKER.

COVER

2.9 • 5.2

6 4

¢1.

ENGINE

FRONT

.7

ECU.

new

i:IDLT ft·lbs

ELECTRICAL

·JUMPER

JUMPER

gasket

the

TORQUE

(Smm

(4 • 7Nm)

1

(slightly

coat

cover bolts

is

positioned

BOLT).

to

both

the

ENGINE

ADJUSTMENTS

INSPECT

FOR

WEAR & CARBON

INSPECTING

THE

SPARK

PLUGS

INSPECT

FOR

DAMAGE

·CHECK

FOR DETERIORATiON AND

DAMAGE

DRIVE

The generators have and drive belts

than the the

BELT

alternator

are

3/8

inch

belt

is

depressed with the

two

pulleys

A

WARNING:

drive

belt's

ADJUSTMENT

and

the

properly adjusted if

(lOmm)

on

tension

~

two

drive belts, one

other drives and

no

the longest span of the

Never

while

the

more

thumb

attempt

the

engine

it

can

than

at

to

raw

the

check

drives

water

be

deflected

1/2

inch

midpoint

belt.

or

is

in

operation.

the

governor

pump.

(12mm)

between

adjust

no

The

less

the

as

SPARK

The spark first thereafter

SPARK SPARK

NOTE:

the spark plugs will retard corrosion, making future removal of

HIGH

Check compartment heat

Check because separated or the cap,

THE

PLUGS

plugs

should

50

hour break-in period,

and

replaced

PLUG

GAP:

0.031 -0.002in.

PLUG

TORQUE:

wctite

the spark plugs easier.

A

WARNING:

the

engine

removing

TENSION

the

ignition

the

resistance of each

the

wires

from

then

pull

RESISTANCE

11-151b-ft (1.5-

Anti-Seize applied to the threaded portion

Do

is

hot.

Allow

them.

CORDS

wires

can

wire connection inside

the

insulator

the

spark plug,

the

cap

VALUE

IS

be

cleaned

then

as

needed.

(0.8-

not

remove

the

engine

(IGNITION

every

500

deteriorate

wire.

may

be

grasp

off the spark

410

OHM

PER

and

re-gapped after

inspected

0.7mm).

2.31

kg-m).

the

spark

to

cool

WIRES)

operating

the

wires.

Do

not

the

cap

damaged.

and twist

plug.

INCH

OF

WIRE.

every

plugs

pull

may

When

250

while

before

hours

on

the

become

removing

the

moulded

hours

as

wire

the

of

engine

OIL

PRESSURE

TEST

GAUGE

TESTING

To threads) Install

place. running

NOTE:

reading up to pressure reading as low as depending upon the load placed on the generator.

OIL

PRESSURE

test engine oil pressure, remove the

in

the

tee

fitting

located

an

accurate mechanical

Start

the

engine

and

RPM

(1800).

A newly started, cold engine may have an oil pressure

70

Observe and record

or

80

psi. A warmed engine can have an oil

oil

allow

30

psi. Oil pressure will vary

hex

on

the

oil filter

pressure test

it

to

operate

plug

the

(1/8npt

adapter.

gauge

at

normal

pressure

in

TESTING RESISTANCE

its

..

10

VALVE

CLEARANCE

/IGNITION

TIMING

VALVE

NOTE:

engine' e valves. See TORQUING THE BOLTS. .

1.

2. Remove the spark plugs to observe the piston position in

3. Adjust the intake and exhaust valves in the firing order

VALVE INTAKE EXHAUST

CLEARANCE

Retorque the cylinder head bolts before adjusting the

Remove the rocker cover and gasket.

each cylinder head when positioning that piston at TDC.

the engine (1-3-2) as follows: Rotate the crankshaft in its normal direction

observing valve movement and piston locatiion placing No.I piston at compression stroke with the intake and exhaust valves completely closed. Then adjust the intake and exhaust valve clearances.

CLEARANCE

VALVES

Rotate the crankshaft 120 degrees to position the piston in cylinder #3 at adjust this cylinders exhaust and intake valves. Rotate the crankshaft another

cylinder #2 at this cylinders intake and exhaust valves.

4. Replace the rocker cover and rocker cover gasket.

ROCKER

COVER

ADJUSTMENT

CYUNDER HEAD

TDC

(Top Dead Center)

0.20mm

0.30mm

(.008in)

(.012in).

TDC

of

its compression stroke and

120 degrees to position the piston in

TDC

of

its compression stroke and adjust

TORQUE

2.9-

5.11b-H

of

(0.4-

its

of

0.7

rotation,

kg-m)

of

IGNITION.

1.

2.

3. Using the timing light, align the timing mark in the front

0.20mm

0.30mm

TIMING

Attach a timing light to the front timing pointer to indicate mark

on

the cr!!Ilkshaft pulley and mark it with white

or

chalk

Start the engne and warm it up to its normal operating

temperature. Make sure the generator is operating

without a

crankshaft pulley so it is just slightly before the first timing pointer. rotating the distributor body. Use the following timing specifications:

TIMING (No-load

crayon.

load

on

it.

Do

this by loosening and slowly

SPECIFICATIONS

on

generator)

(.008

Inches)

(.0121nches)

#1

spark plug and inaik the

15°.

Locate the timing

15° ± 1.0°

BTDC

at

1800

RPM

IGNITION

TIMING

MEASURING

Exhaust systems normally produce resistance to the flow exhaust gases, causing back-pressure. Back-pressure must be

kept within a certain limit. the

generator

To

test exhaust pressure, connect either a water column or

PSI tube to the test part on the exhaust elbow as shown. Check the exhaust back-pressure before the generator is put

into service. Measure the back-pressure after the engine has reached its normal operating temperature, and at the point where it is about to reach its rated load at either (for

50Hz applications) or 1800 rpm (for 60Hz applications). '

Back-pressure should not exceed 1.5 psi (0.11

is

put

back

Check

the

into service.

back-pressure

EXHAUST

of

before

1500 rpm

kg/em\

BACK

PRESSURE

'£.

~

•i

/·

MEASURING

EXHAUST

PRESSURE

PSI GAUGE

BACK

TESTING

NOTE:

An analog meter must when

making this

be

type

used

test.

THE

IGNITION

COIL

HT

HIGH

TENSION..-'

COIL

CONNECTION

NOTE:

An

analog

type

meter must

when

i

J

making

be

used

this

test.

Unplug noting

as Place

A

Place connection.

A

Place connection.

8

they

to

the

electrical connections

the

position of

must

be

reconnected

the

ohmmeter

8 •

1.5

ohm

.

the

leads

between A

HT

•

25.0 · 27.0

the

leads

between 8

HT

•

25.0 -27.0

leads

ADJUSTING

the

two

K.O.

THE

fron

the

coil

electrical connections A

in

the

exact

same

on

terminals

and

the

and

the

high

A

and

tension

PICK-UP

carefully position.

8

as

shown.

coil

GAP

HT

and

8

SWITCH

THE

BACK

AND

THE

FORTH VALUES

TERMINALS

READ

OHMMETER

SG

AND C AND

LEADS

BETWEEN

Instructions

Unplug care reconnected ohmmeter

and again

In

In value value igniter

the

two

connectors at

to

note the two seperate connections, they must be

in

the exact same position.

leads

on

the

read

the

meter.

Then

read

the

meter.

one

direction,

the

other direction, above found

is

100

with

faulty.

the

ohm

there

ohms

the

meter conections

TESTING

the

terminals

reverSe

reading

should be

indicates a

THE

PICK-UP

distribution

SG

and

C

the

ohmmeter

will

be

no

faulty

igniter.

in

Place

as

100

ohm

either

plug.

Take

your

shown

leads

and

ohms

g_r

reading.

Any

ohm

direction,

COIL

less.

Any

the

Adjust

the

point

gap

of

the

pick-up

rotor

and

the

pick-up.

assembly

between

Engines

the

12

Check that the

pick-up

& Generators

when

a screwdriver

assembly,

the

needle of

is

passed

PICK·UP

the

COIL

near

tester

the

iron

deflects.

core

of

BLEEDING

THE

FUEL

SYSTEM

BLEEDING

1. Insure that the fuel cell harness, and that the

2. Attach Snap-On

pressure gauge

A

safe

THE

FUEL

set

CAUTION:

use

of

the

Follow

gauge

SYSTEM

is

not connected

lift

pump

#EEF

1500

ACORE

to

the Schrader valve

manufacturer's

sets

to

purge a high-pressure

is

connected.

to

the wiring

or

equivalent fuel

on

the

fuel cell.

instructions

for

fuel

system.

3. While holding

position, purge the air from the fuel purged

drain line attached

typically

4. Remove the pressure gauge set from the fuel cell and connect

5. Connect the fuel cell to the wiring harness

6. Open the valve not prime the system without the fuel gauge purge valve open

or

happens, repeat steps

air from the fuel cell.

the

stop switch in the

when

no

air bubbles are visible escaping from the

to

the Schrader valve. Ptessure shoul

be

3-4 psi.

it

to the Schrader valve

on

the fuel pressure gauge purge line.

air can

be

forced back into the fuel cell.

1,

2, and 3 to remove the trapped

(prime)

cell. The fuel cell is

on

the throttle body.

..

depressed

If

this

Do

· 7. Repeat step the Schrader valve should

NOTE:

purged. visible

8. Remove the pressure gauge set, and cap all Schrader

valves.

9. Insure that all wire connections are secure and that there are no leaks in the fuel system.

3,

after attaching the pressure gauge set

on

the throttle body.

be

40

psi

after' purging all the air.

The

system can develop 40 psi witlwut being fully

The

system

is

fully purged when

in

the

purge

line.

The

no

bubbles

pressure

are

to

A

WARNING:

fuel

that

may

dispose

"SNAP-ON" #EEF1500 ACORE

or equivalent set

to the

SChrader

fuel

of

pressure

valve.

the

be

spilled

fuel

gauge

Take

care

rags.

to

and

properly

catch

any

PUMP

FUEL

SUPPLY

Engines & Generators

13

WIRING

DIAGRAM 5 AND

#49166

6.5

KW

SBCG

i

r[P·~-

I

,_..,

~~

~

:

::

~-------~--------~

~

N'

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I

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~

i~!

:

IF.:======:::l-1:·

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cc. c.c

.....

:

u

-

=:

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==

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u

en

c:s

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-

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I 0

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0 0 0 0 0

•o

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.,.____,_llll

i

14

RELAY

CONTROL

PC

BOARD

OPERATION.

DESCRIPTION

The Main Control electrical devuce that causes continuois power flow (latching) to the on engine computer (ECU) after momentarily pressing the start switch. It utilizes five relays (K) for accessory power as well as run and start/stop functions. Normally open normally open K2 is for run or engine accessory power, normally open K3 is the power latching relay, normally closed K4 is the shut down relay amd K5 has both normally open and normally closed contactors and its primary function is for fuel pump power. The combination relays and four diodes (D), in their designated orientation, provide a means components based ECU

and "latching"

The coil side

one side. The K3 and K5 relays rely initially on power provided by the start/stop switchs relay relies solely upon power from the stop switch to actuate it. The

Kl after the K3 relay latches for actuation.

Momentarily pressing the start switch sends power through Dl

and D3. Power through

closing its normally open contacters which causes power to

flow through the normally closed contactors the ECU. Power through D3 at the same time flows to coil

of

K5 which then actuates closing its normally open contactor sending power to the fuel pump timer's common and initiate connections. The closed contactors flow through the in series connections strip and through Power flow through continuous power to the K3 relay coil causing it to stay closed

or

"latched". There is continuous power to the ECU at this point and it will stay this way until the stop switch is pressed.

Latching K3 and powering up the ECU, 12V power is measured between p2-1 and P2-2, is called booting up the ECU

pr

initiation the start sequence the green LED signal to the K2 relay. When the K2 relay closes flows to the and ignition coil and through the normally closed contactors on

K5

providing continuous power to the lift pump circuit.

Mter

a 2 to 3 second delay for priming the fuel system, the

ECU

then sends a ground signal to the

cranks the engine and it begins running.

PC

Board (pn#49021) is an analog

on

engine

Kl

provides a starter solenoid signal,

of

these

of

high current power flow to on engine

on

low current capacity signals from the

of

power.

of

K3, K4 and K5 have ground continuously

to actuate them. The K4

and K2 relays rely on power to their coil provided

and· ground signals from the

Dl

flows to the coil

of

D2

as well as to the coil side

D2

is at that point is providing

of

the start sequence., After initiation

ECU

immediately illuminates the

on

the start/stop switch.and it provides a ground

on

engine accessories such

as·

Kl

of

K3 ·

of

K4 and to

of

K4 provide

the fire biy terminal

of

Kl

..

power then

the hour meter

relay, the starter

on

ECU

the:;

and K2.

of

When the engine starts, the magnetic pick-up signals the ECU

to stop cranking the starter, the computer takes over.

The

ECU takes information from all

and it controls all fuel delivery and speed control functions. When the stop switch is momentarily pressed, it actuates the

K4 and K5 relays. When the K4 relay sees a signal from the stop switch it opens its contactors coil making Interrupting power to the unit shuts down. Pressing and holding the stop button closes the K5 relay allowing power flow to the lift pump timer initiate and comon connections for purposes from the fuel system.

it

un-latch turning off power to the ECU. ·

ECU

Sl

_lo

~

•

1

•

r

REM01l1.

START/STill'

.......

5

4

'

::;:>-!-;:>--!-

l

sz

'

•

1

•

-

5

•

3

•

of

the on engine sensors

off

power to the K3 relay

shuts off the K2 relay and the

of

bleed air

TSIPIN-21

REI.AY

CCNTIUX.

J)l

02

l

$

··t

3

1

f•

aw.c40-L®

KZ

••

$

~I

K4

I .

~

••

K5

K

,.

...

"KI

::::o2-

~

I

Tl

CJ

OIL

PRESSURE

There is an Oil Pressure Protective Circuit that insures that

power to the fuel pumps is shit-off when the engine is not rotating. The primary component is a very robust mechanical pressure switch that disconnects power to the fuel pumps when oil pressure drops below 5 psi. There is a timer module that allows the pumps to run briefly when there is no oil pressure. This is required for two purposes, one is for start-up before oil pressure is built up and the other is when the fuel system is manually primed.

PROTECTIVE

rz6

Q 0

Tl

14

6

CJ

CIRCUIT

T5

0

PCB

,_

OS

·:;.

E

ECU

PUMP

IDP

IND

J2·20

RUN

J2-l

rwR

PWR

~

J2->l

INU

c~

GHO

[,_"_·

T

"l'k==

INU

IHD

K

LOAD

OUT

BAT

-

.---

--

IND.

---

-

<

-

.,

pI

••

14

13

L

Engines & Generators

15

DESCRIPTION

When

the

engine

start/stop

switch

are

in

their center positions

illuminated

·the

engine

When the

ECU LED on

the approximately in

tum

sequence Should

seconds"

will

·

When disengage

light latched engine

and

the

electrical components

the

start

switch

is

powered

will

illuminate.

ignition

and

4 seconds,

energizes

the

go

~o

the

on

the

on.

is

the

will

result -starting

engine

fail

start

sequence

the

off

state

engine

starts,

(start

relay

switch

The

generator will

now

under

CONTROL

switch

and

the

remote

and

the green

generator

up

The

the

starter solenoid and

to and

Kl

is

on

the

is

not

running,

are

in

is

actuated (momentarily depressed),

and

a start

is

K2

run

relay

fuel

pump.

After a.time

the

Kl

relay

the

engine.

start

within

approximately

will

be

terminated

the

green

LED

the

starter will automatically

is

de-energized). The green

and

circuit power

come

up

control of

the

an

off state.

assumed.

will

energize turning

w11l

ene~,

an

engme

and

light

to

the

to

speed

ECU.

will

s~stop

LED

IS

ECU

and

The green

de~ay

of .

wh~ch

cranking

10-12

the

ECU

go

out

L~D

ECU IS

and

the

CIRCUIT

not

all

OPERATION

When

a stop switch, de-energize the ignition, engine. MPU

the

Once

AC circuit power ECU

will

Should a fault occur of

low

oil pressure, temperature, high engine antifreeze coolant temperature, engine

rpm

this

as

a valid stop command. The stop sequence

previously described except that the circuit power remain cause

on

by

will remain

To

reset the ECU and turn off the fault breaker on ON.

This

permit

the

is

initiated

ECU will take this command

K2

the

fuel pump, and the injector, shutting

the

signal) it then releases the latch,

on.

revert

to

or low eqgine rpm, the ECU

and

the fault LED board will register

illuminating the related fault

on

and will not allow

the

control panel must

by

momentarily depressing

and

run

relay.

This removes

DC

ECU senses zero rpm engine

which

The green LED light will

an

off state ..

to

initiate

~gh

an

engine

water injected exhaust

go

shutdown

will

LED.

This

the

engine to

LED,

be

cycled OFF

then

power

speed

out

elbow

ackn~wledge

be

the

reset action must be performed before the

engine

to

be restarted.

the

down

(no

holds

and

as

Will

be

will

the

faulty

fault

restarted.

DC

circuit

and

ECU

stop

to

the

the the

the

a result

.

high as

LED

then

will

ENGINE

STOP/START

SWITCH

8AMP

..PRl1TEG'TS

ELECTRONICS HIGH

WITH

GREEN

FUSE

THE

PANEL

FROM

AMP

OVERWAD

DC

CIRCUIT

BREAKER

LED.

NOTE:

components are on the same side

A

On some models these

of

the control box.

1...-IWE"SIE:RBEKE

(Engines & Generators

16

ELECTRONIC

CONTROL

·UNIT

(ECU)

DESCRIPTION

The ECU (Electronic Control Unit) is factory programmed and requires no adjustments by the generator operator. controls all starting, operating and safety shutdown features on the engine.

The

Gain Pot (early models) is set at #50 midpoint for optimum system response.Later/current models, the Gain has been removed from the

Program dipswitches are in the be disturbed.

The vacant program connector is used the operating program into the

The electrical connections from the engine electrical harness

are made to the pin and one 35 pin and may therefore vary in number according to the generator model. For further details, consult the engine circuit wiring diagram in this manual.

ECU

The when the generator is factory tested. hertz could be field changed with positioning dipswitch #1 on the 50 hertz operation. factory programmed when a field gertz is made.

ECU

ADJUSTMENTS·

Stability

When changing engine speed, condition should occur, the gain pot may require adjustment. There is no specific set point for this adjustment and it is

normally set to the middle range which obtains optimal engine speed response without any tendency

ECU

is set to operate the generator at the specific hertz

Trim

of

hunting.

ECU

OFF

position and should not

by

the factory to input

ECU.

through two plug connections, one 23

On

earlier models, the

of

ECU.

Off

for 60 hertz

On

later models, the ECU must be

or

if

an engine hunting

of

its range

and

or

to a point in its

the

On

It

Pot

for

Setting

The engine's speed (earlier models) by ,positioning

ECU and ECU the field.

1. Set up whatever equipment is to be used to measure

2. Start up and run the generator at the current operating

3. Adjust the GAIN setting between

On later models the GAIN

Engine

dipswitch #1 for

1500 rpm for

must be factory reprogrammed for a hertz change in

engine speed

speed and frequency.

reaction to

NOTE:

A higher GAIN adjustment can induce unstable engine operation. In such cases, lessen the GAIN adjustment.

Speed

60

or

50

hertz, 1800 rpm for 60 hertz

50

hertz.

On

later (current models), the

or

generator output frequency.

AC

amperage load changes.

pot

was removed from the ECU

ELECTRONIC

"of

40 - 60 for best system

CONTROL

UNIT

the

(ECU)

ENGINE

HARNESS

CONNECTIONS

REPLACING

Remove the control box cover. Before attempting to remove the

ECU, tum

fuse from its holder in the control panel

control panel's connections to the screws holding the its holder.

INSTALLING

To install the new ECU, reverse the above procedure.

Engines & Generators

17

THE

ECU

OFF

DC

power by either removing the buss

or

tum

OFF the

DC

breaker. Unplug the engine harness

ECU. Then unscrew the four securing side

ECU

in place and remove the ECU from

THE

NEW

ECU

ELECTRONIC

FUEL

INJECTION

DESCRIPTION

The illustration shows the throttle body assembly that attaches to the intake manifold.

An electronic control unit (ECU) controls the fuel injector and the throttle actuator.

The

ECU

is

supplied with engine operating conditions from sensors that monitor intake air tempeature, engine coolant temperature, map sensor )intake manifold absolute pressure), engine rpm and battery voltage.

ECU interprets this information

The appropriate injector pulse rate and throttle opening position.

A high pressure fuel pump supplies fuel injector and the regulator maintains the fuel pressure area at

35-40

PSI maximum.

THROTTLE

BODY

The throttle body, mounted on the intake manifold, is an assembly

of

the principal components

(Electronic Fuel Injection System). The EFI is controlled by the ECU (Electronic Control

Unit) which interprets data from sensors that monitor the

vital parts

flow

of

the· engine. The ECU uses this continuous

of

data to determine the appropriate injector pulse

rate and throttle opening position. A high pressure fuel pump supplies fuel to the area around

the injector and the regulator maintains the fuel pressure in

. that area at 35 -

40 PSI.

The injector is a solenoid operated pintle valve that meters fuel into the intake manifold depending on engine operating conditions and generator amperage load as determined

by_

the ECU.

Air flow into the intake manifold is through the flame'

arrester/air filter and is controlled by the ECU operation the throttle plate via the actuator (stepper motor). The throttle plate positioning for proper air flow into the engine is accomplished through the engine operating conditions. The Schrader valve is used to monitor the fuel pressure at the fuel injector and to bleed

air after fuel system servicing.

On

some models an air intake heater is positioned in the

intake to heat the incoming air during a cold start.

to

determine the

to

the area around the

of

the EFI

ECU interpretation

of

in

the

that

The injector

is

a solenoid operated pintle valve that meters fuel into the intake manifold depending on engine operating conditions and generator amperage load ECU.

Air flow into the intake manifold.engine

of

ECU's operation

the throttle plate via the stepper motor. Throttle plate positioning for proper air flow into the engine is accomplished through the ECU's interpretation engine's operating conditions. The Schrader valve on the

throttle body is used to bleed the system and top monitor/check fuel pressure around the fuel injector.

NOTE:

The Stepper Motor

field as this will upset the calibration

seriously affect the operation

FUEL

REGULATOR

of

STEPPER

MOTOR THROTTLE ASSEMBLY

AIR FLAME

SHAFT

SCREEN

ARRESTER

AND

must

never

of

the engine.

as

determined by the

is

controlled by the

of

be

disassembled in the

of

the throttle plate

UPPER THROTTLE BODY

AIR

/SENSOR

the

and

TEMPERATURE

18

LOWER BODY

THROTTLE

COMPONENT

GENERAL

A1l

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·

B+

indicated as AC voltage measurements should be made with a true RMS

AC meter to insure accuracy.

MAP

SENSOR

The Manifold Absolute Pressure (MAP) sensor is a solid state pressure transducer which measures the intake manifold pressure (vacuum). (+5V, Pin 4; Gnd, only when the ECU is in an measured to ground. Typical output voltages

Map

Sensor

Pin 4 (sig)

4 (sig) to

4 (sig)

and should rrieasure no less than

It derives its operating power

1)

from the ECU and receives power

on

state. Its output (Pin 3) is

are

as follows:

••

Voltages

to

Grnd

(at

rest)

___________

Grnd

to

Grnd

(prime delay (running

1800

in

start

rpm

11.5

volts.

mode) 4.089

no

AC

load) 1.73

STATIC

GROUND

TESTING

AND

CONNECTIONS

EFI Generators

5.0/6.5Kw

o

VDC.

VDC

(typical)

B(+)

Pin 3 (+SV) to

3 ( +SV) to

Map

Sensor

••

Pin 1 (grnd) Pin 1 (grnd)

1 (grnd)

Grnd

(at

rest)

__________

Grnd Grnd

(prime (running

delay

1800

in

rpm

start

mode) 4.997

no

AC

load) 5.005

Resistances

to

Pin 2 ____________

to

3 5.9n

to

Pin 4 5.3n

o

VDC.

VDC VDC.

(typical)

EFI

Generators

All

Models

1.9il

TESTI~G

THE

MAP

SENSOR

19

COMPONENT

TESTING

STEPPER

The throttle plate rotary stepper motor operates voltage supplied operating coils in typically

A resistance value test only should stepper motors as

it

Check and

red)

There should connectors

MOTOR

from

the

ECU.

There

are

the

stepper

2.61

ohms.

two

coils. Do

will

damage

the

and

the coils.

resistance value of each coil between coil

coil #2 (black

be

no

continuity

and

the

metal case of

STEPPER

motor.

not

and

found

MOTOR

Each coil resistance

be

performed

apply

green).

between

the

stepper

two

12VDC

body.

on a low

independent

on

the

to

these

#1

any

of the

DC is

coils

(blue

coil

.

TESTING

RESISTANCE

FUEL

INJECTOR

The

fuel

injector

The

coil.

r:esis~ce

The

posttlve

the

contacts of relay running. and a wire input perceptible; if may could

To

test the injector, disconnect

connect a ground

from

pin.

When touched, a

be

assumed

be

clogged.

has

no

polarity and operates

is

~ic~lly

wtre

to

the

K2,

wire

a point of B+ and repeatedly

not,

resistance test the coil.

to

be

functioning electrically. However it·

If

in

in.

the

ord~r

InJector

doubt, replace the

1s

supphed power

which

is

off

to

one of

low

audible click should

A

LOW CLICK BE

HEARD.

when

its

AUDIBLE

SHOULD

.TESTING

on

12

of

14

to

the

engine

its

cable connector

input

pins.

touch

the other

If

okay,

the

injector.

VDC.

16

ohms.

through

is

not

Connect

be

injector.

~»

COIL

RESISTANCE

/;

~

'l

-

TESTING

Connect a the throttle body readings should indicate

Pressure gauge kit cally designed

, Schrader test ports.

SYSTEM

fuel

pressure test gauge

for

FUEL

PRESSURE

to

the

Schrader valve

as

shown and

MT

fast accurate testing

run

the

engine.

35

- 40

psi.

337B "SNAP -ON-TOOL" is specifi-

of

fuel pressure

on

Pressure

for

20

COMPONENT

STATIC

TESTING

An exhaust temperature switch is located on the water injected exhaust elbow. Normally closed, this switch will open and the perature and open the K2 run relay stopping the generator. The exhaust temperature LED on the panel will illuminate.

The switch opens at

resets (contacts close) at approximately

When testing,continuity should be found (switch is normally closed).

THE

EXHAUST

ECU will interpret this as a high exhaust tem-

260-

TEMPERATURE

270°F

(127-

132°C). This switch

225°F (107°C).

'rr

1

SWITCH

1((\\~

COOLANT

A temperature sensor is located at the thermostat housing. This sensor sends a as engine (antifreeze) coolant temperature. Should this voltage reach a set value, the high temperature and open the K2 run relay, stopping the

generator. The overheat LED on the panel will then illuminate.

Test the sensor as shown. Resistance should indicate

(WATER)

TEMPERATURE

DC

voltage to the ECU that it interprets

10,000

Ohfl!S.

SENSOR

ECU will interpret this as a

at

room temperature

~

"'~

HOUSING

TESTING

The oil pressure sensor sends a the below a certain level, the and illuminate the oil pressure LED.

Test the sensor by checking resistance (at rest):

Ohm

ENGINE

The generator's engine type DC

also serves as an Emergency Stop Switch). Excessive DC current draw or DC electrical overload anywhere in the instrument panel wiring or engine wiring will cause the breaker to trip to the power to the ECU will No panel LED will illuminate. Check and repair the source of restart the generator.

HIGH/LOW

The ECU monitors engine speed by the AC voltage produced by the ECU will interpret this as an engine overspeed (2175 rpm approximately) and open the K2 relay, stopping the generator. The panel Overspeed LED will illuminate. Should the

as an underspeed condition, the ECU will open the K2 relay and stop the generator. The Overspeed LED will then blink.

THE

OIL

PRESSURE

ECU interprets as oil pressure. Should this voltage fall

ECU

Value- 240 -

20 amp breaker mounted on the control box (this

the problem. After repairing the fault, reset the breaker and

MPU. Should this voltage reach a preset value, the

MPU produce a low AC voltage that the ECU interprets

DC

CIRCUIT

RPM

270fl

BREAKER

DC

OFF

position. In this event, the DC

be

interrupted, stopping the generator.

SHUTDOWN

SENSOR

DC

voltage to the ECU that

will shut the generator down

circuit is protected by a rocker

TESTING

RESISTANCE

21

COMPONENT

TESTING

Test the magnetic pick-up AC voltage output while cranking. Voltages are listed below.

Test the magnetic pick-up coil winding in a static mode.Resistance values are shown below., voltage is not present or lower than listed and the resis-

tance value insulating the

and clean the tip end

Coil winding resistance being lower or not present would damage the

NOTE:

provided with the new

THE

MAGNETIC

of

the coil winding is correct, debris maybe

MPU

tip end. remove the MPU and examine

of

MPU.

Carefully follow the installation instructions

debris.

MPU.

PICK

UP

COIL

If

the AC output

Speed Sensor Test Values Voltage

(while cranking)

5.0,

6.5

Kw

EFI-

1.33

VAC

8,

10, 12.5,

20,

22.5

Kw

14

EFI-

Kw

EFI-

1.26

0.98

VAC

Resistance (at rest) - 950-10000 (all models)

NOTE:

The

AC

signal produces by the MPU will be greater the closer the gear tooth and weaker the farther away from the tooth.

MPU is positioned to the flat

of

the ring

TESTING

RESISTANCE

TESTING

Testing the fuel pumps in a static mode. Check for integrity

of

the pump winding. Unplug each pump from the engine

harness and check the resistance value The lower pressure pump should produce

when operating measured at the Schrader valve on the fuel cell. The high pressure pump should produce pressure when operating measured at the Schrader valve on the throttle body.

Fuel Pump Resistance (at rest)

There should be either terminal

/ /

I I

THE

FUEL

High

Pressure 1.5 - 2.0 Ohms

Low

/

I

Pressure

-------

/,

9.0-

no

continuity between the metal case and

of

the plug connector.

PRESSURE

PUMP

of

3.5-

13.0 Ohms

the winding.

8-10 psi

of

35-40 psi

14.5 Ohms

pressure

of

I I

I

\

TESTING

FUEL

PUMPS

FUEL

CELL

(PUMP

FILTER)

22

COMPONENT

TESTING

Two band sensor wide lyst. interprets

TESTING

oxygen

band

These

and

sensor

OXYGEN

sensors

on

sensors

adjusts

THE

SENSORS

are

the

exhaust inlet

on

the

monitor engine operation that

air/fuel ratios

OXYGEN

used

in

exhaust discharge

SENSORS

MODE

Narrow .Band Sensor: Unplug harness. two

Resistance Value 2.0 - 4.0

There should white

Wide

harness. lead.

Resistance Value 110.0 - 130.0

No any

Sensors not meeting these should scratch,

LoCate

the

pins

with

an

ohm

be

no

lead

pins

and

Band

Sensor: Unplug

Locate

the

Measure

continuity should

of

the

other

be

taken

damage,

across

four.

when

or handle

2 white

continuity between either of

the

red

meter.

OHM

black or

the

lead

these

two

be

found

tests

installing a replacement

the

EFI

system. A narrow

side

of

the

catalyst

side

accordingly.

IN A STATIC

the

sensor

from

leads,

measure

(approximately)

grey

lead

pins.

sensor

from

and

the

vacant black

pins

with

an

OHM

(approximately)

between

are

sensor

these

presumed

end

in

of

across

the

ohm

two

faulty.

sensor.

any

and

the

engine

the

two

engine

ll!-eter.

pins

way.

a

cata-

ECU

these

and

care

Do

not

TESTING

RESISTANCE

WIDE

BAND

PH:049077

SENSOR

TESTING

NARROW

PN:049076

RESISTANCE

BAND

SENSOR

23

COMPONENT

AIR,

COOLANT,

TEMPERATURE

These three sensors contain

identical negative temperature coefficient (NTC) thermistors whose internal resistance inversely changes to a change in temperature (i.e., temperature increase, resistance decrease). The thermistors nominal resistance value

no

F (25° C) is 10,000 ohms. When the ECU is in an

at

on state, the thermistors

and its ( a fixed series

source. Therefore, the voltage at the thermistors ( should be approximately +2.5 volts at a temperature

no

220° not linear over this range and therefore it should only serve as

Generally, the thermistor may be assumed to be good there is a perceptual resistance change for a corresponding temperature over the indicated range, otherwise replace the sensor.

+) lead

F and decreases to a voltage

F.

The voltage - temperature relationship however,

an indicator that the thermistor

Resistance Values (at room temperature) Air

Temperature Sensor - 10,000!1

Coolant

Temperature

AND

WATER

SENSORS

as

their sensing elements

(-)

lead is connected to ground,

is

connected to the ECU and then through

10,000 ohm resistor to the +5V power

+) lead

of

approximately +.25V at

is

functioning.

Sensor - 10,000!1

of

is

if

TESTING

INTAKE

.

A

~·

THROTTLE

(TYPICAL)

BODY

:-__--

f;~

HEAT

ELEMENT

INTAKE

The with

An intake heater is located in the air inlet area body incoming air operating conditions.

Testing

Unplug the heater from the engine harness. Put the ohmmeter probes across the two heater plug pin contacts.

Resistance Value 1.5 - 2.5 There should be no continuity between either

contacts and the metal case

HEATER

4. 5 and the

INTAKE

on

all

ELEMENT

the

6.5

are

not

HEAT

four cylinder models. the heater operates

on

a cold engine start and in adverse cold

(static)

equipped

ELEMENt

the

Heater

Element

OHM

(approximately)

of

the element.

of

the throttle

to

warm

the two pin

24

BATTERY

CHARGING

CIRCUIT

DESCRIPTION

The DC,Cjrcuit on stop

the

generator's engine. The circuit

reviewing

The engine's circuits:

The engine has a shown when system

the

start,

on

the

troubleshooting or

or

the

DC

Wiring

DC

wiring

run

and 12

Wiring engine.

the

BAnERIES

A

CAUTION:

charging switch

wh1le

battery

when

Specifications

Th~

the

switch,

working

minimum

engine's 12-volt

To

circut,

never

the

engine

however,

on

recommended capacity of

SBCG

functions

Diagram

is

designed with three

stop.

volt

DC

electrical control circuit that

Diagr,llms.

when

servicing

avoid

damage

shut

off

is

running~

to

avoid

the

engine's

DC

control circuit

to

is

and

Wiring

Refer

to

the

engine

Shut

electrical.

electrical

is

start, operate

best understood

Schematic.

simple

these

diagrams

the

DC

electrical

battery

off

the

engine

shorts

circuit.

the

battery

used

800

CCA.

and

by

basic

is

in

BAnERY

The generator supplies a continuous

charge the

battery

and

to

13.4V

is

indicated, check that connections (+)and(-) terminals indicated, replace

CHARGING/TESTING

from

its

battery charger

charger,

negative(-)

with

put a multimeter between

leads

to

the

engine

running.

the

battery charger

are

tight.

With

the

for

13.0V

the

charger.

(+)

TERMINAl

BRIDGE

to

the

battery.

unit

to

RECTIFIER

12

amp

starting

It

should indicate

If

only

the

terminal

running,

13.4V.

If

no

TO

/.

/ ·

rf

'

TO

(maximum)

battery.

battery

test between

:RED

CIRCUIT

.

BRIDGE

the

positive ( +)

charge

TO

BREAKER

GREEN(-)

To

voltage

RECTIFIER

test

13.0V

the

is

GENERATOR

CONTROL

PANEL

TESTING BATTERY

r-------

I .

~

. I

~

FUS£

I

I I

I

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

60

~

Hz

+ I

I

L----------:---

CHARGING

-------

SYSTEM

SCHEMATIC

THE

CHARGER

DC

I.C.

~~

CONTROllER

BATTERY

CHARGER

_________

I :

I

: I

j

Engines & Generators

25

DEVICE

AND

EFI

GENERATOR

CONDITION

ELECTRICAL

AU

Models

.TESTING

·

GENERATOR

5.0/6.5Kw

VALUES

.

MODELS

8,10,12.5.14Kw

20

/22KwEFI

Speed

Sensor-

Speed

Sensor-R

DistributorRed

(ECU) and Red (ECU) and Blue(-)

Black/White ( + Blue(-) Red

(ECU) and

Distributor-Re

Red Red·(ECU) and Blue(-) Black/White ( + Blue(-) Red

Map

4 (sig) to

Pin 4 (sig) Pin 4 (sig) to Gr Pin

3 (+5V) to Pin 3 (+5V) to Pin

3 (+5V) to Map

Pin 1 (grnd) to Pin Pin

Intake

Air

Water

Oil

Stepper

Black and Gre Red

Vo

and

Bl

and

En

(ECU) and

and

Bl

and

En

(ECU)

an

Sensor-

to

Sensor-R

1 (grnd) to 1 (grnd) to

Heater

Tempera

Tempe

Pressure

Moto

and Blue

oltage (while cranking) (AC Volts)

Vi

esistance (at rest) (in

ltages (in AC volts)

Black/White ( +) Blue(-)

ack!White ( +)

) and Engine Ground

gine Ground

Engine Ground

sistance (in Ohms)

Black/White(+) Blue(-)

ack/White ( + )

) and Engine Ground

gine Ground

d Engine Ground .

oltages

Vi

ound (at rest)

Gr

ound (prime delay

Gr

ound (running Ground (at rest) Ground (prime delay

. Ground

esistance (in Ohms) Pin 2 Pin3

Pin4 Element

ture

Sensor

rature

Sensor

r (at rest)i'n Ohms en

__

(in

DC

(running.1800 rpm no AC load\

in

Ohms

(room temp:)in Ohms Sensor (at rest)in Ohms

Ohms)

Volts)

in

start mode)

1800

rpm

no AC load)

in

start mode)

(room temp.)in Ohms

·---·-------~

..

950-10000.

·--~-

r-None

None (open) None (open) None (open) None (open)

_1.5

--·-

--

·-

(open)

None(open)

1.9.0

5.9.0

5.30.

-2.50.

10,0000.

10,000.0

2450.

2.61.0

1.33

_0.55

0.44

..

0 0

,_o.on_

0

0.60'

0.98

0.447

0.44--'-

0.011

0

0.45_~------

0

4.05

1.25*

n

4.997

5.003*

1.

0.

_o.

0 0 0

_o.

0

4 1 0 4

26

253

177

277

.056 .300*

.999 .014* 5

Stepper Purple:

Blue:

Part

Black: Part # K1,2, MandoAltem

B+

(typical at B+ (typical w At Excitation At Excitation

Fuel

Pump Low Pressure High Pressure

Note: * Approximate

r-Resistance (in Ohms)

Moto

2221

Part #4

#4

8921 49556

elay (between terminal 86 and 86)in

or3

R

ator-part

rest)

hile running)

(typical while running) (at rest)

Ohms

in

#39139 (in

Voltages

DC

Volts)

Ohms

---------

1.5-

9.0-

·-·

·-

26

2.0.0

13.0.0

...

-

12.50.0.

---

'

14.55.0

8~n

12.7

14.1

13.4

0

14.55.0

86.0

12.7

14.5

13.6

0

GENERATOR I ENGINE

DISASSEMBLY

DESCRIPTION

The engine component of the or heavy

disass~mbled

certain however that not topple off can not

as

most engines (approx. 250

and

repaired

the

bench

tip

over.

Set the generator breakers and panel switches in the off

position. Disconnect

the terminal block/circuit breaker and unplug control

pane.

Disconnect the battery cable connections

the engine ground cables.

Close off the

raw

water seacock

water components. Separate the exhaust at

and

elbow

A

off properly

~<2i,r::_"''fr

disconnect the

CAUTION:

and

drained.

~·

;-;REMOVE

TO OIL

Make

Clean

dispose

USING

DRAIN

THE

UP

THRU

of

BC

generator

lbs)

on

a sturdy work bench. Make

engine

is

securely fastened

and

that

the

bench is also secure

AC

wiring connections at

and

disconnect the

fuel

supply.

certain

the

AN

OIL

THE

up

all

rags.

BMM

OR

PUMP

HOSE.

the

fuel

and

(11116")

THE

SOCKET WARMED

is

not

so

it

can be

the

harness

the

water injection

lines

are

oil

spills

as

bulky

so

the

raw_

closed

and

it can

'and

at

the

and

Unfruiten

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

harness, be certain

motor.

Disconnect and remove

to

tag all the wiring

·connections

the

so

wiring

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

refer

to

se,rvicing

the

GENERATOR

and testing

ASSEMBLY BOLTS

section

of

the

in

this

back-end

manual.

(generator),

TYPICAL

BC

BACK-END.

ASSEMBLY

GENERATOR

·

COOLANT

.

LOCATED THE

INTAKE

DRAIN

JUST

BELOW

MANIFOLD

GENERATOR

SEE

SPECIAL DISASSEMBLING GENERATOR

BACK-END

TOOLS

THE

COMPONENTS

FOR

27

GENERAL

•

Be bolts

•

During are correct direction pistons,

•

Apply Insure rotate excessive

•

If

reference

•

Use

•

Tighten

to

•

When bolts

•

Most make

Torquing

Prevent three yield torqued brought center damaged care.

INFORMATION

careful

not

are

used

assembly,

being

assembled

piston

lubricating that

moving

or

slide

tension.

there

are

mating

them

new

gaskets,

the

bolts

specified

steps-112, bolts

bolts

See

torques

required,

and

gaskets.

gaskets

certain

Hardware

mechanical

and

rocker arm shaft fasteners.

as

indicated.

down

in

out.

during

TORQUE

ENGINE

to

mix bolts

on

various engine

recheck clearances

in

relation

rings, bearings

oil

parts,

and

are not subject to

marks scribed

correctly for

lockwashers, 0-rings,

and nuts on important

use liquid sealants

Refrain from using

and

many bolt washers

they

are positioned

damage

'l/3, and

The latter-rocker shaft fasteners-should

very

small increments,

Gaskets, especially head

assembly, they should

SPECIFICATIONS thru out

and

nuts.

assemblies.

in

their proper order

to

the and

to

moving parts

when

assembled

during

assembly.

using a reliable

properly.

by

running

111

torque. Exceptions

Metric

and

engine

bearing

during

binding

torque

when

tape

are

fasteners

working

gaskets,

be

and

insure and

block,

caps.

on

or

disassembly,

packings

parts

wrench.

required

sealants.

asymmetrical,

are

The

former

positioned

S.A.E.

that

parts

facing

in

such

assembly.

the

engine,

and

of

the

engine

on

down

in

torque-to-

are

.from

the

might be

with

this

manual.

ASSEMBLY

When

installing

passages, Do

not

the

as,

seals.

nuts,

great

HIGH-COPPER ing

a gasket

Specialized applications is

particularly effective

resists

fuel,

NOTE:

TAPE

fitting that

Bolts

Lightly

them.

Bolts

should be

When

assembling

LOCTITE LITHIUM

bearings Antiseize

LOCTITE protect threaded components

come apart locking

be

Heavily use

clean

coat

both

use

sealant

in

gasket

requiring

oil , and

SEALANTS

connect

and

Fasteners

oil

head

and

sealed

blue.

based

and

stuffing

compounds

when

according

oil

all

sliding

engine

gaskets

position

bolts other

that

seal

around

sides

with WHITE

when

installing a

ADHESIVE

sealers

non-hardening

water.

water coolant passages.

and plugs

with

PERMATEX

the

flywheel,

grease

boxes.

and

necessary.

to

the

and

oil.

SPRAYS

during

assembly.

such

as

on

copper

should

be

other fasteners

that penetrate

coat

is waterproof,

thread locking

LOCKTI1E

job.

reciprocating

water

Sll..ICONE

new

gasket.

are

useful

HYLOMAR

properties.

cylinder-head

used

on

pipe

as

you

the

water

#2

or

HIGH

the

bolt

threads

ideal

for

adhesives

yet

allow

offers

components,

(coolant)

GREASE.

for

hold-

work

well

HYLOMAR

gaskets

and

plugs

and

assemble

jacket

TACK.

with

water

pump

such

as

them

to

levels

of

always

in

Sealants

Oil excellent any coating gaskets

LOCTITE hoses

Coat

Sll..ICONE

based

joint

and

both

all

in of and

and

PERMATEX

oil

hydraulic

the surfaces

Lubricants

#2 and

purpose sealers. They

contact with coolant,

or

LIQUID TEFLON

o-rings.

red sealant should

oil

filter assembly.

of the oil pan gasket

SEALER.

its

HIGH

are

raw

can

TACK

effective

water,

be

used

be

used

with

equivalent

in

oil,

or

on

high

just about

fuel.

A light

rubber

oil

adapter

temp

RED

are

28

NUMBERS SUGGESTED DISASSEMBLY

INDICATE

ORDER

THE OF

TIMING

BELT

DISASSEMBLY

15

TORQUE 1-9 10-12Nm

FT-LBS

EAR

COVER

12

CRANKSHAFT BOLT

TORQUE 135-145

98-

Nm

1

TIMING COVER

3ACCESS

105

FT-LBS

TORQUE

1 -9

10-12Nm

BELT

A

Ft-Lbs

COVER~

TIMING COVER

13

CRANKSHAFT SPROCKET

BELT

C

\

1 Q

\

FLANGE

TORQUE

[50-56

Nm]

NUT

36 -40

FT-LBS

TIMING

BELT

INSPECTION

CAN

ENGINE

AND

BE

PERFORMED IN

THE

ADJUSTMENT,

REPLACEMENT

WITH

BOAT

INSmUCTIONS THE

TIMING

FOR

BELT

INSPECTING

AND

REPLACING

WES1ERBEKE 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

Timing

1.

Belt

Removal

Turn the crankshaft clockwise to align the timing mark on

IS

#043036

the camshaft sprocket and timing belt rear cover.

NOTE:

Always

tum

the crankshaft clockwise.

2.

Remove the plug on the left surface and insert a rod with a diameter

of

the cylinder block

of

0.31 in (8 rnm) to lock

the counterbalance shaft.

NOTE:

0.31

in

Be sure to use

(8 mm).

an

inserting rod with a diameter

of

OD

0.311n

[8

mmJ

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.

CRANKSHAFT SPROCKET

29

5.

Remove

NOTE:

the belt to indicate the direction

the

timing

belt.

If the timing belt

is

TIMING

to be reused, draw

of

rotation (clockwise) . .

an

a"ow

BELT

DISASSEMBLY

on

Crankshaft

1.

Lock

NOTE:

2.

Remove

the

crankshaft

Do not

the

Bolt

Removal

in

tum

the crankshaft.

crankshaft

position.

bolt.

Cams~aft

1.

Remove camshaft.

Sprocket

the

camshaft sprocket bolt without turning

Removal

the

Timing

Replace

•

the

Hfn'dening pressed

Cracks Cracks Cracks Cracks Abnormal

are

sharp Abnormal Tooth

HARDENING

Belt

Inspection

belt

if

any of

of the back

with

fingernail

on

rubber or peeling of on

tooth on

belt

wear of

as

if

cut

wear

missing and

the

rubber,

(back

back.

canvas.

bottom.

belt

sides.

by a knife.

on

teeth.

canvas

following

leaves

side

is

·

The

sides are

fiber

exposed.

CRACKS

conditions

no

indent

glossy).

normal

ON

EDGE

exist:

when

if

they

Oil

Pump

Sprock~

1.

Remove

2.

Insert counterbalance shaft.

3.

Remove

the

an

the

plug from

0.31 in

oil

Flange

the

left side of the cylinder

(8

mm)

diameter round bar

pump sprocket

Nut

Removal

flange

nut.

to

lock

block.

the

$

CRACKS

ON

UNDERSIZE

CRACKS

ON

Tensioner

1.

Replace when

Inspection

the

turned.

TOP

tensioner if

the

pulley

ROUNDED FLUFFY

binds,

EDGES

STRANDS

TOOTH

MISSING

CANVAS

rattles

EXPOSED

or

is

noisy

30

ENGINE

TIMING

BELT

Flange

1.

Installation

Mount the flange so that its side shown by the heavy arrow in the illustration faces toward the sprocket.

FLANGE

A-mi~

-~

CRANKSHAFT

Crankshaft

1.

Lock the crankshaft.

NOTE:

2.

Tighten the crankshaft bolt to the specified torque.

Oil

Pump

1.

Insert the round

the cylinder block to keep the counterbalance shaft from turning.

2. Install the oil pump sprocket.

3. Tighten the nut to the specified torque.

...---7

SPROCKET

Bolt

Installation

Do not

tum

Sprocket

bar

[)

the crankshaft.

Flange

into the plug hole in the left side

Nut

Installation

WASHER

of

Tensioner

1.

Install the tensioner spring and timing belt tensioner.

2. Hook the tensioner spring onto the bend

tensioner bracket and the stopper pin on the cylinder block.

3. Move the timing belt tensioner as close as possible

water pump; temporarily tighten the tensioner nut.

Timing

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 (65 mm.) or longer, the plug hole in the left side

Spring/Timing

Belt

Installation

marking on the front case, and then insert a 2.56 in.

Tensioner

0.31 in (8mm.) diameter round bar into

of

the cylinder block.

Installation

of

the timing belt

to

the

Camshaft

1. Tighten the bolt to the specified torque.

CAMSHAFT

Sprocket

BOLTTORQUE

Bolt

Installation

58

-72

Ft-lbs

SPROCKET

(80

-100

BOLT

Nm)

31

TRIANGLE

CAMSHAFT

MARK

ON

SPROCKET

NOTCH

IN

SPROCKET

CRANKSHAFT

MARK

ON

FRONT

CASE

At

this

time,

oil

pump sprocket

STANDARD

check that

VALUE: 4 to 5 teeth

the

is

according

1

to 2 teeth

ENGINE

moveable range of teeth

to

specifications.

in

forward reverse

direction.

in

TIMING

on

the

BELT

8.

Thm

teeth

sprocket

rear

cover.

A

CAUTION:

proper

crankshaft check

the

crankshaft clockwise

(81

°)

to

align

the

with

the

tensioner set mark

This

operation

tension

to

the

counterclockwise

the

tension.

timing mark

timing

belt,

and

by

nine camshaft

on

the

on

the timing belt

is

perfonned

so

do

not

push

the

sprocket

camshaft

to

give

tum

the

belt

to

a

4.

If

the movable range of

exceeds

a. Pull out

b. Turn

c. Check that

5. Set the timing belt over the crankshaft sprocket over order.

NOTE:

slack.

the

specified range, correct the

round bar from the plug hole in

side of the cylinder block.

the

oil pump sprocket one turn at a time

round bar can

the

is

in

the

specified value.

the

oil

pump

Ensure

that

Keep

the

round

been placed. After this

6.

Apply counterclockwise force make

the

belt taut

all timing

marks

the

teeth on the oil pump sprocket

as

follows:

again

be

inserted.

movable range

sprocket and camshaft sprocket,

the

tension side bar inserted until

step,

be

on

the tension side, and make sure that

are lined

of

the oil pump sprocket

of

the timing belt

the

sure

to

remove the

to

the camshaft sprocket

up.

timing belt

the

until

and

in

is

round

left

then

not

has

the

that

bar.

to

TENSIONER

9.

Make sure that camshaft sprocket teeth along the portion of shown

by

tighten

the

lO.Pull the timing belt

toward the sealing gasket line for trated. Make sure that the clearance between the the

belt

STANDARD

the

curved arrow

tensioner

and

the

VALUE:

the

sealing line

0.47in.

SET

MARK

timing belt teeth are engaged

in

the

illustration

nut.

in

the center of

(12mm)

the

is

the standard

tension

belt cover,

0.47

the

below.

&ide

value.

In

!12

with

the

sprocket

Then

as

illus-

back

of

mml

CAMSHAFT

7.

Loosen water use

of

SPROCKET

TENSION

the

temperorarily tightened tensioner nut on

pump

side

1 or 2 turns, and tension

the spring

force.

SlOE

the

belt making

the

ll.Pull out

the

tighten the plug

Specified sealant equivalent.

TIGHTENING

32

the

rod

from

cylinder block

to

TORQUE:

the plug hole

and

apply

the

specified

value:

3M

11-16

ft.lbs.

on

the left surface of

the

specified sealant.

torque.

AID

Part

No.

(15-22

Nm)

8660

Then

or

DISASSEMBLY

FROM

FUEL:

INLET

FILTER

OF

"LOW

CO"

COMPONENTS

FUEL

FILTER

DISASSEMBLY

NOTE:

Be prepared to drain

that may have accumulated in the hoses

Unplug the wiring harness connections and lift the harness up and off the engine. The wiring connections should be tagged for re-connection.Remove the cooling

Using the illustration above as a guide, disassemble the bracket that holds the fuel pump and the upper fuel cooler from the engine block. Remove the fuel filter, fuel lines (blue) can be disconnected as necessary.

Remove the lower fuel cooler, the fuel cell, and the bracket their mounted on. Unplug the wiring connection at the fuel injector and disconnect the fuel hose.

The bracket assembly can now block.

Set all the components aside and cover them over to protect them.

off

any fuel and cooling water

and

fuel lines.

watf(r hoses.

be

removed from the engine

The

Timer

shown in the illustraction above on later models is mounted inside the unit's control box. The is to terminate DC voltage to the unit's fuel pumps at engine shutdown.

Timer

function

Engines & Generators

33

DISASSEMBLY

TO

OF

FUEL

COOLER

"LOW

(UPPER)

CO"

COMPONENTS

TO

FUEL

PUMP

FUEL

CELL

DISASSEMBLY

Remove the lower field fuel cooler, the fuel cell, and the bracket they are mounted on.

at the fuel injector and disconnect the fuel hose. The bracket assembly can now

block. Set all these components aside and cover them over to

protect them.

(cont.)

Unplug the wiring connection

be

removed from the engine'

(BOTTOM)

REMOVE

COMPONENT

Fuel coolers should be cleaned in a mild muriatic acid bath

and pressure tested to

No

air bubbles should occur when submerged in water for

30 seconds with the inside

pressurized The fuel regulator should All the fuel filters should be changed and replaced. Inspect carefully all the hoses and replace as needed.

MAINTENANCE

to

50

psi.

BRACKET

50

psi.

be

ASSEMBLY

of

the cooler shell being

changed.

Engines & Generators

34

OIL

GALLERY

ASSEMBLY

ENGINE

DISASSEMBLY

FILTER

Disconnect the

oil gallery/filter

Remove chambers. reassembling. Replace the thermostat

GASKET

APPLY

SEALANT

TO

GASKET

iNSTALLING

THERMOSTAT

WHEN

and

drain

the

thermostat

Inspect the

the

assembly,

seals

oil

hoses.

replace

assembly

in

the

remove,

the

filter.

and

clean

the

pressure

cap

and

gasket.

THERMOSTAT ASSEMBLY

clean

interior

wHen

and

inspect

Remove Inspect

Remove

COOLANT

Detach

spark manual.

See wires

the

the engines coolant

and

plugs.

ENGINE

and

fuel

filter

assembly.

0-ring

and

PUMP.

remove

spark

the

Refer

to

DISTRIBUTOR

ADJUSTMENTS

plugs.

replace

ignition

~

FUEL ASSEMBLY

Drain

and

inspect

the

filter

element.

pump.

For

servicing,

wires,

the

distributor

DISASSEMBLY

for

information

FILTER

the

refer

and

in

on

ignition

hoses.

to

this

Loosen remove

the

raw

water water

pump,

pump.

remove

the

drive

belt

and

then

SPARXPLUD#

~

WESTERBEKE

Engines & Generators

35

4

CYUNDER

TORQUE

60-70Nm

HEAD

43 -51

FT-L/3$

CYLINDER

HEAD

AND

VALVES

9¥ftlE

1QVALVE

REMOVING FROM

Disassemble to

lose

rocker Loosen

as

to

avoid several sequence

THE

CRINDER

the

washer and insert. Remove

cover

gasket.

each

of

the

times

until the bolts are unfastened. Follow the

shown

CRINDER

HEAD

BLOCK

cover bolts

the

cylinder head bolts, a little at a

possibility of distorting

in

the

as

diagram.

shown

above, the

the

taking

care

rocker cover

time

cylinder.

Repeat

not

and

so

NUMBERS SUGGESTED DISASSEMBLY

INDICATE

ORDER

5 7

8 6

CYLINDER

LOOSENIN~

HEAD

THE

OF

BOLTS

SEQUENCE

Remove

the

cylinder head and the cylinder head

gasket.

Engines & Generators

-

36

Use

pliers

to

stem

seals.

CYLINDER

Before cracks

Clean

.

sealant.

that

no

'Ib

check

distortion,

and a

by

grinding.

cleaning

and

other

by

completely

After

portion

the

as

feeler

gauge.

HEAD

cylinder

indicated in the

remove

the

INSPECDON

check the

possible

removing the

flUshing

of the

If

the

on

passage is clogged.

head

distortion

valve

stem

cy~

damage.

on

passage.

bottQm

diagram,

exceeds

CYLINDER

seals.

Do

not

reuSe

head for water

on,

scaling,

blow

surface for

use a straight edge

the

air

ftatness

limit

leaks,

carbon

thru

to

c:cnrect

HEAD

the

and

ensure

and ·

AND

VALVE

Valve

Jf

contact coat of Prussion Blue (or Redhead)

face,

the

Check tion

correct the

the

THICKNESS

Intake

Exhaust

CDNTACTwmi

VALVE

Do

ofna

VALVE

Standard.

Valva

Measure

spring

VALVE

Standard

VALVES

ASSEMBLY

StemNalve

the

valve

S1lml

between

then insert the valve into

valve

on the

if

the

Valve

0f

the

valve

v~ve

valve.

OF

VALVE

Standard D.D391n

D~0511n

BEAT

Ill

allldar

LENBTH:

.lola~

ijExhausl

SEAT

wumi

• .

0.0351n • O.Q61

Spring

the

free

if

it

is

out

SPRING

FREE

1o8231n

INSPECTION

Seat

is

bent or

the

valve

seat.

seat

contact face.

seat.

If

HEAD

(1.Dmm)

(1.3mm)

UBhi

3.DD81ri

OF

CONTACT

height of

of

limit.

LENGTH

(46.3mm)

worn,

and

valve

the

Do

contact

face

If

the

margin

MARGIN

(B1DD.Bmm)

(1DUmm)

.

(0.9

·1.3mm)

the

valve

rephlce

not

it is

the

valve.

Check

seat

by

applying

on

the

valve

valve guide and press-fit

rotate

the

valve.

contacts

is

the

not

correct

out

of

the

Limit

0.020I~O.Iimm)

0.031Jil

{lJ~Biii.ii)

a

thin

seat

contact

·

center

posi-

concentric,

limit,

replace

.

---r--

VALVE

LENGTH

' .

spring

and

replace

the

Umlt

1.7831n

(46.3

mm)

CYLINDER

A

stot:k

t:yllndllf

See head

HEAP

·

'

IJ.II07eln·(Pa2mm) . ..

Total

-4.287

the

rework

FI,ATNeSS

standard·

CAUTION:

may

..

·O.IJI)18Jn

HEAD

GRINDING

re&ll~~deplh

HEAD

HEIGHT

(NEW)

•.

4.29&111

(10&8 • -1&1

No

btl.l'lllllownl

bl1111k

mating

STANDARDS

dimensions

.

(!J.08mm)

UMIT

of·lnder·lmada~

mn

from

SIIIIIJt:BS

AND

UMITS

of the valve seat

Umlt

.

mm)

fllan,D

min

tbs cyllntlst

In total.

CHART

·

o.lirmln

OJ,2mm)

.

Also

blaok

-check

limit

'VALVE

Standard

{D.2mm}

hBBd

and

for

cylinder

hole.

of

Refer

s~fications

1....-IWES'JERBEICE

I

Eng/IUJS

&

GeiJerators

37

the

replace

SPRING

the

SQUARENESS

lm

lban

to the

Standards/Limits

spring for

spring.

2•

on

~ves.

squarencss

chart for

·

TESTING

and

if

it

exceeds

Umlt

4•

additional

BQUARENESBIANBLE

the

Valve

Stem

and

Measure stem valve

MEASURING

STEM

VALVE

Standard

Limit

VALVE

Standard

Valve

·B-efore between gUide

To seat the

After lapped

the

clearance

and

,

if

the

clearance

guide

or

valve,

VALVE

DIAMETER

STEM

Seat

·correcting __

the

if

necessary;··

recondition,

grinder,

specified

correction~

with

TO

Intake

EXhaust

·Intake

Exhaust

OUTER

DIAMETER

lntl$e

Exhaust

Reconditioning

the

valve

g~e

use

repair

so that

configuration.

the

lapping

VALVE

CYLIND-ER

HEAD

Guides

betWeen

or

replace

l

'

I

VALVE

--if.iiii3iiin-(D~1ilmm)

valve

an.c;l

a valve

valve and the

COJD.pound.

SEAT

.035 • .051

the

valve

guide1ana

exceeds

GUIDE

o.oo_oo

O:oo2~o.o~31n

0.0059111

sea(

and

the

In

the

limit,

both.

CLEARANCE

·-0.0020in

(0,02 • o.o&mm)

(0;005 • o.ooa&mm)

(0.1_1imm)

U585 •

0.25911n

0.2571 • D.2579ln

check_

for

the

valv~.

replace·

seat cutter

seat

width

valve

seat

CONTACT

WIDTH

[0.9

·1.3

mmJ

replace

(6.565 • 5;58Dmm) (6.530··

clearance

the

and

a pilot or a

and

seat

should

the

6.55Dmm)

valve

angle

be

valve

are

AND

Valve

Install the

ENAMEL

COATED

SIDE

Use

springs. retainer

REMOVING

RETAINER·

LO~KS

Cylinder

Clean surface

Piace a new fa:cing

VALVES

.Springs

the

rocker ann

the

valve

With the

locks.

Head

the

residue

of

the

its

identification

valve

side.

spring

cylinder

~

spring

with

it's

enamel

compressor

valve

spring

,

Gasket

of

gasket

block

head

mark

to

compressed,

and

oil

and

the

gasket

on

upward.

from

coated

compress

remove

~

the

gasket

cylinder

the

cylinder

side

the

head.

block

toward

valve

the

mounting

INSTALLAT~ON

Valve

Install the valve spring seat, then using the valve stem seal

installer,

Do

NOTE:

installation

Stem

Seal

install a new

' .

not

use

th~

old

Use

the installer tool

can

cause.

stem

valve

oil

seal

stem

to

leak

to

seal.

insert

into

the

valve

stem

cylinder.

guide.

seal,'

improper

.Eti_gines

&.·Generators

38

CYLINDER

HEAD

GASKET

CYLINDER

HEAD

Cylinder

Tighten

gram

1.

2.

3.

CYLINDER

Rocker

Install sides specified properly.

ROCKER

the

using

Temporarily

.

22ft-lbs Tighten

(40-

SONm).

Tighten torque.

HEAD

Cover

the

rocker cover using a

with

clean

torque

COVER

2.9 • 5.2

Head

Bolts

cylinder head bolts

in

a stepped-up tightening

tighten

the

bolts in numerical order

(20 -30 the

the

Nm).

bolts

again

bolts

in

TORQUE

in

numerical order

43

-51ft-lbs

new

oil).

Gradually tighten

making certain

BOLT

TORQUE

ft·lbs

(4 • 7Nm)

(6mm

the

BOLn

the

order

shown

torque.

to

29

to

the

specified

(60 • 70Nm)

gasket (slightly coat

the

cover bolts

cover gasket

is

in

the

dia-

to

14-

- 36ft-lbs

both

to

the

positioned

ENGINE

FRONT

INTAKE

SIDE

EXHAUST

CYLINDER nGHTENING

HEAD

SEQUENCE

2

SIDE

BOLTS

Engines & Generators

39

ROCKER

2

INTAKE

3

WAVE

ARM

NUMBERS

SUGGESTED DISASSEMBLY

WASHER

) 1

4ROCKER

INDICATE

ARM

EXHAUST

ORDER

CAMSHAFT

THE

OF

AND

TORQUE

21 • 25

21·35Nm ,

1 Q

ROCKER

ARM

EXHAUST

ROCKER

Ft·Lbs

ARMS

TORQUE

2

35

1"

@

21 • 25

Nm

FT-LBS

~

14CAMSHAFT

INSPECTING

1. Visually inspection the camshaft for cracks and damage.

If

necessary, replace the camshaft.

NOTE:

If

camshaft with an oil soaked fine emery grindstone. special

2. Inspect the camshaft journal and, limit, replace the camshaft.

CAMSHAFT STANDARD

CHECK FOR

THE

CAMSHAFT

the

damage is slight, you

care

to

not damage the original

JOURNAL

WEAR

DIAMETER

1.6118

·1.6124in

JOURNAL

DAMAGE

BEARINGS

may

be able

cam

if

wearing exceeds the

(40.940 • 40.955mm)

to

form.

correct the

Take

Camshaft

NOTE:

If

the

Journal is seized, also check

3. Measure the replace the camshaft.

cam

height and,

if

the

cylinder head!

it is less than the limit,

CAMSHAFT

HEIGHT

c:r:-~o·

~-

4. Inspect the clearance between the camshaft journal and

BEARING STANDARD

HEIGHT

Intake

Exhaust

t1

#2

13

t1

#2

#3

STANDARD

1.3815in

1.3807in

1.38031n

1.3839ln

1.3831in

1.3854in

(35.09mm) (35.07mm) (35.06mm) (35.15mm) (35,13mm) (35.19mm)

UMIT

1.36181n

1.3610in

1.36061n

1.3642in

1.3634in

1.3657in

(34.59mm) (34.57mm) (34.56mm)

(34.65mm) (34.63mm) (34.69mm)

MEASURING CAMSHAFT

the camshaft support bore as follows:

a. Measure the camshaft journal diameter and the

camshaft support bore.

b. Calculate the clearance and replace the camshaft

cylinder head

OIL

CLEARANCE

0.0018 • 0.0033in

if

the clearance exceeds the

(.045 • 0.085mm)

limit.

HEIGHT

or

40

CAMSHAFT

AND

ROCKER

ARMS

Rocker

Check

carefully

Arm

each

inspect

indicate.

ROCKER

INSPECTION

ARM

Inspecting

Check

the

clearance

exceeds

it

ROCKER

Rocker

1.

2.

ROCKER ROCKER

the

ARM

standard

Limit

Shaft

Inspect water

and

Measure (O.D.). the

shaft.

SHAFT SHAFT

CLEARANCE

the

If

component

the

individual

Clearance

between

limit,

replace

(ROCKER

0.0005 • 0.00171n

0.0041n

rocker

shaft

damage.

the

LENGTH

0.0.

shaft

length

shaft

Standard,

Replace

fails

Standard

part

of

the

rocker

rockers

Rocker

the

(0.1mm)

where

and

to

0.6687 • 0.66921n

Arm

the

rocker

ARM

TO

(0.012 • 0.043mm)

·

the

shaft

the

shaft

meet

the

9.134ln

arm

where

And

arm

or

SHAFT)

rocker

if

worn.

outel

standards,

(232mm)

l16.985

~senibly

the

and

arrows

Shaft.

and

shaft

and,

shaft.

anns sit

·

for

·diameter replace

-16.998riliT!l

if

3.

4.

Measure feeler plate

Using

the

end

gauge

in

and

the

new

.

END

PLAY

·

the

oil

seal

cylinder head

play

the

gap

front

Standard Limit

installer

of

the

camshaft

between

camshaft

0.0024-

0.11Bin

tool,

the

rear

journal.

o.00551n

(0.3mm)

install

by

inserting

of

the

thrust

(0.& • 0.14mm)

the

front

oil

a

seal

in

·~

OIL

HOLES

~"'\~

INSTALLATION

1.

Apply

11

coating of

and

cams

and insert

cylinder head. ·

2.

Install

the

camshaft

tighten

the

bolts

THRUST

PLATE

BOLT

TOR"OUE

BOLT

_,,

tT"on

engine

the

thrust

to

the

TORQUE

oil

camshaft

plate

specified

7 •

9ft·lbs

to

the

as·

torque.

(10

orl

OIL

HOLES

c!mlShaft

througli

shown

·12Nm)

journals

the

rear of the

in

the

·

diagram

5.

Install rocker located

6.

Tighten then

ROCKER

ARM

to

the

rocker

shaft

on

the

rocker

the

specified

SHAFT

annlrockershaft

so

the

portion

front.

BOTTOM

arm

torque.

BOLT

TORQUE

shown

VIEW

shaft

assembly.

in

the

BOLT

HOLE

OIL

bolts

(4

bolts)

21 • 26ft·lbs

Install

diagram

HOLE

uniformly

(29 • 36

the

is

FRONT

and

Nm)

Engines & Generators

....

41

ARROW

FRONT

MARK

PISTONS

901L

AND

RING

CONNECTING

111

PISTON

112

PISTON

RODS

RING RING

NUMBERS SUGGESTED DISASSEMBLY

INDICATE

ORDER

I I

THE OF

STOPPER NOTCH

CYLINDER NUMBER

REMOVING

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. are worn away be certain to remark them.

Disassemble

Using the ring remover, remove the piston rings. While

removing the piston rings, note the order they are removed and which side

THE

CONNECTING

the

Pistons

of

the ring faces the piston crown.

RODS/PISTONS

If

the marks

Remove

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. press, drive out the piston pin.

NOTE:

Keep the disassembled piston, piston pin and

connecting rod in order according to the cylinder

Engines & Generators

42

the

Piston

Pins

Using a

number.

PISTON

Reinsert You

the

sides.

or

NOTE:

Measure

PISTON

the

should

will

Replace

if

there

The

the

0.0.0.6300 • 0.63021n

INSPECTION

piston

into

feel

a

sligh~

resistance, if

click

or

bind

the

piston

is

excessive

piston

outside

play.

and

diameter of

PISTONS

the

piston

the

as

it

enters.

Try

if the

can

piston

are

replaced

the

piston

{16.001·16.007mm)

hole

be

with

bore the

too

pin.

your

is

misaligned

from

easily

as

an

AND

CONNECTING

thum~;

both

inserted

assembly.

Check

the replacing replace

the

piston

the

rings

piston

RODS

ring

for

damage,

if

anything

rings

when

wear,

seizure

unusual

installing a

RING CLEARANCE

is

SIDE

noted.

new

and

Always

piston.

bends

Pistons

Check

the streaking. Inspect hole Check Replace diameter

PISTON

If

the

NOTE:

Piston

Insert the right When

PISTON

No.1

No

PISTON

No.1 No.2 011

the

in

the

at

0.0.2.5579 • 2.55911n

the

piston

piston;

The

Rings

the

piston

top

of

the

angle,

the

gap

RING

2

011

RING

piston

smfaces for

If

any

damage

oil

return hole

piston

boss.

Clean

piston

pin hole for

piston

if

damage is evident

90°

(perpendicular)

diameter

piston

.measure

GROOVE

Standard

0.0480 o.0471i • 0.04841n

0.1108 • 0.11161n

END

Standard 0;0059 • o:o11a1n

0.0138o:ooa -o.o2Bin

is

and

piston

ring

into the cylinder

head and

the piston

is

tOo

large, replace

• O

•.

Q4.BBin

GAP

0.0197ln

less

(0.2 -o.

wear,

seizure,

is

evident,

in

(64.97 • 65.00mm)

then

the

signs

to

oil

piston

the

are

ring

of

replace

seizure

standard

replaced

bore

pressing

ring

(1.22 (U1

(2.815 • 2.B35mm)

(0.15(0.35

-0;50inm):

7mm)

it

gap

the

piston

·1.24mm)

-1.23mm)

o.aomm)!

with a feeler

Limit o.amm O.Bmin

1.omm

cracks the

piston.

groove

if

these

or

Measure

bore

axis.

replace

as

placing

in.

When

ring.

(0,03151itl

(D.0315ln)

(D.D394ln)

and

the

are

clogged.

damage.

the

piston

an

assembly.

it against

it

marks

gauge.

oil

·check the groove,

or

both.

PISTON

No.1 No.2

Connecting

Vlsualiy which seizure discovered undersize severe

Measure and

a

clearance) essary, and

CONNECTING

clearance

if

it

exceeds

RING

SIDE

standard

ring ring

0.0012 • 0.002Bin

0.0008-

check

are

lopsided,

are

excessive, on

machining.

thermal

the

inner

tl).e

outer

exceeds

the'Crankshaft

replace

.

the

ROD

Standard

0;0009"

o.oo~Oin

between

the

limit,

CLEARANCE

0.00241n

Rod

Bearinu

the

surface

streaked

check

the

crankshaft, either

If

the

damage,

replace

diameter

· ·

of

the

limit,

...

or

bearings

BEARING

with

OIL

(0.022 • 0.052mm)

the

piston

replace

(0.03-

0.07mm)

(0.02-

o.o&mm)

of

the

bearing.

or

seized.

the

crankshaft.

replace

connecting

the

bearing.

of the

connecting

the

crankshaft

replace

undersize

CLEARANCE

machine

an

appropriate

the

When

the

ring

and

rings,

Limit

0.00471n

0.00391n

Replace

If

it

rod

bearing

pin.

If

bearing,

the

undersize

Limit

0.0041n

the

(0.12mm) (0.10mm)

those

streaks

damage or

reuse

indicates

rod

bearing

the

gap

and,

crankshaft

(0.1mm)

ring

piston

or

is after

(oil

if

nec-

type.

PISTON

RING

GAP

Engine~

& Generators

'43

PISTONS

NOTE:

See Crankshaft/Bearing section

clearance with a Plastigauge.

Use a rod aligner to check the connecting rod for bend and twist.

CONNECTING

CONNECTING CONNECTING

CONNECTING

ROD

ROD ROD

Standard

ROD

Standard

BEND

LIMIT

TWIST BIG

END

CENTER

0.004in

LIMIT

TO

CRANKSHAFT

0.0039-

LENGTH

4.0138-

0.004in

(0.05mm)

(0.1mm)

0.0098in

4.0178in

for

measuring the oil

SIDE

CLEARANCE

(0.10-

(101.95

AND

0.25mm)

-102.05mm)

ASSEMBLY

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,

Connecting

Rod,

Piston

CONNECTING

Oil

Ring

Assemble the oil ring spacer into the piston ring groove. Then, after assembling the upper side rail, assemble lower side rail.

NOTE:

There is no difference between the upper and

side rails

The chart below identifies the color coding bn new spacer and side rails according to size.

SPACER

AND

SIZE S.T.D.

0.0098in

0.0197in

0.0295in

0.0394in

Install the three-piece oil ring in the piston. Then, make certain the side rails move smoothly

side rail my be easily installed by pushing it in with your finger after fitting the one end over the piston groove. use

an

expander ring on the oil ring.

RODS

or

the spacers.

SIDE

RAIL

(0.25mm) (0.50mm) (0.75mm) (1.00mm)

1/~~·h

m

CODING

Oversize Oversize Oversize Oversize

END

OF

SIDE

~~,.---

._____,....,~

Color

Two

One

Two

One

RAIL

Identification

Blue Red red

lines

Yellow

in

both directions. The

Lines

Line

the

lo>ver

SIDERAIL

SPACER

Do

not

PUSH ROD

GUIDE

A

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 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 fitted in the specified position by bottom end surface until it the base. replace the pin (piston assembly) or connecting rod, or both.

PISTON

in

the connecting rod. The piston pin

is

seated on the bottom surface

If

the press-fitting load

PRESS-FITTING

LOAD

of

the piston pin and

is

press

press-fitti,ng the Guide A

is

out

of

the specification,

1102-

33071bs

(5000

-1500Nm)

of

Piston

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.

Rings

1-----,/-11

-------...

~

PISTON

RING

112

PISTON

RING

44

PISTONS

AND

CONNECTING

RODS

Installing

Apply piston ring

Insert cylinder, toward

Securely the

piston

Keep

the

an

ample

and

the

(side

rail

FRONT+

112

the

piston

working

the

camshaft

FRONT ARROW'

MARK

pressing the piston ring with

and

in

mind

strongly.

PISTON

RING

BAND

INSTALLER

Piston

amount of

Assembly

oil

to

piston rings. Position

spacer) end

gaps

~

SPACER

~

and connecting rod

from

connecting

that

the

-:;::::>

the arrow mark

sp~;ocket

side.

rod

assembly into

piston ring may

the outside surfaces of

the

piston

rings

as

shown.

!J

'\SIDE

RAIL

assembly

the

LUBRICATE

into the

on

the

piston

ring band, insert

the

cylinder.

be

damaged if hit

WITH

OIL

and

top

the

oil

too

CRANKSHAFT Identification

CONNECTING

Identification

CONNECTING Identification

Brown Blue

CONNECTING

Crankshan

Identification

(1)

(2) (3)

I

IT

(1)

(2)

(3)

marks

//\A

GB

cc

ROD

Marks

ROD

Color

ROD Pin

Marks

1/\

B

[

DIAMETER

1.4171

·1.4173in

1.4167

·1.4171in

1.4165

·1.4167in

BIG

END

INNER

1.5354

·1.5356in

1.5356

·1.536Din

1.5360

·1.5362in

BEARING

THICKNESS

0.0586 • 0.0588in

0.0588 • 0.059Din

0.0590 • 0.0592in

BEARING

SELECTION

Connecting

Identification

I

A

li

m

I

8

n

m

I

c

li

m

Journal

Diameter

(35.995 • 36.000mm) (35.985 • 38.995mm) (35.980 • 35.985mm)

DIAMETER

Big

End

Inner

(39.000 • 39.005mm) (39.005 • 39.015mm) (39.015 • 39.020mm)

Bearing

Thickness

(1.488 (1.493 (1.498

TABLE

Rod

Bearing

Marks

Brown Brown

Brown Blue

Blue Blue

N0.3 N0.2

N0:1

Diameter

·1.493mm)

·1.498mm)

·1.503mm)

Crankshaft/Bearing

When

the

bearings bearings for

for

assembly according

the

crankshaft and the connecting

Assembly

are

to

be

replaced, select

to

the identification

rod.

CRANKSHAFT

the

appropriate

marks

IDENTIFICATION MARK

Engines & Generators

45

CONNECnNG

ROD

STOPPER

NOTCH

IDENTIFICATION COLOR

CYLINDER NUMBER

PISTONS

.AND

CONNECTING

RODS

..

Installing

Since the connecting using the plastic examined before reuse. down",

Necking can be checked by running a nut with fingers to the full length smoothly, the bolt should be replaced.

Before installation thread portion and bearing surface

Install each nut to the bolt and tighten it with your fingers. Then tighten the nuts alternately to Tighten the nuts to the proper torque.

CAP

NUT

A

before the

Make a paint mark

mark on the bolt

paint mark made

nut.

Give a

paint mark on the

If

the nut is turned less than 90°, proper fastening performance may rum it sufficiently.

If

the nut is overtightend (exceeding 100°), loosen-the nut completely and then retighten it by repeating the tightening procedure.

the

Connecting

area

the bolt should

of

the bolt threads.

TIGHTENING

TORQUE

CAUTION:

installing

spark

plugs.

end

on

90° to 100°

nut

not

Rod

Bearing

rod

cap bolts and nuts are torqued

tightening method, the bolts should be

If

the bolt threads are "necked

be

replaced.

If

the nut does not run

of

each nut, apply clean engine oil to the

of

the nut.

install the cap properly.

11+90"

tum

(15Nm

If

the

cylinder

the

connecting

on

the head

at the position 90° to 100° from the

the nut in the direction

tum

to the nut and make sure that the

and that on the bolt are in alignment

be

expected. When tightening the nut,

head

rod

of

each nut.

cap

+90"

has

been

nut,

Make

of

the tightening

Caps

turn)

installed

remove

a paint

Engines & Generators

46

FRONT

CASE I COUNTERBALANCE

SHAFT

AND

OIL

GASKET

PAN

TORQUE 6 -1

Ft-Lbs

'·'l

601LSEAl

I

..

. . SlhL

PUMP

CoVER

NUMBERS SUGGESTED DISASSEMBLY

INDICATE

ORDER

THE

OF

CONFIGURATION OF

FRONT

ASSEMBLY

OIL

PAN

Remove bolts

COUNTERBALANCE

1.

Remove

0.32in counterbalance

CASE

REMOVAL

the

oil

drain

and

then

use

the

plug

(8mm)

the

rod

shaft.

hose

special

on

into

assembly.

tool

SHAFT

REMOVAL

the

cylinder block

the

hole

Remove the oil

to

break

the

and

to

lock

the

pan

insert

pan

seal.

an

2.

3.

·

4.

Remove the

gasket.

Remove to

release

Remove

the

oil

pump

cover

the

oil

pump

driven

the

counterbalance

the

counterbalance shaft

FLANGE

OIL

GEAR

and

BOLT

PUMP

gasket.

gear

tightening

shaft.

DRIVEN

Drive

Discard

flange

it

from

the

bolts

front.

47

4.

Using a special bearing

5.

Use

the

bearing

FRONT

tool

drive

from

the

cylinder

same

tool

and

from

the

cylinder

CASE I COUNTERBALANCE

the

counterbalance shaft

block.

drive

the

counterbalance shaft rear

EARING

front

REMOVER

TOOL

FRONT

Check the

the or solvent

SHAFT

CASE • INSPECTION

front

case

oil holes.

to

If

the

clean

block.

AND

for

oil

them

OIL

cracks or other damage

holes

are

clogged,

out.

PUMP

also

use

compressed air

inspect

OIL

PUMP

Fit

the feeler indicated

DRIVEN

DRIVE

DRIVEN DRIVE

Using indicated

There

the

cylinder

ASSEMBLY • INSPECTION

oil

pump

gauge,

check

in

the·

GEAR

BODY

A.

B.

GEAR

BODY

C. D.

GEAR

SIDE

GEAR

SIDE

a straight edge, check

in

the

should

block

gear

into

the

clearance

diagram

CLEARANCE

0.0161 -O.D2661n

0.0051 -0.00691n

CLEARANCE

0.0173-

0.0059-

CLEARANCE

illustration

be

no

uneven

or

on

the

cylinder

with

below.

STANDARD

(0.410 -0.675mm) (0.130-

STANDARD

0.02761n

(0.44-

0.0771n

(o.150-

.0024 • 0.00471n

0.0027-

the

side

with

a feeler

wear

on

the

pump

gear side of

block,

then,

using a

the

body

at

the

points

0.175mm)

0.70mm)

0.195mm) (0.06 • 0.12mm)

0.00511n

(0.07-

clearance at

0.13mm)

the

point

gauge.

the contact surfaces of

the

pump

CRANKSHAFT

Check

the

lip for hardening.

COUNTERBALANCE

Inspect the Inspect with clearance.

the

COUNTERBALANCE

Front Rear Front Rear

the

bearing.

standards.

Journal Journal

Journal

FRONT

oil

seal

for

If

SHAFT

oil

holes

for

shaft journal

Check

Replace

Dlanieter

Diameter

011

the

SHAFT

Clearance

OIL

wear

and

there

any

SHAFT • INSPECTION

clogging and clean

for

seizure, damage

the

counterbalance shaft

counterbalance shaft if it

STANDARDS

0.7869 • 0.7874in

1.7317

0.0014 • 0.00271n

0.0014-

SEAL • INSPECTION

damage. Inspect

signs

of

wear,

·1.7322in O.OD28in

(19.987(43.984(0.035 • 0.068mm) (0.035 • 0.071mm)

the

replace

if

necessary.

and

its oil

fails

20.000mm)

44.000mm)

oil

seal

the

contact

to

meet

seal.

Engines & Generators

48

FRONT

CASE/BEARINGS

AND

OIL

PUMP

INSTALLATION

Counterbalance

1.

Install

the

tapered

hole of the cylinder block

Rear

Bearing

special tool guide pins (bearing Installer)

as

shown.

~~)~

OIL

HOLE

,

::--

~\

2.

Mate

the

ratchet ball of

rear bearing and install the bearing in the bearing

installer.

3.

Apply

clean engine oil

bearing

4.

and

the bearing hole in the cylinder block.

the

bearing

to

the outer circumference of the

in

the oil hole of

in

(

J G r

BEARING

the

Crankshaft

1.

Front

Install the front case assembly through the bolts

FRONT

CASE

There are they are positioned properly.

NOTE:

the inner

the front case assembly

lip

seal the

crankshaft.

Oil

Seal

Case

Assembly

to

the

specified torque.

BOLTS

TORQUE

two

different length front case

When

installing

circumference

on

the

stepped

A

the

up

6 •

7ft.lbs.

See the diagram.

front case

of

the oil seal

take

care

not

portion

of

(8

the

gasket

·10

Nm)

bolts.

Make

assembly,

lip.

to

the front end

When

damage

A

B

apply

BOLT BOLT·

and

tighten

certain

oil installing the

oil

of

-18mm 3Dmm

to

(.71

(1.18

In}

::/

'

Counterbalance

1.

Apply

engine oil to the bearing outer circumference

the

bearing hole

2.

Press-in the front bearing using the installer tool.

Front

Bearing

in

the cylinder block.

FRONT INSTALLATION

BEARING

and

Oil

Pump

1.

Apply

an

pump

driven gear

positioned

2.

Using the same reinsert Then tighten the

Y(~M

~

.

(--;

~

Driven

the

Gear

ample amount of clean engine

and

insert it so that

as

shown.

hole

on

the side of the cylinder

8mm

rod

to

lock the counterbalance

flange

bolt

to

/RI"\

'-"' \ C

ihe

the specified

0

@

~~

oil

to

the

timing

mark

block,

shaft.

torque

SETTING DRIVEN

FLANGE 25 • 29

=·

oil

.

THE

GEAR

BOLT

ft.lbs,

B

is.

TORQUE (34 • 40

Nm)

Engines & Generators

49

FRONT

.DEBURR

_

..

LOCTITE

TO

NOTE:

Deburr this edge area as shown. Clean

from the deburring process and clean with a cleaning agent.

Wipe

dry with a clean cloth and use compressed air to blow

dry.

the block surface and oil pump cover must be clean and

of

oil.

free

#518

SHADED

off

all metal

CASE

AREA

AND

OIL

GASKET

BmmROD

PUMP

Oil

Pump

Cover

Re-install the pump cover. Press the alignment sleeves. the two long bolts go where the

sleeves are - install these bolts first. Install the rest bolts in a criss-cross pattern. bolts

to

80 inch-ll>s.

or

lightly tap the cover onto

Torque

the

oil

pump

of

cover

the

Drive

Gear

TIMING

MARKS

DRIVE

GEAR

Oil

Pump

Block

Apply a very small bead block surface as shown. Spread it into a thin, even layer on the surface. Remove any excess.

Surface

of

LOCTITE #518 to the engine

/"

<)- /'

I

Oil

Pump

Seal

Press the seal into the oil pump cover flush with the surface using the seal installer tool.

COVER

OIL

PUMP

INSTALLING

OIL

PUMP

OIL

PUMP

ASSEMBLY

SEAL

THE

SEAL

GASKET

Oil

Pump

Cover

Gasket

Fit a new oil pump cover gasket into the groove in the oil pump cover. The fiat side

the pump cover.

of

the gasket is positioned against

Engines & Generators

50

FRONT

CASE

CONFIGURATION

CRANKSHAFT I BEARINGS

AND

OIL

SEAL

NUMBERS SUGGESTED DISASSEMBLY

CYLINDER

8

CRANKSHAFT

INSPECT

THE

FOR

UNEVEN

CHECK

FOR

AND

CLOGGED

INDICATE

ORDER

BLOCK

BEARING

JOURNALS

.wEAR.

CRACKS,

BENDS,

OIL

HOLES.

THE OF

(UPPER)

OIL

SEAL

PULLEY

BOLT

TORQUE

98-

(135-

CRANKSHAFT

1.

Check

the

journals and pins

cracks.

wear

2.

Measure the outside diameter of the journal

inside

Check the journals ·contact surface

and

replace

diameter of the main bearing.

105

145

Nm)

INSPECTION

if

badly damaged.

_d

FT-LBS

MAIN

BEARING

TORQUE

36-

for

40

damage,

[50-56Nm] ·

clearance) exceeds the limit, replace

also

the

crankshaft, undersized cranksh'aft and replace an

undersized one.

Standard O.OQ08-

0.00181n

(0.021 -0.045mm)

3.

When

grinding the crankshaft

the "R" dimensions

if

nece-ssary.

of

the

Otherwise, fabricate

the

to

under-size,

fillets

of

area.

_@)

·

BOLT

FT-LBS

seizure and

for

and

If

the clearance (oil

the

main bearing and

main

bearing with

Limit

.004in

(0.1mm)

take

the

journal and pin

uneven

the

note

an

MEASURING

of

MEASURING DIRECTION

_

POSmON

MEASURING

CRANKSHAFT

AND

THE

O.D.

BEARING

I.D.

-c)~

Engines & Generators

51

CRANKSHAFT/BEARING

AND

OIL

SEAL

CRANKSHAFT

INSTALLING

1. Apply a coat the oil groove faces outward as illustrated.

THE

THRUST

of

oil to the thrust beating and install so that

BEARINGS

MEASURING

Push the crankshaft to the rear. Then, insert a feeler gauge the gap between the crankshaft journal side surface and the thrust bearing end surface to measure the end play.

CRANKSHAFT

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.

END

PLAY

PLAY:

D.DD20 -0.0098

REAR

OIL

in

SEAL

(0.05 -0.025

mm)

in

BEARING

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-lbs

(50 -55Nm)

CAPS

3. Install the oil seal case into the cylinder block through the

(If

gasket. entire circumference with clean engine oil.

OIL

SEAl

NOTE:

OIL

CASE

there is no gasket, coat with sealant.) The

of

the oil seal lip should be coated

CASE

Make

certain

the

lips

of

the

oil seal

BOLT

TORQUE:

7-9 Ft-lbs

(10

-12Nm)

are

not turned

up.

Engines & Generators

52

CRANKSHAFT,

BEARING

AND

OIL

SEAL

R -

0.059/N

(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 journal and bearing inner surface.

2. Install the crankshaft.

3. Cut the plastic gauge

the bearing and place it on the journal in parrallel

to

the same length as the width

witli.

of

its

axis.

4. Gently place the main bearing cap over it and tighten the

bolts

to

the specified torque.

5. 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.

CRANKSHAFT Upper

and

When the bearings are to

BEARINGS

Lower

SPECIFICATIONS

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

Identification

CRANKSHAFT Identification

JOURNAL Marks

1

2

3

/N0.4

/N0.3

-No.2·_.,

-N0.1

~N0.2

BEARING

Colors

brown-

blue

yellow

green

DIAMETER

1.5746-1.5748

1.5743

1.5741

ARM

THICKNESS

0.0783-

0.0784-

0.0785 -0.0786

0.0786 -0.0787

0.0787-

-1.5746

-1.5743

--........J

0.07841n

0.0785

0.0789

Journal

Bearing

in in in in

in in in

Diameter

(39.994(39.988(39.982-

40.000mm)

39.994mm)

39.988mm)

CAMSHAFT

Thickness

(1.988

-1.991mm) (1.991 -1.994mm) (1.994 -1.997mml (1.997 -2.000mm (2.000-

2.003mm)

JOURNAL

MAIN

BEARING

36-

BOLT

40

FT-LBS

THE

CRANKSHAFT

REAR

OIL

TORQUE

[50-56Nm]

PlASTIGAUGE'

INSPECTING

I.

Inspect the oil clearance lip for wear or damage. Check the rubber portion for deterioration and hardening. Replace the seal

2. Check the oil case for cracks and damage.

if

at all suspect.

If

damage, replace the case.

SCALE

SEAL

here

is

CYLINDER

Identification

CRANKSHAFT

Crankshaft

Identification

BLOCK

Marks

0

I

II

BEARING

Journal

Marks

1

2

3

BEARING

·

1.7323

1.7325

1.7328-1.7330

SELECTION

Crankshaft

Identification

~('I')N...-

c:)c)QQ

zzzz

DIAMETER

Bearing

Inner

-1.7325

in

-1.73281n 44.006in

CHART

Bearing

Marks

brown

blue blue

yellow

blue

yellow

green

CYliNDER

Diameter

l44.000 -44.006mml

44.012-

Cylinder

Identification

BlOCK

44.012mm

44.018mm)

BEARING IDENTIFICATION MARKS

Block

Bearing

Marks

I

li

I

JI

I

li

53

CYLINDER

BLOCK

INSPECTION

AND

PISTON

CLEARANCE

NUMBERS

SUGGESTED

DISASSEMBLY

CYLINDER

1. Before inspecting, clean the cylinder block to ensure that

2. Chepk

3. Inspect the mating surface. Using a straight

4.

CHECKING

Calculate the difference between the minimum cylinder bore

in the

. the illustration.

replace

PISTON

o.oooa

INDICATE

THE

ORDER

OF

BLOCK

the water with

pound

feeler

Grind or replace

FLATNESS

LIMIT:

Inspect the cylinder sure Calculate ues.

CYLINDRICITY

LIMIT

and

compressed

for

as

needed.

gauge·

STANDARD

0.0041n

the

bore

the

If

worn

~)'~INDRICITY:

MEASURING DIRECTION

THE

thrust

direction and the piston outer diameter

the

piston or cylinder block, or rebore the

TO

CYLINDER

•

o.oo~&ln

INSPECTION

oil holes are not plugged.

air.

cracks and

Replace

measure the

if

VALUE:

(0.1

mm)

at six places (as shown in

difference between the max.

or damaged, rebore or replace

STANDARD BORE:

2.5591 • 2.56021n

O.OOO~In

PISTON

If

the difference exceeds

CLEARANCE

(0.0 • 0.04

damage.

the limit is

bor~.

VALUE:

Use a

the block

flatness

e~.

0.0020

In

Using

·a

0.004in

(O.D2mm)

of

(0.05

cylinder gauge, mea-

(65.00 • 65.03mm)

CLEARANCE

STANDARD:

mm)

If

clogged, clear

ftaw

detecting

if

defective.

the

top surface.

mm)

the

and

the

{0.01mm)

the

specified

. . . .

edge

and

diagram).

min.

cylin(ler.

or

less

..

CENTER

LOWER

shown

range,

cylinder.

com-

val-

in

BORING

1. Select an oversize piston based

2.

Boring (Piston

OVERSIZE·

(INNER

0.26

o.&O

0.76

1.00

3.

4.

5.

THE

CYLINDER

on

the cylinder

maximum bore and maximum damage

Using

the

outer

diameter

point) of the selected oversize piston, calcubite

dimension.

dii,Jienslon

O.D.) DIAMETEifflNISH

Size

O.S.

o.s. o.s.

o.s.

Bore

Hone

Check

=

+.(piston

PI~N

.OuTsiDE

Mark

25 50

75

100

the

cylinder to

to finish

again

for

ulearance) • (honing

the

cylindricity

(at the specified

DIAMETER

DIMENSION

·

2.6677

(65.22 • 65.25mm)

2.5776 • 2.57871n (65.47 • 65.5Dmm)

.

2.6874. (65.72 • 65.76mm)

·2.5972 • 2.69841n

(66.97 • 66.00m)

obtain

cylinder inner

Piston

Dla.

•

2.66891n

2.58861n

the calculated

AND

(REF))

and

margin : O.OOOBin

CYUNDER

diameter.

piston

with

the

depth.

measurement

the

boring

(0.02mm))

Cylinder

Inner

Dla.

2.5693 • 2.66971n (65.26 • 65.27mm)

2.6791 • 2.67951n (65.51 • 65.62mm)

2.5890.

2.68941n

(65.76 • 65.77mm)

2.5988 • 2.69921n

·

(66.01 • 66.02mm)

dimensions.

clearance.

·

1-...riWESTERBEKE

I

~ines

.

&

Generators

54

.

COOLANT

CIRCULATING

PUMP.

REMOVING

1.

Loosen the belt guards thumbscrews and remove the engine's belt guard from its brackets 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].

Unscrew the five bolts that hold the pump to the engine

3. and remove the coolant pump and its gasket. Note that the

· pulley is an integral part

THE

COOLANT

PUMP

at

the front

of

the pump assembly.

of

the

COOLANT

PUMP

PULLEY

FLANGE

REPAIR

If

the pump does not pass inspection, replace the entire pump

assembly which includes the pulley.

RAW

WATER

PUMP

PULLEY

INSPECTION

Carefully check the damage. Inspect the weep holes for and rust that would indicate a faulty seal. The pulley should

tum

the shaft (and impeller) smoothly, without noise or

sluggish rotation.

The pulley edges should

locknut should be drawn up tight.

pump

body and impeller for cracks and

si~

of

water leakage

be

smooth and undamaged and the

THREE

BOLTS

0.24 X 1.381N (96X35

mm)

TWO

BOLTS

0.24 X 0.71 (6

X18

INSTALLATION

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. sealant when assembling the new gasket.

CIRCULATING

PUMP

BOLTTORQUE

6-7ft-

lbs

(8

-10

Use

Nm)

mm)

IN

Engines & Generators

55

EXHAUST

MANIFOLD I HEAT

EXCHANGER

EXHAUST

The exhaust manifold, cylinder

1.

Remove and corrosion and damage, replace

2.

If

temperature sensor and clean and re-paint WES1ERBEKE heat resistant

3.

Carefully inspect the exhaust connections noting the location of

manifold. WES1ERBEKE heat resistant

MANIFOLD

which

was

head,

should

be

inspected

the exhaust elbow

discard the old gasket Inspect

the

exhaust elbow passes inspection,

alignment at reassembly; Clean

If

the manifold can be

from

manifold,

disassembled

before

if

enamel.

ASSEMBLY

1.

If

the

manifold intact, it can reverse order of

MANIFOLD

2.

Attach

the exhaust running, carefully check these connections for leaks.

was

removed

be replaced

·rem<;>Val.

MOUNTING

hose connections

elbow.

BOLTS

Once

on

TORQUE

the

engine

as

the

Install a

to

the

assemblies

reassembly.

the

manifold.

the

exhaust elbow

necessary.

each

the

exterior

reused,

an

assembly

cylinder

new

12

-17

manifold

has

been

from

Scrape off

remove

remove for

gasket

ft-lb

the

elbow

the hose

proper

and

interior

repaint with

and

head

in

(16

-

23

and

re-installed

and

hose

the

left

the

high

Nm)

for

with

and

INSPECT

HOSES. REPLACE OR ENDS

IF

WORN

SOFT

ON

THE

TEST

PORT

HEAT

EXCHANGER

The heat exchanger should

an

engine overhaul.

1.

Disconnect the petcock, drain plugs end

fittings

and gaskets.

2. Inspect the tube (casing)

suspect replace

3.

Clean

out

any

and

raw

water passages.

4..

When

reassembling, install

Apply

some lubricant

petcocks

5.

Install a

NOTE:

· heat exchanger

They

6. Repaint

WES1ERBEKE heat resistant

HEAT

Reinstall the heat

brackets

exchanger

and

new

All

of

the

to

will

also

service

the

assembled heat

EXCHANGER

and

once

and

hose connections

.

hoses

the

heat

zinc debris

fittings zinc

anode.

above

can

a heat

transmission

ASSEMBLY

exchanger.

the engine

be

and

remove

and

zinc

for

exchanger.

and

to

the

as

you

be

inspected

wear

new

install

accomplished

the

anode.

and

pressure

gaskets

them.

and

Also,

exchanger/radiator

and

engine

exchanger

spray

enam~l

Tighten

is

down

running,

for

leaks.

check

serviced

hose

dents,

test

and

by

with

the

fittings,

remove

if

the

0-rings.

arid

to

sending

service

oil

holdown

the

during

·

the

at

all

coolant

the

shop.

coolers.

heat

56

ENGINE

HARDWARE

TORQUES

.

liming

Bell

Flywheel

bolt

·

Timing

belt

cover

Camshaft

Oil

Timing Tirolng

Ro~;~er

Rocker

.

C!litt'shaft

·Rocker

Cylinder

Cylinder Spark

Miscellaneous

Exhaust Thermostat

sprocket

pump

sprocket

tensioner

belt

rear

Arms

and

cover

thrust

arm

adjust

Head,

head

plug

f\ocket

cover

Coolant

temperature

Coolant

temperature

Generator

Crankshaft

mounts

manifold

housing

bolt

nuts

cover

Rocker

shaft

plate

Valve

bolt

(front)

bolts

nuts

nut

{cold

sender switch

bolts

Shaft

bolt

engine)

Nm

88

10-12

80-100

50-:5'1 22-30 10-12

29-35 10-12

8-10

60-70

15.2

12·13

12·18 12·18

34-41

16-23

8-11

135-145

ft.lbs.

-l

65

7-9

58-72 36-41 16-22

7-9

21-25

7-9 6-7

43-51

10.8 9-10

9-13

9-13 23-34 12-17

6-8

98~105

Front

Case,

Counterbalance

Front

case

Oil

pump

cover

Oil

pan

bolts·

Oil

drain

plug

Oil

screen

bolts

011

pump

driven

Rear

cover

Piston

and

Connecting

Crankshaft,

Cylinder

.

Water

Bearing

Oil

seal

case

Bearing

cap

Block

Taper

plug

Taper

plug

Water

drain

Taper

plug

Oil

P,r~ssure

Oil

pressure

Pump

Water

pump

bolts

rod

bolts

1/16 1/8

plug

1/4

NPT

switch sender

bolts

gear

cap

bolt

Rod

nut

ShaH

Nm

8-10

10-12

35-45

15-22 34-40 10-12

15 + 90"tum

10-12 50-55

8·12 15-22 35-45 35-45 12-18 12-18

8-10

ft.lbs.

6-7 6-7

7-9

25-33

11-16

25-29

7-9

11 + 90"

7-9

36·40

6·9

11-16

25·33 25-33

9-13 9-13

6-7.

turn

f=fj'giri_fJ.I!.:.~

(.;!lnerator$

57

RAW

WATER

PUMP

(PN.042026)

PUMP

,_.;-

~6BRASS

_.....

~

/

Disassembly

The pump when removed from the engine, will have hose attachment nipples threaded into its inlet and outlet ports

of

along with the drive pulley attached to the shaft In most cases the hose nipples can be left in place. Note their' positioning. Remove the drive pulley.

1.

Remove the four cover plate screws 3 and the end cover

"0"

8 and

2.

Remove the impeller 5 using a pair impeller hub and pull it out motion.

3. Remove the screw 12 and washer 13 that holds the cam in place. Remove the cam 14 and the inner wear plate

4.

Remove the brass circlip 7 and the brass-holding washer 6 along with the spring half

5. Remove the dust plate 20 along with circlip 19.

6.

Support the pump body on with a drift, push the shaft 15 with bearing assembly 17, 18, 16 and 17 out

7. Remove the

8. Support the outer bearing 17 and push the shaft out bearing.

9. Remove the spacer

10. Support the inner bearing 17 and push the shaft out bearing.

Using a thin drift, knock the porcelain half

11.

out

ring 4.

of

an

of

the pump body

"0"

ring 10 from the shaft.

16

and the circlip.18 from the shaft.

of

its boss in the pump body 1.

of

pliers, grasp the

the pump with a twisting

seal 2. ·

appropriate surface and

l.

the pump.

of

the seal 2

of

9:

the

Inspection

Inspect all parts. Review the components in the Overhaul Kit #046623 and proceed to re-assemble the pump. ·

OVERHAUL

.......-:::_.....

-------

.---

_.....

INNER

./

---~

Reassembly

1. Install the porcelain half pump

2. Install the circlip

bearing 17 and,press the shaft into the bearing until it

contacts the circlip.

3.

Install the spacer push the outer bearing 21 onto the shaft until it contacts the

4. Apply glycerin to the shaft about

5. Support the pump body on an arbor press and push the shaft and bearing assembly into the pump body until the

outer bearing

6. Install circiip

so the outer bearing the

7. Install the dust plate

8. Apply glycerin to the inner surface

seal 2 and with a twisting motion install it over the shaft and slide it down until the plastic surface seal contacts to porcelain half. Install the spring seal brass

washer 6 and secure it

9. Install the wear plate 9, cam screw 12 and sealing washer 13.

10. Apply glycerin to the surface

inner surface Fit the

11. With a twisting motion, install the impeller 5 into the

pump so it mates properly with the slot in the shaft 15.

12. Install the drive pulley onto the shaft the pump onto the engine. Check the pulley ment. Ensure the pulley is properly secured raw water hose.

_.....

---

...-

5

IMPELLER

9

WEAR

body

1.

spacer.

liS" away from the inner bearing.

shaft to ensure

"0"

ring into its recess in the pump housing.

of

the· seal 2: into it's boss in the

18

onto the shaft. Support the inner

16

onto the shaft. Support the shaft and

"0"

ring 10 and install it on the

just

clears the boss for the circlip 19.

19

and push the shaft and bearing assembly

17

just

contacts the circlip 19. Rotate

no

binding.

20. of

the

2nd

half

of

the spring

in

place with the brass circlip 7.

14

and secure the cam with

of

the impeller housing,

of

the cover plate 8 and sealing

of

"0"

the pump. Install

/belt align-

Re~attach

of

ring

the

4.

the

Engines & Generators

58

STARTER

START

MOTOR

.BATIERY

SWITCH

STARTER

PART

NO.

MOTOR

038384

BATIERY

-

NEGATIVE

~~---

TYPICAL DIAGRAM

TROUBLESHOOTING/INSPECTION

Prior to testing, make certain the ships batteries are at full

charge and that the starting system wiring connections (terminals) are clean and tight.

ground wire connections

the To

check the wiring, try cranking the starter for a few cycles, not more than three crank cycles at a time, then run your

hand along spots that indicate resistance. Repair spots.

U~ing

a multimeter, test the voltage between the positive terminal stud (ground).

If

you

read

If

nothing current connections. It is also possible that the solenoid is defective.

the

wires

on

the start solenoid and the engine block

12

volts,

the

happens

Check the battery and inspect the wiring

at

Pay particular attention to

on

the engine block.

and

terminals looking for

or

replace any trouble

starter

all,

the

is faulty.

solenoid

is

not

warm

getting

TESTING

.

REFER

·

..

Remove the

the lead from the electrical jumper. Leave the

·battery

·terminal.

·If

the

wiring

needs to

·

NOTE:

standard push button

TO

1.

Tum

· 2.

If

to the starter motor.

3. Label and disconnect the wiring from the starter. (Do not

allow wires

;4. Remove the starter mounting bolts.

Remove

5. starter will obstructions,

NOTE:

approved by the

replace the

WESTERBELE dealer/distributor.

WITH

AN

ELECTRICAL

TO

THE

ILLUSTRATION

Terminal

att~ched

The

push

button fails

and

wired

be

removed

This electrical

REMOVE

necessary,

WESTERBEKE uses an ignition proof starter

off

the

the starter

starte1;

FOR

to

have

S wire from the ignition and attach

and

clip the

button should crank the starter.

connections have been checked, the starter

jumper

to

crank

for

service.

jumper

and

can

two connecting wires.

SERVICE

DC

battery switch.

remove

U.S.

any components to gain full access

touch, tape

to

Coast Guard.

purchase a new starter from a

over

from

the

be

turned to a different angle to clear

JUMPER

BELOW

aligater fitting to that

the starter and the batteries

be

fabricated using a

the terminals).

engine)n

If

some cases the

it

is

necessary

+ positive

to

REFER

TO DIAGRAM FOR

WIRE

THE

.WIRING

IN

THIS

MANUAL

CONECT/ONS

TO

SERVICE

STARTER/SOLENOID

.

THE

STARTER

TESTING

REFER

TO

THE

FOLLOWING

PAGES

Q

59

STARTER

MOTOR

BENCH

When bench testing the starter motor, make certain it is securely held in place.

Motor

1.

2. Connect another jumper from the battery (-) post to the

TESTING

THE

STARTER

MOTOR

Test

Using a fully charged battery, run a jumper from the bat-

teries ( +) post to the connecting lead that has been removed from terminal C

starter motor's housing (momentarily). to run, the motor is the problem.

DISASSEMBLING

STARTER

MOTOR

TYPICAL

BEFORE

DISCONNECTING

THE

YOKE,

PUT

YOKE

TALLY

AND

.

THE

ON

THE

BRACKET

..

THE

MOTOR

SERVICE

STARTER

MARKS

FRONT

...

-·-~---

If

the motor fails

.

STATIONARY

PLU~~YOKE'

GEAR

~

Magnetic

1. Connect a jumper lead from the starter's S terminal to the battery ( +) post.

2. Connect a jumper from the battery (-) post to the starter motor's C terminal (momentarily).

If

3. magnetic switch.

DISASSEMBLING

1.

Remove the drive end frame mounting screws.

2. Disassemble carefully the overrunning clutch, ball, spring, gears, rollers, and retainer.

3. Remove the plunger end cover screws and take out the

NOTE:

the

TIGHTENING

APPLY BALL,

OR

AN

ASSEMBI.:

FLAT

Switch

the pinion gear fails to pop out, the problem

plunger.

When

overrunning dutch and

TORQUE B TERMINAL

GREASE

TO

AND

SLIDING

EQUIVALENT

WASHER

Test

THE

reassembling,

THE

GEARS,

SHAFT.

BEARINGS

USE

DENSO

MAGNETIC

apply

the

NUT

50

Bt\L1-

SWITCH

grease

ball.

5.9

·11.8

4.3 • 8.7

BUSHING~

/.

~o

~~A~~~~---------~

l

~

:~GEAR

'

' '

~--------------·-'

to

all

H·lb

COV~~

is

the

Nm

~BUSHIN~

with the

gear

,:

'

teeth,

j

j:STOPRING

,

NEEDLE

~

RETAINER BEARING

/

59

A

BRUSH

HOLDER

ASSEMBLY

STARTER

MOTOR

SERVICE

BRUSH

1.

2. Measure the brush length (A) with vernier calipers.

3.

ARMATURE

1.

2. If it conducts, replace the armature.

3. Check the continuity across the segments

4.

BRUSH

1.

2.

3.

WEAR

If

the contact face

with emery paper.

If

the length

yoke assembly and brush holder.

BRUSH

lENGTH

liMIT

11.0MM

of

the brush

is

less than the allowable limit, replace the

(A)

18.0MM

(0.43311N)

is

(0.70861N)

dirty or dusty, clean it

COIL

Check the continuity across the commutator and armature coil core with an ohmmeter.

of

the

commutator with an ohmmeter. If

it does not

RESISTANCE:

cC!nduct,

COMMUTATOR COMMUTATOR

replace the armature.

ARMATURE SEGMENT • OQ

COil • INFINITY

HOLDER

Check the continuity across the brush holder and the holder support with an ohmmeter.

If

it conducts, replace the brush holder.

If

the length

yoke assembly and brush holder.

RESISTANCE:

is

less than the allowable limit, replace the

BRUSH

HOLDER

TO

HOLDER

SUPPORT·

INFINITY

BRUSH

LENGTH

A

.

..

·'

:·;

,.~::~·:~

J/

CHECKING

~~tS~\~!::.

SEGMENT

CONTINUITY

;;,·:! .. ':·•;

~~:

::~~~:

·::

~:·}~-

)f:\

·:~.

:;:.:

~

.

.\Vi::,;;·:.:·:-:>::;:-

'·

FIELD

COIL

1.

Check the continuity across the lead (1) and brush (2) with an ohmmeter.

2.

If it does not conduct, replace the yoke assembly.

3. Check the continuity across the brush (2) and yoke (3) with an ohmmeter.

If

it conducts, replace the yoke assembly.

4.

RESISTANCE:

lEAD

(1) • BRUSH

(2)

D.Q I BRUSH

(2) • YOKE

(3) • INFINITY

BEARING

1.

Check the bearing for smooth rotation.

2.

If

it does not rotate smoothly, replace it.

.

STATOR

1.

Measure the resistance across each lead with

an

ohmmeter.

2.

If

the measurement

replace

3. Check the continuity across each stator coil lead and core

4.

it.

an

with If

RESISTANCE:

ohmmeter.

infinity in not indicated, replace

lESS

is

not within factory specifications,

THAN

1.00

it.

of

the stator coil

CHECKING STATOR

COIL

Engines

& Generators

60

STARTER

MOTOR

SERVICE

OVER-RUNNING

1.

Inspect the pin\on gear for wear any defect, replace the over-running clutch assembly.

2. Check that the pinion gear turns freely and smoothly in the over-running direction and does not slip in the

ing direction.

directions, replace the over-running clutch assembly.

COMMUTATOR

1.

Check the contact face

grind the commutator with emery paper worn.

2. Measure the commutator micrometer at several points.

If

the minimum O.D. is less than the allowable limit,

3. replace the armature.

If

the difference

4. correct the commutator on a lathe to the specifications.

5. Measure the mica undercut.

If

the undercut is less than the allowable limit, correct it

6. with a saw blade and chamfer the segment edges.

COMMUTATOR

MICA

UNDERCUT·

CLUTCH

or

damage.

If

the pinion slips or fails to rotate in both

AND

MICA

of

the commutator for wear, and

O.D. with an outside

of

the O.D. exceeds the allowable limit,

0.0. •

32MM

(1.25981N)

LIMIT-

31.4MM

(1.23621N)

0.50 • O.BDMM LIMIT·

(0.0197 • 0.03151N)

0.20MM

(0.00791N)

If

there is

if

it is slightly

factory

crank-

A

CAUTION:

starter paint

the

quality of grade to

the

"ange

and

between

terminal.

SEGMENT~DEP111

CORRECT

~

INCORRECT

~·WCA

OF

MICA

....

rust.

CHECKING

Before

and

moun1ing

Starter

the

wiring.

the

battery

performance

MICA

installing,

surfaces,

Use

wire

and

starter

thoroughly

remove

largely

depends

of sufficient

and

fully

clean

all old

size

tighten

the

on

and

61

DISTRIBUTOR

1

CAP

CHECK CAP

FOR

AND

EVIDENCE

OR

BURNING.

THESE

CONDITIONS

REPLACE

THE

DJSmiBUTER

CRACKS,

OF

ARCHING

IF

ANY

THE

DISTRIBUTER

WEAR

OF

EXIST.

CAP.

DISTRIBUTOR

Check

the

1.

Cracks

CAP

INSPECTION

following points. Replace

or carbon deposits.

2. Burnt or corroded terminals.

3.

Worn

distributor center contact.

3COVER

ASSEMBLY

if

necessary.

VACUUM

CONTROL

1

0-RING

NUMBERS SUGGESTED DISASSEMBLY

INDICATE

ORDER

THE OF

61GNITER

PICK-UP

ASSEMBLY

1QBREAKER

PLATE

IOTE:

When engaging the Distributer Drive into the Camshaft match the markings

·

engagement.

for

correct

HOUSING ASSEMBLY

Engines & Generators

62

SERVICE

DATA I STI'NDARDS

AND

LIMITS

..

BCG-

ENGINEiGENERATOR

Component

FRONT

CASE/COUNTERBALANCE

011

Pump

Side

Driven Drive

Counterbalance

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

Counterbalance

. .

Counterbalance

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

Counterbalance

..... ; ..........................

CYLINDER

C~llnder

Out-of-Roundness Taper

Gasket

CYLINDER

Aatness. overall Cylinder

Intake Intake

Exhaust · 0.3 Exhaust

Cylinder

0.05

0.25

0.50

Intake

Exhaust

Intake Exhaust Valve

Clearance Exhaust intake

Valve

Head

(intake) (Exhaust)

Valve

Length

(Intake) (Exhaust)

Valve

Stem

Intake Exhaust

Stem

to

Intake

Exhaust

Valve

Guide (intake) (Exhaust)

Clearance

Gear

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

Gear

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

Shaft

Front

Shaft

Rear

Front

Rear

1.

0.0014-

0.0014 -0.0028

..

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

BLOCK

Bore

of

Cylinder

Surface

and

Bore

Flatness

HEAD

of

Gasket

Surface

Helght

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

Head

oversize

0.3

0.6

Head

o.s

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

o.s

......... , ........

o.s

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

Valve

Seat

Valve

Seat

Valve

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

..................................... : ...

Thickness

.................... : ..................... 039

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

..................................... 3.960

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

O.D.

......... : .............

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

Guide

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

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

Length

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

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

rework

O.S

......

1.2323

o.s

.....

1.2441

O.S

....

1.1535 -1.1544

0.6

O.S

....

1.1653 -1.1662

rework

of

valve

0.4744-

0.4823 -0.4830

0.4921 -0.4928

Angle

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

Seat

Angle

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

Width

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

Seat

Width ...............

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

(margin)

:0.2585 -0.2591

0.2571 -0.2579

Clearance

0.0008-

0.0020 -0.0033

Specified

Value I Standard

lnches(mm) lnches(mm)

SHAFT

0.0024-0.0047

0.0027-0.0051 Journal

0.7869-0.7874 Journal

7317-1.7322 ( 43.984-44.000)

Journal

2.5591-2.5602

0.0004

0.0020

..

.less

4.287-4.295 dimension

-1.2333

-1.2451

guide

0.4751

3.968

1.949

(0.06-0.12) (0.07-0.13)

Diameter.

(19.987-20.000)

Diameter

Oil

Clearance

0.0027

(0.035 ~ 0.068)

Oil

Clearance

(0.035 -0.071)

(65.00-65.03)

(less· than

(less

than

th~n

0:

001

(108.9-109.1)

of

valve

(31.300

(31.600(29.300 -29.321)

(29.600 -29.621)

hole

(both (12.050 (12.250 -12.268) (12.500

.45"

30"

0.079

(2.0)

0.079

(?.0)

..

0.012

(0.30)

0.008

(0.20)

(1.0)

051

(1.3)

(100.6) (100.8)

(6.565 -6.580) (6.530 -6.550)

0.0020

(0.02-

(0.0050-

1.73

(44)

(49.5)

M1)

0.05)

~

(O.Oq) , .........

seat

hole

-31

;32~)

31.625)

intake

and

-12.068)

-12.518)

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

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

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

0.05) ...... 0.0039 (0.10)

0.0085)

Repair

0:0039

o.007D

exhaust)

0.004

020

031

..

0.0059

Limit

(0.1)

(0.2)

(0.1) (0.1)

(.5) (8)

(0.15)

Component

-VALVES

Valve

Guide

Service

Valve

Seat

Seat Valve Valve Valve Valve

Load/Installed ibs./ln Squareness

Width

Contact

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

Seat

Angie

Seat

Sink

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

Spring

Free

Spring

Height

(N/mm)

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

... ~ .... ~ ............................

TIMING -BELT

.

Seal

Une

Clearar~c~

ROCKER

Camshaft

Camshaft Diameter

Bearing End Rocker Rocker

PISTON

Piston Piston

Pistan

Piston Piston

Piston

Piston Piston

ARMiCAMSHAFT

Height

No.1

(lntake)

No.2

(lntake)

No.3

(intake)

No. 1 (Exhaust) No.2

(Exhaust)

No.3

(Exhaust) Journal

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

Oil

Clearance

Play

.................................... 0024-.0055

Shaft

Length

Arm

Shaft

Outer

Diameter

Ciearance

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

AND

CONNECTING

Outer

Diameter

to

Cylinder

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

Ring

Grove

No.1

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

No.2

..... , .......................

011

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

Service

Slze

Ring

End

No

.1

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

No.2

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

011

................................ : ...

Side

Clearance

No.1

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

No.2

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

0.0

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

Phi

Press-In

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

Specified

Value I Standard

inches(mm)

Size

0.05, 0.25,

of

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

Length

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

4611.48

.. , ...

. ,

..... : .... , .........

.........

.....

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

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

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

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

1.6118-1.6124(40.94D-40.955)

..........

0.0018-0.0033

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

.....

:.0.6687 -0.6692

0.0005-

0.50

035-.051

(0.9-1.3)

30"/44"/65"

1.823

(46.3)

(210/37.7)

.less

than

, .

.47

1.3815

(35.09)

1.3807

(35.07)

1.3803

(35.06)

1.3839

(35.15)

1.3831

(35.13)

1.3854

(35.190)

9.134

(232)

(16.985 -16.998)

0.0017

(0.012-

(0.045-ll.085 (.06-.14)

ROD

......

Clearance

Width

0.1108-

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

Gap

0.6300-

Load

lbs(N)

2.5579-2.5591

0.0008-

0.0480 -0.0488

0.0476-0.0484

0.25,

0.0059 -0.0118

0.0138-

0.008 -0.028

0.0012 -0.0028

0.0008-

11

02 -3307

0.0016

0.1116

0.50, 0.75,

0.0197

0.0024

0.6302

(16.001

(5000 -15000)

(64.97-65.00)

(0.02-

(1.22 -1.24) (1.21

(2.815-

(0.15 -0.30) (0.35(0.2 -0.7)

(0.03 -0.07) (0.02

oversize

.......

.. ,

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

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

2"

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

(12)

.

................. :1.

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

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

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

0.043)

0.04)

-1.23)

2.835

1.00

OS

........

0.50)

........

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

• 0.

06)

-16.007)

Repair

h'lches(mm)

0.008 (0.

1.

783

(45.3)

..4"

3618

(34.59)

1.3610

(34.57)

1.3606

(34.56)

1.3642

(34.65)

1.3634

(34.63)

1.3657

(34.69)

118

(.03)

......

0.004

(0.1)

0.0315

(0.8)

0.0315

(0.8)

0.0394

(1.0)

......

0.0047

0.0039

(0.12) (0.10)

......

Limit

2)

63

SERVICE

DATA I STANDARDS

AND

LIMITS • BCG

ENGINE/GENERATOR

Component

PISTON

AND

CONNECTING

Piston

Press-in

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

Connecting

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

Parallelism

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

Connecting Connecting

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

temperature

Rod

Center

between

Rod

Twist..

Rod

Big

End

Specified

inches(mm)

ROD

ordinary

length

.4.0138

4.0178

End

and

Small

0.004

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

to

0.004

Crankshaft

0.0039-

0.0098

Value I Standard

temperature

(1

01.95

-1

02.05)

End

(0.05)

(0.1)

Side

Clearance

(0.10-

0.25)

..........

Repair

Limit

inches(mm)

0.16

(0.4)

Component

CRANKSHAFT,

Crankshaft Crankshaft Crankshaft Cylindericity

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

Concentricity

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

Oil

Clearance

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

Oil

Clearance

Undersize

o.25

0.50

0.75

Undersize

0.25 o.5o

0.75

End Journal Pin

of

rework

u.s

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

u.s

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

u.s

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

rework

u.s

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

u.s

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

u.s

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

BEARING

Play

..........

O.D

.........

Journal

........

dimension

of

Specified

0.0020 -0.0098

...

1.5740

-1.5748

1.4165

-1.4173

and

Less

than

and

Less

than

0.0008 -0.0018

0.0009 -0.0020

of

Journal

1.5644

-1.5650

1.5545 -1.5551

1.5447 -1.54539

dimension

of

1.4069 -1.4075

1.3970 -1.3976

1.3872 -1.3878

Value I Standard

inches(mm)

(0.05 -0.25)

(39.98-

40.0)

(35.98-

36.00)

0.0002

(0.005)

0.0006

(0.015)

(0.021 -0.045)

(0.022 -0.052)

(39.735-

39.750)

(39.485 -39.500)

(39.235 -39.250)

(35.735-

39.750)

(35.485 -35.500)

(35.235 -35.250)

Repair

inches(mm)

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

......

0.0039

Limit

..

(0.1)

Engines & Generators

64

NOTE:

Grade4

6mm

bolt

8mm

bolt

1

Onim 10mm 12mm 1

2mm 1

3mm 14mm 14mm 16mm 16mm

Grade&T

6mm

bolt

Bmm

bolt

·1

Omm

1

Omm 12mm 1

2mm

12mm

Unless

head/nut head/nut

bolt

head/nut

bolt

head/nut

bolt

head/nut

bolt

head/nut

bolt

head/nut

bolt

head/nut

bolt

head/nut

bolt

head/nut

bolt

head/nut

bolt

head/nut

head/nut head/nut

bolt

head/nut

bolt

head/nut

bolt

head/nut

bolt

head/nut

bolt

head/nut

stated.

otherwise

Pitch

1

1.25

1.5

1.25

(ISO)

1.5

1.75

1.5

1.5 2

1

1.25

1.5

1.25

(ISO)

1.5

1.75

STANDARD

for a

specific

2.9-5.1

7.2-11.6

1a1-22.4

13.0-21.7

25.3-39.8

21.7-36.2 32:5-50.6

36.2-57.9

34.0-55.7

54.2-79.6

51.4-76.7

4.3-6.5

10.8-15.9

21.7-32.5

19.5-30.4

36.2-57.9

36.2-50.6

34.7-49.2

assembly,

lb-ft

HARDWARE

.

kg-m

0.4-0.7

1.0-1.6

1.9-3.1

1.8-3.0

3.5-5.5

3.0-5.0

4.5-7.0

5.0-8.0

4..7-7.7

7.5-1"1.0

7.1-10.6

0.6-0.9

1.5-2.2

3.Q-4.5

2.7-4.2

S.D-8.0

5.0-7.0

4.8-6.8

use

.

the

following

TORQUES

torque

values

Grade

7T,

8T

and

8.8

6mm

bolt

head/nut

Bmm

bolt

head/nut

1

Omm

bolt

head/nut

10mm

bolt

head/nut

12mm

bolt

head/nut

1

2mm

bolt

head/nut

12mm

bolt

head/nut

13mm

bolt

head/nut

14mm

bolt

heail/nut

14mm

bolt

head/nut

16mm

bolt

head/nut.

16mm

bolt

head/nut

Grade 5 Cap

1/4 1/4 5116

5116

318

7116

7116 1/2UNC 1/2UNF

Screw

UNC

UNF

UNC

UNF UNC UNF

UNC

UNF

when

1.25

tightening

Pitcll

1

1.25

1.5 (ISO)

1.5

1.75

1.5

1.5 2

standard

I

b-It

5.8-8.7

14.5-21.7

28.9-39.8

26.8-37.6

54.2-75.9

50.6-65.1

43.4-61.5

57.9-86.8

72.3-,08.5

68.7-101.3

108.5-166.4

101.3-159.1

9-11

11-13

18-20

.

21-23 28-33 30-35 44-49 50-55

a&.73·

73-80

hardware.

kg-m

0.8-1.2

2.0-3.0

4.0-5.5

3.7-5.2

7.5-10.5

7.0-9.0

6.0-8.5

8.0-12.0

10.0-15.0

9.5-14.0

15.0-23.0

14.0-22.0

1.2-1.5

1.5-1.8

2.5-2.8

2.9-3.2

3.7-4.6

4.1-4.8

6.1-6.8

6.9-7.6

9.4-10.1

10.1-11.1

'

PARTS

Taper Taper Taper Water

00

·

Side Seal Bearing

REQUIRING

Screw

112"

Screw

1/4"

Screw

1/8"

Dtain

Plug

Pressure

Switch

cap

No.

SEALANT

1

BOLT

DIAMETER

M6

M8

M10 M12 M14

lllread

Thread lllread lllread lllread

portion

portion portion portion

portion Periphery Contact

surface

(Gear

(Cylinder (Cylinder (Cylinder (Cylinder

(Main

4

0.3-0.5 0.8-1.0

1.0-1.3

1.8-2.5

3.0-4.2 5.5-7.5

5.0-7.0

SURFACES

(where

Bearing

with

to

mount

case)

Block Head Block Block Caps

Cylinder

REQUIRING

sealant

right

rear

right right

No. 1 and

Block

BOLT

HEAD

MARK

7

1.5-2.2

3.0-4.2 5.0-7.0

8.0-11.0 16.0-19.0

SEALANT

coated

parts)

side,

pump

cover)

surface)

side,

rear

middle

portion)

side

surface) No.

5)

10

1.0-1.3

2.5-3.5

9.5-12.0

SEALANT

Liquid

Teflon

Liquid

Teflon

Liquid

Teflon

Liquid

Teflon

Liquid

Teflon

Permatex

#68 #6B

Engines & Generators

1.

Carefully grease.

2.

Apply threads

3.

Tighten torque)

4.

Draw a line

5.

Draw

to

line

ANGULAR

wash

the nuts and bolts

a coat of molybdenum disulfide grease

and

setting

faces

of the

the

nuts

and

bolts

with

another

be

clamped.

(A-B).

a torque

CENTER

(A-B)

liNE

across

line

(C-D)

This

line should be

wrench.

tl1e

on

to

the

center of

tlle

to

nuts

specified

face

an

NUT

remove

and

of

all

bolts.

torque

each

bolt.

each

of

extension of

AND

to

oil

the

(snug

tlle

and

parts

tl1e

BOLT

TIGHTENING

6.

Draw

another

to

be

clamped. specified bolt.

7.

Use point

Example:

angle

a socket

where

Specified A B

c

D

E

METHOD

line

(F-G)

This

line

(Q)

across

wrench

the

30° 60° 90°

180°

360°

line

to

tighten

(A-B)

Angle

on

the

will

be

the

is

aligned

and 1/12 1/6

of a

1/4 of a

1/2

of a

One

face

of

in

the

direction

center.

(E) of

each

nut

with

Tightening

of a

tum tum turn tum

full

tum

each

or

bolt

the

Rotation

of

the

tl1e

of

nut

to

line

parts

the

or

tl1e

(F-G).

G

66

CAMSHAFT MD

999569

PISTON

Used

to

pull-out

the

piston

pin.

MD

999583

OIL

SEAL

SETIING

and

INSTALLER

BASE

press

in

SPECIAL

NOTE:

These special tools are available from

TOOLS • ENGINE

your local Mitsubishi Automotive Dealer

VALVE

STEM

SEAL

MD

998302

BEARING

For rear

MD

REMOVER

pulling

bearings

999593

out

(counterbalance

INSTALLER

the

front

and

shaft).

CRANKSHAFT MD

998376

PUSH

Used

to

the

piston

MD

999584

For

when

the

loosened

MD

998715

END

YOKE

For

supporting

when

the

loosened

MD

990767

REAR

ROD

AND

pull-out

pin.

supporting

camshaft or

tightened.

HOLDER

camshaft or

tightened.

the

OIL

SET

and

press

the

sprocket

SEAL

GUIDE

in

sprocket

is

INSTALLER

FRONT

BEARING

(Counterbalance

MD

999591

INSTALLER

(Counterbalance

MD

CRANKSHAFT

MD

OIL

999592

999570

PUMP

FOR

FRONT

OIL

SEAL

INSTALLER

shaft}.

THE

REAR

shaft).

OIL

SEAL

INSTALLER

OIL

SEAL

INSTALLER

Use panel start function. (ideal comf'ression test...

The OFR

An Electrical Jumper

a standard push button and two connected

Engines & Generators

67

ELECTRICAL

This

Electrical Jumper to by-pass the control

DC

breaker

JUMPER

on the control panel must be turned

( Owner fabricated )

when

or

to start the engine

can

easily be fabricated using

performing a

.

from

below).

wires.

BC

GENERATORS

DESCRIPTION

TheBC requires only the driving force

AC output. The stator houses two sets stator windings and the exciter windings. When the generator is started, residual magnetism in the four rotating poles induces a voltage in the larger voltage in the exciter windings. This mutual build up

of voltage in the four rotating poles and ings quickly reaches the saturation point and a regulated energy field is then maintained in the stator.

At the same time, this regulated field produces a steady voltage generator's AC

generator is a brushless, self-excited generator which

of

the engine to produce an

of

windings; the main

statbr which then generates an even

in

the exciter wind-

of

the capacitor(s)

in

the stator windings which can then be drawn off the

termina,Is to operateAC equipment. generator two-wire or at

Winding generator has 4 stator leads and can be configured to

120

Bearings: The bearings are sealed type and permanently

greased requiring no maintenance during their working life (approx.

is

a single-phase, reconnectable 120 volt AC

115

voltAC

50 hertz.

Connections: The single-phase synchronous

volt output.

30,000 hours).

two-wire or 230

voltAC

The

two-wire,

'

INTRODUCTION

The

following test procedures can be used to troubleshoot

WESTERBEKE'S 4 POLE DUAL BRUSHLESS

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

than one ohm and with a specific diode testing function. Basic electrical tools including cutters, soldering iron, wire

strapper/crimper, terminal connectors, etc. Repair

A

multimeter

parts

CAUTION:

use a large

quickly. make

certain

as

it

will

ROTATING

TO

TROUBLESHOOTING

EXCITER

GENERATORS.

such as diodes, fuses, bridge rectifier, etc.

(ON

enough

Excessive

melt

heat

no

soldering

the

insulation.

soldering

FIELD/AUXILIARY

Due

to the simplicity

(multitester) capable

SOLDERING)

iron

will

damage

splashes

WINDINGS

When

to

get

the

onto

CIRCUIT

of

soldering, the diodes.

the

of

the

reading less

job

done

Also

windings

A

WARNING:

same

distributor

cords

and

shut off circuit leave

hot

wires

AC

panel.

down

breakers

on

and

Be

DC!AC

will

the

supply

DC

circuits

certain

inverters.

not

do

the

side

often

to

unplug

Simply

job

of

the

share

since

panel.

tlie

AC

power

switching

it

will still

WINDINGS

Two sets

voltage is produced in two groups turns at its rated rpm. This AC voltage passes through each of

the rotor carrier bearing. The AC sine wave is changed to and this DC voltage is passed through the two groups rotating field windings producing a DC field around these

windings. This field affects the stator groups inducing an is available at the

of

windings are found in the

the two diodes mounted

AC

terminal block connections.

BC

GENERATOR

AC

WINDINGS

rototl

assembly. An AC

of

windings as the rotor

on

the isolated fixture just before

AC

winding

voltage in these windings that

of

the two main

TROUBLESHOOTING.,.

of

DC

68

BC

GENERATORS

' .

TROUBLESHOOTING

CHART

A,B,C,&D their

test

NOTE:

This

the

correct

FAULT No

AC

Residual

4-6

VAC

at

No-Load

High

AC

at

No-Load

refer

to

procedures

the

fault

finding

speed/hertz.

Output

Voltage

(Hot

N)

Output

components

in

the

following

chart

is

compiled assuming

CAUSE

Shorted Open Shorted

Faulty

Open Shorted Engine is

too

Electrical

are

Incorrect on

Incorrect Incorrect

on Engine

too

of

the

INTERNAL

pages.

stator

diode

.capacitor

exciter

speed

low

connections

faulty

voltage

capacitor

capacitor hertz

capacitor

speed

high.

(two)

(hertz)

tap

(hertz)

WIRING

the

DIAGRAM

engine

is

operating at

·

TEST/CORRECTION

B B

A

c

B B

Adjust* Inspect

wiring

connections

c

Adjust*

and

WINDING

MAIN

STATOR:

#1

TO

#3

#4

TO

#6

ROTOR:

(Each

pair)

EXCITER:

(Each

winding)

CHARGE

WINDING:

INTERNAL

RESISTANCE

VALUES

5.0KW

0.4 0.2

0.4

4.0

3.9

0.08

WIRING

(OHMS)

..

6.5lW

0.2

2.0

2.5

0.08

SCHEMATIC

Low

AC

60-160V

Voltage Under

Load

(or

at

No-Load)

No

Battery

Low

Battery

High

Voltage Output is

applied

Unstable

Noisy

Operation

Output

Drop

Charge

when

Voltage

Lolld

Faulty

rotor

winding

Faulty

diode

Faulty

capacitor

Faulty

diode

Faulty

capacitor

Engine

speed

is

too

Faulty Faulty BIOWil

Faulty

.

Engine is

too

·

Electrical are

faulty, Faulty Generator

connection is

loose

(hertz)

low

Bridge

rectifier

integral

fuse

(S)

wiring

speed

high

connections

loose

support

rotor

to

cqntroller

(hertz)

bearing

engine

A A

B

A

c

Adjust*

D D

B

Adjust*

Inspect

wiring

connections

Inspect

rear

bearing**

Check

rotor

.security**

A

·ROTOR

8 •

STATOR

C

·CAPACITOR

0

·BATTERY

WINDINGS

WINDING

CHARGE

WINDING

*

Refer

to

the

**Refer

GENERATORS

to

the

GENERATORS

OPERATOR

SERVICE

MANUAL

69

NO

AC

VOLTAGE

BC

OUTPUT

GENERATORS

TROUBLESHOOTING

EXCITER

WINDINGS

EXCITING

To

quickly determine a short or winding, excite the generator winding group

The between low.

NORMAL

12

-16

THE

GENERATOR

to

accomplish

AC

voltage that the generator will produce measured

the

line

and

neutral during excitation will be

AC

VOLTAGE

VOLTS

DURING

AC

---::

11=:::3--o

~::::

MAINST~~~R

with this

12

an

..

VDC

open in 12

the

main stator

VDC

using one exciter

EXCITATION:

s--o

50Hz

60Hz

very

·

• •

7 8 9

~

~.

9 7 8

~

~.

50Hz

60Hz

• •

EXCITING

Locate one of the exciter winding groups in the Unplug all connections from both capacitors. Connect VDC Winding group between

PROCEDURE

across

the

winding using the winding end connection,

generator.

#50Hz and #9.

12

'RBEKE

Engines & Generators

70.

BC

GENERATORS

REACTION

(Unit

NORMAL

1.

A very low AC output and loading and a growling boise 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 continuity should be found between the two isolated stator winding groups.

2. No reaction from the generator or drive engine. No AC output. This winding groups. Isolate the winding groups and verify and open winding.

No

Continuity

DURING

running -12

VOLTAGE

is

an indication

between

EXCITATION

VDC

applied

DURING

EXCITATIIN

of

an open in one

Isolated

Stator

to

winding)

Winding

IS

12

-16

of

the drive engine

to

ground. No

of

the main stator

Groups

VOLTS

AC

rMrM

65

432

1

TROUBLESHOOTING

No

Continuity

between

6 5

!!

Isolated

Stator

4

1!

Windings

---~E

FGROUND

TEST

EACH

WINDING

TO

CASE

GROUND

and

Ground

I

I I

I

l :

. J !

TEST

EACH

OF

INDIVIDUALLY

THERE CONTINUITY

THE

AS

SHOULD

BETWEEN

WINDING

SHOWN

BE

NO

LEADS

~

LEADS

!

Engines & Generators

71

BC

GENERATORS

TROUBLESHOOTING

TESTING

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 rnicrofared rating as would be necessary when troubleshooting a capacitor whose has dropped causing a low AC voltage output. In such cases, the capacitors rating MUST be verified accurately.

A

handling tlally power

CONTINUITY

WARNING:

as

lethal

source.

Capacitors

they

store

charge

even

must

electricity

when

disconnected

be

discharged

and

can

MF

rating

before

pack a poten·

from

their

DISCHARGING THE

CAPACITOR

MFRAT/NG

PRINTED CAPACITOR

CAPACITOR

NOTE:

When changing a capacitor due to a capacitor failure, reference the capacitor rating as printed on the body capacitor and order the correct replacement. Installing a

of

capacitor output voltage and installing a capacitor rating will result in low

a higher

RATINGS

25MFD

31.5MFD 35MFD

40MFC

MFD

AC

AND

PART

NUMBERS

Pn.#046875

Pn.#046978

Pn.#049627

Pn.#054730

rating will result in

of

a lower

output voltage.

IS

ON

of

highAC

MFD

THE

the

Engines & Generators

72

BC

GENERATORS

TROUBLESHOOTING

TESTING

AC

connections

may

This

winding capacitor saturating

imbalance of

The coMections

operating

EXCITER

The

by

producing

To

the

AC

the by way. indicate a faulty

THE

voltage

can

while

be

as

high

AC

voltage

for

each

discharges

AC

type of

the

rotor:

AC

voltage

on

at

its

WINDING

condition of

the

residual

with

do

this:

Unplug

electrical

volt

meter

generator

the

winding.

Residual

in

cOMection

and

EXCITER

be

measured

the

generator

as

350

to

400

build-up

capacitor

the

· reading

each correct

back exciter

filed

separate

that

is

no

is into

load

INTEGRITY

each

exciter

AC

voltage

the

generator

all coMections

for

coMects

Check

AC

across

observe

the

voltage

winding.

WINDINGS

across

the

capacitor

is

operating.

volts

AC.

accomplished

charges

taken

the

winding.

winding

affects

between

capacitor

speed.

the

capacitor

produces a phase-

the

auxiliary

with

(RESIDUAL

winding

each

ruMing at

each

the

residual

other

lower

exciter

from

winding

these

exciter than

can

winding

proper

the

two

AC

winding

listed

electrical

This

voltage

as

the

exciter

and

This

flow

windings

the

two

electrical

the

generator

AC

be

determined

should

no

load

capacitor.

end.

Place

coMections.

voltage

below

produced

in

the

will

the

of

VOLTAGE)

be

speed.

Locate

your

·

Start

same

MEASURING GENERATOR

SET ATAC

50Hz

~

THE

METER

VOLTS

60Hz

.

VOLTAGE RUNNING

DIAL

RESIDUAL

MEASURED 7-9

VOLTS

TESTING FOR

·

TO

WINDING

NO

CONTINUITY

METAL

THERE CONTINUIIY 50HZ

AND

GROUNDS

VOLiAGE

AC.

(EACH

BETWEEN

LEADS

CASE

SHOULD

BE

BETWEEN

19

TO

CASE

#50

NO

LEADS

WINDING

AND

#9

OF

GROUP)

EACH

GROUP

MAIN

LESS

THAN

MAIN

LINE

TO

(THIS

INDICATES

STATOR

NEUTRAL

WINDING

ONE

OHM

RESIDUAL

4-6

GOOD

FOR

EACH

AC

VOLTS

STATOR

RESISTANCE

WINDING

GROUP

VOLTAGE

WINDINGS)

/Engines & Generators

73

TESTING

THE

BC

ROTOR

Testing

out

removing

armature

the

generator

to

the

allow

can

bearing

access

THE

GENERATOR

IS

IDE.NTIFIED

BACK

GOVER

BY

FOUR

be

accomplished

support

for

the

testing

BY

THAT

HEX

SCREWS

bracket.

lJ.S

ITS

LOUVERED

IS

FASTENED

with-

Simply

shown.

tum

the

·

TESTING

Unsolder

fully

walled, With

rotating field/auxiliary windings interference

Check placing

THE

ROTOR

the

winding connection

remove

the

diode

deep

well

diode removed, both

from

the

resistance value of the rotating

an

ohmmeter's probes

FIELD

from

7/16" (llmm)

a possibly

its

faulty

WINDINGS

from

the

isolated

leads

across

socket.

for

will

be

diode.

the

heat

the

isolated

windings

two

diode

sink

first

exposed

and

care-

using a thin

group

of

with

no

by

leads.

TESTING

Rotate a

quick

test

ture

the

test of

the

connection

and

test

THE

armature

WINDINGS

into position

the

windings,

at

each

the

other

side.

THROUGH

to

access a diode.

assume

end

of

the

ROTATING WINDING

FIELD/AUXILIARY

RESISTANCE

4.0

THE

the

diode

diode.

OHM

DIODES

To

to

be

Tum

the

VALUE

make

OK

arma-

and

CONTINUITY

Check that

·

leads

and in

short

Repeat these tests on opposite side.

TESTING CONTINUITY (TEST

TEST

no

continuity exists between either of

the

generator shaft.

the

windings.

FOR

BOTH

LEADS)

the

second set

If

continuity

.

WINDINGS--

of

~\

.

c:::n____]

the

is

found,

windings on the

winding

there

is

a

74

BC

GENERATOR

-COMPONENTS

·CONTROL

BOX

INTERNAL

TYPICAL

ASSEMBLY

COMPONENTS

TESTING

THE··BATTERY

CHARGING

CIRCUIT

INTEGRAL

The Integral Controller (I.C.) unit that starting battery while the generator

Charging Voltage: Charging Amperage:

A separate bridge rectifier which converts the AC

I.

C.

unit. The

and

supplies a DC charge when one is needed.

that the I. low), check the charging circuit and it's components described in the following steps. Check all connections for

cleanliness and tightness including the ground before replacing the I.C. unit.

NOTE:

produce a low

the

generator

Testing

·

To

test positive(+) indicate the

battery voltage is indicated, check that the battery charger terminal between for

13.1V

charger.

CONTROLLER

'Supplies

C.

When

the

th~

13.1V

connections are tight. With the unit running, test

the(+) and(-) on the battery charger (as illustrated)

a DC charging voltage

·group

of stator windings supplies AC voltage to a

I.

C.

unit senses the needs

unit

is

faulty (that is,

the

generator

charging

is

operated.

Battery

battery charger, put a multimeter between the

arid

negative(·) leads

to

13.4V

to

13.4V.

If

FUSE·

INTEGRAL

WINDING:

Pn#43634

250V

(I.C.)

is

an encapsulated; solid-state

to

the generator's

is

opening.

13.0 - 13.40 volts DC

.5

- 12.0-

amps

DC

current to supply the

of

the starting battery

If

you suspect

if

thy

battery's charge

as

is

first started,

rate.

This

charging

Charger

to

with the engine running.

no charge is indicated, replace the

CONTRotLER

NO

TIME

30A

MDA-30.

the

rate

the battery.

DELAY

I.

C.

unit will

will

rise

It

should

If

only

Normal DC voltage running out

is

measured across the two DC connections

DC)

is

;1-

bridge rectifier; that DC voltage running from the bridge rectifier

'(approximate):

No-load Full-load

is

ds

BRIDGE RECTIFIER

2.

AC

Lift the two AC wire leads off the bridge rectifier and

measure, the resistance between these two leads with ohmmeter.

should exist between these two leads and the ground or the main AC stator windings.

3. Testing multimeter)

MOTE:

off

the

off

the

winding: 0.14

It

should measure 0.14 ohm. No continuity

the

Bridge Rectifier (meter used - FLUKE

Different types and/or brands

produce opposite test

A.

Set the

mete~

oq the Ohms scale

B. Connect the ( +) positive lead from the meter

#4. Taking the meter's negative(-) lead, momentarily

touch points #1, #2, #3, and #5. There should be no Ohm value registered on the meter.

C. Remove the positive ( +) lead from point

connect the negative(-) lead to points #1, arbitrary

D. Leaving the negative

· #5 with .the positive lead. The meter should register

•Ohm value.

E.

Place the positive(+) lead on point

'

(-)lead

value. Reverse these connections and the meter should register no

If

the rectifier fails any

replace the rectifier because it is defective.

#2, and #3. The ohmmeter should register an

Ohm value at each point it touches.

on point #3. The meter should register no Ohm

Ohm value.

and

generator

ohm

results.

(-)

of

the rectifier (in volts

of

the

-.

17.0 volts DC

18.5 volts DC

of

test

meters

may

..

to

point

#4 and

it.

Momentarily touch

lead on point #4, touch point

no

#I

and the negative

the previous tests

(B

- E),

an

Testing

1.

the

Battery

Bridge Rectifier

AC

Normal engine

two

AC

voltage running No-load Full-load off the generator 17.5 volts A C

veltage running to the rectifier (while the

is

operating at 1800 rpm) is measuredacross the

AC

connections on the bridge rectifier.

off the generator 16.0 volts

Charging

to

the bridge rectifier (approximate):

Circuit

AC

76

BATTERY

CHARGER

(I.

C.)

tmRNAL

WIRING

30A(spsde

Located

harness.

AC

GENERATOR

type)

FUSE

in

tne

wiring

BATTERY+

·

BATTERY

CHARGING

CIRCUIT I BRIDGE

RECTIFIER

TESTING

Note:

AC

output

circuits

Nonnal is

operating at its rated RPM) is measured across the ~o

connections on the bridge rectifier (shown below).

AC

VOLTAGE NO-LOAD FULL-LOAD

Nonnal is

measured across the two DC connections

rectifier,

THE

..--

The

battery

of

the

generator.

output,

but not the

AC

voltage running

TO

TH£

OFF

THE

OFPTHE

DG

voltage running out

that

is

+ and -

BAnERY

..........

.60HZ

charging

'BRIDGE

GENERATOR

CHARGING

-·o

circuit

The

reverse.

to

the rectifier (while the engine

RECTIFIER

as

illustrated.

CIRCUIT

is

totally separate from the

generator output-affects

(APPROXIMATELY)

16.0

VOLTS

AC

17.5

VOLTS

AC

of

the rectifier (in volts

of

the bridge

the

AC

DC)

TESnNG CONn

NUlTY

BEnNFEH

ACLEAOS

&

CASE

GROUND

TESTING

(meter used - FLUKE multimeter)

A. Set the meter on Ohms scale.

B. Connect the positive (

#4. Taking the negative (-) lead, momentarily touch points #1, #2, #3, and #5. There should be value registered on the meter.

C. Remove the positive ( +) lead from point #4 and

connect the negative (-) lead to it. Momentarily touch points #1, #2 and #3. the Ohm meter should register arbitrary Phm value at each point it touches.

D. Leaving the negative (-) lead on point.#4, touch point

with the positive ( Ohm value ..

E. Place the positive ( +) lead on point

(-) lead on point #3. The meter again should register

Ohm value. Reverse these connections and the meter

should register no Ohm value.

If

the rectifier fails

replace the rectifier as

..

TtiE

11RIDGE·

GROUND

+)

lead. The meter should register

any

of

it

RECTIFIER

lead from the meter to point

no

#1

and the negative

the

previous tests B through E,

is defective.

Ohm

an

#5

no

DC

VOLTAGE NO-LOAD FULL-LOAD

.

CHECKING

Lift the resistance between the #50 and the AC and the #60 and theAC.

RESISTANCE #50TOAC #60TO

two

AC

FROM

THE

BRIDGE

OFF

THE

GENERATOR

OFF

THE

GENERATOR

THE

AC

leads off the bridge rectifier. Measure the

RECTIFIER

17.0

18.5

WINDING

0.40hm·

0.3:0hni

(APPROXIMATELY)

VOLTS

AC

VOLTS

AC

Engines & Generators

76A

THE

ACJDC

VARY

PIN ON

MAY RECTIFIERS

LOCATIONS

SOME

BRIDGE

RECTIFIER

CHANGING

1.

Select the correct rated converting new

2.

Reconfigure breaker and

3.

Reconfigure the output connections to the breaker.

4.

Change the hertz connection on the Battery Charge

Circuit's bridge

5.

Change the hertz connection on the Exciter Winding

capacitor(s).

NOTE:

Models capacitor and

the

Reference

ACBREAKER

6.5

SBCG

11038798

5.4

SBCG

11038797

5.0

SBCG

11039082

4.2

SBtG

11038797

to.

Remove the

AC

breaker.

the

RED

6.5

SBCG-614 AND 5.4 SBCG-514

change.

5.4 SBCG-514 uses pn#046639. Service Bulletin

6.5 SBCG-614 uses capacitor pntto49627

NOTE:

230V/50H,z.

AC

terminal connections

isolation post.

rectifier.

#263.

Correctly

1.

6

GENERATOR

circuit breaker for the model

exis~g

breaker and install the

to

AC

TERMINAL

position

ISO~TED

POST

the

cas~

. ·

the

circuit

require

ground

new

VOLTAGE/HERTZ

6.

Shut off the 20 amp panel DC breaker. In the control move the # 1 dipswitch on the ECU (Electronic Control

Unit) to the corresponqing_position for the operating hertz

AC

desired. 2,

7.

The DC

60 hertz models pn#053082.

8. Open the generators Monitor the

NOTE:

a

capacitor connections capacitor.

STOPPED. .

9.

Close the AC breaker and load test the

ON for

3,

and 4 have no function.

circ~it

AC

No-Load AC'valtdge output

Change these connections only

OPERATION

SO

hertZ,

Rev-Limjter must be changed.

use·

pn#052854 and 50 hertz

AC

voltage

#7,

CONNECTIONS

wire

(white/green)

ISO~

TED

POST

onto

the

neutraVground

CIRCUIT

BREAKER

OFF

for 60 hertz. Dipswitches

breaker and start the

'and

hertz.

can

be

adjusted

#8,

or

#9.

One

of

with

generator.

terminal.·

2

box

models

engine.

either

the

REV·HIMITER

6.5

SBCG

5.4

SBCG

5.0

SBCG

4.2

SBCG

use

using

the

on

each

generator

#052854 11053082 #052854 11053082

L1

N

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

I I

I

ROTOR

WINDIN~

ill

I I

I

I I

I

I I I I

I I

. !

i J[l;l i

1 t£1 I

RDTDRWIND\

____

j

1

WHEN

CHECKiNG

CAPACITOR,

THE

CHECK

CAPACITOR

SAME

RATING.

EXCITER

OR

REP!-ACING

THE

AND

REPLACE

WINDING·

A O t

RATING

ON

WITH

I

STATOR

-----o3

r-------o4

STAmR

rrn

9,

8

7..

so11z

&ollz

~0

b

.CAPACITOR

WINDING

5

6

n

· 9 8 7

bt

CAPAJITOt

L1

·sBCG

GENERATOR

SCHEMATIC

&DI!z

50Hz

66

WINDINGS

..

Engines & Qenerators·

77

SPECIAL

TOOLS • GENERATOR

FIELD

FABRICATED

These

drawings

made

to

assist

en

gin~

and

in

A

local

machine

modest

price,

dealer

to

see

Housing

This

gently a

nut the tool any tor

HOUSING

(FIELD

Puller

tool

allows

pushed

of

the

same

pilot

tool

would

be

twisting.

end

is

removed.

PULLER

FABRICATED)

provide a

in

the

removal

the

replacement

shop

should

but

first

check

if these

tools

Tool

the bearing in

straight off

specifications

were

to

be

able

to

pull

Please refer

TOOL

TOOLS

means

by

which

simple tools

of

the

generator end from

of

the

generator

be

able

to

with

your

are

on

hand

the

generator housing

the

housing without any twisting.

as

that of the tapped hole

welded

the

to

on

bearing

these

the

drawings

1/2-13

eye

bolt

end

fabricate

local

WES1ERBEKE

for

loan.

end

of the eye

back

into place without

before tlie

UNC

Store-bought

with

tapered

on

these

tip.

the

tools

to

bolt,

genera-

can

be the engine.

at

a

be

If

in

this

Lifting

This end Eye use screw the Lifting Eye

Eye

Tool

tool allows a meehanic

from

the

engine

to

the

four screw holes located under

this

Lifting Eye, remove ihe generator's

by

attaching

to

the

to

safely remove

generator

.

Center

Jilting

baseplate

the

generator

this

Generator

end.

~.

2·1{;!"

(63.5

the

mm)

End

control

4

(6

Lifting

panel.

panel

HOLES

1/4"

mm)

>

eye

on

and

weld

securely.

To

and

r-"'"t--+--\-1,

2"

)&

/

112"

DriiiTyp. 4 holes

---

(12.7

'

mm)

\'

£)

Dia.

Disk

Alignment

l

This tool allows a mechanic

generator drive disks

Guide Pin. The Pin screws into the

guide.

Also the pin helps

drive plate's weight while removing

Tool

to

by

aligning the disks

to

support some of

safely remove

with

flywheel

or

replacing

and

the

install

the

acts

rotor

these

Drive

as

and

parts.

the

Plate

a

the

rmummumw

Material:

Cold-rolled

,_

Steel

... ! ...

1Umm

1·1/4"

M18 x 1.5

Tap

Material: One screwdriver slot cut

Pilot

Tool

Screwed into the end of the rotor shaft, this used

to

without damaging the stator windings.

used

at reassembly.

. . .

;-~

DRILL

f.S50l

(31.75

mm)

Pitch

1"

(25.4

mm)

Deep

M8

bolt with

in

(

PN.

043133)

pull the stator assembly away

I(

I

----/;

t

Deep

m~~EAW

· .

3.

MINIMUN

the

hex

the machined

13.50

(342.9)

--------------

s~~:~sEDGES.

EFFECTIVE

LENGTif•

head

end.

from

This tau!

..

I·O'

machined

tool

the engine

off

and

a

can

be

can

be

~

I

8.11"

~

R.13,

---·--:-~.

3.50

(88.~m)

.

PROPER

USE

OF

HOUSING

PULLER

.Engines & Generators

78

Material:

Aluminum

SHORE

POWER

TRANSFER

SWITCH

GENERATOR

:GENERATOR

~

N

~

;j;

.CJ

Q

z,

::1

0

a:

.----ili-+--.,--~-~L~

...

~-N_)

SHORE

POWER

230V

GOHZ

230

VOLT/50

HERTZ

L1

~

,GENERATOR/SHORE

::l

SWITCH

.....

' I

,

..

4,<-~.J

7

....

' I

-=-

SHORE

GROUND

HZ

TWO

WIRE

CONVERSION

_.....

®/

_

_..

CONFIGURATION

.

SHIP'S

LOAD

OJ:.

SHIP'S

-GROUND

NOTE~

at your

LOW

Ship-to-

Shore

PN

32008

(40Amps/Pole) PN

32009

(80

Amps/

PN

32010

(125

Amps/

PN

32133

(200

Amps/

S.~ip

to

shore

WESTERBEKE

PROFILE

Switch

(3

Pole)

switche.v

dealer.

Pole)

are

GASOLINE

Generator

~

N 01

.:.

1._

~;

_,.

;::'

ID

:c.

~

amilable

!

120

VOLT/60HZ

GENERATOR

NOTE:

Olegram

showa wire. 120-Voll system from thwgenerator. wllh three-wire, 120•Yoll boat system.

___

THREE

oonneollona

..._..:......,

WIRE

CONFIGURATION

MODELS

for

a two•

Switching

If

the circuit; Transfer

diagrarfls

simultaneous

1.

Reconfigure configuration/hertz desired. Reference elsewhere

NOTE:

is

correctly

2. Install output

3.

TI1e tion

4. The Exciter circuit connection

5. Install hertz operation.

6.

Open speed Governors voltage voltage if

NOTE:

7.

Close load test

Shore

installer

connects

this

mvst

Switch;

to

lhe

OFF

connection of

the

in

this

Ensure

the

positioned.

the

correct rated

leads

correctly

DC

battery

on

the

AC

on

the

correct Overspeed

the

AC

circuit

using

the

Control Board

between

needed

Stop

unit

AC

circuit

unit.

Power

be

done

Set

the

position.

AC

manual.

case ground

ch~e

terminal of

capacitor($).

one terminal ofeach capacitor(s).

speed adjustment buttons

Line

using capacitor

when

breaker,

to

shore power

by

means

tninsfet switch

This

shore

stator output

AC

circuit breaker

to

it.

circuit. Place the correct hertz

the

PC

breaker.

Start the engine

to

the

and

Neutral.

changing

start

Generator

to

the

of

the

shown

s~itch

power

leads

wire

(white/green)

charge circuit bridge

Place

Board corresponding

hertz

desired.

Adjust

taps

taps.

unit

and

Power

vessel's

AC

Shore

Power

in

ihe

prevents

to

generator

to

the

voltage

the

configure

and

connect

the

corresponding hertz

and

on

the

Electronic

Check

No-Load

#7,

#8,

or

#9.

monitor

AC

ou!Jiut.

illustrations

off

the

Neutral

the

connec-

rectifier.

to

adjust

engire

AC

output

voltage

AC

the

output

and

A

CAUTION:

before

switching vice-versa with

cause

heavy

damage

because

AC

generator.

A

CAUTION:

utility

shore

at

the

same

covered

under responsibility correct.

Heary

shore

loads

to

Damage power time.

the

to

make

motor

ponr

voltage

on

the

exciter

to

and

generator

This

type

warranty;

sure

leads

to

generator surges vessel

circuit

the

generator

output

of

generator

It

is

the

all

AC

connections

should

be

power

Induced

being

by

operated

components

can

result

are

connected

damage

installer's

shut

off

or

switching

may

in

the

if

is

nDt

are

Engines & Generators

79

REMOTE

STOP/START

PANEL

PN

049148

:

0

fWJWE~TERBEKE

0

T

Q

...

0!

....

_.

""

m

....

,_

%

!It

110

;

~

.

120

WHT/BLK/YEL

0

12

II

0

LL

~~

•

rl!;

X

Iii

u

REMOTE

REMOTE.

118

ORG

1118

GRN

·

fiB

WHTfBLKIREO

#16

WHTIBLKIBLO

120

WHt/BLK/BRN

YttWED

FROM

II 8 WHT

/BLKlREO

·~~~j

ST.ART

D

PANEL

HARNESS:

STOP/START

SCHEMATIC

.r-

-:t

111!

0

& ® 0

-<Y$G>

_,.

'-

WIRE:

SJ'DE

Q}

!----:-

PANEL

,_£._.

STOP

0

15'

Pn

049210·

30'

Pn

049211

50'

Pn

049667

75'

Pn

049668

1

DO'

Pn

WIRING

#49209

3-POSITION

·START/STOP qNTER

.

049669

DIAGRAM

SW.

OFr

O.P,

W.T.

E.T.

O,S,

lo.s.

t.t.

w.r.lo·•·J

t

~

"

120

WHT/BLK/GRY

t20

WHT

taLK

/GRN

Engines & Generators

80

I

2

3

a.

0

,_

V>

,_

a:

....

""'

V)

'>

'·

~

..

~

II

5

6

"'

w

"'

a:

Q,

_,

0

7

....

:IE,

...

....

1!1

!I!

....

8

11.·

•:IE

...

"'

><

..,

9

Q'

w

...

Q,

VI

...,

.

I

'"'

>

·o

5.0KW

and

6.5KW

SBCG

GENERATOR

SPECIFICATIONS

Engine

Type

Bore & Stroke

Total

Displacement

Bearings Compression Compression Hp@1800/1500 Firing Aspiration Direction Inclination Dry

weight

Governor

General Fuel

Fuel

6.5/5.4

Fuel

5.0/4.2 Fuel

(supply Fuel Fuel Air

Cleaner

(flame

Start

Starting

Starter DC

Charging

DC

Cold

Generator Engine

(all

models)

Engine

NOTE:

generators

Chamber. Ratio

rpm

Order

of

Rotation

Consumption

SBCG

Consumption

SBCG

Hose

Size

and

return) Pump Filter

(on

engine)

arrester)

Battery

Capacity

Cranking

Cooling

Combustion

Cooling

Forced

ventilation

compartment

ENGINE

(full

SPECIFICATIONS

3-cyllnder, w/counterbalance gasoline

2.56 x 2.61

40.3

cubic

Four

main

Semi-spherical

9.8:1

10.0 1-3-2 Naturally Counterclockwise 25°

continuous,

381

lbs

(172.8

Electronic

FUEL

SYSTEM

Throttle

body

Unleaded or

higher

load)

.7

GPH@

.6

GPH@

load)

.6

GPH@

.5

GPH@

1/4"

I.D.

12

volt

electric Replaceable Metal

screen

ELECTRICAL

12

Volt,(-)

Battery

must

generator charge

controller

800-1000 (minimum)

120

Volt,

Solid

state

Amps

150-176

AIR

REQUIREMENTS

225

-250

21

CFM

(0.6

100

CFM

should

be

temperature

4-cycle,,

overhead

shaft,

(65.0 x 66.3

(0.66

viewed

all

directions

Kgs)

injection

with

rpm rpm

3/8"

{high

pressure)

water

liters)

from

an

octane

I.D.

engine

inches

bearings

aspirated

fuel

gasoline

1800 1500

minimum-

cartridge-canister

type -cleanable

SYSTEM

negative

ground

be

totally

and

Cold

reduction-solenoid

controller,

amps

CFM

cmm)

(2.8

provided

below

dedicated

maintained

system

in

Cranking

Amps

12

amp

(6.3-

7.0

cmm)

to

maintain

122°

F

only

the

(50"

camshaft cooled

mm)

the

back

rating

maximum

type

to

the

by

the

AC

generator

(CCA)

mounted

rated

the

C)

DC

end

of

89

General

Fresh

Water

Raw

Water

Raw

Water

Cooling

Water

Operating

General Oil

Riter

Oil

Capacity Operating Oil

Grade

Single

Phase

Ratings:

5.0KW

4.2KW

6.5KW

5.4KW

Spark

Plugs

Ignition

Coil Distributor Spark

plug

Spark

Plug

Cylinder

Head

Bolt

Torque

General

Distributor

Spark

Plug

Spark

Plug

Ignition

liming

COOLING

Pump

Flow,

capacity

Temperature

lUBRICATION

Oil

Pressure

AC

GENERATOR

TUNE-UP

Gap Torque

Torque

IGNITION

Thread

Gap

SYSTEM

Fresh

water-cooled

water-cooled Centrifugal Positive

displacement,

belt-driven.

4.9

US

gpm

(approx.

measure

exhaust

elbow).

3.5

qts

(3.3

170°-190° F (77-

block

heat

exchanger

type,

metal

impeller, rubber

(18.51iters)@

before

liters).

88 o C)

through

discharging

SYSTEM

Forced

lubrication

Full

flow,

3.0

qts.

(2.81iters).

30 -50

psi

API

Specification

Brushless, 1800

rpm/60Hz,

120

volts,

230

volts,

120

volts,

230

volts,

by

paper

element.

(2.1 -3.5

SJ,SL

(Single

four-pole

1500

41.6

amps

18.2

amps

54.1

amps

23.4

anips

gear

spin-on

kg/em').

or

Phase)

capacitor,

rpm/50Hz

SPECIFICATIONS

14mm

12

volt

Breakerless

0.031 ± .002 1

0.8 -15.2 6Q-70 See

with

inches

lb-ft

Nm

(43-51

TORQUING

THE

ignitor

and

(0.8 ± 0.05mm)

ft-lbs)

CYLINDER

SYSTEM

Battery

Ignition

12

volts Distributor Ignition

coil

Solid

state

ignitor 11

mm x 1.25

0.028-

0.031

15°

BTDC

with

and

type

at

1800

pitch inches

ignition

spark

with

signal

(0.7-

RPM

negative

module

plugs

±1°

raw

circuit

belt-driven.

impeller,

1800

rpm

pump.

disposals.

SM

class

regulated.

pick-up

assembly

HEAD

ground.

and

ignitor.

generator

0.8mm

into

and

Engines & Generators

81

DECIMAL

TO

METRIC

EQUIVALENT

CHART

Fractions of

an inch

1/64 1/32 3/64 1/16 5/64 3/32 7/64

1/8 9/64 0.140625 5/32

11/64 0.171875'

3/16

13/64

7/32

15/64

1/4

17/64 .0.265625

9/32

19/64 0.296875

5/16 21/64 11/32 23/64 0.359375

3/8 25/64 0.390625 13/32 27/64 0.421875

7/16 29/64 15/32 31/64

1/2

Decimal (in.) Metric (mm)

0.015625 0.39688

0.046875 1.19062

0.078125 1.98437

0.109375 2.77812 39/64

Fractions of

an inch

33/64

0.03125 0.79375

0.0625

0.09375 2.38125

0.125 3.175

0.15625 3.96875

0.1875 4.76250 11/16 0.6875

0.203125 5.15937

0.21875 5.55625 23/32

0.234375

0.250 6.35000 3/4

0.28125 7.14375

0.3125 7.93750

0.328125 8.33437 53/64

0.34375 8.73125 27/32 0.84375

0.375

0.40625

0.4375

0.453125 11.50937

0.46875

0.484375 12.30312 63/64

0.500 12.70000 1 1.00

1.58750

3.57187 41/64

4.36562 43/64

5.95312 47/64

6.74687 49/64

7.54062 51/64 0.796875

9.12812

9.52500

9.92187 57/64

10.31875 29/32

10.71562 59/64

11.11250 15/16

11.90625

17/32 35/64

9/16

37/64

19/32

5/8

21/32

45/64

25/32 0.78125

13/16

55/64

7/8

61/64 31/32 0.96875

Decimal (in.)

0.515625

0.53125

0.546875

0.5625

0.578125

0.59375

0.609375

0.625

0.640625

0.65625

0.671875

0.703125

0.71875

0.734375

0.750

0.765625

0.8125 20.63750

0.828125

0.859375 21.82812

0.875

0.890625

0.90625

0.921875

0.9375

0.953125

0.984375

Metric (mm)

13.09687

13.49375

13.89062

14.28750

14.68437

15.08125

15.47812

15.87500

16.27187

16.66875

17.06562

17.46250

17.85937

18.25625

18.65312

19.05000

19.44687

19.84375

20.24062

21.03437

21.43125

22.22500

22.62187

23.01875

23.41562

23.81250

24.20937

24.60625

25.00312

25.40000

Engines & Generators

82

STANDARD

AND

LENGTH-DISTANCE

Inches

(in)

x

25.4

"'

Millimeters

Feet

(ft)

x

.305

=

Meters

(m)

Miles

x

1.609

=

Kilometers

METRIC

(mm)

x

3.281

(km)

x

.0621

CONVERSION

x

.0394

"'

Inches

"'

Feet

=

Miles

DATA

DISTANCE

EQUIVALENTS

1

Degree

1

Minute

VOLUME

Cubic

Inches Imperial Imperial Imperial Imperial

MASS·

Imperial Fluid

Ounces

US

Pints

US

Quarts

US

Gallons

WEIGHT

Ounces Pounds

Pints Quarts Gallons

Quarts Gallons

(oz) (lb)

PRESSURE

Pounds

Per

lnch.es

of

Inches

of

Inches

of

Inches

of

Inches

of

Latitude

of

Latitude

3

(in

x

16.387

)

(IMP

pt)

(IMP

x

29.573

(US

pt)

x

.473

(US

qt) x .946 = Liters

(US

gal)

x

28.35"'

x

.454

=

Sq

In

(psi)

Mercury

Mercury Water Water

Water

(Hg)

(Hg) (HzO) (H20)

(H20)

=

60

Nm

= 1

Nm

=

=Cubic

x

.568:::

qt)

x

1.137

gal)

x

4.546

qt)

x

1.201

gal)

x

1.201

=

Milliliters

=

Liters(L)

x

3.785

=

Grams

Kilograms

x

6.895

x

.4912

x

3.377

x

.07355

x

.03613

x

.248

=

111.120

1.852

km

Centimeters

Liters

(L)

=Liters

=

US

=

US

x

.034

x

2.113

(L)

x

Liters

(L)

(g)

x

.035

(kg)

x

=

Kilopascals

=psi

x

=

Kilopascals =Inches =

psi

x

"'

Kilopascals

km

x

1.76

(L)

x.88

(L)

Quarts.

Gallons

=

Ounces

=

Pints

1.057 x

.264

=Ounces

2.205

=

2.036"'

of

Mercury

27.684

(kPa)

x

.061

=

IMP

=IMP

x .22"'

(US

qt)

(US

=

Quarts

,;.

Gallons

Pounds

(kPa)

Hg

(kPa)

"'

H20

x

=in

pt

IMP

x

.833

gal)

x

.145

x

.2961

x

13.783

4.026

qt

3

x

gal

.833

"'

=

IMP

psi

Hg =

H20

=

IMP

H20

qt

gal

TORQUE

Pounds-Force Pounds-Force

Inches Feet

VELOCITY

Miles

Per

Hour

(MPH)

POWER

Horsepower

FUEL

CONSUMPTION

Miles Kilometers Miles Kilometers

Per

(Hp)

Hour

Per

Liter

Gallons

Per

Liter

TEMPERATURE

Degree

Fahrenheit

Degree

Celsius

LIQUID

WEIGHTS

Diesel

Oil= 1 US

fresh

Water Gasoline Salt

Water

= 1

US

(ln-lb)

(fHb)

x

.745

IMP

(MPG)

(Km/L)

US

(MPG)

(Km/L)

·

(°F) = (°C

(°C) = (°F

gallon=

US

gallon

=

gallon

x

.113

x

1.356

=

1.609

=

Kilometers

=Kilowatts

x

.354

x

2.352

x

.425

x

2.352

X

1.8) + 32

-

32) x .56

7.13

lbs

=

8.33

6.1

lbs

=

8.56

lbs

=

Newton

(Kw)

x 1.34"'

=

Kilometers =

IMP

=

Kilometers

=

US

MPG

lbs

Meters

Per

Hour

Per

MPG

(Nm)

MPH

Liter

Per

(Nm)

x

(KPH)

(Km/L)

Liter

x

8.85

.738

=

x

.621

(Km/L)

=in-lb

ft-lb

=

MPH

83

BOLT

HEAD

MARKINGS

STANDARD

HARDWARE

Metric strongest.

bolt

class

numbers

identify

bolts

by

their

strength

w1th

10

9

the

NOTES:

1.

2.

3.

Use These Reduce

STANDARD

Capsrew

Body

(Thread)

1/4 -20

-

28

5/16-18

-24

3/8-

16

-24

7/16-14

-

20

1/2-

13

-

20

9/16-12

-18

518-

11

-18

3/4-

10

-

7/8-

-

1- 8

-14

Size

16

9

14

(Inches)·

t'le

torque

values

listed

torques

are

based

torques

by

30%

BOLT & NUT

SAE

Grade

Torque Torque

FHb(Nm)

8

10

17

19

31 35

49 55

75 85

110 120

150 170

270 295

395 435

590 660

TORQUE

5

(11) (14)

(23)

(26) (42)

(47) (66)

(75) (102)

(115) (149)

(163) (203)

(231)

(366) (400)

(536) (590)

(BOO) (895)

below

when

specific

on

clean,

dry

threads.

or

more,

when

threading

SPECIFICATIONS

SAE

Grade

Ft·Lb

10

19

34

55

85

120

167

280

440

660

6·7

(Nm)

(14)

(26)

(46)

(75)

(115)

(163)

(226)

(380)

(597)

(895)

SAE

Torque

FHb(Nm)

105(142) 120

155

170 210

240 375

42!f\569) 605

675 910

990

torque

Reduce

capscrews

Grade

8

12

(16)

14

(19)

24

(33)

27

(37)

44

(60)

49

(66)

70

(95)

78

(106)

(163) (210)

(231) (285)

(325) (508)

(820)· (915)

(1234) (1342)

values

torque

are

not

by

10%

into

aluminum.

METRIC

Bolt Dla.

M3 M4 M5

MB M9

M10

M12 M14 M16

M18 M20 M22

M24 M27 M30

M33 M36

available.

when

Wrench

5.5mm 7mm 8mm

10mm 13mm 16mm

18mm 21

mm

24mm

27mm 30mm 33mm

36mm 41

mm

46mm

51

mm

55mm

engine

oil

is

BOLT & NUT

Grade

Ft·Lb

0.3

0.8

1.5

3

7

14

26 37 59

81

118

159

203 295 402

546 700

4.6

(Nm)

(0.5)

(1.1)

(2.5

(4)

(9.5)

(19)

(35) (50) (80)

(110)

(160) (215)

(275) (400) (545)

(740) (950)

Size

used.

TORQUE

Grade

FHb(Nm)

0.5

(0.7)

1

(1.5)

2

(3)

4

(5.5)

10

(13)

./18(25)

r

33

(45)

55

(75)

85

(115)

118(160) 166

(225)

225

(305)

288

(390)

417

(565)

568

(770)

774

(1050)

992

(1345)

SPECIFICATIONS

4.8

Grade

8.8 -9.8 (Nm)

(3)

(6)

(10) (25) (50)

(85) (140) (215)

(305)

(435)

(590)

(750)

(1100)

(1495)

(2035)

(2610)

Grade

Ft·L~.

1.5 3

(4.5)

6.5

11 35 55

97

(130)

151

~32

321

457 620

789

(1070) 1154 1571

2139 2744

Ft-Lb

1

(1.3)

2

4.5

7.5 18 37

63

103 159

225 321 435

553

811

1103

1500 1925

10.9

(N_Ij)}.

(2) (9)

(15) (26) (75)

(205) (315)

(435) (620) (840)

(1565) (2130)

(2900) (3720)

GASKETS/SEALANTS

Oil

based

PERMATEX

purpose

sealers.

coolant,

raw

A

light

coating

and

0-rings.

LOCTITE

hydraulic

filter

assembly.

Coat

both

surfaces

When

installing

sides

with

WHITE

High-copper ing

assembly.

Specialized Ing

non-hardening

copper

cylinder-head

#2

They

water,

oil

of

OIL

or

reel

of

the

gaskets

SILICONE

ADHESIVE

gasket

sealers

prC'perties.

qaskets

and

are

effective

or

fuel.

LIQUID

sealant

oil

pan

that

seal grease.

SPRAYS

such

it's

HIGH

TACK

in

just

TEFLON

should

be

gasket around

are

useful

as

HYLOMAR

as

it

resists

equivalent

about

can

used

with

water

for

is

particlarly

fuel.

any

be

used

on

high

(coolant)

holding

work

oil

SEALANTS & LUBRICANTS

Use

LIQUID

TEFLON

for

use

bolts

the

levels

grease

and

oil!

sealing

tape

sealants!

and

other

water

flywheel,

and

thread

yet

allows

of

locking

is

waterproof,

reciprocating

joint

oil

adapter

temp

well

and

are

excellent

in

contact

on

rubber

hoses

RED

SILICONE

passages,

gaskets

in

opplications

effective

water.

--

all

with

gaskets

and

the

oil

sealer.

coat

both

in

positio~

dur-

requir-

on

...

passages.

Do

not

BOLTS & FASTENERS/ASSEMBLIES

Lightly

oil plugs HIGH

When

Anti-seize threaded LOCTITE

LITHIUM ing

Heavily use

head

that

penetrate

TACK.

assembling

compounds components offers

based

boxes.

oil

all

clean

engine

sliding

84

pipe

plugs

fasteners

jacket

should

coat

the

locking

them

according

and

fillings

as

you

assemble

be

sealed

bolt

threads

adhesives

to

came

apart

to

the

ideal

for

water

components

such

job.

when

that

with

LOCTITE as

when

pump

assembling

them.

connect

coolant

Bolts

blue.

LOCTITE

protect

and

#2

Always

PERMATEX

necessary.

bearings

or

stuff-

jr~

'WESTERBEKE

~

WESTERBEKE CORPORATION • MYLES STANDISH INDUSTRIAL PARK

J 150

JOHN

HANCOCK ROAD, TAUNTON, MA 02780-7319 U.S.A.

1215/11-2015