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12.5KW-60Hz9.4KW-50Hz

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12.0KW-50Hz

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:\D~NEt-D1ESEL-GENERATORS

PUBLICATION NO.54600

REVISIONl

JANUARY 2010

~

WESTERBEKE

WESTERBEKE MYLES WEBSITE:

....

..,.~~

NMMA

--

CORPORATION • 150

STANDISH

Member

INDUSTRIAL

www.WESTERBEKE.COM

National

Marine

JOHN

PARK·

Manufacturers

HANCOCK

TAUNTON

ROAD

MA

02780

Association

I]

A

WARNING

Exhaust colorless unconsciousness

exposure

-Dizziness

-Nausea

-Headache

IF

GET seek until

WARNING

Generators

gasses

Weakness

YDU

DR

OUT

medical it

has

Produce

Regular

Maintenance

rry~~~;.~

contain

gas.

Carbon

can

include:

IIIId

ANYONE

INTO

THE

attention.

been

CARBON

Required

Carbon

Monoxide

and

death.

Sleepiness

ELSE

FRESH

Inspected

MONOXIDE

Monoxide,

is

poisonous

Symptoms

-

-Inability

EXPERIENCE

AIR

IMMEDIATELY.

Shut

down

and

repaired.

A

WARNING WESTERBEKE bulkhead

WESTERBEKE CARBON living/sleeping They obtainable

of

Throbbing

Muscular1lvitching

Vomiting

ANY

the

unit

DECAL

near

MONOXIDE

are

inexpensive

at

an

odorless and

Carbon

in

Temples

to

Think

OF

THESE

If

symptoms

and

do

is

provided

and

should

your

engine

also

recommends

DETECTORS

quarters

and

your

local

and

can

cause

Monoxide

Coherently

SYMPTOMS,

persist,

not

restart

by

be

fixed

to

or

generator.

installing in

of

your

vessel.

easily

marine

store.

a

the

CALIFORNIA

PROPOSITION

Marine

exhaust

are

known

to

cause

and

diesel

and

some

to

the

cancer,

other

reproductive

65

and

of

State

WARNING

gasoline

its

birth

engine

constituents

of

California

defects,

harm.

SAFETY

INSTRUCTIONS

INTRODUCTION

Read this safety caused

by

tions.

Know necessary precautions and your machinery. The following American Boat and

PREVENT

A

WARNING:

while

engine

power.

•

Do

not

enclosures

• Shut off electrical

equipment.

•

Use

insulated

equipment.

•

Make (particularly

•

Remove electrical equipment.

•

Do

not

circuits, except through a ship-to-shore double

transfer result if

• Electrical shock tor.

Discharge

PREVENT

A

WARNING:

exhaust

very

hot!

•

Always

recovery

A

WARNING:

•

In

case

before

lfUmual

failure

when dangerous conditions exist and

safety

ELECTRIC

is

Lethal

voltage

operate

and.

sure

your

shoes)

wristwatch

connect utility

switch. this

procedure

BURNS -HOT

system

check the engine coolant

tank.

of

an

touching

carefully.

to

follow fundamental rules and precau-

to

protect yourself, your

instructions

Yacht

Council (ABYC)

Most accidents

are

in compliance

SHOCK

00

not

touch

AC

electrical

running,

this

covers

mats

capacitor

Is

machinery

in

power

whenever

clothing

when

and

shore

Damage

results

Of

when

connected

pfesent

is

at

these

without electrical

place.

before

accessing

working

and

skin

are

handling

all

to

not

from

by

electrical

jewelry when

power

to

vessel's

shorting terminals

AC

followed. handling a charged capad-

ENGINE

00

not

touch

hot

engine

components. A running

level

Steam

can

cause

injury

engine

overheat,

the engine

allow

or

checking the

the

are

take

personne~

with

standards.

connections

to

shore

connections!

electrical

on

electrical

dry,

not

damp

equipment.

working

vessel's

AC

generator

together.

parts

engIne

at

the

coolant

Of

death!

engine

coolant.

throw

may

Of

gets

to

the

on

cool

the

PREVENT

A

. • Prevent

sparks pump, vapors. removing

•

Do

arrester

death.

•

Do Backfire

•

Do the engine/generator chances

•

Be

PREVENT

A

injury

• Follow re-fueling hatches closed after fueling.

•

• Make sure a

BURNS -FIRE

WARNING:

flash

fires.

to

occur

or

other

Use a

the

not

operate

removed.

not operate

can

cause

not

smoke

fuel

system.

of

fire.

aware -

diesel

BURNS -EXPLOSION

WARNING:

Of

death!

ning

the

blower.

starting All

when tilated area out of

Do Shut

the spill.

Do

your

fuel

vapors

handling

away

the

reach of children.

not

fill

the

off

the

fuel

system.

DO

NOT sources ing. fuel

Be Be

of

fire

Ensure proper ventilation

system. not alter or sure

all

fuel

certain

fuel

free ofleaks.

properly Extinguishers for

maintained.

all

applications

Fire

can

Do

not

near

the

potential

suitable

fuel

container

line,

with

a Coast

Backfire

with

the

severe

or

pennit

Keep

the compartment

clean

Wipe

up

fuel

carburetor,

and

Explosions

safety

when

fueling.

Check

below

Run

the

engine.

are

highly

and

storing

from

spark-producing equipment

fuel

tank(s)

service

Take

care

allow

any

near

the

fuel

modify

supplies

line

fittings

fire

extinguisher

Be familiar

rated

ABC

encountered

cause

injury

smoke

or

carburetor,

sources

air

flames

will

instructions.

valve

the

of spilled

to

or

Guard

can

cause

cleaner/silencer

injury

or

sparks

free

of

all

spilled

bum.

;fom

fuel

Open

for

fumes/vapor

blower

for

explosive.

fuels.

Store

while

the

.t

the

in

catching

smoking,

system

exists

fuel

system.

have a

positive

are

adequately

is

installed

with

by

the

NFPA

in

Of

death!

pennit

fuel

line,

fuel

catch

all

fuel

filters.

Approved

severe

death.

to

and

debris

to

fuel

and

vapors

Keep

and

ventilate

four

minutes

Use

extreme

fuel

engine

any

open

fiames,

or

engine when

shutoff

nearby

its

proper

are

this

environment.

flames

or

filter,

fuel

or

fuel

fuel when

flame

injury

or

removed.

occur

near the ruiniruize engine

oil.

can

cause

the vessel's

cabin

before

run-

before

care

in a well-ven-

and

is

running.

when

servicing

fuel that

servicing

tightened

appropriate

when

ruight

or

other

servic-

valve.

and use.

the

and

the

is

Engines

& Generators

i

SAFETY

INSTRUCTIONS

ACCIDENTAL

A

WARNING:

or

death!

• Disconnect the battery generator.

last.

it

•

Make starting.

•

Make re-installed before starting

BATTERY

A

WARNING:

or

death!

•

Do

not smoke or being highly explosive

arcing equipment during

• Never connect positive (+) connection Do

not test the battery together. Ventilate

accumulation of explosive

disturb

being

is

•

Avoid bums wristwatch, the

battery.

•

Always the

battery

and

reconnect it last

BATTERY

A

WARNING:

severe

STARTING

Accidental

Remove

certain

all

personnel

all

covers,

the

EXPLOSION

Batteryexplosion

allow

serviced.

Or

servicing.

the

contacting the

or

Lead

gas,

by lit

tobacco

in

the

vicinity

the

negative

Sparks could ignite battery

any compartment contaiuing batteries

battery

charger

charged.

sparks that could

rings,

and

turn

the battery

connections.

ACID

Sulfuric

injury

or

death!

starting

cables negative

are

guards,

the

an

open

acid

batteries emit

which

products.

to

prevent

(-) battery cable

terminal

condition

gases.

connections

terminals

cause

any

other

charger

Remove

when

disconnecting

acid

can

cause

injury

before

servicing

lead

fust and reconnect

clear

of

and

hatches

engine.

can

cause

flame

near

can

be

ignited

Shut off

electrical

of the starter

by

shorting the

gases

To

avoid

with

Iools,

an

explosion.

jewelry before handling

off before disconnecting

the negative lead

in

batteries

the engine/

the

engine

are

injury

the

hydrogen,

by

electrical

all

electrical arcing

to

solenoid.

or

fuel

sparks,

while

the battery

etc.,

the

battery.

can

cause

battery

the

10

Remove

before

a

terminals

vapors.

to

prevent

do

not

prevent

first

TOXIC

• Ensure that the

•

• For additional

•

EXHAUST

A

WARNING:

discharged regularly manifolds/water-injected

Be

sure the unit and

Run

Do

not equipped detector that boat builder or detectors.

(educational information

A

WARNING:

odorless nausea

Do fumes

systems.

copper tubing Do

through portholes, exhaust discharge outlet enter flow

• Although exhaust gas symptoms poisoning

Vomiting

Dizziness

Headache Nausea

AVOID

from

for

leaks

blowers

or

not

not install exhaust outlet

the

of exhaust.

is present in

when

run

the

with a functiOning

complies

information

gas.

Inhalation

death!

use

copper

can

rapidly

Exhaust sulfur

resulting

exhaust

diesel

fumes

or

signs

are:

MOVING

GASES

Carbon

monoxide

exhaust

generator

dealer

Carbon

system

the

engine.

and

make

elbow

its

surroundings

running

set

with

for installation of approved

monoxide

produces

(CO)

is

adequate

Check

sure

the

is

securely

the

generator

or

engine

marine

ABYCA-24.

refer

to

on

Carbon

(CO)

flu·like

.

tubing

in

diesel

destroy

discharge

Avoid engine

from

diesel

Inability Throbbing Muscular twitching Weakness

copper

causes

rapid deterioration of

in

exhaust/water leakage.

where

vents,

or air conditioners.

is

near the outlet

overloading

exhaust

gasoline

exhaust

of carbon

to think coherently

engines, monoxide

in

temples

and

sleepiness

gases

fumes.

tubing

and

PARTS

is a deadly

the exhaust system

exhaust

are

well ventilated.

set

unless

carbon

Consult your

ABYC

Monoxide).

is

an

to

expel gases

attached.

or

engine.

the boat

monoxide

T-22

invisible

gas!

symptoms,

exhaust

systems.

in

exhaust

exhaust waterline,

close

or

the

craft.

are

not

carbon

Some

inhalation or

Diesel

can

be drawn

If

the engine

water could

restrict the

as

toxic

monoxide

of

the

is

as

•

When

servicing

level,

wear protection. Batteries contain sulfuric destructive.

at

once

off into

the eyes inadvertently

caps.

the

rubber

If

it

comes

with

water.

battery

or

checking

gloves,

a rubber apron,

in contact with your

Acid

may

when

acid

splash

removing electrolyte

the

electrolyte

and

which

skin,

on

the skin or

eye

is

wash

it

...v'

WESTERBEKE

Engines & Generators

ii

A

WARNING:

or

death!

•

Do

not service the situation make operating touching components .

Rot~ting

arises

in which it

adjustments,

moving

engine

parts

can

while

it

is

absolutely use

extreme

and

hot exhaust system

cause

is

running.

injury

If

a

necessary

care

to

avoid

•

Do

not

wear

loose

equipment;'tie

jackets.

could

•

Make

Keep places

•

Do the

•

Stay when be

HAZARDOUS

A

shirts,

be

caught

sure

all

attaching

protective

at

all

times.

not

check

fluid

engine

is

operating.

clear of

caught

the

engine

in

these

NOISE

WARNING:

loss!

•

Never

operate

•

Do

not

run

an

removed.

•

Do

not

run

engines

open.

A

WARNING:

mentally

or

physically

clothing

back

long

sleeves,

an engine

in

moving

shields

levels

drive is

running;

rotating

High

engine

for

Do

not

rings,

shaft

noise

with

long

work

incapacitated

or

jewelry

hair

and

necklaces

parts.

hardware

and

guards

or

the

and hair

parts.

levels

without

the

air

periods

on

SAFETY

when

avoid

wearing

or

bracelets

is

properly

in

their respective

drive

belts

tension

the

transmission

and

clothing

can

cause

its

muffler

intake

(silencer)

with

their

machinery

by

fatigue!

'when

servicing

loose

that

tightened.

while

coupling

can

easily

hearing

installed.

enclosures

you

INSTRUCTI'ONS

ABYC, INSTALLING

Read for

recommendations

ABYC

"Safety Order

NFPA

are

NFPA

the

safety

(American

Staudards

from:

ABYC

3069

Edgewater,

(National

"Fire

Protection

Order

from:

NFPA

11

Tracy Avon Avon,

USCG

(United

"USCG Order

from:

U.S.

Washington,

AND

USCG

DIESEL

following

codes

Solomon's

Industrial Park

MA

33CFR183"

Government

and

MD

Standard

Drive

02322

States

D.C.

ABYC,

standards.

when

Boat

for

Island

21037

Fire

Small

Protection

Printing

20404

PUBLICATIONS

ENGINES

NFPA

and

USCG

Follow

their

installing your

and

Yacht Craft"

Rd.

for

Motor

Coast

Guard)

Office

engine.

Council)

Association)

Craft"

FOR

publications

OPERATORS

Many

of

in

your

notes

to

carefully,

procedures.

GASOLINE

Preparations

thorough Council's combination

Sections

H-2 P-l Exhaust P-4 E-9

All

installations

Regulations

MANUAL

the

preceding

Operators

highlight

maintain

ENGINE

to

install

examination

(ABYC)

of

sources

of

the

ABYC

Ventilation

Inboard

DC

Electtical

(FCR).

Manual

critical

must

safety

along

information.

your

equipment,

AND

an

engine

of

the

standards.

including

standards

Systems

Engines

Systems

comply

tips

and

warnings

with

other

cautions

Read

your

and

follow all

GENERATOR

should

American

These standards are a

the

of particular interest

with

INSTALLATIONS

begin

with

Boat and Yacht'

USCG

and

the

Federal

are

manual

sarety

the

Code

repeated

and

a

NFPA.

are:

of

~

WESTERBEKE

Engines & Generators

iii

TABLE

OF

CONTENTS

Installation

Parts

Introduction·

Serial Engine Testing Engine.Disassembly

Engine Assembly Thermostat Actuator

Heat

Exchanger hijection Injection

Governor Fuel

Injectors

Glow

Starter

Raw

Water Valve Air

Intake

Testing

Drive

........... ~ .................................................. 2 Oil

Ide

rr

Ica

rD'

Ion

rawlngs

n I

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

Number

Location

Troubleshooting

for

Overhaul..

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

Inspection

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

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

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

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

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

Pump

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

Pump

Timing

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

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

.~~

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

Plug

Testlng

Motor

Pump

Clearance

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

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

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

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

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

Engine

Belt

CompreSSion

Adjustment

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

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

.3

4

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

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

..4

5

9

10

16 28 34

.34

35 36

37 A

38

.40 .41 .42 .46

.48

.49

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

.49

Pressure Actuator Service

Alternator Wiring

#54193 1O-15Kw #54655 1O-15Kw #53477 5.5Kw EDCI7.6-15 EDT

#54628 5.5Kw EDCI7.6-15 EDT ..................

#54680 5.5Kw EDCI7.6-15 EDT

#52793 5.5Kw EDCI7.6-15 EDT ..................

Specification

Generator . Information BT

Generator

I t

mal

n e

BT

.

Troubleshooting 3 Phase

Voltage Torque Special Remote Remote Hardware Metric

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

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

Limits

Chart..

Testing

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

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

Diagrams

EDT

3 Phase .....................

EDT

Charts

3 Phase

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

24V

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

Single

FrequencyNoltage

W"

iring

Phase

D'

lagram

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

Changes

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

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

Regulator

Specifications

Tools

Oil

Filter

Stop/Start

Chart

Conversion

AdJustments

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

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

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

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

PaneL

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

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

Data

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

24V

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

...........

..

, ... : ...

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

50 51 52

54

57 58 59 60 61 62

63

68 70 75

78

79

81

82

83

84

85

86

.

~

WESTERBEKE

Engines & Generators

1

When

installing

attention

WESTERBEKE

be

paid

to

the

following

INSTALLATION

engines information:

and

generators

it

is

important

that strict

CODES

Strict when

AND

federal

regulations,

installing

REGULATIONS

engines

SIPHON-BREAK

For

installations

or

will

be

break

in

the

minimum

the

exhaust

raw

water

If

you

have

to

the

vessel's

siphon-break.

NOTE:

A operation. engine

damage.

EXHAUST

The

exhaust

prevent

of

the

water

vessels

where

below

the

vessel's

raw

water

of

20"

above

manifold

damage

any

doubt

waterline

to

siphon-break

Failure

to

Consult

SYSTEM

hose

must

from

entering

hull.

injection the

about

requires

properly

ABYC

and

generators

the

exhaust

waterline,

supply

the

vessel's

engine

the

under

the

siphon-break

be

certified

the

guidelines,

manifold/water

hose

to

waterline.

port

and

.position

the

vessel's

periodic

in a marine

provisions

the

exhaust

is

at

or

possible

of

the

various

inspection

and

safety

environment.

injected

must

elbow.

Failure

below

the

flooding

water-injected

operating

and

maintain a siphon-break

manufacturer

for

marine

use.

The

exhaust

under

any

sea

codes

mnst

be

exhaust

be

made

This

to

use a siphon-break

load

of

the

elbow

to

install

hose

must

waterline

boat.

exhaust

conditions,

.

cleaning

can

for

system

conditions

to

result

proper

must

ensure

in

catastrophic

maintenance.

be

and

complied

is

close

iI

siphon-

be

looped

when

will

result

elbow

relative

install

proper

designed

at

any

angle

.

with

in

a

to

a

AVAILABLE YOUR

DEALER

FROM

WESTERBEKE

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detailed engine can

and

be

obtained

Marine

Installation

generators

from

is

suppied

our

website

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~

covering

with

each

unit.

in

pdf

form.

WESTERBEKE

Eng/ntis & Generators

2

gasoline

and

Additional

diesel

copies

www.westerbeke.com.

PARTS

IDENTIFICATIO'N/GENERATORS

CONTROL

•

I

OIL

LEFT

SIDE

FRONT

RAW

WATER

PANEL

CONNECTION

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EXHAUST.

TEMPERATURE

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us

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.

The

following problems these

problems, problems.'This

these

the

need

ing

ENGINE

troubleshooting chart

relating

to

engine

service, the probable

and the recommendations to overcome

chart

may

for

an

engine overhaul.

be

describes

of

assistance

certain

causes

in

determin-

TROUBLESHOOTING

NOTE:

The

of

.

ampere mounted

engine's electrical

manual

on

reset circuit

the

same

bracket.

system

breaker.

is protected

The

preheat solenoid

by a 20-

is

PROBLEM

HARD

STARTING

LOW

CRANKING

1.

Engine

011

viscosity

2.

Run-down

3.

Worn

4.

Battery

5.

Defective

6.

Defective

DEFECTIVE

1.

Air

2.

Clogged

3.

Low

4.

Inadequate

5.

Injection

6.

Injection

MAIN

1.

Low

a.

b. c. d. e.

g.

2.

Burnt

3.

Faulty

4. Incorrect

5.

Governor

battery.

terminals

starter.

main

INJECTION

trapped

fuel

injection

pump too

ENGINE

compression.

Incorrect

Inadequate

Valve

stem

Broken

Compression

t .

Piston Worn

piston

glow

governor

spring

PROBABLE

SPEED

too

high.

loosely

connected.

drive

section.

SYSTEM

in

fuel

passage.

filter.

pressure.

spray.

delivering

early.

TROUBLES

valve

clearance.

contact

of

seized.

valve

spring.

leaks

through

ring

seized.

ring

and

plug.

plug

operation.

lever

out

of

POSITION

CAUSE

insufficient

valve

seat.

cylinder

cylinder.

posnion.

fuel.

head

gasket.

1.

Replace

2.

Recharge

3.

Replace

4.

Clean

5.

Repair

6.

Check

1.

Bleed

2.

Clean

3.

Adjust

4.

Clean

5.

Repair

6.

Adjust

a. b.

c. d. e.

t

g.

2.

Replace

3.

Correct

4.

Set

lever

5.

Correct

VERIFICATION/REMEDY

engine

oil

with

less

viscous

battery.

terminals

clutch

air

or

Adjust Lap

Replace Replace Replace Replace Overhaul

or

replace

for

from

fuel

replace

Injection

replace

or

replace

injection

valve

valve.

valve valve gasket. piston

engine.

glow

plug.

lead

wire

to

starting

spring

and

correct

cables.

starter.

disengagement.

system.

filter.

pressure.

nozzle,

injection

pump.

timing.

clearance.

and

valve

guide.

spring.

and

piston

ring.

connection.

position.

011.

lOW

LOW

OUTPUT

COMPRESSION

INJECTION

1.

Incorrect

2.

Insufficient

3.

Low

injection

INSUFFICIENT

1.

Airtrapped

2.

Clogged

3.

Contaminated

INSUFFICIENT

1.

Clogged

SYSTEM

injection

filter.

air

OUT timing.

injection.

pressure.

FUEL

in

fuel

system.

fuel

tank.

INTAKE

cleaner.

OF

ADJUSTMENT

AIR

Engines & Generators

5

See

HARD

STARTING

.

1.

Adjust

injection

timing.

2.

Repair

or

replace

3.

Check

1.

Check

2.

Clean

3.

1.

Clean

injection

and

retighten

or

repiace

tank.

or

repiace

injection

nozzle

filter.

air

pump.

and

adjust

pressure.

connector.

~ieaner.

(continued)

PROBLEM

LOW

OUTPUT

(cont.)

ENGINE

PROBABLE

OVERHEATING

1.

Low

coolant

level.

2.

Loose

V-belt.

3.

Incorrect

4.

Low

injection

engine

all

timing.

level.

TROUBLESHOOTING

.,

CAUSE·

1.

2.

3.

6.

VERIFICATION/REMEDY

Add

coolant.

Adjust

or

replace

Adjust

injection

Add

engine

oil.

)

V-belt.

timing.

EXCESSIVE CONSUMPTION

OIL OIL

FUEL

LEAKAGE

1.

Defective

2.

Broken

3.

Loose

4.

Loose

5.

Loose

6.

Broken

7.

Loose

OIL

1.

Worn

2.

Worn

3.

Incorrectly

4.

Displaced

OIL

1.

D~fective

2;

Worn

ENGINE

1.

Noisy

2.

Smoky

3.

Moving

4.

Poor

5.

Improper

6.

Improper

oil

gear

case

drain

oil

pipe

rocker

LEVEL

RISING piston piston

posit.ioned

or

LEVEL

FALLING

stem

valve

and

BODY

knocking.

exhaust.

parts

compression.

valve valve

seals.

case

gasket.

attaching

plug.

connector. cover

gasket.

cover

attaching

ring

..

or

cylinder.

twisted

connecting

seal.

valve

guide.

TROUBLES

nearly

seized

timing. clearance.

bolts.

piston

or

bolts.

ring

gaps.

rod.

excessively

worn.

1.

Replace

2.

Replace

3.

Retighren

4.

Retighten

5.

Retighten

6.

Replace

7.

Retighten

1.

Replace

2.

Replace

3.

Correct

I

4:

Replace

1.

Replace

4.

Replace a valve

1.

See

KNOCKING.

2.

See

SMOKY

3.

Repair

4.

See

LOW

5.

Adjust.

6.

Adjust.

all

seals.

gasket.

bolts. plug. oil

connections.

gasket.

attaching

ring. piston

ring

connecting

stem

or

replace.

COMPRESSION;

bolts.

and

rebore:cylinder.

gap

positions.

rod.

seal.

and

valve,guide.

EXHAUST.

HARD

)

STARTING.

SMOKY

EXHAUST

INSUFFICIENT

1.

Air

Intake

NOZZLE

1.

Seized

2.

Worn

IMPROPER

FUEL

LEAKS

WHITISH

1.

excessive

2.

Excessive

a. b.

c.

INTAKE

obstructed.

TRDUBLES

nozzle.

FUEL

OR

PURPLISH

engine

rtse

Poor

piston

Seized

piston

Excessive

AIR

011.

of

oil

Into

combustion

contact.

piston-to-cylinder

.

ring.

clearance.

E,?glnes & Generators

chamber.

1.

Remove

1.

Replace

2.

Replace. Replace Find

fuel

1.

Correct

a. b. c.

obstruction.

..

with

proper

leaks.

oil

level.

Check. Replace Replace

fuel.

or

clean.

or

correct.

(continued)

6

PROBLEM

SMOKY

EXHAUST

(cont.)

WHITISH

d.

Worn

e.

Low

I.

Excessive

3.

Injection

4.

Insufficient

ENGINE

PROBABLE

OR

PURPLISH

valve

engine

timing

compression.

stem

and

oil

viscosity.

oil

pressure.

is

too

(cont.)

late.

TROUBLESHOOTING

.

CAUSE

valve

guide.

3.

4.

VERIFICATIONJREMEDY

d.

Replace.

e.

Replace.

I.

Correct.

Adjust.

See

LOW

COMPRESSION;

HARD

.

STARTING.

(

ABNORMAL OR

NOISE

SOUND

BLACKISH

1.Engine

2.

3. CRANKSHAFT

1.

2.

3. CONNECTING

1.

2.

3. PISTON,

1.

2.

3.

4. VALVE

1.

2.

3.

4.

OR

body

a.

Poor

compression.

b.

Improper Insufficient Improper

Badly Badly Melted

Worn Worn

Bent

Worn Worn

Piston Piston

Worn

Excessive Worn Worn

fuel.

worn worn

bearing.

connecting crankpin.

connecting

PISTON cylinder. piston

seized.

seized

MECHANISM

camshaft.

valve timing fan

pulley

DARK

troubles.

intake

AND

bearing. crankshaft.

ROD

pin.

gear.

GRAYISH

valve

clearance.

air

(air

MAIN

AND

rod

big

rod.

PIN,

AND

and

ring

clearance.

bearing.

cleaner

clogged).

BEARING

CONNECTING

end

PISTON

worn

bearing.

RING

or

damaged.

ROD

BEARING

a. b.

2.

Clean

3.

Replace

1.

Replace

2.

Grind

3.

Replace

1.

Replace

2.

Grind

3.

Correct

1.

Rebore

2.

Replace

3.

Replace

4.

Replace

1.

Replace.

2.

Adjust.

3.

Replace.

4.

Replace.

See

LOW

Adjust.

air

cleaner.

wfth

proper

bearing

crankshaft.

bearing

bearing.

crankshaft.

bend

or

cylinder

piston.

piston

COMPRESSION;

fuel.

and

grind

and

check

replace.

to

oversize

and

rebore

and

rings.

HARD

crankshaft.

lubrication

and

replace

cylinder.

STARTING.

system.

piston.

ROUGH

OPERATION

INJECTION

1.

Uneven

2.

Control

3.

Worn

delivery

4.

Inadequate

GOVERNING

1.

Governor

2.

Fatigued

PUMP

SYSTEM

injection.

rack

malfunctioning.

valve.

Injection

SYSTEM

lever

malfunctioning.

governor

spring.

..,...

nozzle

spray.

WESTERBEKE

EngInes & Generators

7

1.

Adjust

injection

2.

Disassemble,

3.

Replace.

4.

Replace

1.

Check

governor

2.

Replace.

orreplace

check

Injection

shaft

and

correct

nozzle.

and

parts.

Injection

correct

pump.

operation.

(continued)

PROBLEM

KNOCKING

ENGINE

KNOCKS

1.

Main

engine

a.

Overheated

b.

Carbon

2.

Too

early'lnjectlon

3.

Too

high

4.

Improper

ENGINE

PROBABLE

WITHOUT

troubles.

cylinder.

deposits

in

Injection

fuel.

cylinder.

timing.

pressure.

TROUBLESHOOTING

CAUSE

MUCH

.'

SMOKE

2.

3.

4.

VERIFICATION/REMEDY

a.

See

OVERHEATING;

b.

Clean. Correct. Correct.

Replace

with

proper

fuel.

LOW

OUTPUT.

INTERMITTENT EXHAUST

OVERHEATING

LOW

SOUND

DlL

PRESSURE

KNOCKING

1.

Poor

2.

Injection

3.

Improper

1.

Fuel

2.

Fuel

3.

Water

1.

V-belt

2.

Damaged

3.

Lack

4.

Low

5.

Knocking.

6.

Moving

7.

Defective

1.

Worn

2.

Relief

3.

Clogged

4.

Diesel

WITH

compression.

pump

a.

Poor

b.

Poor

c.

After-injection

d.

Nozzle

filter

pipe

sucks

mixed

slackening

of

coolant.

oil

level

parts

thermostat.

Bearings. valve

011

dilution

DARK

malfunctioning nozzle. spray. chattering.

drip.

needle

valve

clogged.

air.

in

fuel

or

slippery

water

pump.

or

poor

seized

malfunction. cooler.

of

the

SMOKE

seized.

oil

quality.

or

damaged.

011.

•.

with

011.

1.

See

LOW

2.

Adjust/Repair

a.

Clean

b.

Repair

c.

Repair

d.

Replace.

1.

Clean

or

2.

Retighten

3.

Replace

fuel.

1.

Adjust,

replace

2.

Replace.

3.

Add.

4.

Add

or

change.

5.

See

KNOCKING.

6.

Replace.

7.

Replace.

1.

Engine

overhaul

2.

Overhaul

3.

Repair.

4.

Injection

COMPRESSION;

or

replace

or

replace

or

replace

replace.

pipe

jOints

or

clean.

replace

011

pump.

pump

repair.

HARD

nozzle.

or

replace

bearings.

STARTING.

pipe.

)

Engines

8

.&.

Generators

LCD

DISPLAY

FAULTS

(continued)

ENGINE

TROUBLESHOOTING

LCD

DISPLAY

FAULTS,

PROBLEM

LCD

DISPLAY

NOT

ILLUMINATE

LOW

OIL

HIGH

COOLANTTEMPERATURE

HIGH

EXHAUSTTEMPERATURE

BATTERY

GENERATOR overspeed Underspeed

LED

DISPLAY

TURN

WAITING

DOES

PRESSURE

VOLTAGE

FREQUENCY

(steady

(flashing

EDGES

PINK

FOR

ECU

LED)

PROBABLE

1.

Check

2.

20

amp

3.

Loose

4; 1

amp

1.

Oil

level

2.

Lack

of

3.

Ground

4.

Faulty

5.

Faulty

1.

Check

2.

Sea

water

3.

Check

4.

Faulty

5.

Ground

6.

Faulty

1.

Check

2.

FaultY

3.

Ground

4.

Faulty

5.

Sea

water

6.

Faulty

1.

Check

2.

Check

3.

Che,ck

4:

Faulty

1.

Check

2.

Check

3.

Amperage

4.

Crank (underspeed

1.

Compartment too

high.

1.

ECU

and

2.

Loose

3.

Panel

4.

Blown 8 amp

5.

Terminating

6.

Battery

CAUSE

ballery.

breaker

off.

display

connection.

fuse

blown

(faulty)

low/oil

leak.

oil

pressure

connection.

control

module

oil

pressure

system

pump.

water

temperature

connection.

control sea

exhaust

Connection.

control

fire alternator charge

battery

control

engine fuel

cycle

LCD

cable

DC

Voltage

sensor.

coolant

pump

sensor.

module

water

flow.

temperature

module

pump.

suppression

drive

voltage.

connections. module

speed.

supply.

load.

with

no

fault)

ambient

display

connection.

breaker

OFF.

fuse.

ReSistors.

to

•.

(ECU).

level.

drive

belt.

(ECU).

switch.

(ECU).

system.

belt.

(ECU).

start

temperature

not

compatible

ECU.

VERIFICATION/REMEOY

1.

Ballery

on.

2.

Turn

breaker

on.

3.

Check

all

cable

connections.

4.

Check/replace.

1.

Check

2.

Test

oil

filter.

3.

Check

4;'

Inspect

5.

Check

1.

Add

coolant.

2.

Inspect

3.

Adjust

4.

Check

5.

Check

6.

Check

1.

Inspect as

needed.

2.

Test/replace.

3.

Check

4.

,Check

5.

Inspect

6.

BY'pass

1;

Adjusttensionireplace

2.

Check

3.

Check + and·

4.

Check

1.

Check

2.

Inspect

3.

Check + and·

4.

Check

1.

Ventilate Nola:

display.

1.

Check

2.

Check

3.

Turn

4.

Check/replace

5.

Check per

resister

6.

Check

unplugged

present.

Determine

oil

level.

add

pressure.

inspect

ground

connection.

all

the

plug

sensor/replace.

Check

Impeller/pump/replace.,

belt

tension.

sensor/replace.

ground

circuit.

plug

connections/replace.

thru

hull

ground

circuit.

plug

connections.

impeller/replace.

system/check.

excitation.

cables

plug

connections/replace.

speed

selling.

filters/replace

cables

cause

for

compartment.

Heat

will

This

will

compatibility all

cable

ON.

check

fuse.

alilerminating

measured

between

from

ECU

is

cause

oil

and

repair

leaks.

If

OK.

test

oil

pressure

oil

pump.

connections/replace.

for

leaks.

replace

belt.

filling.

hose

and

strainer.

if

worn.

Replace/repair

from

filters.

from

no

start.

often

change

not

effect

with

connections.

DC

vollage

Check

resislors

across

pins

P2-24

ECU.

Power

faulty

.

alternator

ballery

to

Test

fuel

ballery

to

the

c%r

the

operation

Westerlink

across

breaker.

DC

voltage

ara

In

#4

and

P2-25.

turned

sendor.

Correct

engine.

pump

engine.

of

an

of

or

NMEA.

across

place.

and

#5.

P2

ECU

ON.

If

inspect

operation.

LCD

the

engine.

fuseholder

120

ohm

plug

voltage

Is

...

WESTERBEKE

Engines & ,Generators

SA

TESTING

FOR

OVERHAUL

HOW

TO

DETERMINE

Cause

Generally, is

power fuel is not necessarily

sometimes

wear.

many or inspection is a caused symptoms

of

Low

Compression

the

time

at

which

determlned

and

The

factors.

causes

good

by

various

outpu~

decreased

oil

consumption.

due

to

caused

by

injector

decrease

on

and

means of

by

wom

will

1 Low engine power ontput

in

It

is,

therefore,

the

basis

maintenance.

monitoring

cylinders

occur:

compression

of

2 Increased fuel consumption

3 Increased

4 Hard engine starting 5

Noisy

engine operation

symptoms

These can result

timing,

tion also

by

defective electrical

.

alternator,

judge

the compression pressure plus increased obtained eugine of operating haul, it is important pressure

which should be checked with engine front end of the

NOTE:

ADJUSTMENT section of

ouly

lacks·

fuel

will take place

regularly.

the measurement of compression pressure is

To

often

also

from

excessive

and

wear

of

starter

and

glow

optimum

properly.

test engine compression see the

engine

caused

oil

consumption.

under

sufficient

compression pressure, incomplete combustion

even

To

to

At

the

because

rpm.

The

engine

crankshaft.

ENGINE

conditions

compression

The

trouble

data

or piston

oil

consumption

appear

plugs

overhaul time

determlne measure

same

this

OVERHAUl.

an

engine should be

such

as

pressure, and increased

lowered

nozzle

necessary

produced

Oil

engine internal

together. fuel

and devices plugs.

by

compression

if

other parts of the engine

the compression pressure

rpm can be measured

manual.

engine power

with

the

engine iiself, but

wear

pressure

to determlne a cause by periodic

analysis

warn cylinders and pistons

Satisfactory combustion

the period of engine

the engine compression

time, the engine speed

on

rings,

Symptoms 2 and mjection, improper injecnozzles.

such

as

Therefore it

by

PERIOD

overhauled

lowered

or

is

a seasonal basis

the following

They

the

the lowered

pressure.

ENGINE

injection

caused

wear.

When

are

battery,

is

desirable

made at

engine

output

caused

If

is

pump

by

4

is

an

are

over-

at

varies

the

to

OVERHAUL

Compression pressure engine until piston Thereafter,

. of these parts.

When limit, the engine must be overhauled.

The engine requires

blowby evideut, and compression values below.

290

rpm.

not

exceed

Minimum

for

overhaul.

CONDITIONS

it

decreases

decrease

Engine

of

compression pressure

compression

Tlje

maximum

IO%.

compression

tends

rings

gradually

overhaul

difference

of

to

increase a little in a new

and

valve

seats

with

when

oil

should

be

between

384 psi (27

kglcm')

DISASSEMBLY

1. Before disassembly

defects

which

cleaning.

2. Drain

3.

4.

5. Perform disassembly in a proper order

6.

7.

8.

water,

Clean

or

wash

Do

not remove

disassembly.

Keep

disassembled necessary. from

Parts which parts its reproduced

Pay parts necessary,

Carefully check each part or component

faulty

tell accurately

Take

intrasion of

must

be

they

were

must

be

component,

at

attention

for their positions or directions. Put

to

condition

you

how

during removal or cleaning.

and

cleaning, carefully check

cannot

be

found

after

fuel and

restored set

assembly.

to

aid

it acted or what

oil

before

disassembly.

the

engine

exterior.

or

disassemble the parts that require

parts

in

order.

Apply

special

care

to

keep

dust

and

dirt.

to

their

respective

removed

aside

so

that

marks

assembly

during

at

disassembly.

separately

the

same

on

assemblies, ..

removal or

in

groups,

combination

was

abnonnal

have

been broken

the

progress

reaches

consumption is high,

are

30

kglcm',

disassembly

using

the

components

This

components

cleaning.

of

the

at

minimum or

427 psi at

cylinders

is

an

indication

proper tools .

oil

when

fuel

system

means

each

marked

or

set

on

marks,

fore

any

The part

about

wear

repair

must

for

and

no

parts

from

that

can

be

and

if

sign of

it

more

in.

all

for

will

)

ASSEMBLY

1.

Wash

all

parts,

except

for oil seals, O-rings, rubber

etc.,

with cleaning solvent and dry

2.

Always you

job.

3.

Use of oil, grease or sealant

4.

Be torques

5.

Ant a-rings must be installed.

use

tools

nnderstand

only good

sure

are

time the engine

how

quality

to

use a torque

specified.

that

are

in good condition and be

to

use

lubricants. Be sure

to

parts

wrench

is

assembled,

them

them before perfonning

as

specified

to

tighten parts for

new

with pressure

to

apply·a coat

..

gaskets and

-.,.y:

OVERHAUL

sheets,

air.

sure

any

which

When rebuilding

and

inspected.

and

the

altemator termlnal wire brush. Make certain the wiring connections that connect

Turn

the rotor pulley

Depending brushes

send it For additional information

ALTERNATOR

may

to

WESTERBEKE

Engines & Generators

9

CONDITIONS

the

engine,

The housing can be wiped off

on

when

the

need replacing.

a service

shop

TROUBLESHOOTING

the alternator

studs

by

hand.

It should tum

alternator

If

for testing and

on

alternators refer

should

to

the alternator

are the

was

should

with

be

cleaned

tight

and

wiring

smoothly.

last

serviced.

is

overhaul.

in

this

be cleaned

a solvent

with a

clean the

harness.

at

all

to

the

manual.

the

suspect,

ENGINE

DISASSEMBLY

(

GENERATOR

Disconnect wiring battery

NOTE:

Separate the exhaust

disconnect the fuel

Drain the engine

Carefully support and then from

Additional generator information

GENERATOR

PROPULSION

Switch off the batteries and disconnect the battery from

Drain or pump out from

Unplug the instrument panel ttansmission

Detach the

the

engine.

NOTE:

BLOCK

COOLANT DRAIN

NOTE:

A

coolant

hose

may

boss

plug.

be

in.

lieu

Remove

If

the transmission is not being rebuilt it should inspected. Flush out replace the coolant hoses. Inspect

linkage and the propeller shaft the

For

ttansmission WES1ERBEKE dealer or

center:.

the

AC

wiring

and

unplug

the engine's

harness

cables

Label

the

from

any

engine.

section

at

the generator control panel.

the engine

lines,

hoses

hose

supply

oil

and

See

SPECIAL

of

at

an<j

the

this

and

tape

or

cables

the

water

return

lines.

coolant

from

unbolt

the generator backend

TOOLS

will

be

manual.

injected

ENGINE

the

engine and

t1Je

engine and engine

ojl'

Label

any

PLUG

on

this

of

the

hosa·

transmission

transmission service and maintenance reter

tape

over

the

terminals.

all

the engine oil and drain

hoses.

wiring

harness. Drain

fluid

and the transmission oil cooler

cooler hoses

lines,

and

manual.

and

unbolt

hoses

or

cables

and

pressure test the oil cooler

and

coupling.

cbange the transmission

To

rebuild a transmission contact your

an

authorized transmission service

lubricate the

DC

Remove

over the

as you

in this

the transmission

tis

the

engine.

found

you

Clean

DAMPER

BOLTS

terminals.

separate

elboW

manual.

in the

cables

the

coolant

the

hoses,

separate

be

visually

and

gear

and

repaint

fluid.

to

your

PLATE

.

the

them.

and

from

them.

.

sbift

ENGINE

Take

•

• Arrange parts in the order

• Mount the engine on a suitable engine

With following

l.Remove the transmission damper plate

2.

3. Remove the engine heat exchanger.

4.

5.

6.

7. Remove the engine monnted raw water

S.

9.

COOlANT

lO.Remove the 1l.Reinove

l2.Unbolt the elbows and remove the exhaust manifold

l3.Remove the fuel injection pump. Disconnect the

NOTE:

and

l4.Remove the fuel injection nozzle

NOTE:

·

gasket

DISASSEMBLY

the

following

Oean

the

dirt

and

Be

careful not to

label parts as needed to insure proper reassembly.

disassembly.

the

lrljnsmission

step

engine flywheel. Remove

hose

connections

one

end

Remove the bell housing

preheat solenoid monnting braeket.

Remove the engine back plate. Remove the start motor, drive belt and

Label the wires

complete with its adapter mounting plate. See

WAT.l?R

With the hoses disconnected, remove the thermostat housing sender in

Remove the coolant circulatblg pump. Refer

engine block.

its entirety.

injection

PU\IlP

and

Put plugs or

nozzle

injection gaskets

Remove

scraper.

precautions:

exterior of the engine of

oil.

damage

Keep parts clean. .

separated

by

step

the

engine oil cooler and

from

of

each

hose

and

PUMP

for

and

housing gasket,

place.

CmCULATING

air

intake silencer and the intake manifold.

the oil

61ter

pipes

and

nozzles,

caps

connectors.

nozzles

from

with a wrench.

the

cylinder

the

gaskets

Discard

the disassembled parts.

of

from

procedure

connected

cables.

parts breakdown.

the

oil

and

to

cooler

leaving

PUMP

and the mounting bracket from the

fuel

leak-off pipe

on

the

openings

Golf

tees

work

head.

from

the

gaskets.

any

deposits of

disassembly.

the engine,

disassemble the

uil

to

If

to

the

the circuit breaker!

Mark

mating

stand

hoses. Note

the engine.

possible, leave

part being

begin

from

the

alternator.

pnmp,

and

for

engine.

the

removed.

RAW

the

temperature

to

ASSEMBLY.

from

the fuel

of

the

injection

well

as

plugs.

..

Loosen the

Remove

the

fuel

nozzles

.

cylinder

head

with

oil

fuel injection

or

the

in

pump

and

a

DAMPER

.

PLATE

'"

Engines & Generators

10

15.

Remove

a.

b.

c.

16.

Remove

a.

b.

17.

Fuel injection pump

a.

b.

18.

Remove

NOTE:

in11tallation.

19.

Remov~

blOCk

20.

Remo~e

a.

b.

governor Remove Remove

disconnect

Remove

Remove Remove

disconnect

the the

the

governor weight.

the the

the fuel injection pump.

Keep a record

..

the pressure relief valve from

.•

ii'·····

, :

, '

. .

th~r;;~ker

Remove

and

Remove

the

remove

the

assembly.

tie

rod

cover.

spring

from

the

tie

rod

from

governor

sliding sliding

tie spring

the

..

,"

.

\

'UNDER

. .

•

'.

bolts

the

valve

assembly.

sleeve. sleeve

removaL

rod

cover.

from

tie

rod

from

of

the

LOCATEiiJusr'

THE

FUEL

PUMP

DN

THE

ENGINE

BLGCK.'

..

-. ; .

shaft assembly.' ',' .

that

hold

rocker

shaft

caps.

the

tie rod

t\1e

fuel

shaft

the

tie rod

the

fuel

thickness

.

."

.

'

the

rocker stays

assembly.

ENGINE

with

pliers

injection

and

governor

with

pliers

fujection

of

the

shims

. .

.

to

pomp.

weigbts.

to

pomp.

for

in

position

DISASSEMBLY

23.

Remove the cyfuider head assembly. Lift head

straight

NOTE:

be

separated

Siile1WrtiOI:!

.

ORDER

up

with a hoist.

if

the

gasket

is

from

the

of

the

cylinder head

OF

DISASSEMBLY

seized and

cylinder

the

cylinder hedd

block,

tap

with

a plastic

the

cylinder

around

hammer.

cannot

the

)

thick

"'iIIISASSEMIBLlIIG

•

ROCKER

21.

Disassemble the rocker shaft assembly. Put tion

on

each

rocker

arm

as

to its location

shaft.

22.

Remov~

head

.

NiltE:

the before

the .cylinder head bolt. Loosen the

bolts

in

two

or three

it

~ny

p~ris

cylinder head bolts for

loosening

them.

07

$3

.5

.12

steps

in the sequence

on

the

g,iinde~

tightness

G9

.10"

.14

.13

head

1118

SHAFT

are

with a

THE

ASSEMBLY

identifica-

on

the rocker

cylinder

shown.

faUlty, torque

.

check wrench

)

"

CYLINDER

HEAD

BOLT

LOOSENING

SEQUENCE

".3'tYEINDER

.

11

(

VALVE

SPRING

REMOVAL

•

24:

Removethe valve

a.

Compress the

, remove

b.

Remove

NOTE:

be cylinder

25.

Remove the valve stem

NOTE:

",

26.

Remove the flywheei. a.

wrench

b.

in

c.

Install a Remove the remaining bolts .

.

d.

the

The

valves,

set aside separately

./lumber,

Do

not

Have

someone hold the crankshaft pulley

to

Remove one of the bolts'that

position.

safety

in

the

flywheel

Hold the crankshaft. facilitate

'

and

valve

retainer,

retainers,

for correct

reuse

prevent

bar (MI2 x

from

flywheel

Joggling

removal.

,

valve spring.'

spring with a valve lifter

lock.

spring and

in'

groups,

se31s

the

valve

the

flywheel

which the bolt

by

hand and withdraw it

the

valve.

springs and valve

each

tagged for

installation.

with

pliers.

stem

seals.

froin

rotating.

hold

the

1.25)

into the

was

flywheel

back and

,

ORDER

OF

ENGINE

lock.!

with

flywheel

threaded

removed.

from

forth

DISASSEMBLY

and

must '

a

hole

the

to

DISASSEMBLY

27.

Remove position. removing

28.

Remove the oil seal case

ey

the Pull the

it.

the

linder

blC)ck

A

CAUTION:

rear plate.The rear plate

plate

as

straight

oil seal case. Remove the bolts that hold

in

position.

with a

Do

Remove

screwdriver.

not

caUSB

seal.

29.

Remove cylinder

NOTE:

is

, 30. Remove the crankshaft pulley.

the

tappet.

block

with a valve

The

tappets

removed

REMOVING CRANKSHAFT

B. Install two

,holes

, "between

prevent it

b.

Remove

before

THE

PULLEY

safety

in the

rear

the

safety

from

the crankshaft

Remove

will

fall

the

tappets

bars

end

of

bars

rotating.

the

push

into

are

(MI2 x

tile

.crankshaft.

to

hold the crankshaft

pulley.

is

as

possible when

the case from

damage

tappets

rod.

the

'oil

pa~

removed.

1.25)

doweled in

to

the

oil

from

the

'

if

the

camshaft

BAR

into the

threaded

Put a bar

the

to

A

WARNING:

heallY

gloves

to

When

avoid

removing

hand

injury.

the

flywheel,

wear

A

WARNING:

,pulley,

slips

be

oft

the

When

pmpared

crankshaff

rBmoving

to

stop

to

the

Job

prevent

crankshaff

in

case

the

injury.

bar

'

,

12

ENGINE

DISASSEMBLY

TIMING

ORDER

OF

GEARS

DISASSEMBLY

·12

FUEL

.

'PUMP

'REMOVE

AS

NUMBERS

.

SUGGESTED DISASSEMBLY.

iNJECTION"

CAMSHAFT

12

THRU

AN

ASSEMBLY

INDICATE

ORDER

a

14 .

THE

,

OF

.

IDLER

GEAlf

.

REMOVE 9 THRU

AS

AN

ASSEMBLY

.14

INJECTION

PUMP

CAM~I:IAFT

11

1.;J~r.'nINu.

CAMSHAFT'

\

/

Q

t:RANKSHIIFT

PULLEY

7TIMING

'....v'

GEAR

CASE'

WSTERBEKE

Englnes-& Generators

i

13

31.

Remove hold

32.

Timing gear backlash measurement. lash ment.

the timing gear case.

the

timing

A

WARNING:

timing

gear

case.

plate

along

with

of

each

gear

and

case

The

Do

the

keep

in position

front

plate

not

attempt

timing

a record

if

the

Remove

and

Is

to

gear

case

fOr

backlash

ENGINE

the

bolts

that

remove

bolted

remove

by

Measure correct measure.

exceeds

the

Inside

the

this

tapping.

the

back·

the

limit.

DISASSEMBLY

37.

Remove the oil pump.

case.

pump

to

the

cylinder block

38.

Remove front hammer

39.

Remove the oil pan.

a. b.

tIie

plate in

to

separate

Turn

the

engine

Tap

the

bottom comers

hammer

A

pan the oil

to

CAUTION:

by

Inserting a screwdriver

011

pan

can

front plate.

position,

remove

and

be

the

upside

the

Do

the

result.

Remove

and

Remove

Tap

the

gasket.

down.

of

the

oil

pan.

not

attempt

cylinder

the

bolts that hold

remove

plate lightly with a plastic

block.

oil

four

P!'ll

to

or

a

the

pump.

bolts

with a plastic

pry

off

chisel

Damage

the

that

hold

the

oil

between

to

the

oil

MEASURING' TIMING

,

GEAR

BACKLASH

TIMING

GEAR

BACKLASH

CRANKSHAFT GEAR· CAMSHAFT GEAR PUMP

CAMSHAFT

FUEL GEAR

33.

Remove the out

34.

Remove

a.

b.

GEAR

IDLER

GEAR

GEAR·

AND

FUEL

CAMSHAFT

INJECTION

AND

Remove

INJECTION

GEAR/P.T.O.

OIL

PUMP

the idler

gear

in a direction

of

mesh.

the camshaft.

Pull

the camshaft

PUMP

AND

IDLER

GEAR

CAMSHAFT

GEAR

the

bolts

IDLER

GEAR

gear.

that out

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

of

Th

the

hold

of

the

remove

STANDARD.

0.0016··

0.0047

(0.04'

0.12mm)

0.0031

·0.0075'10

(0.08·0.19mm)

0.0028·

0.0079

(0.07'

0.20mm)

the

idler

helix

of

the

teeth

the

thrust

plate.

cylinder

block.

LIMIT

In

0.01.18

In

(0.30mm)

..

'o~dm

(0.30mm)

In

0.0118

(0.30mm)

gear,

rotate 4 I

to

pull

.

In

it

40. Remove the oil screen.

screen in position

8~~

9---.~,u

10

6

~

INDICATE

t-UlJ,----5

.

_

~

...

Ji

.•....

THE.

OROER

OF

11----i~

3~

... . ...

NUMBERS SUGGESTED

.

DISASSEMBLY

and

. \

ORDER

Loosen

the

remove

the

screen .

OF

DISASSEMBLY

nut that

holds

the

oil

A

CAUTION:

or

bearing

35.

Remove the fuel injection pump camshaft.

a.

Remove

b.

Thp

the rear end

push

it out of the

36.

Remove the gear ( when required). gears

from

camshafr,

use

Joumals

the

stopper

the

camshafr

an

arbor

Do

not

cause

when

bolt.

of

the camshaft

front

side of

and

press.

damage

removing

the

fuel

injection

the

with

a copper

cylinder

To

remove

to

the

lobes

camshaft

bar

block.

the

pump

.

C'(LlNIIERiii.IICK

to

Englnes-& 'Gene;ators

CRANKSHAFT PISTONS

OIL

PAN'

AND

.

14

""""'1"<'--1

ENGINE

41.

Thrust clearance measQrement for connecting rod big end. Install

the

cap

clearance

limi~

THRUST

CLEARANCE STANDARD: LIMIT:

MEASURING· THRUST

FOR ROD

CLEARANCE

CONNECTING

BIG

END

42.

Remove the connecting

a.

Lay

b.

Put identification

combination

c.

Remove

43. Remove the piston. a.

Thrn

b.

Push

crankshaft with the

piston and

removal

the

connecting rod

nuts

to

the

specified

with a feeler<

replace

the connecting

0.0039'

0.0138

0.0197

in

to.50mrn)

•

the

cylinder block on.its

on

as

to

the caps.

the

crankshaft

the

piston and connecting

rings

are

above

connecting

of the

rod.

other

to

torque.

gauge.

If

rod.

in

rod

cap.

each

connecting

its

location in the

until

the piston is

handle

of a hanuner until the

the

cylinder.

Repeat

steps a and

pistons.

its

the

side.

rod

crankpin

Measure

clearance

rod

engine.

at

top

away

Remove

b for the

REMOVING PISTON

and

tighten

the

thrust

exceeds the

and

cap

center.

from

the

the piston

.

DISASSEMBLY

46.

Remove the crankshaft.

A

CAUTION:

bearings.

NOTE:

Put

identification

location

47.

THE

in

the

engine.

Separate the piston from the connecting rod.

a.

Use

Piston Pin Setting

the

connecting

b. Insert the push rod

for

piston

remove

c.

Also

connecting rod

A

piston

.

requires a <greater

the piston pin

the piston

use

the Piston

.

CAUTION:

by

Do

not

on

each

rod.

of

pin.

to

the

Do

not

tapping.

force

cause

main

Tool

to

the

tool

and,

Setting

piston.

attempt

Replace

for

removal.

damage

separate the piston from

into the

using an

Tool

bearing

to

remove

any

piston

to

the'

as

bore

arbor

install

to

in

press,

the·

the

its

the

which

)

44. Measuring the crankshaft end play. Set a dial indicator

so

that

it

will

touch

the

end of the crankshaft and measure

the

end

play.

If

the end

flanged

CRANKSHAFT

STANDARD:

45.

bearing.

END

PLAY

0.00197·

LIMIT:

Remove the main bearing cap •

••

b.

c.

<Lay

the

side<up.

Remove

position.

Remove

hanuner.

0.01969

cylinder block with its bottom

the bolts

Remove

the

frcint

0.00689

In

(0.500

that

the

and

play

exceeds the

In

(0.050·

0.175mm)

mm)

hold the

caps. . rear bearing

main

limit,

(oil

bearing

caps

with a sliding

replace the

pan).

caps

in

15

PISTON

___

'PU!;"

ROD

TOOL

<CONNECTING

"CONNEC:TlNG

ROD

CYLINDER

HEAD'AND

CHECK THREADS

'"

VALVE

CHECK

CHECK IN

BORE

MECHANISM

OIL

HOLES

FOR

WEAR

. .

..

.

ENGINE

CLOGGING

' .

INSPECTION

1.

Cylinilei:'

a feeler gauge,

positions;

shown in

refaee.

WARPAGE -CYLINDER

STANDARD LIMIT'

head.

lengthwise,

the

ihe

bottom

Usil1g

check

ilfustration.

face

HEAD

0.0020

0.00391n

a

he~vy

the

accurate straight

bottoril

face

for warpage in three

edge

two crosswise and two widthwise

If

warpage

with a

IiOTTOM In

(0.05mm)

((0.10mm)

surface

FACE

MAXIMUM

exceeds the

grinder.

limit,

and

as

INSPECT

TEST

SPRING

CHECK AND

€.\l.'~-INlfpEl:TFOR

CLOGGED

FOR.

WEAR

OIL

HOLES

2.

BORE

DIAMETER

CLEARANCE

AND

.

FOR

WEAR

-INSIPECT

(iUU,lAIV I

OFF

SCALE

DEPOSITS

GALLING

FOR

AND

CRAcKS, LEAKS.

CLEAN

CARBON

OIL

Rocker

roclier

arms

arm

. rocker shaft

shaft.

If

the

rocker

arm.

shaft.

IN

ROCKER

STANDARD

OF

STANDARD STANDARD

LIMIT

SHAFT

BETWEEN

~INSI~EClr~N~

CYLINDER BOnDMFDR

WARPAGE'

IIDd

rockershaft. Measure the bpre

for

the

rocker shaft

to

find

the clearanee between the

clearan~e

has reached

and

the

di!lljJ.eter

limit, replace

If it exceeds the limit, replace both

ARM

FOR

SHAFT

0.74449 -0.74527 FOR

ARM

0.74331 -0.74401 ROCKER

0.00047 -0.00197

0.00787

(0.200mmr

ARM

In

(18.910

In

(18.880

AND

SHAFT

in

(0.012 -0.050mm)

-18.930mm)

-18.898mm)

arm

THE

HEAD

in

of

the

and

the and

the

k

__

-INSPECT .

ORDAMAGE

INSPECTFO

..

WEAR

AND

CONTACT

CHECK

ENDS

FOR

WEAR

AND

DAMAGE

~---INSPECT

FOR

RIDGES

FOR

BEND

Engines & Generators

16

MEASURING AND

ROCKER

SHAFT

ARMS

ENGINE

INSPECTION

3. Valve springs.

the'squareness andlor replace

VALVE

SPRING SPRING

the

SPRING

STANDARD

LIMIT STANDARD (1.54

STANDARD

LIMIT

FREE

SQUARENESS

TEST

FORCE·

in

(39.1mm)

spring.

Check

free

.

LENGTH

1.85

In

(47mm)

1.81

in

(46mm)

1.5'

MAXIMUM

LENGTH

30.6 ± 1.5

13.9 ± 0.7

·15%

the

Squareness

length

UNDER

Ib·n Kg·f

exceeds

TEST

and

FORCE

free

the

length.

limit,

If

CHEJ:KING

5. Valves, valve guides

a.

Measure

the

illustration.

it is

abnormally

VALVE

STEM

.

EXHAUST)

INlET

VALVE:

EXHAUST:

VALVE

the

diameter

DIAMETER

STANDARD

LIMIT STANDARD

LIMIT

(NORMAL

If

STEM

WEAR

and

valve seats.

of

the

valve

the stem

worn,

0.25846 -0.25905

0.25591

0.25709 -0.25787

0.25591

is

replace

SIZE

0.260

In

in

(6.500mm) (6.500mm)

stem

woni

beyond the

the

valve.

in

(6.6mm)

In

(6.565 -6.580mm)

in

(6.530 -6.550mm)

MEASURING.

DIRECTIONS

as

shown

limit,

INLET

in

or

ANO

4:

V.d~~

p~h

check

for

bend.

push

rod.

BEND

(DIAL

INDICATOR

LIMIT

0.012

INSPECTING BEND

OF

THE

ROD

.:.

...;;.i.:

U,;j~g-V=-blocks

If

the:.bend

READING)

in

(0.3mm)

Mj\](I.iIIUM

yxeeeds

OF

VALVE

and a

the

PUSH

dial

limit,

ROD

indicator,

replace

.

the

THE

PUSH

1------

.

b.

The

valve

than

any

the

stem

to

find

the clearance whichever

CLEARANCE INLET

EXHAUST

BETWEEN

VALVE:

l

guide

wears

more

other

parts.

Measure

at

its

ends

with

clearance between

exceeds

STANDARD

LIMIT

the limit, replace

is

badly

worn.

THE

STANDARD

LIMIT

VALVE

0.008 -0.0020

0.0039

. :

MEASURING

.

THE

VALVE

rapidly

an

inside micrometer caliper

STEM

in

0.0020 -0.00336

0.0059

at

the

bore

the

stem

the

AND

VALVE

In

(0.02 -0.05mm)

(0.10mm)

in

(0.15mm)

its

both

in

the

guide

and

guide.

guide

GUiDE

In

(0.05 -0.085mm)

or

1.0.

GUIDE

ends

for

If

valve

OF

the

''''''WESTERBEKE

I Engines & Generators

17

ENGINE

INSPECTION

'

(

VALVE

CYLINDER

HEIGHT

TO

NORMAL

c.

Valve

(1) Remove the

(2) Install a

(3) Insert a

(4) Mter the

(5) Put a

0.39±,0.02o (io±0.5

GUIDE~t7r..."._-,·_......;t,-'

HEAD

'

THE

TOP

OF

THE

SIZE

0.39

in

(lOmm)

guide replacement.

guide

pushing it

bottom

with a tool

side

of the head.

new pushing it of

the

head

guide

with

is

new

until

obtained.

valve

valve slides in the

valve

valve contact with

small

amount

the

valve

face.

tool

(commercially

, the seat

to

check

VALVE

guide

an

the

guide

Hold the

--}

from

the

cylinder head

and

an

into

the cylinder head

arbor

press

specified

into

the

guide

freely.

has been.replaced, check

its

seat.

of

Prussian blue

valve

available)

its

contact.

In

mm)

_"

e

:.

'"

.e

ill

..

by

arbor

press

from

by

from

the upper

height

to

and

make

or

with a valve

and press it against

the

read

side

top

sure

lead

lapping

the

of

the

on

GOOD

CONTACT AROUND CIRCUMFERENCE

VALVE

AND

6. Valve refacing.

a.

Set

the

valve

valve.'

b.

The valve

margin

is

refaced,

margin

seems

replace the

MUST

THE

COMPLETE

VALVE

SEAT

n;facer

must not

to

be less

BE

UNIFORM

CONTACT

at

an

angle

than

valve.

be

less

the limit

of

45°

than

and

'

the

when

grind

limit.

the

If

the

valve

LAPPING VALVE

IN

THE

SEAT

(6) The width of contact must be uniform

(7)

VALVE

MARGIN

STANDARD LIMIT

'(8)

around

reface

If

limit, replace the

the

If

the

a:

closed

both

the

valve

(LIP)

THICKNESS

0.039

0.020

valve

seat

and

valve.

valve

and

seat

margin

(valve

valve.

In

(l.omm)

In

(0.5mm)

sinkage (the dimension

to

the

face

,exceeds the lintit, recondition the

VALVE

SINKAGE'

STANDARD LIMIT

replace the

cylinder

0.020 ± 0.0098io

0.05910

head

(1.5mm)

/

all

the

way

If

the contact is

bad,

lip thickness) exceeds the

from

the

top

of cylinder head)

valve

seat

or

assembly.

(0.5 ± 0.25mm)

of

7. Valve seat refacing.

a. Before refacing the

valve and

face

FACE:

SEAT

0.098

valve

seat with a

availlible),

finish

to

the correct

STANDARD

0.051 -0.071

In

(2.5mm)

between the

necessary,"

b.

Curthe (commercially grinder, of seat

ANGLE

OF

WIDTH

OF STANDARD LIMIT

SEAT

VALVE

valve

and

the

seat,

guide,

valve

or

width

values.

45"

In

(1.3

grind it of

check

the

clearance

and replace the

seat cutter

with a valve

valve

seat and

-1.8mm)

guide

seat

the

if

angle

Engines '& Generators

18

c.

After

refacing

the

valve

8.

Valve

lapping.

refacing a.

or replacing the

Put a small amount-of lapping

seat.

face

Be

the

and

sure

valve

lap the

to

seat,

valve

lap

valves

put lapping

in

the

valves

or

valve

compound

OF

VALVE

•

0.071

ENGINE

c.ompound

valve

seat.

in

the

seats

after

seats.

on

the

valve

SEAT

IN

(1.3 • 1.8MM)

INSPECTION

on

9.

Combustion

only

jets

a.

b.

when

To

remove

round

bar through the bore

glow

plug

To

install a

with

its tangential orifice

of the main chamber

jet

replacement.

they

are

the

jet, inseit a

and

tap

around

new

jet,

I-L.

__

'\UU'\U

L

__

Replace

cracked

put

and

or

defective.

6mm

(O.2Sin)

in

the

cylinder

the

jet.

the jet

in

position

in

alignment with the center

tap it

with

a plastic

BAR

COMI~USTIIONJET

the

combustion

diameter

head for

in

the

head

hammer.

NOTE:

Do

not

Use a lapping

lapping

and a compound lapping. Mixing

the

compound

help

put

the

b.

Using

rotate seat,

rotating it to a

against the operation cutting

c.

Wash

the

solvent.

d.

Apply

e.

Check the

put

lapping

compound

of

120

to

of

finer

with a sl'fIIlll

compound

a lapping it

only

property.

valve

engine

on

the

valve

tool,

hold the

a part of a turn, then ralse the

new

position. Press

seal

for another part of a

until

the

compound

and

valve

seat with dry

oil

to

the

valve

face

for contact.

. -

on

th~

150

meshfor'initial

than

200

amount

face

uniformly.

valve

wears

and lap it in

valye

stem.·

mesh

for

finish

of

engine

oil

against the seat

valve

off its

the

valve

turn.

Repeat

this

and

loses

its

c1earting

the

seat.

will

and

COMBUSTION

JET'

\

j

LAPPING

VALVE

IN

SEAT

APPLYING

COMPOUND

LAPPING

Engines

19

-&

Generators

ENGINE

INSPECTION

GEARS

CHECK

TEETH

TIMING

BEARING

CHECK

FOR

AND

WEAR.

NOlllE

WEAR.

BURRS.

GEARS

AND

(S'PINAIING)

OR

CHIPS

FLYWHEEL·

CAI\lSHAFT

INSPECTION

GASKET

POINTS

TAPPET

INSPECT

FOR

,,~n

__

(

CRANKSHAFT

INSPECT

BELT:

':':"~:.-

r-----:-----"TINII.A

iii",;",..,

.

FLYWHEEL

CHECK OR

RlOGES.

OR

WEAR

CONTACT

CHECK

TO

TEETH.

FACE

GEAR

FOR

GEAR

CASE

<(io

CRACKS/DISTORTION

GASKET'

SCORING

FOR

OA~'AGE'--

CHECK

__

FOR

BEND

-=-_--.i

OR

DAMAGE

TO

THE

LOBES

FOR

OAMAGE/AGING

Engines & Generators

20

10.

Camshaft

Measure

a.

bushing

the

illustration.

replace

CLEARANCE

BETWEEN

STANDARD

the

for

the

diameter

the

shaft

If

the

bushing.

THE

CAMSHAFT

0.0059

of

to

clearance

In

(0.15mm)

the

joUrnal

find

the

JOURNAL

and

clearance

exceeds

AND

ENGINE

the

bore

as

shown

the

limit,

BUSHING

INSPECTION

in

the

in

(3)

Measure

LOBE

the

lobe

in

the

illustration. Subtract lobe'height exceeds'

HEIGHT

STANDARD LIMIT

the

OF

CAMSHAFT

height

to

find

limit,

1.4063

1.3669

and

the

lobelift.

replace

in

(35.72mm)

in

(34.72mm)

base

the

camshaft.

circle

baSe

If

circle'

the

as

shown

lobe

from

lift

the

.

MEASURING

JOURNAL

b.

Use

Camshaft

camshaft

(1)

Remove cylinder, block. block.

CAMSHAFT BUSHING

THE

Bushing

bushing

the

push

Crush

CAMSHAFT

Installer(

replacement.

oil

pan.

Using a "remover"

out

the

bushing into

and

take

out

~pecial

tool)

end

the

cylinder' .

the

bushing

from

CAMSHAFT

for

the

of

the

11.

Fuel injection pump camshaft.

and

.

LOBE

base circle

base

circle

the

lobe

HEIGHT

OF STANDARD LIMIT

from

lift

FUEL

as

shown

the

exceeds

INJECTION

1.73

1.69

lobe

the

In

(44mm)

in

(43mm)

~~~~MIEASURifo"

MEASURING' DIRECTION

Measure

in

the

illustration.

height

to

limit;

replace

PUMP

CAMSHAFT

..,.,.-:-----.¢

MEASURING

LOBE

.

THE

the

Subtract

find

the

lobeliftc If

the

camshaft.

.....

LOBE

HEIGHT

FUEL

INJECTION

CAMSHAFT

THE

HEIGHT

OF

CAMSHAFT

lobe height

the

THE'

OF

THE

PUMP

(2) Install a

.

in

---+-11--

new

alignment

bushing

with

..

~~

in position

those

of

the

oil

-L.JF~"~-"-cW

0.04in·(1

mm,..JL

.

OIL

HOLES

INSTALLING

THE

.·CAMSHAFT

BUSHING

~~~i:P

'--Jk,<-I--IENDS

with

its

gallery.

·.NOTCH BUSHING

oil

holes

IN

OF

BUSHING

~

12. Tappets.

a.

Check

wear.

Replace the tappet if

b.

Measure cylinder clearance

CLEARANCE

.

BETWEEN

STANDARD

OOe]

..

GOOD

WESJERBEKE

Engines·&

Generators

21

the

cam

the

diameter

block for

exceeds

0.0059

'.

CAM

contact

face

of

the

tappet

the

limit,

THE

TAPPET

In

(0.15mm)

CONTACT

FACE

the

replace

AND

BAD

of

each

face

tappet

to

find

THE

.

OF

tappet

is

defective.

and

the

clearance.

the

tappet.

CYLINDER

THE

BLOCK

TAPPET

for

abnormal

bore

BAD

in

If

the

(

13. Idler gear.

a.

Measure

the diameter of the shaft to clearance whichever is

CLEARANCE

BETWEEN STANDARD LIMIT

b.

Install a'new idler shaft

dimension

(26.5

±

O.Smm).

DIMENSION IDLER

SHAFT

THE

BLOCK

14.

J!1ywheel

a.

Put the

mid

flywheel indicator at and

move it

shown

in exceeds

.

FLATNESS

STANDARD LIMIT

MEASURING

the

OF

THE

FLYWHEEL

FLATNESS

bore

in

exceeds

badly

THE

0.0012'

0.0079

from

OF

THE

the

worn.

IDLER

In

the

FROM

FACE

ring gear

on

one

side of

over

to the opposite side of the face

the

illustration to

limit,

grind the

FLYWHEEL

0.0059

in

0.0197

in

the

idler gear find

limit,

for

the

clearance.

replace the gear

.

GEAR

AND

0.0028 (0.20mm)

to

THE

In

(0.03 • 0.07mm)

the

cylinder block

face of the block

the

surface

(0.15mm) (0.50mm)

plate.

the

friction (clutch contact) find

fiatness.

face~

MAXIMUM

ENGINE

the shaft and

If

SHAFT

is

1.043 ± 0.020

Set a

dial

If

fiatness

the

or

so

the

shaft

that its

face

.s

INSPECTION

15.

Pistons; piston rings

a. Measure the diameter

direciion transverse to the piston pin with as

shown in the illustration.

limit,

in

replace difference between average weight of all pistons engine does not exceed

DIAMETER

MAXIMUM

ALL

OF

STANDARD

3.0709

In

OVERSIZE

0.0098

in'(0.25mm)

(NOMINAL

78.25nim) OVERSIZE

0.0197

In

(NOMINAL

78.50mm) PERMISSIBLE

PISTONS

STANDARD

MEASURING PISTON DIAMETER

the

PISTON

(NOMINAL

(78.00mm)

SIZE

3.0807in

(0.50mm)

SIZE

3.09051n

IN

ONE

ENGINE,

0.18

DIFFERENCE

and

piston pins.

of

the

piston

If

piston. Select a

the

standard.

SIZE

In

STANDARD

3.0681 (77.93

3.0719 -3.0787 (78.18

.

3.0878 -3.0886 (78.43 -78.45mm)

BETWEEN

g(oz)

(5ml1\)

MEASURING DIRECTION

at

its

skirt in a

a micrometer

the diameter exceeds

new

piston so that

in

·3.0689

-77.95mm)

-78.20mm)

LIMIT

in

3.063 (71.80mm)

in

3.0728 (78.05mm)

in

3.0827 (78.30mm)

AVERAGE

WEIGHT

In

in

In

the the

one

OF

b.

Check the

abnormally

(1)

Removal

Heat the

Tap

• hammer from the

(2)

Installation

Heat a (150°C)

flywheel

ring

gear and replace it if its teeth are

worn

or

chipped.

ring

gear evenly

the ring gear all the

as

shown

with

way

in

the

illustration to remove it

flywheel.

new

ring

up

to

a temperature of

with

a piston heater

with

its unchamfered side foremost.

an

acetylene

torch.

around with a bar and

'..

..

302"F

and

install ii to

REMOVING RING

GEAR

the

THE

h.

Measure the clearance between

with

a strrught edge

exceeds

COMPRESSION

NO.1 RING

NO.2 RING

OIL

c.

If

rings

.

th~

limit, replace the ring.

RING

COMPRESSION COMPRESSION

RING

the

CLEARANCE

clearance still exceeds the limit

have

been installed, replace

NO.1

MEASURING THE

and

a feeler

STANDARD

0.0024 -0.0039 (0.06 -0.10mm)

0.0020 -0.0035

(0.05·

0.0012 -0.0028 (0.03 -0.07mm)

THE

PISTON

RIN~

the

groove

gauge.

If

the clearance

In

in

0.9mm) In

after

the

piston.

RING

CLEARANCE

AND

GRDOVE

and piston

LIMIT

0.0118

In

(0.30mm)

0.0079

In

(0.20mm)

0.0079

In

(0.20mm)

new

piston

COMPRESSION

BETWEEN

RING

22

ENGINE

INSPECTION

CYLINDER

PISTON

RINGS

CHECK

END

AND

INSPECT

ANDOAMAGE

PISTON~.

INSPECT

SCORING,

OVERHEATING

EXCESSIVE

.

OF

CONNECTING

CHECK CHECK CLEARANCE

CRANKSHAFT

INSPECT TEETH

---:::=:c:-:;>-.

FOR

WEAR,

CRACKS,

AND

WIDENING

RING

GROOVES,

RODS

FOR

BEND

BIG

END

THRUST

u

n

GEAR

•

FOR

DAMAGE.

OR

,,,--

BLOCK,

CLEARANCE

FOR

WEAR

________

TWIST.

CRANKSHAFT,

CYLINOERS

~~~

A

INSPECT

OR RING

I I

I

1"\

_

\)p

~.'

@

PISTONS

RIDGES

TRAVEL':

FOR

AT

AND

CRACKS,

TOP

OF

OIL

PAN

-"

INSPECTION

o"c'n;~:...:s~

. .

CYLINDER

CHECK

ON INSPECT

:

HOLES. TO

'\\~j,---

CRANKSHAFT

CHECK FOR

INSPECT DO

IF

THERE

OVERHEATING/BURNING.

POINTS

BLOCK

FOR

WARPAGE

TOP

FACE.

FOR

CHECK

PLUGS

OR

JOURNALS

WEAR,

CRACKS,

FOR

NOT

USE

IS

EVIDENCE

PLUGGED

FOR

DAMAGE

DOWELS.

AND

CLEAR

OIL

THIS

CRANKSHAFT

OIL

CRANKPINS

BENDS.

HOLES.

OF

.

)

AND

OIL.

TUBE INSPECT AND

RUST.

MAIN

INSPECT LOSS

WITH

FOR

REPAINT

KEROSENE.

DETERIORATION

IF

NECESSARY.

BEARINGS'

FOR

SCRATCHES

OF

OVERLAY.

MAIN

BEARINGS

\

~

INSPECT

FOR

/NSPECTFOR

."

LOSS

OF

~

FOR

DETERIORATION

SCRATCHES

OVERLAY

~

WESTERBEKE

Engines & Generators

23

d.

Pul'the piston ring cylirider ends

of

clearance

INSIDE

DIAMETER

STANDARD OVERSIZE

(0.0098 OVERSIZE

0.0197

NOTE:

Put

the

piston.

with

plock

the

ring

exceeds

OF

GAUGE

3.07·'''.'

3.08····'

In

(0.25mm)

3.09····'

In

(0.5Omm)

piston

In

a gauge or in

and

measure the clearance

with

a feeler gauge

the

limit, replace all the

in

(78

···mm)

In

(78.25·"

in

(78.50·"

ring

in

the

gauge

the

mm) mm)

or

ENGINE

bore in a

between

as

shown.

rings.

cylinder

squarely

If

new

the

INSPECTION

f.

Check

the

connecting

(1)

.

BENDING

NOTE:

OR STANDARD LIMIT

(2)

To

connecting

torque.

Measure

(0.05mm) the

Generally,

the

check

"C" and

per 3.94

connecting rod

TWIST

OF

CONNECTING

0.0020

0.0059

a connecting rod aligner

connecting rod

the

rod

and

tighten

.!

,R.

-rod

in

for

<

"k'.

in

/3.94 /3.94

bend, 'the

0.0020

for

bend

or

If

"C" exceed 0.0020

in

(100mm)

with a press.

ROD

maximum

for

bend

or

install

cap

nuts

(0.05)

3

.•

94

(100)

twist

as

follows:

in

of'1",

straighten

(0.05/100mm)

(0.15/100mm)

is

used

to

check

twist.

the

cap

to

the

to

the

specified

~.R~

' .

CLEARANCE

NO.1

NO.2 OIL

RING

BETWEEN RING

RING

THE

STANDARD

0.0059·0.0118 (0.15 -0.30rnm)

0'.0059·0.0138

(0.15·0.35mm)

0.0079'0.0157 (0.20·0.40mm)

.

. .

'H

e.

Measure the clearance exceeds whichever

DIAMETER

STANDARD

CLEARANCE

STANDARD LIMIT

the

piston

for

OF

THE

BETWEEN

diameter of the piston

the

is

badly

PISTON

0.90527.·0.90551 THE

0.00024'

0.00197

ENDS

OF

THE

PISTON in in

in

MEASURING PISTON

AND

BORE

.

. . :

+

to

find

the

clearance.

the

limit, replnce the piston

worn.

(NOMINAL

PISTON

0.0071

In

(0.050mm)

SIZE

In

AND

In

(0.006·

(22.994,

PISTON

RINGS

LIMIT

0.0591 (1.50mm)

0.00591

(1.50mm)

0.0591

.(1.50mm)

.

and the bore

0.91

in

(23mm))

23.000mm)

0.018mm)

in

In

in

DiRECTION

If

the

or

pin,

in

PISTON

.

BEND

(3)

To

check

·the

bend,

put the connecting rod

surface

plate

diameter equal

in

the

big

with

a dial

the

bend (''C'').

.

CHECKING CONNECTING

ROD

BEND

USING CONNECTING ROD

connecting rod

as

shown,

to

that of the crankpin into

end

of

the

indicator.

\-"

TWIST

A

ANGLER

fitted

to

the

piston

and

piston

on

the

insert a round bar having a

the

rod

and

Subtract

measure

"A"

from

"A"

"B"

and

B

to

for

bore

liB"

find

Engines & Genera/Drs

24

16. Crankshaft

a.

Clearance between crankpin and connecting rod

bearing.

(1) Install the bearing (upper and lower halves)

to

the big end cap nuts to in

the bearing for crankpin as shown.

TIGHTENING

MEASURING

BORE

TORQUE

25.7

± 1.8Ib·n

3.55 ± 0.25

34.8 ± 2.5

THE.~~~

IN

THE

8!l:

Kg

Nm

.,

of

the connecting rod and tighten the

the

specified torque. Measure the bore

.

MEASURING DIRECTION

CONNECTING

ROO

BEARINGS

(2) Measure the diameter of the

\

clearance between the bearing.

ENGINE

to

find the

connecting rod

INSPECTION

and

cap

A

CAUTION:

crankshaft Finish

the

Grind

to

the

same

crankpin

al/

tlul

undersize.

fillets

crankplns

to a radius

of

0.098

one

in

(2.5mm).

a. Inspect the clearance between the journal and the main

bearing.

(1)

Install the main bearing (upper and lower halves)

and the cap to the cylinder block and tighten the cap bolts bore in the bearing for the journal.

TIGHTENING

TORQUE:

to

the specified torque. Measure the

38 ± 1.8

Ib·n

(5.25 ± 0.25

kg·m)

,

MEASURING BORE

IN

THE

MAIN

~fu

I

-VI

MEASURING DIRECTlQN _ ...

MEASURING DIAMETER THE

DIAMETER

STANDARD

CLEARANCE BEARING

STANDARD LIMIT

(3) If the clearance exceeds the limit, install a

(4)

CRANKPIN

0.25mm

{0.0098

FINiSH..

0.50mm

{0.0197

FINISH

0.75mm

(D.0295

FINISH

:

THE

OF

CRANKPIN

OF

CRANKPIN

BETWEEN

bearing and check the clearance again.

If

the clearance still exceeds the limit, grind the

crankpin to 0.25mm (0.0098 in), or 0.75mm (0.0295 connecting rod bearing.

UNDERSIZES

47.75·'·' 47

47.25·'·'

{NORMAL

1.88779 THE

CRANKPIN

0.00098·0.00283

0.00591.1n

In)

mm

In)

.50

,~,

mm

In)

mm

SIZE

·1.88838

(0.150mm)

in)

(1.8799 (1.8701

(1.8602

1.89

In

(47.950 • 47.965mm)

AND

THE

In

(0.025 • 0.072mm)

undersize and use.a undersize

•.

"'"'

in)

. ..,,,.

in)

.,.,."

In)

in

(48mm)

CONNECTiNG

0.5Omm

.

ROD

new

(0.0197 in)

(2)

Measure the diameter of the journal as shown

find

bearing.

DIAMETER

CLEARANCE

OF

NOMINAL

STANDARD

BETWEEN

STANDARD' LIMIT

-rb.

-VH

MEASURING DIAMETER THE

the clearance between the journal and main

JOURNAL

(STANDARD)

SiZE

2.05

in

2.04665·2.04724 JOURNAL

0.00118·0.00303

(0.030·

0.00394

(52mm)

AND

MAIN

O.077mm)

in

(0.100mm)

In

(51.985·

BEARING

in

52.000mm)

H

THE

OF

JOURNAL

to

\

I

~

WESTERBEKE

Engines & Generators

25

(

(3)

If

bearing

(4)

If

journal to or 0.75mm (0.0295

main

JOURNAL

0.25mm FINISH

0.50mm FINISH

0.75mm FINISH

UNDERSIZES

(0.0098 (0.0197

(0.0295

JOURNAL

RADIUS

A

CAUTION:

crankshaft Finish {2.0mmj.

(5) Support

in

center journal the grinding exceeds

CRANKSHAFT

STANDARD

LIMIT

ENGINE

the

clearance

and check

the

clearance still exceeds the limit, grind the "

bearing.

In)

51.75

•.• ,

in)

51.50· in)

51.25

... , mm

FILLET!

to

the

crank

V-blocks

amount

RUNOUT

O.25mm

mm

•.• , mm

exceeds

(2.0374 (2.0276 (2.0177

the limit, install a

the

clearance

(0.0098

in)

undersize and

......

In)

...... , In)

.......

In)

.;

.

~.

Grind

all

the

crankiins

the

same

undersize;

fillets

to a radius

the

crankshaft or in a lathe

with

of

mnout, repair the crankshaft

or

by straightening with a

the limit, replace

0.00098

0.0020

In

on

its front and rear journals

and

a dial indicator. Depending

the

In

(0.025mm)

(0.05m!11)

again.

in),

0.50mm (0.0197 use

of

one

of

0.081n

check the ronout

press.

crankshaft.

INSPECTION

new

in)

undersize

at

on

by

If

ronout

the

17. tyUnderBlock

a. Measure

.

PISTON

TAPER

,b. Using a

the

,. on axes A

,

one

of the

cylindiirs

bores

for

oversize

AND

PISTON

STANDARD' CODE,

STD

OVERSIZE

0.009B

In

AND

, '

25

liD

,"

(0.25mm)

in

(0.50mm)

OUT

OF

"

" ,

CODE: OVERSIZE

0.0197 CODE:

'6j'

If

,

- '

heavy

gauge,

check the

'lengthwise,

warpage

'surface

exceeds

grinder.

bore

at

the

top,

middle

and bottom points

and,

B with a cylinder bore gauge.

eXceeds

the

limit, hone

pistons.

,

LIMIT, +0.0008

(+O.2mm)

+O.OOOB (+0;2mm)

+O.OOOB (+0.2mm)

RING

ROUND

BORE

3.07

in

•.•• ,

(78mm

••.•

3.0807

In

(7B.25mm

3.0905

In

(7B.50mm

0.0004

In

)

•.••

.... )

....

•.

0)

(0.01mm)

·~6~~D

MEASURING DIRECTION

(I

' t

.-

accurate straight edge and a feeler

top

face for warpage in two positions

two

crosswise

the limit, reface the top face with a

.

'~TANDARD

and

WARPAGE

OF

LIMIT

two

widthwise.

CYLINDER

0.0020

0.0039

If

any

out

all

In

,.

in

o

=~

DO~

MEASURING

,BORE

;'IN

,

CYLINDER

,

BLOCK

If

BLOCK

TOP

In

(0.05mm)

In

(0.10mm)

the

THE

FACE

(6) Use a gear puller

to

remove the

crankshaft.

NOTE:

Do

not

remove

is

defective.

(7)

Installation of the crankshaft position position with

the

gear.

Wlless

.

on

the crankshafi; Install the

its

keyway

.

the

gear.

•

ge';"

from

gear

or

Install the

gear

the

crankshaft

key

in .

with

the

key.

Engines & Generators

26

18. Manifold inspection. Using a straight edge gauge,

check the flange faces 'of the manifold

warpage.

If

warpage

e)lceedS

the limit, recondition

replace the manifold. "

WARPAGE

OF

THE

FLANGE:

0.0059

In

(0.15mm)

,

~d

a feeler

for

Or

ASSEMBLY

PISTON

COAT

THE

WITH

ENGINE

ENTIRE

OIL

CYLINDER

SURFACE

BLOCK,

CRANKSHAFT;

PISTONS

'PISTONPIN~

FORCE

FIT

BEARINGS

LUBRICATETHE

SURFACES

CONNECTING

CAP

TORQUETO:

3.55

34.8

NUTS

±

0.25

±

2.5Nm

WITH

ROD

Kg-m

INSIDE

ENGINE

--------.

OIL

I

Z~

~

@

~

AND

OIL

PAN

~~,

~

~.

CAMSHAFT

APPLY

ENGINE

JOURNALS

BEARINGS

LUBRICATE

SURFACES

AND

OIL

LOBES

THE

WITH

TO

.

INSIDE

ENGINE

OIL

)

OIL

PAN

COAT

THE SURFACE Hf-TACK SEALER

WITH

GASKET

ENTIRE

-.c--'---SIDE

~----

BEARING

TORQUE

.

5.25

±

.51.5 ± 2.5

OIL CAP

TORQUE

3.55

34.8

SEALS

COAT

CAP

TO:

0.25 Nm

PAN

NUTS

± ±

WITH

BOLT

Kg·m

BOLTS

TO:

0.25

2.5Nm

WCTlTE

Kg·m

ULTRA

BLUE

Engines & Generators

27

1.

Main bearing installation.

a.

Install

the

upper

halves cylinder block bearing cylinder

b.

Install

..

c.

Lightly

with

engine

the

caps

so

block

flanged

lubricate

oil.

ano

their

and

the

of

the

the lower

tabs

fit

the

main

bearing in

inside

main

halves

into

the

bearing the

No.3

surfaces

bearings

in

the

main notches caps

..

journal.

of

the

bearings

ASSEMBLY

4.

Side sesi installation.

in

the

in

the

A-"--_

a.

b. Insert

c.

Coat !he side

the

side

front

and

rear caps

possible,

the

Using a flat

care

with

cylinder

not

to

seals

with

seals

between

and

their rounded

block.

plate,

push

bend

them.

Loctite

Ultra

the cylinder block

push

them

in

side

toward

the

seals

into

Blue.

by hand

the

position,

and

as

far

outside

taking

the

as

of

\-,,~~

2.

Crankshaft installation.

a.

Clean

the

crankshaft with

dry

with

compressed

b.

Fasten a hoist

position.

cylinder

c.

Lightly

3.

Main bearing cap installation.

a.

Coat

cylinder block

b.

Install

number the

c.

Tighten

A

caps end

d.

Tighten

.

to

TORQUE:

e.

Make

or

f. Measure

. reference

the main

Carefully put

block.

lubricate

the

mating

the

main

(arrow

front of

the

main

CAUTION:

in

position

faces

of

the

bolts

the

specified

38

± 2

Ib-fl

(5.25 ± 0.25

sure

the

catching.

the

end

to

End play measurement

end

play

is

bearing

air.

to

the

crankshaft

the

crankshaft journals

surfaces of

with

Loctite

bearing caps head) engine.

bearing

Install so

their

cylinder

holding

torque.

crankshaft rotates

play

incorrect, loosen !he

caps

once

'-./

on

for

the

cap

the

end

Kgl·m)

!he

and

cleaning

and

crankshaft

the

rear

Ultra.'Blue.·

In

positiort.

main

bolts

front

and

faces

block.

the

main

freely

crankshaft.

tighten

solvent

hold

in

position

with

bearing

finger

rear

are

even

bearing

without

for

crankshaft. bolts them

and

it

in

horizontal

engine

cap

Make

cap

tight

bearing

with

caps

Make.

holding again.

blow

in

the

and

sure

is

toward

only.

the

in

steps

binding

If

the

oil.

the

. .

.

ROU~DED

suie

~OOll

5. Piston assembling to connectfug rod.

a.

Set Piston Setting

press.

b.

Put

!he

connecting

bore

in

the

c.

Put

!he

piston

sure

the

model

side

as

the

piston

II. Insert

A

when is

the

connecting

e.

6. Using a piston ring pliers, install fhe piston rings on piston •

NOTE:

has

The

apart

the

piston

for

press.

CAUTIQN:

pressing

ready

to

exceed

and

check

rod

After

assembling

sure

!he connecting

The

piston

the

mark "T" toward

oil

ring

must be installed

from

the

coil spring

-::JI

.0'

rod

for

in position

identification

arrow

in

position.

push

rod

the

piston

Observe

the

piston

50kfg

the

for

alignment.

rings

~

.

SIDE

SEALS

Q a

Tool

(special

rod

on

the

!he

piston

on

head

on

the

of

the

Tool

and

the

indicator

pin.

If

(110

Ibf)

bores

in

!he

piston

rod

moves

must

be

installed

the

top

with

joint.

~

ROUNDED

°1\ofJ:

0 0

..

~

tool)

in a

hydranlic

Tool

and

with

the

connecting

on

the

top

into

press

the

force

[490N],

the

piston

and

connecting

freely.

of

the

coil

engine

rod

of

the

of

the

with

piston.

ring

.

lubricate

is

piston.

bore

of stop

and

the

..

the

oil.

rod,

making

on

the

Put

in

the

with

the

press

the

press

preSSing

rod,

make

side

end

gap J 8(f

sIDe.

,1)

sarne

!he

that

in

the

INSTALLING

PISTON

Engines·& Generators

RINGS

28

THE

.

CHECK GAPS

WITH

RINGS WITH

DETAILED

THAT

OFTEN

THE

SERVICE

THE

PISTON

CARE.

ARE

PACKAGED

SUPERSEDE

MANUAL

I

•

~

RING

NEW

INSTRUCTIONS

OIL

~

RING~?::

o

~

RING'

.

ASSEMBLY

MARK

TO

~~

NO.1

COMPRESSION

RING

NO.2

COMPRESSION RING

RiNG

SIDE

CLEARANCE

8.

Connectfug rod

a.

Push

the connecting rod Then

turn

of

the

piston.

b.

Install

the

connecting

of

the

bearing

c.

Install

the

NOTE:

Make number ort rod the

notches

d.

TORQUE:

e.

havi(lg

Tighten

specified

25.7

Check

end.

the no

on

± 2 Ib·ft

the

cap

piston

into

is

the

crankshaft

lower halfof

rod

is

in

bearing

sure

the

number

connecting

cylinder

the

same

the

connecting

torque.

(3.55 ± 0.25

thrust

installation.

position

put

into

position

1800 while

the

cap,

making

the

notch

cap

to

the

on

rod.

In

number,

side.

rod

clearance

until

connecting

sure

of

the

connecting

the

cap

case

of a new

install

the

cap

nuts

Kgf.m)

for

the

big

end

over

the

crankpin.

pushing

rod

the

tab

cap.

rod.

is

the

same

connecting

cap

to

in

steps

connecting

of

the

on

the

bearing

in

the

as

the

rod

to

the

rod big

top

in

back

the

with

(oil

position

oil

pan.

surfaces

with

Hi-Tack

oil

pan

the

specified

'"rUNIJ.H

pan

so that

to

FRONT

OF

/l;

ENGINE

~

~~~PRESSION'~'

RING

7.

Piston and connecting rod installation.

a.

Lubricate

b.

Move are piston

c.

Install rod, the

d.

Thrn

connecting

e.

Hold

mark front

f.

Using a piston

piston

top

the

piston

apar!

from a direction

pin.

the

connecting

making

notch

of

the

crankshaft

the

piston

(arrow

(timing

and

connecting

of

the

cylinder

Pl'

""

piston

and

rings

on

rod

sure

the

tab

the

connecting

until

rod

to

be

installed

and

connecting

head)

on

the

gear

case

side)

guide

(commercially

rod

block.

y

-~IJ

:,....r

'NO.2

COMPRESSION

RING

AND

OIL

piston rings

the

piston

parallel

bearing

in

the

rod.

crankpin

is

top

of

into

to,

(upper

back of

at

rod

the

COIL

SPRING

with

so

that

or

traverse

half)

the

for

the

top

with

"FRONT"

piston

engine.

available),

cylinder

engine

the

bearing

the

piston

center.

toward

from

RING

JOINT

oil.

end

to,

to

the

put

the

gaps

the

is

and

..

the

in

.

9.

Oil screen installation.

a.

Lay

the

b.

Install

NOTE:

below

the

The

cylinder

the

oil

level

screen

block

oil screen in

must

line

and

with

position.

be

installed

away

to.Oil pan installation. Clean

pan.

and cylinder block

Sealer.

Tighten cylinder block in a crisscross pattern torque.

TORQUE:

8.3 ± 1.1

OIL

PAN

4CYL

o 0

Ib-fl

the

bolts

(1.15 ± 0.15

o

and

that

cqat

the

from

the

hpld

Kgf·m)

bottom

in

the

mating

them

the

to

of

the

side)

the

Gasker

NO.

up.

it

oil

is

)

A

CAUTION:

the

pistlln

piston

rings

011

and

cllnnecting

and

nllt

use a hammer

crankpin.

rlld

as

this

when

will

Installing

damage

NOTE:

the

Engines & Generators

pound flange

thick

Squeeze

Hi-Tack

of

the

bar,

cut

29

out a 4mm

Gasker

oil

pan

the

nozzle

(0.2

sealerfrom

as

shown.

of

the

in) To

tube

thick bar

the

tube

squeeze

as

shown.

of

sealing

and

put it

out a 4mm

comon (0.2

the

in)

)

ASSEMBLY

THRUST

PLATE

TORQUE

1.1

±

0.1

10.8

± 1

TO:

Kg-m

Nm

TIMING

.

GEARS

ANIl'FLYWHEEL

NEW

TAPPETS

LUBRICATE ENGINE

VVl/11'--_

OIL

NUT

TORQUE

TO:

17.5 ± 2.5

172±25Nm

Kg-m

GASKET

APPLY

JOURNALS

GASKET

ENGINE

AND

OIL

TO

LOBES

BACK

± 1

64

±

OIL

APPLY

.

TO

SEAL

PLATE

TO:

Kg-m

10Nm

SEAL.

ENGINE

LIP

BOLT

OIL

Engines & Generators

30

11. Front plate installation, a. Scrape the gasket from the cylinder block and front

plate.

b.

Coat the gasket contact surface of the cylinder block with adhesive sure the holes the holes in the cylinder

c.

Put the front plate in position. Install four bolts and tighten them.

12. Oil pump installation. a. Make sure the packing

oil

pump.

b.

Put the oil pump Install the bolts

c.

Make sure the oil pump gear rotates freely.

13. Engine turning ... a. Install

holes

in

b.

Put a bar between the bolts and

bring

No.1

illustration.

INSTALLED BOLTS

and

put a

in

the gasket

in

and

two

bolts (M12 x

the crankshaft.

piston

to

~

J'~r:~"

new

gasket

in

position, making

are

all

in

alignment with

block.

has

been put in position

position

tighten them

on

the cylinder block.

evenly.

1.25)

in

the

flywheel

turn

the crankshaft

the top center as shown in the

~~

ASSEMBLY

16. IdIer gear installation.

on

the

.

bolts

to

a. Lubricate the idler gear with engine oil.

b. Install the'idler gear

c. Check the backlash of the gears. Make reference

17. Timing gear case installation. a. Coat the gasket with adhesive and put

b. Lubricate the oil seal with engine

. c. Tighten the bolts that hold the timing gear case.

18. Crankshaft pulley a. Install

b. Tighten the crankshaft pulley nut

TORQUE:

. '

in

position with its "3", "2"

"11"

marks in alignment with the the "33" mark fuel injection pump camshaft the camshaft gear and the "1" mark

gear respectively.

Timing

gear

backlash

. the front plate.

nut

two

bolts

(M12

in the crankshaft

torque. .

127 ± 181b·ft

and

(17.5 ± 2.5

gear,

the "22" mark

on

measurement.

oil..

tightening.

x 1.25)

in

the flywheel bolt holes

hold the crankshaft.

to

Kgl·m)

and.

on

the

on

the crankshaft

to

it

in position

the specified \

on

14. Fuel injection pump camshaft installation.

a.

Put the camshaft (with bearing the cylinder block. .

b.

Hit the gear with a plastic hammer position.

c.

Make sure the camshaft rotates

d. Tighten the stopper·bolt.

. 15. Camshaft installation.

a.

Lubricate the lobes and journals with engine oil.

b.

Put the camshaft (with block.

A

CAUTION:

and

journals

Co

Tighten the bolts that hold

specified turque ..

TORQUE:

8 ± 0.7Ib·fI

d. Make sure the camshaft rotates

plai

for the camshaft.

when

(1.1 ± 0.1

00

gear)

not

the

camshaft

and

gear)

to

fit

freely.

in position in the cylinder

cause

ihe

Kgf·m)

damage

thmst plate

Is

installed.

freely,

to

Check the end

in.

position

the bearing

the

lobes

to

the

in

A

WARNING:

bar

used

for

19. P.T.O. gear installation. Install the position

oil hole toward the rear of the engine .

20. 'fuppet installation. Lubricate the tappets with engine and put them

21. Oil seal case installation.

a. Put a

b. Lubricate the oil seal with engine oil

22.

Rear

a. Put a b. Put the rear plate

TORQUE:

NOTE:

plate installation.

in

the timing gear case with the side that

new

seal

in position in the cylinder block.

plate installation.

new

its dowel holes the bolts that hold the rear plate to the specified

47

± 7

Install

the

to

the

cylinder block for

Check

the

strength

holding

in

gasket

gasket in position

Ib·1I

starter

the

crankshaft.

position in the cylinder block.

in

position

in

position

in

alignment with the

(6.5

± 1

to

on

Kgl·m)

the

rear

convenience

the oil seal case.

the rear plate.

the cylinder block

plate

of

P.T.O.

and

dowels.

before

of

the

bolts

gear

install

installing

rear

and

in

has

the

Tighten

torque.

plate

no

oil

with

t"e

Engines

31

& Generators

23.

Flywheel installation.

a.

Install a crankshaft.

b.

Put the safety

c.

Install

,

them

d.

Remove wheel

e.

Have

to

f.

Tighten

specified

TORQUE:

.A

prevent

safety

flywheel

bar.

three

finger

the

and

tighten

someone

prevent the flywheel

the

torque.

98 ± 41b-H

, '

WARNING:

possible

bar

(M12x

1.25)

in

in position in aljgnment

of

four

bolts

in

the

flywheel

tight

only.

safety

bar.

Install

the

it finger tight

hold the crankshaft pulley

from

four

bolts that hold

(13.5 ± 0.5

Always

personal

Kgr-m)

signal

injury.

only.

rotating.

the

to

each

the

rear end of the

with

and

last bolt

flywheel

in

with

other

ASSEMBLY

24.

NOTE:

the,

tighten

the

fly

a wrench

to

the

to

from

,

thoroughly

REMOVING HEAD

CyliDder head fr011lthe

the

After

face

bottom

scraping

with

clean

the

THE

CYLINDER

GASKET

WHITE

b~ttom

an

face cleanmg. Scrape the gasket

face

of the cylinder head.

the

gasket,

rub

oilstone

face,

ENAMEL

off

gasket

engine

remnants

oil

and

(

INSTALL

GASKET

A

LUBRICATE

WliH

CYLINDER

USE A NEW,

STEM

ENGINE

OIL----~

HEAD

SEAL

AND

VALVE

MECHANISM

'ff,'''';-'--T0i1Q~'E:

.mRQU'E:

(14.7±

±

1,15

±

1,5Nm)

1,5

:!:

5Nm)

0.15

0,5

Kg-m

'

25.

INSTALLING

VALVE

Valve

in position in

sure

NOTE:

U.

Install the valve spring with the white enameled end

up.

27.

Valve

spring with a on

28.

Cylinder head gasket installation.

a. Thoroughly

b.

c.

THE

SPRING

stem seal installation. Install

the

va!ve

guide,

the

sea!

is

in

its

correct

Improper seal

the

A

on

the

hit

and

Install

the

Put a

cylinder alignment

stem

seal

installation

against

block installation. Put

valve

CAUTION:

and

piston's,

cylinder

downward

valve

lifter

top.

Do

valve

spring.

damage

two

new

the

clean the top

guide

bolts

block.

cylinder head gasket

block,

making sure

with

their respective

and

not

This

stem

(MIO x 1.25)

,

I

the

After installation,

position,

can

flow

of

oil

along

compression

install

the

put

excessive

can

cause

seal.

faces

of

the

in

position

the

guide

holes

va!ve

stem

seal

make

cause a failure

the

stem,

on

the

valve

block

in

position

compression

the

retainer

cylinder

in

the bolt

bolts

in

the gasket.

on

block

the

are

to

holes

'

all

to

in

INSTALL A __ NEW

GASKET

---~i\\!

32"

A

CAUTION:

other

substances

block.

Do

on

not

the

use

top

any

face

gasket

of

the

adhesive

or

cylinder

29. Installation head guide bolts are

holes in the head.

Cylinder

30. a. Remove the guide bolts and install the bolts that hold

the cylinder

b.

Tighten the bolts

steps

TORQUE:

65

of

the cylinder head. Place the cylinder

in

position on

all

in

head

bolt tightening

head to the cylinder block.

to

the specified torque.

± 4

Ib-fl

(9

±

'Oa

06

014

the

cylinder block, making sure the

aligmnent with their respective bolt

-

in

number sequence in two

0.5

Kgf-m)

on

05

03

Ol~

02'

4

CYLINDER

01

012

FRONT

08

....

11

""'"

.06

\

31. Valve

32. Rocker

33. Rocker

push

rod

. a. Put the valve push rod into position through the bore

the cylinder head

b.

Make sure

into position over the top

the

sIuiftas~embly.

a. Install the {ocker arms, brackets and springs on the

rocker shaft. Secure the brackets to the shaft by

.

tightening the bolts.

b. Make sure the rocker arms move freely.

shaft

assembly installation.

a. Install the valve caps in position on the top

04

. 3

01

010

. . .

installation.

..

ball end

()2

CYLINDER

()3

~9

of

the

push rod

of

the tappet.

OIl

_~

\

OS

J

has

valves.

b. Put the rocker shaft assembly in position on the

cylinder head. TIghten the bolts that hold the rocker shaft assembly to the specified torque.

TORQUE:

. 35. Tighten

11.

± 4

Ib:f1

(1.5 ± 0.5

c. Adjust the valve clearance, see

this manual.

cover

34. Rocker a. Make sure the gasket is assembled to the rocker cover, b. Tighten the bolts that hold

specified torque.

TORQUE:

36. Tighten

TORQUE:

8.3

specified torque. .

13.4 ±

specified

13.4 ± 2.5Ib-fl

installation.

±

1.1Ib~ft

the

bolts

2.5Ib-f1

the

bolts

to~que.

Kgf-m)

(11.5 ± 0.15

that

hold

(1.85 ± 0.35

that

hold

(1.85 ± 0.35

VALVE

the

rocker cover to

Kgf-m)

the

air

intake

Kgf-m)

the

exhaust

Kgf-m)

CLEARANCE

to

manifold

ASSEMBLY

37_

TORQUE:

38.

or

three

39.

TORQUE:

40. Install

in

been put

. 44. Install

of

the

. '46.

in

the

to

the

Fnel

injection nozzle instaIIation.

a. Put the gasket on the nozzle.

b. Put the nozzle assembly in position in the cylinder head

and tighten it to the specified torque.

40

± 4

Ib·fI

(5.5 ± 0.5

Put

the

fuel injection

block

and

tighten

specified

Put

of

slIding sleeve

make Fnel

41. a. Install the governor assembly in position while putting

b. Install the tie rod to the pin

c. Install

42.

Fnel

s.

b. Put the fuel injection lines in position and connect them

Pressure

43.

position on the cylinder block and tighten it

'specified torque. .

TORQUE:

engine oil and install the When the gasket contacts the base, tighten one more turn.

45. Coolant

If

coolant Put

. flange. Install the water pump onto the cylinder block,

torque.

the

flywheel assembly

the

~el

injection

shaft

26

± 4.3

Ib-ft

(3.6 ± 0.6

the

sliding sleeve 'on

sure

the

sleeve moves freely.

injection nozzle installation.

the tie rod and spring into position in the injection

pump.

secure it with the tie rod spring.

the

tie rod cover

injection line installation •

Put the foelleak-off in position and connect

fuel injection nozzles. .

to the fuel injection pump. Install

relief

valve installation. Put the relief valve in

36

± 4

Ib-f1

(5

the

1.';1

filter. Lightly lubricate the gasket with

pump.

Check the impeller and shaft

they do

pump

a new

not

rotate freely or have noise, replace the

assembly.

gasket

the

±

in

pump

to

0.5

Kgf-m)

pump

in

position

bolts

that

in

position

camshaft

the

specified torque.

Kgf-m)

the

sliding sleeve

of

the control rack and

in

position.

Kgf-m)

new

filter element

p'osition

on

hold

the

on

and

the

clamps.

the

water

COOLANT

the

cylinder

pump

the

rear

tighten

shaft

it

to the

to

the

by

hand.

for

p';'mp

GASKET

PUMP

to

the

end

the

rotation,

and

,

)

Engines & Generators

33

HOUS.ING

47. Install the thermostat. thermostat housing thermostat housing in position

48.

Oil pump. roatalon

if

defective.

49.

Oil pressure reliefvalve. Check the valve seat for

VISually

or

other defects. Replace the pump

contact and check pressure at with is

not correct, decrease tap

is

RELIEF

which

the engine

the

amount

located

VALVE

on

OPENING

remove

Put

the

thermostat in the

with

anew gasket and install

on

the cylinder head.

eheek the pump for rough

the

spring for

the

relief valve

running

at

the

damage.

opens

rated

rpm).

the cap nut and increase or

of

shims.

The engine oil pressure

the

right side of the engine.

PRESSURE:

50

± 7

psi

(the oil pressure

(3.5 ± 0.5

assembly

Measure

If

the pressure

'.

. - .

ASSEMBLY

52. Actuator Installation. a.

Apply

and thread the actuator

tums.

b.

Connect harness. Note:

(l500or

c.

With

verify goes until

112

II.

Unplug

. .

harness reconnect them into the engine harness.

e.

Tum

to

ensure

shutdown.

f.

The actuator

has additional

the

Kgf·m)

oil

under idle

some teflon sealant

the actuators electtical

Tum OFF

The

engine speed may not be at

1800

rpm).

the engine

running,

the engine will shut

toa

very

slow

it shuts down and

tum

an~

secure it in place with the jarn nut, .

to

the

threads

into

its mounting boss 4

wires

the

AC

breaker and start the engine.

depress

down,

into

the

stop switch

If

it

does

of

idle, slowly thread the actuator

then

thread it in an additional

the actuators electtical connections from the

and untwist the

ON

the

AC

wires

so

breaker and start

they

lay properly'

and

stop the engine

proper actuator adjustment for good engine

may

need further adjustments once the

been

run under a

112

such conditions

and

not a

tum

full

shutdown.

good

arnperage

maybe

needed after the unit has

and

is

found

load. An

only-

to

the

actuator

to

5

the

engine

desired speed

to

not and just

in

and

unit

run

go

to a slow

N.liUT'·

.

..

• . I

50. Install

51. a. Put the alternator in

b.

c.

d.

the

glow

pIngs chamber testing, refer to

TORQUE:

and

tighten them to the specified torque. For

GLOW PLUGS in

12.7 ±

1.B

psi

(1.75 ± 0.25

Alternator installation.

position.

bolt

in position

Put

the belt in position on

alternator

to

the belt.

Tighten the

Make

sure the

2"deflection

away

bolts.

at

to

hold

from

tension

the

center

in

position in the precombustion

Kgf·m)

Install the adjusting

the alternator in position.

the

pulley,

the

engine

to

of the belt is correct, about

with

pressure.

iLOC.I1~.EDJUST.

UNDER

•

'fUEL

INJECTION

JPUMP

ON

ENGIN.E

. .

this

manual.

THE

BLOCK'

".

-

\

-~

\

-,

I

Move the

make an adjustment

~

WESTERBEKE

Engines & Generators

.

34

EXHAUST

The cylinder

1.

Remove manifold. Replace

2.

Remove manifold.

3.

Remove Be each

4.

Exantine replace

5.

Flush rinse

6.

Use a pipe coolant

7.

Flush tube.

ASSEMBLY

1.

If

,

intact, reverse

new

2.

If

below.

a.

b.

c.

Check it

and upper replace the cap. .

MANIFOLD

exhaust

Manifold

Bolts

Manilold Bolts

manifold,

heed,

the exhaust

Clean and

as

the exhaust

water

sure

to

for

proper

all

as

needed.

out

the

thoroughly

recovery

out

the coolant

the

manifold

it

can

order

ones.

Mounting

Torque

the

manifold has

Loosely manifold sealant

Graduany aligrunent

steps.

Mounting

Torque

Reinstall manifold

the

manifold

make

sure it closes

and

lower seals

which

was

should

be

inspected

elbows inspect

needed.

nipples,

connectors

note

the

aligrunent.

parts

for

manifolds

with

cleaner

tank

was

be

replaced

of

removal.

Value.

attach the

using

new

tighten of

all

Value.

the exhaust connections

using Loctite-Anti-Seize

pressure

proper

defects,

interior

fresh

to

clear

tubing.

recovery

removed

on

20 -24

been

disassembled,

elbows

gaskets.

each

the

parts.

20 -24

when

are

in

from location

the

Do

fitting

good

MANIFOLD

disassembled

before

from

the

for

cracks

elbows

the

endS

and

corrosion

with a liquid cleaner

water.

passage that connects

tank and it's connecting

as

an

assembly

the

cylinder

not reuse the gaskets; install

H-Ib

(2.7 -3.3

to

the cylinder heed and

Do

not

to

make

'This

should

H-Ib

(2.7

-,3.3

cap.

Open

released.

condition. If any doubt,

from

the

reassembly.

lower surface of

and

defects.

and

plugs

from

of the manifold.

arrangement of

and

wear and

and left

head

in

the

m-kg)

follow

the

steps

use

any

gasket

sure

of

proper'

be

done

in

m-kg)

and

,plugs

into

,the

on

the

threads.

the

valve

by

pulling

Make

certain

'

the

and

the

three

the

I

HEAT

HEAt

The heat exchanger should be

an

1.

2.

3. Clean out

4. When reassembling, install

5.

NOTE:

heat exchanger

also service transmission

6.

AFTER

7.

8. Refill

9.

EXCHANGER

engine overhaul.

Disconnect the hoses petcock, end

Inspect'the tube (casing) for suspect replace the heat

and

Apply sblne lubricant

petcocks Install a

Repaint

h!'!~t

HEAT

Reconnect

Pressure test system and

drain plugs

fittings

and gaskets. '

any

zinc

debris

raw ",ater passages.

and

fittings

new

zinc

anode.

All

of

the

above

can

to

a heat

the

assembled heat exchanger with

r<"isltant

EXCHAtiGER

spray

enamel.

COMPLETED

all

hoses,

the

system with coolant ~ detailed

inspected

and

remove

and

zinc

wear

exchanger.

and

new

to

the

new

as

you

install them.

be

accomplished by sending

exchanger

and

engine

ENGINE

replacing

check

and serviced during

the

hose

anode.

Also, remove the

and dents, if

pressure test the coolant

gaskets and

service

oil coolers.

ASSEMBLY

them

as

for

leaks.

fittings,

O-rings.

shop.

Westerbeke

ANODE

needed.

above.

at

to

They

all

the

will

HEAT

EXCHANGER

)

\

j

CHECKING

THE

PRESSURE

CAP

Engines & Generators

35

NOTE:

Injector

qualified

pump

injector

shop.

servicing

should

FUEL

be

peiformed

INJECTION

by

a

PUMP

1

(

Disassembly

1.

Tappet removal.

a.

Hold the

b. Straighten the lock

c.

Rotate

housing.

d.

Remove while

e.

Do

tappets.

A

CAUTION:

housing

tappet

2.

Plunger removal.

, ,a.

Remove

b.

Remove

c.

Remove

d.

Remove the

e.

Do plungers.

f.

Remove

3.

Delivery valve removal.

a.

Thm

a

vise. b. Remove the c.

Remove d. Remove the e.

Remove

f.

Do

delivery

g.

Remove

NOTE:

When

valves,

pumping After these parts

quantity needed

Keep diesel

Procedure

the injection

tappets

Steps

up.

with a

screwdriver.

the tappet

pushing

(b)

through

The

when

the

to

prevent

the tappet adjusting

the

,lower

tweezers.

the

plunger

upper

Steps (b)

the injection

Steps (b)

the disassembled injeciion

fuel.

the control

the

valves.

the

replacing

do not

elements.

must

for

the

through

delivery

through

barrels

loosen

be

measurement

pump

in a vise with

plate

away

guide

180'

guide

pin with a needle-nose pliers

down

on

the tappet.

(d)

again for the remainder

tappet

can

be

tappet

guide

it

from

falling.

shim.

spring

seat

spring.

spring seat and

(d)

again

rack.

pump

upside

valve

holder.

valve

spring.

valve

gasket.

valve

with a tweezers.

(e)

again

from

the

housing.

the

plungers

the

adjusting

have

been

replaced,

measured. A Pump

of

the

from

the

tappet guide

to

unlock

Remove

thrown

from

is

removed.

and

plunger

control

for

the

remainder

down

and hold it in

for

the

remainder of the

and

barrels

plates between

the

injection

Tester

injection

pump

parts

side that

it from the

the tappet.

of

the

Hold

the

with a

sleeve.

of

or delivery

the

Cam

Box

quantity.

in

clean

has

the

is

DISASSEMBLY SEQUENCE

•

AND

INSPECTION

A

CAUTION:

barrels

are

POINTS

finely

The

finished

possible.

Keep

the

plungers

installation.

barrels

or

plungers.

Assembly

1. Put each barrel in position alignment straight

NOTE:

the

housing,

after

2. Install the delivery valve, the tight. valves.

procedure

down

If

the

slot

the

delivery

barrel

Do

this

A

CAUTION:

with

Do

not

use

with

the dowel of

into the

in

the

O-ring

valve

and

tighten the delivery

step for the remainder of

Anytime

disassembled, a new Make

sure

the

threads

not

cause

damage

','

delivery

barrel

holder has been

parts.

their

plungers

in

bore.

is

will

not

gasket,

O·ring

of

to

the

valves,

Keep

respective

or

the

housing

the

housing

not aligned

seat

correctly

spring and O-ring

the

injection

must

the

delivery

O·rings.

CHECK

,

FOR

'.

plungers

them

barrels

and

with

installed.

valve

holder

the

be

installed.

THE

FATIGUE

and

as

clean

with

its slot

put

the

(still

finger

delivery

pump valve

holder

SPRING

for

other

it

dowel

visible)

on

is

as

in

of

do

WESTERBEKE

Engines & Generators

36

3.

Install

each

control

sleeve alignment the

it.

Is

4.

Tappet installation.

while tappet pin. position.

it.

disassembled,

5.

Put the delivery valve holders

them

it.

holders. resulting If torque,

with

the

plungers

in

position

CAUTION:

toward

the

adjusting

pushing

with

Install

the

down

hole

lock

CAUTION:

new

to

the specified torque.

CAUTION:

This

can

in a failure

the

holders

engine

are

oil

line

mark

in

Make

Move

on

each

in

the

plates

Anytime

lock

Do

not

put

of

not

would

with

the

of

the

.barrels.

sure

the

notch

plate

the

control

tappet

housing

and

tappet

the

Injection

plates

must

in

position and tighten

overtighten

end

force

the

plungers

tightened

leak

in

center

control

rack

to

align

for

the

gnide

the

on

the

to

the

injection

FUEL

tooth

in

rack.

Put

In

the

plunger

back

and

the

slot

tappet

guide

pins

in

pump

is

be

used.

delivery

barrels,

to

move

freely.

specified

pump.

INJECTION

forth

in

the

PUMP

6.

Inspection after assembly.

a.

After

see it'the control rack

. binding or

b.

If

the

causes

'.

Pumping

•

Foreign

sleeves.

•

Overtightening

Disassemble the

c.

After

check

IMPORTANT NOTE:

valve

the

injection

control

are:

cause of the

the

injection

the

injection

When

by

a fuel injection shop. shims the

pump.

injection shop does not need the shims

repairs or service being performed

Install

timing shims to place proper timing with the

pump

has

been

assembled,

moves

freely

without

catching.

rack

fails

to

move

freely,

the

element(s)

particles

removing found under the injectIon pump with

Leave them

the

pump back on

sticking

lodged

betweell

of

delivery

and

check

the

tro~ble.

pump

has

timing.

the

injection pump for service

the

.

control

valve

holder(s).

injection

been

DO

witb

the

injection pump

engine.

pump

finally

assembled,

NOT send the timing

the engine. Tbe

Oll

engine using tbese

check

any

possible

rack

to

for

the

pump.

back

to

and

locate

'

any

into

DELIVERY

VALVE

HOLDER

TORQUE

4.5±

D.5

Kg-m

(44± 5 Nm)

Engines & Generators

37

GOVERNOR

DISASSEMBLY

AND

INSPECTION

·GOVERNOR

1.

Assembly.

a.

Install

b.

Put the O-ring

c.

Put the governor shaft in position

and

put

d.

Insiall the

hammer

e,

Install

Z.

Torque spring

The torque spring

an

adjusunent

speed,

with .. ; Remove b.

Move

and

hold

c.

Pull

the

where

point

position, spring.

d.

Tum

in

tie

rod

with

the line

e.

With

these

in

position

set

f. Install

the

stake

SEQUENCE

CASE

the

levers

in

position.

on

the

levers

on

grooved

..

the

tie rod

the engiue

the tie

the

speed control lever

it

tbere.

tie

rod

the tie

the torque spring

until the line mark

line

the

sealing

cap

and

set

installation.

set

is

made

rod

cover.

in

the

a slight resistance is encountered.

rod

does

mark

on

marks

by

tightening the special nut

.cap

in

position.

.

~

6

SHAFT/

CHECK

SHAFT

FOR

DEFECTS

AND

WEAR

governor

the

and

tie

to

at

direction of

the

aligned, lock the torque spring

over

shaft.

in

the governor case

governor

rod

be installed and adjusted after

the

a stahdstill.

not

set

on

pump

shaft.

spring pin in position with a

spring in position.

low

idle speed and high

,

to

the high idle position

arrow

head to the

In

pull on the governor

while lightly pulling the

the

control rack is aligned

body.

the torque spring set and

idle

this

k----3

SPEED

~_---+

CONTROL

SPRING

GOVERNOR

SPEED

CONTROL

SEALING

CHECK

;FACE

FOR

LeVER

SEALING

TORQUE

·~---2

1

SLIDING

SLEEVE

WEAR

INSTALLING

CAP

SPRING

CONTACT

THE

.'.<OIJ'L

FOR

SET

TIE

ROD

TORQUE

SPRING

NUT

Engines & Generators

38

FUEL

INJECTION

TIMING

(

PREPARATION

a.

Close the

b.Disconnect the

cylinder head

c.

Remove pump. holder. injection

.d.

Connect the fuel injection pipe

e.' Hold the

(Generator) remove the

INSPECTION

a.

Open prime button.

NOTE:

n,;,

sending

D!~ct

b. Slowly

open end of coming out is the fuel injection

NOTE:

Tum

and

c.

The

crankshaft pulley is aligned

gear case

FUEL

INJECTION

fuel

shut-off

No.1

and

No.1

delivery valve holder

Remove

Restore the delivery

the

fuel

;rime

high

this

tum

the

do

step b again

fuel injection timing

the

pump.

speed

control lever

{Fuel

Flow

shut-off valve.

button

pressurefuel

fuel

flow

the

crankshaft

the injection

crankshaft

when

fuel

TIMING:

valve.

fuel injection pipe from the

injection

delivery

pump.

from

valve

and spring

valve

holder oniy

to

the injection

in

the low speed position. ,

actuator.

Method}

Depress

energizes

through

into a proper

clockwise,

pipe.

in

the

reverse

to

verify

the

is

correct

stops

from.the

BTOC

17"

(STANDARD)

and hold

the

electric

the

injection

container.

looking

The instant fuel

timing.

direction

injection

if

the

with

the mark

injection

fuel

timing.

IT

~~~

the injection

from

the

to

the

pump.

the

pump

pipe

..

.

at

the

stops

just a

little

mark

on

the timing

pipe.

the

ADJUSTMENT

a.

If

the fuel injection timing

thickness

increase or decrease

will

b.increase the

or

ADJUSTMENT

Four kinds of shims are available in thicknesses

0.2mm (0.0079 in),

(0.0157

no with

A

shim

c.

After

correct.

d:Close

and injection pipe

f

is

incorrect,

of

shims under the fuel injection pump.

of

the shims

vary the timing by

thickness

decrease it

RANGE:

identification, measure the

calipers before using

to.

in) and 0.8mm (0.0315 in). These shims

CAUTION:

to

prevent

the timing has been adjusted, make sure it is

the fuel tilter valve and restore the delivery

ANGLE

BY

WHICH

INJECTION

TIMING

1°.

of

the

advance the

STANDARD

0.3m

Apply

sealant

oil

leaks.

to

the original

TDCMARK

FUEL.

~

shims

timing.

±

1.5°

(0.0118

thickness

it.

....-'...,~c:::2:1r

•

to

by

to

both

state.

change the

O.lmm

retard the

in),

0.4mm of

each

faces

19°

23°

ANGLE

INJECTION 15

AOVANCEO

(0.004

of

BY

WHICH

TIMING

An

in)

timing

have

shim

each

valve

FUEL

ALTERNATE

in the fuelliow' method, the delivery As

a resnit, there is a good chance for dirt particles inside the fuel injection however,

a. Disconnect

injection nozzle (cylinder b.Prime the fuel system. , c.

Slowly

swells at the free end of the injection pipe

instant, cbeck the position of

'to the mark

. approximately

ihto

METHOD

pump.

in

it is not necessary

No.1

tum

the

on

accouitt.when making a

to

fuel injection

crankshaft

the gear 1°

case.

retarded

remove

v!\lve

this

alternate method,

the delivery valve.

pipe

head).

clockwise until

the

This timing is

Take

this

shim

has to be removed.

to

at

the

fuel

and,

IT

mark with respect

1°

retardation

adjustment.

..-v:

get

just

at that

WESTERBEKE

Engines & Generators

39

"0

, _ J. "<::::I='

~~-

,

I

,

~.

ADVANCED

r-~

:-

~

REMOVING

NOTE:

Injector

THE

must

environment.

1.

Disconnect loosen

the lines

and

move

them

2.

3.

4.

bending Remove

the

and injector.

Unscrew

suitable

NOTE:

prior any hole.

by

side lift

The sealing injector injector

NOTE:

the and original

zle Carbon

the

injectors.

banjo

bolt that attaches the

the

deep

Clean

to

lifting

rust

or

If

the

injector

carbon

liuild

with

the

it

out.

injector seats

washer.

and is

reinstalled.

Greatest

nozzles

the

.needle

combinations.

assembly

deposits with a piece able

not

to

fice

to

avoid

INJECTORS

be

.serviced

the

high

pressure

at

their

attachment

out of

the

lines.

fuel

return line in

Take

care not

injector

the

debris

replaced

as

of

clean

possible

from

socket.

area

around

it

out

of

from

will.not

up or

the

aid

of

the

in

the cylinder head

This

washer

with a new

possible

they

are

precisely

valve

are

separately.

on

the

hard

wood.

the

surrounding

domage

the

falling

socket

Disassemble

in a "clean

lines

way

to

lose

the

cylinder

the

cylinder

lift

like,

wrench

should

care

should

matched

nozzle

However,

from

to

the

of the

injeCtors.

its

entirety

the

fuel

return

base

head

down

into

out

easily

work

the

be

washer

be

machined.

parts.

and

body

must

it

area

to

the

orifice.

FUEL

room"

the injectors and

injection

from

sea1ing

line

head using a

of

the to

the and

injector

to

free

on

a copper

removed

when

taken

Do

wash

be

would

of

the

Avoid

the

washers

to

injector

help

prevent

injector

is

held

side

it and

with the

the

in

handling

The

nozzle

not

mix

each

removed

be

nozzle

pump

top

each

then

advis-

INJECTORS

'a.

If

the

diesel

replace it. At the same

filter.

h.

Mount

the

c.

Operate bleed

the

at

intervals

injection

of

in

to

their

noz-

ori-

INJECfOR

STARTING

d.

If

the specification, shims

NOTE:

0.004

.

psi

(10

from

1.25

increments

e.

When vise

and

retaining nut

NOZZLE

BODY

INJECTOR

TEST

SPRING

TENSION

CHECK

AND

ANO

FOR

WEAR.

DAMAGE

fuel

in the injector body

An

in

replacing

TORQUE

FOR

SDII,4REnIF88

fuel

of the nozzle tester

time,

clean

nozzle

and

nozzle

the hand

air in the nozzle line,

starting

(O.lmm)

kgf-cm).

remove the

lever

of

nozzle

of

one

stroke per second while reading the

pressure.

PRESSURE

injection starting pressure

it

increase

mm

of

to

.

can

be adjusted

or

will

Ten

to

170

0.0020

the

specified

27

1991

'"

psi

to

decrease

vary

the

shims

are

mm

(0.0492

in

(0.05

shim,

grip

body

with a

±

1.8Ib-ft(3.7~

@'·...,.---INSPECTFOR

1-+'-'----

is

or

replace

holder

on

tester

then

move

(140·

kgl-cm)

is

by

removing

achieve

proper pressure

of

shim

injection

available

in

to

min).

the retaining

wrench.

torque.

.

±

0.25kgl-m)

TOIIQUE:

discolored,

the

fuel

the nozzle

several times

the hand

not within the

thickness

pr~ssure

in

0.0669

Tighten

tester.

to

lever

.

or

adding

..

by

142

thickness

in)

in

nut

in a

the

40

± 4 lb'- II

(5.5 K 5Kg! -m)

54Nm

6

WEAR

5

1

INJECTION

1.

Using injection

limit,

tester,

A

nozzle deeply tissue. blood

TESTING/ADJUSTMENT

the

nozzle

tester,

check the

starting pressure of

adjust or replace the

take

the

following precautions:

CAUTION:

Is

into

If

poisoning.

of

such the

it

enters

The

spray

velocity

skIn

of

the

fingers

bloodstream,

nozzle

nozzle.

injected

that

spray

When

It

may

and

and,

~~

!

.........

RECONDITION

.iT

Y. . ....

pattern

if

it exceeds the

using

from

the

penetrate

hands,

destroying

it

may

cause

(REPLACE

_

and

nozzle

V

I '

-.¥

WESTERBEKE

Engines & Generators

CHECK

FOR

.cAjl'BOAI

IN

OR

AROUND

NOZZLE

ORIFACE

DISASSEMBLY

1.

Clamp.

the

and

disassemble the nozzle

2.

Clean

the disassembled parts with clean

INSTALLING

L Install

2.

NOZZLE

NOTE:

with

new

TIghten

torque.

TORQUE

in

the

The

washers.

the nozzle

40

__

+.,~

'H(~---_J~

~·-+----.:1

AND

INSPECTION

nozzle holder in a

reverse

order of

copper

washers

on

the cylinder head

.

40

± 4lb-ft

~_<----TORQlIE:27

vise;

·remove

body,

spring,and

diesel

removal.

sliould

not

be

to

(5.5 ± 0.5

kgl·m)

±

1.81b

(3.75 K 0.25Kgf -m)

37Nm

the

nozzle

nut

needle.

fuel.

reused.

'Replace

the

specified

-H

GLOW

PLUG

TESTING

GLOW

To inspect the

then unscrew Thoroughly clean each ping's

and cleaning solution While cleaning, has eroded

Touch

PLUGS

plug,

remove the electrical tenninal connections,

or

unclamp

to

examine

too

much,

replace the

An

accurate

other to the body of plug will have a

used with multimeter

Re-install the plugs should seconds.

circuit. When reinstalling

compound

A

to

testing

way

to

test glow

one prod

to

the glow plug's wire connection,

1.0·-

the

plug

in

to test

.the

plugs

in

get

very hot

If

the plugs don't heat on

the

threads.

WARNING:

the

touch.

Be

careful

the

plugs.

the

1.5 or power drain

the engine and test them

These

each plug from the cylinder head.

remove

the

glow

olnn resistance. This

out of the engine.

(at the

glow

not

tip

and threads with a

all

the carbon and

tip

for

wear and burn erosion; if

plug.

plugs

is

with

an

ohnnneter.

plug,

as

shown. A good

You

(8

- 9

amps

per

the tenninal

up

glow

plugs

to

end)

quickly,

plugs, use anti-seize

bum

check for a short

Wi;,

become

your

fingeTS

.

soft

oil

deposits.

and

glow

method

can

withio 7 to

also

plug).

again.

COl} be

use a

The

very

when

brush

the

15

hot

it

TEstiNG A GLOW WITH

TESTING A GLOW

USING A .TEST

PLUG

LIGHT

AN

OHMMETER

TERMINAL END·

PLUG

TIP

A

WARNING:

than

3D

seconds.

GLOW

PLUG

TIGHTENING

Do

not

TORQUE.

keep a glow

7-11

ft-Ib

plug

(1.0

on

-1.5

for

m-kg)

+

more

Engines & Generators

41

STARTER

MOTOR·

DESCRIPTION

The

starter

can

be

roughly

• A

motor

section

•

An

overrunning

ture

torque,

• A

switch

ating

the overrunning

supplies

The high-speed arate ion

shaft. shaft exposed smoothly motor lever are

identical

load current te the mater.

starter

is a new

internal-reduction

from

the

A reduction gear

and

a pinion

outside the starter

without

shaft is supported

mechanism,

to

ADJUSTMENT

If

any

abnormality

should

be

disassembled and repaired.

Pinion

1.

2.

3.

Gap

Connect a battery

and

the

starter

out

and

stop.

A

CAUTION:

seconds

continuously.

Lightly stroke

If

decreasing

push the pinion back and measure the return

(called

the

pinion

0.0788in

is

decreased

which

clutch

preventing mater

section

(solenoid)

type,

motor

shaft;

shaft.

becoming

switch

conventional

AND

is

found

Inspection

body,

.

Never

pinion

gap

is

(0.5

to

2.Omm),

the

number

as

the

divided into

generates a drive

section

which

clutc!>

small,

starter.

the pinion

is

installed

The pinion

so

that the pinion

fouled

at

both ends

and

overrunning

ones.

the

following

power.

which

transmits

overrun

thi:ough

light-weight and

after starting.

is

operated

a lever

The pinion shaft

slides

only

between

sliding

part is

may

with

dust and

on

ball bearings. The

clutch inner circnit

an

when

and

is

called a

on

the motor

not

slide

grease.

REPAIR

by

the

following tests, the starter

(12V)

between

and the pinion drive should rotate

apply

battery

gap).

not within

of shims

number

voltage

the

adjust it

on

of

shims

the

starter

standard

by

increasing or

the

solenoid. The

increases.

terminal

for

over

range,

sections:

arma-

actu-

which

is

sep-

the

pin-

The

S

10

0.0197 gap

No-Load

1.

2.

Test

Connect as

When the the current

semble

the anuneter,

illustrated.

the switch is

starter must

the starter and repair it.

or

.-----------1

A

CAUTION:

tighten type

that

every

starter

which

of a direct-drive starterrotatlon in

contact

with

SOLENOID

Perform

.

satisfactory.

1.

the

Inspect (+)

and

M

and between between

the

body.

following replace the solenoid

the solenoid

(-)

and between terminals S and

the

body. terminals S and tenninals S and the body

voltmeter,

closed,

run

smoothly

starter

speed

UsB

thick

wlrss

tennlnal

securely.

makes a rotating

type

at

the

pinion

the

pinion

tests.

If

for

continuity

There should be

M.

and

battery

to the starter

the pinion

(at

is out of specification, disas-

as

starter.

tip,

geal

any

assembly.

Continuity

must

3000

rpm

BATIERY

much

as

This

is a solenoid

sound

When

be

careful

!fIhen

it

protrudes.

test result

between

no

continuity

and

tenninal M

protrude

or more).

possible

louder

than

detecting

nono

is

not

terminals

the

body

and

found

wiJJ

be

found

and

If

.

and

shift-

come

and

\

J

GENTLY

PUSH

BACK

-,,;,,,---n

,

.

PINION

GAP

NOTE:

Disconnect

2.

Connect a battery

and

M for (-). Have a switch in the +

The

pinion drive

A

CAUTION:

than

10

seconds

Engines & Generators

42

MULTIMETER

the

wire

to

should

Do

not

apply

when

from

the

solenoid's

extend

battery

testing

tennilUll

terminal

fully

current

the

solenoid.

M.

lead

out.

S for (+)

and close

for

more

it.

AnRACTlON

3.

Holding

terminal the

pinion

even

when

TEST

..-':~~~

test.

With a battery

S (+)

and

fully.

The

released

to

pinion

from

the

starter body.

must

remllin

holding

with

STARTER

~

COI.MICITOA

the

solenoid

manually

at

that

your

hand.

Off

pull

out

position

MOTOR

4:

Return

test:

With

minal M (-)

pinion fully.

when

and

'The

released

a.

battery connected

to

the

starter

pinion

from

must

holding

to

the solenoid

body,.

nianually pull

return to its original position

by

hand.

out

ter-

the

(

HOLDING

STARTER

1.

2.

3.

TEST

ASSEMBLY

Disconnect Loosen

the Remove

the

solenoid

the

fastening

4.

With

the

brushes

. remove

the

5.

Remove the

6.

Unscrew same

the

armature

the

washer.

iime;

adjustment

,....t::;;l.-Q-,

DAnERY

the

wire

two

screws fastening

assembly. two

long through bolts

the

brush

holder.

pulled

yoke

and

out.

cover,

pry

the

bolts

and

the

washers

will

come off

from

the

solenoid ierminal M

the

solenoid. Remove

and

Remove the rear bracket.

away

from

the armature,

brush holder

the

snap ring

remove

for

assembly.

Qut,

the

center bracket. At the

the pinion shaft

..

Inspect

tor

wear & chlppillfl.

LCtlNNEICTOR

OFF

(-).

two

screws

Then

pu1l

and

remove

end

play

RETURN

7.

Pull

out

the

reduction

front

brackei.

8.

On

the

pinion

side,

pinion

and

pinion

9.

At

eilch

end of

a

bearing ing worn

puller.

press-fitted

off,

replace

.

ADJUSTING SHIMS

TEST

gear lever

pry

the

sh~ft.

the

armature,

It

is

impossible to

in

the

front bracket.

the

front bracket

TERMINAL

snap

remove

and

lever

ring

out,

the

replace

If

that

assembly.

spring

from

and·pullout

. .

ball

bearing

the

ball

bearing

the

with

bear-

has

.

STARTER

LEVER

PINION

MOTOR

SNAP

SPRING

RING

Engines & Generators

it't

NOTE:

inspect.

(if

necessary) commutator, etc.

See

the

clean

replace

solenoid,

following

and

the

brush,

annature.

pages.

STARTER

MOTOR

STARTER

INSPECTION

Solenoid

Inspect the solenoid for continuity between terminals S M 'l'ld-between terminals S and

qe

found

between S and

between S

Inspecting

1. 'Check the armature with a growler

and

the body and M and the

CONTINUITY

The

circuited, replace the armature. Also check for insulation between insulated, replace the armature.

the commutator and its shaft.

CHECK

Armature

body.

No continuity should

M:

Continuity should be found '

'body.

tester.

If

it is short

If

poorly

,

ARMATURE

CHECK

and

Brush

1. Check

and

Brush

the

replace

the

2. Check

the

spring

will

springs if suspect. '

Holder

brushes.

brushes. ' ,

brush spring tension. A weak or defective

cause.excessive brush wear;

If

Insl~ec

worn out beyond

,BRUSH

i

--~I:RVICt

"','"

aRUSH STANDARD

LIMIT

'I,'

fiEIGHt' ' ,,'",

6.6 4,0

,CI

••

the

LIMIT

replace

Ibl

eIJSeLOTH

service

the

" "

",;

(3.0

kgl)

(l.B

kgl)

lirui~

2.

Measure the commutator O.D. and the depth Repair

or replace it

check

the commutator outside surface for dirtiness and roughness. crocus

COMMUTATOR

If

cloth.

0.0.

if

the service limit

rough, polish the commutator with

COMMUTATOR

STANDARD

,

LIMIT

of

is

exceeded. Also,

OUTSIDE

1.26

In

1.22

(32

DIAMETER

In

(31

undercut.

fine

mm)

SRUSH

HOLDER

3. Check for insulation between the positive and holder base. assembly,

If

piiorly insulllted, replace

Also check the brush holders for proper staking.

brush

the

holder

Engines & Generators

44

STARTER

MOTOR'

COMMUTATOR

Measure cent mica

STANDARD LIMIT

•·.·

the

segments.

or

replace

..

~CDMMUTATOR'

.~

Field

C~illnspection

.1.

Check

coil

and

2.

Check

of

the

coil.

3.

Check

undercut

If undercut

0.020

0.008

for

insulation

yoke.

for

continuity

the

poles

MICA

the

annature.

in

(0.5

in

(0.2

and

UNDERCUT

of

micaiusulation

exceeds

mm)

.

mm

..

UNDERCUT'

between

between both

coil

for

tightness.

one

between

the limit,

end

(brush)

ends

MULTIMETER

the

recondition

.of

the

(brushes)

adja-

the

HACKSAW

·BLADE

.

MICA

.

STARTER

A

CAUTION:

starter paint,

and

the

quality

grade

between

to

the

telminal.

Reassemble the starter

. disassembly, making

1. Pinion

(thrust iuijusting

reduction

a. Fit

ring

b.

Measure

axial

increase

WASHER

ADJUSTMENT

Bef~/e

Insta/llng,

Bange

and

mounting

lust.

startel

pertDnnance

of

the

wiring.

Use

the

battery

assembly

sure

of

shaft

end play adjnsbnent. Set

gap)

to

between.O.S

washer

between

gear.

the

pinion

shaft,

reduction gear washer

to

the

center

bracket.

end

play

by

moving

direction.

the

If

the

number

end

of

GEAR

AND

REASSEMBLY

tholoughly

surtaces,

lemove

lalgely

wire

of

sufncient

and

starter

and

in

the

reverse

the

following:

to

2mm

by

inserting

the

center bracket

the

pinion

play

exceeds

adjusting

washers

clean

all oil,

depends

fully

order

the

end

and

shaft in

O.5mm,

inserted.

the

size

and

tighten

of

play an

the

snap

the

old on

a8nlly

push

back.

FIELD

COIL

TEST

.

SNAP

RING

-_4f.<E'-O.5

2.

Greasing. apply

grease

a. Annature shaft

b.

All bearings.

c. Bearing

d. Bearibg

e.

Pinion.

f. Sliding

A

CAunON:

telminals,

3.

After

reassembly.

test

again.

Whenever

to

the

geaF

shaft

washers

sleeves.

portion

oflever.

Nevel

brushes,

check

mm

MAX

the

starter

following

and

reduction

and

smeal

DI

commutatDr

by

has

been

overhauled,

parts:

gear.

snap

rings.

the

startel

fitting

with

glease.

conducting a no-load

surtace,

Engines & Generators

.45

BIlWWATEBRUMR

fRN.

48Q~q)

. "

~

Disassembly

NOTE:

Refer

to

the

following

vievv.

The

pumP,1!S attru:hment They

may

the

puinp

if

removed.

1.

Remove cover

NOTE:

mended; gasket

If

reusable.

2.

Remove·the housing

3.

Remove cam

4.

Remove

S.

Remove

6.

Remove

7.

Support

Using

press

8.

The

Remove

9.

Support the

removeli

nipples

be

left

disassembly.

the

plate

Replacement

however,

submerged

it~

allowed

..

the'screw

from

the

the the

the

an

arbor

the

shaft

slinger

the

bearings.

in

six

gasket

to

impeller

the

pump wear front rear

pUmp

and

oil

bearings

fro!Il

threaded

place

or

Note

cover

plate

oj

the

if

you

in

water

dry,

the

with

and

housing. plate circlip,

circlip

housing

press

and

with

bearings

oil

seal

se~

and

inner

poge

for

parts

list

and

.

the

engine,

hito

removed the

port

. . .

screws,

cover

are

going

until

gasket

its

will

inlet

and

if

they

location

cover'

plflte

to

the

pump

will

shrink

have

outlet interfere

and

plate,

gasket reuse

is

and

is

it,

reassembled.

.

its

drive

screw

from

sealing

washer'

and

leave

washer

at

the

with a suitabie

from

will

remain

slinger.

race

and

the

and

water

mounting

the

pump

hi

the

and

push

remove

in

place. seal.

flange

drift,'

housing.

the

exploded

hose

ports.

with

positionhlg

and

the

recom·

keep

the

not

be

the

pump

tlie

end.

carefully

shaft

out

of

2. . Install 3

•.

Support

oil

:sem

s0t?R!' retaining

4;

Install

that

S.

Lubricate is

visible

pump

6.

Lubricate shaft harf,

7. Install #1) Remove

8.

Lubricate not

NOTE:

Coat

9.

Iilstall

the

oil

the

and

the

groove.,

the

outer

the

~dway

h\lUsrng.

the

imd

seat

washer

the

to

the

excess.

matter.

U!e

only

the

press

outer

rear

wear

cam

and

the

O-ring

seal'in

the

pump

pump.Lubricate

the

bearings

bearing

circlip

bearing

slinger

inner

it

in

and

plate

screw

install

lubricant

surface.

and seats

and

thruugh

harf

the

pump

front

and threads

the

and

cover

just

. ,

press

slide

the

of

clip

cam.

impeller.

that

Do

housing.

the

shaft

with

clears

the

on

the

it

onto

slotted

the

water

housing.

to

hold

Apply

and

comes

not

over-apply.

plate.

and

slide it

shaft

into the

the

rear

shaft

with

rear

circlip.

·the

shaft

openings

seal,slide it

Install

the

seal

sealant

inner

cam

Blade

positioning

with

the

thru housing

circlip .

bearings

so

that

of

the

over

the

outer

in

place.

(permatex

surfaces.

impeller.

.

(continued)

the

so

it

the

.

does'

)

Inspection

Inspect

corrosion.

all

parts

.

and

Reassembly

1.

Suppon

bearings the

1/32"

NOTE:

numbers

the

so

second

(.5mm) , .'

The

face

bearings

that

bearings

seals'

replace

the

drive

fiat

toward

those

inner

end

inner

race

suifaces

each

showing

race,

of

by

that

other.

Press

the

19/32"

have

wear,

the

shaft

cracks

shaft

extends

(15mm.)

printing

.

or

into

the

beyond

ana

Engines & Generators

46

g.1~

'9.

~!

Ii,l:ti

~

Iii

,

~

,

OJ

./'""'

,---"

NOTE'

THE

PUMP·REPAIR

KIT

(49000)

INCLUDES

ALL

THE

USTED

COMPONENTS

JI)(CEPT

ITEMS

1

AND

7..THE

KlT

ALSO

INCLUDES

A

PUMP

MOUNTING

GASKET.

ASSEMBLED

VIEW

EXPLODED

VIEW

,

ALIGN

;SLOnNTO

DOWEL,

.......

'/lVlt'cLLcH

FITS

INO

'

THE

SLOT

IN

THE

SHAFT

KEY

NO.

1 2 3 4 5

'6

7

8

9

10 11 12 13 14

'

15 16 17 18

PART NUMBER AND'PART NAME

QUANITY

48080

RAW WATER PUMP

1

49172 SHAFT

1

49170 IMPELLER COVER

1

48500

IMPELLER KIT (D-RING

& GLYCERIN) ,

1

34458 CAM

1

49171 WEAR PLATE

1

302575 DOWEL

1

48253 SPRING SEAL WASHER

, 1

34463 IMPELLER COVER SCREW

6

48359 IMPELLER COVER O·RING

'1

33041 D-RING

1~

33037 CAM WASHER 46662 CAM SCREW

1==

48254

SPRING SEAL

49169 LIP SEAL

1

:e

34464,

BALL BEARING

2

!;

33046 RETAINING INTERNAL RING

1

33044:

RETAINING EXTERNAL RING

1

m

49000

PUMP REPAIR KIT

1

=

37431 PUMP KIT (MOUNT!NG

BASKET

& FITTINGS)

,1

."

·C

WHEN

ASSEMBLING:

APPLY A THIN

COAT

OF

GLYCERIN

TO

THE

INSIDE

OF

THE

COVER,

THE

·COVER

O-RING,

AND

THE

IMPELLER

'

,,:s:,

."

,

..--...

-0

Z

..f:>.

CO

o

CO

o

--

·

ENGINE

ADJUSTMENTS

VALVE

NOTE:

engine s valves.

BOLTS.

Pull

off rocker shaft

Remove the cylinder

Valves adjusted stroke. order

Valve craokshaft cylinder #1. piston the look now in

Align

tinting marker the by and should

CLEARANCE

Retorque

A

WARNING:

engine to

is

cOld.

ing

order

of

theenginil.

the

specified

,-

off

the

air breather pipe

the

rocker cover bolts

aod

the

glow

craokshaft

(1-3-2

adjustment beginning with cylinder #1.

is

cylinder).

for

starting it's

the

cylinder the

#1

Piston at

rotating

after

for

are

at

Each

on

the

IDC

this

not

valve

adjusted

Top

slowly

Watch

it's intake

intake

the

move.

to

cylinder

for

Continue

towards

mark

on

craokshaft

point aod.the

ADJUSTMENT

the

cylinder

See

TORQUING

Adjust

Valves

torque

".

valve

plugs

be

easily

adjustmeot.

with

Dead

WESTERBEKE

and

for

valve

compression

the

IDC

head

the

valve

are

adjusted

Tighten

before

'

from

and

the

assembly.

from

each

rotated

the

cylinder in

Center

(TDC) of

is

adjusted

observe

the

intake

stroke

(the

to

rotate

to

close.

stroke

IDC).

on

the craokshaft

front

gear

of it's

compression

approximately

two

adjusting

_

following

three cylinder

the

valve

the

case cover

~alves

bolts

before

TIlE

CYLINDER

clearance

by

cylinder

the

cylinder

the

the rocker

rocker cover

of

by haod

operation

piston

craokshaft

This indicates

(the

cover

the

cylinders

to

position

the

piston

its

compression

the

of

to

open indicating

is

moving

piston

front

pulley

when

stroke.

20

degrees

for.the#lcylinder

.

adjusting

HEAD

when'

the

in

the

head

bolts

valves.

and'

to

expose

to

eoable

each

being

engine's

engines).

Rotate

the

valves down

slowly

the

piston

is

moving

with

positioning

Confirm

before

the'

tir-

take

the

firing

the

in :

and

the

for the

is

up

this

Adjust

the

Proceed to

Rotate

the

rotation

order. the

Adjust (0.25mm) stem.

Rotate

valves

IT

MARK

ON

PULLEY

each

Make

and

valves

in

#1

cylinder

the

next cylinder in

craokshaft

adjust

the

of

the

valve's clearance

feeler

sure

240

the

next craokshaft next cylinder in

gauge between

to

adjust

for

both intake and

the

firing

order:

degrees

all

in

the normal direction of

cylinder's valves in the

another

240 degrees and adjust .

the

firing.

order.

TIMING

POINTER

by

inserting a {O.0098

the

rocker

valves

while

TIMING

arm

t!'e

engine is

exhaust.

fiting

CRANKSHAFT

PULLEY

MARKS

INCHES)

and

!he

valve '

cold.

CYLINDER

\

SEQUEMtE

:

Make

a.

b.

,

...

1

""I

c.

cz:;

...

,

HEAD

the

following

Remove Slightly

to below.

TIGHTENING

the

specified

06

the

loosen

TORQUE

010

BOi.l'

LoilSENING

adjustments

cylinder

Os

head

the

cylinder

torque

65± 4Ib-!t (80", 5

06

014

3.CYLINDER

01

09

THREE

. .

in

the

()12

03

;18

when

cover.

head bolts

number

4

CYLINDER·

01

the

()11

~~----~-------4

engine

and

retighten

sequence

Nm)

..

03

is

cold.

themi

shown

EngInes & Gilnerators

Re-install the threads) belts. manual.

and

See

TIGIITENING

glow

plugs

assemble

(use

the

rocker cover

TORQUE

,O.25mm

(0.0098

INTAKE & EXHAUST

anti-sei1Oe

INCHES)

compound

and

rocker

SCHEDULE

en cover in

this

the

.

181166

AQ.JDIIMENtS

tESl'ING·ENGINE:U6\'v1PRESStOtl

....

a.Wamt:tlie'~iill,!ojiioj!/jlIDiJeerati

b,~m"J:il!l~·~il!t.Q);l~.)!!\!;

ff\~J;

·~I1j~Jl!'i.)l~~l]:.l,tIl!llW~$.i

lsq~e~n;

."

.

·etafffi'e.

'\)t!i~~'

:$l'1111l\Oit(

Alwitlr4({E~Lg.Q,~~Gat

OIL

PRESSURE

The engine's

by

the

oil

pressure

normal

operation,

60

psi

(2.8

and

NOTE:

A

newly reading an readings engine

OIL

Oil of

TESTING

To install a warming read

OIL SENDER

up

to

oil

pressure

will

and

the

PRESSURE

pressure

50

psi.

OIL

test

the

oil

mechanical

up

the

oil pressure

PRESSURE

AND

SWITCH

oil

pressure,

4.2

started,

60

psi

reading

vary

the

during

gauge

on

oil

pressure

kg/cm').

cold

(4.2

kg!clrf).

as

low

depending

rpms.

[GENERATOR)

at

1800

(or

1500)

PRESSURE

pressure,

the

remove

oil

pressure

engine,

set

gauge.

50

psi

at

1800

TORQUE 9 -13

operation,

the

instrument

will

engine

can

A warmed

as

35 psi (2.5

upon

the

rpm

should

the

oil pressure

gauge in it's

the

engine speed

rpm.

range

have

temperature

maintain

ft-Ib

(1.2

-1.8 m -

ENGINE

is

indicated

panel.

During

between

an

oil engine kg/cm').

sender,

place.

at

1800

ADJUSTMENTS

40

and

pressure

can

have

These

of

the

a reading

then

After

rpm

and

kg).

.

OIL

~~~SSUllE,

SENDDR

OIL

~~~SSUIRE----;~§H~"""'""

SWITCH

OIL

."

T·.R~~

OIL

PRESSU!RE-...-->il~~~

VALVE

OIL

FLOW

DIAGRAM

OIL

DRAIN

HOS,E,--'l

LOW

OIL

PRESSURE

The

specified

+

0.1

kg/cm'). A gradual

a

worn

sure

readings,

OIL

PRESSURE

An

oil pressure relief valvejs located

just

below

appoximately

safe

bearings.

see

the

injection

5'0

minimum

loss

For

additional

the

ENGINE

RELIEF

pump.

psi

[343

oil

pressure

of

oil

information

is

pressure

4.3 + 1.4

TROUBLESHOOTING

VALVE

on

the

This

valve

opens

kpal

and

maintains

usually

on

low

engine

at

that

psi

(0.3

indicates

oil

pres-

chart.

block

pressure.

.

)

Englnl's & Generators

50

ENGINE

ACTUATOR

The

BCU generator controls the engine senses (Magnetic Pick over

the.flywheel's monitors this signal the positioning allow speed Maintaining a

The following instructions

actuator.

1.

2. Unplug

3.

4. Start the

5. With

A final adjusiment

operated approximately

normal operating temperature. properly under normal operating conditions, but down

high amperage extreme ambient temperatures. The actuator turned in an additional

(

,

\.

(ELECTRONIC

(Electronic

engine

signal

BCU

its

more

or

depending

Tum

OFF

7/16

the 1 unscrew it

Apply a threads

turns.

Just

to

the

engine

control

on

the

generator.

frequency

the test for not shut loosen until a

full actuator nut.

Un-twist the actuator

adjustment should

under

stop

fully

under

;_.r

Control

speed

from a signal

Up)

positioned

ring

and

adjusts

plunger

less

fuel

on

the

steady

Hertz

the

DC

the

actuator

jam nut that

from

small

amount of

and

screw

snug

harness.

box.

NOTE:

engine.

that it is

engine ronning,

proper

engine shut

down

the

jam nut

shut

in

112

turn and

normal

may

more

loads

for a long

. ,

··d

;:.

GOVERNING)

Unit)

in

speed

electronically.

sent

on

the

gear

teeth.

The

if

there

is

any

the

DC

voltage

to

let

the

injection pump

delivery

amperage

the

up

Monitor

and

down

be

20

extreme conditions

112

~

operation

are

for

breaker

from

secures

engine

it into

the

jam

Turn

Tum

operating

only

and

thread

takes

secure

now

allow

operating

necessary

minutes

If

'tI

to

maintain a constant engine

load

of the

adjusting or replacing the

on

the control

the

engine hamess. Back off

the actuator

block.

teflon

engine block 4

nut.

ON

OFF

the

generator output

at the selected

depress

down.

goes

to a slow the

place.

it

wires

the

conditions. .

after tllegenset has

and

tlle

engine

period

the control

to

it

flywheel

BCU

discrepancy

to

the

on

sealant Reconnect

the

the STOP switch to

If

actuator in

Then thread the

in place with a jam

as

needed.

engine

has teached its

of time and/or under

box

The

from a MPU

bellhousing

continuously ACTUATOR

fuel

the

generator.

AC

generator.

box.

and

to

the actoators

to

the

DC

breaker

AC

circuit

frequency

the engine

idle

This

to

start and

shuts

down

fails

sUch·

as

may

need

ADJUSTMENTS

.

MAGNETIC

on

BCU

in

this

rack

5 full

actuator

on

breaker

does

speed,

slowly

to

shut

miming

to

the

to

the

be

The MPU is installed in the threaded opening of the flywheel bellhousing. This positions the the

teeth of the flywheel ring gear. Viewing crankshaft so as

gear's teeth directly under the opening. Thread the

into the opening until it gently contacts the flat of this

tooth opening one tom and then lock it in

jam nut.

approximately 0:030 inches away gear teeth.

'Ib ensure the MPU

the

.physical contact between the

If contact is felt between the the it. Replace installation procedure.

..

NOTE:

be

wiring the

through this opening, manually rotate the engine

(Thread is 3/8" x 24). Back the

This

crankshaft by 3600 by hand

MPU may

If

replaced

cable.

controller.

GOVERNOR

Below are the voltages normally circuit when the system is functioning normally. These

at

voltages are an approximate and should be

troubleshooting a system that is not functioning correctly. DC

Voltage into Controller Bat + to (Terruinal block

DC Voltage to Actuator ACT (Terruinal block

AC Voltage from MPU into Controller MPU (Terruinal block

This positioned from the flat The closer further

Bat·

to

ACT (5.5 -

to

MPU (2.5

voltage ;pread is the result of the distance tlle MPtJ is

away,

PICK~UP

will position the end of the

be·

if

necessary and repeat the above

replacing

without cutting and

Doing

CIRCUIT

(battery charging voltage

to

the tootll, tlle higher the the lower tlle AC signal.

[MPU]

to

position the flat of one

is

positioned

damaged. Remove the MPU and inspect

the

INSTALLATION

from

correctly,

to

assure

MPU

and

MPU

and

Resislance

Magnetic

Pick-Up

splicing

so

will

cause

VOLTAGES

found

#1

and

#2)

6.5

VDC)

#5

and #6)

-7.0

VAC)

#3

and #4)

of

tlle

flywheel

on

the side

MPU over

of

the ring

MPU

out of the

this

position with the

MPU

the flats

the ring gear teeth.

the flywheel teeth,

of

slowly rotate

there is no

(al

resl)

950

the

·1000

m~

~

-----

(MPU)

into

an

erratic

in the governor

13.5 . 14.5

ring gear

AC

signal. The

it MUST the existing AC signal

of

help in

tootll.

VDC)

ring

ohm

0.03Din

to

Engines & Generators

51

Component

ENGINE

COMPONENTS

Compression

Maximum between pressure

Injection Rocker

Rocker

Clearance

arm

Valve

Height

Valve

Stem

Exhaust

Valve

(valve

Valve

Testforce

Test

Warpage (bottom

Bend Timing

Lobe

pressure

"

permissible

average

compression

01

all

cylinders

timing

at

BToC

arm

bore

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

•.

and

stem

01

clearance to

Intake

margin

lip

Sinkage

seat Angle Width

spring Free Length

[kgl

(dial

Crankshaft

Idler

Idler pump

Camshaft

Fuel gear

height

lor

arm

shaft

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

Gear

0.0

between

shaft

guide

length

(lbf)(N)]

force

(lbl)(N)]

lace)

gear/camshaft

gear#uellnjection

injection

and

rocker

(oil

clearance)

0.0

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

valve

guide

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

clearance

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

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

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

thickness)

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

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

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

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

under

test

39.1

(1.54)

30.5

(1.20)

" 284.20

01

cylinder

head

reading)

01

Backlash

gearfldler

camshaft

gear·

gear/P.T.O.

pump

oil

pump

01

camshaft

SERVICE

Standard

inm

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

.427

..

"

difference

.......••..............•

shaft

..........••••....

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

0.05 -0.085

force

valve

gear

camshaft

gear

psi

(30.0

2942

•.

..42.7

(3.0kg/cm')

294

.....•..•..

18.910

(0.74449 -0.74527)

18.880

(0.74331-

.........

0.012 -0.050

0.00047 -0.00197

0.260

0.39

0.25

0.02 -0.05

1.0

0.5.0.25

(0.020 • 0.009B)

1.3

-1.B

.47

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

39.1

30.5

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

13.9.0.7

30.6.

136.7

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

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

(0.0020)

push

rod

.........

0.04 -0.12

(0.0016 -0.0047)

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

0.04 -0.12

(0.0016 -0.0047)

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

0.04 -0.12

(0.0016 -0.0047)

.........

0.08 -0.19

(0.0031 -0.0075)

...

0.07 -0.20

(0.0028 -0.0079)

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

35.72

DATA·

(inches)

at

280

rpm

kg/cm')

kPa

psi

kPa

17'

'18.930

-18.898

0.7440)

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

(6.6)

(10)

(0.0098)

(0.008 -0.0020)

(0.0020 -0.00335)

(0.039)

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

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

45'

(0.051 -0.071)

(I.B5)

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

(1.54) (1.20)

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

1.5

29. 2 ................................

64 • 4.4

0.05

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

max

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

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

(1.4063

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

Repair mm

............••.....•

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

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

(27.0

......

0.10

....

0.15

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

34.72

384

2648

0.200

(0.00787)

0.5

(0.059)

2.5

.46

-15%

(0.0039)

0.3

(0.0118)

(O.OIIB)

(0.011.8)

(0.011

(inches)

kg/cm')

(0.0039)

(0.0059)

(0.020)

1.5

(0.09B)

(I.Bl)

-15%

0.10

(0.012)

0.30

STANDARDS

Umlt

psi

kPa

B)

(1.3669)

'Component

ENGINE

Lobe

height

pumpcamshaft Aatness Clearance

and

cylinder

Clearance

joumal

and

Clearance gear

and

Warpage top

lace

Bore

in

Taper

and

round

of

Piston

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

Diametllr

Standard

0.25 Oversize

0.50 OverSize

Clearance

and

Clearance

No.1 ring

No.2

ring

Oil

ring

Clearance

No.1 ring

"No.2

ring Oil

Clearance piston

and

Clearance and

connecting

Thrust connecting

Connecting

AND

LIMITS

COMPONENTS

of

fuel

injection

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

ojflywheel

shaft,

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

cylinder

(0.009B)

(0.0197)

piston

Compression

ring

clearance

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

between

tappet

block

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

between

camshaft

bushing

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

between

Idler

of

cylinder

block

out·ol-

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

0.0

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

01

piston

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

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

between

piston

betlwen

piston

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

between

ends

CompreSSion

Compression

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

between

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

cylinder

between

crankpin

Jod

bearing

for

rod

big

end

rod

bendflwist

OJ5

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

0.05

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

78.0~·

(0.90527 -0.90551)

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

(0.00024 -0.00071)

ring

and

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

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

01

piston

......... _ .........

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

(0.00138 -0.00339)

..........

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

Standard

mm

(inches)

44

(1.73)

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

(0.0059)

max

0.03 -0.07

(0.0012 -0.0028)

O.Ol

22.944 -23.00

77

(3.0681 -3.06B9)

78.18-78.20

(3.0779 -3.0787)

78.43 -78.45

(3.0878 -3.0886)

0.006 -0.01 B ..........................

groove

0.06 -0.10

(0.0024 -0.0039)

0.05 -0.09

(0.0020 -0.0035)

(0.0012 -0.0028)

ring

0.15 -0.30

(0.0059 -0.0118)

0.15 -0.35

(0.0059 -0.0138)

0.20 -0.40

(0.0079 -0.0157)

0.035 -0.086

0.025 -0.072

(0.0009B -0.00283)

0.10 -0.35

(0.0039 -0.013B)

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

(0.0020)

max

(3.07

''''')

(0.0004)max

.93 -77.95

0.03 -0.7

0.05/100

0.15/100

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

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

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

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

(0.0020/3.94

(0.005913.94

Repatr Limit

mm

.43

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

0.50

0.15

.

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

0.l0

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

78.2

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

max.)

(Inches)

(1.3669)

(0.0197)

(0.0059)

0.20

(0.0079)

(0.0039)

(3.079)

77.80

(3.0630)

78.05

(3.0728)

78.30

(3.0827)

0.050

(0.00197)

0.30

(0.0118)

0.20

(0.0079)

0.20

(0.0079)

1.50

(0.059)

1.50

(0.059)

1.50

(0.059)

0.300

(0.01181)

0.150

(0.00591)

0.50

(0.0197)

'\

)

Engines & Gimerators "

52

SERVICE

DATA·

STANDARDS

AND

LIMITS

(

Component

ENGINE

COMPONENTS

Crankshaft

Diameter

of

Diameter

of

Runout

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

Clearance and

End

between

main

bearing between

connecting play

......•.........•...........••............

LUBRICATION

Presure

relief

valve

Presure which switch

FUEL

Injection

(valve

pressure)

STARTER

Pinion

No·load

No-load

Brush

spring

tension

Runout

Diameter

Undercut

...•...........••...••...............

setting

difference

oil

pressure

is

closed

SYSTEM

pressure

opening

MOTOR

clearance

characteristics 3 Cylinder

Terminal

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

Current

draw

Rpm

....•••••.•.••...................••....•

characteristics 4 Cylinder Terminal... Current Rpm

.•••••..................•.............•..

draw

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

length

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

.....•••....•.•......••...•............•..........

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

.•••.......••.....••..•••.......•..•........•••••.

of

commutator

of

commutator

of

mica

Specified

journal

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

crankpin

...........

journal

......•••..•.

crankpin

rod

bearing

SYSTEM

at

..........•...•...••....

.•..............•.......••.•

..........•....... : ..............

•...•..........••..••.....

.•..•.•••.................

.•...•........•.•.•.•.....

•.........•..............

......•.•......•...•.•.•.•••.•.•....

Value I Standard

Repair

inches(mm) inches(mm)

51.985 -52.000

(2.04665 -2.04724)

..47.950 -47.965

1.88779 -1.88838)

0.025

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

(0:00098)

0.030 -0.077

(0.00118 -0.00303)

....•.....

0.025 -0.072

(0.00098 -0.00283)

0.050 -0.175

(0.00197 -0.00689)

50

• 7

psi

3.5 ± 0.5

343.49

49.10

13729

(0.20 -0.079)

100A

3000

130A

3850

kgflcm'

kPa

7 ±

1.4

psi

0.5 • 0.1

kgf/cm'

kPa

1991

."

psi

140"

kgflcm'

...

kPa

0.5 -2.0

l1.5V

maximum minimum

llV maximum minimum

3.0

kgf------1.8

6.6lbf

.....•••.........•.......•••...

29.4N

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

0.03

...••......•.•.•..................

(0.0012)

32

••.•....••..•......•........... : ......

(1.26)

0.5

.................••............••.....

(0.020)

......••....•.....••...•..

•••...............•....••.

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

(0.0020)

(0.00394)

(0.00591)

(0.01969)

wear

.4.0

(0.0039)

Limit

0.05

0.100

0.150

limit

kgf

Ibf

17.7N

0.10

31

(1.22)

0.2

(0.008)

line

Component THREAD

PRESS

PARTS

Stop

solenoid

....•.........•..........

Water

drain

jOint...

Oil

pressure

switch

Torque

spring

set

FIT

PARTS

Sealing

cap : .....•.........•...........

Sealing

cap

......••........••..........

Sealing

cap

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

Expansion

Dipstick

plug

guide

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

OTHERS

Side

seal

.........•.................•.....

Main

bearing

(front

Oil

pan

caps

and

rear)

.•••....•.•..•...•.........•...•••.

.loctite

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

.Loctite

.

or

High-Tack

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

.Loctite

or

High-Tack

.....•.............

.•...•.........•...•..

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

Loctite

or

High-Tack

Loctite

or

High-Tack

.Loctite

or

High-Tack

Loctite

or

High-Tack

Loctite

or

High-Tack

Loctite

Sealant

#587

Ultra

Gasket

Sealer

Gasket

Sealer

Gasket

#587

Ultra

Gasket

Sealer

Gasket

Sealer

Gasket

Sealer

Gasket

Sealer

Gasket

Sealer

Gasket

#587

Ultra

#587

Unra

#5699

Ultra

Blue

.....•••••

#2

..........

Sealer

#2

..........

Sealer Blue

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

#2

.......•.•

Sealer

#2

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

Sealer

#2

....

Sealer

#2

..........

Sealer

#2

Sealer

Blue

......•.

Blue

....•.•.....

Gray

..........

Mating

Governor

Cylinder

Governor

Cylinder

Governor

Cylinder

main

Cylinder

Part

case

block

case

block

head

head & block

block

and

bearing

caps

block

Engines & Generators

53

ALTERNATORS

50

AMP

TESTINGJTROUBLESHOOTING

MITSUBISHI

ALTERNATOR

VOLTAGE

The integral voltage regulator device the voltage applied

. system

The regulator desigu utilizes all-silicou thick-film adjusted encapsulated possible

REGULATOR

which

senses the

to

the

voltage.

assembly

to

the

damage

techniques.

proper regulating valve,

to

protect the circuit and

due

to

is

an

system

voltage level

field

in order to

After the

handling or

e1ectronic

maintain

semi

voltage

the

entire

the

components

vibration.

switching

and

switches

a proper

conductors

has been

circuit is

and

from

DESCRIPTION·

The

following

that

are

Generators.

ELECTRICAL

The

charging regulator, circuit breaker and a of

the

use regulator back of the alternator.

It

is

desirable

voltage

loads

that provide charging

electrlcal

ALTERNATOR

The stator is connected rectifier package converts battery

Power alternator package

These

alternators produce a rated output of 50 or

rated

output is

rpm

at alternators range

of -40°

infonnation applies

supplied with WESTERBEKE'S Engines and

CHARGING

system

an

engine

DC

of

integrated circuits (IC's), the electronic voltage

is

very

compact

to

test

the

regulator)

are

the technician

system

system. .

using

a pennanent part of the

as

well

CIRCUIT

consists

battery

of

an

wiring harness, a mounted

with connecting cables.

and

is mounted

charging system (alternator the

wiring

with

an

operational test

as

the

major

DESCRIPTION

to

a three-phase,

which

contains six

the

AC

generated

charging and accessories,

to

the regulator

is

provided

contained in

achieved

an

ambient

are

temperature

desigued

to

212"F

in the stator

and

the field

by

the

field

the

alternator.

at approximately

of

to

operate

(-40°

to

100°C).

REFER

TO

THE

:

OIAGRAM

MANUAL WIRING

to

the

stal)dard

alternator with a voltage

interna1ly

hamess and electrlcal

system

and

components

full-wave

diodes.

The

to a DC

of

the

integral regulator

diode (or diode

6000

75°F

(23.8°C).

in

an

ambient

WIRING

IN

THIS

FOR

ALL

CONNECTIONS

alternators

DC

Because

or

on

and

will

then

of

the

of the

bridge

output for

trlo)

51

amps.

alternator

The .

temperature

the

ALTERNATOR

Use

this

exists

with

detenuined that the alternator or voltage

qualified

have a

A

WARNING:

alternator alternator

LOW

BATTERY/FAULTY

If

the

starter

of

spinniug

faulty

connection

problem.

PRELIMINARY

Before

starting

the

testing

1. Make

2. Check

if

it

is

3. Check tight.

and resistance and this could cause undercharging corroded battery cables could prevent the reaching a fully charged condition.

4.

Check A low readings in the

NOTE:

An selector the

batteries

with

the

starting

OK

and

TROUBLESHOOTING

troubleShooting

the

charging circuit or with

technician

can

become

until

section to detenuine

check

A

working

very

If

has

cooled.

it.

alternator

hot.

CIRCUIT

only

moans

or

makes

a clicking

the engine

to

life it is likely a

in the starting circuit

INSPECTION

the

actual alternator and

following checks

certain

your alternator is securely

the

drive belts for proper tension.

worn

or

glazed.

that

all tenuinals, connectors and

Loose or

or

the

condition

or

discharged battery

tests.

isolator

switch

house

battery

the

with a diode, a solenoid,

is

usually

so

the

starting

batteries.

but

not

problem

corroded

damage

of

the

mounted

If

the

is

in

the

are

recommended.

connections

overcharging,

to

the charging

battery

may

battery

the

isolator

hause

battery,

battery

Do

cause

in

is

if

a problem

the

alternator.

regulator

run~

not

touch

low

and

not

voltage

mounted.

Replace

.

plugs

cause

and

charge

false

or a

the

circuit

not

discharged

is

charging

the

charging

If

is faulty,

hot. A failed

the

sound

instead

battery

an

alternator

regulator,

the belt

are

high

system.

Badly

battery

from

if

necessary.

or misleading

battery

to

isolate the

alternator

circuit.

it is

or

a

•

clean

along

is

Engines & Generators

54

TESTING

A

certain away

1.

2.

THE

CAUTION:

that

from

Start the Engine.

Mrer

the

starting

battery

multimeter

a. If

the

voltage

alternator

b.Ifthe

voltage

exists

with

continue

ALTERNATORS

ALTERNATOR

Before

starting

everyone

sheaves

engine

set

is

with

is

clear

and

belts

has

run

for a

voltage

on

working.

either

at

DC

volts.

is

increasing

remains

Steps 3 through

the

alternator

around

the

engine

of

moving

during

test

few

minutes,

battery

toward

12

volts, a problem

or

6,

make

parts!

procedures.

measure

teIDJinals

14

volts,

the

charging

TESTING/TROUBLESHOOTING

MEASURING

Keep

using

the

circuit;

BAnEBY

ENGINE

the

a

VOLTAGE

OFF)

(

\.

MEASURING

BAnEBY

(ENGINE

3. Thrn off the engine.

Ensure

connections

4. If a t\1at

5.

Check condition

VOLTAGE

RUNNING)

that

battery

it is

on

the

battery

are

tight

selector

the

correct

battery

reading

voltage.

~pect

teIDJinals

and

clean

switch

is

setting.

If

should

all

in

the

your be

wiring

and

the

charging

battery

12

to

and

connections.

engine

circuit,ensure

is in

13

volts.

ground

good

TESTING

1.

2.

.

3. Start the engine.

4.

5.

THE

Connect connect

Wiggle voltmeter. battery obtained, output damaged

Repeat ground, The

volts.

it If

termlnaI terminal. inspect Jump battery) is

the

voltage,

circuit for

the

voltage

If

your

repaiJed

the

12

and

13-14

the

positive

negative

engine

The meter

and

or

if

the

wiring.

same

positive

reading

alternator is

at a reliable

test

B,

use

the

If

12

volts

wiring for

volts

from a 12

operate

volts;

.•

probe

to

probe

to

wiring

harness

should

indicate

should

not

reading

loose

measurement,

then

probe

should

service

reads

meter

is

not

breaks

the

varies,

or dirty

to B with

be

over

only

to

measure

present

volt

alternator.

alternator

the

output

ground.

while

the

vary.

If

no

check

connections

the

negative

the

between

or

under-charging,

shop.

battery

voltage

the

at

exciter

and

poor

oonnections.

source

(such

If

the

is

OK.

terminal B

observing

approximate

reading is

the alternator

engine

13.5

DC

as

voltage

the

or

probe

to

runuing.

and

14.5 have

at

excitation

terminal

the

output

and

R,

.

...

WESTERBEKE

Englneil & Generators

55

TESTING

CIRCUIT

THE

ENGINE

OUTPUT

RUNNING

i100RANGEB

TO

STAH:rEllliOLE~liIlD

1It6V10LET

TO

~£

..

'

K'3RELAY

R

ALTERNATORS

TESTlNG/TROUBLESHOOTlNG

TESTING

1.

THE

EXCITATION

Connect excitation terminal (-) lead

the positive (+) multimeter probe to the

to

ground.

CIRCUIT

R

on

the alternator and the negative

2. Thrn the ignition switch to the on position

the

2.5

TESTING

THE

multimeter volts

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OUTPUT

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3.

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field

rotor

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4. field

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the multimeter voltage, the voltage regulator is defective and must be replaced. excitation damaged wiring.

circuit probably is shorted or grounded.

is

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reading is obtained, an open exists in the

regulator.

and

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R.

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wiring

ALTERNATOR

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tests

sembled

do

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NOTE:

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BATTERY

The

minimum

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<::ranking

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•

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engine

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USe.

level.

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of

voltage

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hamess.

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circuit

checking

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problem

in

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studs.

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bas

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clean

REPAIR

indicate a failed

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12

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been

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control

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schedule

batteries.

charging

specific

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connections

to

your

engine).

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the

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the

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clean

terminals

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solenoid,

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SPECIFICATIONS·

ENGINE

(

Engine

Type

Displacement Aspiration

'Combustion

Bore & Stroke

Fi~ng

Direction

Compression

Dimensions Engine

Inclination

Weight

12.5f9.4KW

15.0!12.0KW

.

Fuel (full

12.5KW

9.4KW

15.0KW

12.0KW HP@1800RPM

HP@1600RPM

Chamber

Order

of

Rotation

Ratio

-Inches

Only

(dry)

Consumption amperage

load)

GENERAL

Diesel,

four-cycle,

oooled,

mechanism.

107.3cub~

Naturallyaepirated.

Swi~

1;Jpe.

3.07 x 3.62 1-3-4-2 Clockwise, 22:1

(mm)

Height Width: Length:

Continuous Temporary

5611bs 5691bs

1.19

gph

0.19

gph

1.42

gph

1.12

gph

25HP 22HP

12.5/9.4KW

vertical

Inches

inches

when

24.0

Inches

19.0

inches

34.6

inches

15'

25'

(254.5 (258.1

(4.50

(3.44lph)

(5.38Iph)

(4.24Iph)

four-cylinder,

In-line

(1.758Ifter)

(78 x 92

viewed

(609.6

(482.6

(878.8

(all

directions)

(not

to

kgs)

Iph)

fresh

overhead

valve

mm)

from

the

mm)

exceed

30

front.

minutes)

EDT

water-

&

15.0/12.0KW'EDT

ELECTRICAL

Starting

Batteiy

Capacl\Y

OC

Charging

Starting

Starter

Battery

Alternator

Aid

12

Vott, 800 50

Amp

Glow

12

Volt,

COOLING

Geneial

.

Operating

Temperaiure

Fresh

Water

Pump

Raw

Water

Pump

System

Capacl\Y

(Fresh

Water)

Raw

Water

1800

rpm

elbow)

Combustion

1800

rpm

Combustion

1500

rpm

Row

before

Into

at

(Measures

discharging

exhaust Engine

Requirements

at

Engine Requirements at

Air

Fresh controlled

170-190' F

.

Centrifugal Positive

beltdrtven

8.0

7-8

56

46

SYSTEM

(-)

negative

-1000

Cold

rated,

belt-driven

plugs,

sheathed

reduction

SYSTEM

water-cooled

with

(77

typ~,

displacement,

US

qts

(7.61tters)

gpm

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elm

(1.60

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cfm

(1.31

cmm)

ground

Cranking

Iype

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heet

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Angle

Speed

Seat

Angle

Clearance

Pressure

llming

TUNE-UP

427 384

(StaUc)

17' Intake

Exhaust 1800

1500 Intake

Exhaust

SPECIFICATIONS

psi

(30

kg/cm')

at

280

mm)

(140

rpm

+ 5 -0

psi (spill)

0.25 1991 17'

BTDC

(27

BTDC

45'

30'

rpm

(60Hz)

rpm

(50Hz)

45'

30'

Inches

+ n -0

kg/cm')

(0.0098

psi

kg/fcm').

General Oil

Filter

Sump

CepaCi\Y

(not

including

Operating (engine

011

Oil

hot)

Grade

LUBRICATION

Pressure Full

fitter)

Pressure

4.5

40 -60

API

SAE

SYSTEM

fed

system.

flow,

paper

element,

U.S.

qts

(4.3

liters)

psi

(3.5 -42

Specmcation

30,

10W-30,

CF

15W-40

spin-on

kg/cm')

or

CG-4,

type.

~

WESTERBEKE

Engines & Generators

63

AC

Single

Phase

Voltage

,

Voltage

Regulation Frequency Rating

SO

11.5KW 50

9.2KW

Generator

NOTE: Engine

Air

Generator

Ambient Recommendations

Regulation

(Volts

AC)

liz

(1800

rpm)

liz

(1500

rpm)

Cooling

Incmase

Combustion

Requirements

Compartment

Temperature

SPECIFICATIONS·

GENERATOR

BllIshless,

'Pre-lubricated,

Reconnectable, regulation regulator)

120 230

.511ertz

120 1201240

230

air

.supply

15%

(Single

four

(optional

or

1201240

Volis -50

:!:5%

no

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225 -250 Air

42

cfm

requirements

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50

Hertz

cfm

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12t'F

Phase)

pole,

revolving

single

bearing

single

phase

tmnsformer

soll~

state

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opel1lUon

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hertz

fullloa~.

no

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to

lull

95.8

amps

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40.0

amps

(60

Hz)

maximum

amps

cmm)

at

1800

(1500

GENERATOR

flel~.

design.

voltage

load.

rpm

rpm)

11.5/9.2KW

AC

General-3 P)1ase

11.5

Kw

·80

9.2

Voltage

(60

Voltage (50

AmpelJlge

(60

AmpelJlge (50

Engine Air (60

Engine Cooling

Generator

Ambient

Recommendations

Hertz

Kw·

50

Hertz

-3

phase

Hertz)

-3

Phase

Hertz)

-3

phase

Hertz)

,

-3

phase

Hertz)

Combustion

Requirements

Hertz),

at

1800

Compartment

Air

Compartment

Temperature

GENERATOR

BllIshless, lubricated, reoonnectable

voltage

Delta.

protection

Low

High DELTA

Low High DELTA

High DELTA

42cfm(I.19cmm)

rpm

100 -200

circuitry

Voltage

cfm

12t'F

EDT

(3

Phase)

siX-pole,

revoMng

single-bearing

lor

801l~

mE

WYE

mE

WYE

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design.

low

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12

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high

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240

Volts

480

Volts

24o,Voits 400

Volts

220

Volts

34

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17

Amps

34

Amps

16

Amps

29

Amps

emm)

Lead

)

with

AC

Single

Phase

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regulation: Frequency Rating

60

12.SKW 50

10AKW

Genemtor Air (60

Engine

Air

(60 Engine

Cooling

Generator Ambient Recommendations

regulation:

(Volts

Hertz

Requirements

Requiremenls

AC)

(1800

rpm)

(1500

rpm)

Cooling

Hertz)

at

1800

Combustion

Hertz),

at

1800

Compartment

Air

Compartment

Temperature

SPECIFICATIONS·

GENERATOR

BllIshless,

regulation).

rpm

(Single

or

1201240

Volts -50

no

load

Hertz

(.60%)

Volts

Incmass

cfm

(1.19

12t'F

lour-pole,

(optional

cfm

(1500

chn

Pre-Iubricate~,

Reeonnectable, regulation

120 230

.5%

.5

120

1201240

23OVoils

175 -200 NOTE:

operation

42

100 -200

Phase)

revolving

single-bearing

single-phase

solid-state

Volts -60

Hertz.

to

lull

(4.95-

cmm)

(2.83 -5.66

(SO't)

Hertz

load.

no

loa~

to

fullloa~.

66

Amps

6B133Amps 27

Amps

5.66

cmm)

aIr

supply

15%

rpm).

cmm)

maximum

fiel~.

design.

banslormer

voltage

for

GENERATOR

50

Hertz

12.6/1

General

-3

1l.6KW ~ 60 Hertz

10.4KW -50

Voltage

-3

(60

Hertz)

Voltage

-3

(50

Hertz)

Amperage (60

Ampemge (50

Engine Air

(60 Engine

Cooling

Generator

Ambient

Recommendations

-3

Hertz)

-3

Hertz)

Combustion

Requirements

Hertz),

Compartment

Air

Temperature

O.4KW

AC

GENERATOR

Phase

Hertz

phase

Phase

phase

at

1800

rpm

Compartment

EDT

(3

BllIshless, lubricated, reconnectable voltage proiectlon

Low High DELTA

High DELTA

Low High DELTA

High DELTA

42

100 -200

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cireuitry

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cfm

12t'F

lor

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WYE

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cmm)

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(SO't)

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deSign.

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maximum

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high

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240

Volts

480

Volts

240

Volts

400

Volts

220

Volts

38

Amps

19

Amps

38

Amps

18

Amps

32

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Engines & Generators

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AC

Single

Phase

Voltage

.

Voltage

regulalion:

Frequency

Rating

60

12.5KW 50

9.4KW

Genemlor Air (60

Generator

Ambient

Recommendations

regulation:

(Volts

Hertz

AC)

(1800

rpm)

(1500

rpm)

Cooling

Requiremenls

Hertz)

all

BOO

Compartment

Temperature

SPECIFICATIONS

GENERATOR

Brushless,

rpm

(Single

or

120/240

Volis -50

no

load

Hertz

(.60%)

Volts

Volis

Increase

12fF

four-pole,

slngle-beartng

single-phase

(optional

Volis -60

Hertz.

to

full

no

104

104/52

60

cfm

(6.37 -7.0B

air

(1500

rpm).

(sot)

Pre-luMcaled, Reconnectable, regulation regulation).

120 230

.5%

.s

120

120/240 230

225 -250

NOTE:

operation

Phase)

revolving

solid-stale

Hertz

load.

load

10

full

Amps

cmm)

supply

15%

maximum

field.

design.

transformer

voltage

load.

-

GENERATOR

Three 12,5

9.4

Voltage

(60

Voltage (50

Ampemge

(60

Ampemge

(50

Generator

for

50

Herlz

Ambient

Recommendations

Genemlor Air (60

12.5/9.4KW

AC

GENERATOR

Phase'

KW;

6D

HERIZ

KW -50

HERlZ

-3

phase

Hertz)

-3

Phase

Hertz)

-3

Compartment

Temperature

Cooling

Hertz)

at

phase

1800

Hertz)

Herlz)

Requirements

.

rpm

EDT

(3

Brushless, lubrtcaled, 'reconnectable voltage protection

Low High DELTA

High

DELTA'

Low High

DELTA

High DELTA

225 -250

NOTE:

operaUon

six-pole, single-bearing

for

Delta.

Solid

clrcuHry

Voltage

WYE

Voltage

WYE

Voltage

WYE

Voltage

WYE

Voltage

WYE

Vollage

WYE

12fF

(Sot)

cfm

Increase

(1500

(6.37-7.0B

air

Phase)

revolving

design.

low

voltage

stale

voltage

maximum

supply

rpm).

field.

WYE,

regulalor

240Volis 480

.

240 400Volis

230

3BAmp,

18

Amps

37

Amp'

17

Amps

30

Amps

cmm)

15%

for

Sealed

12

read

high

Volis Volts

Volts

50

Herlz

with

•

AC'GENERATOR

Single

Phase

Voltage

regulation:

Frequency

Rallng 6D

15.0 50

12.0KW Genemtor

Air

(60

Generator

Ambient

Recommendations

regulation:

(Volts

(1800

KW

(1500

Cooling

Hertz)

at

Temperature

AC)

rpm)

1800

Compartment

Hertz

Requirements

rpm

(Single

Bru,hless,

Pre-lubricated, Reconnectable, mgulation regulation).

120 220

.5%

.S

120

120/240

220

225 • 250

NOTE:

opemUon

or Volts·

no

Hertz

Volts

four-pole,

single·bearing

single-phase

(optional

120/240

50

Hertz.

load

10

no

load

Volts

cfm

(5.66 • 6.37

Increase

(1500

12fF

(Sot)

Volts·

full

10

105

105152.5

45.2

air

rpm).

Phase)

revolving

solld'state

60

Hertz

load.

fuliload.

Amps

cmm)

supply

15%

maximum

15.0/12.0KW

field.

design.

transfonmer

vollage

for

50

Herlz

Three

15.0

12.0

Vollage

(60

Voltage' 3 Phase (50

Ampemge

(60

Ampemge· 3 phase

(50 Genemtor

Air

(60

Generator Ambient

Recommendations

EDT

AC

Phase

KW·

60HERIZ

KW·

50

HERIZ

• 3

phase

Hertz)

·3

Hertz)

Requirements

Hertz)

phase

.

Cooling

at

1800

rpm

Comparbnent

Temperature

GENERATOR

Bru,hless, lubricated, reconnectable voltage protection

Low High DELTA

High DELTA

Low

High

DELTA

High DELTA

225.250

NOTE:

operation

(3

siX-pole, single-bearing

for

Della.

Solid

circuitry

Vollage

WYE

Voltage

WYE

Voltage

WYE

Voltage

WYE

Voltage

WYE

Voltage

WYE

cfm

Increase

(1500

12fF

(Sot)

(6.37'

air

rpm).

Phase)

revolving

design.

low

voltage

slale

vollage

7.08

cmm)

supply

15%

maximum

lleld.

Sealed

12

Lead

WYE,

high

regulator

240

Volis

480

Volts

240

Volts

400

Volts

230Volls 38

Amps

18

Amps

37

Amps

17

Amps

30

Amps

for

50

with

Herlz

(

'"'

WESTERBEKE

Engines & Generators

65

SPECIFICATIONS·

ENGINE

8.0/6.0

Engine

Type

Displacement Aspiration Combustion Bore & Stroke Firing Oirection Compression Weight

Inclination

Compression Minimum

Spilled Valve Engine

Injector Valve

Valve (engine

Engine

General

Oil

Sump

(not

Operating

(engine

011

Order

of

Rotation

liming

Seat

Angle

liming

Pressure

Seat

Angle

Clearance

cold)

Speed

Filter

Capacity

including

Oil

hot)

Grade

Chamber

Ratio

Pressure

(Static)

filter)

Pressure

KW

EDT,

10.0n.5

GENERAL

OIesel,

four-cycle,

coo~d,

vertical

mechanism.

80A

cubic

Inches

Naturally

aspirated.

Swirtlype.

3.07 x 3.62 1-3-2 Clockwise, 22:1

8.0

10.0

11.5

12.6 Continuous

Temporary

TUNE-UP

427

384

17· 45·

17·

1991 Intake

Exhaust O.25mm

1800 1600

when

EDT

EDT EDT EOT

25·

SPECIFICATIONS

psi

(30

psi

(27

(spill)

,

BTOC

.71 - 0

45·

30·

(0.0098

rpm

(60

rpm

(50

LUBRICATION

Pressure

fed

Full

flow,

paper

3.9

U.S.

q1s

50 -60

psi

API

Specification

SAB

IOW-30

three-cylinder,

in-lna,overhead

(1.318

liter)

inches

(78 x 92

viewed

from

477lbs

(216

520

Ibs

(236

520

Ibs

(236

520

Ibs

(236

15·

(not

to

exoeed

kg/cm,)

at

psi

(140.5 -0

IncheS)

Hz) Hz)

280

kglcm')

SYSTEM

system.

elemeni,

spin-on

(3.71i1ers)

(3.5 -4.2

or

kg/cm')

CF,

CG-4,

l5W-40

mm)

the

rpm

,

KW

fresh

water-

valve

front

kilos) kilos) kilos) kilos)

30

min.)

kgflcm').

type.

CG-4

EDT,

or CI-4'

11.5/9.2

General Fuel

InJection

Fuel Nozzle Fuel Air

Cleaner

Fuel

Starting Battery

DC

Charging

Starting

Starter

Cold Engine

Requirementa 60

Hz

General

Operating Fresh Raw

Raw at

1800 (Measures discharging exhaust

Systam

(Fresh

Pump

Filter

Lift

Pump

Battery

Capacity

Altemater

Aid

Cranking

Amp

Combustion

at

1800rpm

Temperature

Water

Pump

Water

Pump

Water

Row

rpm

before

Into

elbow)

Capacity

Water)

KW

EDT.12~6!10.4KW

FUEL

SYSTEM

Open

flow,

self

priming;'

No.2

diesel

ali

(eotane

rating

of

45

In-line

plunger

type

(BOSCH).

Throttle

type.

Cartridge

type

(PN#030200).

Replaceable

12

ELECTRICAL

12 800-1000

'

50 Glow

12

Draw

240 -250

Air

41

GODLING

Fresh controlled

170-190·

CentJffugal

PosHive

beildrlven 7-8

5.0

paper

voil

DC

lift

SYSTEM

Vol~

(-)

negative

Cold

Amp

rated,

plugs,

sheathed

Vol~

reduction

amps

chn

(1.16

cmm)

SYSTEM

water-cooled

wilh

F

type,

displacement,

gpm

(25.9 -29.6

us

q1s

(4.7

filter

cartridge.

capacity

of

5'

(1.5'mm)

ground

Cranking

Amps

beil-drtven

type

gear,

(approx.)

,

blOCk,

heat

(77

thennos!atlcally-

exchanger.

-88'

C)

me1allmpeller,

robber

gpm)

liters)

belt-driven.

impeller,

or

higher).

solid

(CCA)

EDT

state

\

)

Engines

66

& Generators

Single

Phase

Voltage

regulation: Frequency Rating

60 lo,oKW

50

7.SKW

Generator

NOTE:

Engine·

regulation:

(Volts

Hertz

(1800

Hartz

(IS00

Cooling

Increase

Compartment

SPECIFICATIONS·

AC

GENERATOR

Brushless, Pre-lubricated, Reeonneclable,

regulation

regulation). 120

230

>5%

.5

AC)

rpm)

air

supply

120

120/240

230

225 -250

Air

15%

100 -200

(Single

four-pole,

single-bearing

single-phase

(optional

solid-state

or

1201240

50

load

to

(.60%)

Volts

elm

Hertz

elm

Volts -60

Hertz.

full

load.

no

load

83.3

83.3/41.6

22.6

(5.66 -6.37

opera6on

(2.83

-

Volts -50

no

Hertz

Volts

Requirements(60

for

GENERATOR

Phase)

revolving

field.

daslgn.

transformer

voltage

Hertz

to

full

load.

Amps

emm)

Hertz)

at

1800

rpm

(1500/pm).

5.6Itcm~I~,

1

Three

PhaSe

10,0

KW-60

7,S

KW -50

Voltage

-3

(60

Hertz)

VoHage

-3

(50

Hertz)

Amperage

(60

Amperage (50

Engine Generator

Air (60

NOTE:

-3

Hertz)

-3

Hertz)

Compartment

Cooling

Requirements

Hertz)

at

Increase

o.on

Hz

phase

Phase

•

1800

.5KW

AC

GENERATOR

phase

rpm

air

supply

15%

EDT

Brushless,

.

lublicated,

reeonneclable

voltage

protection Low

High

DELTA High

DELTA

Low High DELTA

High DELTA

100 -200 225 -250

Delta.

Voltage

VoHage

for

50

Hertz

six-pole, single-bearing

eimuHry

efm elm

(3

Phase)

revolving

for

low

Solid

state

WYE

(2.83 -5.66 (5.66 -6.37

operaUon

field.

design.

voHage

WYE,

voltage

240 480 240

400 230

35 IS 30

14

24 emm) emm)

(1500

Sealed

12

Lead

high

regulatorwtth

Volts Volts Volts

Volts Volts

Amps Amps Amps

Amps Amps

rpm).

Single

Phase

Voltage

regulation: Frequency Raling

60

8.oKW 50

6,oKW Generator

Air

(60

NOTE:

Engine

regulation:

(Volts

HedZ

(1800

Hartz

(1500

Cooling

Requirements

Hertz)

at

Increase

Compartment

8.0/6.0

AC

GENERATOR

Brushless, Pre-lubricated, Reconneclable, regulation regulation).

120 230

.5%

.5

AC)

rpm)

1800

rpm

airsupply

120 1201240

230

175 -200

15%

100 -200

KW

or

1201240

Volts -50

no

load

Hertz

(.60%)

Volts

for

50

EDT

(Single

four-pole,

single-bearing

single-phase

(optional

Volts -60

Hertz.

to

full

no

66

Volts

66133

22.6

elm

(4.95 -5.66

Hertz

operatIon

elm

(2;83 -5.66

Phase)

revolving

design.

transformer

solid-state

Hertz

load. load

to

full

Amps

Ainps

Amps

emm)

(1500/pm).

emm)

field.

voltage

load.

NOTE: Generator compartment ambient temperature should not exceed must be provide to maintain temperatures below this stated temperature.

(

l2:tF

(5ifC). Forced ventilation

HBEKE

67

GENERATOR

INFORMATION·

USE

OF

ELECTRIC

The

power

than

more Some

motors

others.

Split-phase

under

similar

commonly

machines,

started, 7 avoided,

ven motors to load

compressor, motor

In

nected

such

times

as

whenever

by a small

reqnire

run.

The current

connected

to

which

general,

to

medium starting loads

required

is

required

require circumstances,

used

or

where

as

much

for

the current

MOTORS

to

start

an

electric motor

to

keep

it

much

more

(AC)

motors

than

on

easy-starting

loads

are

applied

small

power

tools.

current

generator. from 2 to 4 times

to

example,

no

possible,

required

it.

An

load

is

required

to

start

if

the

Capacitor

to

start

electric

will

require more current

connected.

is

considerably

running

current

after

to

it is

start

started.

them

require more current

other

types.

They

loads,

such

as

washing

after

the

motor is

Because

as

to

electric motor

run,

they

their

require 5

use should

is

and repulsion-induction

as

much

current

any

motor

varies

motor

to

will

connected

start

115-Volt

be

approximately

to

motors

to

are

to

be

start

with

an

than

start,

to

be

dri-

as

the

air

a

con-

as

follows'

MOTOR

SIZE

(HP)

116

1/4 1/3

1/2

3/4

1

'NOTE:

In the above table the maximum

more

for

some small motors than

for

this is that the hardest starting types (split-phase) are

made in larger sizes.

Because

motors

be

seconds.

off

on

REQUIRED

Run

generator's

indicted

should

the

heavy

is

required

damaged

all the

if

it

can

If

difficulty

other electrical

electric

motor.

OPERATING

the

generator

capacity,

on

the generator's data plate. The output voltage

be

checked

generating plant

voltmeter or ampmeter

load,

check

itwith a

NOTE:

When the vessel in which the contains that the vide one 120 volt panel. This will ensure good motor starting response from the

generator:

AC

equipment

generator~

AMPS

FOR

RUNNING

(AMPERES)

3.2

4.6

5.2

7.2

10.2 13

AMPS

STARTIN,~)

(AMPERES

6.4

.

9.2

10.4

14.4

20.4

Amps

for

larger ones. The reason

surge

of current needed

for

only

an

instant,

bring

the

motor

is

experienced in starting motors, tum

loads

and,

if possible, reduce the load

the

up

for

generator

to

speed

SPEED

first

with

no

load

applied,

and

finally

loaded

periOdically

and

is

portable

of

AC

hot leg

to

ensure proper operation of

the

appliances it supplies.

not

installed meter and

generato~

120 volts only,

terminal block be configured

for

the

vessel~

then at half the

to

its

full capacity

to

monitor voltage

amprobe.

it

is

distribution

FOR··

.

to

22

..

4'

to

32.2'

to

72.S'

to

29.2'

to

40.S'

26

to

52

for Starting

is

not

starting

will

not

in a few

as

If

an

AC

and

is

i~ttilled

recommended

to

pro- .

GENERATOR

Frequency indicated

•

When output

•

When output

·

Theref~,

· generator's dipswitch

generator changed

·

sensmg

GENERATOR

•

Maintaining Connections corroded,

salts,

build sive

• For petroleum-base over

•

In

addition

inspected

FREQUENCY

is a direct result of engine/generator speed,

by

the

following:

the generator

frequency

is

60

the generator

frequency

is

50

to'change the generator's

drive

engine's speed must be changed using the .

on

the

ECU.

The

and

the

PC

board

changed

MAINTENANCE

reasonable cleanliness

of

terminal

and

insulation surfaces may start conducting if

dust,

engine

exhaust,

up.

Clogged ventilation openings

heating

unusually

all

surfaces

and

reduce<;llife

severe

coatings

to

reduce

to

periodic cleaning, the generator should be

for

tightness of

overheated terminals

•

The

drive discs

on

single checked petiodically if possible and

for

any

evidence of incipient cracking

sho~ld

not

be

allowed

accelerate cracking. The bolts which

to

the generator shaft must

g,

identified

ners

•

The

rear maintenance noisy

• Examine of shaft should motion wear. will

rub

Carbon

by 6 radial marks,

of

the

head.

armature

or

roUgh-sounding,

bearing

is

required.

at petiodic intervals.

be

detected

is detectable, inspect the bearing

Repair

must

be

and

cause major damage

Monoxide

Detector

WES'IBRBEKE recommends mounting a monoxide

monoxide, even in small amounts, is deadly,

The

leak elbow/exhaust

.

are

If

carbon

clean air

detector

presence

from

the

of

engine

hose,

entering your

monoxide

and

correct the problem

in

carbon

boat.

ADJUSTMENT

is

run

at

1800

rpm,

the

AC voltage

Heitz.

is

run

at

1500

rpm,

tlle

AC voltage

Hertz.

frequen~y/voltage;

AC

output configuration

connections

..

boards and

carbon,

conditions, thin rust-inhibiting

should be

rusting

all

and

loose or danlaged bearing

to

become

be

is

However,

have it replaced.

when

made quickly

the vessels living

monoxide

or

generator or

or

that

is

present,

on

the

voltage

is

important.

of

windings.

and

rectifiers

etc.

sprayed

may

are

allowed

may

cause exces-

or brushed

corrosion .

connections, evidence of

wires.

generators

for

tightness

should

of

failure.

rusty

because

fasten

the

hardened

one

lubricated

at

each

if the

force

or

to

generator.

steel

and

bearing

No

side

is

applied.

and

major

SAE

of

the 6 cor-

sealed;

shaft for

components

carbon

quarters.

fumes

ventilate

indicates

from a nearby

from

the

an

the exhaust

area

immediately!

as

the,

of

the

become

to

be

Screws

Discs

rust

may

dtive

disc

grade

no

becomes

movement

If

side

Carbon

exhaust

vessel

with

)

....

WESTERBEKE

Engines & Generators

68

The following insight into problems

brushless

ulation.

trols,

troubleshooting

between cause

lems

are

Keep

in mind

ity

is

required

that

lethal

extreme Only a few

NOTE:

generators

Owing

covered in

that a basic for

voltages

caution

basic

When

fault

troubles\1ooting

to

the simplicity

and·

effect

this

are

is

essential

tools

jindin~,.

BT

GENERATOR

chart

is

desigued

which

may

be encountered with the BT

operating

is

the

troubleshooting,

present

on

compound

of

the equipment

relatively

is

text

fundaroental

are

easy,

once

understood. Most potentialprob-

of

this

manual

knowledge

and

always

in the

circuitry;

when

troubleshooting a generator.

necessary for diaguosis

troubleshoot components

TROUBLESHOOTING

to

give

transfonner

the relationship

of remember

therefore,

and

electric-

and

in

reg-

con-

repair.

the

order

CHART

These

are

hmd tools:

meter capable of reading

sion

required

Before attempting

the

problem nessing problem

equipment

than initial trip to the problem equipment, bridge

of these died early

indicated

as

the

problem. In

which

rectifier,

easily

and

below.

in

an

arnpprobe

less

reading component

any

repairs, get a clear

possible, preferably

some

is related

fault.

so that replaceableparts, the problem can be efficiently.

to

the

Bring

basic

if

the problem

and

a quality volt-ohm-

than

one

ohm

due

to

the

winding

from

cases,

this

method of operation rather

repair

an

may IDols

such

should

as:

resistances. explanation of

individual

bring to light a

with you

diodes and

be found in

reme-

preci-

wit-

on

one

the

1.

LOW

VOLTAGE

F.

Selector

8.

Rotor

Components

8-2

Exciter

8·3

Rotor

8-1

Exciteor

A.

(1-1

+2)

Exciter

2.

RESIDUAL

A. G.

D-3.Transformer

C-3.Main F.:

VOLTAGE·

(1-1

+2)

Bridge

Rectifier

StatorA~xlliary

Selector

A

r r

+ - I . b I

1

COMPONENT

REFER

60-100

VOLTS

AC

Switch

Rotor

Diodes

Field

Windings

Rotor

Windings

Stator

Windings

EXCITER

Exciter

Stator

Windings

Auxiliary

SWitch

r--------------~----l

1 B :

.1 ,

1 ,

+1

II

21

~---~-------------~.

Windings

: * : i

1 2 3 I

a,b,

CIRCUIT

00'

TO

c

FAULTY

1

THE

INTERNAL

3.

NO

AC

C.

·(1

+2) 8-4.Suppressor 8·2.Diodes D.

(1

+2) B-3.Rotor

i,',~2

: I I

:rI_~"1

: 3 I

.-------~~

CHECKS

WIRING

VOLTAGE

Exciter

(4-6

Compound

Field

~!rl~.~I~i~'-~~'

DIAGRAMS

OUTPUT·

Stator

open/sh'qrtened)

Windings

1

I

I :

-'

MAIN

Windings

Transformer

'1'

2

I·

=#:=

I :

'1

2 3 I

1:.:. _ ---

STATORJROTOR

Windings

!i

_______

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COMPONENTS/TRANSFORMER

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WESTERBEKE

Engines & Generators

69

~

'r

__

~YE_~_OW~&_RE_0-J

____

REO

GREEN

:II

~~_

=

~

"

BLUE BLUE

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w

:3

=

60cyc.

50

eye.

w

~

BT

GENERATOR

Main

Stator

1. Group #1. The

lifted

fonner

Lead

to

totally

2. Group

lifted

former order lead #2 should be lifted

NOTE:

lifted stator connections

3. Main Stator Auxiliary Windings. for

,

double

bridge

VoltagelHertz

NOTE:

' "

these

Compollnd

1. Group 1. Resistance lead transformer and

2. Group lead transformer

Windings

resistance

lead

#4 from

and

lead #6 lifted

#5 should be lifted

isolate

#2. The

lead

#1

and

lead #3 lifted

to

totally isolate

No

continuity

these

windings

lead connection lifted off

rectifier (0)

No

continuity

winding

the

resistance

from

leads

and

of

the

connection

groups

the

insulated

stator

the

ins1llated

the

should

the

two

are

measured

and

should

or

from

groups.

the

Transformer

value

#4 from the

2.

#1

from

red

iead

Resistance

the

red

and lead

insulated tenninal stod

#8

value

insulated

#7

value

is

teni:linal

from

the

from

the

windings value

is

terminal

from

the

stator

windings

the

be

jowul

case

ground

red #3

bar.

be

found

to

the

generator

is

measured between lifted

lifted off

is measured'between lifted '

teni:linal

lifted off

TROUBLESHOOTING/SINGLE

.

)

measured

AI!:;

terminal block in order

of

measuted between ACterminal

teni:linal

The

between

the

lead

the

between

below

teni:linal

group

#1, .

billow

of

g.:pup

block:

between

or

between

resistance

the

AC

terminal of

lifted

off

between

case.

below

AC

terminal

stad

below

AC

terminal block'

the

trans·

block.

the trans· '

blocl<;.

#2,

any

of

the

values

black

the

either

the

block.

the

of

the

In

PHASE

3.

Transformer Auxiliary Windings. Resistance is measured minal block switch in the the windings be

ta the case/ground

Selector

This

switCh

optional position

NOTE:

'stator

bridge

Bridge

The illustration below

AC

terminsls and

tenninals.

NOTE:

correct

between

the

VoltageIHe~

#2

and

#3 red leads that come

to

no

continuity found

Switch

is is

AV'R

is

..

With

the

windings

rectifier

Rectifier

When

removing

polarity

the

yellow

of

the

bridge

EI:.EC

position

connection

totally isolate

from

or

to

(6

Stud

normally

installed,

selector.

are

and

set

the

switch divided, the

other

Wiring

shows

the

cOlor

or

reinstalling

connection

either

coded

wire

lifted off the

rectifier (0)

and

bar.

these

either

BT

in

the

switchis toggled ki the

i1)

ELEC

one

group.is.

group

with

the

#1

red lead lifted off

Off this same bar, lift

from

the

windings.

of

these,

of

the

transformer groups.

only)

COMP

position.

position

exCited

through

.

the

color

coded

wires

at

the

connections.

on

the

(+) and

(-)

AC

ter-

the selector

aw\jliary

There should

connections .

If

BLEC

the

exciter

through

the

A.1T.R.

wires

at

the

(+) and

(-)

maintain

DC

tenninals.

an

the,

two

DC

\

j

BLACK

(TO

BRIDIIE

NOTE:

No

continuity

these

lifted

leads

RElm~ER)

(TO

SELECTOR

t~

SWITCH)

or

(TO

.

should

to

the.

generator

SELECTOR

be

found

between

either

of

'

case/ground.

TWO

",'

1~~II~:-1r+.:::~

"

AVRPLUG

REO

'

,

(TO

HERtz

BAR)

SWITCH)

Engines & Generators

illii.TAGE/iiERTZ

CONNECTION

BAR

BLACK

SELECTOR

SWITCH

70

BT

GENERATOR

TflO.UBLESHOOTING/SINGLE

PHASE

('

CURReNT ARe

1

DIFFeRENTLYBIlrTEST.

POINTS

ReCTIFieRS

CONFIGUReD

ARE

THE

4

TESTING

BRIDGE

4. Leaving the negative (-) ohmmeter lead on point #4, touch point #5 with the positive (+) lead. No deflection of the needle should occur.

S.

Place the positive and the negative (.) lead on point #3. The ohnuneter should not register any deflection deflection indicates connections deflection.

If

the rectifier fails any

defective and should be replaced.

NOTE:

results

Component

A. Exciter

A-I

&A-2 A-I A-2 12.9 ohm

C.

Main

C-I 0.089 C-2 0.089 ohm

Auxiliary Windings

C-3 0.85 ohm

lind the ohnuneter should again register no

Different

from

the

Resistance

Stator

49.4 ohm

Stator

ohm

THE

RECTiFIER

(+)

lead of the ohimneter on point

infinite resistance). Reverse these

style/model above

testi.

.

of

the needle (no

of

the previous tests

meters

may

produce

Values·

B.

Excitor

11.5 ohm B-1 1.05 ohm,

Compound

D.

D-I D-2 0.007 ohm

Auxiliary Wmdings

RotorlField

B-3 8.9 ohm

Transformer

0.007 ohm

D-3

5.02ohm

C

(I

- 4)

opposite

r-------------------l

I B I

, ,

A

-

+:

'00:

II

. : * 4 I

I b I

~

_________________

I 1

,

3 I

J

2'

I !

! !

SLIGHTLY

SAME.

. 3 . bearing.

#1

it

is

D

E.

j A.C. 'Thrminal

G.

Bridg~

The model code number is found stamped in the generator housing on a flat surface above the rear generator carrier

.

NOTE:

rated the

drive

.

COMPONENT

Exciter

1. Windings A-1

2.

3. Wmding A·2

NOTE:

has

colors,

Rectifi~

These

lower

generator

engine

Stator

Resistance readings for exciter windings A-I and A-2

with the selector switch in the between the positive the bridge ·rectifier

have the continuity to the generator case/ground.

WmdingA·1

Resistance readings for exciter windings A-I with the

selector switch yellow wire and the black at the AY.R. plug

Resistance readings for exciter winding

selector switch green wire lifted off the negative (-) tenninal rectifier tenninal

Tlie

been

changed

however,

E

.,

3

V1

.,

.7

Bo~rd

.

two

model

BT

than

the

capabilities

is

rated

according

since

horsepower

RESISTANCE

E Selector

H.

~Optlona1

generators

of

to

produces

CHECKS

are

the

generator.

the

capabilities

kilowatts.

Switch

AVR

used

Windings

and

A·2

COMP position are taken

(+)

and negative (-) leads lifted off

(0).

Neither

in

the ELEC position is taken between

in

the ELEC position is taken between the

(0)

and the red wires lifted off the positive

of

the bridge rectifier (0).

white

striped

wiring

to

solid

colors

.remain

.s

W2

'7

the

GREEN

on

same.

RED

..

-

of

these two leads should

earlier

model

on

current

\ 'la'

I

\I\.ACK

'"

wu.c:m

BUICK

.,

RED/WHITE

(l'O

HI!RTlNOLTS

BLUE/WHII'E

(fO

BLUE/WHITE

(TO

18TERM.

HEFI17NOLTS

BAR)

BLACK/WHITE

(TO

BRIDGE

RECTIFIER)

on

models

However,

of

(0).

A·2

with the

of

the bridge

generators

generators,

+

AVR

eAR)

PLUG

BLACK/WHITE

(TO

YELLOW

(l'O

the

SELECTOR

(+)

the

IWHITE

SWITCH)

L.

~fErro.r----------~~~j_~;;;:;;~~~;;=

~

WESTERBEKE

Engines & Generators

71

BT

INTERNAL

SCHEMATIC

·50c~

(W/OPTIONAL

GENERATOR

WIRING

AVR)

..

BTGENERATOR

"

""NOTE:

Refer

to

the

text

and

12

diagrams

STUD

INTERNAL

for

the

proper method

WIRING

of

testing

for

SCHEMATIC

resistance

and

continuity.

A+

11

I 2 I I I

L

~

L

L-~

A

EXCITER

D

AUXILIARY DIODES ROTATING

SUPPRESS()R'.

C

MAIN MAIN

D

COMPOUND

AUXILIARY

G

BRIDGE

:

___________

____

______

~~~~~~~~J

ORANGE

~~~~

GREEN

COMPONENT

STATOR

(6)

" '

STATOR

RECTIFIER

WINDINGS

ROTOR

FIELD

WINDlNGS

WINDINGS

_____________

WINDINGS

AUXILIARY

TRANSFORMER TRANSFORMER'

1>t

4

3:

nJ

G I ' WHT/GREEN •

+

AC

BLACK

-Kf-

AC~~~----------------------------~

YELLOW

RESISTANCE

(A,B,C)

WINDlNGS_1.5-1.BQ

WINDlNGL.019-.021Q

____

r-------.,

I I

'I i i

I I 3 I 3 , WHTI

L

____

nJ

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10.0Q

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1.0-1.2Q 11Q/inlinile

7.0-B.OQ inlinile

20-22Q

_

VALUES

[OHMS]

=9"...==

L4~ll.-I'-~-J

I

DT

GENERATOR

I

SINGLE

PHASE

6'

5'

9

3

2'

7

8

BlK

•

12

STUD

COMPOUND TRANSFORMER

--',

)

ACTERMINAL BOARD

BRIDGE RECTIFIER

I

,.

WESTERBEKE

Engines & Generators

72

",

JUNI:TlON

TERMINAL

1 & 4

BREAKER

Testing

1.

Residual

2.

,

Residual

The

amount generator the problem/fault

Voltage

This voltage is from

magnetism in the exciter stator measured between the no·load The presence following generator components

INTERNAL

a. Exciter Rotor (B·l a,

b.

c.

d. Compound

The fault

in

a. Exciter Stator (A·l & A·2) b. c.

d.

e.

'!\velve ings should cause the generator

150 volts the bridge Correct indicates components

.

,lithe

then include a

on

Rotating Field (B·3); Main

Stator (C·I &C·2); and

the

exciter

Bridge Rectifier Selector Switch (F) Main Stator Auxiliary Compound

(12)

volts

DC

voltage

generator

Voltage

of

no·load

can

be

10·14

the

the generator running

of

WIRING

Thansformer

lies

in

circuit:

'Il:arisformer

volt

AC

between each

is

applied between the lifted (+) and (.) leads of

rectifier, + to + and . to . ).

the

fault

b, d or

and

voltage

an

indicator of where in the generator

may

lie.

volts

AC

voltage produced

AC

residual

SCHEMATICS.

one

or

more

(G)

DC

excitation

produced

is

in one

e.

does·not produce

c.

' . ,

BT

GENERATOR

produced

(6

~tud)"

Neutral and Hot

at

voltage

b, & c)

Wmdings

is are

& (B·2);

(D-I & D·2).

of the following components

Auxiliary

of

to

hot

lead and the

with

twelve

or

more of the

by

the

18,22

volts

by

the

field.

This.

leg(s)

60

hertz.

an

indication that the

OK.

Refer

(C·3) .

Wmding

the exciter statoi wind·

produce between 140 •

neutral

volts

DC

above

140 • 150

volli!

AC

(12stuif)

generator voltage is

with

to

(D·3)

(12

excitation

listed .

Ac

TROUBLESHOOTING

3.

The absence of fault with the the compound transformer Apply

1~

as

explained m paragraph andlor compound transformer will

cause the generator engine shorted excitation is

4.

Voltage output

(25 rotor/field explained in paragraph 2 should voltage to

the

original

BRIDGE

The

windings transformer terminals lows:

Diodes supply through measured

fier

RECTIFIER

bridge rectifier

in the

of the rectifier during engine operation is

120Volli!

17·55

in therectill.er'convyit

it

to

which the exciter rotor

across

during

120

g·17volli!DC

Failure

of the produced sent, cause the generator

due

by

to

any

voltage

main

stator

vol~

DC

excitation to the e:,citer stator

windings

output greater than residual

output

(D·3).

.

NILFIL

tl:je

engine operation is

NILFIL NILFIL

the magnetism in the exciter

to

continued.

• 100

volts)

B·I, B·2

volli!AC

'Windings

Volts

bridge

the exciter stator

or

and,

when

low

output.

is

supplied

generator

The

AC

the (+) and (-)

rectifier

to

produce residual

from

the

windings

2.

A fault m

windings

to

load down and

eventually produce smoke

indicates a

B·3.

Excitation

produce

removed,

AC

voltage

stator

(C3)

voltage

measured

120/240

,

NILFIL

,

17·

55

'volts

!Iris

AC

of

the exciter stator to induce a

revolveS.

terminals

as

follows:

120/240

g·17voltsDC

will

result in a weak

windings.

C~1

fault

and

voltage

generator

D·I and D·2.

the

and

in the exciter

of

the

voltage

the

AC

The DC

of the bridge recti·

A weak

stator,

voltage.,

and C·2

main'stator

such

as a short

less than

the

generator as

a partial

from the

compound

across the

to

DC

voltage

field

which

indicates

andlor

windings

as

will

auxiliary

as

field

the the

rated

rise

return

AC

fol·

and

being

is

pre·

will

a

.

in

field

,

BRIDGE

RECTIFIER~~~;~~

,

TESTING BRIDGE

NOTE:

conjigured

THE

RECTIFIER

Currimt

BT

differently,

Generators'use a bridge

connectiQns

are

~~~~~~

the

rectijier

same.

that

r.'

=~I

~

is

Testing

,for

(Meter

:

1.

2.

3.

the

Faults,

Set

needle Connect the

#4. contact points register no

Remove the lead, meter's needle should deflect showing a passage the

with

used:

the

ohmmeter

to

Thking

the positive (+) lead

negative

momentarily touch points

rectifier.

WESTERBEKE

Engines & Generators

73

Bridge

Simpson

zero.

the deflection

Rectifier

an

Ohmmeter

260

at 70DF

scale

positive

(.) lead to point #4

(+) lead

ohmmeter's

#1, #2, #3,

for

of meter

on

and

any

(21

RXI (+

from

negative

#5.

of

the

from

and,

#1, #2,

when

voltage

DC)

and set the

the

ohmmeter

(.) lead,

The ohmmeter

points

point #4

with

each

through

touched.

the

and

#3.

point is

and

the

momentarily

positive

to

point

should

connect

(+)

The oinn·

touched,

diodes

in

BT

GENERATOR

TROUBLESHOOTING

Exciter

1.

DIODE'

2.

Rotor/Field,

Auxiliary windings group a, b and

terminal winding illustration

0'

a, b and oftenninaIpointsA & B, B need appears. fault. of ground.,

Rotating Field Windings. of noted striped

ohmmeter connections

ing

verify lifted,

This

windings.

points

on

groups.

clock

point either left or right

c.

to

unsolder

If

There

the

three

the

exciter

as

wires.

appears.

the there should

would

Position

and count off

Measure

these

this

occurs,

shouldbe,no continuity found between

terminal points and

"RED,wHIT~(REliI

rotor.

the

(+)

and

Measure

between these two connection points.

need

not

If

this

resistance reading.

indicate a short to

the

occurs unsolder

be

c.

Locate the

exciter rotor

the

resistance

connections

unsolder

The

field

(-) connections of the red &

the resistance

be unsoldered unless a

no continuity

for

these

exciter

rotor

porcelain

&C,

R<)fer

winding

With

ground

knobs

to

locate terminal points

value

between the pairs

and

C &A.

unless a faulty

and

verify

the

rotor shaft/case

to

the

illustration

connections

value

the

connection

these connections

to

the rotor shaft.

with these

auxiliary

as

shown

,from

There

the

with your

faulty

three

in the

the

is

reading

winding

any

above

are

white

These

read-

and

field

12

no

RESISTANCE

.

' "

:

in

place

with

on

the

diodes

as

illustrated, volt-

the

headlight

High

'flOWS

beam 12V

INFINITE

BLOCKING

NOTE:

meter

the

auxiliary

4.

When age

pas,8es

giow

11

OHMS

THROUGH

,

'-

,-'

--I

rlllr::ki=·:-=:----~~'---:-.:..--

Attempti~g'

will

give

erroneous

winding's

leads

are

put

through

brightly.

+

----~

THE

_~;

-j::I-

INFINITE--"

to

check

,readings

connections.

across

the

diode

'

DIODE

oilMs

diodes

diode,

'allowing

o

1:iiJ

BATtERY

S.

Reverse the leads across the diode. The diode should block

voltage passing through

not

glow,

or it

a.

ShoUld

the

directions,

b.

Should

the

directions,

In

botb

a

and

Check tbe resistance and

the

integrity of

field

windings.

may

bulb

tbe

bulb

tbe

b

'.

glow

not

diode

glow

diode

above,

tbe

~!9,Q,E

it,

and the headlight should

faintly.

glow

with

leads

connected in

is

open

internally.

witb leads

is shorted

tbe diode should

values

resistors connected between the

connected

internally.

of tbe rotating

be

replaced.

field

VALUE

an

ohm-

due

bright

in both

windings

BATTERy

to

bulb

botb

)

3.

Diodes. rectify auxiliary voltage The

a some battery. A the

diode

Six

diodes are mounted

the

AC

voltage produced

windings

to

the rotating field

diodes

common

short

automotive

jumper leads and the generator's 12 volt starting

or

an

above

without having

to'

check it

can

be

open

with

to

DC

easily checked

12-volt

in

a diode

an

on

the

by

the three

voltages

to

ohmmeter.

and supply

windings.

in

place with the

high

beam headlight

can

easily

unsolder and isolate each

exciter rotor;

groups

this

be found

with

~

they

of

DC

use

bulb,

of

6. Rotating Field between

.,'

IUld.(-)

7;

S~ppressor.

"lifted

A

shorted

the

AC

WESTERBEKE

Engines & Generators

74

Wmdings

the

two

terminals

(Infinite

from

tbe (+)

suppressor

output voltage

(Reading

red&\i>hite wiiesconnected

of

tbe exciter rotor

reil<fugs

and

(-) terminals

will

destroy the rotatiag field and

to

drop

taken

as

between

on

to

zero.

shown.

hoth

yellow ieads

tbe

exciter

.

to

the (+)

rotor.)

cause

GENERATOR

FREQUENCY

NOLTAGE

CHANGES

NO-LOAD

Voltage being

,1.

2;

3.

VOLTAGEJHERTZ

If do Bar. AC

The Hertz

The VoltageJHertz

diagrams

blue/white connect to

,

for

NOTE:

and if

to

lator will produce

VOLTAGE

adjustment

governed

The

To

confinn

a

momentary The momentary the

voltage (230 between at

50.0-50.5

To

raise (non-conductive under transformer. soften at smaIl times laminated'sreel ing

shims

there

not

change

Simmy

tenninal

blue or

terminal

order of

60

Hz.

When

the

correspond

by

the

sele,ctor

voltage

switch,

no-load

(moderate)

produces

load

output

volt

50

hertz).

121-124

hertz).

or

lower

the

steel

laminated bar

The

reITiperatures

redilctiQR

be a"cbmplished

bar

and

the

is

no

automatic

the

reconfigyre

for

the

blue/white

that

the

numbered

Connection

below).

sense

abnormally high putput

To

or

blue lead

the

correct tenninal:

See

the

optional

Blue/White

to

the

incorrect

ADJUSTMENT

is

made

compound

is removed is

from

volts

the

material)

material used

in

rio-load

to reduce

transformer

CONNECTION

wiring

hertz

the generator

ensure a

BT

(Blue)

Hertz

with

the

transformer.

must be in

voltage, start

by

the

voltage,

iu tM'176° F (80

voltage

the

lead

to

WIRING

the

load

to

the

generator

no-load

the

generators

no-load

at

by

on

chang~

the

voltage

60.0-60.5

shims

are

placed,

on

for

voltage

gently

the

core.

regulator

the

VoltagelHertz

AC

voltage

should

will

connections

Bars

may

proper

AC

tenninal

stud

SCHEMATIC.

regulator

lead

is

the

unit is operating

and

voltage.

generator regulation

COMP

position.

ille

generator

excite

the

after

voltage,

120

hertz

of

varying

or

top

of

the

shimming

(l

to 3

tapping the

gap

between

and

transformer.

the

volt

should

be

(232-236

thickness

remoVed

cClInpouriif

should

0

C)

range.

volts)

top

the

Note

leg(s)

from

can

of

exist

BAR

(AVR)

installed,

Connection connections ,

be connected

be

set

on

be

reversed

connection

6(Vl}

not

correctly

cause

to

the

to

~roduce.

some

(as

in

follow

block,

it

should

for

50

Hz,

is

installed

positioned

at,

the

generator

apply

volts

not

A

some

the

at

the

5CW2)

regu-

.

N

~.

to

~C;;;:~~

6 5 4 4

,

N~:::~:::::j~H1120V60HZ

6 5 4 " 8

u~=~=~

Terminal

Wiring

connections needed

quency

NOTE:

below

are illustrated in

Connections

the

compound

::::;;;;"0:::::::::;;;'

N

Block

...

Wiring

1 and 4

transformer.

,

:::~:::2~(

'

-'

Connections

to

obtain

proper voltage

the

diagrams

are

above.

located

B

o~

two

L1230V

•

L2

240V

and

fre-

red

terminals

50Hz

60Hz

CURRENT

(REPOSITiON FOR

50Hz)

BLUE

MODELS

THIS

WiRE

VOLTAGE/IIERTZ

CONNECTION

EARLY

BAR

MODELS

'YELLOWIWHITE

/ ,

"

RED/WHITE

...

WESTERBEKE

Engines & Generators

'

RED/wHITE

'"

' .

75

'

GENERATOR

FREQUENCYNOLTAGE

. .

CHANGES

GENERATOR

1.

Frequency 1800

lSilo

2.

To

change

a.

Reconfigure

stud

Install

F~EQUE~CY

is a

direct

rpm = 60

rpm =

50

Hertz Hertz

generator

terminal block following

the

correctly

selected.

b. Properly

board

the

115V

0

'®

1'3

I-

\'§'

N

connect

to

the

neutral/ground

breaker

box.

unused line

50Hz

®

~

Ll

result

frequency,

the

AC

the

line

connections

When

sense

230V

CHANGES

of

engine/generator

follow

output

connections

the

rated

AC

breaker

leads

from

on

to

the

brass neutral/ground

Druy

one

connection.

SIX

50Hz

N

LI

(HERTZ)

these

on

illustrations

for

the

voltage

the

AC

breaker

line

is

present,

STUD

c.

Note:

On

six

AVR

is

speed.

steps

the

below.

Hertz

below.

6/12

d. Shut off

Then

e.

sensing

and

stud

in

tie

off

AC

VOLTAG.ECONFIGURATIONS

50

f.

Close

120V

installed,

correspond

connection

the

#1

dipswitch

hertz

selected -

turn the

Shut

OFF

the

no,load

needed,

add

laminated 60

Hertz

the

monitor

operation.

60Hz

to

bar.

20

the

AC

or

steel bar

No-Load No-Load

AC

stud

AC

reposition

the

hertz selected

amp

DC

on

the

BCU

ON

for

DC

breaker

AC

breaker

voltage.

remove

.of

models

the

panel

to

the

50

hertz,

back

and startihe

If

voltage

shim

material

the

q)mpound

oruy

when

blue/white

on

the

breaker

proper

OFF

on.

adjustment

voltage 121-124yolts

voltage

b~i.ker

120/24.0V

Ll

2 5 N

and

load

60Hz

the

generater

an

optional

lead

to

voltage/hertz

and

move the

position for the

for

60

hertz.

unit.

Monitor

is

from

under the

transforriter.

232-236

volts

and .

THE

GROUND

TERMINAL

TilE

SHOWN

BLOCK

GENERATOR

IS

BOX

ON

INSIDE

)

THE

I~/"

~

li

W'

~.

~I

~.

I-

LOAD

CONNECTION

115v

1

U;

:

1

:

..

r-I~

50Hz

a=o 0

®:

(j)

®

®j'

'I~

rJ

_w·

:::'1<::-'

u~1

~w

-~

u~.

0

,

N

L

~I

..

1:-

LOAI)

CONNECTION

~.

:

l;;l

:

~

1

I-L

~

W'

~.

~

u

~

~I

u

~.

1-

.

LOAD CONNECT I ON

230v

lo:::J'

rJ

-w'

~~.

u<

~w

-~

u~

=-1

:)

"'I-I~

TWELVE

50Hz

=

(j)

®

=

....

N

If.·

1

•

I-

..

LOAI) CONNECTION

lHE

GROUND

TERM I NAl

:

THE"

GENERATOR

1

~

,.

:

11

.

~

111'w~HT

~1~9.:

L

tf~k'

STUD

0

®

U

"1

T

HE

GROUND

TERMINAL

:

T

HE

GENERATOR

1

I-

:

~

I-I~

~

BLK

_w

I

~~

SHOWN

BLOCK

ON

t

s.

I

NS I DE

BOX

-§:~

..

121118

_

AC

VOLTAGE

SHOWN

BLOCK

ON

IS INSIDE;

"BOX

~~

THE

u~

~w

-~

u~

CONFIGURATIONS

N

THE

_r~ . I-'-'+"~

~

! =>:0: •

:

~~

;~u~

LOAD

CONNECTION

WHEN

WIRING_I,OV/50Hz,

A

JUMPER

LOAD

CONNECTIONS.

120v

60Hz

o a=o

2 @ ®

® 0

l"i7q7fj

1

~B;~

LOAD

CONNECTION

WHEN

WIRING

A

JUMPER

LOAD

CONNECTIONS.

IS

REQUIRED

L,

-

:::

a:::r

120V/60Hz.

IS

REQUIRED

120/240v 60Hz

/ ® ®

N

L,

~ ~

"

LOAD CONNECTION

BETWEEN

LOAD

COI'INECT

BETWEEN

0=

,~

(j)

L,

1

'4

1

:

1

:

1-

..

f-I

)

l~ri!!'K~~.~=~-~.

ION

(j)

i@

L2

THE TERMINAL THE

:

1

:

~

:::~

;;;

~ ~

11m]

GROUND

SHOWN

BLOCK

GENERATOR

lo:=~·ol

~3J'K~

==

ON

THE

IS INSIDE

BOX

I!n

!

Engines &'Generators

.

76

.

GENERATOR

FREQUENCYNOLTAGE

CHANGES

GENERATOR

Generator Frequency

rotational speed, When the generator

voltage ontpnt frequency When the generato! is runnlng

voltage output frequency

FREQUENCY

is

as

indicated

is

CHANGES

a direct result of engine/generator

by

the following:

runnlng

is

60

at

HertZ.

at

is

50

Hertz.

Therefore to change the generator's

To

speed must be changed.

~n

tJ:e

D-Net diesel

FREQUENCY

WHEN

CH~Ii4:~NG~/N~G~ig'~f'~~';rnR!'~";:

ON

THE

BOARD

MUST

ON

FOR

50

HZ

accomplish

~nit

is

a very

BE

AND

OFF

FOR

CONTROL INTERNAL

COMPONI,NTS!

(HERn)

1800

rpm. The AC

1500 rpm. The AC

frequency,

simple

60

HZ

the

frequency change

task.

engine

1.

Thrn

the

DC

breaker on

.position.

2.

Open

the cover of

. (Electronic Control Unit).

,

3. Locate the position that

See

#1

dipswitch on the ECU

correspond&

the

illustration below showing

control box.

4.

Replaqe

and start engine/generator

the

control box cover, turn the DC breaker

the

unit. Monitor the frequency that the

is

frequency.

the

control panel to

the

OFF

.

the

control box

to

and

the

Hertz operation

the

view the ECU

move it

to

desired).

ECU in the

operating is operating at the correct

ECU

CONNECTIONS

the

ON

(

CAUTION

The

electronic

Diesels

draw amperage generator's starting battery unit

is

in

much

as

ECU

and 50 milli-amps for

This

can

time

with

. concerned

seasonal used

for a number

best

to

disconnect the

NMEA·2000

gener~tor:S

NOTE:

Keep

the

DC

power supply for

(WESTERLINK

components

a very small

(milli.amps)from

a static state.

50 milli-amps for

be

as

no

generator

with

use.

However,

system

control boxfor a,WESTERLlNK

in

Dr

NMEA·2000):

in

amount

the

wflen

This

maybe as

the

much

this slight

of

mind that

each

as

72

amp-hours

use,

[t

amperage

if

the

months.

DC

power

or

shut off the DC breaker

the

Digital

of

the \

system

display.

is

not necessary

generator set

such as winter

to

the

Westerbeke

vessel ~ NMEA-2000

'.

in a monthS

draw

to

during

is

not

storage.

generator with a

on

system.

generator

be

nonnal

to

be

it

the

maybe

ne/Work.

is

BliMP

PROTECTS"

ELECTRONICS HIGH

AMP

OVERLOAD'

.

pANEL~

FROM

LCD

Ai

DiSPLAY

.

20

AMP

DC

BREAKER

CIRCUIT

(ECU)

Periodically clean the control panel

LCD

DISPLAY

and

its

PANEL

LCD

screen using

a soft cloth.

NOTE:

vary affect

Operating

in

color.

the

temperatures

This

operation

is nonnal

of

the

control

may

cause

and a clumge

panel.

the

in

LCD

color

display will

not

to

""""

WESTERBEKE

EngineS & Generators

...

77

'

BT

3

PHASE

r-

------:------,

I I

A

I

I I

I

I I

L_I-~_:_--------J

EXCITER

STATOR

r -

--

-

-I-

I

I I

B

EXCITER

I I

+

I I I I I I I

-

I

L-----r---------_~

a '

b

c

E

VOLTAGE

GENERATOR

TWELVE

I I

INTERNAL

WIRE

- - - - - - - - - -

I

I I I I

l

-~

ROTOR

(6)

C

FIELD

I.

V

~

*

DIODES

I

REGULATOR

~

WIRING

RECONNECT

~

12'

I

10'

I I

8·

I I

6·

I I

2'

I I

I

ABLE

r------,

I

DSTATOR

I I I

I I

I

I :

L.

_____

l~

:

I I

I

I I I

I

! I

...1

.11

·9

7

5

1

jW

..

RESISTANCE

A.

EXCITER

B.

EXCITER

C.

ROTATING

DIDOES

.

SUPPRESSOR

D.

MAIN

STATOR

AUXILIARY.

E.

VOLTAGE

F.

AUXILIARY.

VALUES

STATOR ROTOR

(17.9

WINDINGS

FIELD

(2.49

(6)

WINDINGS

WINDING

REGULATOR

CIRCUIT

YelLOW

ohm)

(0.05

(1.2

ohm)

FUSE

abc

ohm)

(0.6

ohm)

Engines & Generators

, .

78

NOTE:

AC

GENERATOR

BT

GENERATOR

TROUBLESHOOTING

TROUBLESHOOTING/3

MUST BE

PERFORMED

WITH

PHASE

THE

ENGINE OPERATING

AT

60 HZ

NO

AC

VOLTAGE

RESIDUAL NO

LOW

NO

HIGH

150

UNSTABLE

AC 60

VOLTAGE

LOAD

15 • 20

AC

VOLTAGE

LOAD

60

AC

OUTPUT

VAC

OR

VOLTAGE

·100

VOLTS

FAULT

OUTPUT

PRODUCED

VOLTS

OUTPUT

·100

VAC.

VOLTAGE

HIGHER.

OUTPUT.

DROP

UNDER

AC.

AT

AC.

NO

AT

LOAD

LOAD.

,

AT

1.

Short

or

main

stator

2.

Shorted on

exciter

3.

Four..ar open

diodes

1.

Blown 6 AMP auxiliary

2,

Faulty

1.

Open

or

exciter

2.

Shorted

1.

Faulty

1.

STB

pod

needs

1.

Diode(s) breaking applied

PROBABLE

open

In

the

winding.

suppressor

rotor.

more

shorted

or

on

exciter

rotor.

fuse

circuit

feed

to

AVR.

voltage

regulator

shorted

diodes

in

rotor 1 to 3 diodes.

exciter

rotor

winding.

voltage

regulator.

on

regulator

adjustment.

on

exciter

down

(inductive)

rotor

when

1-3

load

diodes.

is

CAUSE

4.

Open stator

5.

Open field

3.

Shorted stator

3.

Faulty

2.

Faulty

In

exciter

winding.

in

rotating

winding.

or

open

auxiliary

voltage

main

winding.

regulator.

r------------...,

I I

I A

I I

I I I

I r - - - - -

I

I I I C I I I I I

EXCITER

STATOR

I

~

1.1

I

EXCITER

B I

I I I

- - - - - - - - -

I I

ROTOR

FIELD

-,

r------,

DSTAToR

12~··

===~1=:::::::1t====:·11

I

10'"

8.

I

::===jl~:::=tl

6.

I I

I 5

:

.9

===:7

I a I I

I

: c

...-_-.1

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I

I..

,,'

~

THe'"

•

Am,

e

Slab

'i

Vol!

I

~

___

bl

--1----

.J

* I

(6)

DIDOES

____ , ____

:

I

-l

BLUE

GREEN

"

Engines & GimeratorR .

,.

7Q

BT

GENERATOR

SINGLEJTHREE

PHASE

This generator which requires' only the duce AC stator are responsible for erator. The magnetic be induced into the related exciter rotor windings during rotation. Diodes located DC and creates an electromagnetic windings

, supplied

parallel to produced main stator tifier.

The

the exciter stator windings, enabling the generator to produce a rated

AC

available produce a

AVR

is

a four-pole, brushless, self-excited generator

driving

force

of

the engine to pro-

output.

The

copper

and

laminated iron in the exciter

the

self-exciting featore of

field

produced causes an

in

the

exciter rotor rectify

supply

it to the

of

the

main

to a load.

the

AC

in

the

auxiliary windings

and

is,

rectifier produces a DC voltage to further excite

output.

to

work

more

stable

windings

stator,

A step

output

of

in

turn,

An optional solid-state voltage regulator

in tandem

AC

of the rotating

field

which rotates through the

inducing an

down

transformer is connected

the main stator.

supplied to a full-wave bridge rec-

with

output '

AC

An

of

the transformer and the

the transformer regulator

.....

~I'Lt."

AC

voltage

this

field.

Voltage

AC

UH

SWITCH

this

voltage to

which

voltage

This

gen-

to

in

is

to

NO

A circuit breaker is installed

tors.

This circuit bre\lker will automatically disconnect generator power in case breaker can be manually shut off tor

to

ensure no power is coming

NOTE:

This,circuit

aildron

kit for earlier

WESTERBEKE

LOAD

SHIMS

of

breaker

dealer.

CIRCUIT

PART

15

,12

on

all WESTERBEKE genera-

an electrical overload. The circuit

when

servicing the genera-

into

the boat. '

is

available

model

generations;

BREAKER

NUMBERS

KW

-42710

KW -42709

as'a

WESTERBEKE

contact your

AC

TERMINAL

BOARD

BT

GENERATOR

SINGL~

PHASE

[GSTUD]

BA

20A

__

••

~~

..

,~~~~i~~~,~

BRIDGE

VOLTAGE

FUSE

RECTIFIER'

)

..

...

WESTERBSKE

Eng/nes &

'."

80

Generators

BT

GENERATOR

THREE

PHASE

;

[12S'nio]

.

BT

GENERATOR

VOLTAGE

REGULATOR

ADJUSTMENTS

Description

The

voltage optimum complete

conditions

regulator

AC

generator performance.

protection circuitry

that could

is

an advanced

to

be

detrimental

design

It

is

equipped with

guard against operating

to

the

.........

Volts

TIris

potentiometer

engine

operating speed the output voltage should be ±1 % from and

variations

VOLT

driver) until HER1Z

same

normal

possible VOLT stabilize. Increase the voltage to the desired

situation,

a no-load condition

from

power factor 1.0 -

up

and

STAB

fully

you

feel

trimmers

manner.

speed,

that

adjust

only

is

used

to

adjust output

to

a full rated generator output

0.8

with engine

to

-6%.

Prior

to

starting

tiimmers (using a mini phillips screw-

in a counter clockwise

them hit their

completely clockwise

With the generator running at no-load,

and with

output voltage will oscillate.

clockwise. The voltage output

the green

stops.

VOLT

LED

will stay

the

(Minimum)

Tum the AMP and

(Maximum)

adjust at

minimum,

lit.

Stability

TIris

potentiometer permits variation of the regulator's response pensation voltage

In running

Turn

starts

terclockwise

a

order

volt.

~

-

to

generator load changes

and obtain a miuimum

output

to

adjust the regulator stability

at

no-load and the output must

the

STAB

adjust slowly clockwise until

to

fluctuate.

red

green

yellow

Hertz

Am~

Stab

Vol!

VOLTAGE

At this point rotate the

until the voltage is stable within 1 or 2

'-

REGULATOR

recovery

DIAGRAM

so

as

the

be

which

ensures

AC

~enerator;

1I0LIllGE

voltage.

engine,

Slowly

to

time

monitored.

STAB

REGULATOR

At proper

held

drive

speed turn the

direction

in

at-

it

is

rotate the

will

increase and

value.

In

this

limit overcom-

to the normal

generator must

the

voltage

adjust

coun-

tenths

at

the

be

of

Amp-Hertz

These

two

adjustments protection by

1. Delayed overload protection (yellow

2.

Both

adjusted circuits voltage overheating.

The temporary motor lator tor with

Setting

In order must

'1. Load.tha generator

2.

3.

4.

NOTE:

remove

Setting

NOTE:

jumper

two

setting,

1.

2.

3.

With

tion

circuits

the illumination of colored LED

Low

speed

protection (red LED).

systems

overloall

also

operation

the

be

the hertz

Rotate its put of should

Slowly output age yellow

Return

and Should

have

using

the

are

able

to

safeguard

protection system

overloading

start-up

stop.

or

has

a third

to

generator.

the

Overload

to

set

the

loaded

engine

by

on

50 hertz units). .

the

AMP

Wait

the

generator should

come

rotate

voltage

output

at

LED

to

nominal

the

generator voltage will rise

this

When

changing

the

60

the

Underspeed

lftheunit

strap

is

60

Hem.

terminals.

the

generator

To

adjust

the

lower

the

engine

(54

hertz

on

Rotate

the

Hertz adjustment counterclockwise the generator's the

same

time

Increase The red put

the

"LED" light will

will

return

the

above

ilomtally.

are used in conjunction with

in

the

voltage regulator that are indicated

lights.

an

intervention threshold which

respective potentiometer. Each

to

cause an adequate reduction in excitor

the

excitor windings

.

has a delay

of

the generator

other similar load

LED

(green), that

indicate correct operation of

surge

Protection

AMP

overload protection, the generator

to

its

full

output rating.

to

its rating, then

10.10%

about 15-20 seconds on.

the AMP adjustment

increases

the start of the

light should come

not

hertz

(54 Hertz

adjustment counterclockwise

to

speed, the

happen, repeat

from

jumper bar

on

drop

and

approximately 97% of the volt-

adjustment.

on.

yellow

the

60

hem.

from

Protection

is

operating

in

place

should

underspeed

speed

60

hertz

AC

the red "LED" light

engine speed

to

normal.

adjustments made, the

at

60

Hem.

on

the

regulator

In

order

to

be

running

Qow

frequency)

at

90%

of

nnits,

45

hertz

output voltage

to

its

norma!

go

out and

adjust

its

LED).

and

prevent their

which permits

during

demands.

glows

during genera-

the

decrease

60

hertz units,

after

which the

the

yellow

clockwise

At

LED

will

to

its

normal

adjustment.

to

50

hem.

the

regulator

ensure

board

the

'underspeed

at

no-load.

protection

nOimai

on

50

hertz

starts

to

decrease

comes

on.

speed

the

AC

regulator

the

two

can

be

of

the

times such

The

regulator

the speed

45

until

it

AC

LED

until

the

this point

tum

off

value.

operation,

board.

that

the

between

circuit,

running

speed

units.

slowly

and at

(frequency).

voltage

should

two

as

regu-

of

hits

out-

light

the

until

out-

func-

~

WESTERBEKE

Engln/'$ & Generator$

81

.

METRIC

..

CONVERSIONS

LENGTH-DISTANCE

Inches

(In) x 25.4 " Millimeters

Feet

(It)

x .305"

Miles x 1.609 " Kilometers

Meters

(mm) x .0394 " Inches

(m) x 3.281

(km) x .0621 = Miles.

"Feet

.

DISTANCE

1

EQUIVALENTS

Degree

of

Latitude"

MInute

of

latitude

VOLUME

.

cubic

Inches

(in') x 16.387 = Cubic Imperial Imperial ImperIal

Imperial Imperial Fluid US US US

Pints

(IMP

Quarts

(IMP

Gallons

(IMP

Quarts

(IMP

Gallons

(IMP

OUQces x 29.573 = Milliliters x .034 = Ounces

Pints

(US

pt) x .473 = Liters(L) x 2.113 = Pints

Quarts

(US

qt) x .946 = Liters

Gallons

(US

gal) x 3.785 = Liters

MASS-WEIGHT

Ounces

(oz) x 28.35 = Grams

Pounds

(Ib) x .454 = Kilograms

PRESSURE

Pounds Inches

Inches Inches

Per

Sq

of

Mercury

of

Mercury

of

Water

of

Water

of

Water

In

(H20) x .07355 = Inches (H20) x .03613 = psi x 27.684

(H20) x .248 = Kllopascals

60

Nm"

111.)

20

km

= 1

Nm = 1.852

pt)

J\

.568 " Liters

qt) x 1.137 = Luers

gal) x 4.546 = Liters

qt) x 1.201 = US

gal) x 1.201 = US

(psI) x 6.895 = Kllopascals

(Hg) x .4912 = psI x 2.036 = Hg (Hg) x 3.377 = Kllopascals

km

Centimeters x .061

(L) x 1.76 = IMP

(L)

x.B8 = IMP

(L)

x .22"

Quarts

(US

Gallons

(L) x 1.057 = Quarts

(L) x .264 = Gallons.

(g) x .035 = Ounces

(kg)

x

2.205 = Pounds

(kPa) x .145;'

(kPa)x

of

Mercu/y x 13.783 = H20

=1:1,0

(kPa) x 4.026 = H,O

=in'

pt

qt

.

IMP

gal

qt) x .B33 = IMP

(US

gal) x .833';

psI

.2961 = Hg

qt

IMP

.

gal

.

TORQUE

Pounds-Force Pounds-Force

Inches Feet.{ft-lb) x 1.356 = Newton

VELOCITY

Miles

Per

Hour

(MPH) x 1.609 = Kilometers

POWER

Horsepower

FUEL

CONSUMPTION

Miles KlI.ometers

Miles Kilometers

Per Per

Hour

(Hp) x .745

IMP

Per

Liter

Gallons

Per

Liter

TEMPERATURE

Degree

FahrenheIt

Degree

Celsius

('C) = ('F -32) x .56

LIQUID

WEIGHTS

Diesel

011

Fresh

Water Gasoline Salt

Water

= 1

US

= 1

US

(In-Ib) x .113 = Newton

=

Kllowa~s

(MPG.) x .354 = Kilometers (KmfL) x 2.352 = IMP

US

(MPG) x .425 = Kilometers

(KmIL) x 2.352 = US

('F) = ('C X 1.8) + 32

gallon

~

7.131bs

US

galion = 8.331bs

gallon = 6.1

gallon = 8.56

(Kw) x 1.34 = MPH

Ibs

Meters

Per

MPG

(Nm) x B.85

(Nm) x .738 = ft-Ib

Hour

(KPH) x .621 = MPH

Per

Liter

(KmIL)

Per

Liter

(KmIL)

=in-Ib

-

)

./

~

WESTERBEKE

.

~~gl~~s:!,-.G~nerators

86

FOR

SmlNG

PISTON

TOOL

REMOVAL

SPECIAL

[0335821

AND

INSTALLATION

TOOLS -ENGINE

(

COMPRESSION

FOR

COMPRESSION

OIL

PRESSURE

TO

REMOVE

CAMSHAFT

FOR

REMOVING

CAMSHAFT

GAUGE

SWITCH

THE

BUSHING

AND

BUSHING

ADAPTER

PRESSURE

SOCKET

OIL

PRESSURE

INSTALLER

INSTALLING

[0392541

MEASUREMENT

WRENCH·

SWITCH

[0335831

THE

FRONT

03

9254

033583

THE MITSUBISHI

NOTE: TOOLS

BEARING

VALVE

RING ALSO

ABOVE

IN

AODITION

WOULD

PULLER,

GUIDE

PLIERS,

REFER

TOOLS

ARE

DEALER.

TO

BE

NEEDED:

VALVE

INSTALLER

ETC.

TO

SPECIAL

AVAILABLE

THESE

SEAT TOOL,

TOOLS -GENERATOR

FROM

TOOLS

CUTTER

VALVE

YOUR

THE

FOLLOWING

TOOL,

SPRING

enerators

WESTERBEKE

PROPER

COMPRESSOR,

IN

THIS

OR

ADDITIONAL

DIAL

GAUGES,

SNAP

MANUAL

INSTALLATION

.

frhls

popular

accessory

ter

from

the

~ngine

flOTE:

lnatructions

instaJJ,'simPIY

~

nstsll

Contact

engine

room

bulkhead.

Refer

to

on

1ERBEEB's

this

kit with

your·WES1ERBEEB

is used to

to a

ENGINE

removing

remove

remote

the

nil

more

OIL

the

oil

filrer

convenient

CHANGE

oil

filter.

engine

filrer

facing

dealer

REMOTE

relocate

the

engine's

location

such

in

this

numualfor

-

oil

filrer

and

kit

as

down

for

shown.

more

thread

JUways

as

illustrated.

infoxmation.

OIL

FILTER

oil

fil-

as

an

.

on

(OPTIONAL)

NOTE:

Westerbehe

incorrect

installation

A

CAQTlDN:

rectly.

If

pass

valve

flom

reaching

failure.

Immediptelyand

'he

If

there

in

is

011

the

Is

not

0/

It

Is

flows

tilter

engine no

check

responsihlefor

the

Remote

Oil

vital

to

Install

In

the

reverse

assembly

011

the

will

cal/slng

pressure

hose

connections.

an

reading,

engiM

failure

Filter.

the

on

Ones

direction,

prevent

Intemal

shutdown.

due

cor-

the

by· .

the

oil

engine

to

DESCRIPTION

A

remote

panel

and

started

harnesses

can

be

additional

is

CO)llbined

dealer.

stopped

connecting of

these

NOTE:

For

.

eWESTERBEKB

availaple

from

any

come

in/onnation,

JU'PLY A miN

INSTAWNB

liGHTEN

CONTACTSTHEBASE.

&,OAT

OF

iHfs

KIT.

AN

ADDmONAL

REMOTE

AND

that

allows

location

in

three

fur a maximum

the

oli the

different

contact

CLEAN

DlL

TO

THE

KIT

ON,

AFTER

0-IIING

THEN

THE

ntHfADlHE

3/41URH

STOP/START

EXTENSION

generator

run

your

boat.

'The

lengths

at

75'

local

to

be

and

two

(22.17M).

WHEN

KAND

Q·RING

.

CQ,NTACTS

PANEL

HARNESSES

APPLY A THIN liASKETWHEN

COAT

INSTAWNG.

THE

IIAS~!

OF

CLfMJ

AFJER

l1B1ITEtl1T

OIL

m lllE

mE

AN

ADDmONAL·

filTER

FILTER

)

3·1/'"

"2.!'5MI~I·

REMOTEPANEl)PIG

PN

052560

Engine~

& GeneratDls

84

TheS<!

two

dimensions

are

the

CONNECTING

.

CABLES·

15'

(4.75M)

30'

(9.1M)

60'

(18.2M)

measurement

EXTENSION

PN

052959

PN

052789

PN

052960

of

the

cut-out

opening.

BOLT

HEAD

Bolt

strength

Customary (strongest). I.e.; a grade

(inch)

NOTES:

MARKINGS

classes

are

embossed

bolts

are

The

marks

seven

corraspond

'bolt

will

on

Identifed'by

to"twomalks

display

five

the

head

of

markings

embossed

less

STANDARD

each

bolt.

two

to

grade

eight

than

the

actual

marks.

grade,

HARDWARE

Metric

boll

class

numbers

identify

strongest.

bolts

by

their

strength

with 1 0.9

the

STANDARD

Capsrew

Body

(Thread)

1/4·

20

·28

5116-18

·24

318,16

·24

7116

·14

·20

112

·13

·20

9t:t6-12

·18

518·\1

·18

314

·10

·16

7/8· 9

·14

1· 8

·14

FotmukI

Size

(Inches)'

NOTE:

BOLT & NUT

5AEGrade5

Torque

fl-lb

(Nm)

.

8

(11)

10

(14)

17

(23)

19

(26)

31

(42)

35

(47)

49

(66)

55

(75)

75

(102)

85

(115)

1\0

(149)

120

(163)

150

(203)

170

(231)

270

(366)

295

(400)

395

(536)

435

(590)

590

(800)

660

(895)

to

convert

Ft~Ibs.to

TORQUE

5AE

Grail.li-7

Torque

F\·lb(Nm)

10

(14)

19

(26)

34

(46)

55

(75)'

85

(1\5)

120

(163)

167

280

440

660

. ,--

Nm

(Newton

SPECIFICATIONS

5AE

Grade

8

TOrque

R-LbINm)

12

(16)

14

(19)

24(33) 27

(37)

44

(60)

49

(66)

70

(95)

78

(106)

105

(142)

120

(163)

155

(210)

170

(231)

(226)

(380)

(597)

(B95)

210

(285)

240

(325)

375

(508)

420

(569)

605

(820)

675

(915)

910

(1234)'

990

(1342)

Meters),

multiply

Boll

Dla.

MS M4 M5

MB

M9

MID

M12 M14 M16

M18 M20 M22

M24 M27 M30

M33 M36·

Ft·lbs

METRIC

Wrench

·10mm

by

BOLT & NUT

Size

5.5mm 7mm

Bmm

13mm 16mm

18mm 21mm 24mm

27mm 30mm 33mm

36mm

41

mm

46mm

51mm 55mm

1.356.

Grade

4.6

R-Lb(Nm)

D,S

(0.5)

0.8

(1.1)

1.5

(2.5

3

(4)

7

(9.5)

14

(19)

26

(35)

37

(50)

59

(80)

81

(110)

118

(160)

159

(215)

203

(275)

295

(400)'

'

402(545)

546

(740)

700

(950)

TORQUE

Grade Ft-Lb

0.5

118(160)

166 225

288 417 566

774

992

SPECIFICATIONS

4.8

(Nm)

(0.7)

1

(1.5)

2(3)

4

(5.5)

to

(13)

lB

(25)

33

(45)

55

(75).

85

(115)

(225) (305)

(390) (565) (770)

(1050) (1345)

Grade

Ft·Lb

, 1

2

4.5

7.5

18. 37

63

103 159

225 321

435

553

811

1\03

1500

1925

8.8' (Nm)

(\.S)

(3)

(6)

(10) (25) (50)

(85)

(140)

(215)

(305)

(435)

(590)

(750) (1100)

(1495)

(2035) (2610)

9.B

Grade

10.9

FI·Lb

(Nm)

1.5(2) 3

(4.5)

6,5(9)

11

(15)

35(26)

55

(75)

97

(130)

151

(205)

232

(315)

321

(435)

457

(620)

620

(840)

789(1070)

t154

(1565)

1571

(2130)

21S9

(2900)

2744

(3720)

GASKETS/SEALANTS

Oil

based

PERMATEX

purpose

sealers.

cootan~

raw

A

light

coating

and

O·rings.

LOCTITE

hydraulic

filter

assembly.

Coat

both

surfaces

When

Installing

sides

with

WHtTE

Hlgh·copper Ing

as~embly.

Specialized ing capper

'gasket

non·hardenlng

cylinder·head

#2

and

ifs

HIGH

They

are

effective

TEFLON

should

all

pan seal

grease.

such

as

HYLOMAR

as

In'just

gasket around

are

HYLOMAR

it

resists

water,

oil

or

fuel.

of

OIL

or

L1aUID

red

sealant

'

of

the

gaskets

that

SILICONE

ADHESIVE'SPRAYS

sealers

properties.

gaskets

TACK

about

can

be

used

with

water

useful

is fuei

equlvatent

high

for

particlariy

SEALANTS & LUBRICANTS

are

excellent

any

be

used

on

ail

temp

(coolant)

hotding

work

oil

and

all

joint

in

contact

with

on

rubber

gaskets

adapter

hoses

and

the

RED

SILICONE

passages~

gaskets

well

In

,applications

effective

watet

coat

In

position

on

sealer.

both

requir·

Use

L1aUID

TEFLON

passages.

Do

not

for

use

BOLTS & FASTENERS/ASSEMBUES

Lightly

oil

head

bolts

the

levels

grease

sliding

oil!

and

the

and

all

dur·'

plugs

that

penetrate

HIGHTACI<' When

assembling

Anti·seize threaded

LOCTITE LITHIUM

ing Heavily

use

compounds

components

offers based

boxes.

011

all

clean

engtne

'--"'!!!t,

Engines & GIfiIerl!ltors

85

sealing

tape

flywheet,

yet of

pipe

seatants\

other

fasteners

water

jacket

coat

and

thread

locking

allows

them

locking

according

iswaterproo!,

reciprocating

plugs

and

fillings

as

Y9u

should

be

sealed

the

bolt

threads

adhesives

to

came

apart

to

the

Ideal

for

water

components

that

assemble

with

such

when

job.

pump

when

them.

with

LOCTITE

as

assembling.

connect

coolant

Bolts

PERMATEX

LOCTITE

necessary.

bearings

and

112

blue.

protect

and

Always

stuff·

'

or

METRIC

..

CONVERSIONS

LENGTH·DISTANCE

Inches

(in) x 25.4 " Millimeters

Feet

(ft) x .305 = Meiers

Miles x 1.609 = Kilometers

(mm) x .0394 = Inches

(m) x 3.281 = Feet

(km) x .0621 = Miles.

.

DISTANCE

1 1

EQUIVALENTS

Degree

of

Latitude"

Minute

of

Latitude" 1 Nm = 1.852

VOLUME

Cubic

Inches

(In') x 16.387 = Cubic

Imperial

Imperiai

Imperial Imperial Flulc US US US

Pints

(IMP

Quarts

(IMP

Gallons

(IMP

Quarts

(IMP

Gallons

(IMP

Ouqces x 29.573 = Milliliters x .034 = Ounces

Pints

(US

pt) x .473 = Lilers(L) x 2.113 = Pints

Quarts

(US

qt) x .946 = Liters

Gallons

(US

gal) x 3.785 = Liters

MASS·WEIGHT

Ounces

(oz) x 28.35 = Grams

Pounds

(Ib) x .454 = Kilograms

PRESSURE

Pounds Inches

Inches

Per

Sq

Of

Mercury

Of

Mercury

of

Water

Of

Water

Of

Water

In

(H20) x .07355 = Inches (H20) x .03613 = psi x 27.684

60

Nm"

111.~20

pt) ~ .568 " Liters

qt) x 1.137 = ltters

gal) x 4.546 = Liters

qt) x 1.201 = US

gal) x 1.201 = US

(g) x .035 = Ounces

(kg) x 2.205 = Pounds

(psi) x 6.895 = Kllopascals

(Hg) x .4912 = psi x 2.036 = Hg (Hg) x 3.377 = Kllopascals

(H20) x .248 = Kilopascals

km

Centimeters x .061

(l) x

1.76 = IMP

(l)

x.B8 = IMP

(L)

Quarts

(US

Gallons

(l) x

1.057 = Quarts

(l) X

.264 = Gallons

(kPa) x .145

(kPa) x .2961 = Hg

of

Mercury x 13.783 = H20

(kPa) x 4.026 = H20

"In'

pt

qt

x

.22 = IMP

qt) x .833 = IMP

(US

gal) x .833

.

;.

=~20

.

gal

psi

qt

~

IMP

.

gal

)

TORQUE

Pounds-Force

.

VELOCITY

Miles

Per

Inches Feet

Hour

(MPH) x 1.609 = Kilometers

POWER

Horsepower

FUEL

CONSUMPTION

Miles KII.ometers

Miles Kilometers

(Hp) x .745 = Kilowatts

Per

Hour

IMP

Per

Liter

Per

Gallons

Per

Ltter

TEMPERATURE

Degree

Fahrenheit

Degree

Celsius

(DC) = (OF -32) x .56

LIQUID

WEIGHTS

Diesel

011

Fresh

Water Gasoline Salt

Water

= 1

US

= 1

US

.

(In-Ib) x .113=

(ft-Ib) x 1.356 = Newton

(MPG) x .354 = Kilometers (Kmll) x 2.352 = IMP

US

(MPG) x .425 = Kilometers

(Kmll) x 2.352 = US

(oF) = (DC X 1.8) + 32

gallon';

US

gallon' = 6.1

7.131bs

gallon = 8.33

gallon"

8.56

Newlon

(Kw) x 1_34 = MPH

Ibs

Meiers

Meters

Per

MPG

MP.G

(Nm) x B.85

(Nm) x .738

Hour

(KPH) x .621 = MPH

Liter

(Kmll)

Per

Liter

(Kmll)

=in-Ib

=ft-Ib

.

EngInes &. Gener"tors

,

86

DECIMAL

".

Fractions

an

of

inch"

1/64 1/32 " 3/64

1/16 5/64 3/32 7/64 ' 0;109375

1/8

9/64 5/32 0,15625

11/64

3/16

13/64

7/32

15/64 '

1/4

17/64

9/32

19/64

5/16

21/64 '

11/32 0.34375

23/64 0.359375

3/8

25/64 0,390625

13/32 27/64

7/16

29/64 0.453125

15/32

31/64

1/2

, Decim'af(in.)'

",',

!<":;' ...

,

,,0.015625'"

';0.03125,."

.•

l-:

'"

, ;0,046875,,';;,;,

'

:.

'i"f.

:'"

;'0.09375

"

','

,

'",

",c',

','

",

"

"0.2'65625

"

I

'0.26125

,

TO

METRIC

"-,

:

...•

:.",-,;~,",':.;.'

i'.:.'"

":";!~';;

"0.0625

0.078125

0.125,

,0;140625

0.171875 4.36562 '

0.1875

0:203125' '

0.21875

0:234875'

0.250"·'"

0.296875

0.3125 '

0.328125

":-" ..

,.'

",'

'

:

,

'

"

Metric (Plm)

0.39688

0.79375

1.19062

1.58750

1.98437 37/64

2.38125

2.77812 39/64

3.175

3.57187

3.96875

4.76250

5.15937 '

5.55625 23/32 0.71875

5.95312 47/64

6.35000

,

6;74687 49/64 0.765625

'7.14375

7.54062

7.93750

8.33437

8.73125

EQUIVALENT

. ,

.'J.,"

"

~

..

,

;fr!!ctlo,!,s

.-{

an inch

' ,

;'33164

.

"

' 19/32

"

I

'

'11/16

;;13116

35/64

of

Decimai'{il1.)

0.515625,'", ,

17/32

0.53125 '

0.546875 '

9/16

0,5625 " '

','0.578125.";,,

0.59375

0;609375'" '

518

41/64 21/32 43/64 0.671875

""

'0.625

"'0.640625" "

0.65625, 16.66875

' 0.6875

45164

3/4

25132 51/64 0.796875

53164 27/32

0.703125'

"",

, 0.734375 '

' 0.750

' '

0:18'125

,

':0;8125,

0.828125

0.84375

CHART

,.,

.•

~

:

c"

.-

.:

';;'.,",i

9.12812 55/64 0.859375

0.375 9.52500

7i8

0.875

9.92187 57/64 0.890625

0.40625

10.31875

29132

0.90625

0.421875 10.71562 59/64 0.921875

0.4375

11.11250

11.50937

0.46875

0.484375

11.90625

12.30312

0.500 12.70000 1

15116 61/64 ' 31/32 0.96875 63/64 0.984375

0.9375

0.953125

1~00

~

..

,'"

,

'.'

Metric (mm)

13.09687

.,",

..

13.49375

':,

',,'i'"

c' ,

"

13.89062

14.28750

'i"

, 14;68437

";;"1,5;08125

"

"'15:47812

.-

' 15;87500

'>.~

' ,/;16.27187

•

17.06562

,

17.46250

I'

17.85937

18.25625 18:65312

."c·:,

19.05000

,",'

."

",.

'.

'"

'

19.44687

19.84375

20.24062

" "

20.63750,

21.03437

21.43125

21.82812

22.22500

22.62187

23.01875

23.41562

23.81250

24.20937

24.60625

25.00312

25.40000

~

WESTERBEKE

Engines & Generators

87

INDEX

Actuator . . . . .

Air Intake Filter Alternator Testing Assembly Bolt Tightening BT

Generator Regulator Adjustments

BT

Generator Resistance Values

BT

Generator Troubleshooting

BT

Internal Wiring

BT

Troubleshooting Three Phase Bushing-Camshaft Camshaft Combustion Jet Crankshaft Crankshaft Pulley Cylinder Block (Exploded View) Cylinder Block Bore Cylinder Block, Crankshaft, Pistons and

(Exploded View)

Cylinder Head and Valve Mechanism

(Exploded View)

Cylinder Head and Valves (Exploded View) Cylinder Head Assembly (Exploded View) Cylinder Head Bolt Tightening Cylinder Head Gasket Disassembly -Engine Drive Belt Adjustment Engine Compression Engine Disassembly Engine Inspection Exhaust Manifold Filter, Air Intake Flywheel Frequency Changes

Fuel Injection Pump

Fuel Injectors

Generator Information

Glow Plug Testing . . . . . . . . . . . . . . . . . . . . . . . .

Governor (Exploded View) Heat Exchanger Idler Gear Injection Pump Injection Pump Timing Injectors Magnetic Pick-Up (MPU) Main Bearings

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

...........

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

;

...........

..........

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

Oil Pan

-

.34 ,

...

21,

.14,27,29

....

......

.33, 48

......

...

......

20, 22, 30

75,76,77

.36, 39

22 &

.37 A, 39

51 49

.54

28

.33

81 72 69 78 79 21 31 19 25

12 23 26

.32 .16

11

.32

10

.49 .49

.10

16

.35 .49

.40

68

.41

38

.35

31 36

40

51

28

Measuring Piston Metric Conversion Data

Oil

Pan

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

Oil Pressure Oil

Pump

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

Piston Clearance

Piston Pins

Piston Rings Piston/Connecting Rod Push

Rod;

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

Raw Water Pump Raw Water Pump (Exploded View)

Remote

Remote Panel Ring Gear Serial Number Location Service-Standards and Limits Chart Side Seals Special Specifications Charts Standard Hardware Chart Starter Motor Thermostat Timing Gear Backlash Timing Gears (Exploded View) Torque Specifications Troubleshooting Engine Charts Valve Clearance

Valve Gnide

Valve

Valve Spring Valve Voltage Changes Water Pump Wiring Diagram

#54193 1O-15Kw EDT 3 Phase Wiring Diagram

#54655 1O-15Kw EDT 3 Phase Wiring Diagram

#53477 5.5Kw Wiring Diagram

#54628 5.5Kw EDCI7.6-J5

Wiring Diagram #54680 5.5Kw

Wiring Diagram

#54193 5.5Kw EDCI7.6-J5 EDT

Oil Filter

..........

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

Tools

Seat

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

Stem

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

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

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

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

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

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

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

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

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

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

. . . . . . . . . . . . . . . . . . . . .22

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

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

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

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

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

..............................34

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

..........

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

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

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

.,'

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

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

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

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

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

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

24V

EDCI7.6-15

EDT 24V

EDT

EDT 24V

86, 87

. . .

24, 28 24,

...........

13,20,30

75, 76, 77

.:

.........

..........

(ungrounded)

.........

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

..

22

29

.50

31

..

22

29

15

17 .46 .47

84

..

84

.4

:52

28 . 83 63 85

.42

14

82

. . . .5

.48

17 18 17 32

33

57

58

59

..

60

61

62

)

.

Engines & Generators

88

Engines & Generators

1146WM/DW1/2D1

D"