Westerbeke 38B FOUR, W-33, 42B FOUR, W-27, W-33A Parts Manual

SERVICE

MANUAL

4-CYLINDER

MARINE

&

DIESEL

GENERATORS

MARINE

38B

FOUR W-27 R08D W-27A

MARINE

WMD WMD

11.0

8.3

11.0-60Hz

8.3-50Hz

BTO

BTD

PUBLICATION NO. 43440

2nd Edition / April 1998

DIESEL

W-33 W-33A

DIESEL

WMD WMD

12.5

9.4

12.5-60Hz

9.4-50Hz

BTD

ENGINES

42B

FOUR

GENERATORS

12.5

BTDA

9.4

BTDA

WESTERBEKE

150

JOHN

CORPORATION·

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

MYLES

STANDISH INDUSTRIAL PARK

PROPOSITION

Diesel engine exhaust and some

of

its constituents are known to the State cancer, birth defects, and other reproductive harm.

Exhaust colorless unconsciousness exposure

-Dizziness

-Nausea

-Headache

-

gasses

gas. can

Weakness

contain

Carbon

include:

and

Sleepiness

CALIFORNIA

65

of

California to cause

A

WARNING

Monoxide

and

death.

Carbon

Monoxide,

is

Symptoms

-

Throbbing

-

Muscular

-

Vomiting

- Inability

WARNING

an

odorless

poisonous

and

of

Carbon

in

Temples

Twitching

to

Think

and

can

cause

Monoxide

Coherently

IF

YOU GET seek until

OR

ANYONE

OUT

INTO

medical

it

has

THE

attention.

been

inspected

ELSE

EXPERIENCE

FRESH

AIR

Shut

and

ANY

OF

THESE IMMEDIATELY. down

the

repaired.

unit

If

and

SYMPTOMS,

symptoms

do

not

restart

persist,

SAFETY

INSTRUCTIONS

INTRODUCTION

Read

these safety instructions carefully. Most accidents are

and

caused by failure to follow fundamental rules tions. Know when dangerous conditions exist necessary precautions to protect yourself, and

your

machinery.

The following safety instructions are in compliance with

Boat

and

the American

PREVENT

A

while

power.

•

Do

enclosures and covers

• Shut equipment.

• Use insulated mats whenever working on electrical equipment.

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

• Remove wristwatch and all jewelry when working on electrical equipment.

• Do not connect utility shore power to vessel's circuits, except through a ship-to-shore double throw transfer switch. Damage result if this procedure is not followed.

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

PREVENT

A

exhaust very

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

A

• In case before touching the engine or checking the coolant.

ELECTRIC

WARNING:

engine

is

Lethal

voltage

not operate this machinery without electrical

off

electrical power before accessing electrical

BURNS -HOT

WARNING:

system

hot!

WARNING:

of

an engine overheat, allow the engine to cool

Yacht Council (ABYC) standards.

SHOCK

00

not

touch

AC

running,

or

when

is

present

in

place.

to

vessel's

ENGINE

00

not

touch

hot

components. A running

Steam

can

cause

your

electrical

connected

at

these

AC

generator may

engine

injury

precau-

and

take the

personnel,

connections

to

shore

connections!

AC

parts

or

gets

or

death!

PREVENT

A

• Prevent flash fires. Do not smoke sparks pump, or other potential sources vapors. removing the fuel line, carburetor,

•

Do

arrester removed. Backfire can cause severe injury death.

•

Do

Backfire can cause severe injury

•

Do

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

• Be aware - diesel fuel will burn.

PREVENT

A

injury

• Follow re-fueling safety instructions. Keep the vessel's hatches closed when fueling. after fueling. Check below for fumes/vapor before running the blower. Run the blower for four minutes before starting your engine.

• All fuel vapors are highly explosive. Use extreme care when handling and storing fuels. Store fuel in a well-ventilated area away from spark-producing equipment and out the reach

•

Do

• Shut the fuel system. Take care

spill. sources ing. Ensure proper ventilation exists when servicing the fuel system.

•

Do

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

• Be certain fuel line fittings are adequately tightened and free

• Make sure a fire extinguisher is installed nearby and is

properly maintained. Be familiar with its proper use. Extinguishers rated

for all applications encountered

BURNS -FIRE

WARNING:

to

Use a suitable container to catch all fuel when

not operate with a Coast Guard Approved flame

not operate with the air cleaner/silencer removed.

not smoke

Fire

can

cause

injury

or

death!

or

permit flames

occur near the carburetor, fuel line, filter, fuel

of

spilled fuel

or

fuel filters.

or

death.

or

permit flames

of

debris to minimize the chances

or

sparks to occur near the

or

fuel

BURNS -EXPLOSION

WARNING:

or

death!

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

off

the fuel service valve at the engine when servicing

DO

of

not alter

of

leaks.

Explosions

of

children.

NOT allow any smoking, open flames, or other

fire near the fuel system

or

modify the fuel system.

from

fuel

vapors

Open and ventilate cabin

in

catching any fuel that might

or

engine when servic-

ABC

by the NFPA are appropriate

in

this environment.

can

cause

or

of

Engines & Generators

SAFETY

INSTRUCTIONS

ACCIDENTAL

A

WARNING:

or

death!

• Disconnect the battery cables before servicing the engine/ generator. Remove the negative lead first and reconnect

it

last.

• Make certain all personnel are clear starting.

• Make certain all covers, guards, and hatches are reinstalled before starting the engine.

BAnERY

A

WARNING:

or

death!

•

Do

not smoke being serviced. Lead acid batteries emit hydrogen, a highly arcing or by lit tobacco products. Shut off all electrical equipment in the vicinity to prevent electrical arcing during servicing.

• Never connect the negative tive (+) connection terminal not test the battery condition by shorting the terminals together. Sparks could ignite battery gases Ventilate any compartment containing batteries to prevent accumulation disturb the battery charger connections while the battery is being charged.

• Avoid contacting the terminals with tools, etc., to prevent bums or sparks that could cause an explosion. Remove wristwatch, rings, and any other jewelry before handling the battery.

• Always tum the battery charger the battery connections. Remove the negative lead first and reconnect it last when servicing the battery.

BAnERY

A

WARNING:

severe

STARTING

Accidental

starting

can

cause

injury

of

the engine before

EXPLOSION

Battery

or

explostve gas, which can be ignited by electrical

of

explosion

allow an open flame near the battery

explosive gases. To avoid sparks, do not

can

cause

injury

(-)

battery cable to the posi-

of

the starter solenoid. Do

or

fuel vapors.

off

before disconnecting

ACID

injury

Sulphuric

or

death!

acid

in

batteries

can

cause

TOXIC

• Ensure that the exhaust system is adequate to expel gases

• Be sure the unit and its surroundings are well ventilated.

•

• For additional information refer to

• Do not use copper tubing in diesel exhaust systems. Diesel

• Do not install exhaust outlet where exhaust can be drawn

• Although diesel engine exhaust gases are not

AVOID

EXHAUST

A

WARNING:

discharged from the engine. Check the exhaust system regularly for leaks and make sure the exhaust manifolds are securely attached and attention to the manifold, water injection elbow, and exhaust pipe nipple.

In

addition to routine inspection

install a carbon monoxide detector. Consult your boat

or

builder

tional information on Carbon Monoxide).

A

WARNING:

odorless nausea

gas.

or

death!

fumes can rapidly destroy copper tubing in exhaust systems. Exhaust sulfur causes rapid deterioration tubing resulting in exhaust/water leakage.

through portholes, vents, or air conditioners. exhaust discharge outlet is near the waterline, water could enter the exhaust discharge outlet and close flow

of

exhaust. Avoid overloading the craft.

exhaust fumes from gasoline engines, carbon monoxide gas is present in diesel exhaust fumes. Some

or

toms ing are:

Vomiting Dizziness Throbbing in temples Muscular twitching Intense headache Weakness and sleepiness

signs

MOVING

GASES

Carbon

monoxide

no

warping exists. Pay close

dealer for installation

Carbon

Inhalation

of

monoxide

produces

carbon monoxide inhalation

PARTS

(CO)

is a deadly

of

the exhaust system,

of

approved detectors.

ABYC

(CO)

flu-like

T-22 (educa-

is

an

invisible

symptoms,

If

or

restrict the

as

of

or

gas!

of

copper

the engine

toxic as

the symppoison-

• When servicing the battery

level, wear rubber gloves, a rubber apron, and eye protection. Batteries contain sulfuric acid which is destructive. it comes in contact with your skin, wash it with water. Acid may splash on the skin inadvertently when removing electrolyte caps.

or

checking the electrolyte

off

at once

or

into the eyes

A

WARNING:

or

If

Engines & Generators

death!

•

Do

not service the engine while it is running.

arises in which it is absolutely necessary to make operat-

ii

Rotating

parts

can

cause

injury

If

a situation

SAFETY

INSTRUCTIONS

ing adjustments, use extreme care to avoid touching moving parts and hot exhaust system components.

• Do not wear loose clothing or jewelry when servicing equipment; avoid wearing loose jackets, shirts, sleeves, rings, necklaces or bracelets that could be caught moving parts.

• Make sure all attaching hardware is properly tightened.

Keep protective shields and guards in their respective

places at all times.

• Do not check fluid levels or the drive belt's tension while

is

the engine

• Stay clear when the engine is running; hair and clothing can easily be caught

HAZARDOUS

A

WARNING:

operating.

of

the drive shaft and the transmission coupling

in

these rotating parts.

NOISE

High

noise

levels

can

cause

in

hearing

loss!

• Never operate

• Do not run an engine with the air intake (silencer) removed.

• Do not run engines for long periods with their enclosures open.

an

engine without its muffler installed.

ABYC, INSTALLING

Read the following ABYC, NFPA and USCG publications for safety codes and standards. Follow their recommendations when installing your engine/generator.

ABYC "Safety Standards for Small Craft"

NFPA (National Fire Protection Association) "Fire Protection Standard for Motor Craft"

USCG (United States Coast Guard)

"USCG 33CFR183"

NFPA

AND

USCG

PUBLICATIONS

DIESEL

(American Boat and Yacht Council)

Order

From:

ABYC 15 East 26th New York, NY 10010

Order From: NFPA

11

Tracy Drive Avon Industrial Avon, MA 02322

Order U.S. Government Printing Office

Washington, D.C. 20404

Street

From:

ENGINES

Park

FOR

A

WARNING:

are

mentally

OPERATORS

Many

of

the preceding safety tips and warnings are repeated

in

your Operators Manual along with other cautions and notes to highlight critical information. Read your manual carefully, maintain your equipment, and follow all safety procedures.

ENGINE

Preparations to install an engine should begin with a thor· ough examination (ABYC) standards. These standards are a combination sources including the USCG and the NFPA.

Sections

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

INSTALLATIONS

of

H-2 Ventilation P-l

Exhaust systems

PA

Inboard engines

E-9 DC Electrical systems

Do

not

work

or

physically

incapacitated

MANUAL

of

the American Boat and Yacht Council's

the ABYC standards

on

machinery

of

particular interest are:

when

by

fatigue!

you

of

Engines & Generators

iii

Engines & Generators

TABLE

OF

CONTENTS

Introduction

Product Software .................................................................... 3

Engine/Generator Model Designations .................................

Notes,

Ordering Parts/Serial Number Location ................................ 3

Engine/Generator Testing

How to Judge Engine

Overhaul Conditions .............................................................. 6

Service Technical

Tightening Torque ..... ~ ..........................................................

General Screws ..................................................................... l1

Sealants .................................................................................

Engine Engine Cylinder

Construction ......................................................................... 17

Cylinder

Disassembly ......................................................................... 18

Inspection ............................................................................. 18

Reassembly .......................................................................... 19

Cylinder

Construction .........................................................................

Cylinder

Disassembly ......................................................................... 23

Inspection ............................................................................. 23

Reassembly ..........................................................................

Governor

Description ........................................................................... 31

Disassembly ......................................................................... 31

Inspection ............................................................................. 31

Reassembly and Adjustment ............................................... .31

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

Cautions and Warnings ..............................................

Specifications

for

Overhaul

Cause Measuring Compression

Disassembly ................................................................... 6

Reassembly .................................................................... 7

Standards

Data

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

Overhaul Period ................................. 6

of

Low Compression ........................................... 6

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

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

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

Pressure .................................. 6

Troubleshooting .....................................................

Parts

Identification

Head

...

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

Head

Service

Cylinder Head .............................................................. 18

Valve Guide .................................................................. 18

Valve Seat. .................................................................... 18

Valve ............................................................................. 19

Valve Spring ................................................................. 19

Rocker Arm and Rocker Shaft ..................................... 19

Partial Reassembly ....................................................... 20

Installation

Valve Clearance Adjustment ....................................... .20

of

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

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

Cylinder Head Assembly ...................... 20

Block ....................................................................

Block

Service

Cylinder Block ............................................................. 23

Piston, Piston Pin and Piston Rings ............................. 24

Connecting Rod ............................................................ 25

Crankshaft .................................................................... 25

Main Bearings and Connecting Rod Bearings ............ 25

Gearcase .......................................................................

Timing Gears and Lube

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

Fuel Injection

Ball Bearings ................................................................

Tappets .........................................................................

Push Rods .....................................................................

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

Oil Pump Gear ......................

Pump Camshaft ....................................

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

Governor Lever ............................................................

Governor Spring ...........................................................

Needle Bearing ............................................................. 31

.

3

.3

11 11

11 12 16 17

18

21 21

23

26 26 26 26 26 26 26 26

31

31 31

5 6

8

Engine

Lubrication

Fuel Fuel

Raw Raw

Fresh Fresh

Shutoff

Engine with Manual Stop (Standard) ..................................

Optional Key Switch Shutoff (38B and

Adjustments

Tightening the

Adjusting Valve Clearance ................................................... 33

Adjusting Fuel Injection Timing .......................................... 33

Adjusting No-Load Engine Speeds ......................................

Description ........................................................................... 35

Disassembly ......................................................................... 35

Inspection ............................................................................. 35

Reassembly ..........................................................................

Testing the Oil Pressure .......................................................

Oil Pressure Switch .............................................................. 36

System

Description ...........................................................................

System

Disassembly .........................................................................

Inspection .............................................................................

Reassembly .......................................................................... 40

Water

Description ........................................................................... 44

Water

Pump Overhaul - Raw Water Pump PN 33636 .................. .45

Pump

Water

Description ........................................................................... 47

Water

Disassembly ......................................................................... 48

Inspection ............................................................................. 48

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

42B

Installing and Adjusting the Key Switch

Shutoff Solenoid ........................................................

Key-Stop Solenoid System

Checking

Procedure ...................................................

Operation

only) ............ .32

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

Cylinder Head .............................................. 33

System

Oil Filter and Oil Pump ............................................... 35

Oil Pump ...................................................................... 35

...

Fuel Filter .....................................................................

Fuel Lift Pump .............................................................

Fuel Injection Pump .....................................................

Injector .........................................................................

Fuel Filter .....................................................................

Fuel Lift Pump ............................................................ 40

Fuel Injection Pump .................................................... .40

Nozzle .......................................................................... 40

Fuel Filter ..................................................................... 40

Fuel Lift Pump ............................................................. 40

Injection Pump ............................................................. 40

Installation and Adjustment

Injection

Injector ......................................................................... 42

Adjustment and Installation

Holder Assembly ........................................................

Cooling Pump

Disassembly ................................................................. 45

Inspection ..................................................................... 45

Reassembly .................................................................. 45

Overhaul-

Disassembly ................................................................. 46

Inspection ..................................................................... 46

Reassembly .................................................................. 46

Water Pump .................................................................. 48

Thermostat. ................................................................... 48

Service

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

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

Service

Cooling Cooling

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

of

Fuel

Nozzle

Pump

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

Circuit

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

Service

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

Raw Water Pump PN 24143 .................. .46

Circuit

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

Service

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

(continued)

32 32

32

32 33

34 35

36 36

37 37

.39

39 39 39 39 40 40 40

41

42

.44

.45

.47

.48

Engines & Generators

1

TABLE

Reassembly .......................................................................... 48 Engine Wiring Diagram.#36467 .......................................... 70

Drive Belt Adjustment ................................................ .48 Engine Wiring Schematic #36467 .......................................

Admiral Captain Control

Control Starter/Solenoid

DC

Alternator/Regulator

Transmissions ....................................................................

DC

Control

Description ...........................................................................

Control

Description ...........................................................................

Panel

Tachometer/Hourmeter ........................................................

Hourmeter Inoperative .................................................

Tachometer Inoperative ................................................

Tachometer Sticking ....................................................

Tachometer Inaccurate .................................................

Manual Starter Disconnect (Toggle Switches) ...................

Troubleshooting Water Temperature

and

Panel -Early

Activation by Key Switch ....................................................

Description ...........................................................................

Adjustment and Repair ........................................................

Pinion Gap Inspection ..................................................

No-Load Test. ...............................................................

Solenoid ........................................................................

Starter Disassembly .............................................................. 55

Starter Inspection .................................................................

Solenoid ........................................................................

Inspecting the Armature ...............................................

Brush and Brush Holder Inspection .............................

Field Coil Inspection ................................................... .57

Starter Adjustment and Reassembly ....................................

Electrical

Description ...........................................................................

Engine 12-

Charging System ..................................................................

Alternator Troubleshooting ..................................................

Checking for

Battery Maintenance ............................................................

Glow Plugs ...........................................................................

Description ........................................................................... 60

Alternator Troubleshooting .................................................. 60

Testing the Charging Voltage ....................................... 60

Output Test ...................................................................

Disassembly .........................................................................

Inspection ............................................................................. 62

Diode ............................................................................ 62

Checking for

Checking Diode Trio .................................................... 62

Stator ............................................................................ 63

Field Coil (Rotor) ......................................................... 63

Checking Brush and Brush Spring .............................. 63

Checking the

Regulator .............................................................................. 63

Reassembly .......................................................................... 64

Electrical

Engine Wiring Diagram #24666 .......................................... 66

Engine Wiring Schematic #24666 ....................................... 67

Engine Wiring Diagram #33685 .......................................... 68

Engine Wiring Schematic #33685 ....................................... 69

Panel

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

Panel

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

Troubleshooting

Oil Pressure Gauges ................................................... .52

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

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

Models ...........................................

Service

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

System .........................................................

Volt

Control Circuit. ...................................

~roper

Voltage ........................................

Service

Short Circuit.. ......................................... 62

Open Circuit ........................................... 62

Slip Ring ................................................ 63

System

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

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

OF

CONTENTS

.49

49

.50

50

.51

51 51 51 51 51 52

53 Description ........................................................................... 79

53 54

54 54

55

56 56 56 56

57 58

58 58 58 58 58 59 59

60

61 61

65 66

Engine Wiring Diagram #36844 .......................................... 72

Engine Wiring Schematic #36844 ....................................... 73

Engine Wiring Diagram #39144 .......................................... 74

Engine Wiring Schematic #39144 ....................................... 75

Standard Metric Generator

WMD

WMD WMD

BT BT

BT BT BT

Hardware

Conversions

Information

Use

of

Electric Motors ......................................................... 78

Required Operating Speed ................................................... 78

Generator Frequency Adjustment ........................................ 78

Generator Maintenance ........................................................ 78

Generator Troubleshooting .................................................. 78

Generator

Disassembly ......................................................................... 79

Inspection ............................................................................. 79

Reassembly .......................................................................... 79

Generator

No Electrical Output ............................................................ 80

Flash Field Coils .................................................................. 80

Replacement

Low Voltage

High

VOltage

Solenoid with Throttle Linkage ........................................... 82

Generator Generator

WMD Generator Wiring Diagram

WMD Generator Wiring Schematic

Generator

Description ........................................................................... 86

Generator

Residual Voltage Check ....................................................... 89

Bridge Rectifier .................................................................... 89

Testing the Bridge Rectifier for Faults with

an

Internal Wiring Diagram ...................................................... 90

Component Resistance Values .............................................

Models 11.0 & 12.5(A) BT ..........................................

Component Resistance Checks ............................................

Exciter Stator Windings ...............................................

Exciter Rotor/Field ............................................................... 92

Main Stator Windings .......................................................... 93

Compound Transformer ....................................................... 93

Selector Switch .................................................................... 93

Bridge Rectifier Wiring ........................................................ 93

No-Load Voltage Adjustment. .............................................. 94

Voltage/Hertz Connection Bar ............................................. 94

Generator

Generator Frequency ............................................................ 95

Generator 6 Terminal

Wiring Connections ............................................................. 96

Generator

BT

Generator Wiring Diagram #34651 ............................... 98

BT Generator Wiring Diagram #36412 ............................

BT

Generator Wiring Schematic #36412 ...........................

Torques

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

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

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

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

Troubleshooting

of

Field CoiJ(s) ...............................................

Output .............................................................

Output ............................................................ 82

AC

Internal

DC

Electrical

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

Wiring

Diagrams ..................

System

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

#24700 .......................... 84

#24700 ....................... 85

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

Troubleshooting

Ohmmeter .............................................................. 90

AC

Voltage

DC

Electrical

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

Connections

Block

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

System

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

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

....

.100

71

76 77 78

79

80

81 81

83 84

86

87

91 91 91 91

95

96

98

101

Engines & Generators

2

INTRODUCTION

This service manual contains detailed information relating to

of

the proper operation the engine service, and reassembly instructions for the guidance ably equipped and staffed marine engine service and rebuild-

ing facilities. The necessary procedures should be undertaken only by such facilities and their personnel. Refer also to your Westerbeke parts catalog when performing an engine overhaul.

PRODUCT

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

or

generator. Included are disassembly, inspection,

SOFTWARE

the major components and systems

WESTERBEKE'S

control.

WESTERBEKE CANNOT BE RESPONSIBLE FOR CONTENT OF SUCH SOFTWARE, MAKES NO RANTIES OR REPRESENTATIONS THERETO, COMPLETENESS BE LIABLE FOR INCURRED OF

THE

WESTERBEKE customers should also keep in mind the time span between printings ware and the unavoidable existence BEKE with WESTERBEKE products, whether from WESTER-

BEKE or other suppliers, must not and cannot be relied upon exclusively as the definitive authority on the respective prod-

It

uct. appropriate representatives

plier currentness customer.

ENGINE/GENERATOR

This manual contains certain descriptions, procedures and specifications that vary depending on the engine/generator model. Where references to specific models are necessary, three basic model group designations are used:

ENGINES

388

Four

W27

R080

W27A

INCLUDING ACCURACY, TIMELINESS OR

THEREOF AND

ANY

TYPE OF DAMAGE OR INJURY

IN CONNECTION WITH OR ARISING OUT

FURNISHING OR

manuals.

not only makes good sense but

in

question be consulted to determine the accuracy and

In

summation, product software provided

of

the product software being consulted by the

USE

of

MODEL

A

MODELS

GENERATORS 60Hz

50Hz

11.0

BTD

8.3

WMD11.0

WMD8.3

11.0

BTD

8.3

BTD

B

MODELS

ENGINES

W·33 W·33A

WMO

12.5

WITH WILL

OF SUCH SOFTWARE.

WESTERBEKE product soft-

of

earlier WESTER-

is

imperative that

WESTERBEKE

DESIGNATIONS

GENERATORS 60Hz

12.5

BTD

50Hz

WMD9.4

9.4

BTD

ENGINES

42B

WAR-

RESPECT

IN NO EVENT

or

the sup-

C

MODELS

GENERATORS

60Hz

Four

12.5

of

THE

BTDA

suit-

50Hz

9.4

of

BTDA

NOTES,

As this manual takes you through the service procedures, maintenance schedules, and troubleshooting engine/generator, critical information will be highlighted by NOTES, CAUTIONS, and WARNINGS. An explanation follows:

NOTE:

A

observed,

your

A

lowed,

ORDERING

Whenever replacement parts are needed for engines, always provide the engine model number and engine serial number

as they appear on the silver and black identification name-

plate located on the manifold. For generators, provide the

generator model number, engine serial number, and generator

serial number as they appear on the silver and black decal located on the generator end.

The engine serial number can also be found stamped into the engine block just above the injection pump. serial number is stamped into the generator housing on the flat surface on the left side

You erly identify your engine/generator. complete part description and part number for each part

needed (see the separately furnished

upon WESTERBEKE packaged parts because generic parts are frequently not made to the same specifica-

tions as original equipment.

NOTE:

from the front

Left and right sides straddling the engine, facing

front

is

CAUTIONS

AND

WARNINGS

An operating procedure essential

CAUTION:

Procedures,

can

result

in

the

damage

which

if

or

engine/generator.

WARNING:

can

must provide us with this information so

Component locations

of

the engine: the left side is at your

at your

right.

Procedures,

result

in

personal

PARTS/SERIAL

of

the engine which

are

determined as follows: imagine

which

injury

NUMBER

of

the generator.

in

this manual

in

the same direction as the

if

or

In

addition, include a

Parts List). Also insist

is

the pulley/drive belt

of

your marine

to

note.

not

strictly

destruction

not

properly

loss

of

life.

LOCATION

The

generator

we

may prop-

will fit

are

referenced

left,

the right side

of

fol·

or

end.

Engines & Generators

3

INTRODUCTION

Owners may find it convenient to fill in the data on the decal or identification

nameplate shown below to provide a quick reference when using this service manual.

SPECIFICATION

MODEL

RPM

KW

KVA

VOLTS _ ...

AMPS

ENG. ENG.

GEN.

PF

WIRES

RATING

INSUL

TEMP.

BAlTERY

C.'.D.

_______

...

_________

_____

...

_____

__________

__

.........

____

..........

HP _ ......

SER.

NO.

SER.

NO.

IPHASE

________

.......

__

CLASS

RISE

_____

_________

_

__

..

___

_

___

_

......

_

__

...........

_

50

HZ.

60

/

PROPULSION

ENGINE

GENERATOR

DECAL

IDENTIFICATION

NAMEPLATE

Engines & Generators

4

Engine

Type

ENGINE/GENERATOR

A

MODELS

ENGINES

38B

Four W27 RD80 W27A

60Hz

11.0

WMD

11.0

Vertical,

GENERATORS

11.0 BTD

inline,

BTD

50Hz

8.3

BTD

WMD

8.3

BTD

4-cycle,

8.3

QHV,

SPECIFICATIONS

B

ENGINES

W-33

W-33A

freshwater-cooled

WMD

MODELS

GENERATORS

60Hz

12.5

BTD

with

50Hz

WMD

9.4

8TD

heat

exchanger,

9.4

-

ENGINES

428

Four

diesel

engine.

C

MODELS

GENERATORS

60Hz

12.5

BTDA

9.4

50Hz

BTDA

Cylinders Bore & Stroke Total

Displacement Combustion Compression Injection Injection Injection Injection

Chamber

Ratio

Order

Timing

Pump

Nozzle Governor Fuel lubrication Oil

Filter

Sump

Capacity

Fresh

Water

Pump

2.87 x 3.07

79.6

cu.

in.

(1.30

(73 x 78

liters)

Paper-element

mm)

Engines:

Diesel

Forced

5.0

Filter

requires

Swirl

23° ± 1.5°;

Centrifugal

#2

lubrication

filter

quarts

(4.8

approximately

4

chamber

23:1

1-3-4-2

Generators:

Bosch M type

Throttle

type

flyweight

cetane

rating

(trochoid

(full

flow

liters)

not

Centrifugal

3.07 x 3.07

type

45

or

type)

including

.5

quarts

type

90.9

cu.

19° ± 1.5°

higher

pump)

.5

liter

capacity

filter.

(.5

in.

liters)

(78 x 78

(1.49

mm)

liters)

Fresh

Water

Coolant

Capacity Raw Starter DC Inclination

Starting

Compression

(approximate)

Water

Pump

Motor

Alternator

Angle

Battery

Value Standard Minimum Overhaul

Difference

between

Cylinders

8.0

quarts

(7.5

Positive

displacement

12

volts -1.6

12

volt -50

15°

Continuous

20° 12

volt

455

psi

370

psi

312

psi

35.5

Engines & Generators

kW

amp -internal

(in

Temporary

300

C.C.A.

at

280

rpm

at

280

rpm

at

280

rpm

psi

(2.5

liters)

(Neoprene

reduction

voltage

all

directions)

(20

minutes)

or

greater

(32

kg/cm2)

(26

kg/cm2)

(22

kg/cm2)

2

)

kg/cm

impeller)

type

regulator

5

TESTING

HOW

TO

JUDGE

Cause

Generally, the time at which is determined by various conditions such as lowered engine power output, decreased compression pressure, and increased fuel and oil consumption. The lowered engine power output, in with the engine itself, but is sometimes caused by injector

judge by a decrease compression pressure is caused by many factors. fore, necessary to determine a cause or causes on the basis data a seasonal basis is a good means

following symptoms will occur:

These symptoms often appear together. Increased fuel consumption and hard engine starting can result also from excessive fuel injection, improper injection timing, and wear

cal devices such as the battery, alternator, starter and glow

overhaul time by the lowered compression pressure caused

only under sufficient compression pressure. If an engine

will take place even

compression pressure is made should be checked because the compression pressure varies with engine rpm.

The engine rpm can be measured at the front end crankshaft.

of

Low

the case

nozzle wear or injection pump wear.

of

periodic inspection and maintenance. Oil analysis on

nal wear. When caused by worn cylinders or piston rings, the

Low engine power output Increased fuel consumption Increased oil consumption Hard engine starting Noisy engine operation

plugs and nozzles. They are caused also by defective electri-

plugs. Therefore

by worn cylinders and pistons plus increased oil consumption.

In

diesel engines, satisfactory combustion is obtained

lacks compression pressure, incomplete combustion

properly. tant to measure the engine compression pressure regularly. At the same time, the engine speed at which measurement

To

ENGINE

OVERHAUL

PERIOD

Compression

an

engine should be overhauled

of

diesel engines, is not necessarily due to trouble

It is most reasonable to

in

compression pressure. The decrease in

It is, there-

of

monitoring engine inter-

it

is desirable to judge the optimum engine

if

other parts

judge the period

of

the engine are operating

of

engine overhaul,

it

of

fuel

is impor-

of

the

FOR

of

OVERHAUL

in

5. Install a pressure gauge adapter or glow plug hole to be tested.

6. Connect the pressure gauge to the adapter.

7. Crank the engine with the starter motor until the pressure reaches a maximum value. Read the engine rpm and the pressure gauge when the starter rotation has become ble.

8. Repeat the above procedure for each cylinder.

9. If the compression differs kglcm2)

pressure, and repair as necessary.

NOTE:

result pression pressure for each cylinder. Look for cylinders with dramatically (at least 20%) lower compression than the average

of healthy cylinders, the problem is either valverelated. to gasket failure. Abnormally high readings on all cylinders indicate heavy carbon accumulations, a condition that might be

accompanied

NOTE:

have the injectors overhauled by an authorized fuel injection service center. Poor fuel quality, contaminates, and loss positive fuel pressure to the injection injector faults.

OVERHAUL

Compression pressure tends

engine until piston rings and valve seats have been broken in. Thereafter, of

these parts.

When decrease

value, the engine must be overhauled.

The engine requires overhaul when oil consumption is high,

blowby evident, and

below. Engine compression should be

rpm). See SERVICE STANDARDS chart.

NOTE:

repair

these values

at 200 rpm, then determine the cause

Do

not guess the conditions

of

testing one cylinder.

the other cylinders.

Very

low compression in an adjacent cylinder points

by

high pressures and noise.

In case

of

severe vibrations and detonation noise,

CONDITIONS

it

decreases gradually with the progress

of

compression pressure reaches the repair

compr~ssion

The SERVICE STANDARDS chart gives the values for or

replacement

and

measurements during engine overhaul.

by

Be

If

the weak cylinder is flanked by

to

of

the engine components. Refer to

the first injector hole

more than 42.7 psi (3.0

of

the low

of

other cylinders from a

sure to measure the com-

or

head-gasket

pump

will result in

increase a little in a new

of

valves at minimum

32

kglcm2

(at 280

sta-

of

wear

or

Measuring

To

check the compression pressure, follow this procedure:

1.

Warm the engine.

2.

Remove all the fuel injectors or all the glow plugs from the cylinder block.

3. Disconnect the fuel solenoid from the throttle arm (generator models only).

4. Place the stop lever els only).

Compression

Pressure

in

the OFF position (propulsion mod-

Engines & Generators

Disassembly

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

cleaning.

2. Drain water, fuel and oil before disassembly.

3. Clean

4. Do not remove

or

wash the engine exterior.

disassembly.

or

disassemble the parts that require no

6

TESTING

FOR

OVERHAUL

5. Perfonn disassembly

Keep disassembled parts sary. Take special care to keep the fuel system parts free from the intrusion

in

a proper order using proper tools.

in

order. Apply oil when neces-

of

dust and dirt.

Reassembly

1. Prepare

2.

Clean or wash the parts. Apply oil on surfaces where needed or specified.

3. Carefully check gaskets, packings and oil seals even

not specified tive.

4. Be sure to install

(Pay attention to dowel pins, mating marks and specified directions.) Where tightening torque is not specified, tighten evenly to an ordinary torque. Apply sealant where specified.

5. After completion

engine crankshaft two complete revolutions there is no binding the engine and idle the engine sufficiently for a test run.

all

parts necessary for reassembly.

to

check. Replace with new ones if defec-

in

proper directions and positions.

of

the reassembly, manually rotate the

or

obstructions. Prepare for starting

to

ensure

if

Engines & Generators

7

SERVICE

STANDARDS

These SERVICE STANDARDS specify the values at which the engine components will require optional), or wear).

REPLACEMENT (due to maximum component

It is important to observe these standards for your

REPAIR (replacement is

engine/generator, and to take action when necessary to main-

of

tain a high level

All

measurements

To convert mm to inches,

ENGINE

COMPRESSION INTER-CYLINDER INJECTION INJECTION

(BTDC

on

CYLINDER

Bottom Valve Valve

Valve

VALVE

CLEARANCE

safety, dependability and performance.

are

in

mm

unless otherwise noted.

multiply

by .03937

DESCRIPTION

PRESSURE

DIFFERENCE

(max) ORDER TIMING

compression

stroke)

HEAD

surface

distortion

seat

angle

(IN

and

EX)

seat

width

(IN

and

EX)

seat

sinkage

(IN

and

EX)

MODELS

B

A

B C

A

B C

A

B C

A

B C

A

B

A

B

A

B C

A A

B C

C

C C

VALVE

Stem

0.0.

A

C

B 8

Stem

to

guide

clearance Intake Exhaust

Valve Valve

face head

angle

thickness

(margin

width)

A A

B

C

B C

B

C C

B

VALVE

SPRING

Free

length

A

C

8

I

nstalled

load/length

A

C

8

Squareness

ROCKER

Arm

ARM

to

CYLINDER

Camshaft

Front

Cylinder

shaft

clearance

BLOCK

hole

bushing

bore

1.0.

A

A A

8

B

C

B

Cylinder

bore

oversize

finish

NOTE:

Taper

Valve

of

seats

cylinder

are

a part

of

the

tolerance

cylinder

head.

A machine

A A

8 8

shop

can

C

install

STANDARD

32

kg/cm2

2.5

kg/cm 1-3-4-2 23°±

1.5°

19° ± 1.5°

Within

0.05

45°

1.3

-1.8

.12-.13

0.25

(when

6.6

.012 .025

45°

1.0

1.5

43

45.85

14.0

kg ± 0.7

27.9

kg ± 1.4

1.5°

45 73

78

o

to

0.03

within

0.01

valve

seats and cut

A

MODElS

Four

11.08TD

WMD11.0

11.0

GENERATORS

60Hz

ENGINES

388 W27 RD80 W27A

VALUE

(at

280

rpm)

2

(Propulsion) (Generator)

engine

is

kg/36

mm

kg/37.3

for

each

oversize

the

BTO

cold)

mm

seats

8.3 WMO

8.3

ENGINES

50Hz

BTO

W-33

8.3

W-33A

BTD

to properly fit

B

MODELS

GENERATORS

60Hz

WMD

12.5

WMD9.4

12.SBTD

9.4

REPAIR

replacement)

Required

26

kg/cm

0.1

2.5

41.7

44.5

+0.2

the

valves.

50Hz

BTD

(or

at:

C

MODELS

ENGINES

428

Four

12.5

REPLACEMENT

Required

2

-1

0.10

0.15

0.5

-15%

-15% 3°

-0.2

+.95

Replace

or

sleeve

+.95

Replace

or

sleeve

GENERATORS

60Hz

50Hz

BTDA

9.4

BTDA

at:

block

(continued)

Engines & Generators

8

All measurements are in mm unless otherwise noted.

To convert mm to inches, multiply by .03937

DESCRIPTION

PISTON

0.0.

(skirt

end)

Piston

to

cylinder

clearance

Oversize

PISTON

Type

0.0.

Piston

to

clearance

to

connecting

Piston

protrusion

PISTON

RINGS

Number Number

Ring

CONNECTING

Sideplay

CONNECTING

Standard

Undersize

CRANKSHAFT

Bend End Main

MAIN

of of

side

Compression

Ring

gap

Bend

and

clearance

Type

Oil

clearance

play

0.0.

Conn.O.O.

Undersize

Main

(common

Conn.

(common

BEARING

Standard

Oil

type

clearance

rod

above

compression oil

rings

clearance

No.1 No.2

Oil

ROD

distortion

ROD

BEARING

finish

tolerance

to

all)

to

clearance

block

surface

rings

& 3

ring

all)

Undersize

SERVICE

MODELS

A

B C

A B C A B C

A C

B

A

B B -.002

A C

B

A B

A B C A B

A B C A B C A B C

A B C

A B C A B

A

B

A B C A B

A B C A B A C

B

A

B

A

B

A B C

B-

A A B

73 78

0.07-0.08

0.25,

Semi-floating Full-floating

C

19 23

Press-fit

.014 -.038

0.6

C

3 keystone.

1

C

.06 .05 -.09 .03 -.07

.22

0.1 -0.35

C

Kelmet

C

0.035 -0.05

0.25, 0.50,

C

0.06 -0.3

C

52 57 42

C

48

0-0.015

C

0.040 -0.055

-0.035

Kelmet (flanged

e

0.04 -0.05

0.25,0.50,0.75

C

Engines & Generators

STANDARDS

STANDARD

0.50,

(slight

load:

-1.1

(No.1:

chrome

No.2

(chrome

.11

-

040

metal

- -0.050

metal

plated

0.75

type

force

500 -1500

plated

and

NO.3:

with

0.75

with

for

center

VALUE

fit-heat)

barrel

taper

coil

back

metal

back

metal

bearing

kg

type,

semi-

ring.)

expander)

only)

REPAIR

replacement)

(or

Required

REPLACEMENT

at:

Required

.178

.015

1.25

0.06 0.15

-0.3

-0.15

-0.15 -0.90

-0.15

.06

at:

0.3

BIO

0.08

.015

0.3

0.2

1.5

0.15

0.5

0.05

-0.90

0.10

(continued)

9

All measurements are

11

o convert mm to

.

mc

DESCRIPTION

CAMSHAFT

Front

bearing

Oil

clearance

Cam

lobe

height

PUMP

CAMSHAFT

Front

bearing

Cam

lobe

height

TAPPET

0.0. Tappet

to

cylinder

PUSH

ROD

Bend

ENGINE

OIL

Oil

specification

API

service

Viscosity

OIL

PUMP

Trochoid Check Outer Outer Rotor

OIL

PRESSURE

Contact Engine Generator

type

valve rotor rotor to

cover

closing

in

mm unless otherwise noted.

hi'

es,

classification above 5° below

opening to to

I 0393

mu

tlply

(IN

and

block

20°C

to

20°C

5°C

pressure

body

clearance

inner

rotor

clearance

bv .

EX)

clearance

SWITCH

pressure

SERVICE

7

MODELS

A B A B

A B

A

B C

A B C

A B

A B C

A B

STANDARDS

STANDARD

Lead

bronze

C C

C

0.04 -0.08

35.6 -35.7

Ball 44

23 .025 -.050

Within

alloy

bearing

0.3

VALUE

with

back

metal

REPAIR

(or

replacement)

Required

at:

0.10

REPLACEMENT

Required

at:

0.15

-1.0

0.15

LUBRICATION

Class

CF

or or or

10W-30

0.4

kg/cm

0.12

psi

normally

psi

normally

CG-4 10W-30 10W-30

2

(at

500

rpm

open

of

pump

speed)

0.3

0.25

0.20

A B C A

B C

A B A B

A B A B A B A B A

A B A B

B

C

C 4 ±

C C C

C

SAE30 SAE20 SAE

0.15 -0.2

0.05

0.03 -0.07

4 - 6 4 - 6

FUEL

INJECTION

Model: At

smoke

Pump Pump

At

start

Pump

Pump Difference Prestroke

NOZZLE

Throttle Model: Injection

PUMP

NO-PFT4M

set

(SS)

speed

set

(MS) speed speed

from

reference

type

NO-ON4S024

start

pressure

cylinder

A

B C

A C

B

A

A B

C

B

C

A B C

A B A B A B

C

FUEL

SYSTEM

1500

rpm:

27.5 ± 1.0

1500

rpm:

38 ± 1.0

150

rpm:

34

± 5

mm3/st

150

rpm:

36 ± 7.5

Within 2 mm3/rev.

2.2 ± 0.1

120 ± 10

Engines & Generators

kg/cm

mm3/st

cylinder

2

10

mm3/st

TECHNICAL

DATA

DESCRIPTION

CYLINDER

CRANKSHAFT

MAIN CONNECTING CONNECTING FLYWHEEL

OIL OIL FUEL

NOZZLE

GLOW

HEAD

BEARING

MOUNTING

(8T)

(WITH

DRAIN

HOSE

FILTER

INJECTION

Delivery

HOLDER

Holder

mounting

Holder

body

PLUG

PULLEY

ROD ROD

valve

BOLT

NUT

CAP

BOLT CAP CAP

BOLT

WASHER:

BANJO

PUMP

holder

and

retaining

NUT BOLT

BOLT

bolt

(with

OLD)

nut

flange)

TIGHTENING

MODELS

A A

A C

A B A C

A B C A B C A B A B

A B

A B C A B C A B

C

C B B

B

C

B

C

TORQUE

TYPE/QUANTITY

bolt bolt bolt

(10)

(4)

(10)

(4)

M12 M10

M14 M14 M18t M20

bolt

tappet

side

TIGHTENING

11.5 -12.5

TORQUE

6.5 -8.0 15

-16

10

-11

15

-20 20-25 5

-5.5

3.2

-3.5

5.5 -6.0 13

-14

11.5 5-6

1.1

-1.3

4 5

1.5

-2

6-8

1.5

-2

(kg-m)

(wet)

12.5

PARTS

Taper Taper Taper Water Oil Side Bearing

REQUIRING

screw screw screw

drain

pressure

seal

cap

plug

switch

No.

SEALANT

1/2

/I

1/4

1/

1/8

1/

1

BOLT

M6

M8 M10 M12 M14

Thread Thread Thread Thread Thread

Periphery

Contact

DlA.

GENERAL

SURFACES

(where

portion

(Gear

portion

(Cylinder

portion

(Cylinder

portion

(Cylinder

portion

(Cylinder

(Main

surface

with

SCREWS

4 7

0.3 -0.5 0.8

1.0

-1.3

1.8 -2.5

4.2

3.0

5.0

-7.0

SEALANTS

REQUIRING

to

mount

sealant

case)

block

right

head

rear

block

right

block

right

bearing

caps

No. 1 and

cylinder

block

BOLT

1.5 -2.2

3.0

5.5

8.0

coated

side,

surface)

side, side

HEAD

MARK

-1.0

-4.2

7.5

-11.0

SEALANT

parts)

pump

cover)

rear

middle

surface)

No.5)

10

1.0

-1.3

2.5

-3.5

5.0

9.5

-12.0

16.0

-19.0

portion)

7.0

SEALANT

Liquid

Teflon

Liquid

Teflon

Liquid

Teflon

Liquid

Teflon

Liquid

Teflon Permatex Permatex

#6B #6B

Engines & Generators

11

ENGINE

TROUBLESHOOTING

The following troubleshooting table describes certain

problems relating to engine service, the probable causes these problems, and the recommendations to overcome these problems.

PROBLEM

HARD

LOW

STARTING

OUTPUT

LOW

CRANKING

1.

Engine

2.

Run-down

3.

Worn

4.

Battery

5.

Defective

6.

Defective

DEFECTIVE

1.

Air

trapped

2.

Clogged

3.

Low

4.

Inadequate

5.

Injection

6.

Injection

MAIN

ENGINE

1.

Low

a.

Incorrect

b.

Inadequate

C.

Valve

d.

Broken

e.

Compression

f.

Piston

g.

Worn

2.

Burnt

3.

Faulty

4.

Incorrect

LOW

COMPRESSION

INJECTION

1.

Incorrect

2.

Insufficient

3.

Low

INSUFFICIENT

1.

Air

trapped

2.

Clogged

3.

Contaminated

INSUFFICIENT

1.

Clogged

PROBABLE

SPEED

oil

viscosity

battery.

terminals

fuel

injection

too

compression.

glow

injection

filter.

air

loosely starter. main

drive

INJECTION

in

fuel

filter.

pressure.

spray.

pump

delivering

early.

TROUBLES

valve

contact

stem

seized.

valve

spring.

leaks

ring

seized.

piston

ring

plug.

plug

operation.

governor

SYSTEM

injection

injection.

pressure.

FUEL

in

fuel

INTAKE

cleaner.

CAUSE

too

high.

connected.

section.

SYSTEM

passage.

clearance.

of

through

and

lever

position.

OUT

OF

timing.

system.

tank.

AIR

of

insufficient

valve

cylinder.

ADJUSTMENT

fuel.

seat.

cylinder

Note: The engine s electric..al system is protected

ampere manual reset circuit breaker located on a bracket on

of

the left front side mounted on the same bracket.

head

gasket.

the engine. The preheat solenoid is

VERIFICATION/REMEDY

1.

Replace

engine

oil

with

less

2.

Recharge

3.

Replace

4.

Clean

5.

Repair

6.

Check

1.

Bleed

2.

Clean

3.

Adjust

4.

Clean

5.

Repair

6.

Adjust

2.

Replace

3.

Check

4.

Set

See

1.

Adjust

2.

Repair

3.

Check

1.

Check

2.

Clean

3.

Clean

1.

Clean

terminals

clutch

air or

injection

or

a.

Adjust

b.

Lap

c.

Replace

d.

Replace

e.

Replace

f.

Replace

g.

Overhaul

glow

lever

HARD

injection

and or tank.

or

battery.

and

or

replace

for

from

fuel

replace

filter.

pressure.

replace

nozzle.

or

replace

injection

injection or

timing.

valve

valve.

valve valve gasket. piston

engine.

glow

plug.

plugs

to

starting

STARTING

timing.

replace

nozzle

retighten

replace

filter.

replace

air

correct

starter.

disengagement.

system.

injection

clearance.

and

valve

spring.

and

piston

and

solenoid.

position.

injection

and

connector.

cleaner.

viscous

cables.

pump.

guide.

pump.

adjust

oil.

ring.

pressure.

by

a 20-

Engines & Generators

12

(continued)

ENGINE

TROUBLESHOOTING

PROBLEM

LOW

OUTPUT

EXCESSIVE CONSUMPTION

SMOKY

(cont.)

OIL

FUEL

EXHAUST

OVERHEATING

1.

Low

coolant

level.

2.

Loose

V-belt.

3.

Incorrect

4.

Low

OIL

1.

Defective

2.

Broken

3.

Loose

4.

Loose

5.

Loose

6.

Broken

7.

Loose

OIL

1.

Incorrectly

2.

Displaced

3.

Worn

4.

Worn

OIL

1.

Defective

2.

Worn

ENGINE

1.

Noisy

2.

Smoky

3.

Moving

4.

Poor

5.

Improper

6.

Improper

INSUFFICIENT

1.

Air

NOZZLE

1.

Seized

2.

Worn

IMPROPER FUEL WHITISH

1.

Excessive

2.

Excessive

injection

engine

LEAKAGE

oil

gear

case drain oil

pipe

rocker

LEVEL

RISING

positioned

or piston piston

LEVEL

FALLING

stem

valve

BODY

knocking.

exhaust.

parts

compression.

valve

intake

obstructed.

TROUBLES

nozzle.

FUEL

LEAKS

OR

PURPLISH

engine

rise

a.

Poor

piston

b.

Seized

piston

c.

Excessive

oil

seals. case

plug.

twisted ring.

or

and

TROUBLES

INTAKE

PROBABLE

level.

connector.

cover

cylinder.

seal.

valve

nearly

timing. clearance.

of

piston-to-cylinder

CAUSE

timing.

gasket.

attaching

gasket.

attaching

piston

connecting

guide.

seized

AIR

oil.

oil

into

combustion

contact.

ring.

bolts.

ring

or

bolts.

gaps.

rod.

excessively

chamber.

clearance.

worn.

1.

Add

coolant.

2.

Adjust

or

3.

Adjust

injection

4.

Add

engine

1.

Replace

2.

Replace

3.

Retighten

4.

Retighten

5.

Retighten

6.

Replace

7.

Retighten

1.

Correct

2.

Replace

3.

Replace

4.

Replace

1.

Replace

2.

Replace a valve

1.

See

KNOCKING.

2.

See

SMOKY

3.

Repair

or

4.

See

LOW

5.

Adjust.

6.

Adjust.

1.

Clean

or

1.

Replace.

2.

Replace.

Replace

with

Find

fuel

leaks.

1.

Correct

a.

Check.

b.

Replace

c.

Replace

VEmFICATION/REMEDY

replace

V~belt.

timing.

oil.

oil

seals.

gasket.

bolts. plug. oil

connections.

gasket.

attaching

ring

connecting

ring.

piston

stem

replace.

COMPRESSION;

remove

proper

oil

level.

bolts.

gap

positions.

rod.

and

rebore

seal.

and

valve

EXHAUST.

obstruction.

fuel.

or

clean.

or

correct.

cylinder.

guide.

HARD

STARTING.

Engines & Generators

13

(continued)

ENGINE

TROUBLESHOOTING

PROBLEM

SMOKY

ABNORMAL

EXHAUST

OR

NOISE

ROUGH

OPERATION

(HUNTING)

(cont.,

SOUND

WHITISH

3.

4.

BLACKISH

1.

2.

3.

CRANKSHAFT

1.

2.

3.

CONNECTING

1.

2.

3.

PISTON,

1.

2.

3.

4.

VALVE

1.

2.

3.

4.

INJECTION

1.

2.

3.

4.

GOVERNING

1.

2.

OR

PURPLISH

d.

Worn

valve

e.

Low

engine

f.

Excessive Injection Insufficient

Engine

Insufficient Improper

Badly Badly Melted

Worn Worn Bent

Worn Worn Piston Piston

Worn Excessive Worn Worn

Uneven Control Worn Inadequate

Governor Fatigued

timing

OR

body

a.

Poor

compression.

b.

Improper

fuel.

worn worn

bearing.

connecting crankpin.

connecting

PISTON

cylinder. piston

seized. seized

MECHANISM

camshaft.

valve timing fan

pulley

PUMP

injection.

rack

delivery

SYSTEM

lever

governor

compression.

intake

AND

bearing.

crankshaft.

ROD

injection

PROBABLE

CAUSE

(cont.,

stem

and

valve

oil

viscosity.

oil

pressure.

is

too

late.

DARK

GRAYISH

troubles.

valve

clearance.

air

(air

cleaner

MAIN

BEARING

AND

CONNECTING

rod

big

end

rod.

PIN,

AND

PISTON

pin.

and

rings

worn

clearance.

gear.

bearing.

SYSTEM

malfunctioning.

valve.

nozzle

spray.

malfunctioning.

spring.

guide.

clogged).

bearing.

RING

or

damaged.

ROD

BEARING

d.

Replace.

e.

Replace.

1.

Correct.

3.

Adjust.

4.

See

LOW

a.

See

h.

Adjust.

2.

Clean

air

3.

Replace

1.

Replace

2.

Grind

crankshaft.

3.

Replace

1.

Replace

2.

Grind

crankshaft.

3.

Correct

1.

Rebore

2.

Replace

3.

Replace

4.

Replace

1.

Replace.

2.

Adjust.

3.

Replace.

4.

Replace.

1.

Adjust

injection

2.

Disassemble,

3.

Replace.

4.

Replace

1.

Check

governor

2.

Replace.

VERtFICATION/REMEDY

COMPRESSION;

LOW

COMPRESSION;

cleaner.

with

proper

bearing

and

bearing

and

bearing.

bend

or

replace.

cylinder

to piston. piston

and

piston

and

or

check

injection

nozzle.

shaft

fuel.

grind

check

oversize

rebore rings.

replace

parts.

and

correct

and

correct

HARD

STARTING.

HARD

crankshaft.

lubrication

and

replace

cylinder.

injection

operation.

STARTING.

system.

piston.

pump.

Engines & Generators

14

(continued)

ENGINE

TROUBLESHOOTING

PROBLEM

KNOCKING

INTERMITTENT EXHAUST

OVERHEATING

SOUND

ENGINE

1.

2.

3.

4.

5.

6.

KNOCKING

1.

2.

3.

1.

2.

3.

1.

2.

3.

4.

5.

6.

7.

KNOCKS

Faulty

injector.

Bent

rod.

Main

engine

a.

Overheated

b.

Carbon

Too

early

Too

high

Improper

Poor

compression.

Injection

a.

Worn

b.

Pinion

c.

Broken

d.

Worn

Improper

a.

Poor

b.

Poor

c.

After-injection

d.

Nozzle

Fuel

filter

Fuel

pipe

Water

mixed

V-belt

slackening Damaged Lack

of

coolant.

Faulty

thermostat. Low

oil

level Knocking. Moving

parts

PROBABLE

WITHOUT

troubles.

cylinder.

deposits

injection

WITH

pump

sucks

timing.

pressure.

fuel.

DARK

malfunctioning.

plunger.

is

not

in

delivery

nozzle. spray. chattering.

needle

valve

clogged.

air.

in

fuel

or

water

pump.

or

poor

seized

in

cylinder.

SMOKE

mesh

valve

drip.

slippery

oil

or

damaged.

CAUSE

MUCH

with

spring.

seat.

seized.

with

quality.

SMOKE

control

oil.

rack.

1.

Foul

exhaust -rebuild

2.

Fuelish

a.

See

b.

Clean.

4.

Correct.

5.

Correct.

4.

Replace

1.

See

LOW

a.

Replace.

b.

Correct.

c.

Replace.

d.

Replace.

a.

Clean

b.

Repair

c.

Repair

d.

Replace.

1.

Clean

2.

Retighten

3.

Replace

1.

Adjust,

2.

Replace.

3.

Add.

4.

Replace.

5.

Add

or

6.

See

KNOCKING.

7.

Replace.

VERIFICATION/REMEDY

injector.

exhaust

OVERHEATING;

with

or

replace.

fuel.

replace

change.

check

compression,

LOW

proper

fuel.

COMPRESSION;

or

replace

or

replace

or

replace

pipe

joints

or

clean.

HARD

nozzle.

nozzle. nozzle.

or

replace

OUTPUT.

pipe.

repair.

STARTING.

Engines & Generators

15

DRIVE

BELT---"

ENGINE

EXHAUST

PARTS

VALVE

IDENTIFICATION

CYLINDER

HEAl

TAPPET

CAMSHAFT

REAR

OIL

SEAL

,CRANKSHAFT

CRANKSHAFT

PULlEY

GEAR

CASE

INTAKE

NOZZLE

CYLINDER

INJECTION

7

CBANKSHAFT

SILENCER

HOLDER

HEAO

PU~P

GEAR

OIL

SCREEN

SIDE

EXHAUST

\~-#++-:+----PISTON

CONNECTING

JIII

...

Il-I----PUSH

ROD

CAMSHAFT

FLYWHEEL

VIEW

MANIFOLD

ROD

PUMP

CAMSH~FT

Engines & Generators

16

FRONT

VIEW

CYLINDER

HEAD

CONSTRUCTION

The

cylinder

high-rigidity special cast iron and has an excel1ent cooling

effect.

intake port on the right-hand side and left-hand side, ensures high intake-exhaust efficiency.

CYLINDER

The

precombustion

(Ricardo) made

in the cylinder head. This chamber, therefore, requires no disassembly.

Intake

and are commonly usable in either port. The valve guides are oil-impregnated to improve wear resistance.

Valve seats, when needed, can

and knowledgeable machine shop.

CYLINDER

head

is

of

an overhead valve type made

The

cross-flow type cylinder head, provided with its

t~e

exhaust port on the

ROCKER

SHAFT

HEAD

and

HEAD

chamber

of

heat resisting steel and

exhaust

valve guides are made

ROCKER

COVER

is

of

a swirl chamber type

is

press fitted

of

sintered alloy

be

installed by a competent

of

'

The cylinder

provided with stainless steel sheet bores for improved heat and pressure resistance. The gasket requires no sealant when assembled.

Intake

large-diameter head to provide greater intake efficiency. The heads peratures by a special heat-resisting steel facing welded to the valve head.

head

gasket is made

valves are made

of

the exhaust valves are protected against high tem-

of

heat-resisting steel and have a

of

carbon graphite. It is

grommets around the

Valve springs are 'coated with red enamel which marks the

of

rocker arm end to aid in proper placement ing assembly.

mon to intake and exhaust valves. The valve stem seal at the

top

of

the combustion chamber.

and

over) are provided with a valve spring seat between the

valve springs

Rocker

made

of surface. An oil hole is on the upper side rocker arm shaft is a carbon steel tube, the interior forms a lubricant passage. The rocker arm area induction-hardened. Four rocker shaft stays alloy casting are used. sage connected to the cylinder head. to the front stay.

The

spring retainer and retainer lock are com-

the valve guide prevents downward seepage

The high speed engines (3000 rpm

and

cylinder head.

VALVE

GUIDE

VALVE

STEM.

SEAL

arm, rocker

special cast iron and are gas carbonized on the entire

shaft

and

stay.

The

rearmost stay forms an oil pas-

The

the spring dur-

of

oil into

rocker arms are

of

each arm.

of

rear stay is identical

The

of

which

of

the shaft is

aluminum

Intake manifold and exhaust manifold. An intake manifold

with its gasket is on the right side exhaust manifold is on the left side shape

of

each

mani~old

The crankcase

the cylinder block to circulate inside the engine, thus preventing them from exhausting. This system leads blowby gases

from the cylinder block through tappet

holes into the rocker cover and, further, through the air breather pipe (rubber pipe) into the air intake manifold, so that blowby gases are carried into the combustion chamber and are burned during combustion.

vent

depends on the engine model.

system allows blowby gases produced in

of

the cylinder head and an

of

the cylinder head. The

holes and push rod

Engines & Generators

17

CYLINDER

DISASSEMBLY

1. Remove the air breather pipe. Remove the water bypass hose if provided.

2. Remove the fuel injection lines.

3. Remove both the intake manifold and exhaust manifold assemblies.

4. Remove the rocker cover.

S.

Remove the rocker arms and rocker shaft as an assembly.

6. Remove the push rods.

7. Remove the cylinder head assembly by loosening the

head bolts in the numerical order shown below.

HEAD

SERVICE

3. Check the lower surface tion using a straight edge and a feeler

of

the cylinder head for distor-

~.

®

CYLINDER

8. Remove the cylinder head gasket. Partly disassemble the cylinder head assembly as fol-

9. lows:

a.

Remove the thermostat housing. Remove the thermostat and thermostat gasket.

b. Remove the fuel injectors and sealing washers.

c.

Remove the glow plug lead wires and remove the

glow plugs.

d. Using a valve spring com presser, compress the

spring for each valve. Remove the retainer lock and then remove the retainer, spring and valve. the removed valves and other parts cylinder.

e.

A valve spring seat

on

the cylinder head surface. Be careful not to lose

ted the spring seats.

INSPECTION

Cylinder

NOTE:

surements. .

1. Before cleaning the cylinder head, check it for cracks,

2. Hot tank the cylinder head to thoroughly clean all sur-

Head

See SERVICE STANDARDS for tolerances and mea-

damage and water leaks.

faces and oil passages.

HEAD

BOLTS

of

2mm thick for each spring is fit-

®

LOOSENING

SEQUENCE

in

order

by

Place

each

CHECKING

Valve

Guide

1.

Check the valve stem to guide clearance. ment value is reached, replace the valve guide and valve.

2. To remove an existing guide, press ver from under the cylinder head.

it

press until the specified height is obtained.

Valve

Seat

1. Check each valve seat for damage and improper contact.

If necessary, correct

correction, lap the valve into the seat using lapping com-

pound.

NOTE:

valve guide has been checked and

2. If the valve seat sinkage reaches the replacement value

SERVICE STANDARDS), install a new valve seat.

(see

CYLINDER

into the top

Correction

INTAKE

. -

HEAD

DISTORTION

it

upward with a dri-

To

install a new guide,

of

the cylinder head with a driver

12:0.5

MODELS

A & C

VALVE

GUIDE

INSTALLING

it

as shown

of

a valve seat should

SIDE

CORRECTING

EXHAUST

VALVE

in

the illustration. After

be

if

necessary, replaced.

SIDE

SEAT

If

the replace-

VALVE

GUIDE

done after the

2.9

t

Engines & Generators

18

CYLINDER

3. Check the valve seat sinkage by measuring the installed length

of

each valve assembly. When measuring the size up to the top thickness (at the conar)

of

the valve spring retainer, include retainer

of

1.7 ± 0.3 mm.

STANDARD VALUE

HEAD

SERVICE

VALVE

SEAT

.SINKAGE

4. Check the valve seat inserts jf provided, for proper fit. Replace any that

fit

loosely.

f t

Valve

1.

Check the valve face and stem for excessive wear, damage and distortion. valve.

2. If the replacement value reached, replace the valve.

3. Check each valve stem for wear and pitting in the areas shown by the arrows rect or replace the valve.

If

there is any, correct or replace the

of

the valve head thickness is

in

the illustration. If necessary, cor-

NOTE:

The thickness

CHECKING

INSTALLED

of

LENGTH

OF

VALVE

SPRING

the valve spring retainer collar is 1.7

± 0.3.

3.

Check the squareness

if

it

tilts excessively.

of

each spring. Replace the spring

1r

SQUAREjj~D

GAUGE

~

CHECKING

SPRING

SQUARENESS

CHECKING

Valve

Spring

.

1.

Check the valve springs for cracks and damage.

2. Measure the free length and load the spring

VALVE

of

if excessively deteriorated.

each spring. Replace

Engines & Generators

Rocker

1.

2. Measure the rocker arm

Arm

and

Rocker

Check the valve contact surface excessive wear and damage. If there is any, replace the rocker arm. Check the push rod contact surface adjusting screw for wear and damage. replace the screw.

ence between them is excessive, replace the

Shaft

of

1.0. and shaft

each rocker arm for

If

there is any,

0.0.

REASSEMBLY

To

reassamble the cylinder head, reverse the order

sembly, taking care to observe the following instructions.

19

of

each

If the differrocker- arm.

of

disas-

CYLINDER

Partial

1. Press in the valve guides to the specified height. (For the

2. Install the valve stem seals securely on the valve guide.

3.

4. To assemble the rocker arms and shaft, place the rocker

Reassembly

installation procedure, see

Apply oil to the valve stems and insert them into the valve guides. Install the springs, retainers and retainer locks in that order.

shaft in such a manner that the identification mark mm hole) at the front end

of

front retain it with a snap ring. In a similar manner, install the other rocker arms, one after another. Finally, install the rear-most rocker arm and retain it with a snap ring. Then install the assembly on the cylinder head. When tightening the front and rear stays, be sure to install the bolt seats and washers.

the engine. Install the front-most rocker arm and

Valve Guide.)

of

the shaft faces toward the

(4)3

HEAD

SERVICE

3.

Be

sure to use only new gaskets and packings. Apply

sealant to the specified sealing points.

Valve

Clearance

Position the piston in sion stroke. Observe the valves and timing mark on the front crankshaft pulley clearances for cylinder

normal direction for the next cylinder in the engine's firing order, cylinder #3. Rotate the crankshaft another cy linder #2.

NOTE:

For additional information, see Adjusting Valve

Clearance

LOCKNUT

under ENGINE

Adjusbnent

#1

cylinder at the top

(T.D.C.) when doing this. Adjust the valve

#1. Rotate the crankshaft 90° in the

of

rotation (clockwise) and adjust the valves

90° and adjust the valves for

AD]

USTMENTS.

ADJUSTING

SCREW

of

its compres-

IDENTIFICATION

S. Tighten the glow plugs to the specified torque.

6. Install the nozzle holders and tighten the bolts temporar-

7. Install the glow plug lead wires. (The glow plugs are a

Installation

1.

2. Tighten the cylinder head bolts to the specified torque in

MARK

•

FRONT·

INSTALLING

ily. After installing the high pressure injection lines, retighten the bolts evenly to the specified torque. Do not reuse any sealing washers.

taper sealed type; they do not require gaskets.)

of

Cylinder

Install the cylinder head assembly with a new gasket.

gasket does not require any sealant.

the numerical order shown in the illustration. Start with a slight torquing of

moderate torquing, finally tighten to the ,specified torque (see wrench.)

of

TECHNICAL DA1A). (Be sure to use a torque

,

ROCKER

ARMS

O~

ROCKER

Head

Assembly

the bolts, and after two

SHAFT

or

three stages

The

ADJUSTING

VALVE

CLEARANCE

(COLD)

0.25

MM

<:J

~F_RO_N_T

____________

,O®

CD

~

______________

(~y

@ ®

®

CYLINDER

(See

HEAD

Engine

BOLT

TIGHTENING

Adjustment

SEQUENCE

section)

~

Engines & Generators

20

CYLINDER

BLOCK

CONSTRUCTION

The special iron casting cylinder block is

type in which cylinder liners are integrated with the cylinder block.

CYUNDER

The main bearings are made

tered alloy (Kelmet) and an aluminum alloy. To improve runin characteristics, they are coated with a lead-tin alloy plating on the journal surface, and tin flash-plating on the journal surface and tin Crankshaft thrust is received by the flanged center bearing. On the front bearing area special copper alloy rolled bushing is

flash~plating

of

metal-backed copper sin-

over the entire bearing surface.

of

the camshaft, a metal-backed

The crankshaft is a precision-forging

is supported by five bearings to provide high rigidity. Journals, pins and oil seal contact areas are induction-hardened to improve wear resistance and durability.

of

a full jacket

BLOCK

pre!?sfitted.

of

carbon steel, which

The piston pins are hollow, carbonized forgings. When con-

necting a piston to its rod, a piston pin is press-fitted into the

small end

The piston rings are made

provided with three compression rings and one oil ring. The outside surfaces are hard chrome plated. The top rings are stone type and the oil rings are provided with a coil expander.

of

the rod.

of

special cast iron. Each piston is

of

the top compression rings and oil rings

of

the semi-key-

The flywheel is made

of

carbon steel and is shrinkage-fitted to the flywheel. The

gear teeth are induction-hardened.

The pistons are made

weight and to decrease bearing load during high-speed operation. Each piston forms a tapered cylinder with elliptical cross section contour so as to obtain the best contact with the cylinder bore. The piston crown surface has a cavity to improve fuel combustion.

of

cast iron, and the ring gear is made

of

an aluminum alloy to reduce engine

Engines & Generators

PISTON & PISTON

RINGS

The connecting rod has an I-beam cross section and a hori-

zontally split big end to provide high rigidity.

The big end bearing is made

per alloy and is flash-plated all over.

The front piate

tioned by a dowel pin located

camshaft area and a dowel pin

tion pump area. gasket. bearing housing is installed together with the gear case. The aluminum casting gear case is attached to the front end surface

On the left end rear surface, the lube oil pump gear

of

the cylinder block through the front plate. The case houses the lube oil pump front bearing and the governor related parts. stopper.

and

gear case. The steel front plate is posi-

It is bolted to the cylinder block through a

It serves also as a camshaft and idler gear thrust

of

a metal-backed special cop-

in

the upper part

in

the lower part

of

21

the

of

the injec-

CYLINDER

BLOCK

The Camshaft

carbon steel forging. The cam surface and journals are induc-

tion hardened to improve wear resistance. The shaft is supported on three bearings: the front bearing is a bush bearing

(with the exception

duced in the initial period

and rear bearings are in the holes cut in the cylinder block.

All bearings are 'lubricated by a forced lubrication system. The camshaft rear journal has a slot for intermittently lubricating the rocker arms through the cylinder head. The rear

the shaft is provided with

return to the oil pan. The helical timing gears are finished by shaving and crown-

ing to provide high durability and to reduce chattering.

Valve timing is as follows.

VALVE

TIMING

and

Timing Gears. The camshaft is a high

of

a bushless bearing for engines pro-

of

production), while the middle

an

oil escape hole to let excess oil

INTAKE

VALVE

OPENS

T.D.C

EXHAUST

VALVE

of

CLOSES

The tappet

hardened at the bottom and gas-carburized at low temperature over the entire surface to improve wear resistance. Each tappet is offset from the cam center to prevent uneven wear of

the tappet bottom. The steel-bar push rods are flame-hard-

ened at each end.

The injection

Its cam surfaces are induction-hardened resistance. The front end bearing is connected to a gear. The rear end is provided with an

Oldham's coupling groove for connecting to the oil pump

drive shaft.

The high-pressure oil

tion pump camshaft at the rear Oldham's coupling groove.

and

OFFSET

OF

push rod. The tubular type tappets are

-~II-I""'~-OFFSET

TAPPET

AND

CAMSHAFT

pump

camshaft is made

of

the shaft supported on a ball

pump

is directly coupled

of

high carbon steel.

to

improve wear

to

the shaft, mating into the

chilI~

the

injec~

The sheet metal oil sump has an oil drain hose that routes

from the lube oil drain plug to a bracket at the front side the engine.

of

Intake

valve Exhaust I

ntake

valve Exhaust

opens

valve

closes

valve

VALVE

TIMING

(BTDC)

closes

(ATDC)

(ABDC)

opens

(BBDC)

B.D.C

EXHAUST

18° 18°

46° 46°

VALVE

OPENS

Engines & Generators

22

CYLINDER

DISASSEMBLY

1. For removal

DISASSEMBLY under CYLINDER HEAD SERVICE.

to

2. For removal refer to their respective sections.

3. Pull off the push rods, then pull out the tappets upward.

4. Remove the fuel filter.

5. Loosen the crankshaft pulley nut, then take off the pulley and washer.

6. Loosen the flywheel mounting bolts and remove the flywheel.

7.

Remove the back plate and rear oil seal case.

8. Remove the lube oil pump gear bearing housing. Remove the gear case, but first rod located of

the cylinder block and to remove the stopper spring

and tie-rod from the injection pump's fuel rack.

A

pump gear block

ful

nDt

front

dowel

9. Remove the fuel injection pump.

10. Remove the governor weight bolts. Remove the weights.

11. Remove the pump camshaft bolt.

12. Remove the oil filter and the oil pump assembly. Then pull out the injection pump camshaft.

13. Remove the gears. Then remove the front plate.

14. Remove the camshaft.

15. Turn the engine upside down. Remove the oil pan and oil screen.

16. Remove the nuts from the big end and remove the cap. Push the piston and connecting rod assembly upward out removed parts in order for each cylinder. When pushing out the piston and connecting rod assembly, put a wooden block against the cap mating surface so as not to damage the metal surface.

17. When separating the piston from the connecting rod, use the following procedures. Keep the disassembled parts order for each set. Take care to prevent confusion, especially for each set

a. Set the piston and connecting rod assembly on the

special tool (piston pin setting tool) body. '

h. Insert the push rod

and press the pin out. .

of

a the cylinder head and related parts, refer

of

the water pump and electrical equipment,

at

the right front (beside the injection pump)

CAUTION:

rack

case.

frDm

tD

plate.

from

The inside

drive

Also,

Be the

front

the

Dut

be

pins.

of

it

is

necessary to remove the tie-

sure

tD

separate

tie-rod

before

plate

is

gear

case;

the

gear

case

careful

of

piston and wrist pin.

not

the cylinder block. Keep

of

the tool into the piston pin hole

the

injection

removing

bolted

to

the

therefore,

tDgether

to

damage

of

each connecting rod

cylinder

be

with

the

of

the

care-

the

Hie

the rod

in

BLOCK

SERVICE

A

CAUTION:

remDve sive a

ting

18. Remove the main bearing caps. Keep the caps and bearings the crankshaft end play before removing the caps (see

Crankshaft, para. 3., under CYLINDER

VICE). Mark the caps and rod with a number punch 1 4

as needed.

19. Remove the crankshaft.

it. A

pulling

IDad

of

tool.

in

order for each cylinder. It is necessary to meaure

stuck

force

mDre

Do

should

than

not

hammer a piston

piston

which

be

replaced.

3,000

kg

tD

the

REMOVING

"///'//./~~---TOOL

PISTON

requires

pistDn

IDENTIFICATION

BLOCK

INSPECTION

Cylinder

1. Check the cylinder block for cracks and damage. If there

Block

is

any, repair or replace the block. Check the camshaft front journal bushing for wear and damage. any,

replace the bushing using a special tool (Tool

#033583).

A

CAUTION:

fit

in

the

be

crushed

not

to

burn

as

this

will

bushing.

cylinder

or

damaged

or

scratch

interfere

The

camshaff

block.

The

camshaff

when

the

bushing

with

the

installation

REMOVING

bushing

removed.

boss

CAMSHAFT

tD

exces-

Do

not

BODY

If

there is

is a

fDrced

bushing

Take

care

in

the

of

the

BUSHING

apply

set-

MARK

SER-

will

block,

new

BUSHING

Engines & Generators

23

CYLINDER

BLOCK

SERVICE

2. Check the water jacket for scale and corrosion. Clean the block thoroughly and ensure that all oil passages are clean.

3. Check the cylinder walls for scratches, dents and wear. If necessary, repair by honing

in

der bore ferent depths.

right-angled directions A and B at three dif-

or

boring. Measure the cylin-

¢::J

FRONT

CHECKING

4. When cylinder bore wear is not excessive and only the piston rings require replacement, check the upper part the cylinder for ridge wear. der bore and hone when necessary.

CYUNDER

If

WEAR

any exists, ream the cylin-

of

3. Measure the side clearance between each piston ring and its groove. If necessary, replace the ring.

As to the semi-keystone type top ring, allow its own weight into the groove, then measure its depth from the piston surface.

PISTON

RING

SIDE

CLEARANCE

WEIGHT

OF

RING

it

to sink by

Piston,

1.

2. Measure the piston

Piston

Check the piston for seizing, scratches and wear. If necessary, replace the piston.

sively worn. sively large, machine the cylinder to an oversize bore or replace the piston. The piston at the lower end the piston pin hole.

MEASURING

and

Piston

O.D. Replace the piston if exces-

If

the piston-to-cylinder clearance is exces-

of

the skirt at right angles to the axis

PISTON

0.0.

Rings

O.D. should be measured

of

4. Measure the gap its gap is excessively large. To measure the ring gap, insert a ring into the least worn place (skirt) using a piston and measure the gap with a feeler gauge.

of

each piston ring. Replace the ring if

of

the cylinder bore

o

JL:HG

.

RING

GAP

Engines & Generators

24

CYLINDER

BLOCK

SERVICE

Connecting

1. Using a connecting rod aligner, check each connecting rod for bending and distortion. If necessary, correct or replace the rod.

2. Measure the connecting rod thrust clearance with a rod assembled on the crankshaft. If the clearance is excessive, replace the rod assembly.

!

Rod

CONNECTING

ROD

THRUST

CWRANCE

Crankshaft

(JOURNAL)

R2.5~

(PIN) R

2.5

3. Check the crankshaft end play. If the specified limit exceeded, replace the flanged No check the end play, install the and main bearing caps, then tighten the cap bolts to the specified torque. Measure the end play with a dial gauge

held against the front end

..

3 main bearing.

ma~n

bearings, crankshaft

of

the crankshaft.

is

To

1. Measure the crankshaft bend, If excessive, repair or replace the crankshaft.

CRANKSHAFT

2. Check the crankshaft journals and pins for damage,

If

seizure and other faults.

machine to the undersize diameter. At the same time,

replace the corresponding main bearing or connecting rod bearing with the same undersize bearing. When machin-

ing a crankshaft journal

sure to finish its fillets to R2.S mm. Check that all oil

passages in the crankshaft are clean and open.

excessively worn or damaged,

or

pin to the undersize one, be

0.0.

Main

Bearings

Check the surface ing and poor contact. If any the bearing.

Fit the main bearings to the cylinder block and the connecting rod bearings to the connecting rods. Tighten the bolts to specification. Measure the sure the the oil clearance (a plastigauge may be used). If any oil clearance is excessive, replace the corresponding bearing. excessive clearance still remains even after replacement the bearing, grind the crankshaft to install the same undersize bearing.

0.0.

and

Connecting

of

each bearing for flaking, melting, seiz-

J.D.

of

the crankshaft journals and pins

R"d

Bearings

of

these conditions exist, replace

of

eac~

bearing. Then mea-

th!f!

undersize

to

calculate

If

0.0.

an

of

and

Engines & Generators

25

MEASURING

CONNECTIN~

ROD

BEARING

1.0.

CYLINDER

Gearcase

Check the gearcase body for cracks and damage, and the oil

seal for damage. Also check the governor related parts. If the camshaft thrust plug press-fitted in the gearcase has been worn or damaged, install a new thrust plug.

22 ± 0.4

BLOCK

SERVICE

PRESS-FIT CAMSHAFT

Timing

Check each gear for poor contact, wear and damage. If there

is any, replace the gear. Also check the splined bore

lube oil pump gear for faults.

HEIGHT

THRUST

Gears

OF

and

PLUG

Lube

Oil

Pump

Gear

of

the

Camshaft

Measure the clearance between the center journal and the cylinder block, and between the rear journal and the cylinder

or

block. If either camshaft, front bushing or cylinder block. Replace the camshaft

badly worn.

Fuel

Replace the camshaft or

if the cam surface is damaged

MEASURING

Injection

damaged or if the Oldham's coupling is damaged.

both clearances are excessive, replace the

or

the cam lobe is

CAM

LOBE

HEIGHT'

Pump

Camshaft

if

the cam surface

is

excessively worn

MEASURING

Ball

Bearings

Check each ball bearing for excessive wear or damage and

or

for irregular bearing.

noisy rotation. If there is any, replace the

INJECTION

PUMP

CAMSHAFT

LOBE

Tappets

1. Check the bottom nicks. If any

2. Check the clearance between each tappet and the cylinder

block. If any clearance exceeds the specified limit,

replace the tappet.

Push

Rods

1. Replace a push rod if both its ends are excessively worn.

2. Place each push rod on a surface plate and check for

bending at the center

specified limit, correct or replace the rod.

of

each tappet for cracks, flaking and

of

these conditions exist, replace the tappet.

of

the rod. If the bend exceeds the

REASSEMBLY

A

CAUTION:

passages,

cial

care.

Before

assembling,

ing

and

press

inner

walls.

Replace Apply

ified Observe

fied.

screws

clearances

gaskets,

sealant

sealing

tightening

For

or

sliding

points.

other

bolts

and

Clean

surfaces

fit

parts

packings

to

gaskets

parts,

as end

each

apply

such

torque

tighten

the

torque

plays

part

and

engine

as

and

packings,

and

to

table

during

sufficiently.

rotating

bearings

oil

seals

to

parts

all

and

sequence

the

torque

specifies.

assembly

Clean

with

sliding,

cylinder

with

new

to

where

for

ordinary

Check

work.

rotat-

the

speci-

oil

spe-

ones. spec-

Engines & Generators

26

CYLINDER

1. When the camshaft front bushing is pressed in, align the bushing oil hole with the oil hole using a bushing installing tool. For proper alignment, make a mark indicating the block's oil hole position on the front end face

of

the block. After installing the bush-

ing, confirm that the oil holes are properly aligned with

each other.

,.

DRAW A MARK OF

BLOCK

2.

ALIGN

BUSHING

OIL

HOLE,

2. When pressing

ment and length Failure

to

in

the idler gear shaft, follow the align-

of

protrusion shown

do

so will

result

engine operation.

MODelS

A & C

-26.5:tO

in

,CYLINDER

AT

OIL

(BEFORE

INSTAlliNG

OIL

PRESS

IN

in

low oil

..

5

the cylinder block

BLOCK

FRONT

OF

HOLE

CENTER

BUSHING).

HOLE

WITH

BUSHING.

BLOCK

in

the diagram.

pressure

during

BLOCK

SERVICE

4.

Install the main bearings to the cylinder block.

NOTE:

bearing fitted correctly

5. Install the crankshaft. Apply engine oil to the journals and pins.

6.

Install the main bearing caps and tighten the cap bolts to the specified torque. Each cap carries and numeral to prevent incorrect installation When installing the No. the upper surface (cylinder block mating surface) .

........

7. Check the crankshaft end play.

S.

Apply sealant to the outside surface Press the side seals into the front and rear caps, thus completing the reassembly

The oil ports must be properly positioned and the

into the block recess.

an

embossed arrow mark

of

the caps.

1 and

No.5

caps, apply sealant

FRONT

of

both side seals.

of

the crankshaft.

to

PRESS-FiniNG

IDLER

GEAR

SHAFT

3. When replacing the dipstick guide, coat the new guide (without a flange) with press-fit into the cylinder block.

30 ± 0.5

(1.1811" ± 0.0197")

surface.When installing the former type is increased in diameter at the midpoint, press caught

in

the hole. (There is no difference in the press-fit

HERMESEAL

Press-fit to a height

from the cylinder block

52B

sealant, then

of

guide, which

of

it in until

position between the former type and later type guides.)

FORMER

LATER-TYPE

GUIDE

INTO

BLOCK

GUIDE

Engines & Generators

27

.

INSTALLING BEARING

CAP

SIDE

SEALS

CYLINDER

BLOCK

SERVICE

9. Install the oil seal into the crankshaft rear oil seal case. Install the seal case to the cylinder block. Remember to install the lution

10. Install the back plate.

11. Install the flywheel. The bolts should be tightened to the specified torque.

12. Assemble the piston and the connecting rod using the Piston Pin Setting Tool.

gasket. Turn the crankshaft one complete revo-

to

ensure there is

no

unwanted binding.

CONNECTING

ROO

h. Insert the assembled push rod, piston pin and guide

into the piston pin hole from the guide side, and into the small end the arrow (front mark) on the piston head and the identification mark on the connecting rod are positioned upward. Before insertion, apply engine oil to

the piston pin and to the connecting rod small end

hole.

c.

Set the piston, connecting rod and guide as an assembly on the tool body. When setting, insert the tool guide into the tool body with the cut alignment with that guide

90°. Make certain the small end

ing rod rests properly on the tool body. Also, confirm that the front mark on the piston head and identification mark on the connecting rod face up.

d.

Press the piston pin kg. If the piston pin is easily pressed sure than above,

replace the connecting rod or the piston and pin assembly. The piston pin will be positioned by the guide. After installation, tum the push rod so that the cut in the guide comes in alignment with the cut in the tool body. Detach the piston and con-

necting rod assembly from the tool body.

of

the connecting rod.

in

the tool body and then turn the

in

under a pressure

or

if the pin needs a greater pressure,

In

this case, both

in

the guide

of

in

with less pres-

to

be

the connect-

500 to 1500

in

place

90°

in

/////';I'E'-

PISTON

SETTING

TOOL

3.

Insert a piston pin into the push rod screw a guide (see illustration for proper guide) fully into the push rod.

__

TOOL

of

the tool, then

/1);0"

~9~m

~

G~;>

~.~m

~

~~

~

BOOY

GUIDEE

PUSH

ROD

A

CAUTION:

connecting small

end

the

piston

the

proper

case,

check

Each

pislon therefore, confused

and

pins

to

same

size

13. Piston rings differ in shape from one another. Be sure to install them illustrated, and with the stamped manufacturer mark and size mark facing up. When installing the piston ring with a coil expander, position the expander joint opposite

'the ring-gap position.

in

After

assembling

rod,

make

certain

is

properly

pin.

position

the

and

a set

with

be

(same

their proper positions and directions, as

II

any

piston its

01

other used

mark).

positioned excessive

is

lound!l

are

piston

and

pistons

in

an

engine

the

connecting

at

deviation

correct

setting

tool

matched

must

and

pins.

must

piston

the

it.

parts

center

Irom

In

this

also.

and!l

not

All

pistons

be

of

and

rod

be

.the

to

01

PISTON

PN#033582

SETTING

TOOL

Engines & Generators

28

CYLINDER

BLOCK

SERVICE

PISTON

RING

POSITIONS

m

NO.1

~BNO.;

~~NO.3

PISTON,

<lOll

PISTON

RINGS

..

,.§>'

~

\\

In

'\.

this case,

of

the

RING

GAP

POSITIONS

ENGINE FRONT

14. Install the piston and connecting rod assembly from the top

of

the cylinder block using a ring band. make certain the piston ring gaps are properly positioned and the arrow mark on the piston faces the front engine. After insertion, install the connecting rod end halves

in

place and tighten the rod cap bolts to the specified torque. Apply oil to the bearing surfaces before assembly

15. Install the front plate. Remember to install the gasket and dowel pin.

16. Tum the crankshaft until the to the top dead center.

17. Align the keyway in the crankshaft gear with the key on the crankshaft. Install the gear on the shaft.

of

the connecting rod ends.

No.1

'..

'~~.

cylinder piston comes

1

18. Align the mating mark the crankshaft gear; install the idler gear on the idler shaft. Insert the camshaft and gear assembly into the cylinder block so that the mating mark camshaft gear aligns with that on the idler gear. Then

insert the injection pump camshaft assembly into the cylinder block and align the mating mark pump gear with that on the idler gear

injection pump drive shaft gear assembly.

19. Confirm that mating marks on the gears are in proper alignment with each other.

20. Fit the governor weight assembly to the injection pump cam gear.

21. Install the gear case

previously installed) and gasket. When installing the gear

case, insert the tie-rod and tie-rod stopper spring into the

hole

in

the cylinder block so to position

injection pump fuel rack.

GEA~

MATING

MARKS

~'1"

on the idler gear with that on

"2"

on the

"3"

on the

..

Finally, install the

(wfth the governor and related parts

it

next to'the

Engines & Generators

29

CYLINDER

BLOCK

SERVICE

INSTALLING

22. Insert the crankshaft pulley. Install the washer and nut. Then tighten to the specified torque.

23. Install the back plate. Be sure to install the gasket.

24. Install the oil pick up, then install the oil pan.

25. Apply oil to the periphery into the cylinder block. Then insert the push rod properly into the tappet hole. Check to see lightly.

INCORRECT

CORRECT

GEAR

CASE

of

the tappet. Insert the tappet

if the tappet moves

PUSH

ROD

INSTALLING

28. Install the oil pump and oil filter (see

under LUBRICATION SYSTEM SERVICE). When the oil

pressure switch and oil pressure sender with adapter has not yet been installed, apply sealant to the threaded por-

tion when installing.

29. Install the fuel filter.

30. Install the fresh water pump.

31. Install the starter (see and alternator (see ALTERNATOR/REGULATOR SER-

VICE).

32. Install the raw water pump.

INJECTION

STARTER/SOLENOID SERVICE)

PUMP

REASSEMBLY

INSTALLING

26. Install the cylinder head assembly (see CYLINDER

HEAD SERVICE, REASSEMBLY).

27. Install the injection pump assembly (see Installation

Adjustment SYSTEM).

of

Fuel Injection Pump under FUEL

TAPPET

AND

PUSH

ROD

and

Engines & Generators

30

GOVERNOR

DESCRIPTION

The

governor keeps engine speed constant by using a bal-

ance between the centrifugal force acting on the governor weights and the tension

If engine speed increases, the governor weights will open,

forcing the sliding shaft forward. This moves the injection

pump fuel rack, linked to the sliding shaft through the nor lever assembly, tie-rod and spring, injects less fuel into the cylinders. The movement is stopped

at a point where the centrifugal force

balances with the tension If engine speed is decreased by an overload, the control rack

is pushed against the smoke set spring in the direction that injects more fuel. The Angleich mechanism restricts the increase and quantity load, saving fuel, and decreasing exhaust smoke.

of

the governor spring.

in

the direction that

of

the governor weights

of

the governor spring.

of

fuel injection thus preventing over-

GOVERNOR

lEVER

GOVERNOR

WEIGHT

gover-

3. Remove the fuel injection pump (see

Fuel Injection

Pump under FUEL SYSTEM)

4. Remove the gear case mounting bolts and remove the gear case (see

DER

BLOCK

CA UTION under DISASSEMBLY, CYLIN-

SERVICE).

5. Remove the governor spring.

6. Remove the nut, washer, spring lever. Remove the speed control lever from the gear case.

7.

Remove the nut, washer and spring lever, remove the governor lever set bolt, and remove the governor lever.

S.

Remove the governor weight assembly and the sliding shaft from the injection pump camshaft.

9. Remove the tie-rod and spring from the governor lever.

PUMP

CAMSHAFT

GOVERNOR

~"":::::::::::ll.~I~:;;±::H1

r:....!...U--_--lolER

f---,..........-rJ'---

__

SLloING

SHAFT

GOVERNOR

SHAFT

PUMP

GEAR

CASE

GEAR

NEEDLE

BEARING

GOVERNOR

LEVER

GOVER~IOR

SHAFT

NEEDLE

BEARING

GOVERNOR

SPRING

SPEED

CONTROL

lEVER

DISASSEMBLY

1.

Remove

SERVICE).

2. Remove the crankshaft pulley nut and remove the pulley.

the,

drive belt (see FRESH WATER COOLING

GOVERNOR

LEVER

SECTION

OF

GEAR

CASE

INSPECTION

1. Check the governor weights for wear and damage. Replace if defective.

2. Check the sliding shaft for damage and stiff movement. Replace

Governor

Check the sliding shaft contact area check the tie-rod and spring which connect the governor lever to the fuel rack. Replace

Governor

Check the spring for deterioration and breakage. Replace defective. When overhauling, replace the spring.

Needle

Check the needle bearing supporting the governor lever shaft in

the gear case for damage.

REASSEMBLY

To

reassemble the governor, reverse the order

After reassembly, check the governor for smooth operation.

if

defective.

Lever

Spring

Bearing

AND

of

the governor lever and

if

defective.

ADJUSTMENT

of

disassembly.

if

Engines & Generators

31

ENGINE

SHUTOFF

ENGINES

A manual stop lever is located on the outboard side engine block just below the fuel injection pump. The damper spring is also mounted on this same lever assembly. A throttle bracket is attached direction by the cable, a lever inside the cover assembly

moves the fuel rack position, stopping the engine. cable is pushed in to return the shutoff lever back into the fuel/run position. A heavy return spring on the shutoff lever assists in doing this. Periodically lubricate the lever and

push-pull cable to ensure free movement.

WITH

MANUAL

is

provided to attach a push-pull cable. This cable

to

the shutoff lever. When pulled fully

of

~/Id

~~?'

· i I

,

STOP

(Standard)

in

the injection pump to the fuel stop

Once the engine stops, the

MANUAL

,~-:

.

THROTTLE

of

the

the stop

STOP

LEVER

\

OPTIONAL

(Models

An optional key switch shutoff solenoid #037100 is offered

for the above two models only. This solenoid mounts in a

boss directly behind and slightly below the injection pump

mounting location, This solenoid, when energized by turning

the key-switch on, allows the injection pump fuel rack to

move to the fuel/run position allowing the engine to start to

run. When the key switch is turned off, the solenoid plunger

moves the fuel rack to the stop fuel position stopping the

engine.

Installing

Shutoff

1. Remove the large plug just behind the injection pump and slightly below it on

the engine block.

2. Visual access to the fuel injection pump fuel rack is

needed. cover assembly.

3. Thread the locknut all the way onto the solenoid and

apply a small amount ward

4. Thread the solenoid into the boss on the engine block and

observe the solenoid plunger through the side cover opening. Allow the plunger to contact the fuel rack and move pump. Do not thread the solenoid further into the boss so that the plunger against the fuel rack is pushed into the solenoid.

S.

Back the solenoid out secure the solenoid in position with the locknut.

6. Properly connect the three electrical leads from the sole-

noid. The black eye lead goes to block ground.

KEY

388

and

SWITCH

and

428

Adjusting

SHUTOFF

only)

the

Key

Switch

Solenoid

or

side oil filler assembly located

To

obtain this, remove the shutoff lever side

of

Teflon sealant to the threads for-

of

the nut.

it

fully into the shutoff position on the injection

of

the boss 1/4 to 1/2 tum and

The

white

pull-in lead should be run to the heavy solenoid terminal on the starter. Connect the red hold lead (splice into) the

"R"

connection on the

SIDEO~l.FlllER

(REMOVE)

--

...........

DC

alternator.

<,~e~

",,~Y'>'"

:,

'\

Key-Stop Procedure.

1. Wire the system making reference to the wiring diagram.

2. Viewing with the tie-rod cover off, confirm that when the

3. Tum the key switch to

4.

A

to amp be noid engine

NOTE:

required, sible without removing

The engine will now start. manual shutoff lever. Disconnect the two leads red and white from their power source.

Solenoid

key switch is turned to the the engine, the solenoid energizes and brings the fuel injection pump fuel rack to the

The

shutoff sequence is as follows: When the start button is depressed during the normal starting procedure, the solenoid is energized by the pullin

lead. Once the engine starts and the start button is released, the solenoid remains energized by current to the hold lead connection on the alternator which receives voltage/current once the engine starts and the oil pressure switch closes from engine oil pressure.

CAUTION:

energize

to

keep

connected

will

be

operation.

Should the solenoid fail and engine operation is

unscre,w the solenoid as far out

KEY

System

of

the solenoid coming from the

The

the

solenoid.

the

solenoid

incorrectly

damaged

STOP

SOLENOID

~

, ,

Operation

ON

OFF and reinstall the tie-rod cover.

pull-in

lead

The

hold

energized.

during

from

excess

it.

Lock

it in position with the locknut.

To

shut the engine off, use the

~,

I "

Checking

position before starting

MS STOP plate position.

"R"

terminal

draws

about

8-10

lead

draws

about

Should

installation

current

these

the

sole-

draw

during

of

the boss as pos-

amps leads

one

Engines & Generators

32

ENGINE

ADJUSTMENTS

TIGHTENING

Pull

off remove the rocker cover. Before adjusting the valve clearance, retighten the cylinder head bolts to their specified torque

in

engine is cold when this is done. Before applying the speci-

fied torque

the torque (see

THE

CYLINDER

the air breather pipe from the rocker cover and

the sequence shown in the diagram. Make sure the

to

a bolt, loosen

TECHNICAL

CD

HEAD

it

1/4 to 1/2 a turn and then apply

DA1'4.).

CD

®

¢

FRONT

ADJUSTING

VALVE

LOCKNUT

ADJUSTING

CD

CYLINDER

VALVE

cb

HEAD

BOLT

CLEARANCE

ADJUSTING

Cl.EAR4NCE

CD

TIGHTENING

SCREW

CLEARANCE

CD

SEQUENCE

CD

(COLD)

®

0.25

MM

The engine's valves must be adjusted in this order while the valves are closed. engine's crankshaft is more easily accomplished when the engine's glow plugs are removed before the crankshaft is rotated.

a. Rotate the engine in the normal direction

placing the sion stroke. The should be in line with the pointer on the front gear case cover, and the valves for the should be closed. Now adjust the intake and exhaust valves for cylinder

h.

After adjusting the valves for cylinder front crankshaft pulley clockwise mark on the pulley is positioned approximately in the position shown Now adjust the intake and exhaust valves for cylinder No.3.

c.

Rotate the crankshaft pulley clockwise another 180 and adjust the valve clearances for the intake and exhaust valves for cylinder

d.

Rotate the crankshaft pulley clockwise another 180 and adjust the valve clearances for the intake and exhaust valves for cylinder

Adjust each valve's clearance by inserting a 0.25 mm (0.010") feeler gauge between the rocker arm and the valve stem as shown.

No.1

You

may find that turning the

Cylinder at the top

mc

mark on the crankshaft pulley

No.1.

in

the illustration for cylinder

No.4.

No.2.

of

No.1,

1800 so the

of

rotation

its compres-

of

No.1

cylinder

rotate the IDC

No.3.

the

0

1.

Adjust the valve clearances at for each cylinder when they are on their compression stroke.' Remember the engine's firing order is 1-3·:4-2.

mc

(Top Dead Center)

ADJUSTING

1.

Position the number one piston at the beginning compression stroke. Remove the high pressure injector line from between the number one cylinder's injector and the injection pump. Remove the number one delivery valve holder. Remove the spring below it and reinstall the holder. Attach the high pressure injector line to the holder and have the other end pointing outboard Open the throttle and energize the fuel lift pump. Fuel should flow out catch the fuel. Slowly turn the crankshaft in the normal direction injector line. The instant injection point. crankshaft pulley and the timing pointer on the front gear case. Refer to timing for the model being checked.

Engines & Generators

a3

FUEL

INJECTION

of

this line. Have a container under

of

rotation and watch the fuel flowing from the

Observe the timing mark on the front

SERVICE STANDARDS for the injection

TIMING

of

the engine.

it stops is the beginning

of

its

the

it

to

ENGINE

ADJUSTMENTS

INJECTION TIMING

MARKS

2. When the specified injection timing is not correct, increase or decrease the shim material thickness under the fuel injection pump. Injection timing varies

0.1 mm increase or decrease tion

of

shim thickness will retard the timing and reducing

shim

thickness will advance the timing. Another method

of

checking injection timing without removing the spring

from under the delivery valve holder is

of

shim thickness. The addi-

to

1°

disconnect the high pressure injector line from the injector. With the number one piston at the beginning stroke, tum the crankshaft

in

tion and watch carefully the fuel in the end

of

its compression

the normal direction

of

the high pressure line. The moment this fuel starts to swell and come out

of

the line, this

is

the injection timing point. By this method, the timing is about 10 later than the spill timing method previously discussed.

ADJUSTING

To

adjust the engine speed on a generator, adjust the linkage

NO-LOAD

ENGINE

SPEEDS

between the throttle arm and the fuel run solenoid. Shortening the linkage increases the engine speed. Lengthening the linkage reduces the engine speed.

NOTE:

This adjustment is performed with the engine operat-

ing

and at normal operations temperature, with no amperage

being taken from the generator. See the chart below:

with

of

rota-

2. Tighten the damper spring adjusting bolt speed is set to (a)

+ 40 rpm, shown

unti1

the engine

in

the table below as (b) rpm. Lock the adjusting bolt at that position with a locknut. (Apply Locktight to the threads

of

the adjusting

bolt.)

ENGINES

W·27,

RD80,

W-27A,

W-33,

W-33A

38B

Four,

42B

Four

a.

Seal the above-mentioned adjusting bolt with its brass cap and crimp

h.

Seal the maximum speed set bolt with wire and sealing

it

on the bolt.

"b"

3150

3750

rpm

+0

·50 +0

-50

material.

SOLENOID (OPTIONAL)-

DAMPER·SPRING

ADJUSTMENT

APpF/OX.1O"

STOP

RANGE

STOP LEVER

GENERATOR

60 50

NOTE:

Any only with the linkage between the fuel solenoid and the tle

lever.

MODElS

hertz

models

hertz

models

adjustment

NO-LOAD

1850-1880

1550

of

the throttle on a generator is done

-1580

SPEED

(rpm)

(61.5 -62.0

(51.5

52.0

hertz)

throt-

Propulsion Models. This adjustment need only be performed

after

an

engine overhaul

cir

when the governor system

or injection pump overhaul/repairs have been performed. This adjustment is performed after engine assembly during testing at

th~

factory. See the chart below for no-load engine speed.

1.· With the damper spring released (by loosening the

damper spring adjusting bolt), set the engine at

"a"

rpm specified in the chart with the maximum speed set bolt. lock

the bolt at that position.

"a"

W-27,

ENGINES

RD80,

38B

Four,

W·27A,

428

W-33,

Four

W-33A

3110

3710

rpm

+0

-30 +0

-30

Engines & Generators

SPEED

CONTROL

LEVER

DAMPER

SPRING

ADJUSTMENT

c.

Adjusting the Idling Speed. Idling speed for most

engines is

oetween 800 and 1,000 rpm. Set the engine

to the idling speed with the idling set bolt and lock the

bolt at that position.

34

LUBRICATION

SYSTEM

SER\(ICE

DESCRIPTION

The lubrication system uses a trochoid gear pump and a full

flow oil filter. The oil pump is driven through the coupling at the rear end

of

the fuel injection pump camshaft. Oil from the oil pump flows into the cartridge type oil filter via the relief valve. After being filtered by this filter, oil is delivered to various engine parts through oil galleries in the engine block.

OIL

PUMP

DIP

STICK

__

..

_"

..........

Oldham's

OIL

PUMP

ASSEN\BL

Y

FILTER

OIL

PRESSURE

SWITCH

.......

GASKET

DISASSEMBLY

Oil

Filter

and

Oil

Pump

1.

Remove the oil filter.

2. Remove the pump cover assembly, housing and gasket.

INSPECTION

Oil

Pump

1.

Outer rotor to body clearance. Using a feeler gauge,

check the clearance between the outer rotor and body. If

excessive, .replace the rotor assembly.

The cartridge type oil filter,

gral with the filter element, is easy to handle. pump is led into the filter element. When a pressure difference between before and after the element exceeds 1 kglcm excessive clogging

of

ment will open an oil passage bypassing the element.

in

which the filter body is inte-

Oil from the oil

2

due to

the element, a bypass valve in the ele-

As a

result, oil flows to various engine parts without filtration. Therefore it is important to replace the oil filter regularly. The oil filter should be replaced after the initial tion and thereafter every

The trochoid gear type oil

100 hours

pump

is mounted on the back

. the fuel injection pump on the right side

The oil pump houses a relief valve. sure exceeds 4

kglcm2,

the relief valve will open to by-pass oil

50

hours

of

operation.

of

the cylinder block.

If

pump delivery oil pres-

opera-

of

into the oil pan, thus preventing further oil pressure rise.

OUTER

ROTOR

TO

HOUSING

CLEARANCE

2.

Rotor clearance. Check the clearance between the outer

If

and inner rotors with a feeler gauge.

excessive, replace

the rotor assembly.

Check the

Old pam 's coupling

of

the inner rotor shaft for

cracks, damage and wear.

FEELER

GAU(lE

OUTER

ROTOR

CLEARANCE

~'P=~=FSTANDARD

TO

iNNER

REPLACE

.

VALUE

0.15-0.2

0.15-0.3

Engines & Generators

35

LUBRICATION

3.

Rotor

to cover clearance. With the outer rotor inserted

the pump body, insert a straightedge and check the clearance between the rotor and the straightedge with a feeler gauge. If excessive, replace either the rotor or the body.

ROTOR

TO

COVER

CLEARANCE

4.

Pump

body O-ring. Check the pump body O-ring for

cracks and damage.

S.

Oil

pressure switch/sender: Replace the oil pressure

switch and the oil pressure sender. engines, the oil pressure switch is norma]]y open. generators, this switch is normally open; the oil pressure gets to

A

CAUTION:

lock

pliers,

vise

pressure

available ers. and/or

switch.

from

Damage

switch

to

5-10 psi.

Oil

Pressure

grips

or

Use

the

Snap-On,

the

switch

failure.

Proto,

REASSEMBLY

1. Install the oil filter and tighten fully by hand. (Tightening torque: proper fitting ring with a small quantity

2. Install the gasket. Then install the oil pump housing,

ring, rotor assembly and cover assembly Apply oil to the rotating parts.

3. With sealant applied to the threaded portion, screw in the oil pressure switch taking care not with sealant.

4. Apply liquid teflon sealant to the threaded portion oil pressure sender. Take into the sender. Thread the sender into its fitting on the oil pump's housing.

1.1

to 1.3 kg-m.) Before installation, check for

of

the O-ring

of

care not to close off the oil hole

On propulsion

it

closes when

Switch -Do

pipe

wrenches

correct

New

will

cause

in

the groove and coat the

oil.

to

on

the

socket

which

Britain

oil

leaks

in

that order.

close the oil hole

not

and

On

use

oil

is

oth-

of

0-

the

SYSTEM

in

TESTING

1.

Start and warm up the engine.

2. Check for

3. Remove the oil pressure sender and connect a mechanical oil pressure gauge to the hole.

4.

Set the engine speed at 3000 rpm and measure the oil

pressure.

(50

NOTE:

CF

OIL

PRESSURE

1.

Later propulsion engines and all generators have a two-

prong oil pressure/water temperature switch. When the oil pressure drops to circuit for the fuel run solenoid by opening, shutting

down the engine/generator.

On early propulsion engines, this switch activates

alarm that emits a pulsating signal when the oil pressure

drops too low

NOTE:

the normal pressure

NOTE:

engines

operating temperature reaching

OIL

PRESSURE

SERVICE

THE

OIL

PRESSURE

oilleaks

It

Ib/in2).

Insure that

or

CG-4

should be fairly constant at

at the filter and pump assembly.

oil

meets specification standards: Class

or

better/SAE

30

SWITCH

5-10 psi, this switch interrupts the

(5-10 psi).

This alarm will also emit a

engine starts up, as the oil

(a

good

check

If

this alarm emits a

only),

it

indicates an engine overheat, with the

....

continuous

'ARLY ENGINE

+

LATER ENGINE

t-

OIL

PRESSURE

+

wt.

pulsating

has

not

o/the

alarm).

210~

PROPULSION

MODELS

P

PROPULSION

MODELS

3.5

kg/cm2

an

signal when

yet

reached its

signal (propulsion

"1

%

~

Engines & Generators

36

t-

OIL

PRESSURE

,ALL

MODElS

.

OIL

PRESSURE

GENERATOR

J

SWITCHES

FUEL

SYSTEM

DESCRIPTION

An

electrom.agnetic

supply through

. the engine's primary fuel filter and on to the fuel injection

pump. The pressurized fuel is then injected into the combustion chamber through the injection pipes and nozzles. Excess fuel is returned to the fuel supply through the fuel return

pipes that connect to the top

NOTE:

Fuel supplied to the fuel lift

75-200 microns by the (owner supplied) fuel/water separator.

fuel

lift

pump

draws fuel from the diesel .

an

(owner supplied) fuel/water separator to

of

each nozzle holder.

pump

must be filtered to

The built·in four-cylinder

on the right side

of

fuel

injection

the cylinder block.

pump

It

consists

is mounted

of

the pump elements (plunger assemblies), delivery valves, tappets and smoke set unit. As the pump camshaft rotates, the plungers are moved up and down through a fixed stroke, thus delivering pressurized fuel to engine cylinders.

Fuel

injection control. Fuel injection rate is dependent on

the relative positions

of

the plunger lead and barrel. The plunger is rotated by the control pinion which is mounted on the plunger barrel. This pinion meshes with the plunger's lower collar which transmits the rotation

of

the pinion directly to the plunger. As the engine runs, the injection pump camshaft rotates to move the control rack through the

centrifugal type governor weight, governor sleeve and lever, The control rack slides to tum this pinion. Rightward move-

ment

(STOP mark side)

of

the control rack decreases the

fuel injection rate; as the rack moves to the left, the fuel

increases.

AIR VENT

SCREW

.....

~~_.-.::::=:lII.oo.I=:=:::::lI

__

~

SMOKE

SET

STOPPER

CONTROL

RACK

FROM

FUEL

,~

FUEL

SYSTEM

ALL

Fuel

Pump. Two types

WESTERBEKE INSTALLATIONS FUEL/WATER.

ENG'lNEiGENERATOR

REQUIRE

AN

SE~ARATOR.

of

OWNER·INSTALLED

(7.5:-200

MICRONS)

fuel lift pumps are shown illustration; both operate on the same electromagnetic principal. Earlier model engines use a lift pump with a replaceable fuel element. This element should be changed at regular maintenance intervals (at

250 hours). Later model engines use a smaller lift pump that does not require maintenance. Electrical connections should be kept clean and tight with either pump.

The primary

fuel

filter encloses a highly effective paper ele-

ment. This filter assembly is located on the engine between the fuel pump and the injection pump. The paper element should be changed at regular maintenance intervals.

FUEL/WATER

.

SEPARATOR

in

the

RETURN

SPRING

FUEL INJECTION

PUMP

Smoke set unit. The smoke set unit restricts the maximum

fuel injection rate by a spring in the position shown position is

of

the injection pump. The stopper is held

in

the illustration. This

the

smoke set position. When starting the engine (propulsion models), pull the throttle control lever fully toward the maximum speed position, and the tie-rod (with stopper spring) will move the control rack in the arrowed direction against the spring force, thus causing over-injection for easy engine start. For the injection pump with the Angleich mechanism, over-injection requires releasing that mechanism.

SMOKE

SET

POSITION

OVER-INJECTION

Engines & Generators

37

FUEL

SYSTEM

Angleich Mechanism. The Angleich Mechanism restricts the

movement (Angleich effect emission

of

the smoke set plate

"L") to save fuel consumption and decrease

of

exhaust smoke.

ANGLEICH

in

the narrower range

MECHANISM

o

The intercylinder injection control. Fuel injection control

among the cylinders is performed by the adjusting plates which have their own cam mechanisms. These adjusting plates are located on the opposite side Necessary turning cylinder injection control is attained by turning the respective adjusting plates. This adjustment is performed on a fuel shop flow bench only.

of

the plunger barrels required for inter-

ADJUSTING

PLATE

of

the control rack.

PLUNGER

BARREL

o

ADJUSTING PLATES

Delivery valve operation. The delivery valve's function is to

deliver fuel to the injection pipes after the fuel pressure has been increased sufficiently, and to prevent the nozzles. When the fuel pressure above a plunger has deceased after injection, its delivery valve piston closes the delivery valve seat. At this time the compressed fuel remaining in the injection pipe drips from the nozzle. this

"after-drip", the delivery valve piston makes a stroke to draw back the fuel before the delivery valve reaches the seat, thus reducing the fuel pressure zero.

in the injection pipe to nearly

"after-drip" from

To

prevent

ANGLEICH

Releasing the Angleich Mechanism. It is necessary when

starting the engine tion (MS) condition by moving the throttle control lever fully to the

FULL~OPEN

plate to be released from its set position. Usually the Angleich set plate is released by pulling the throttle lever until

it

is caught by its stopper when stopping the engine. After starting the engine, the Angleich set plate is returned automatically to the applied position during warm-up running of

the engine.

to

set the injection pump in the over-injec-

position. This requires the Angleich set

EFFECT

"L"

..

DURING INJECTION

Nozzle

and

nozzle holder. Fuel from the fuel injection pump

flows through the passage and is injected from the nozzle into the combustion chamber.

Fuel overflowing from the nozzle enters the nozzle holder

and returns to the fuel tank through the banjo and attached

return fuel line.

in

the body

of

each nozzle holder

AFTER INJECTION

Engines & Generators

38

DISASSEMBLY

Fuel

Filter

Remove

Fuel

The model fuel lift pumps, disassemble and

Later model fuel lift the nections must pump

the retaining nut, O-ring and filter element.

Lift

Pump

fuel lift

pump

must

FUEL

LIFT

(LATER

pump

requires little

pumps

be

filtered to

be

clean and tight. Fuel connections at the

be

tight and without leaks.

PUMP

MODEL)

or

no maintenance. For early

require no disassembly. Fuel to

75-200

microns. Electrical

FUEL

change

FROM

ENGINE

PRIMARY

j

the filter.

FUEL

FILTER

SYSTEM

con-

SERVICE

a.

h. Take out the valve spring, valve and O-ring.

c. Take out the gasket and valve seat. d.

e. f. g.

h.

A

der has adjust

this mating

Remove

Unbend the lock plate tappet slightly in and pull out the guide pin using a pincette.

Remove

Pull out the plunger barrel upward from the

housing. Keep the removed plunger barrels and

plungers in a set for each cylinder. (Do not mix

plungers

Pull

and

Remove before taking out the control rack.

the delivery valve holder.

of

the tappet guide pin. Push the

Then

remove

the

spring

the pinion.

arid barrels

off

the split pin.

smoke

set stopper.

the AngJeich set spring and plate,

CAUTION:

injection

been

plate

control

disassembled,

the

inter-cylinder

requires

mark

across

the tappet.

and upper seat.

of

other cylinders.)

Remove

Draw

00

not

disassemble

adjusting

it injection

removal,

the

pump

will

remember

pump

the washer, return spring

out the control rack.

if

equipped,

the

inter-cylin"

plate.

When

this

plate

become

body

necessary

by a tester.

to

draw

and

the

plate.

When

a

to

Fuel

Injection

1. Remove the fuel injection pipes.

2. Before removing the side

cover rack. and remove the

3.

Record the thickness and shims to facilitate adjustment at the time

When

4. the following procedure.

A

fuel adjustment tester adjustment such a tester disassembly, clean bled parts

Pump

pump,

be

and disconnect

Then

remove the bolts fastening the injection

pump

partly disassembling

CAUTION:

injection

and

00

pump

of

an

technical

of a

pump

and

close

the

pump's

parts

immersed

neatly

arranged

the

assembly.

number

the

not

attempt

unless

itis

injection

pump

disassembly,

should

technician

the

fuel

outside

in

clean

order

surfaces.

tie-rod and

inlet

sure to

remove

of

pump

fuel injection pump, use

to

disassemble

necessary.

the

spring

adjusting

of

assembly.

Since

pump

from the

pump

the

requires a pump

reassembly

not

be

performed

aren't

available.

and

outlet

Keep

kerosene

to

avoid

and

if

Before

and

disassem-

and

keep

confusion.

all

ANGLEICH

,SET

SPRING

GASKET

VALVE

SEAT--e

i::t)

DELIVERY

VALVE

HottiER

PLUNGER-~

BARREL

8"

0;

O-RING

jj)

~~~

/1/

"/

@--PINIDN

~IUPPER

~

•

PLUNGER

FUEL

_ADJUSTING

t-SPRfNG

~

DELIVERY

RACK

SEAT

SPRING

INJECTION

PLATE

VALVE

PUMP

Engines & Generators

39

FUEL

SYSTEM

Injector

1.

Disconnect the return pipe from the nozzle holder upper nipple.

2. Disconnect the

3. Loosen the nozzle holder attaching bolts and remove the

holder assembly.

4. When disassembling the nozzle holder into parts, use the following procedure:

8.

Holding the nozzle holder body in a vice, remove the retaining nut with a spanner wrench. When holding the vice, be sure to use an aluminum or copper plate adapter.

h.

Remove the shim, pressure spring, flange, pressure pin and distance piece.

c. Remove the nozzle from the retaining nut. If the noz-

is

zle wooden block. Be careful not to damage the nozzle needle valve.

fuel injection pipe from the nozzle holder.

hard to remove, apply light taps to

'r--SANJOBOlT'

~

! I

',;;,.~,

_,

1

r

t

,(,)

BOOY

•

it

with a

in

SERVICE

TESTING

THE

FUEL

LIFT

PUMP

Fuel

Injection

1.

Delivery valve seat. Check the contact surface

delivery valve seat. Replace

2.

Plunger barrel. Check the plunger for seizure, damage

and rust. Also check to see when inserted into the barrel. If defective, do not repair it, but be sure to replace as a set with a new one.

3. Control rack and pinion.

worn

4.

Tappet.

and damage. If defective, replace.

Pump

if

defective.

if

the plunger slides smoofhly

If

the rack and pinion have any

or

damaged teeth, replace.

Check the tappet O.D., roller and shaft for wear

of

the

NOZZLE

HOLDER

NOZZLE

,

.

RETAINING

NUT

INSPECTION

Fuel

Filter

Check the filter element for contamination. The regular element replacement interval is

if

more frequently

Fuel

Lift

Pump

The fuel pump operates during the start sequence when PRE-

HEAT is depressed. Simulate a start and depress PREHEAT. The pump should produce a clicking sound indicating the pumping piston in the pump is pumping. If no clicking is heard, check that there is 12V DC at the pump connection and that the pump is properly grounded.

1.

Checking the pump delivery. Test the pump by connect-

ing a battery and fuel line, as illustrated. Fuel delivery must be 225 cc (.5 pints) or more every 15 seconds.

necessary.

250 hours. Replace the element

Nozzle

1.

Check the nozzle for incorrect contact and damage.

if

Replace the nozzle as an assembly

2. Check the pressure spring for damage.

NOTE:

Also check

the

Angleich set plates and set springs

defective.

for wear and damage .

REASSEMBLY

Fuel

Filter

Install the filter element and filter cup O-rings

Tighten the retaining nut securely.

Fuel

Lift

Pump

To

reassemble, set the plunger, plunger spring, valve, O-ring

in

and washer in position retainer to prevent the above-mentioned parts from popping

of

position, (see illustration).

out Put the filter

cover.

in

tion

Injection

1. Insert the plunger barrel with its slots in alignment with the dowel pins projecting

2. Install the O-ring

in

position and fit the magnet and gasket in the

Using a 17 mm spanner, fasten up to the stopper por-

such a way as to prevent air leakage.

Pump

that order, and as a final step, fit the

in

the pump housing.

in

the delivery valve holder.

in

position.

Engines & Generators

40

FUEL

SYSTEM

SERVICE

3. Install the spring seat gasket and the valve assembly the holder. Tighten the delivery holder to the pump hous-

ing. Make certain that the installed.

O-ring has been properly

GASKET

VALVESEAT-(5

<:::!:')

~

in

DELIVERY

VALVE

HOLDER

PLUNGER-~

BARREL

8'

O·RING

o;

~~~

/1.....

:/

~PINION

@)-

ANGLEICH SET

PLATE

ANGLEICH SET

SPRING

4. Install the control rack.

5. Install the pinions with their deep-root teeth aligned with the respective marks on the rack.

OEEP

ROOTS

~,

UPPER

PLUNGER

FUEL

ADJUSTING

I-SPRING

~

DELIVERY

RACK

SEAT

SPRING

INJECTION

PUMP

.Ii)

PLATE

VALVE

before inserting the tappet guide pin and bend the lock plate after inserting the pin.

INST~LLlNG

TAPPET

9. Install the smoke set stopper, return spring and washer. Then insert the split pin, and split it.

10. Install the Angleich set plate and spring, when equipped.

n.

Torque the delivery holder to specification (4-5 kg-m).

Installation

1.

When installing the pump assembly, select and install the adjusting shim. After installing the pump, fit the tie-rod from the governor lever to the control rack, then install the tie-rod spring to the control rack. Make sure that the end the tie-rod spring positioned at the governor lever side has the shorter straight wire proper selection shim set having the same thickness as before removal, and when adjusting fuel injection timing, replace the current shim set with one formed by a proper combination kinds

NOTE:

tion engine

and

Adjusbnent

of

shim thickness, temporarily install a

of

shims. - 0.2, 0.3, 0.4 and 0.8 mm,

Maintaining

pump will place

as

when

the

previously

of

Fuel

of

the two ends

same shim thickness for

the

pwnp

in

removed.

Injection

Pump

of

the spring. For

in

thickness.

the

the same timing

of

injec-

with

four

the

of

ASSEMBLING

......

6. Install the spring upper seat and spring.

7.

Put the plunger and the spring lower seat together. Install the assembly so that,

in

mentioned groove) is positioned on the opposite side rack.

On former engines, insert the mark

plunger collar into the control rack side.

8. Insert the tappet, taking care not to drop the shim. Align the tappet guide hole with the dowel pin hole ing and insert the tappet guide pin. Install the lock plate

step 5, the plunger front-end lead (slant

RACK

AND

. . -

in

the same alignment position as

PINION

of

the control

"L"

area

of

the

the hous-

Engines & Generators

41

INSTALLING

INJECTION

PUMP

FUEL

SYSTEM

SERVICE

2. Install the tie-rod cover. loaded cover, install the cover with the tie-rod pressed toward the High illustration).

3. Connect the fuel supply hose. Preheat system.

4. Check damper spring adjustment and fuel injection timing. For these adjustment procedures, refer to

ADJUSTMENTS.

In

the case

Speed side by the speed control lever (see

TIE·ROD

INSTALLlN~

TIE·ROD

of

a damper spring-

TIE·ROD

SPRING

GASKET

LOCKNUT

ADJUSTING

BOLT

tf:bAlING

COVER

to

bleed air from the

ENGINE

CAP

Adjustment Holder

1.

Injection Start Pressure

sure the injection start pressure. ent from the standard value, adjust to the specified pressure by increasing or decreasing the thickness adjusting shim. Increasing or decreasing shim thickness by kg/cm:!, in a vise and remove the body with a wrench. TIghten the retaining nut to the specified torque.

and

Installation

of

Nozzle

Assembly

Test.

Using a nozzle tester, mea-

If

the pressure is differ-

0.1

mm will vary the pressure by approximately 10

When replacing the shim, grip the retaining nut

INJECTION PRESSURE

TEST

~

!

"",,,,,,,,,,,-,

~

'-',""-

I

of

the

SHIM-

THICKNESS

'"

0.1

0.2mm O.3mm O.5mm

mm

Injector

A

CAUTION:

kerosene.

When

tightening

body,

be

sure Insufficient Excessive moving

1. Install the nozzle assembly, distance piece, and pressure

2. Install the shim, spring and flange to the body. Install the

freely.

pin in the retaining nut.

retaining nut on the body and tighten to the specified torque.

A

CAUTION:

nut,

be

nut

was

Thoroughly

00 not

wipe

them

the

retaining

to

tighten

torquing

sure

to

will

When

hold

it

cause

prevent

using a vice

the

held, a defonned

clean

with

to

the

body

nozzle

all

rags.

nut

on

specified poor the

nozzle

side.

would

parts

with

the

nozzle

holder

torque.

compression.

needle

from

to

tighten

If

the

retaining

result.

2.

Chattering

lever slowly. If the nozzle sprays sharply and intermittently, the nozzle is considered good. The nozzle should

spray fuel straight in its axial direction. A nozzle is defective separate strips. Also a spray in the form cates a defect. These defects may sometimes be caused by clogging with dust, therefore all parts should be carefully cleaned before assembly.

Test.

if

it sprays fuel

GOOD

For the chattering test, operate the tester

in

a wrong direction

BAD

or

in several

of

particles indi-

BAD

Engines & Generators

42

FUEL

SYSTEM

SERVICE

3. After-drip test.

tive if

it

zle after fuel injection is stopped during the chattering

test. Replace such a nozzle. A very small amount may sometimes remain on the top due to chattering and is not detrimental.

DJ

GOOD

4.

Injection Condition

(at a rate inject a fine atomozed mist direction. A spray in the form rejection.

5.

Install the Nozzle Holder Assembly. Install the tested

nozzle holder assembly bolts

to

bly together with new sealing washers.

An

injection nozzle is considered defec-

drips fuel accumulated on the bottom

of

the nozzle. This is

AFTER

DRIP

TEST

10

BAD

Test.

Operate the tester lever quickly

of

800 strokes per minute). The nozzle should

of

fuel straight

of

particles is cause for

in

the cylinder head. Tighten

the specified torque. Be sure to install the assem-

~

in

of

the noz-

of

~~.

'.

~

,.

BAD

its axial

fuel

A

CAUTION:

assembly

with

two

bolts

the

injection

specified

When

in

the

cylinder

temporarily

pipe,

torque.

installing

head,

tightened.

retighten

fit

the

nozzle

the

bolts

holder

After

fitting

evenly

loosely

to

the

Engines & Generators

43

RAW

WATER

DESCRIPTION

The

raw

water

cooling circuit is driven by a positive dis-

placement impeller pump. This pump draws from an ocean, lake, or river, through the seacock, then to a raw water strainer. The raw water is drawn through the strainer to the self-priming pump and to the heat exchanger where

it

cools the engine's circulating fresh water coolant. The raw water is then discharged into the water injected exhaust elbow mixing with and cooling the exhaust gases. This mixture the exhaust system and overboard.

Transmission

is also used to cool the engine's transmission by passing through a transmission oil cooler. Similar to a heat exchanger, the transmission fluid is cooled by the raw water and then passes into the exhaust elbow. The oil cooler should be cleaned and pressure tested at about the same interval as the heat exchanger, every

of

exhaust gas and raw water is driven through

oil

cooler.

In

some installations the raw water

1000 hours.

in

water directly

COOLING

The

tem and the raw water system. The heat exchanger is a copper tube which encloses a number Raw water is pumped through the small copper tubes and fresh water coolant from the engine is circulated around the copper tubes. The raw water removes heat from the fresh water coolant. A zinc anode is located tion sis. This area inspected and cleaned. To keep the exchanger operating efficiently, hours to be thoroughly cleaned and pressure tested.

CIRCUIT

heat exchanger functions as part

of

the exchanger to help control the effects

of

the exchanger should be periodically

it

should be removed from the engine every 1000

of

the fresh water sys-

of

small copper tubes.

in

the raw water por-

of

electroly-

PETCOCK

TRANSMISSION

OIL

COOLERS

CLEAN

OUT

DEBRIS

HEAT

EXCHANGER

NEW

The

raw

water

rous housing and a Neoprene impeller. The impeller has flex-

ible vanes which wipe against a curved cam plate within the impeller housing, producing the pumping action. The raw water pump impeller should be checked every hours for wear. Should the pump fail, and overhauled. Check for internal wear within the pump such as the cover plate, cam and impeller housing. Replace

components that show excess wear.

REPLACE REPLACE

ZINC

ANODES

pump

is

a self-priming pump with a non-fer-

CLEAN AND

500 operating

it

can be disassembled

REUSE

Engines & Generators

44

.

RAW

WATER

RAW

WATER

PUMP -PN

PUMP

SERVICE

33636

PUMP

OVERHAUL

Disassembly

The pump, as removed from the engine, will have hose attachment nipples threaded into its inlet and outlet ports. They may be

the pump disassembly. Note the port location and positioning if

removed.

1. Remove the six cover plate screws, cover plate, and the cover plate gasket.

NOTE:

mended; however,

gasket submerged in water until the If

it's allowed to

reusable.

2. Remove the impeller with its drive screw from the pump housing.

3. Remove the screw and sealing washer and remove the cam from the pump housing.

4. Remove the retaining ring.

5. Support the pump housing, at the mounting flange end, on an arbor press, and with a drift, press out the shaft and bearings from the pump housing.

6. With the pump housing supported, push the seals out the pump housing. Push the impeller side seal out the impeller side, then lift the spacer out. Then push the bearing side seal out the bearing side.

7. Supporting the bearing's inner race, push the shaft out the bearings.

left

in

place or removed if they interfere with

Replacement

dry,

of

the cover plate gasket is recom-

if

you are going to reuse

the gasket will shrink and not be

pump

is reassembled.

it,

keep the

of

Inspection

Inspect all parts and replace those showing wear or corro-

sion.

2. Install the shaft into the bearings. Support the bearings their center races. Push the shaft into the bearings, pushing at the impeller drive slot end using the base drive slot. flush against each other so the flat-sided end extends beyond the second bearing center race

(19/32

3. Support the pump housing at the impeller side. Apply a small amount inner lips and to the impeller shaft. Carefully install the shaft, rotating contact the housing from the bearing end. tool that will push this shaft and the bearing assembly into the pump housing by applying pressure against the outer bearing race. until the bearings seat fully in the housing. Install the retaining ring.

4.

Position the cam in the housing and secure with the screw and sealing washer.

NOTE:

cam surface and screw threads. Remove any excess from the impeller housing.

5. Apply a light film inner surface

NOTE:

the impeller with the drive screw. the housing with the drive screw mating in the slot

drive shaft.

6. Install the cover gasket and cover, and secure them with

the six cover screws.

7. Reposition and tighten the hose nipples. Assemble the pump to the engine, and attach the hoses.

Push the shaft through both

in.)

±

.5

mm (1/32

it

through the seals until the bearings

Use a small amount

of

the housing for the impeller.

Coat only the surface, do not over-apply. Install

in.).

of

petroleum jelly to the seal's

Push the assembly into the housing

of

Permatex

of

silicone

or

of

#1

petroleum jelly to the

Push the assembly into

of

the

the bearings,

of

the shaft

15

mm

Use a pushing

it

in

place

on the inner

of

the

at

Reassembly

1. Install the seals and spacer in the pump housing. Push the impeller side seal into the housing. Rotate the pump and install the spacer against the seal face. side seal into the housing from the bearing side.

NOTE:

The seals' flat surfaces that have printing and

numbers face toward each other.

COVER

Push the bearing

Engines & Generators

45

PUMP

HOUSING

RAW

WATER

RAW

WATER

PUMP -PN

PUMP

SERVICE

24143

Pump #24143 has been replaced by pump #33636. Complete

#24143 pumps are no longer assembled but their component

parts are still available.

PUMP

OVERHAUL

Disassembly

Remove the pump from the engine. The pump body is a bronze cast unit. Its inlet and outlet hose connections are part

of

the pump housing casting.

1.

Remove the six cover plate screws along with the cover plate and gasket.

2. Using an appropriate drift, push the impeller drive shaft of

and impeller out

3. Using circlip pliers, remove the outer circlip from the impeller drive shaft, then remove the impeller from the shaft.

4. Remove the key from the shaft, and the inner circlip.

5. Remove the screw holding the cam and remove the cam.

6. Using an appropriate puller, withdraw the outer and inner shaft seals along with the slinger ring from the pump body.

7. Support the pump on a press and with a lubricated drift, push the carbon shaft bushing out Note the position prior to removal.

the pump housing.

of

the shaft bushing

in

the pump housing,

of

the pump housing.

in

the housing

Inspection

Examine all components and replace worn If the pump housing is worn internally and requires replacement, we recommend that the pump assembly be replaced

with the current production pump. It

ment kit,

Part #037431.

is

available

or

damaged parts.

in

a replace-

Reassembly

1. The carbon shaft bushing is a slight force fit into the pump housing. To aide

in

the installation

of

the replace

ment bushing, chill the bushing

it's size. Prepare the pump housing

reduce accept the bushing.

2. Apply some light oil to the housing boss that the bushing

will

be pressed into. Using

bushing into the housing so that

impeller housing's inner surface.

3. Using an appropriate installer, install the impeller shaft seal. Ensure that the seal seats properly and that the lip seal is positioned correctly.

4.

Place the slinger ring seal.

5. Install the impeller shaft oil seal into the housing so flush with the housing surface. Again ensure that the lip seal is positioned correctly.

6. Install the inner circlip on the impeller drive shaft, and

install the impeller key

7. Apply some light oil to the shaft, and with a rotating

it

The set

pump

bLades

it

securely.

action, slide side and rotate slinger ring and rotate the shaft through rotating the shaft and slide

8. Install a new cam. Apply some sealant to the cam retaining screw and thread and tighten

9. Apply a small amount inner circumference, then install the impeller onto the shaft and into the housing. Install the shaft.

NOTE:

Once the rotated, the

10. Install the housing cover and gasket. Tighten the cover screws securely.

IMPELLER

in

into the shaft bushing from the impeller

it

through the impeller seal. Locate the

it

into the cam through the housing

of

the impeller blades is

is installed on the engine

will take the correct position.

in

a freezer for 1 hour to

on

a press to

an

appropriate drift, push the

it

is flush with the

in

the housing

the housing against the impeller

it

is

the shaft.

it.

Continue

it

through the housing oil seal.

petroleum jelly on the housing's

outer circlip on the

of

no

concern.

and

the engine

SEAL

SLINGER RING

Engines & Generators

46

RAW

CAM SCREW

WATER

PN

24143

COVER

PUMP

FRESH

WATER

DESCRIPTION

The fresh water cooling circuit consists

driven water pump, a thermostat and thermostat housing,

. heat

exc~anger,

BRACKET

The

water

mounted on the front upper part pump shaft is supported on maintenance-free (grease-filled) double-row radial ball bearings.

engine manifold, and

FRESH

WATER

PUMP

pump

is a centrifugal impeller type and is

of

a circulatory belt-

all

associated hoses.

the cylinder block. The

COOLING

.

IMPELLER

CIRCUIT

and

The water temperature switch

sender are both mounted

water temperature switch, normally open in a propUlsion engine, when activated, will close and sound an alarm. The water temperature switch, normally closed drive engine, when activated, will open and interrupt Voltage to the fuel run solenoid and shut the drive engine down. the water temperature sender is a variable resistor affected by heat. Voltage from the water temperature gauge is grounded through the sender to the block. Depending on the resistance through the sender effected by coolant heat, the gauge will indicate a temperature reading.

Change

scale will be deposited and rust formation will occur in the water jacket and heat exchanger, causing progressive deterioration in cooling system efficiency. For this reason, flush the cooling system every

Antirust

against corrosion and freezing, always use a known brand antifreeze compatible with aluminum cooling system components. The use mended for year-round use. Use antifreeze that is compatible with aluminum components, and never mix different brands of to

NOTE:

antifreeze that

Antifreeze mixtures will protect against an unexpected freeze and they are beneficial to the engine's cooling system. They retard rust and add to the life

of

Coolant. Over a long period

and

Antifreeze.

of

an antifreeze mixture

antifreeze. the cooling system components.

Do

not

Look for the new environmentally-friendly long lasting

is

now available.

in

500 hours

To

use plain water; this can be detrimental

ANTIFREEZE

Antifreeze Freezing

concentration

temperature

23%

14°F

(-10°C)

the water temperature

the thermostat housing. The

in

a generator

DC

of

engine operation,

of

engine operation.

protect the cooling system

of

50/50 is recom-

of

the circulating pump seal.

PROTECTION

35%

-4°F

(-20°C) (-40°C)

50%

-40°F

60%

of

COOLANT

TEMPERATURE

SE~

TYPICAL THERMOSTAT ASSEMBLY

Thermostat. A thermostat housing is located on the cylinder head water outlet. Enclosed is a wax pellet-type thermostat.

The valve opening temperature is not affected by variations

_

of

pressure in the cooling water passages.

Engines & Generators

47

COOLANT

RECOVERY

TANK

FRESH

WATER

COOLING

SERVICE

DISASSEMBLY

1.

Drain the cooling water. A drain plug for draining the

of

engine block is located on the side

of

just right

the heat exchanger is located on the heat exchanger.

2. Disconnect the water hose from the pump.

NOTE:

that will need to be removed.

3. Remove the pump drive belt.

4. Disconnect the bypass hose when equipped.

5. Remove the water pump assembly.

6.

If necessary, remove the water pump adapter when equipped.

7.

On an engine with a thermostat, remove the water outlet fitting bolts the thermostat.

the lube oil

Generator models are equipped with belt guards

in

the front

fi1ter.

A drain plug for draining

of

the cylinder head and remove

the engine block

Thermostat

Visually check the thermostat for damage. Then put it in water and raise the water temperature to test its valve open-

ing temperature. Replace if defective.

A

CAUTION:

closed

if

uncorrected

The

its

heat-sensing

would

wax

cause

pellet-type

part

is

defect(ve.

the

engine

thermostat

Leaving

to

overheat.

remains

this

REASSEMBLY

To

reassemble the cooling system, reverse the order sembly. When adjusting the drive belt tension, use the following procedure.

Drive

Belt

Adjusbnent

A

WARNING:

tension

A

tension the Excessive can temperatures.

while

CAUTION:

can

service

cause

the

cause

life of

slack

belt

Never

attempt

engine

Excessive

rapid

the

fresh

or

the

presence

slipping,

to

is

operating.

water

wear

of

water

resulting

adjust

pump

the

belt

pump's

of oil

in

high

the

drive

and

on

operating

of

drive

belt

reduce bearings. the

belt

disas-

WATER

PUMP

ASSEMBLY

INSPECTION

Water

Pump

1. Check every part for cracks, damage and water leaks. if

Replace

NOTE:

circulation pump.

2. Check the impeller and shaft for rotating condition. If they make noise or rotate irregularly, replace as an assembly.

defective.

No rebuilding kits are available for the fresh water

Adjust the alternator position so that the belt may deflect 3/8" to 1/2" deep when depressed at the middle point between the alternator and crankshaft pulleys. After adjustment, securely tighten the support bolt and brace bolt. If any clearance is

found between the gear case and alternator fitting part, insert

of

a suitable shim inside the support on the back

tor before tightening the bolts. Reinstall belt.

BELT

TENSION

the alterna-

Engines & Generators

48

ADMIRAL

CONTROL

PANEL

DESCRIPTION

This manually-operated control panel is equipped with a

KEY switch and meter which measures the engine's running time in

1/10 hours. The panel also includes a WATER

ATURE gauge which indicates

Fahrenheit, an engine's oil pressure control circuit VOLTAGE gauge which measures the systern's voltage. switch

is

in

operation. The panel also contains two rubber-booted

is pushbuttons, one for

RPM

GAUGE:

TERS

REVOLUTIONS

PER

,MINUTE

ENGINE

AND RECALIBRATED ACCURACY THE

PANEL

REAR

FROM

OF

RPM gauge with an

ELAPSED

water

temperature in degrees

OIL PRESSURE gauge which measures the

in

pounds per square inch, and a

All

gauges are illuminated when the key

turned

on

and remain illuminated while the engine

REGIS-

OF

THE

CAN

BE

FOR

THE

PREHEAT and

WATER

GRADUATED ILLUMINATED

TURNED

TEMPERATURE

one

for START.

TEMPERATURE

IN

ON.

THE

DEGREES

WHILE

THE

ENGINE'S

IS

170°-190°

GAUGE:

TIME

in

hours and

TEMPER-

DC

THIS

FAHRENHEIT

KEY

SWITCH

NORMAL

F

GAUGE

IS

AND

IS

OPERATING

When the engine is shut down with the key switch turned

oJ!,

the water temperature gauge will continue to register the last

temperature reading indicated by the gauge before electrical power was turned

when the key switch is turned

off. The oil pressure gauge will

off. The temperature gauge

faJl

to zero

will once again register the engine's true temperature when electrical power is

restored to the gauge.

A separate alarm buzzer with harness is supplied with every Admiral

Panel.

The

installer is responsible for electrically

connecting the buzzer to the four-pin connection on the

engine's electrical harness. The installer is also responsible

in

for installing the buzzer

where

it

will

be

audible to the operator should

a location where

the engine is running. The buzzer

on

tion key is turned

and should silence when the engine has

will sound when the igni-

it

will

it

sound while

be dry and

started and the engine's oil pressure rises above 15 psi.

Oil

PRESSURE ATED ILLUMINATeD TURNED OIL

PRESSURE

IN

POUNDS

ON.

GAUGE;

PER

WHILE

THE

ENGINE'S

RANGES

THIS

SQUARE

THE

KEY

NORMAL

BETWEEN

GAUGE

INCH

SWITCH

30-60

IS

GRADU-

(PSI)

AND

IS

OPERATlNG

PSI.

IS

HOUR

METER:

TERS AND AS A GUIDE MAINTENANCE SCHEDULE.

PREHEAT THE

PUMP. PUMP. PASSES SURE SunON

START THE ENGINE. ELECTRICALLY

IS

PRESSED

REGIS-

ELAPSED

SHOULD

ALTERNATOR'S

TIME.

BE

FOR

BUTTON:

THE

FUEL

AND

THE

ENGINE'S

ALARM

SWITCH.

ENERGIZES

BUTTON:

STARTER'S

THIS

BUTTON

AND

USED

THE

WHEN

EXCITER,

SOLENOID

ENGINE'S

PROTECTIVE

IN

THE

START

WHEN

PRESSED.

SOLENOID

WILL

UNLESS

THE

HELD

AT

PRESSED.

THE

FUEL

ON

THE

GLOW

PLUGS.

ADDITION.

BUTTON.

ENERGIZES

WHICH

CRANKS

NOT

OPERATE

PREHEAT

THE

SAME

ENERGIZES

LIFT

INJECTION

IT

BY-

OIL

PRES-

THIS

THE

SunON

TIME.

.

I'

AUTOMATIC

/'

HIGH

BEEN FRESH WILL

TINUOUS

lOW

SWITCH SWITCH ENGINE'S CLOSE

EMIT

ALARM

WATER

TEMPERATURE

SUPPLIED

WATER

CLOSE

SOUNDING

SIGNAL.

Dll

PRESSURE

IS

LOCATED

MONITORS

OIL

PRESSURE

SOUNOING

A

PULSATING

SYSTEM

WITH

THE

COOLANT

THE

AlARM:

OFF

THE

ALARM.

SIGNAL.

AlARM:

INSTRUMENT

REACHES

210"

ALARM

A

LOW

THE

ENGINE'S

OIL

FALL

TO 5 -10

IN

THIS

AN

ALARM PANEL.

F

(98°C),

WHICH

WILL

OIL

PRESSURE

OIL

GALLERY.

PRESSURE.

PSI.

THE

EVENT.

KEY

SWITCH: POWER INSTRUMENT CLUSTER.,

DC

VOLTMETER;

INDICATES

THE

CHARGED. SHOW

BUZZER IF

THE

ENGINE'S

THIS

SWITCH

EMIT

A

ALARM

THIS

SHOULD

SWITCH

THE

ALARM

PROVIDES

ONLY

TO

PANEL

THE

SATTERY

SHOULD

13V

TO

HAS

CON·

THE

WILL

THE

AMOUNT

IS

BEING

14V.

Engines & Generators

49

DESCRIPTION'

This manual1y-operated control

KEY

switch,

an

tons,

lamps, one for OIL PRESSURE, TEMPERATURE.

RPM

GAUGE:

MINUTE

BRATED

THE

PANEL

an

RPM

gauge,

INSTRUMENT TEST

ALTERNATOR

and

one

It also includes

REGISTERS

OF

THE

FOR

ACCURACY

ENGINE

REVOLUTIONS

AND

CAN

BE

FROM

THE

for

RECALI-

REAR

CAPTAIN

panel

is

equipped

PREHEAT

button DISCHARGE, one for

high

PER

OF

and

three indicator

ENGINE

an

alann buzzer

Oil

PRESSURE

AlARMU6HT

START

COOLANT

with

for

CONTROL

OIL

a

but-

low low

RPM and

ALARM:

FAUS

PULSA

TEMPERATURE 205°F.

NOTE;

ON.

ENGINE'S

PANEL

PRESSURE

gauge

remains

THE

ALARM

BELOW

15

TING

SIGNAL.

IN

THIS

EVENT,

THE

ALARM

THIS

SOUNDING

OIL

PRESSURE

or

high

is

illuminated

i1Iuminated

WILL

SOUND

PSI.

IN

THIS

THE

ALARM

THE

FRESHWATER

THE

ALARM

WIU

SOUND

IS

NORMAL.

REACHES

WATER

when

while

the

IF

THE

EVENT,

ENGINE'S

THE

ALARM

WILL

ALSO

COOLING

WIU

EMIT A CONTINUOUS

WHEN

THE

ONCE

THE

15

PSI.

THE

TEMPERATURE.

the

KEY

switch

engine is

SOUND

CIRCUIT

KEY

SWITCH

ENGINE

AlARM

/

in

OIL

PRESSURE

WILL

EMIT

IF

THE

WATER

RISES

IS

TURNED

STARTS

WILL

TEST

BOlTDN: PRESSED. ALTERNATOR. PRESSURE. WATER CONTROL WHEN ALTERNATOR. PRESSURE. WATER INDICATOR LUMINATE TO

SOUNDING

ALARM

operation.

A

TO

SIGNAL.

AND

SILENCE.

TEMPERATURE

PRESSED,

TEMPERATURE

BUZZER.

The

is

turned on

THE

WHEN

TESTS

niE

THE

OIL

AND

THE

CIRCUITS.

THE

OIL

AND

THE

LIGHTS

IL-

IN

ADDITION

THE

START

BUTTON:

THE

STARTER'S ENGINE. UNLESS HELD

AT

IT

WILL

THE

PREHEAT

THE

WATER

AlARM

WHEN

SOLENOID

NOT

SAME

TIME.

TEMPERATURE UGHT

PRESSED,

OPERATE

BUTTON

ENERGIZES

WHICH

CRANKS

ELECTRICALLY

IS

PRESSED

THE

AND

PREHEAT

BUTION:

THE

ALTERNATOR'S

PUMP.

THE AND

THE

IN

START

FUEL

THE

ADDITION, BUTTON.

PUMP. PASSES SWITCH.

THE

WHEN

REGULATOR,

SOLENOID

ENGINE'S

PRESSED.

ON

GLOW

OIL

PRESSURE

THIS

BUTTON

KEY

SWITCH: POWER STRUMENT

ENERGIZES

THE

FUEL

THE

INJECTION

PLUGS.

ALARM

ENERGIZES

ONLY

IT

BY·

LIFT

PROVIDES

TO

THE

PANEL

CLUSTER.

IN·

Engines

50

& Generators

CONTROL

PANEL

TROUBLESHOOTING

TACHOMETER/HOURMETER

The

tachometer!hounneter used

ment

panels contains two separate electrical circuits with a common other volts on

The from tachometer input terminal while the engine is running, and the volts

Use

either

Hounneter

Check terminals. '

ground. One circuit operates the hourmeter and the

the tachometer. The hourmeter circuit operates on 12

alternator charging voltage supplied to the

the back

alternator producing battery charging voltage 13.0-14.8

of

the instrument.

tachometer circuit operates on

one

of

the diodes

DC.

the following procedures when troubleshooting a fault in

of

the

two

in

circuits

Inoperative

for the proper

DC

1. Voltage present - meter is defective - repair

2.

Voltage not present - trace (+) and nections for fault. (Jump terminal to verify the operation.)

Tachometer

Check terminal and the

1.

Voltage present - attempt adjusting the meter through the calibration access hole.

Inoperative

for the proper

(-)

AC

terminal with the engine running.

meter.

2.

AC

voltage not present - check for proper alternator

output voltage.

3.

Check for

tor to ground.

4.

Check the electrical connections from the tachometer input terminal to the alternator connection.

AC

voltage at the tach terminal on the alterna-

in

propulsion engine instru-

(+)

terminal

AC

voltage 6-8 volts, fed

the alternator and supplied to the

in

a tachometer/hourmeter.

voltage between (+) and

(-)

electrical con-

12

volts

DC

to meter (+)

voltage between tachometer input

If

no results, repair or replace the

(-)

or

replace.

DC

Tachometer

1. With a hand-held tach ley retaining nut

crankshaft pulley rpm. strobe tach at

2. Adjust the driver through the calibration acess hole in the rear

tachometer. Zero the tach and bring the strobe or hand tach. (Verify the high speed

COARSE

ADJUSTMENT

Inaccurate

on

the front

or

with a strobe-type tach, read the front

Set the engine with a hand

1500-1800

tachometer-with a small Phillips

2500-3000

CURRENT

rpm.

rpm). (Adjust the tach

TACHOMETER

of

the crankshaft pul-

or

type

screw-

it

to

the

rpm set by

rpm at idle and at

as

needed.)

of

the

Tachometer

1. Check for proper

input terminal and the

2.

Check (--)

3.

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

Sticking

AC

voltage between the tachometer

(-)

terminal.

f~r

a good ground connection between the meter

terminal and the alternator.

Engines & Generators

51

EARLY

MODEL

EARLY

TACHOMETER

MODEL

TACHOMETER

(-)

GROUND

(-)

GROUND

TERMINAL

TACHOMETER

(AC

VOLTAGE)

INPUT

CONTROL

PANEL

TROUBLESHOOTING

PREHEAT

fuel

solenoid.

preheat

START

SWITCH

engagement.

START

DEPRESSED,

Start

solenoid

functioning.

NO

IGNmON,

solenoid

ENGINE

STOPS

NOT

CHARGING

BATIERY

mounted

PROBLEM

depressed,

electric

solenoid

not

DEPRESSED,

OK.

cranks,

energized.

BATIERY

RUNS

DOWN

NOTE:

no

panel

fuel

energized.

panel

indications

Fuel

solenoid

does

not

MANUAL

The

engine control system is protected

on

a bracket at the

STARTER

lOp

rear

PROBABLE

indications,

pump

no

starter

start.

and

not

Fuel

OK.

1.

Battery

2.

20

amp

1.

Connection

2.

Faulty

3.

Faulty

4.

Loose

5.

Low

1.

Poor

solenoid.

1.

Faulty

1.

Switch

1.

Alternator

1.

Oil

2.

High

3.

Low

4.

Alternator.

switch

circuit

to

switch. solenoid.

battery

battery.

connections

(PIN

fueling

and

wiring.

drive.

pressure

switch.

resistance

or

breaker

solenoid

connections.

2304)

system.

leak

DISCONNECT

by a 20

of

the engine near the PREHEAT circuit.

{TOGGLE

amp

SWITCHES}

manual

reset circuIt breaker

CAUSE

power

not

to

tripped.

faulty.

fuel

to

ground.

to

ground.

on.

solenoid.

Defective

fuel

run

1.

Check

2.

Reset..breaker. enoid

1.

Check

2.

Check

3.

Check nection.

4.

Check

5.

Check

1.

Check for

2.

Manually plunger

1.

Check

2.

Check Allow

3.

Fulliitt

1.

Inspect

Circuits.

1.

Check

alternator

Check present

1.

Observe when switch.

2.

Check in nections

3.

Check

fault.

Disconnect

4.

charging. bench

VERIFICAnON/REMEDY

switch

and/or

battery·connections.

If

opens

again,

circuit

connection. switch

"that

battery battery mechanical

plunger

check

and

for for

system

pump

all

the the

at

if

the

engine

the

battery

and

all

wires

test.

and

"run"

with

12

volts

connections. charge

positioning

and

throttle

movement

throttle

fuel

to

generator

air

in

the

to

self-bleed.

faulty.

wiring

for

drive

belt

turns

freely.

output

with a voltmeter.

the

regulator

the

gauges

is

wiring.

Insert

lines

(Do

replace

for

alternator

Jfleakage

Repair

ohmmeter.

are

arm.

fuel

and

not

temperature

stops.

or

circuit

present

state.

arm.

of

system.

loose

connections

its

tension.

Check

terminal.

and

panel

running.

senSitive

start

after

short

at

output,

Remove

replace.

check

for

at

of

the

for

engine).

rise

preheat

shorts

to

ground.

the

solenoid

the

fuel

solenoid

fuel

run

solenoid

and

Be

sure

loose

connections.

Ensure

12V

lights

are

the

(0-.25

Remove

located.

to

locate

alternator

activated

oil

amp)

Test

is

after a good

sole-

con-

short

the

are

pressure

meter con-

the

battery

and

TROUBLESHOOTING

If the gauge reading is other than what by the gauge when the instrument panel

WATER

is

normally indicated

is

energized, the first

TEMPERATURE

step is to check for 12 volts DC between the ignition (B+) and the Negative (B-) tenninals

is

Assuming that there

12 volts as required, leave the instru-

of

the gauge.

ment panel energized and perform the following steps:

1.

Disconnect the sender wire at the gauge and see if the

is

gauge reads zero, which

the normal reading for this

situation.

2. Connect the sender terminal at the gauge to ground and

see

if

the gauge reads full scale, which

reading for this situation

is

the normal

Engines

AND

OIL

If both

of

the above gauge tests are positive, the gauge is undoubtedly ductor from

If either

of

PRESSURE

OK

and the problem lies either with the con-

the

sender to the gauge

the

above gauge tests are negative, the gauge

GAUGES

or

with the sender.

probably defective and should be replaced. Assuming the gauge is

OK, check the conductor from the

sender to the sender tenninal at the gauge for continuity.

Check that the engine block is connected to the ground. Some starters have isolated ground terminals and battery is connected to the starter (both plus and minus terminals), the ground side wjJl not necessarily be connected to the block.

& Generators

52

if

is

the

CONTROL

PANEL -EARLY

MODELS

ACTIVATION

Turning

panel. The oil and water temperature gauges will zero, the voltmeter wi1l

start

electric

Pushing solenoid

volts

to

conditions. A noticeable voltage drop will indicate on voltmeter when the preheat circuit is activated.

Continuing

the starter and turns the engine over.

release the keyswitch.

tion and pop out

The

voltmeter should indicate a charge from the alternator

13.5 -

should shut off. Oil pressure opens the-oil pressure

the aJann circuit shutting off the alarm.

ture switch operates the opposite way:

BY

KEY

SWITCH

the

ignition switch ON activates the instrument

will

indicate battery voltage, and the hourmeter

to

record time. The alarm buzzer should

fuel

pump will start

the

key

wiJI

on

the engine with an audible click and

the

engine glow plugs. Preheat as needed for

to

preheat, tum the

of

the preheat position.

14.5

volts. The oil pressure and the alarm

Aeo

·,0

G

....

to

operate.

activate the preheat circuit.

key

to START.

Once the engine starts,

It should spring back to the

The

water tempera-

it

closes when

PROPULSION

ENGINE

sound.

This

supplies

This

energizes

ON

buzzer

switch

closes

weather

the

posi-

an

The

a

12

of

in

@

IN~TAvweNT

overheat condition ex-ists and the operating temperature

the engine reaches 205°F, and sounds the alarm. The tachometer will register the engine speed as from the alternator as produce a charge, the tachometer will not operate. The hourmeter will continue to record time. The hourmeter a separate 12 volt

The

circuit

is

protected by a circuit breaker located engine. Whenever excessive current flows, the circuit breaker will trip. This is a manual reset breaker which must before the engine

A

CAUTION:

instrument

electrical

panel,

devices

it

charges. If the alternator does

circuit:'

wiJI

operate electrically again.

The

builder/owner

Wiring

and

engine

cannot

come

in

it

must

ensure

are

installed

contact

takes impulses

with

on

be

that

so

sea

of

not

is

the

reset

the

that

on

water.

The

latest infonnation regarding your engine's electrical system is included on the wiring diagram shipped with the engine. Be sure to study this wiring diagram and all notes thereon.

GENERATOR

PANeL

0.1".<:.

""O--+-4-10.......Q...1_

A!)SC"'Sl.'Y

r-------

( .. (

........

"':1'.

G..

Ii'

.,.....;:::\V:::..--4--_:::..~::..~

-cr'

-

e .. )

r-

----

- - - I

'.:.;:.'"

--,

• " I I I I

,..----II~I-I-

--i

,----1--1

--

--,

,f

,... - - - -

1--1"'1

- -~ -,-:--

I I

I \ I I

....,

I

I I I I

I

il

I

I I I I

I

,

I I I I

I

I I

I

I~

I

Ii

I

I:;

I

--rl

'I

I I I

: I

:1

I

I:

II

I I

I I I I

r I I I I

I I I I I

--.-I

r

..--+----+-....Jo.-...,

I I I I

-1

I I I

r I I

I I I

I I !

I J I

1-

__

I

J

Engines & Generators

53

STARTER/SOLENOID

SERVICE

DESCRIPTION

The swrtercan

• A motor section which generates a drive power.

• An overrunning clutch section which transmits an armature torque, preventing motor overrun after starting.

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

The starter is a new type, small, light-weight, and is called a high-speed internal-reduction starter. struction from conventional starters are

•

In

conventional starters, the pinion slides on the motor shaft (armature shaft). ion shaft is separate from the motor shaft; the pinion slides only

• A reduction gear is installed between the motor shaft and the pinion shaft.

• The pinion sliding part is not exposed outside the starter .

so

that the pinion

fouled with dust and grease.

• The motor shaft is supported at both ends on ball bearings. The lever mechanism, switch and overrunning clutch inner circuit are identical to conventional ones.

be

roughly divided into the following sections:

In

on

the pinion shaft.

may

Its differences

as

follows:

the new type

slide smoothly without becoming

of

in

starter, the pin-

con-

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

3.

If the pinion gap

2.0 mm), adjust of

shims on the solenoid. The gap

number

No-Load

1.

Connect the ammeter, voltmeter, and battery to the starter (see illustration).

2. When the switch

the starter must the current or starter speed is out semble the starter and repair it.

of

Test

is

not

within the standard range (0.5 to

it

by

increasing

shims increases.

is

closed, the pinion must protrude and

run

smoothly (at

or

decreasing the number

is

decreased as the

3000

rpm

or

more). If

of

specification, disas-

B

M

~

STARTER

ADJUSTMENT

If any abnormality is found by the following tests, the starter

should

be disassembled

Pinion

Gap

1.

Conned and the starter body, out and stop.

A

CAUTION:

10

seconds

AND

REPAIR

Inspection

a battery

cominuously.

(12V)

Never

WIRING

and

repaired.

between the starter lenninaJ

and

the pinion drive should rotate

apply

battery

voltage

for

"S"

over

A

CAUTION:

and

tighten

noid

shift-type

louder

than detecting ful not

to

it

protrudes.

every

starter

that starter come

Use

thick

terminal

of a

direct-drive

rotation

in

contact

wires

securely.

which

makes a rotating

at

the

with

the

as

much

This

type

pinion

as

possible

is a

starter.

tip,

be

gear

sole-

sound When care

when

..

Engines & Generators

54

STARTER/SOLENOID

SOLENOID

Perform tory,

1.

2.

the

following tests. If any test result is not satisfac-

replace

the

solenoid assembly.

Disconnect the wire

from

terminal

"M".

Attraction test: Connect a battery to the solenoid's termi-

nal

S for

(+)

and close

and M for (-). Have a switch

it.

The pinion drive should extend fully out.

in

the (+) lead

SERVICE

3.

Holding test. With a battery connected

"S"

and

to

terminal the pinion fully. The pinion even when released from being held

the starter body, manually

must

remain

by

to

the solenoid

pu))

at

that position

hand.

out

A

CAUTION:

more

than

STARTER

1. Disconnect the wire

2. Loosen the two screws fastening the solenoid. Remove

3. Remove the two through bolts and two screws fastening

4.

5. Remove the cover,

6. Unscrew

DISASSEMBLY

the

solenoid assembly.

the

brush holder. Remove the rear bracket.

With

the

two brushes pulled away from the armature, remove the

washer.

bracket. for adjustment

the

annature out.

the

At

the

pinion shaft

Do

not

apply

battery

10

seconds

yoke and brush holder assembly. Then pull

bolts

the same time, the washers

will

come off.

when

testing

ATTRACTION

from

the solenoid terminal

pry

the snap ring out, and remove the

and

remove the center

end

play

the

TEST

current

solenoid.

for

"M".

CONNECTOR

HOLDING

TEST

4.

Return test. With a battery connected

minal

"~,.,

and to the starter body, manually

pinion

fuUy.

The pinion must return

tion when released from being held

7.

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

On the pinion side, pry the snap ring out,

8. pinion and pinion shaft.

9.

At

each end with a bearing puller. bearing press-fitted

has worn off, replace the front bracket assembly.

of

OFF

RETURN

the armature, remove

It

is

impossible

in

the front bracket.

TEST

to

by

the

to

the

solenoid

pull

its

original

hand.

and

ball

bearing replace If

that bearing

pull

out

posi-

from

the

ter~

the

out

the

ball

PINION

SHAFT

Engines & Generators

55

STARTER/SOLENOID

SERVICE

STARTER

INSPECTION

Solenoid

Inspect the solenoid for continuity between terminals S and

S and

body.

No

M and between terminals

Sand

be found between between

Inspecting

1. Check the armature with

S and the body and M

The

. cuited, replace the armature. Also

between the communicator lated, replace the armature.

M. Continuity should be found

and

Annature

~

growler tester.

and

continuity should

the

body.

COmNUITY

ch~ck

its

shaft. If poorly insu-

CHECK

......

'

If

it's short

for insulation

dr-

Brush

1.

Check

the

2.

Check spring

springs

and

Brush

the

brushes. If

brushes.

BRUSHES

the

brush

will

cause excessive

if

suspect.

CLEANING

THE

COMMUTATOR

Holder Inspection

worn

out

beyond 10

_~EW

spring tension. A weak or defective

brush

wear; replace the

mm,

USED

replace

ARMATURE.

CHECK

2. Measure the commutator

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

COMMUTATOR

it

If

rough, polish

O.D.

0.0.

and

the depth

if the service limit

the

commutator

is

exceeded.

with

of

undercut.

a fine

Also

3.

Check and assembly.

for

holder

insulation

base.

If

Also

check

between

poorly

the

positive brush holder

insulated,

brush

replace the holder

holders for proper staking.

Engines & Generators

56

STARTER/SOLENOID

Field

Coil

Inspection

1.

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

2. Check for continuity between both ends (brushes)

coil.

3. Check the poles and coil for tightness.

FIELD

COIL

TEST

STARTER

A

starter

old depends cient and

Reassemble" the starter assembly sembly, making sure

1. Pinibn shaft end

ADJUSTMENT

CAUTION:

flange

paint,

size

ful/y

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

a.

Fit

the pinion shaft, reduction gear washer and snap

ring to the center bracket.

b. Measure the end play by moving the pinion shaft

the axial direction. If the end play exceeds 0.5 mm, increase the number

and

on

the

and

tighten

Before

and

mounting

rust.

quality

grade

to

AND

REASSEMBLY

installing,

Starter

of

the

between

the

terminal.

of

the folJowing:

play

adjustment. Set the end play

0.5

of

thoroughly

surfaces,

pertonnance

wiring. the

in

to

adjusting washers inserted.

remove

Use

battery

the reverse order

2 mm by inserting an

clean

largely

wire

and

starter

of

all oil,

of suffi-

the coil

of

the

of

disas-

in

SERVICE

2.

Greasing.

apply grease to the following parts:

a.

Armature shaft gear and reduction gear.

h.

All

c.

Bearing shaft washers and snap rings.

d. Bearing sleeves.

e.

Pinion.

f.

Sliding portion

A

face,

grease.

3. After reassembly, check by conducting a no-load test

again.

Whenever the starter has been overhauled,

bearings.

of

lever.

CAUTION:

terminals,

Ne"er

smear

brushes,

the

starter fitting silr-

Dr

commutator

with

Engines & Generators

57

DESCRIPTION

The

DC

Circuit functions to start, operate and stop the

ator's engine. The circuit

DC

ELECTRICAL

The

engine's

circuits:

preheat, slart, and

SYSTEM

DC wiring

DC

ELECTRICAL

is

best understood

WIRING

is

designed with three simple basic

run

or stop.

by

reviewing the

DIAGRAMS.

gener~

SYSTEM

NOTE:

An

isolator with a diode, a solenoid, or a ballery selector switch balleries

the house batteries.

battery

but

the problem

is usually mounted

so

the

starling battery is not discharged along with

not

the house battery, the alternator is

is in lhe battery charging circuit.

in

the circuit to isolate the

If

the isolator is charging the starting

OK

and

Engine

The engine has a ] 2 volt DC electrical control circuit that shown in the wiring diagrams. Refer troubleshooting or when servicing the DC electrical system on the engine.

CHARGING

The charging system consists regulator, an engine DC wiring harness, DC of

regulator is very compact and back

ALTERNATOR

If you suspect that voltage

12-Volt

A

CAUTION:

ing

circuit,

while

the

switch,

working

Control

To

never

engine

however,

on

the

engine's

avoid

shut

is

running.

to

avoid

Circuit

damage

0"

the

Shut

electrical

to

these diagrams when

to

the

battery

engine

battery

off

the

engine

shorts

circuit.

charg-

switch

battery

when

SYSTEM

of

an alternator, a voltage

an

engjne~mounted

circuit breaker, a battery and connecting wires. Because

the use

of

integrated circuits (IC's) the electronic voltage

of

the alternator.

is

mounted internally

or

TROUBLESHOOnNG

the

alternator

to

charge the engine's battery, check the following:

is

not

producing enough

on the

A

WARNING:

is

connect electrical

Checking

If you suspect

tests with the engine off:

1. Using a voltmeter, connect the output

the

2. Connect

engine.

3. Check the battery voltage. If the battery is

tion

it

should

4.

Check the voltage between the alternator (+) positive

terminal B and any engine ground. If the circuit the voltage at the alternator should be the same as the battery (unless there's an isolator reading

A

CAUTION:

ing

citeuit,

when

the

Shut

off

the

engine

from

the

battery

when

battery

working

switch

on

the

system.

for

Proper

the

terminal B.

the

would

never

engine

Voltage

alternator has failed, perform the folJowing

voltmeter red wire clip to

voltmeter negative wire to any ground on the

in

read

]2

to 12.5 volts.

in

the circuit, then the

be zero).

To

avoid

shut

is

running!

damage

off

the

to

engine

the

battery

or

engine

good

is

chalg

switch

dis-

condi~

good,

..

A

WARNING:

hot.

Do

o

Make

not

certain your alternator

touch

A

failed

until

aftemator

the

alternator

can

become

has

is

securely mounted.

o Check the drive belts for proper tension.,

o Inspect for loose

MANDO

51

AMP

or

disconnected wires at the alternator.

AlTERNATOR

cooled

very

down.

5. Start the engine.

6. The voltage reading for a properly operating alternator

Engines & Generators

A

WARNING:

fain

that

everyone

from

sheaves

should indicate between alternator is overreliable service shop.

NOTE:

Before

voltmeter to ensure

EXC

at the tery vollage at the B oUlput terminal.

Before

stalfing

is clealof

and

belts

or

uncercharging, have

removing the alternator for

that]

lerminal

if

moving

during

test

13.5 and

2 volts

the previous test showed only bat-

the

engine

make

parts!

Keep

procedures.

14.5

volts. If your

it

repaired at a

repair,

DC

excitation is present

cel-

away

use

your

58

DC

ELECTRICAL

SYSTEM

BAmRY

Review lish a systematic maintenance schedule for your engine's starting batteries and house batteries.

MAINTENANCE

the

manufacturer's recommendations and then estab-

o Monitor your voltmeter for proper charging during

engine operation.

o Check

the

hydrometer.

electrolyte level and specific gravity with a

o Use only distilled water to bring electrolytes to a proper

level.

o Make certain that battery cable connections are clean

to

and tight

the battery posts (and

o Keep your batteries clean and free

A

WARNING:

cause

severe

protective

GLOW

The glow plug bustion chamber. They run off the engine starting battery

The

The tip should glow red hot.

PLUGS

become

When should

Glow plugs can against a good ground (engine block) and turning them on.

test the power drain (8 to 9 amps per plug) to test resistance

red

glow plugs are wired through the preheat solenoid.

PREHEAT is pressed at the control panel this solenoid

"click"

Sulfuric

bums

gear.

is

a small heater installed

hot

when activated.

on

and the glow plug should begin to get hot.

be

checked by unscrewing and holding

(1.1

acid

on

skin

and

You

to 1.2 ohms).

to

your engine).

of

corrosion.

in

lead

batteries

damage

in

can also use an ammeter to

can

clothing.

each pre-com-

or

an

ohmmeter

Wear

and

them

A

WARNING:

to

the

touch.

testing

Reinstall the plugs plugs should get very hot (at the terminal end) within 25 seconds. If the plugs short circuit.

When the threads.

A

than

TYPICAL

plugs.

installing the glow plugs, use anti-seize compound

CAUTION:

30

seconds.

GLOW

PWG

These

glow

plugs

will

become

Be

careful

in

Do

not

to

bum

your

the engine and test them again. The

don't

heat up quickly, check for a

not

keep

glow

plugs

on

PREHEAT

GLOW

PLUGS

fingers

.

for

very

more

hot

when

20

to

on

Engines

59

& Generators

ALTERNATOR/REGULATOR

DESCRIPTION

The alternator serves to keep the battery constantly charged.

It

is

driven from the pulley at the end Y·belt. The type engines having a wide range diodes that convert the generated voltage constant even when the engine speed changes.

A

CAUTION:

as

a

megger.

During nect

the

from

terminal B of

failure

Wdh

altemators

a

short

allow

cu"ent

Do

not tenninalB of voltage

When

charging

sure

to

damage

of

"alternator used is ideal for high speed

AC

Do

not

Otherwise~

high-speed

positive

will

circuit

start

regulator

disconnect

to

diodes.

result.

between

to

the

engine

the

running

or

the

having

flow in

alternator.

will

battery with a the

of

to

DC,

use

any

damage

of

negative

alternator.

Ie

regulatorsJ absolutely terminals the

with

result.

battery

of

the crankshaft by a

engine speeds.

and an IC regulator that keeps

high-voltage

to

diodes

the

engine,

terminal

"this

Band

I>'diode

trio"

the

lead

Otherwise,

quick

tenninals

It

contains

tester

will

result

do

not

discon-

of

the

battery

is

done,

diode

avoid

L.

This

would

and

damage

disconnected

damage

charger,

to

be

prevent

such

..

it.

from

the

SERVICE

NOTE:

The alternator connections and color coding described on the following illustrations ERBEKE engines. Always refer to the wiring diagrams

this manual and also make a quick sketch wiring before disconnecting for service.

ALTERNATOR

If you suspect that the alternator is not producing enough

voltage to charge the engine's battery, check the

TROUBLESHOOTING

o Make certain your alternator is securely mounted. o Check the drive belts for proper tension. o Inspect for loose or disconnected wires at the alternator

may

vary from earlier WEST-

of

your alternator

in

following:

STATOR

SHAFT

A

WARNING:

bot.

Do

not

Testing

If you suspect the alternator has failed, perfonn the following

tests.

1.

2. Connect the other voltmeter wire

3.

The

Using a voltmeter, connect the voltmeter red wire clip

the output terminal

engine. Start the engine and record the voltmeter's readings.

A

CAUTION:

ing

circuit,

when

the

A

touch

until

Charging

To

never

shut

engine

is

tailed

alternator

the

Voltage

B.

avoid

off

running!

alternator

damage

the

engine

can

become

has

cooled

to

any ground on the

to

the

battery

SWitch

very

down.

to

charg-

Engines & Generators

60

ALTERNATOR/REGULATOR

The

voltage should be between 13.5 and 14.5 volts. overshop,

NOTE:

voltmeter to ensure that the R (£XC) terminal voltage at the B output terminal.

Output

1. Disconnect the battery ground cable.

2. Disconnect the and

3.

Connect a voltmeter between terminal B (+) and ground

4.

Connect to the P terminal.

5.

Reconnect the battery ground

The voltmeter

6.

Connect

7.

Start the engine.

S.

Tum of speed

rent. tor's

Output

reading

or

undercharging, have

or

continue

Before removing the alternator for

for a properly operating alternator

If your alternator is

it

repaired at a reliable service

with

the following tests.

repair,

I2

volts

DC

excitation is preselll at

if

the previous tesi showed only battery

+

Test

wire

from terminal B on the alternator

connect

the alternator, accelerate the engine to the specified

The

Hot

Cold

an

ammeter

should

B+

to the R terminal (regulator).

on

12

volt

accessories equaling the

(2000

to

3000

output

current should

maximum

Current 1300

ouput.

between B and this wire.

cable

to the

(-)

indicate the battery voltage.

amperage

rpm) and measure the output cur-

be

close to the alterna-

2500

16 24

rpm

amp amp

41

50

rpm

amp amp

use your

tenninal.

output

5000

rpm

48

amp

(-).

SERVICE

NOTE:

If

the screwariver

coil might be damaged.

2. Hold the rotor remove the pulley, fan, spacer and seal. Next, remove the

rotor from the front bracket and remove the seal.

3.

Unsolder the rectifierfrom the stator coil lead wires and remove the stator assembly.

NOTE:

Make sure that

than

less

in

five seconds).

I50aC (310°F), it might

4. Remove the condenser from terminal B.

5. Unsolder the plates

6. Remove the mounting screw and B terminal bolt and

remove the electronic voltage regulator and brush holder. The

regulator and brush holder cannot be sepearated.

7. Remove the rectifier assembly. S. Brush and brush spring replacement:

When only a brush or brush spring is to be replaced,

be

replaced without removing the stator, etc. With the brush

holder assembly removed, unsolder the pigtail

NOTE:

If

the terminals

damage might result to the rectifier. Therefore, the

bent,

Band

plates

L should

RECTIFIER

ASSEMBLY

is

inserted too deep, the slOtor

a vise and remove the pulley nut.

the

solder is removed quickly (in

If

a diode is heated to more than

be

damaged.

Band

L from the rectifier assembly.

of

the brush.

Land B of

be

gently bent

the rectifier assembly are

at

the center.

TERMINAL B BOLT

REGULATOR BRUSH

STATOR

Then

HOLDER

it

can

&

NOTE:

rpm is thaI

of

(alternator vs crank pulley)

j 3.5 liolts.

at

DISASSEMBLY

1.

After

removing screwdriver prying it,

the three assembly through-bolts, insert a

between

remove

the front bracket and rotor.

the alternator. The pulley ratio

is

1.78 to 1; all readings are

OUTPUT

TEST

SETUP

the front bracket and stator. While

Engines & Generators

61

SPACER

ROTOR

........

REAR

BRACKET

ALTERNATOR/REGULATOR

An

alterlUlte holder from

the

assembly separated from the rear half

1.

Insert a and the edge brush-holder. Raise this side the bracket so as to open a gap

NOTE:

enter far enough

2.

Maintaining the 1/2 inch gap, insert the screwdriver between the stator core and the bracket on the rectifier side and move the stator laterally toward the for a distance from the bracket.

3. Insert a #2 Phillips screwdriver through this opening and

remove the two screws holding the rectifier.

method

regu/o.tor

rear bracket. With the front bracket and rotor

flat~bladed

Be

careful

for

removing the stator winding, brush

unit

and

the

I.e.

diode rectifier assembly

of

the alternator:

screwdriver between the stator core

of

the rear bracket

not

to allow the screwdriver blade to

to touch the stator winding.

of

1/2 to 3/4

on

the same side as the

of

the stator core away from

of

about 1/2 inch.

of

an

inch without lifting

brush· holder

it

SERVICE

INSPECTION

Diode

Diode troubles are classified as open-circuit and

When the diode is open-circuited, no current flows.

short-circuited diode,

Checking

Check for continuity between the (+) heat sink and the stator cojl lead joint terminal and betwecn the

said

tions, the diodes are short-circuited. Replace the rectifier assembly.

for

terminal. If each test shows current flow

Short

curr_ent

Circuit

.

DIODE

TRIOS

flows

in

(3)

HHEATSINK

ASSEMBLY

both directions.

(-)

short~c.ircuit.

In

the

heat sink and the

in

both direc-

4.

Remove the nut anchoring the B terminal bolt and the

capacitor mounted thereto on the outside rear

bracket. Then remove the third Phillips screw holding the brush holder to

the bracket.

of

the

5. Carefully withdraw stator, brush holder and rectifier from

the rear bracket as one loosely connected unit. With the bracket out

stator winding leads from the rectifier quickly heat damage to the diodes and to renew the brushes because there is connecting plates between the brush holder and the rectifier and possibly damage the rectifier.

When reversing this procedure, make sure that the stator winding leads are gently pushed back (from possible contact with the rotor body) after seating the stator into the rear bracket.

of

the way,

it

is

easy to unsolder the

I.C

chips. It

no

need

to

avoid

is

also easier to

bend the

Checking

To

check for an open circuit

the

with your ohmmeter between the diode lead and the body, reversing the leads. open.

Checking

Check each

allows current flow in both directions

current to flow

for

Open

Circuit

in

the diodes which have passed

short-circ.uit test, disconnect the diode leads and check

If

no continllity is found, the diode

Diode

Trio

of

the three diodes for continuity. If any diode

or

does not allow

in

one direction, replace the rectifier assembly.

is

Engines & Generators

62

ALTERNATOR/REGULATOR

Stator

Disconnect the stator lead wires from the coil and check for continuity between the three leads with a circuit tester. continuity is found, the stator windings are open. Next, check

for insulation between each lead and the core. If continuity

found, replace the stator.

If no

is

SERVICE

Field

Coil

(Rotor)

Check resistance between the slip rings. The resistance must

confonn to the· specified value.

Resistance Value: 3.87Q

Check for continuity between. the slip ring and the core. If

it

there is continuity,

grounded. Replace the rotor assembly.

means that the coil or slip ring

± 10%

is

Checking

"Replace the brush if

Check the brush spring force. Also confinn that the moves smoothly

Checking

Because the slip ring wears very little, the diameter must be measured with a micrometer. Replace the rings (rotor assembly) when wear reaches the replacement value.

The slip ring must

sary

Brush

and

Brush

Spring

it

has worn

in

the brush holder.

Brush

Length

(mm)

Brush

Spring

Force

(g)

the

Slip

Ring

Slip

Ring

0.0.

Runout

clean and polish with a fine crocus cloth.

be

sm<?Oth

0.03

to

the replacement value.

Standard

Value

18

3700:60

Standard

Value

33mm

mm

or

less

with

no

surface oil.

Replacement

bnIsh

Required

Replacement

Required

32.2

8

210

mm

0.2mm

If

at

neces-

REGULATOR

The regulator consists

relay; their wires are gathered into a connector. The regulator stant regardless current to the field coil when necessary. The lamp relay used on the Captain panel only to illuminate the panel light

indicating no alternator charge. The

built-in

rent

1.

2. Connect a voltmeter between the generator terminal

is

used to always keep the alternator output con-

Ie

regulator. During alternator operation, field

is

controlled automatically by the

Connect an ammeter (approx. 60A rating) between the battery positive tenninal and its cable.

and the ground.

"0".

If otherwise indicated, a defective alternator

faulty wiring

of

a voltage regulator and a lamp

of

alternator speed and to cut off the flow

50A alternator has a

Ie

regulator.

In

this case, the voltmeter must indicate

is

suspected.

VOltage

is

cur~

L

or

of

Engines & Generators

63

ALTERNATOR/REGULATOR

SERVICE

3. Tum the starting switch key to the ON position, and the

wilJ

voltmeter the battery voltage, a ,defective generator

4.

With

the ammeter short-circuited, start

A

CAUTION:

cuited, a large

ammeter

s.

Increase

and read the ammeter.

6. If the ammeter reading does not exceed SA, read the voltmeter at that state reading is the regulated voltage.

7. If the ammeter reading exceeds the battery until the ammeter reading drops to SA below; or replace the battery with a fully-charged one; or

connect a

restrict charging current.

S.

The

Ie and, therefore, regulated voltage varies with temperature. It

is necessary to measure the temperature bracket (surrounding the regulator) and to use the measurement for correction

indicate a value considerably lower than

vOltage. If the indication

"the

ammeter

starting

coi/~

the

engine

1/4Q (25W) resistor

regulator is

current

s~ed

to between 2000 and 3000 rpm

(2000-3000 rpm). The voltmeter

of

the temperature compensation type

of

is

near the battery

is

possible.

the

is

not

will

bum

5A, continue charging

in

series

regulated voltage.

engine.

short-cir-

out

the

to

the battery

of

the rear

or

to

REASSEMBLY

A

CAUTION:

the

polarity

from

the

battery

diodes

and

1.

Install the alternator support leg (underside) into the engine casting.

2. Swing the alternator into position on the adjusting bracket and fasten. Lightly tighten.

3. Adjust belt tension.

4.

Tighten both bolts and recheck belt tension. Torque values:

Support bolt: Adjusting bracket bolt:

NOTE:

Make certain the belts are perfectly aligned with the alternator spacers

Connect

be

reversed, a powerful

into

the

wiring

harness.

and

engine pulleys.

as

needed,

to

align the alternator.

the

altemator

alternator,

bolt

through the alternator

20-24

12

- 14

If

properly. current damaging

Nm

would

the

(15

18

(9

10

ft~lbs)

not, insert or remove

Should

flow

ft-Ibs)

CHECKING

THE

ICREGULATOR

VOLTAGE

AMMETER

Engines & Generators

64

TRANSMISSIONS

WESTERBEKE uses a variety of by

well~known

BORG

WARNER,

transmission parts, repair

mend

contacting

information

marine manufacturers such

PARAGON

the

transmission manufacturer directly for

on

the

locations of authorized service facilities.

work

and

or

marine others. If

an

overhaul,

transmissions made

as

H

URTH,

ZF,

you

require

we

recom-

Engines & Generators

65

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Engines & Generators

73

BOAT. A

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THIS

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Engines & Generators

75

STANDARD

NOTE:

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

HARDWARE

TORQUES

Grade

6mm 8mm 10mm 10mm 12mm 12mm 12mm 13mm 14mm 14mm 16mm 16mm

Grade

6mm 8mm 10mm 10mm 12mm 12mm 12mm

4

6T

bolt bolt

bolt bolt bolt bolt bolt bolt bolt bolt bolt

bolt

bolt bolt

bolt bolt bolt

bolt

head/nut head/nut

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

head/nut head/nut

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

Pitch

1.25

1.75

1.25

1.75

1.5 (ISO)

1.5

2

1.5

2

1.5 (ISO)

1.5

Ib-ft

2.9-5.1

7.2-11.6

13.7-22.4

13.0-21.7

25.3-39.S

25.3-39.8

21.7-36.2

32.5-50.6

36.2-57.9

34.0-55.7

54.2-79.6

51.4-76.7

4.3-6.5

10.S-15.9

21.7-32.5

19.5-30.4

36.2-57.9

36.2-50.6

34.7-49.2

kg-m

0.4-0.7

1.0-1.6

1.9-3.1

1.8-3.0

3.5-5.5

3.0-5.0

4.5-7.0

5.0-8.0

4.7-7.7

7.5-11.0

7.1-10.6

0.6-0.9

1.5-2.2

3.0-4.5

2.7-4.2

5.0-8.0

5.0-7.0

4.8-6.8

Grade

7T,

8T

6mm

bolt

8mm

bolt

10mm

bolt

10mm

bolt

12mm

bolt

12mm

bolt

12mm

bolt

13mm

bolt

14mm

bolt

14mm

bolt

16mm

bolt

16mm

bolt

Grade 5 Cap

1/4

UNC

1/4

UNF

5/16

UNC

5/16

UNF

3/8

UNC

3/8

UNF

7/16

UNC

7/16

UNF

1/2

UNC

1/2

UNF

and

8.8 head/nut head/nut

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

Screw

Pitch

1.25

1.5 (ISO)

1.5

1.75

1.5

2

1.5

2

Ib-ft

5.8-8.7

14.5-21.7

28.9-39.S

26.8-37.6

54.2-75.9

50.6-65.1

43.4-61.5

57.9-86.8

72.3-108.5

68.7-101.3

108.5-166.4

101.3-159.1

9-11 11-13 1S-20 21-23 28-33 30-35 44-49 50-55 68-73 73-S0

kg-m

0.8-1.2

2.0-3.0

4.0-5.5

3.7-5.2

7.5-10.5

7.0-9.0

6.0-S.5

8.0-12.0

10.0-15.0

9.5-14.0

15.0-23.0

14.0-22.0

1.2-1.5

1.5-1.8

2.5-2.8

2.9-3.2

3.7-4.6

4.1-4.8

6.1-6.8

6.9-7.6

9.4-10.1

10.1-11.1

Engines & Generators

76

METRIC

CONVERSIONS

INCHES TO MILLIMETERS

Inches

1 25.40

2 50.80

3 4 101.60 5

10

mm

76.20

127.00

254.00

MILLIMETERS

INCHES TO METERS

Inches

1 2 3 4 5 0.1270 6 0.1524

TO

Meters Inches

0.0254

0.0508

0.0762

0.1016

CONVERT

METERS

YARDS TO METERS

Yards Meters

1 0.91440 6 2 3 2.74320 8 4 3.65760 9 5 4.57200

1.82880 7

MOVE

DECIMAL

Inches

15 20 25 30 35 40

= 1

CENTIMETER,

7 8 0.2032 0.2 7.874 0.8 31.496 9

10

11

12

TO

CENTIMETERS,

Yards Meters Meters

10

POINT

FOR

mm mm

381.00

508.00

635.00

762.00

889.00

1016.00

100

CENTIMETERS

Meters Meters Inches Meters Inches

0.1n8

0.2286

0.2540

0.2794

0.3048

MOVE

5.48640

6.40080

7.31520

8.22960

9.14400

HIGHER

VALUES

MILLIMETERS TO INCHES

Inches

1 2 0.0787 3 0.1181 4 0.1575 5

10

= 1

0.0394

0.1969 03937

METER = 39.37

-

mm

15 20

25

30 35

40

INCHES

(3.3

METERS TO INCHES

0.1

0.3

0.4

0.5

0.6

DECIMAL

3.937 0.7 27.559

11.811 0.9 35.433

15.748

19.685 1.1 43.307

23.622 1.2

POINT

TWO

PLACES

1.0

TO

THE

METERS TO YARDS

Yards Meters Yards

1 1.09361 6 6.56168 2 2.18723 7 7.65529 3 3.28084 8 8.74891 4 5 5.46807

-

e.g.

4.37445 9 9.84252 10

6,000

METERS

==

6,561.68

YARDS

Inches

0.5906

0.7874

0.9843

1.1811

1.3780

1.5748

FEET)

39.370

47.244

RIGHT

10.93614

Ib

1 0.454 6 2.722 1

2 3 1.361 4 5

kg

0.907 7

1.814

2.268

Ib

10

kg

3.175 8 9

3.629

4.082 4

4.536

GALLONS TO LITERS

POUNDS TO KILOGRAMS

Gallons Liters Gallons Liters Liters Gallons

1 2 3 4 15.14 5 18.93

3.79

7.57

11.36

10 20 30 40 50

37.86

75.71 2 0.53

113.57 5

151.42

189.28

PINTS TO LITERS

Pints Liters Pints

1 2 3 4 5 2.37

0.47

0.95 7 3.31 2

1.42

1.89

6

8 9

10

Liters

2.84

3.79

4.26

4.73

KILOGRAMS TO POUNDS

kg

2

3 6.614 8 17.637

5 11.023

Ib kg Ib

2.205

4.409

8.818

LITERS TO GALLONS

1

10 20

0.26

1.32

2.64

5.28

LITERS TO PINTS

Liters Pints Liters Pints

1 2.11

4.23

3 4 5 10.57

6.34

8.45

TEMPERATURE

32

40

50 60

I I

I I I I I I I I I I

I I I I I I I

0 5 10 15 20 25 30 35

70 75

85 95

105 140

40

60 80 100

6 13.228 7 15.432

9 19.842

10

Liters Gallons

60

90 120 150 180

6 12.68 7 14.79 8 9

10

175 212

I

I I

22.046

15.66

23.77

31.32

39.62

47.54

16.91

19.02

21.13

OF

°C

Engines & Generators

77

GENERATOR

USE

OF

ELECTRIC

The power required to start

more than is required to keep Some motors require much more current to start them than others. Split-phase (AC) motors require more current to start, under similar circumstances, than other types. They are commonly used on easy-starting loads, such as washing . machines, or where loads are applied after the motor is started, such as small power tools. Because they require 5 to 7 times as much current to start as to run, their use should be avoided, whenever possible, if the electric motor ven by a small generator. Capacitor and repulsion-induction

motors require from 2 to 4 times as much current to start as

to run. The current required to start any motor varies with the

load connected to it. An electric motor connected to an air compressor, for example, will require more current than a motor to which no load is connected.

In

general, the current required to start lIS-volt motors connected to medium starting loads will be approximately as follows:

MOTOR

SIZE

(HP)

1/6 1/4 1/3 1/2 3/4

1

*NOTE:

In the above table the maximum "Amps for Starting" is more for some small motors than for larger ones. The reason for this is that the hardest starting types (split-phase) are not made

Because the heavy surge

motors is required for only an instant, the generator will not be damaged se90nds. If difficulty is experienced off on the electric motor.

REQUIRED

Although individual units may vary slightly, the normal voltage and frequency erators described lows: run first with no-load applied, then at half the generator's capacity, and finally loaded to its full capacity as indicated on the generator's data plate.

The output voltage should be checked periodically to ensure proper operation supplies.

in

larger sizes.

if

all other electrical loads and,

OPERATING

MOTORS

an

electric motor is considerably

it

running after

AMPS

FOR

RUNNING

(AMPERES)

3.2

4.6

5.2

7.2

10.2

13.0

ot

current needed for starting

it

can bring the motor up to speed

in

if

possible, reduce the load

it

AMPS

FOR

(AMPERES)

6.4 -22.4*

9.2 -32.2*

10.4

14.4

20.4 -40.8 26

starting motors, turn

SPEED

of

typical 60 (50) hertz engine-driven gen-

in

this manual are approximately as fol-

of

the generating plant and the appliances

is started.

is

to be dri-

STARTING

-72.8*

29.2

52

in

a few

INFORMATION

GENERATOR

Frequency is a direct result indicated by the following:

D When the generator is run

output frequency is

D When the generator is run at

output frequency is

Therefore, to change the generator's frequency, the genera-

tor's drive engine's speed must be changed.

GENERATOR

D Maintaining reasonable cleanliness

Connections become corroded, and insulation surfaces may start conducting are allowed to build up. Clogged ventilation openings may cause excessive heating and reduced life ings.

D For unusually severe conditions, thin rust-inhibiting

petroleum-base coatings should be sprayed or brushed over all surfaces to reduce rusting and corrosion.

Typical materials suggested are

and Daubert Chemical

D

In

addition to periodic cleaning, the generator should be inspected for (a) tightness dence aged wires.

D The drive discs on single bearing generators should be

checked periodically if possible for tightness and for any evidence should not be allowed to become rusty because rust may accelerate cracking. The bolts which fasten the drive disc to the generator shaft must be hardened steel SAE of

the 6 corners

D The rear armature bearing is lubricated and sealed; no

maintenance is required. However, becomes noisy

D Examine the bearing at periodic intervals. No side

movement applied. If side motion is detectable, the bearings are wearing or wear on the shaft side bearing has occurred. Repair must be made quickly

or

major components will rub and cause major damage to the generator.

D Examine the control box at periodic intervals to detect

cracks from engine and generator vibration. If cracks

the box are seen, engine vibration may be severe, requiring bracing

it

resist vibration.

GENERATOR

A complete and illustrated text on troubleshooting and servicing the WMD. and BT generators is furnished lowing pages.

FREQUENGY

MAINTENANCE

of

terminal boards and rectifiers may

if

salts, dust, engine exhaust, carbon, etc.

of

overheated terminals, and (c) loose or dam-

grade 8, identified by 6 radial marks, one at each

of

or

of

the shaft should be detected when force

TROUBLESHOOTING

ADJUSTMENT

of

engine/generator speed, as

at

1800 rpm, the

60 hertz.

1500

rpm, the

50 hertz.

is

Ashland Tectyle 506

Co.

Non-RustAC-410.

of

all connections, (b) evi-

of

incipient cracking failure. Discs

the head.

if

rough-sounding, have

of

the bearing socket out-

in

the box for additional strength to

AC

important.

of

the bearing

it

replaced.

in

voltage

wind-

screws

is

in

the fol-

Engines & Generators

78

'

WMD

GENERATOR

DESCRIPTION

The

WMD

model generator is a self-exciting and self-regu-

lating brush style generator, requiring only a driving force to produce voltage. It is four lead reconnectable for 115 volts or

115/230 volts, and has a four pole revolving armature with no

DC

tifier

brushes

in

or

commutator.

It

has a solid state bridge rec-

the exciter circuit, AC slip rings, a drip-proof con-

struction, and a single bearing design. Voltage regulation is

"F"

3-4

as

7% no-load to full-load, and frequency regulation is

hertz no-load to full-load. It is

in

insulation class defined by MEMA MGI-1.65, and it's temperature rise is within MEMA

load. It's centrifugal-type blower fan is direct connected

MGI-22.40 definition when operating at full-

to the armature shaft for cooling. Capacitors across the hot leg and neutral minimize radio interference within the limits

of

most commercial and civilian applications. The armature is

balanced laminated steel, double dipped and baked. The field

ring is thick hot rolled steel with a welded bearing support

bracket, machined as an assembly for precise bearing align-

ment. The rear carrier bearing is pre-lubricated, double sealed

with an anti-rotation lock.

WMD

RPM

NOTE:

unit to 50 must

Voltage

Excitation Field

Excitation

FREQUENCY

To

convert a 60 Hz

Hz,

the armature

be

changed.

Normal Maximum Minimum

Voltage

GENERATOR

SPECIFICATIONS

60

1800

for

1500

for

115VAG 132

VAG

108

VAG

115

VAG

190

VDG

HERTZ

60

Hertz

50

Hertz

(output

voltage

(approximate)

STANDARD

230

VAG

264

VAG

216

VAG

supplied

to

rectifier)

DISASSEMBLY

1.

Lift and support the back end

generator is not resting on its isolators.

2. Remove the generator endbell cover. This exposes the fan

and brush rig assembly. Remove the fan assembly with

its hardware.

3. Remove the brush rig assembly. This can be done in two

half assemblies.

Unbolt the two half-moon assemblies from the frame attachment and lift the two halves away from the slip rings. Mark the polarity the bridge rectifier that go to the field coils and unplug these from the bridge rectifier. The two half-moon brush assemblies can be removed from the generator by remov-

ing the heavy output leads G 1, G2, G3 and G4 from their attachment point on each brush holder. Make a rough sketch as to where each assembly half. There are 8 leads that are paired control panel to provide four reconnectable leads. Inspect and replace components

not totally disassemble as this is not

4. Remove the control panel from the top housing. Mark all leads as needed for proper assembly.

Unbolt the generator housing from the bell housing. A

5.

puller may be needed at the bearing end to assist the housing with or without the bearing off the armature. Some gentle prying at the bell housing end will be needed

of

the engine so that the

of

the two leads on

of

these leads attaches on each

in

the brush rig as needed. Do

n,eeded.

of

the generator

in

the

pulling

as well. The housing housing has cleared the armature shaft,

with field coils is heavy. Once the

it

should be supported and slowly drawn over the armature. Try not to drag

it

over the armature.

INSPECTION

1. Inspect the bearing and replace as needed. If the unit is going through a major overhaul, bearing replacement is recommended.

2. Check the field coils resistance values. Remove the field coils from the housing. Note and mark each field coil's position a different part number and a specific position

in

the housing. Do not mix them

up!

Each coil has

in

the hous-

ing. Incorrect assembly will cause low voltage output.

3. Unbolt the armature from the flywheel. Test the armature with an ohmmeter. Clean the slip rings and polish using a crocus cloth.

REASSEMBLY

Reassemble

NOTE:

ture, ing

with

The fan on the back end plays an important part air through the generator for cooling. surrounding air is limited, outside air should be ducted to the area

of

for cooling, and combustion as well. The security

checked at installation (commissioning), at the initial servicing (200-300 hours). The cooling fan securing nut should be tight enough so that when force is applied to rotate the fan by

pushing on the outer edge and blades with the palm hand (protect the hand with a cloth

be able to tum the generator and engine without the fan slip-

ping on the shaft. replace the lockwashers.

Recirculation

must be avoided. The generator compartment ventilation must be sufficient to prevent generator air recirculation.

Insure that the screened endbell inlet and the screened discharge slots at the flywheel are not obstructed, preventing good air circulation through the generator while

in

reverse order.

When

be

assembling

sure

to

the hole

properly

the

housing onto

align

the

anti-slip

in

the

housing and install a new lock pin.

the

groove

In

installations where

generator

in

the

in

moving

the screened endbell inlet to provide this needed air

of

the generator fan hold down nut should be

of

the generator unit, and periodically thereafter

of

or

a glove), you should

If

properly torqued and the fan still slips,

of

generator cooling air through the generator

it

is running.

FAN

armabear-

50-hour

your

~~03

NUT

flAT

WASHER

STARWASHER

Engines & Generators

79

'",

WMD

NO

ELECTRICAL

1.

Remove directly at the generator output leads with a voltmeter.

Check

2.

for

OUTPUT

the load from the generator and verify no output

proper

electrical connections. Refer to the

GENERATOR

INTERNAL WIRING DIAGRAMS.

NOTE:

are numbered from illboard at the willdings end

3.

The generator armature slip rings and brush rigs

or

outward toward the rear support bearing.

For

a residual voltage check, disconnect the field leads

from the bridge rectifier. Note the position the rectifier (+) to (+) and tor

and

check

the

AC Measure lead(s) (3 and 4 wire unit - 2.5 volts

the voltage between the neutral lead

(-)

output

to

(-).

(no

load on generator).

of

Operate the genera-

AC

each hot lead

the

and

to neutral approximate).

If

the

residual voltage rotating problem

If residual voltage is not present: Check the brush rig and the static capacitors. Check the rotating armature resistance

armature

lies in the rectifier and/or the field .coils.

values

and

ch~cks

OK:

you can

and

brush rig are

the continuity check found under Flash

OK.

assume

The

generator's

Field Coils.

2.5

VOLTS

AC

2.5

VOLTS

AC

flywheel

leads

the hot

the

TROUBLESHOOTING

no

5. If

FLASH

1. Units may lose their residual magnetism from extended

on

voltage is produced; check the static capacitor(s)

it

is

that remove the connection from the output tenninal at the

brush rig and repeat

storage, sembly and assembly for installation, etc., requiring the

field coils the magnetism lowing manner:

Stop the engine and remove the generator endbell cover. This will expose the cooling fan, brush rig assembly

rectifier. Check internal wiring (see diagram). tive (+) lead from the field coils is connected to the positive marked terminal on the rectifier and the negative lead from the field coils is connected to the opposite

not shorted

FIELD

COILS

or

rough handling during installation

to

ground. If one is found faulty,

Step #3.

be excited with 6 to ] 2 volts

to

the generator. This is done

unmarked terminal on the rectifier. Using

with insulated alligator clips, connect 6 to battery positive to the positive tive to the mately ] stationary field coils.

A

to

age

Remove the alligator clip connections; replace the endbell cover and operate the generator and check voltage.

t----23Qv----...I

unmarked terminal

0 seconds. This should restore magnetism to the

CAUTION:

the

AC

the

rectifier.

Be

terminals

careful

on

the

or

DC

to restore

in

The

jumper

12

volts

of

the rectitier and nega-

of

the rectifier for approxi-

not

to

connect

reclifiet;

INTERNAL

WIRING

BASIC 4 WIRE

as

Ihis will

DC

DIAGRAM

disas-

the fol-

posi-

leads

DC

voltage

dam-

AC

output

anc~

(-)

4. Test the bridge

bridge

the erator ator

leads.

to

the field

volts

AC

ator

is

HOT

NEUTRAL

3 & 4

WIRE

UNITS

operation

rectifier. Apply

rectifier (+) to (+) and

(no-load). Measure the voltage output at the gener-

Generator

is produced, this should indicate that the gener-

OK,

of

the generator by bypassing the

12

volts

DC

(-)

output with

coils

should be

and

that the bridge rectifier is defective.

50

to 70 volts

12

HOT

to the field leads on

to

(-).

Run the gen-

volts

DC

excitation

AC.

If

50

to 70

Engines & .Generators

80

Armature

AC

6-12

vott

OCBanery

WMD

GENERATOR

TROUBLESHOOTING

2. Check for a short the stationary field coils.

ROTATING

WMD

11.0

and

NOTE:

4-wire units: there should between slip rings (1&2), (2&3) and (3&4). is found, an internal short exists between these windings and the armature should

NOTE:

There should be no continuity found between any

of

the slip rings and the armature's central steel shaft. continuity is found, the windings are shorted to the shaft and the armature should be replaced.

Rotating armature slip rings are numbered from inboard of

the generator flywheel end outward to the rear support bearing. When referring to 2, 3 and 4-wire units, these are the number to the load. You will find on the 11.0 and 12.5 KW units that there are are in pairs that are combined for a total leads. The number number

of

REPLACEMENT

1.

Field coils are connected in series and the resistance value given To determine the resistance value Each field coil has a mounting position on the generator housing and cannot coil.

When installing a replacement field coil(s), the installer must ensure that the coil is correct for the mounting position in the housing and will have the correct polarity when excited with

The

field coil shoes that hold the coil securely to the generator housing are held in place by bolts that must be properly tightened when the coil and shoe are installed to the generator housing. When connecting the coils in series ensure the butt connections are good and secure and positioned away from rotating parts.

To ensure the field coils have been positioned properly in the generator housing and will have the correct polarity, the following test generator.

3.

Connect a coils that would normally be connected to the (-)

connectors unmarked and the polarity in their connection to the DC

battery is not important.

NOTE:

When removing the leads from the battery and

reconnecting them to the bridge rectifier, you should maintain the same polarity as used in this test: plus lead to

(+) on rectifier and negative to unmarked

tion to rectifier.

or

open

in

the rotating armature or in

ARMATURE

12.5

KW

of

generator output leads being connected

8 leads coming from the brush rig and they

of

slip rings on the rotating armature.

OF

FIELD

in

this text is the total

be

9-12

must be made before reassembly

9-12

volt

of

the bridge rectifier. These leads are

(RESISTANCE

1

ohm

or

&3)

be

replaced.

and

less

(1

1

wires can also

VALUES)

between

(2&4)

be

no

continuity found

of

be

related to the

slip

rings

If

continuity

4 output

COIL(S)

of

the four field coils.

of

one, divide by four.

interchanged with another field

volts DC.

DC

battery to the leads

off

(-)

of

the

(+) and

connec-

If

I·----~

i j

~

j

I,

__

J

~

I

'\

II

I:~

1----1

RAil

9-12

VOLT

BATTERY

DC

TESTING

THE

FIELD

COILS

h. Using a 3-inch iron bolt

bolt between each adjoining field coil/shoes. be

held in place by the magnetic attraction set up between the coil/shoes by the the field coils. Should this fail to happen between any of

the four adjoining coils/shoes, then an incorrect coil is installed and must installed; otherwise the generator, when assembled, will not produce proper voltage.

LOW

VOLTAGE

1.

Verify the voltage output at the generator output leads with load applied to the generator; check the no-load condition also. Check the voltage at the load. Check the rat-

ing for the generator and verify the load with an probe at the output leads. Check all connections to ensure they are clean and secure. Ensure that the wire size carry-

ing the voltage to the load is produce a voltage drop.

NOTE:

draw placed on the generator from these types Generally, the amperage draw be

3-5

Ensure that the engine no-load speed is producing 125-132 load voltage can result amperage output.

OUTPUT

Beware

of

motor starting loads and the amperage

times the amperage needed when running.

(250-264)

or

its equivalent, place this

9-12

volts excitation

be

removed and the correct one

of

sufficient size

of

a motor at start-up will

volts from the generator. Lower no-

in

low output voltage at rated

\'

,\

~~!

"---J

It

so

of

RAIL

should

of

amp

as not to

(oads.

Engines & Generators

81

WMD

GENERATOR

TROUBLESHOOTING

2. Check the generator with a Hertz meter:

No-Load

Hertz

61-61.5 (51-51.5)

No-Load Voltage 130-132 volts (generator cold) No-Load Voltage 126-130 volts (generator hot)

3. Test the Bridge Rectifier. The bridge rectifier may be faulty and should be checked asiollows:

The field excitation rectifier is a full-wave bridge rectifier.

This type

DC

positive, and a the following manner: Connect one ohmmeter lead to the positive AC

terminals will be obtained. Reverse the meter leads, and site reading should be observed. Now check from the negative terminal same procedures as above. Check each terminal to the case, and no resistance reading should be observed.

If a battery-powered test light is used, follow the dures described above. If the rectifier is good, the light will come on,

If the rectifier fails any considered defective and replaced.

TESTING BRIDGE

of

rectifier has four terminals: two AC, a

DC

negative. The rectifier is tested

DC

terminal, and the other lead to each

in

turn. A high or low resistance reading

to

each

of

the AC terminals, using the

in

one direction only.

of

the above tests,

THE

RECTIFIER

of

an

it

should be

oppo-

proce~

the

in

5. Insufficient cooling the generator should not exceed efficiency temperature entering the generator endbell increases

above

the ducting

directed toward the inlet at the generator endbell.

6. Check the condition with the slip rings on the armature. Ensure that the brush-

es are not sticking

7. Condenser Testing. Condensers are built into the genera-

tor circuit to minimize radio interference during operation. put. the generator, disconnect the lead wire from the brush holder to which the condenser erator and check the output. If the generator then provides power, the condenser was at fault and should be replaced. lead wire was disconnected, the problem was not caused by that condenser.) Reconnect the lead wire.

NOTE:

of

104°F. Generators

of

If

a condenser shorts out,

To

determine whether a condenser is shorted, stop

(If

There should be no continuity found between the lead end from the condenser and the metal case condenser.

HIGH

VOLTAGE

1. Verify the voltage at the generator output leads. No-Load Voltage

2. Check the internal wiring to

the brush rig and the leads from the brush rig feeding AC brush rig and the other must be from a neutral brush rig.

If

to the bridge rectifier. One connection is from a hot

of

the generator. Ambient air entering

104°F (40°C). Operating

the generator decreases as the ambient air

in

confined areas may require

cool outside air into the compartment,

of

the brushes for wear and contact

in

the holders.

it

shorts the generator out-

is

connected, start the gen-

the generator did not provide power after the

of

the

so,

the condenser is shorted.

OUTPUT

126--130 volts (generator hot)

61.5-62.0 hertz of

the generator leads attached

B~ACK H --"';;;;::;:~~:b

TEST

lEAD

4. Check the field coil resistance as per the following specifications:

FIELD

COIL

WMD

and

11.0

12.5

KW

RESISTANCE

Aluminum

14.2

(3.5

ohms

Copper

22.6

(5.65

ohms

(TOTAL)

Windings

ohms

per

coil)

Windings

ohms

per

coil)

::t5%

Engines & Generators

SOLENOID

The solenoid plunger must move smoothly and rapidly into the solenoid when the solenoid is electrically energized, drawing with position. Failure solenoid will result

WITH

THROTIlE

.

ADJUSTMENT LINKAGE

THROTILE

it

the engine throttle arm into the set speed run

of

the solenoid plunger to bottom

in

a failed solenoid.

FUEL

SOLENOID'

LINKAGE

in

the

82

WMD

1o.----23Ov---ioro-j

GENERATOR

Armature

60

HERTZ

AC

INTERNAL

- 4

WIRE

RECONNECTABLE

AC

Field

Excitation

Rectifier

AC

WIRING

DIAGRAMS

Field Rectifier

Same

Excitation

Wiring

as

for

230v

50

J..

I

HERTZ

. ·220

Armature

- 2

Volts.

WIRE

RECONNECTABLE

AC

Field

Excitation

Rectifier

Engines & Generators

83

BT

GENERATOR

DESCRIPTION

This generator is a brushless self-excited generator, which

of

requires only the driving force

output The copper and laminated iron

responsible for the self-exciting feature magnetic field creates an electromagnetic field which rotates through the windings which is supplied to a load. A transformer is connected parallel to the produced main stator and is, tifier. The rectifier produces a the exciter stator windings, enabling the generator to produce

a rated

rpm. An optional solid-state voltage regulator is available to work

in

tandem with the transformer regulator to produce a more

stable

AC

in

the auxiliary windings

AC

output as the generator speed reaches its set hertz

output.

of

the main stator, inducing

output

of

in

tum, supplied to a full-wave bridge rec-

the engine to produce

in

the exciter stator are

of

this generator. The

the main stator. An

of

the transformer and

DC

voltage to further excite

AC

voltage

in

voltage is

AC

A circuit breaker is installed on all current WESTERBEKE generators. This circuit breaker will automatically disconnect

in

case

of

generator power

breaker can be manually shut off when servicing the generator to insure that no

NOTE:

This circuit breaker is available as a WESTERBEKE

add-on kit for earlier model generators; contact your

WESTERBEKE DEALER.

an electrical overload. The circuit

power is coming into the generator.

CIRCUIT

BREAKER

AND

CONNECTIONS

DRIVE

.

IT

GENERATOR

DISC

PLATE

Engines & Generators

84

-------,

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ELECTRICAL

WMD

GENERATOR

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!:lENDER

Engines & Generators

85

BT

GENERATO~

DESCRIPTION

This generator

requires only

output The copper

responsible for magnetic field creates through the windings of which

is parallel to the produced

.

~ain

stator and

tifier.

The rectifier produces a

the

exciter stator windings, enabling the generator

a

rated

AC

rpm.

An

optional solid-state voltage regulator

ii'l

tandem with

stable AC output.

is

the

supplied

AC

in

the

output

the

a brushless self-excited generator, which driving

force

of

the

engine

and

laminated

self-exciting

an

electromagnetic

the

to a load.

output of auxiliary is,

windings

in

turn,

as

the

generator speed reaches

transfonner regulator

iron

feature

main

stator, inducing

A transformer

the

main

stator.

of

supplied

DC

to

voltage

to

produce

in

the

exciter stator

of

this

generator.

field

which

AC

is

connected

An

AC

voltage

the

transformer

a

fulJ~wave

to

is

to

bridge

further excite

to

its

set

available

produce a

AC

are

The rotates voltage

in

and

rec-

produce

hertz

to

work

more

is

A circuit breaker generators. This circuit breaker

generator power

breaker tor

NOTE:

add-on W£STER'BEKE DEALER.

can

to

inspre that

This circuit breaker is available as a

k.{l

is

installed

in

case of

be

manually shut off when servicing the genera-

no

power

for earlier mode! generators; cOn/act

on

an

is

all

current WESTERBEKE

will

automatically disconnect

electrical overload. The circuit

coming into the generator.

WESTERB£K£

your

CIRCUIT

BREAKER

AND

CONNECnONS

STARTER

BT

GENERATOR

Engines & Generators

86

BT

GENERATOR

TROUBLESHOOTING

This troubleshooting guide will give you insights into problems which may be encountered with the WESTERBEKE BT

brush less, transformer regulated generators. Most potential problems are covered the simplicity bleshooting is relatively easy, once the relationship between cause and effect is understood.

Keep in mind that a basic fundamental knowledge tricity is required for this troubleshooting, and always remember that lethal voltages are present in the circuitry; therefore, extreme caution is essential when working on troubleshooting a generator.

Only a few basic tools are necessary for diagnosis and repair.

These are hand tools:

meter capable sion required

of

the equipment and controls, this trou-

of

reading less than one ohm due to the preci-

in

reading component winding resistances.

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

I B I

I I

A

+:

II

, b I

I 2 I

in

the text

an

amp probe and a quality volt ohm-

of

this guide. Owing to

aoo!

::* 4 j

_____________

3

__

J

of

elec-

or

i~

1,N=

LIIIIII I • I ,

I I I :

I " I

I

: I I I

t

_____

3

____

NOTE:

Do

not always rely on the vessel S instruments for

accurate readings; bring your own instruments for testing.

Before attempting any repairs, get as clear an explanation the problem as possible, preferably from nessing the problem. problem which is related to the method than an equipment fault.

Bring basic repair parts with you on the initial trip to the problem equipment, such as a regulator board when installed,

diodes and a bridge rectifier, so that if the problem should be found in one can be remedied early and efficiently.

The internal and external wiring diagrams are important tools

in troubleshooting this generator or any generator modeL Be sure to have both with you and be sure they are for the specific model you will be working on. (e.g. Model 12.5

:

4)

:1

1i

::

J

of

...

_2

~

In

some cases, this may bring to light a

these easily replaceable parts, the problem

1--+1----:

1--

....

1---_:

,

J

an

individual wit-

of

operation rather

~: ~:

of

BID).

G

GREEN

F/

YELLOW

BLACK

A EXCITER STATOR WINDINGS 1 & 2

A-1 (Selector

B. EXCITER

1. Auxiliary Windings (a-b-c)

2.

3. Rotating Field Windings

4. Pozi-resistor

C. MAIN

1. Main Stator Windings

2.

3. Main

/

i

\

L-~Y~E~LL~O~W~--------------,

and A-2 Exciter Stator Windings

in

COMP position)

ROTOR

Diodes (6)

STATOR

Main Stator Windings

Stator Auxiliary Windings

\

YELLOW

~--------~B~L~AC~K~-----~+AVR

BLACK

,--"--"""""

• • •

PLUG

',INTERNAL

CD

r-

f;

RED

GREEN

BLACK

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

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

D.

COMPOUND TRANSFORMER

1. Compound Transformer Windings

2. Compound Transformer Windings

3. Compound Transformer Auxiliary Windings with Voltage/Hertz Connection Bar

E.

SELECTOR SWITCH F-1

Compound

F-2 Electronic and Compound

F.

BRIDGE RECTIFIER WIRING

A.VR. Optional Automatic Voltage Regulator Plug (6 prong).

;:0:::

BLUE

WIRING

SCHEMATIC

5

.6

w

:::;)

-'

.....J

CD

8

~

60cyc.

50cyc.

Engines & Generators

87

NOTE:

The following is a list

regulation (no A.

V.R.

BT

offaults

installed).

GENERATOR

TROUBLESHOOTING

with the generator operation on compound (COMP) transformer

Low

Voltage

voltage

as

speed

and

High

voltage

correct

voltage

(115

-120

High

voltage

low

voltage growling engine

speed

Generator

o

volts

at

low

voltage load

is

applied,

(70

load

hertz).

at

volts).

at

noise

when

does

NIl.

at

FAULT

vo~s)

at

is

applied

NIL

(125 -135

when

loaded

NIL

and

Nil

(0

- 5

from

generator

load

not

excite;

NIL

(10 -20

voltage

drops.

NIL (no

F/L.

volts)

is

applied.

voltage

and loss

volts)

with

and

volts);

loss of

engine

with

loss

is

when

of

1.

Selector

1.

Generator's

1.

Generator's

2.

Short windings

1.

Main

2.

Compound 0-1, 0-2.

1.

Generator's

2.

Short in

transformer.

3.

Failed

4.

Shorted

1.

Diodes(s)

CAUSE

switch

engine

in

compound

0-3.

stator

windings

transformer

engine

in

the

main

diodes

on

pozi-resistor.

in

rotating

in

wrong

speed

transformer

shorted

speed

stator

exciter

position.

(rpm)

high

(rpm)

high.

C-1,

windings

(rpm)

is

windings

rotor.

(B-2)

at

NIL

auxiliary

C-2.

shorted

slow.

or

shorted.

1.

Place

1.

Check

1.

Check

2.

Check

1.

Check and

2.

Check Excite

1.

Adjust

2.

Excite

3.

Check failed

4.

Visually shorted field.

1.

Check this

selector

switch

NIL

speed

NIL

rpm

and

continuity

connections.

continuity unit

with

12

the

engine's

the

unit

on

the

diodes

will

examine resistor

Remove

B-1

and

with

engine,

will

and

B-2

load

manual.

CORRECTION

in

COMP

position.

and

adjust

NIL

voltage.

adjust

NIL

voltage.

and

connections

and

resistance

Excite

unit

and

resistance

VOC.

speed

12

VDC.

growling

on

the

terminate the

pozi-resistor

be

burnt.

test

run.

in

the

with

and

Short

exciter

the

This

rotating

of

values

12

values

adjust

will

of

the

rotor.

rotating

on

will

exciter

0-3

windings.

of

C-1 , C-2

VOC.

of

0-1,

NIL

voltage.

appear

generator.

Four

or

field.

the

exciter

short

as

windings

0-2

windings.

as

a

more

rotor.

out

the

rotating

explained

The

in

Voltage loss

of

engine

Voltage

loss

of

engine

Unstable Low

voltage further

as a load

Voltage

correct

at

rpm

correct

at

rpm

voltage.

at

NIL

OK

at

Nil

unstable.

NIL,

(hertz).

NIL,

(hertz).

and

is

applied.

and

but

not

but

not

voltage

low

at

drops

F/L.

F/l

F/L

with

2.

Bridge

3.

Auxiliary

4.

Auxiliary

.

1.

Selector

2.

Exciter are

3.

Generator's

1.

Generator

2.

low are

1.

Engine's

1.

Diodes

2.

Auxiliary (B-2).

1.

Auxiliary

2.

Exciter is

open.

3.

Auxiliary

1.

Defective

rectifier

stator

open.

power

open.

in

stator

defective. windings windings

switch

in

windings

engine

overload.

factor

rpm

fluctuating.

exciter

windings

compound

windings

regulator

B-1 0-3

ELEC

speed

load

rotor

in

exciter

in

the

0-3

board.

shorted.

andlor

position.

A-1

and

is.low.

(motor

shorted

rotor

exciter windings

or

C-3

open.

A-2

loads).

(B-2).

shorted

rotor.

A-2

open.

2.

Follow

3.

Check

4.

Check connections.

1.

Place

selector

2.

Check

3.

Check

1.

Check amp-probe.

2.

Check regulator

1.

Check

1.

Check in

this

2.

Check

1.

Check

2.

Check

3.

Check

1.

Check windings.

test

procedure

the

continuity

the

continuity

switch continuity generator

data

plate

type

of

load

board.

the

engine

the

diodes

manual.

the

resistance

resistance continuity

continuity stability

of

Operate

for and and

in

COMP.

and

resistance

NIL

rpm

and

monitor

applied.

operation in

the

exciter

values

and

connection

and

connection

DC

voltage

unit

on

the

bridge resistance resistance

values

and

adjust load

on

Consider

and

the

rotor

and

continuity

of

from

regulator

COMP.

Replace

rectifier. values. values

of

A-2

NIL

voltage.

generator

use

of

optional.

fuel

system.

as

illustrated

to

ground.

windings.

to

regulator

windings

windings.

with

ground.

exciter

board.

and

stator

2.

Engine

3.

Electrical

is

hunting.

connections.

Engines & Generators

88

2.

3.

Check Check

engine for

clean

operation

and

secure

and

the

fuel

connections.

system.

BT

GENERATOR

TROUBLESHOOTING

RESIDUAL

1. Residual Voltage 10-14 volts AC.

NOTE:

generator can be an indicator the problem/fault may

This voltage is the from magnetism in the exciter stator field. This voltage is measured between the load on the generator running at

The following generator components are

The nents

2. Twelve (12) volts windings should cause the generator to produce between 140-150 volts (Twelve volts (-) Correct voltage produced with twelve volts indicates the fault is components B, D or 140-150 volts AC, then include A

3. The absence a fault with the main stator windings C-1 and C-2 and/or the compound transformer windings

VOLTAGE

The amount

presence

1. Exciter Rotor (B-1 a, b, & C) & (B-2)

2. Rotating Field (B-3)

3. Main Stator (C-1

4. Compound Transformer (D-l fault lies

in

the exciter circuit:

.

A. Exciter Stator (A-1 & A-2)

B. Bridge Rectifier C. Selector Switch (F) D. Main Stator Auxiliary Windings (C-3) E. Compound Transformer Auxiliary Winding (D-3)

leads

of

the bridge rectifier, + to + and - to

CHECK

of

flO-load

lie.

AC

of

residual voltage is an indication that the

in

one or more

DC

excitation

AC

between each hot lead and the neutral.

DC

is applied between the lifted

in

E.

of

any voltage from the generator indicates

voltage produced by the

of

where in the generator

voltage produced by the generator

AC

neutral and hot leg(s) with no-

60 hertz.

OK:

& C-2)

& D-2)

of

the following compo-

(0)

of

the exciter stator

(+)

-.)

DC

excitation

one or more

If the generator does not produce

of

the above listed

and

C.

D-1

and D-2. Other

and

failed components that can produce this same no-voltage

in

output are the pozi-resistor

in

more failed diodes a.

Apply 12 volt windings as explained main stator and/or compound transformer windings such as a short will cause the generator engine to load down and the shorted windings to eventually produce smoke as the excitation is continued.

4. Voltage output greater than residual and less than rated output

(25-100 rotor/field B-1, B-2, B-3. Excitation explained voltage output and, when removed, the voltage return to the original low output.

BRIDGE

The bridge rectifier is supplied windings transformer (D-3). The AC voltage measured across the terminals

in

paragraph 2 should produce a partial rise

RECTIFIER

in

the generator stator (C-3) and the compound

of

the rectifier during engine operation

120

the exciter rotor.

DC

excitation to the exciter stator

volts) indicates a fault

Volts

the exciter rotor and 4 or

in

paragraph 2. A fault

in

the exciter

of

the generator as

AC

voltage from the auxiliary

is

120/240

in

the

wi)]

AC

as follows:

NIL F/L N/L F/L

10-20

volts

AC

Diodes

in

the rectifier convert this

it

supply to induce a field through which the exciter rotor revolves. The the bridge rectifier during engine operation is as follows:

to the windings (A-l and A-2)

DC

voltage measured across the (+) and

120

Volts

N/LF/L

10-20

volts

AC

Failure

of

the bridge rectifier will result

produced by the exciter stator windings. A weak field is pre-

, sent, due to the magnetism in the exciter stator, which will

cause the generator to produce residual voltage.

AC

10-20 volts

voltage to

of

120/240

N/LF/L 10-20

in

DC

the exciter stator

(-)

terminals

volts

a weak field being

AC

and

AC

in

of

/

BRIDGE

RECTIFIER

Engines & Generators

89

DC

(+)

RED

BT

GENERATOR

Testing

an

1.

2. Connect the (+) lead from the meter to point #4. With the

3. Remove the (+) lead from point #4 and connect the

4. Touch point #5 with the (+) lead.

5. Place the (+ ) lead

the

Bridge

Rectifier

for

Faults

with

Ohmmeter

Set the ohmmeter scale on RX1 (+DC). Zero the meter.

(-)

lead from the meter, momentarily contact points #1, #2, #3, and #5. No deflection showing infinite resistance.

lead to point #4 and, with the (+) lead, momentarily touch points #1, #2, and #3. The needle should deflect showing a passage through the diodes

needle should occur.

point #3. No deflection nite resistance). Reverse the connections and the same should occur.

in

the rectifier.

of

the meter on point

of

the needle should occur,

of

the meter

of

meter voltage

No

deflection

#1

of

the needle should occur (infi-

of

and the

(-)

the

(-)

on

TROUBLESHOOTING

NOTE:

Different style/model meters may produce opposite

results from the above tests.

Should the rectifier fail any should be replaced.

of

these tests,

it

is defective and

POINT

#5 (RECTIFIER MOUNTING

HOLE)

A + I

,...-

+

1

-<

CD

m

r

r r

»

C")

0

:;><;;

~

YELLOW

BLACK

INTERNAL

NOTE:

The

AC

terminal block has studs for 1/4 inch wire terminal ends. Multi-strand

copper wire should be used

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

! B .

I

ro-

_a

I

iI~b

I

_c

I

-

I'

-

I

2

GREEN

1 2

I 3

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

RED

RED~

F

,...--.....

,/.

I 1 \

r

\ I

,~

........

-()I-

~-_AC

•

.. ' GREEN

~

\

YELLOW

~

..

I

,/

YELLOW

r--

+

a

4

b

G

-KJ-

AC

----

I--

BLACK

s:

g

uj

>-

WIRING

and

sized for the amperage rating

I

DIAGRAM

I

1,)

1~

I

I I

I

L.

__________

I

z

~

0

0:

co

3

+

A.V.R.

PLUG

-

I I

I

.

I

11

L:.

-'

__

101@/$10101

YELLOW & RED

RED

GREEN

BLACK

of

the generator.

;

2

===?'/===

-

2

3

r--

---

I

-f-.J

a:I

r-

:>

c.->

;;0:;:

BLUE

ACTERMINAL

BLOCK

6

-2

-6

-3

-5

-7

-8

5

I

8

3

2

j

I

...

7

60

eye,

50

eye.

Engines & Generators

90

COMPONENT

NOTE:

Resistance Values

(Simson Meter

Models

A. Exciter Stator

A~1

&

A-I A-2 12.9 ohm

B. Exciter RotorlField

8-1 8-2

C. Main Stator

C-l C-2

RESISTANCE

260

Model).

11.0 & 12.5(A)

AM2

11.5 ohm

49.4 ohm

1.05 ohm

8.7 ohm

0.117 ohm

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

: 8 !

A I I

+:

II

+

_:.

2 : 1 2 3 I

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

BT

GENERATOR

VALUES

-at

70°F (21°C)

BT

D.

Main Stator Auxiliary Windings C-3 0.99 ohm

E. Compound Transformer

D-l

0.007 ohm

D-2

Transformer Auxiliary Windings

D-3

5.02 ohm

COMPONENT

Exciter

as(l!

:*

\

4 i

b:

lr-l··

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

TROUBLESHOOTING

RESISTANCE

Stator

I

·.,

3

NOTE:

BT

model generators are used on models rated lower than the capabilities is rated according to the capabilities since horsepower produces kilowatts.

of

the generator. However, the generator

of

the drive engine

CHECKS

Windings

AC

6

1

~~~11111~~--------

2

5

8

3

2

7

TERMINAL

BLOCK

-2

-5

-6

-7

-3

-8

GREEN

F/

I

YElLOW

i

\

BLACK

A Windings 1 & 2

Resistance readings for exciter windings

A-I

and A-2 with the selector switch

the

COMP the positive lifted off the bridge rectifier (G). Neither of

these two leads should have continu-

ity to the generator case/ground.

position are taken between

(+)

....

and negative

(-)

in

leads

RED

GREEN

BLACK

A Winding 1

Resistance reading for exciter winding

A-1

with the selector switch in the

ELEC position is taken between the low & white striped wire and the black

& white striped wire at the A.V.R. plug.

Engines & Generators

BLACK

yel-

BLUE BLUE

A Winding 2

Resistance readings for exciter winding A-2 with selector switch position is taken between the green

white striped wire lifted off the

minal

of

the bridge rectifier (G) and the

red

& white striped wires lifted off the

(+)

terminal

50cyc.

in

the ELEC

of

the bridge rectifier (G).

(-)

&

ter-

91

BT

GENERATOR

TROUBLESHOOTING

EXCITER

Auxiliary

nal points on the exciter rotor for these auxiliary winding groups. Position the exciter rotor as shown and count off the porcelain knobs from the 12 o'clock point either left or right to locate terminal points a,

Measure the resistance value between the pairs points A der these connections unless a faulty reading appears. occurs, unsolder and verify the winding fault. There should be no continuity found between any

points and the rotor shaft/case ground.

ROTOR/FIELD

windings group a,

& B, B & C, and C &

Red & White

band

c.

Locate the three termi-

in

the illustration

band

of

A.

There is no need to unsol-

of

the three terminal

c.

terminal

If

this

The diodes can be easily checked common automotive 12-volt high beam headlight bulb, some

jumper leads and the generator's 12 volt starting battery.

A short or an open in a diode can easily be found with the above without having to unsolder and isolate each diode to check

it

with an ohmmeter.

NOTE:

Attempting to check diodes in place with an ohmmeter will give erroneous readings on the diodes due to the auxiliary winding's connections.

When leads are put across the diode, as illustrated, voltage passes through the diode allowing the headlight to glow brightly.

in

place with the use

of

a

Exciter

Rotating Field Windings. See the illustration

rotor. The field winding connections are noted as the (+) and (-)

connections resistance value with your ohmmeter between these two nection points. These connections need not be unsoldered unless a faulty reading appears.

connection and verify the resistance reading. With these con-

nections lifted, there should be no continuity to the rotor shaft. This would indicate a short to ground with these field windings.

Diodes. Six diodes are mounted on the exciter rotor; they

rectify the AC voltage produced by the three groups iary windings to

the rotating field windings.

11 ohms Infinite

_----t'.>

of

the red & white striped wires. Measure the

DC

voltages and supply this

Resistance

through

blocking

the

...---

I I*-'

diode

Rotor

of

the exciter

If

this occurs unsolder the

DC

voltage to

value

11 ohms

of

con-

auxil-

Reverse the leads across the diode. The diode

voltage passing through it, and the headlight should not glow, or

it

may glow faintly.

High Beam 12 Volt Bulb Does Not Glow/Is Very Faint

a.

Should the bulb not glow with leads connected directions, the diode is open internally.

h.

Should the bulb glow with leads connected directions, the diode is shorted internally.

In both a and b above, the diode should be replaced. Check the resistance values and the integrity field windings.

Rotating

between the two red (-)

Posi-resistor. (Infinite readings between both yellow leads

lifted from the

Field

terminals

of

the resistors connected between the

Windings 7.0-8.0

& white wires connected to the (+) and

of

the exciter rotor as shown

(+)

and

(-)

of

the rotating field windings

ohm.

terminals on the exciter rotor.)

SDould

in

both

(Reading taken

in

the illustration.)

block

in

both

"l.nfin!

ta

---+-

Engines & Generators

92

BT

GENERATOR

MAIN

STATOR

1.

Group #1. The resistance value is measured between the

lifted lead #4 from the red insulated terminal below the transformer and lead #6 lifted from the block. Also lifted from the so as to totally isolate the stator windings (see illustration).

2.

Group #2. The resistance value is measured between the

lifted lead transformer and lead #3 lifted from the block. so as to totally isolate the stator windings (see illustration).

WINDINGS

AC

terminal block

#1

from the red insulated terminal below the

AC

Also

lifted from the

AC

terminal block

terminal

is

of

group

terminal

is

of

group

lead #5

#1

lead

#2

TROUBLESHOOTING

lifted

off

the

AC

terminal the yellow Connection Bar. There should be no continuity found between these winding connections and the case/ground

as well as the two main stator groups.

NOTE:

below and

COMPOUND

1.

Group #1. Resistance value is measured between the lift-

ed lead

transformer and lead #7 lifted

2.

Group #2. Resistance value is measured between the lift-

ed lead transformer and lead #7 lifted off the

NOTE:

& red striped lead lifted

The Voltage/Hertz Connection

just

to the left

TRANSFORMER

#1

from the red insulated terminal stud below the

#1

from the red insulated terminal stud below the

None

of

the lifted leads should have a continuity to the case/ground nor should either continuity to the other.

3. Transformer Auxiliary Windings. Resistance value is

measured between the yellow

off

the

AC

terminal selector switch in the ELEC position and the white striped leads lifted Connection Bar.

& White striped leads that come from the auxiliary wind-

ings to totally isolate these windings. There should be no continuity found from either case/ground

or

to either

Off

of

the bridge rectifier (G) and

off

the Voltage/Hertz

Bar

of

the

AC

terminal block.

off

the

AC

of

the groups have

& white striped wires lifted

of

the bridge rectifier (G) with the

off

the Voltage/Hertz

this same bar, lift the #2 and #3 red

of

these connections to the

of

the two transformer groups.

is located

terminal block.

#1

red &

YellowlWhite

NOTE:

ON

LATER

MOOELS,

THE

WHITE

STRIPE

ON

WIRE

WAS

REMOVED,

AND

THE

WIRE

NOTE:

There should

of

the lifted stator leads and the case ground. Also, no

be

no continuity found between any

contilluity should be found between the connections

IS A SOLID

THE

COLOR.

of

the two groups.

3. Main Stator Auxiliary Windings. The resistance value

for these windings is measured between the black white and the brown & yellow double lead connection

&

SELECTOR

Selector switch F-2 ELEC (electronic A.V.R. and compound transformer). This is the optional configuration

circuit with the optional A.V.R. installed.

NOTE:

which the exciter stator windings are divided, excited through the bridge rectifier through the

YELLOW BLACK

BROWN BLACK/.

YELLOW

BRIDGE

The

illustration shows the color-coded striped wires at the

AC

two

(-)

DC

NOTE:

correct polarity connection on the

SWITCH

of

the exciter

With

the selector switch

A.

V.R.

YELLOW/YELLOW

- - - - - - - - -

~

: •

r : t -

~

;,.....-Y.~I

/'.

•

!...

COMP

__________

BEARING

SIDE

OF

SWITCH

RECTIFIER

terminals and the color-coded wires at the

terminals.

When removing or reinstalling connections, maintain

in

ELEC F-2 position in

r-

- - - .. - - - - -

:.

.:.

•

!.

: '

!.

________ • _

WIRING

(+) and

one group is

and the other group

TOP

VIEW

ENGINE

SIDE

OF

SWITCH

ELEC

::.:l-

•

.,

___.-:--GREEN

• •

rGREEN

• :

~

RED

(+)

(--)

DC

terminals.

and

Engines & Generators

93

BT

GENERATOR

TROUBLESHOOTING

NO-LOAD

Voltage adjustment is made with the generator regulation being governed by the

1.

2. Operate the generator, apply a moderate load momentari-

VOLTAGE

The

selector switch must

ly and remove it. Note the voltage ator's

120 volt leg(s) (220 volt voltage should hertz

(222-226

NOTE:

The no-load voltage should be adjusted to the volt-

ADJUSTMENT

compound

be

between 121--124 volts at

volts at 51.5

transformer.

be

in the

50

-52

CaMP

output

hertz).

from the gener-

The

position.

no-load

61.5-62

age produced by the generator once started, and a momentary load should be applied to excite the trans-

former, and then removed. The voltage produced

by

the generator after this momentary load is removed is noload voltage.

3.

To raise (non-conductive material) are placed under the steel laminated bar on top transformer. soften' at temperatures in the reduction in no-load voltage be ed and the transformer core.

Varying shim thickness the no-load voltage by raise voltage; lessening shim thickness will lower voltage.) .

or

lower the voltage, shims

The

accomplished steel

bar

to reduce the

of

varying thickness

or

removed from

of

the

compound

material used for

by

gently tapping the top

gap

by

.001 inch (0.025

shimming

176°P (80°C) range. A small

(1

at 3 volts) can sometimes

between

the

mm)

should not

of

the laminat-

existing

will change

shims

4-6 volts. (Adding shim thickness will

VOLTAGE/HERll

1. Locate the Voltage/Hertz Connection Bar.

2. Refer to the illustration.

3.

Connect the blue & white striped

tion (A) tor will

be

BLUEjWHITE

00000

BlUEI WHITE

NOTE:

On some units A and B may be reversed.

a proper connection, be sure the blue

leads coming

on the

AC

50

hertz.

NOTE:

The placement

nection

(A)

CONNECTION

or

(B) to correspond to the hertz that

set to produce.

(8)

BLUE{ WHITE

off

A or B go to the numbered terminal stud

terminal block

of

to

(B)

or

vice versa when converting to 50 Hz

BAR

wire

for

RED!

WHITE

MID

RED/ YEllOW

60

RED/ WHITE

MAX

(Xl

-#5

the blue & white wire from con-

to either connec-

the

(Y)

REOI

WHITE

To

& white striped

hertz and #6 for

is only accomplished when the optional voltage regulator is installed as well. Disregard this wire connection change

4. Connections X, Y and Z are used to increase to the bridge rectifier under heavy generator is supplying. When this connection is moved from X to Y load, ment using the compound transformer will

if

there is no voltage regulator installed.

AC

amperage loads the

or

Z to increase

it

will effect no-load voltage, and a no-load adjust-

AC

output voltage under

be

needed.

genera-

RED! WHITE

#3

LOW

(Zl

ensure

voltage

Engines & Generators

94-

Westerbeke 38B FOUR, W-33, 42B FOUR, W-27, W-33A Parts Manual

Specifications and Main Features

Frequently Asked Questions

User Manual