Westerbeke W-46 Service Manual

-(£R/J·

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SERVICE

MARINE

SINGLE

AND

MANUAL

DIESEL

..

AND

DIESEL

THREE

""

ENGINE

GENERATOR

PHASE

l~

PUBLICATION. N0.34907

REVISION.

OCTOBER. 2017

2

rWESTERBEKE.

~

WESTERBEKE CORPORATION • 150 JOHN

.J

MYLES STANDISH INDUSTRIAL

WEBSITE:

WWW.WESTERBEKE.COM

PARK•

HANCOCK

TAUNTONMA

..

,

ROAD

02780

A

wARNING

Exhaust colorless unconsciousness exposure

•Dizziness

•Nausea

•Headache

•

IF GET seek until

gasses

gas.

can

Weakness

YOU

OR

ANYONE

OUT

INTO medical it

has

been

contain

Carbon

include:

and

Sleepiness

THE

attention.

inspected

Carbon

Monoxide

and

death.

ELSE

EXPERIENCE

FRESH

Shut

Monoxide,

is

poisonous

Symptoms

•

• Inability

AIR

IMMEDIATELY. down

and

repaired.

A

WARNING

WESTERBEKE

bulkhead

WESTERBEKE CARBON living/sleeping

They obtainable

of

Throbbing

Muscular

Vomiting

ANY

the

unit

DECAL

near

MONOXIDE

are

inexpensive

at

an

odorless

and

Carbon

in

Temples

Twitching

to

Think

OF

THESE

If

symptoms

and

do

is

provided

and

should

your

engine

also

recommends

DETECTORS

quarters

and

your

local

and

can

cause

Monoxide

Coherently

SYMPTOMS,

persist,

not

restart

by

be

fixed

to

or

generator.

installing in

of

your

vessel.

easily

marine

store.

a

the

CALIFORNIA

PROPOSITION

Diesel

engine

of

its

constituents

the

State

cancer,

birth

reproductive

exhaust

of

California

defects,

65

WARNING

and

some

are

known

to

cause

and

other

harm.

TABLE

OF

CONTENTS

INTRODUCTION

Serial Numbcr ................................................ 2

TEmNG

Compression Test .......................................... 3

Compression Pressure ................................... 3

ENGINE ENGINE

TROUBLESHOOTING DISASSEMBLY

Fuel lnjectiun Pump Removal ....................... 8

Order

INSPECTION

ENGINE

ASSEMBLY

Fuel

LUBRICATION

COOUNG FUEL

SYSTEM TIGHTENING STARTER ALTERNATOR

TRAISMISSIOIS

Borg Walter

ZF ............................................................... 83

THE

BT

GENERATOR

Troubleshooting, Testing & Diagrarns ........ 85

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

FOR

OVERHAUl

of Engine Disassembly ..................... 10

AID

REPAIR

Injection Pump

SYSTEM

(Pages

TORQUE

MOTOR

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

(Pages

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

\Vamer ................................................. 78

V~Drivc

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

(Pages

61-68)

(Pages

36-47)

55-60)

4-7)

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

8-15)

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

16-35)

48-50)

51-54)

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

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

...........

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

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

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

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

73-77}

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

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

(Pages

85-1

00)

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

......

....

........

2

3

4

8

16

36

48

51 55

61

69

70

73

78

81

85

ENGINE ENGINE GENERATOR

WIRING

DIAGRAMS

SPECIFICATIONS

(Pages

101-105)

106-

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

..

109) ......

101

106

110

SERIAL

NOTES,

As and information and

NOTE:

NUMBER

CAUTIONS

this

manual

assembly WARNINGS.

An

operating procedure essential

takes

procedure

will

be

An

LOCATION

AND

WARNINGS

you

through

of your engine/generator, critical

highlighted

explanation follows:

the

disassembly, inspection

by

NO'IES, CAUTIONS,

to

note.

INTRODUCTION

RAW

WATER

Siphon-Break

For installations where the water injected exhaust

close to or will be below the vessels waterline, must be made to install a siphon-break supply hose break provides an air vent prevent taw water from filling the exhaust engine's cylinders when the engine is shutdown.

If

you have injected exhaust elbow relative to the vessels the

vessels various operating conditions, install a

break. This precaution is necessary to protect

The siphon-break must

.that

hose the

vessels waterline. This siphon-break must always

above the waterline during all angles of prevent siphoning. .

NOTE:

A

cleaning

·

maintain a siphon-break dmnage.

maintenance.

COOLING

to

the water injected exhaust

any

doubt about the position of the

is looped a minimum

siphon-break

to

ensure

Consult

the

CIRCUIT

in

be

installed

requires

proper

operation.

can

siphon-break

in

the

elbow.

the

raw

water cooling

system

in

the highest

of

20

ioches

vessel

periodic

inspection

Failure..J.o

result

in

catastrophic

11U11J,Ufacturerf6r

elbow

provisions

raw

water

The

and

water-

waterline

siphon-

your

point

(51

em)

operation

properly

is

siphon-

system

the

under

engine.

of a

above

be

and

engine

proper

to

A

CAUTION:

observed,

your

engine/generator.

A

WARNING:

followed,

ORDERING

Whe~ever

generator serial

name-plate us your description the WESTERBEKE parts as

model

number

with

this

engine/generator.

separately

are

frequently

original

Procedures,

can

result

Procedures,

can

result

PARTS

replacement parts are needed, always provide the

number,

as

they

appear on

located

on

information

and

part

number

furnished

packaged

not

equipment.

which

if

not

strictly

in

the

damage

or

destruction

·

which

If

not

properly

in

personal

engine serial number,

the

generator end.

so

In

addition, include a complete part

Parts List). Also insist

made

injury

or

loss

the

silver and black

You

we

may properly identify

for

each part needed (see

parts

because will

to

the

same specifications

of

and

must provide

upon

fit

or

of

life.

generator

generic

SIPHON-BREAK LOOP

FOR

PART

N0.044010

ENGINE

The following sections contain detailed information

relating components disassembly, inspection guidance of suitable equipped service

coolirtg

and

should

be

Additional detailed information vided

in

generator,

WITH

STAINLESS

1"

HOSE

OVERHAUL

to

the

proper operation characteristics of

and

systems of

rebuilding facilities. The necessary

taken only

other sections of

alternator, starter

pumps,

etc. ·

the

engine.

and

reassembly instructions

and

staffed

by

such

facilities.

and

this

manual, covering

motor,

engine

specifications

Included

marine

adjustments,

the are

engine

procedures

the

major

for

are

the

pro-

2

HOW

TO

DETERMINE

CaQse

Generally, is power fuel is sometimes

or

caused

of

determined

output,

and

oil

not

necessarily

wear.

The

many

factors.

causes inspection is a good

by

symptoms

Low

Compression

the

time

at

which

by

various conditions such

decreased compression pressure,

consumption.

due

to

caused by injector nozzle wear or injection pump

decrease

on

and

means

worn

will

1 Low engine .,;ower output

in

compression pressure is caused

It

is,

therefore,

the

basis of data produced by periodic

maintenance.

of monitoring engine internal

cylinders or pistonrings, the following.

occur:

2 Increased fuel consumption

· 3

Iitcreased

4 Hard engine 5

Noisy

These

symptoms

can

result

also

from excessive fuel injection, improper injec-

tion

timing,

and

by

defective starter optimum pressure

oil

consumption.

under

compression

take

place properly. imporbplt.to

larly.

.

surement because

The

engine

crankshaft.

NOTE:

cause Pool

prnssure

NOTE:

properly symptons (cylinder

OVERHAUL

Compression engine Thereafter, of these parts.

When limit,

electrical devices such

and

glow

engine overhaul time by the

caused

sufficient

pressure, incomplete combustion

even

To

determine the period

measure

At

the

sl\!!le

of

compression pressure is made should

the

compression pressure varies with engine

rpm

In

case

of

may

be}'u£1

fuel

quality,

to

the

Make

certain

adjusted.

that

might,

misfire,

CONDITIONS

pressure

until piston rings

it decreases gradually with the progress of

decrease of compression pressure reaches the repair

the engine must be overhauled.

oU

engine operation

often appear together. Symptoms Z and 4

wear of

plugs. Therefore

by

worn

Satisfactory combustion is obtained only

compression pressure.

if

other

the

time,

ca:n·

be

severe

ir{jector

contaminates

injection

the

An

_incorrect

incorrectly,

white

·TESTING

ENGINE

The lowered engine power output

trouble with the engine itself, but

consumption

starting

the

cylinders and pistons plus increased

'parts

engine compression pressure regu-

the engine speed at which the

m~ured

vibrations

pump engines valve clearances

smoke,

tends

and

OVERHAUL

an

engine should

necessary to determine a cause

Oil analysis on a seasonal basis

injectors. They are caused also

as

the battery, alternator,

it

is desirable

·Jowered

If

of the engine

of

engine overhaul, it

at

the front end of the

and

detonation

problems,

and

will

see

loss

result

PERIOD

be

overhauled

as

lowered engine .

and

increased

by

wear.

When

·

to

judge the

compressio!l

an engine lacks

of

fuel

will

are

operating

mea-

be

checked rpm.

noise,

FUEL

lNJECI'ORS.

of

positive fuel

in

injector

faults.

are

valve clearance

suggest

noise,

etc).

to

increase a little

valve seats have been

an

can

engine

in a new

cause

overhaul

broken

wear

is

FOR

is

the

in.

OVERHAUL

COMPRESSI_ON

When

testing

or

the

Instrument

by

connecting

.

in

the

illustration

wires

and a pushbutton.

.

DISASSEMBLY

NOTE:

Befo'f! disassembly

for defects

which·

cleaning.

•

All

disassembled parts should be

order

of

to

insU.re

directions and positions.

• It: the disassembly procedure

parts

to

in

a way that will allow them without its

perfonnance. ·

•

Do

not remove or disassemble the parts

disassembly.

• Carefully inspect each part after deformation, and other problems.

•

Carefully checking

• Be careful not parts clean.

•

Use

proper

care·

to keep the fuel system parts

of dust

ASSEMBLY

1.

Wash

all

etc.,

with cleaning solvent and dry

Z.

Always you

understand

job.

Use

3.

4.

only good quality lubricants. Be

of oil, grease or sealant to parts

Be sure

torques are specified.

TEST

compression

Panel

an

electrical

below. A jumper

cannot

reassembly. Mark or label

proper mating and

be'

disassembled, the parts snould be

any

change

check

is

not

tools.

and

dirt. ·

p~.

use

tools that

to

use a torque wrench

the

Control

(propulsion

jumper

aiu:Lcleaning,

be

found after

in

the engine's

gaskets,

specified. to

except for oil seals, 0-rings, rubber

packings

Replace

damage the disassembled

Apply oil when

are

in good condition ahd be

how

to

use them

Panel

(generators),

engine ) can

directly

can

easRy

COMPRESSION

440

PSI/31kg-cm

355PSI/

be

to

the

.starter

be

fabricated

25kg-cm

ca~lly

disassembly

· · ·

carefullY._

the

partS

reassembly'

is

complex

to

as

to

be

efficiently external

its

removal

and

oil

with

new

necessary. free

from

them

before

sure

specified

tighten

in

the

requiring

that

seals,

ones

with

perfonning

to

parts

by-passed

as

shown

using

PRESSURE:

(normal)

(

limit)

check

and

arranged

It&

appearance

parts.

..

in

needed

proper·

many

disassembled

reassembled

require

no

for

damage,

even

if

defective.

Keep

Ta:ke

special

the

intrusion

sheets,

pressure

sure·

any

apply a coat

for

which

or

the

air.

·Engines & Generators

3

ENGINE

The following troubleshooting chart describes certain problems relating to engine service, the probable causes these problems, and the recommendations to overcome

of

these problems. This chart may be determining the need for an engine overhaul.

assistance in

TROUBLESHOOTING

NOTE:

The

engine's electrical system

of

ampere mounted

manual

on

the

reset

circuit

same bracket.

breaker.

is

protected

The

preheat

by a 20-

solenoid

is

PROBLEM

HARD

STARTING

PROBABLE

LOW

CRANKING

1.

Engine

2.

Run-down

3.

Worn

4.

Battery

5.

Defective

DEFECTIVE

1.

Air

trapped

2.

Clogged

3.

Low

injeCtion

4.

Inadequate

5.

Injection

6.

Injection

MAIN

ENGINE

1.

Low

compression.

a.

Incorrect

b.

c.

d.

e.

f.

g.

2.

Burnt

3.

Faulty

4.

Incorrect

5.

Governor

Inadequate Valve Broken

Compression Piston Worn

'

SPEED

oil

viscosity

battery.

terminals

starter.

INJECTION

in

fuel

filter.

pressure.

spray. pump too

early.

TROUBLES

valve

stem

valve

ring

piston

glow

plug.

glow

plug

governor

spring

delivering

contact seized.

seized.

CAUSE

too

high.

loosely

connected.

SYSTEM

passage.

insufficient

clearance.

of

valve

spring.

leaks

through

ring

and

cylinder.

operation.

lever

position.

out

of

POSITION

fuel.

seat.

cylinder

head

gask.et.

1.

Replace

2.

Recharge

3.

Replace

4.

Clean

5.

Repair

1.

Bleed

2.

Clean

3.

Adjust

4.

Clean

5.

Repair

6.

Adjust

a.

b.

c.

d.

e.

f.

g.

2.

Replace

3.

Check

4.

Set

5.

Correct

VERIFICATION/REMEDY

engine

oil

with

less

viscous

battery.

terminals

or

air or

injection

or

injection

Adjust Lap Replace Replace Replace Replace Overhaul

lever

replace

from

replace

or

replace

valve

valve.

valve valve gasket.

piston

engine.

glow

plug.

preheat

to

starting

spring

and

correct

starter.

fuel

system.

filter.

pressure.

nozzle.

injection

timing.

clearance.

and

valve

spring.

and

circuit.

position.

cables.

pump.

guide.

piston

oil.

ring.

LOW

OUTPUT

LOW

COMPRESSION

INJECTION

1.

Incorrect

2.

3.

INSUFFICIENT

1.

2.

3.

INSUFFICIENT

1.

SYSTEM

injection Insufficient Low

injection

Air

trapped

Clogged

filter.

Contaminated

Clogged

air

OUT

timing.

injection.

pressure.

FUEL

in

fuel

system.

fuel

tank.

INTAKE

cleaner.

OF

ADJUSTMENT

AIR

4

See

1.

2.

3.

1.

2.

3.

1.

Adjust

HARD

Repair Check

Check Clean Clean

Clean

STARTING

injection

timing.

or

replace

injection

and or tank.

or

nozzle

retighten

replace

injection

and

connector.

filter.

air

cleaner.

pump.

adjust

pressure.

(continued)

ENGINE

TROUBLESHOOTING

PROBLEM

LOW

OUTPUT

EXCESSIVE

(cont

OIL

CONSUMPTION

EXCESSIVE

FUEL

CONSUMPTION

••

}

OVERHEATING

1.

Low

2.

loose

3.

4.

OIL

1.

2.

3.

4.

5.

6.

OIL

1.

2.

3.

4.

OIL

1.

2.

l

ENGINE

1.

2.

3.

4.

5.

6.

PROBABLE

coolant

level.

V-belt. Incorrect Low

injection

engine

oil

level.

LEAKAGE

Defective Broken loose Loose

Broken Loose

leaking Bent Worn Worn

Defective Worn

Noisy Smoky Moving Poor Improper

lm~roper

oil

gear

case

drain

rocker

LEVEL

RISING

injection

or

twisted piston piston

LEVEL

FALLING

stem

valve

BODY

knocking.

exhaust.

parts

compression.

valve valve

seals. case

plug.

ccwer

cover

connecting ring. or

cylinder.

seal.

and

TROUBLES

nearly

timing. clearance.

CAUSE

timing.

gasket.

attaching

gasket.·

attaching

pump.

valve

guide.

seized

bolts.

rod.

or

excessively

worn.

VERIFICATION/REMEDY

1.

Add

coolant.

2.

Adjust

or

replace

V"belt.

3.

Adjust

injection

6.

Add

engine

1.

Replace

2.

Replace

3.

Retighten

4.

Retighten

5.

Replace

6.

Retighten

1.

Repair

pump

2.

Replace

3.

Replace

4.

Replace

1.

Replace

4.

Replace a valve

1.

See

KNOCKING.

2.

See

SMOKY

3.

c.

Repair

4.

See

5.

Adjust.

6.

Adjust.

LOW

timing.

oil.

oil

seals.

gasket.

bolts. plug.

gasket.

attaching

connecting ring. piston

stem

or

replace.

COMPRESSION;

bolts.

plungers.

rod.

and

rebore

seal.

and

valve

EXHAUST.

cylinder.

guide.

HARD

STARTING.

SMOKY

EXHAUST

INSUFACIENT

1.

AirJntake

NOZZLE

1.

Seized

2.

Worn

IMPROPER FUEL WHITISH

.

1.

ExcessiVe

2.

Excessive

a.

b.

obstructed.

TROUBLES

nozzle.

FUEL

LEAKS

OR

Poor

piston

Seized

c.

Excessive

PURPLISH

engine rise

piston

INTAKE

AIR

oil.

of

oil

into

combustion

contact.

ring.

piston-to-cylinder

chamber.

clearance.

1.

Remove

1.

Replace.

2.

Replace.

Replace

-

Find

fuel

1.

Correct

a. b.

c.

obstruction.

with

proper

leaks.

oil

level.

Check.

Replace Replace

or

clean.

or

correct.

fuel

(Cetane

#45

or

better).

(continued)

5

ENGINE

TROUBLESHOOTING

PROBLEM

SMOKY

EXHAUST

ABNORMAL OR

NOISE

(cont.

SOUND

I

1

WHITISH

d.

Worn

e.

Low

f.

Excessive

3.

Injection

4.

Insufficient

BLACKISH

1.

Engine

a.

Poor

b.

Improper

2.

Insufficient

3.

Improper

CRANKSHAFT

1.

Badly

worn

2.

Badly

.worn

3.

Melted

·CONNECTING

1.

Worn

2.

Worn

3.

Bent

connecting

PROBABLE

OR

PURPLISH

valve

stem

engine

oil

pressure.

timing

is

compression.

OR

DARK

body

trouble.s.

compression.

valve

intake

fuel.

AND

bearing. crankshaft.

bearing.

ROD

AND

connecting crankpin.

rod.

CAUSE

(cont.

and

valve

viscosity.

too

late.

GRAYISH

clearance.

air

(air

cleaner

MAIN

BEARING

CONNECTING

rod

big

end

guide.

clogged).

ROD

bearing.

BEARING

d.

e.

3.

Adjust.

4.

See

a.

2.

Clean

3.

Replace

1.

Replace

2.

Grind

3.

Replace

1.

Replace

2.

Grind

3.

Correct

VERIFICATION/REMEDY

Replace.

f.

Correct.

LOW

COMPRESSION;

See

LOW

COMPRESSION;

b.

Adjust.

air

cleaner.

with

proper

fuel.

bearing

and

grind

crankshaft.

bearing

and

check

bearing.

crankshaft.

bend

or

replace.

HARD

STARTING.

HARD

crankshaft.

lubrication

STARTING.

system.

ROUGH

OPERATION

PISTON,

1.

2.

3.

4.

VALVE

1.

2.

3.

4.

INJECTION

1.

2.

3.

4.

GOVERNING

1.

2.

PISTON

Worn

cylinder.

Worn

piston

Piston

seized.

Piston

seized

MECHANISM

Worn

camshaft. Excessive Wor.n Worn

Uneven Control Worn

Inadequate

Governor

Fatigued

valve

timing

fan

pulley

PUMP

injection. rack

delivery

lever

governor

PIN,

AND

pin.

and

ring

worn

clearance.

gear.

bearing.

SYSTEM

malfunctioning.

valve.

injection

SYSTEM

nozzle

malfunctioning.

spring.

PISTON

or

damaged.

spray.

RING

1.

Rebore

2.

Replace

3.

Replace

4.

Replace

1.

Replace.

2.

Adjust.

3.

Replace.

4.

Replace.

1.

Adjust

2.

Disassemble,

3.

Replace.

.

4.

Replace

1.

Check

2.

Replace.

cylinder

piston. piston

and

piston

and

injection

check

injection

governor

to

oversize

rebore rings.

or

replace

and

nozzle.

shaft

correct

and

replace

cylinder.

parts.

injection

correct

operation.

piston.

pump.

(continued)

6

ENGINE

TROUBLESHOOTING

PROBLEM

KNOCKING

INTERMITIENl EXHAUST

SOUND

ENGINE

1.

a.

b.

2.

3.

4.

KNOCKING

1.

2.

3.

KNOCKS

Main

engine Overheated 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

1.

Fuel

filter

2.

Fuel

pipe

3.

Water

mixed

deposits

PROBABLE

WITHOUT

troubles.

cylinder.

in

injection

WITH

pump

timing.

pressure.

fuel.

DARK

malfunctioning.

plunger.

is

not

in

delivery

valve nozzle. spray. chattering.

needle

valve clogged.

sucks

air.

in

fuel

CAUSE

MUCH

cylinder.

SMOKE

mesh

with

valve

spring.

seat.

drip.

seized.

control

-

SMOKE

rack.

a.

See

b.

Clean.

2.

Correct.

3.

Correct.

4.

Replace

1.

See

a.

b.

c.'

d.

a.

b.

c.

d.

1.

Clean

2.

Retighten

3.

Replace

VERIFICATION/REMEDY

OVERHEATING;

with

proper

LOW

COMPRESSION;

Replace. Correct. Replace.

Replace.

Clean

or

replace

Repair

or

niplace

Repair

or

replace

Replace.

or

replace.

pipe

fuel.

joints

LOW

OUTPUT.

fuel.

HARD

nozzle.

nozzle. nozzle.

or

~eplace

STARTING.

·

pipe.

OVERHEATING

LOW

OIL

PRESSURE

1.

V-belt

2.

Damaged

3.

Lack

4.

Low

5.

Knocking.

6.

Moving

7.

Defective

1.

Worn

2.

Relief

3.

Clogged

4.

Diesel

slackening

water

of

coolant.

oil

level

or

parts

seized

thermostat.

Bearings. valvl!

malfunction.

oil

cooler.

dilution

or

pump.

poor

of

the

slippery

oil

quality.

or

damaged.

oil.

with

oil.

1.

Adjust,

2.

Replace.

3.

Add.

4.

Add

5.

See

6.

Replace.

7.

Replace.

1.

Engine

2.

Overhaul

3.

Repair.

4.

Injection

replace

or

change.

KNOCKING.

overhaul

oil

pump.

pump

replace

repair.

clean.

bearings.

7

ENGINE

DISASSEMBLY

DESCRIPTION

Switch off the batteries and disconnect the battery cables from the engine and tape over the terminals.

Drain or pump out from the engine and engine hoses.

Unplug the instrumental panel wiring harness. Drain the transmission fluid and the transmission oil cooler hoses. Detach the oil cooler hoses and unbolt the transmission from the engine.

NOTE:

Label any

• Clean the exterior and oil.

• Be careful not to damage the disassembled parts.

• Mount

• Pay attention to marks on assemblies, components and

• Carefully check each part

the

parts for their positions or directions. Put on marks, necessary, to aid assembly.

faulty condition during removal tell you how it acted accurately during removal

all the engine oil and drain the coolant

lines,

hoses or cables as you separate

of

the engine

engine on a suitable engine stand for disassembly.

or

what was abnormal about it more

of

any deposits

or

component for any sign

or

cleaning. The part will

or

cleaning.

of

them.

dirt

if

of

i~~~

DISASSEMBLY

1. Remove

2. Remove one end

removed.

3. Remove

4. Remove Label the wires and cables.

5. Remove adapter cover. The drive is removed by turning in a counter clockwise direction. See breakdown.

6. Remove

RECIRCULATING PUMP for parts breakdown.

7. Remove manifold.

e. Remove the alternator, drive belt, support brackets and

f. Remove the engine mounted raw water pump and its

e. Remove the flywheel. Loosen the front crankshaft

the

engine oil hose connections.

the

engine

of

each hose connected to the part being

the the

the

mounting

the

adjusting strap.

connecting hoses. Refer to the raw water pump in this manual.

pulley nut before removing the flywheel.

heat

exchanger.

engine

back

plate.

start motor,

engine

coolant recirculating

air

intake

drive

mounted

plate,

and

RAW

silencer

belt

raw drive

WATER

and

If

possible, leave

and

the

water

pump,

from

the

PUMP

pump

See COOlANT.

the

intake

alternator.

front

for parts

.

HEAT

EXCHANGER

DRAINS

TRANSMISSIONS

The

transmission information in

the

W-46

If

the

transmission cleaned and and coupling.

To

dealer

and pressure lubricate

Ghange

rebuild

or

section

and

speciffCBtions

engine.

is

repainted.

tested

the

gear

the

transmission

an

authorized

of

this

manual

for

not

being

rebuilt,

The

oH

cooler

and

the

cooling

shift

linkage

transmissirJn

contact your

transmission

~c~

~

..

contains

the

transmissions

it

should

hoses

and

the

fluid.

setvlce

,,

•)

.

general

used

be

inspected

be

nushed

out replaced. propeller

Inspect

shaft

WESTERBEKE

center.

·

WHEN

REMOVING

THE

MOUNnNG

LOCK

THE

.

WITH A RING

BREAK

TOOL

BOLTS

FLYWHEEL

GEAR

.·

FLYWHEEL

BOLT

PAmRN

HSW

HURTH

TRANSMISSION

HYDRAULIC TRANSMISSION'S BOLT

DIRECTLY

BELL

HOUSING

!HAVE A SEPARATE

Oil

COOLER

TO

THE

AND

' .

8

INSPECT

THE

PlATE

FoR

BROKEN

SPRINGS

DAMPER

WEAR

AND

TAB

WASHER

ntANSMISSION

DAMPER

PLATE

ENGINE

DISASSEMBLY

8. With

9. Remove

10. Remove

11.

12.

14. Remove

15. Remove

16. Remove

the

hoses disconnected, housing sender in place.

COOLANTPUMPASSEMBL~

Remove the

Unbolt in

Remove the exhaust manifold/expansion entirety. Disassemble separately, new gaskets when assembling. Use good quality gasket cement.

NOTE:

cast

fuel

NOTE:

to

Disconnect the fuel injection pipes and fuel leak-off pipe from the fuel injection pump and nozzles.

NOTE:

and

injection nozzles with a wrench. Remove the nozzles and gaskets from the cylinder head.

and

the

the the

engine block.

the

its entirety.

Early

unit.

(Cast units

the

lift

pump

The

positions

the

fuel

filter;

the

Put plugs or caps

nozzle

connectors.

the

Scribe

mating

case

before

housing gasket, leaving the temperature

coolant circulating

air intake silencer

oil filter

elbows

versions

engine

fuel injection

fuel injection nozzles. Loosen the fuel

marks

and

were

are

only available

mounted

and

the

injection pump and the electric fuel

on

Golf tees work well

on

removing.

remove

the

mounting

remove

an

assembly,

fuel filter with electric

lines.

sealing washers that attach fuel lines

pump.

the openings

the

pump

pump.

and

the

exhaust

clean

later versions

today).

of

body

and

the

thermostat

Refer to

intake

manifold.

bracket

manifold

tank

in its

aU

surfaces, install

the

injection pump

as

plugs.

the

timing

from

are

pump.

·

gear

FUEL

INJECTION

Early model injection pumps (DTAJ394-2F4-90) had tapered

drive shafts, each with a woodruff key that injection gear by a threaded tang used to drive the raw water pump.

1. Remove

pump

drive

PUMP

drive gear and was held in place in the drive

tang

REMOVAL

locking

plate

fits

and

unscrew drive

into the

tang.

2.

Manually pump when the injection pump is removed, the woodruff key will not drop down into the front cover.

3. Remove injection

4. Loosen

a

the

NOTE:

a

JOmm,

5. Place a driveshaft

through

punch a sharp blow. The should

the drive gear.

6. Remove carefully key

NOTE:

position, it will not change mesh with

Later Later style injection pumps each have a splined drive shaft

with a master spline. The drive gear has a dash mark on the front indicating which splines must engage the master spline

on the drive shaft, ensuring the injection pump is in the

~orrect

1. Remove

onto

the

NOTE:

bolted the master spline on the injection pump drive shaft reinstalling the shaft

2. Removal

a.

NOTE:

banjos and the injectors, these should

b.

c.

d. Put the injectors aside for cleaning and rebuilding

rotate

engine to position keyway

drive

gear/shaft

the

fuel supply

pump.

the

three

front

cover

plate.

Inner hold-down bolt for

flexible,

soft

into

Although

Models DPAJ3942F580

timing sequence with the engine.

the

engine.

When

to

dash mark that indicates

Remove the fuel return line from the top

injectors

There

With a 30mm deep socket unscrew the injectors from

the cylinder head.

Remove the copper injector sealing washers from the

head once the injectors are removed.These sealing washers should be replaced upon reassembly.

shop

Shop.

114

metal

end

of

the

drive

the

injection

so

as

not

the

cover

the

three

front

cover

reinstalling the injection

the

front

of

the

by

removing the four

are

sealing washers between

or

by an authorized

at

12:00. This is important so that

and

return line from

bolts holding

inch drive

drift

punch

the

injection

gear. With a hammer, give the drift

pump

to

drop

and

withdraw.

drive gear will appear

bolts

plate

of

the drive gear must

in

the drive

fuel injectors.

the

injection

injection~ump

socket.

against

pump

dislod~

hold-down bolts

the

drive

the

its

drive

OR

581 ,

that

hold

the

and

remove

pump,

the

splines which

gear.

2Smm

be

CAV

/BOSH Injection Repair

in

injection

the

pump

is

removed

the

threaded

_protruding

tbe pump from

and

shaft

woodruff

injection pump.

very

loose

in

its

idle

gear.

injection

the

be

removed

attaching nuts.

the

replace

pump

drive

mate

with

when

of

the

injector

on

pump

tang

to

expose

return

reassembly.

to

with

from

plate

the

in

~

WESTERBEKE

9

ENGINE

DISASSEMBLY

Disassemble

1.

Remove

cover.

2.

Remove

assembly a.

Loosen

(1)

b.

Loosen

bolts

(

3)

c.

Remove

(

4)

d.

Remove

rings

with

e.

Remove valve

in

cylinder

as

•

new

caps.

the

follows:

and

(2)

rocker

oil

(2

pes-to

ones).

valve

following

head

rocker

remove

and

shaft

pipe

push

union

long

(5)

be

rods

order: rocker

shaft

nut.

short

bolts

assembly

and

a-

replaced

and

3.

4.

Remove assembly

a.

Loosen

in

tightening

b.

Remove gasket.

Remove

assembly

a.

Loosen

bolts

gasket.

b.

Loosen

bolts

assembly.

the

as

reverse

the

as

and

follows:

cylinder

and

the

cylinder

oil

follows:

and

remove

and

cylinder

remove.

pan

and

remove

head

order

head

oil

attaching

oil

attaching

oil

pan

head

bolts

of

and

pump

and

pump

Cylinder

12

Head

4 6

0 0

14

@J

Bolt

8 7

0 0

0

17

16

Tightening

15

5 3

0 0

13

@)

Sequence

0

9

11

Eng1'nes

10

& Generators

5.

6.

Removal a.

Remove pulley pulley.

b.

Remove

(Early tion cover.

c.

Remove bolt thrust idle

d.

Remove nut gear

Remove

follows:

of

pump

(

gear

(4),

(5).

the

1)

front

retaining

timing

models:

drive

)

idler

,

plate

(3),

camshaft

thrust

camshaft

ENGINE

gear

(2),

train.

crankshaft

nut

gear

Remove

gear

retaining

and

bushing.

retaining

plate

assembly

DISASSEMBLY

and

cover.

injec-

with

and

as

7.

a.

Position

that

mounting

b.

Carefully

camshaft block.

c.

Remove

lifters

Remove

injection follows:

a.

Loosen

b.

Remove

c.

Late drive

bearing

suitable

the

surface

(1)

all

from

the

pump

attaching

front

models:

gear

on

puller

engine

cylinder

withdraw

from

push

engine

front

plate.

injection

is

front

block

is

down.

the

rod

block.

plate

assembly

bolts

retained

plate;

to

remove.

so

head

the

engine

solid

and

as

(1).

pump

on

use

Enginds

11

& Generators

8.

Remove plate.

the

flywheel

ENGINE

and

DISASSEMBLY

back

9.

Remove

bearing

(lower and bolts. bearing

the

caps

shells)

removing

Keep

with

connecting

and

by

the

each

respective

bearings loosening attaching

cap

rod.

10.

Remove the main bearing caps by loosen-

ing and removing the attaching

11.

Remove the crankshaft.

bolts.

rod

and

a.

Withdraw each rod and piston as-

sembly from the bottom of the block.

b. Loosely replace the bearing and rod

caps. Make sure that each bearing and rod cap is

location from which it was originally removed. Also make sure that the caps replaced.

are

not

·

repl1:1ced

turned

in the exact

180° when

Engines & Generators

12

12.

Remove

13.

Disassembly necting

a.

b.

the

rod

Remove and

oil

ring Remove

spring.

tool

main

compression

ring

oil

(

piston

as

(A).

2)

bearing

follows:

by

scraper

~NGINE

shells.

and

rings

using

con-

(1)

piston

expander

DISASSEMBLY

/ .

c.

d.

e.

Remove using

Remove

using

Remove and

by down plate

removal

connecting

(upper) (NOTE:

resting

snap

piston

drift

piston

•

on

will

of

snap

ring

punch

Heating

the

an

allow

the

ring

tool

rod

the

piston

electric

for

piston

(C).

(3)

(B).

(4)

bushing bearing

by

piston

crown

hot

easier

pin.)

Engines & Generators

13

14.

Disassemble assembly

a.

Remove both shaft.

as

snap

ends

the

rocker

follows:

rings

of

ENGINE

shaft

(1) on

each

rocker

DISASSEMBLY

b. c.

d. e.

Disassemble

15. as

a.

DOWNTO.F

f.

g. h. i.

Remove Remove

(

2)

•

Remove Remove

(

4)

,

follows: Remove

Remove

(depress

valve Remove Remove Take

out

rocker

the

glow

valve

lifter.)

retainer

valve

assembly.

shaft

assembly~

shaft

cylinder

plugs.

cotters

spring

-(9).

spring

(10).

(11).

bracket

(

3)

spring

head

(8).

by

j.

Remove cylinder remover

valve

head

(A).

guide

(13) by

/

Valve

guide

remover

0.5C

.\

-

30

~~-

(Dimensiops

MATERIAL

(12)

-

-~

188

S 53

from

using

~c

)8

158

C.

·-t 124

~

in

rom)

·

Engines & Generators

14

A

12

13

INSPECTION/REPAIR

CYLINDER

1.

Inspection

Check

the

by

thickness

of

checking

faces.

check

precombustion

removed.

use a surface

the necessary,

flatness.

Warpage

surface head

HEAD

the

cylinder

using

is

cylinder

Item

of

gasketed

of

cylinder

gasketed

head

a

straightedge

gauge

the

:Refer

to

be

grinder

head,

to

Specifications

Standard

0.05,max (0.0020)

sur

for

as

in

crankcase

to

Crankcase.

made

with

chamber

to

as

the

specified

Unit:

Repair limit·

face

flatness

the

case

sur-

This

jets

reface

mm

(in.)

0.2

(0.008)

of

and

the

Checking

for

flatness

cylinder

I

D

head

gasketed

I

E

surface

2.

Precombustion

Replacement Do

not chamber replacement remove noted

machined

ease

flat-faced through shown.

Before

the cavity

into pointing

cylinder. with

remove

jets

is

the

in

it,

jet

or

to

it

out

by

drift

the

glow

installing precombustion clean,

position,

to

the Calk

a

punch.

Chamber

the

precombustion

unless

necessary.

(if

cracks

if

head

specifications)

driving

plug

the

and

drive

with

its

center

one

A-Intake B-Exhaust

C-Jet

D-Caulking

their

must

with

inserted

hole,

jet,

chamber

the

orifice

of

portion

port

position

Jet

To

are

be

as

wash

jet the

a

Removing

precombustion

A

chamber

B

jet

Etjgifles & Generators

15

Valve

1.

Guides

Check

burning,

on

the

and

the

stem

valve

each

head:

and

valve

wear

for if

Valve

Seats

for

or

other

also

check

cracks.

damaged.

INSPECTION/REPAIR

carboning,

defects

cap

end

Replace

Valve

guide

remove~

~

2.

3.

Check

wear. more Measure

the

guide

middle

tions.

diameter

If

the repair below,

Valve Check

valve refacer.

each

valve

Remember,

rapidly

the

inside

at

from

Measure

of

each

measurement

limit

given

replace

face

valve

face

and

To

face

is

reface

the at

each

the

valve

worn

guide

the

diameter

end both the

valve

exceeds

in

the

valve

seat.

and

valve

excessively,

the

Item

Clearance of

valve stem in valve guide

Valve guide length outside hole

for

wears

ends.

and

direc-

outside

stem.

the

table

guide.

valve,

Intake

Exhaust

.~.sc

it

-

.

of

at

seat

30

~-

(Dimensions

Material:

Valve

guide

for

reface

proceed

Specifications

Standard

0.055

(0.00217-0.00335)

(0.00276

-0.085

O.o?0-0.100

-0.00394)

18

±0.3

(0.709 ± 0.012)

.

-~

188

wear

as

follows:

Unit·

II

158

in

rnrn)

S53C

removal

and

it

mm

(in)

Service

limit

0.15

(0.0059}

0.20

(0.0079)

;,c

·-'

12•

tool

contact.

by

using

.

wear on

valve

a

If

valve

guide

the

Angle

Valve seat

Valve margin

Sinkage

Width

Item

Valve stem

diameter

Nominal

value

. 30°

0.8 (0.031)

1.4 (0.055)

1.7 (0.067)

8-0.045

Intake

Exhaust

(0315

. -0.00236

-8-0.060

(0 315

. -0.00315

Specifications

Sti!ndard

±0.2

(±0.008) (0.051)

±0.14

(±0.0055)

±0.1

(±0.004)

-0.060

-0.00177)

-0.080

-0.00236)

Repair

limit

1.3

1.6

(0.063)

Reface up to

1.2

{0.047)

-0.1

(-0.004)

-0.15

(-0.0059)

Unit: mm (in.)

Service limit

angle

margin

Engines & Generators

16

valve

·a.

Refacer

Set angle

b.

When

remove

material

the is in.),

Valve Repair

valve gtinder cutter.

c.

When

cutter, uniform valve cutting. reface

the paper cutter

the

of

grinding

valve

less

replace seat

seat

using

seat

the

cutter

placed

and

valve

45

degrees.

the

least

to

properly

and,

than

cutter.

an

excessively

by

or

carefully

pressure

to

After

seat

with seat.

refacer

the

amount

if

the

1.2

the

valve.

using

valve

a

valve

prevent

by

No.400

between

INSPECTION/REPAIR

to

an

Installing

valve,

reface margin

nun

(0.047

a

valve

apply

to

uneven cutting, rotating

sand-

of

worn seat

seat

a

the

intake inserts

Installing exhaust

valve

4

inserts

3

1

(exhause)

(intake)

5

l-Caultking/ 2-Valve 3-Cylinder 4-Valve 5-Caulking

intake

insert tool

head

body

insert

head

guide

ring

valve caulking

d.

If

cut,

30 seat

(0.063 replace replace

sinkage

(0.051

valve Heat

and

dry

P.~;:ess

until

Seat

cylinder

cool

ice.

the

they

the

valve

seat

repair

degree

width

in.)

the

exceeds

in.).

Installation

head valve

Valve

valve

cool

seat

down

Valve

seat

dimensions

width

cutter.

exceeds

dtie

seat.

seat

to

a

seat

may

into

to

(1.30 +g.0008)

is

it

using

If

1.6

to

when

1.3

temperature

sufficiently

be

cooled

cylinder

room

33

temperature.

A

+0.02

0

over-

a

valve

rom

wear,

Also

valve

mm

of

in

Specifications

8 c

41+0.025

0 .

(1.61 +g.00098)

80"C in

liquid

head

Exhaust

to

lOO•C {176"F

ether

or

nitrogen.

and

leave

7.8 ±0.1

(0.307 ± 0.004)

alcohol

the

head

Unit:

2.8

(0.11

Intake

to containing

and

mm

(in.)

0

±0.1

± 0.004)

...

212"F),

seat

17

INSPECTION/REPAIR

Valve

Inspect length

swface

plate

Valve

Spring

(outer) Valve

Spring

(inner) Valve

Spring

Load

compress initial 43

mm

kg(lb)

Springs

and

ge~ge

Item

Free

Squareness

working

(1.69

in)

each

as-installed

SPECIFICATIONS

Length

spring

to

length

spring

48.85 (1.9232)

40.90 (1.60)

0.4/25 (0.016/0.98) max

19

(41.9 ± 2.21)

for

90"test

Standard

± 1

cracks,

length

a11gle

·-·-·--··-·-··--

Unit:

mm

Repair Limit

47.6 (1.874)

39.65 (1.55)

15

(33.08)

against

(in)

and

check

these

valve spring

it

for

squareness,

specifications.

tester

free

Engines & Generators

18

Cylinder

1.

Using measurements

(parallel crankshaft cylinder

locations If

limit, next

Sleeves

a

cylinder

wear

rebore

specified

in

and

transverse

axis}

sleeve

indicated

reaches

the

oversize.

gauge,

two

,directions

at

below.

the

sleeve

INSPECTION/REPAIR

t~ke

on

the

to

the

each

three

repair to

the

ID

Cylinder sleeve ID

Out roundness

Taper

2.

Two

for: and rebor bore accurately

(0.00138·in.)

Machining

sleeves recommended rings

oversizes).

Item

of

oversizes

+0.25 ing,

to

are

Specifications

Standard

84

+0.035

0

(3.307~.00138)

Q.ot5

(0.00059),

max

0.05

(0.0020),

max

are

and

+0.5

0.01969 be

the

within

the

to

the

specified

sure

or

bores

same

in.).

to

plus minus

of oversize

(Pistons

available

for

Unit: mm (in.)

Repair

limit

+0.20

(+0.008)

Service

limit

0.7

(0.028)

provided

mm(0.00984

After

hone

the

oversize

0.035mm 0

mm.

all

four

and

piston

the

two

is

. NOTE: Cylinder sleeve installed must

gasketed

I

surface.

surface

.1

(

:

·the block

Crankcase

~~~\l

~

1

2

:

3

\1'

Positions

:

I

for

Jt~

checking

sleeve

be

flush with,

bore

diameter

3.

If

any

sleeve worn, which rebored

maximum ensure oversize

(NOTE: with missible In

determine

the

perfect

If

the

these

on

wear

bore.

wear

to

necessary,

sleeve'

the

noted.

the

rebuild

cases,

hone

bore

the

basis

roundness

cylinder

far

be

the

is

This

less the

sure

bore

unevenly

oversize

to

of

the

will

in

the

sleeves

than

engine

to

remove

be

19

are the with

ream

Removing

found

repair

ridge

in

limit,

good

replacement-piston

off

any

the

glossy

ridge

surface.)

with

ridge

condition.

it

1s

and,

reamer

per-

rings.

as

Pistons

1.

Pistons

Inspect

abnormal surface; and fusion.

grooves

sloped

pistons

2.

Piston

Using each listed

radial tion· diameter

mined

and

Piston_Rings

each

evidence

for

wear.

found

clearance

a

piston

below

clearance

by

referring

of

in

piston

wear

of

cracks

of

Examine

stepped

Replace

in

bad

in

micrometer,

at

the

and

at

its

the

its

at

the

melting

condition.

the

compute

each

to

sleeve

for

the

wear

positions

the

any

sliding

crown

or

ring

and

those

bore. measure

the

posi-

bore

deter-

text.

·

Item

Standard

0.25 (0.0098)

Diameter (at skirt A) 0.50 (0.0197)

'

Fit in cylinders

oversize

Top

of

land Bottom

ring land Skirt

2nd ring

of

3rd

Specifications

Standard

83.90

84.15 (3.3130)

84.40

0.545 ~ 0.610

(0.02146 ~ 0.02402)

0.425 ~ 0.490

(0.01673 ~ 0.01929)

o.245

(0.00965 ~ 0.01220)

0.085

(0.00335

Unit:

(3.3031)

(3.3228)

~0.310

~

0.150

~

0.00591)

mm

(in.)

Service

limit

-0.2

(-0.008)

B

-+-~---~~A

--t::::._l-

B

20

3.

Replacing Replace one

if

the

service

pistons

the the

variance

pistons limit. the

cylinder

on

the

in

a

particular

convenient

pistons.

the

piston

measurement

limit.

have

must

It

is

number

piston

identification.

INSPECTION/REPAIR

with

exceeds

When

to

be

replaced,

in

weight

not

exceed

recommended

be

stamped

selected

cylinder

for

a new

any

among

the

that

use

for

Fron't

.of

t

engine

4.

When bored pistons

same be

used. sizes rings:

+

o.somm

variance

pistons grams

Piston

Always

before

piston. cylinder

piston.

gauge.

the

cylinder

to

and

the

piston

oversize

There for +0.25

pistons

mm(0.00984in.)

(0.01969

in

per

engine

(~O.loz)

ring

gaps.

check

assembling

Insert

squarely

Check

Piston

sleeves

oversize,

rings

dimension

are

weight

should

max.

piston

rings

by

gaps

Item

ring gap

two

and

in.).

among

r

~ng

r1ngs

with

of should

over-

piston

be

into

using

feeler

are the the

and

The

the

~3

gaps

on

the

a

Specifications

Standard

0.30

(0.0118

Piston

Checking

~o.5o

-0.0197)

weight

/

ring

piston

Unit· mm (in )

Service limit

1.5

(0.059)

Piston

ring

weight

marking

gap

s.

Piston

Insert rings the

clearance

(A)

ring

the

of

grooves;

•

grooves.

compression

known

measure

with

Fit

in ring

grooves

thicknesses

a

feeler

Item

1 compression

No. ring

No. 2 compression ring Oil ring

and

the

oil

into

side

gauge

Specifications

21

Unit· mm (in l

Standard

0.050-0.080

(0.00197-

O.Q25

(0.00098 - 0.00236) (0.0059)

0.00315)

- 0.060

Repair limit

0.20

(0.0079)

0.15

6.

7.

Piston

Piston Piston

1.

Replacing If

the

gap

width

dard

value,

important,

service

Check

the referring follows.

Pins,

Bushings

Check pin

the

boss

puting

the

two

taken

in

on

the

difference

the

repair

piston

Item

Piston pin diameter

piston

rings

will

provided

limit

bosses.

piston

to

Piston

of

the

difference

diameter

the

boss.

(clearance)

limit,

Specifications

are

exceed

but

is

the

clearance

the

If

with

25

0·984

<

rings.

replaced,

this

not

exceeded.

text

Bosses

piston

readings, and

the

replace

a new

Standard

0

-0.006 _g.00024)

INSPECTION/REPAIR

the

stan-

is

not

that

bosses

computed

Unit:

the

by

which

and

in

the

by

com-

between

one

other

exceeds

the

one.

mm

(in )

Repair

limit

Use a

micrometer

bushing

and

to

measure

piston

EB

piston

2.

Check end

two

the

of

diameter exceeds whichever

clearance

the

is

connecting

readings.

repair

badly

of

rod

limit,

worn.

the

by

If

the

in

the

computing

computed

replace

Piston pin boss

ID

Piston pin clearance in piston pin

boss

Piston pin bushingiD

Piston pin clearance

in piston pin bushing

bushing

the

fitted

difference

the

Item Standard

or

Specifications

25

(0.984

0-0.016

(0-

25

(0

984+0'.00177)

• -0.00079

0.020-0.051 (0.00079-

to

the

small

between

(clearance)

the

+0.010

0

~.00039)

0.00063)

+0.045

-0.020

0.00201)

bushing,

Unit·

mm

Repair

limit

0.05·

(0.0020)

0.08

(0.0031)

the

(in

)

22

INSPECTION/REPAIR

Connecting

Bearings

1.

Check

evidence cracks small

the

in

the

Mount

2.

the check

shown

a

twisted bearing small

must

of a press.

Rod

the

connecting

of

in

the

and

large

:rod

if

fillets.

each

connecting

for

in

bend

the

connecting

is

end

bushing.

be

corrected

Alignment

cracks,

fillets

ends.

any

crack

connecting

:rod

aligner

and

illustrations.

not

trued

with

:rod

especially

of

Replace

is

noted

:rod

twist,

rod,

to

Such

a

the

and

for its

in

and

as

In the the rod use

tJ//ignii1!J

tool

Checking

Check melting. Replace

Checking

connecting

the

conriecting roooearings

if

faulty.

connecting

CHECK

CHECK CLEARANCE

rod

for

FOR

BEND

BIG

END

for

bend

for-peeling,

twist

OR

TWIST.

THRUST

burning,

3.

If

a

connecting

not

available,

checked

a.

To

measure

figure

measurement

than

(0.00197in. of with-the

as

check

!,

the

follows:

the

C

and

a

above.

at

0.

05mrn

per

straighten

use

of

rod

l

-per

rod

as

c

3.937

a

aligner

may

for

shown

If

is

greater

the

press.

is

be

bend,

in

the

lOOmrn

in.)

rod

a.

Checking

ing

rod

Checking

the

for

connect-

bend

o.os

TOO

b.

connecting

Checking

ing

rod

for

the

connect-

twist

Engines & Generators

23

b.

4.

To

place plate round

diameter

large measurements difference measurements

ness

To

check measure b.

1s

If·

greater

lOOmm

3.937in.)

rod.

check

the

as

bar

end

of

the

rod

f

as

shown

the

measurement

than

(0.00197in.

of

,e_,

-

the

rod

shown

on

below,

of

into

and

bore

at

A between tells

rod.

with

the

through

and

the

INSPECTION/REPAIR

for

twist,

in

figure

at

c

o.

osmm

per

correct

a

insert crankpin

and

B.

the

straight-

per the

piston,

sur

face

its

take

The

two

a

When

rods new

in within specification.

s.

Check

play

Tighten

S.Skg-m

feeler.

end clearance

and

clearance

service necting

one

are

rods

weight

as

or

to

be

so

among

the

value

Specification

Variance in weight among connecting rods

the

connecting

follows:

·

the

(39.8

Gauge

play

end

between

crank

measured limit, rod

or

more replaced,

that

capscrews

lb-ft).

to

arm)

•

replace bearing.

connecting

select

the

variance

the

given

Unit: gram (oz)

rods

in

rod

Use

measure

play

the

large

If

exceeds

the

end

to

the

(the

end

the the

con-

is

a

Checking

connecting

rod

on

surface

plate

Specifications

Item

Connecting rod end play

Standard

0.15-0.35

(0.0059-

0.0138)

Unit:

mm (in.)

Service

limit

0.50

(0.0197)

Engines &'Generators

24

6.

Check a.

Inspect

scratches the be

b.

Check

the clearance, ground undersize.

the

bearings

each

bore.

repaired

the

repair

to

bearing

by

imbedded

Determine

or

replaced.

radial

limit

replace

the

INSPECTION/REPAIR

as

follows:

for-

dirt

by

clearance

specified

the

bearing.

undersize,

evidence

particles

inspection

between

below

use

of

wiping

and

whether

crankpin

is

exceeded

Where

a

replacement

or

improper

the

fatigue

bearing

and

bearing;

by

crankpin

bearing

failure,

seating

the

is

on

should

if

checked

to

be

of

that

The

(0.

01969in.)

two

bearing

•

Crankpin diameter

Radial clearance between bearing and crankpin

undersizes

Item

D=

are

Specifications

Standard

58-0.035

-0.055

(2

283

-0.00138)

. -0.00217

0.035-0.100

(0.00138-

Dl + 02

2

Q.25mm

0.00394)

Unit:

(0.00787)

(0.00984in.)

mm

(in.)

Repair

limit

0.20

(0.008)

0.200

and

o.somm

Positions

bearing

for

with a micrometer

measuring

25

connecting

rod

c.

Check

the

on

the operating crankshaft

bench, paste Prussian

the

tighten

the S.Skg-m conta.ct 75%

if

the

contact

connecting-rod

the

cr

ankpin

large

position

and of

blue

contact.

the

specified

(39.8lb-ft).

should

of

the

not,

replace

end

laid

by red

to

Be

capscrews

torque,

entire

the

pattern

bearing

by

placing

into

with

out

applying

lead visualize

sure

occur

surface; bearing.

INSPECTION/REPAIR

of

its

the

on

a a

or

to to

The

over

(NOTE: eliminated tolerance a

replacement

specified

d.

Check crush.

loose

excessive

replaced.

0.

04mm

will

350kg scribed. the some securing without might resulting loading ing,

failure.

Check

crush the large the to

S.Skg-m

The

above

where

and

the

extent

each

bearing

Shells

in

the

A

(.

0016in.),

yield

(772lb.),

As

main

crush

is

a

which

roll

or

in

and

burning

to

be

disappears

bearing

end

capscrews

job the

bearing

of

contact).

found

bore

or

crush

to

a

in

the

bearing

needed

proper

the

jump

localized

consequent

or

sure

cap

to

positively

are

(39.8

lb-ft).

of

checking

crankpin

has

is

precis

shell

for

to

have

must

of

up which

load

is

pre-

case

shells,

for

fit,

bearing

in

place,

over-

flak-

fatigue

that

to

rna

allow

te

the

when

tightened

been

be an be to

of of

the

contact

is

ground

replaced.

ion-finished

Connecting

to

pattern

the

This

to

rod

bearing

may

specified

is

because

ensure

Crush:O

the

(0.0016

crush

be

to

0.04

in.)

mm

26

Crankcase

1.

Inspect

sur cracking. cylinder rusting, abnormal

straightedge,

face head) with

(for

for

2.

Make the the If reface

face within

faces

(for

,

front

mating

flatness.

sure crankcase standard

the

grinder

the

outside

for

Visually

bores

erosion

wear.

mating

plate)

with

that

standard

top

specified

·evidence examine

for

check

with

face

(for

and

rear

the

top

is

flat

specified

is

by

using

to

make

INSPECTION/REPAIR

and

inside

of

the

scuffing,

or

Using

the

cylinder

rear

exceeded,

it

standard.

mating

face

plate)

face

within below.

a

surflat

any

top

of

a

Checking

crankcase

top

for

flatness

-

STRAIGHT

EDGE

Warpage

gasketed surface

Crankshaft

1.

Journals

a.

Inspect surface roughing, and sary, grinding size

crankshaft.

b.

Measure micrometer

four the taper any

exceeded,

to replace

Specifications

Item

of

crankcase

each

flaws

scratches,

burns,

and,

repair

to

the

or

each

(take

readings)

wear,

out-of-round

(cylindricality).

of

the

repair

the

crankshaft.

Standard

0.05, max. (0.0020)

journal

the

journals

journal

a

to

limits

by

undersize

Unit: mm (in.)

Repair

limit

0.2mm (0.008)

such

pitting

as

necesunder-

with

total

determine

grinding

for

as

by

the

of

and

If

are

or

A-

8-

Checking

a

Positions

crankcase

for

with a micrometer

measuring

top

for

flatness

journal

27

INSPECTION/REPAIR

2.

(NOTE: of still

(0.

008 are of o.03mm

journals

If

main

bearings

in

in.)

used,

roundness

(0.0012in.),

to

the

even

or

excess if

the

Crankpins

a.

Inspect

each surface roughing, and

burrs1 pins, grinding size

or

as

to

replace

crankshaft.

b.

Using a micrometer, readings) any

of

the

undersize

or

fit

or

on

if

new

the

taper

is

not

flaws

scratches,

repair

necess·aty,

the

to

determine

limits

replace

clearance

journals

of

0.2mm

bearings

or

less

grind

undersize).

such

pitting

the

c~ank

measure

the

is

exceeded,

the

crankshaft.

is

out

than

the

for

as

by

each

wear,

crankpin

out-of-round

repair

by

(take

a and

grinding

total

taper.

to

of

the

four

If

Diameter

journal

Out

ness

pins and journals Taper

pin~

Diameter crank pin

Fit in main bearings

of

round-

of

crank·

of

crank·

.!Jld Journals

of

journals

Specifications

65-0.015

-0.035

(2

559-0.00059

. -0.00138

o.m

(o.ooo4),

max (0.0012)

···-

---

-o.o35

58

-0.055

(

ro.oot3s)

28

2

. -0.00217

0,03-0.089

(0.0012-

0.00350)

Unit: mm (in,)

Repair

limit

-0.15

{-0.0059)

0.03

-0.20

(-0.008)

0.2

(0.0079)

Uneven

wear:

0.03

(0.0012)

Service

limit

-0.9

(-0.035)

28

c.

Grinding The

dimension than

the

crankshaft·

smaller

the

undersize

INSPECTION/REPAIR

crankshaft.

journals

by

of

and

0.100 bearings

crankpins

.teO

0~120mm

to

be

must

(0.00394

used.

be

refinished

to

0.00472in.)

to

a

Example:

When

the

Too

crankshaft bearing

failure.

Be

extremely

the

desired

corrected occurs, clearance.

grinding

same

small

to

only

it

will

If

0.50mm

be

used:

The

journals

65-0.5-(0.100

(0.01969in.)

must

to

[2.55905-0.01969-(0.00394

The

crankpins

58-0.5-(0.100

must

to

[2.28346-0.01969-(0.00394

the

crankpins

fillet

a

radius

while

ride

radius

of

too

on

the

(shoulder

fillet

large

radius

CAUTION

careful

dimension.

by

not

grinding

present

to

grind

An

over-ground

off

problems

be

0.120)

be

0.120)

and

will

a

fillet

and

off

the

in

undersize

refinished

to

refinished

to

journals,

radius)

result

thereby

the

radius

shoulder

obtaining

to

0.00472in.) to

0.00472in.)

be

sure

as

the

in

fatigue/failure

radius

result

radius

part

face.

a

bearings

to

original

will

in

part

can

If

proper

are

reproduce

cause

a

bearing

beyond

be

this

end

to

one.

of

the

3.

Also

have ness

re-harden

journals, cracks magnaflux particle)

End

Play.

Check

play,

thickness bearing. reached plate.

Journal for

bearing

width

thrust

check

a

Number.

the

as

Item

the

hardness

the

and

by

(magnetic

test.

crankshaft

shown,

guage

If

replace

Specifications

(0.00394-

crankpin

of

If

necessary,

crankpins

check conducting

by

at

the

limit

the

Standard

0.100-0.189

0.00744) (0.012)

620

them

for

using

thrust thrust

Unit:

and

or

and

for

end

is

mm

(in.)

Repair

limit

0.3

journals

more

a

for

hardness.

according

Undersize Journals

0.25

(0.0098)

0.50

(0.0197}

Checking

to

the

Specifications

75-0.015 (2 54921-0.00059)

64

. -0.035 . -0.00138

64 5 -0.015 (2 53937-0.00059)

. -0.035 . -0.00138

crankshaft

They

Vickers

to

be refinished

end

should

Unit:

play

Hard-

mm

to

(in.)

29

INSPECTION/REPAIR

The

end. ence bearing ca

ted

4.

Runout Support

and deflection Distortion deflection

if reduce crankshaft

play

between

and

below:

rqll

it

Item

Crankshaft

is

due

the

dimension

the

crankshaft it with

is

(dial

exceeds

it

by

in a press.

Specifications

runout

to

the

width

to

measure

a

dial

one-half

gauge

the

bending

Standard

0.02

(0.0008)

differ-

of

thrust

(A)

indi-

as

shown

gauge.

on reading:) standard,

Unit: mm (in.)

Repair

limit

0.5

(0.020)

its

the

Journal

A

width

for

thrust

bearing

s.

Main

Inspect evidence

failure,

bedded

improper

tion,

bearing

not.

Check will

reassembly specified The

follows:

Bearing

(bearing

be

checking

each

of

scratches

dirt

seating

cap).

determine

should

each

main

installed

to

radial

main

w1p1ng

particles

on

Upon

be

bearing

during

determine

procedure

bearing

or

from

the

whether

replaced

clearance.

for

fatigue

imand

bore

inspec-

the

that

engine

the

is

or

as

Checking

Measuring

crankshaft

main

for

bearing

runout

ID

Engines

30

& Generators

INSPECTION/REPAIR

Install

the

crankcase,

crankshaft,

bearing

bolts

and two indicated

Measure

cap

to

8.5

measure

positions,

in

the

micrometer.

readings,

clearance~

Item

Fit

of

main

bearings

journals

Check

for

loose

on

each

crush.

in

compute

Specifications Unit: mm (in.)

the

excessive

replaced.

0.

04mm

yield

(1103lb),

(0.

0016in.)

a

is

main

bearings

without

securing

by

tightening

kg-m

the

(61.5

diameter

(A)

and

illustration.

journal

From

the

Standard

o.m

{0.0012-

-o.089

0.0035) (0.008)

main-bearing

Shells

bore

crush

A

crush

load

or

;-

must

of

which

of

recommended.

(B),

with

Repair

that

have

the

each

the

lb-ft)

from

these

radial

limit

0.2

shell

are

up

will

SOOkg

in

as

a

an be to

Positions

for

Main

measurinq

bearing

main

crush

bearing

Crush:

0-0.04

mm

Camshaft

Check

1. Where plate.

2.

Inspect camshaft disrepair.

3.

Using

(cam ween limit,

the

must

a

micrometer,

height)

Dl

and

replace

camshaft

end

play

camshaft

be

and

02. the

end

exceeds

Item

Camshaft end

play

journals

replaced

measure

D2

(diameter),

If

this

camshaft.

play

the

Specifications

Nominal

value

5.0

(0.197)

if

any

each

difference

as

outlined

repair

Standard

0.05-0.112 (0.00197-

0.00441)

for

of

cam

then

limit,

Unit: mm

Repair

{0.012)

abnormal

the

three

of

the

compute

is

for

(in.)

limit

0.3

wear

less

the

replace

and

journals

camshaft

the

difference

than

timing

the

damage;

is

to

the

gears. thrust

found

read

service

the

in

Dl

bet-

Engines & Generators

31

INSPECTION/REPAIR

4.

Item

lntalce

cam profile

Exhaust cam profile

Check

(o,

f¥'

02

the Straighten press necessary.

Item

Camshaft runout

-02)

camshaft

or

Specifications

Standard

Dt:

46.916

:gj

(1

84

708

+0.00394)

.

-0.01181

Ot -D2

Dt:

(l

Dt -D2

45.944 80882

.

= 6.684

(0.2631 5)

:gJ

+0.00394)

-0.01181

= 7.344

(0.28913)

for

the

camshaft

replace

Specifications

Standard

0.02 (0.0008), 0.05

max.

Unit: mm (in.)

· Repair limit

Dt-

02"'

6.184

(0.24346)

Dt-

02

6.844

(0.26945)

runout.

in

it,

(0.0020)

as

Service

limit

CHECKING

:·

=

a

CHECKING

·

INTAKE

. -

CAMSHAFT

AND

EXHAUST

RUNOUT.

CAM

CAMSHAFT

s.

Measure

journal compute

in

the

6.

Use a micrometer

ID

of bosses each

exceeds

machine

bushings.

Item

Fit

of

camshaft

holes on journals {0.00157

the in

the

camshaft

respective

and

compute

journal.

the

diameter

two

directions

fit

or

hole.

to

If

repair

holes

Specif'JCations

0.040-

and

St-andard

-0.00354)

of

clearance

measure

camshaft

the

fit

the

limit,

install

Unit: mm (in.)

0.090

each

to

the

on

fit

Repair

limit

0.15

(0.0059)

MEASURING

CAMSHAFT

JOURNALS.

32

COMPUTING

THE

CAMSHAFT

FIT

INSPECTION/REPAIR

Tappets

1.

Inspect and

2.

Check

repair exceeded, an case

Flywheel

and

Tappet

the

cracks.

the

limit

excessive

must

and

Ring

riding

Replace

fit

replace

radial

be

replaced.

Gear

Holes.

of

in

the

Fit on tappets

Tappet hole diameter

face

defective

the

tappet

chart

the

tappet.

clearance,

Item

of

holes

of

each

tappets.

in

indicated

even

Specifications

Standard

O.Q3S- 0.098

(0.00138-

0.00386)

22 (0.87)

tappet

the

If

the

with

Repair Service

limit

0.13

(0.005

1)

for

hole

below.

hole

a new

Unit:

mm (in.l

limit

+O.lO(hole)

(+0.0039)

+0.10

{+0.0039)

wear,

and is

worn,

contact

confirm

If

tappet,

with

the

limit

resulting

the

pattern

the

is in

crank-

1.

Check pin

2.

Check other

3.

Check

teeth it

Timing

1.

Check condition

2.

Check when when

the

for

the

defects.

the

are

with

Gear

the

stated

excessive

flywheel

proper

threads

ring

defective,

a new

Case

timing

of

oil

conditions

fit.

gear

one.

and

the

seal

oil

for

of

Replace

for

remove

Oil

gear

dowel

for

leaks

cracks

the

broken

Seal.

case

are

flywheel

bolts

or

the

for

holes.

excessive

present.

from

the

and

the

retaining

as

excessively

gear

signs

wear

crankshaft

needed.

from

the

of

and

Closely

bolts

worn

flywheel

cracks

defects;

inspect

end.

flywheel

for

teeth.

and

inspect

the

stretch

and

replace

oil

dowel

If

seal

and

the

it

33

Timing

1.

It backlash the

is backlash gear. place between

Gears.

is

repair

exceeded,

a

Item

important

in

each

limit.

by

replacing

To

feeler

two

gear

Specifications

mesh

reduce

measure

gauge

teeth.

Standard

that

is

If

the

backlash,

Unit: mm (in.)

INSPECTION/REPAIR

the

within

limit

the

worn

squarely

Repair

limit

2.

Check

tween

shaft

micrometer.

clearance taken is bushing.

3.

Check thickness thrust play reading limit.

Backlash

Item

Fit

of

shaft

in

idler

bushing

0.12-0.24

the

by

(0.0047-

radial

idler

measuring

0.0095)

clearance

bushing

Compute

from

and,

if

exceeded,

Specifications

Nominal

36

(1.417) (0.00098 ~ 0.0029 5) (0.004)

the

idler

gauge.

plate

if

the

exceeds

the

repair

replace

Standard

O.D25

~oms

end

play

Replace

to

reduce

thickness

the

0.3

(0.012)

be-

and

with

the

readings

limit

the

Unit: mm (in.)

Repair

limit

0.1

with

the the

gauge

repair

a

Specifications Unit: mm (in.)

Item Standard

Idler end play

0-0.1

(0

-0.004)

Repair

limit

0.35

. (0.0138)

Engines & Generators

34

Checking

idler

end

play

4.

5.

If

the replaced, puller

illustrated. the

replacement

holes

must

Inspect

follows:

a.

Camshaft Replace

show excessive keyway

disfigured.

that

the mounted no

more

(0.

0157

end

play,

If

the

repair

thrust this to

the

Item Standard

Camshaft end play

idler

use

for

be

properly

the

gear.

the

evidence

wear,

is

camshaft

on

the

end

in.)

use reading limit,

plate

gear

camshaft).

Specifications

(0.00197-

shaft

the

idler

removal,

When

shaft,

timing

gear

of

galled,

Make camshaft,

play

To

a

exceeds

replace

is

shrink-fitted

0.05-

INSPECTION/REPAIR

must

installing

the

aligned.

gear

if

flaking

or

if

worn

certain

gear,

than

check

dial

(Important:

Unit: mm (in.)

0.112

0.00441)

be

shaft

as

oil

as

teeth

or

the

or

when

has

0.4mm the

gauge.

the the

Repair

limit

0.3

(0.012)

Removing

!-Crankcase 2-Puller

3-S

tud

4-Idler 5-Nut

Idler

Part

idler

(HlO)

shaft

5

shaft

#36515

shaft

_l)==="o=:

puller

6.

b.

Injection Inspect

bolt

c.

Crankshaft Replace

tact,

d.

Idler Inspect gear.

Inspect at

the replaced. the

and

surface

key

pump

the

holes.

the

excessive

gear.

the

gear

part

ahead

Inspect

in

for

wear.

gear

Replace

gear.

gear

idler

contact

drive

teeth

if

wear

case

of

the

Replace

gear.

for

the

teeth

or

gear

for

the

crankshaft·

with

damage

gear

if

show

other

teeth

defects.

and,

cracks

crankshaft.

the

pulley

and

observed

signs

when

and

for

pulley.

,.oil

if

condition

of

necessary,

evidence

A

seal

found

to

be

defective

cracked

Examine

and

check

defective.

of

the

damaged.

tooth

replace

of

oil

case

condition

the

mounting

con-

the

leakage

must

be of

keyway

35

ENGINE

ASSEMBLY

GENERAL

•

Be bolts

•

During are correct pistons,

•

Apply Insure rotate excessive

•

If

reference

•

Use

•

Tighten

to

•

When bolts

•

Most make

Torquing

Prevent three yield torqued brought center damaged care.

INFORMATION

careful

not

are

used

assembly,

being

assembled

direction

piston

lubricating

that moving parts,

or

slide

tension.

there

are

mating

them

new

gaskets,

the

bolts

specified

steps-1/2, bolts

bolts

See

torques

required,

and

gaskets.

gaskets

certain

Hardware

mechanical

and

rocker

as

indicated.

down

in

out.

during

TORQUE

to

mix

bolts

and

nuts.

Metric

and

on

various

in

rings,

and

correctly for

and

use

and

they

damage

213,

and

very

Gaskets,

assembly,

SPECIFICATIONS

engine

assemblies.

recheck

oil

are

lockwashers, 0-rings,

Refrain

many

are

The latter-rocker shaft fasteners-should

clearances

in

their proper order

relation

marks

using a liquid

arm small

to

bearings

to

moving

when

not subject

scribed

assembly.

nuts

on

reliable

sealants

from

bolt

washers

positioned

by

running

111

torque.

shaft

fasteners.

increments,

especially

they

should

the and

important parts of the engine

and

insure that and

engine

block,

bearing

parts

assembled

to

during

using

properly.

Exceptions are torque-to-

head

during

binding

disassembly,

packings

torque

when

required

tape

are

asymmetrical,

·fasteners

The

working

gaskets,

be

positioned

thru

caps.

assembly.

on

or

wrench.

sealants.

former

out

S.A.E.

facing

such

the

engine,

down

from

might

this

manual.

and

on

are

the

with

parts in

the

as,

seals.

nuts,

in

be

great

.

be

Bolts

and

Fasteners

Lightly them. should

When LOCITIE

LITHIUM bearings

Antiseize LOCITIE protect threaded come locking

Heavily use

Sealants

Oil excellent any coating gaskets

LOCTITE

hoses

Coat

SILICONE

When

passages,

oil

Bolts

be

assembling

apart

according

oil

clean

based

all

joint

in of and

and

both

mstalling

head

bolts

and

other

plugs

sealed

with

PERMA1EX

the

flywheel,

blue.

based

grease

and

stuffing

compounds

when

all

engine

and

PERMA1EX

purpose sealers.

contact

oil

or UQUID 1EFLON

o-rings.

hydraulic

the

oil

surfaces of

SEALER.

coat

both

boxes.

and

necessary.

to the job.

sliding

and

oil.

Lubricants

#2

with

red sealant

filter

assembly.

the

gaskets

that

sides

other

fasteners

that

coat the bolt

is

waterproof,

thread

components

LOCTIIE

reciprocating

and

its

They

coolant,

oil

with

raw

should

pan

gasket

seal

around

WHITE

as

penetrate the

#2 or

IDGH

ideal

locking

IDGH

are

effective

water,

can

be

with

SIUCONE

adhesives

yet

offers

components,

TACK

oil,

used

water

you

assemble

water

jacket

TACK.

threads

for

allow

high

with

water

pump

such

them

levels

of

always

equivalent

in

just about or fuel. A light on

rubber

on

oil

adapter

temp

(coolant)

GREASE.

as

to

are

RED

Do

not

use

sealant

HIGH-COPPER ing a gasket

Specialized applications is

particularly

resists

NOTE:

fitting

in

position

gasket

requiring

effective

fuel,

oil , and

TAPE

SEALANTS

that

connect water coolant

when

installing a new

ADHESIVE

during

sealers

such

non-hardening

on

copper

water.

should

SPRAYS

assembly.

as

HYLOMAR

properties.

cylinder-head

be

used

passages.

gasket.

are

useful

on

pipe plugs

for

hold-

work

well

HYLOMAR

gaskets

and

in

Engines & Generators

36

1.

Reassemble and

a.

b.

piston

Press

of

the

Ensure

bushing

Heat

to

(212"F

piston

between

small

into and

boss piston

inserting

piston.

the

as

follows:

bushing

connecting

that

and

end

of

and

piston

connecting

into

the

oil

rod

are

on

a

1oo·c

248•F).

connecting

connect

ENGINE

ASSEMBLY

rod

small-end

rod.

holes.

in

aligned.

hot

plate

and

12o·c

Install

rod

piston

by

slowly

into

Combustion chamber

side

'-------

-+Camshaft side

(NOTE:

one

end

Install to

cylinder

face combustion the

from assembly crankshaft.

Insert

in

the

piston

the

snap

advance.)

the

connecting

piston

number

camshaft

chamber

will

camshaft

is

installed

so

ring

that

side

and side

face

when

on

into

rod the

will

the

of

away

the

Piston

and

connecting

rod

Stamped cylinder

number

side

assembly

Engines & Generators

37

c.

Install arid shown right, ring

compression

oi

1

control

in

illust~ation

using

expanding

standard

tool.

ENGINE

ASSEMBLY

rings

ring

at

as

top

piston

1

(NOTE:

marked

sure piston its illustration

d.

2.

Reassemble

follows:

that

groove,

Install ring in

illustration

right.

No.

on

this

crown

and

2

ring

its

top

side

when

as

at

center

No.· 3

expander

the

has

side.

faces

installed

shown

right.}

oil

control

as

at

crankcase

an

Be

the

in in

shown

bottom

as

R

This

1-Compression

2-0il

mark

faces

control

the

rings

ring

piston

2

crown

a.

Driving

Press

ings in adapter

exceeds

machine

install

Make

certain

the

cam

bushings

the

oil

ports

Driving

three

(1}

into

crankcase

(A}. the

the

new

bushings.)

the

oil

align

in

the

crankcase.

in

camshaft

(If

repair

holes

in

with

A

by

the

bushing

bushholes using

fit

limit,

and

Oil

1

control

ring

and

expander

installed

b.

Drive

crankcase

c.

Lightly

the

main Securely with

(B)

idler

•

crankpins

bearings

the

shaft

by

using.

apply

engage crankpins.

engine

and the

INSPECTION/REPAIR

(2)

into

installer

oil

to

install

(upper).

bearings

3.

Install

follows:

Install bearing

of

engine

face

external

Position

ring relation shown. assembly

Alignment

necting

camshaft

capscrews advance. assembly the installing

installed

of

connecting

of

gaps

aid

(NOTE:

engine

the

piston

upper

(1)

oil

to

bearing

periphery

piston

are to Then (2)

marks rod side.

(3)

into

of

tool.

Piston/rod

from

block.)

connecting-rod

in

to

the

rod.

the

internal

rings

located

each

insert

into

on

must

Put

into

Insert

its

cylinder

a

crankshaft

assembly

large

and

on

of

piston.

so

90"

other,

piston

crankcase.

the

face

attaching

rod

piston

piston/ring

assembly

as

end

Apply

sur-

the

that

in

as

con-

the

in

with

is

side

Precombustion

No.1

chamber

ring

side

gap

1-w-/WESTERBEKE

. l Engines & Generators

39

ENGINE

ASSEMBLY

4.

5.

Install

follows:

a.

Install two crankshaft

crankshaft

suitable

b.

Install

crankcase.

Install as

follows:

a.

Apply

crankshaft pins, crankshaft case main

bearing

center

the it

crankcase.

the

thrust

woodruff

hollow crankshaft

the

engine

and

securely.

bearing

cap

and

cap

in

with

dowel

crankshaft

keys

and

gear

main

journals

into

rear)

place

plate

(2) drive

(3)

drift

bearing

oil

install

the

Attach

(1)

(2)

and by

(lf

and

to

the

by

using

(A).

to

the

caps

to

the and

the

crank-

lower

to

main

(front,

install

aligning

(A)

as

on

6.

b.

Measure

play

Replace

the cification. bearing

torque

lb-ft)

(NOTE: ensure resistance

Install bearing

a.

Install

bearing apply internal

bearing. cap on

(A)

end

with

the

on

with

No.1

of

Rotate

no

the

caps

lower

engine

cap the

the

play

capscrews

(2)

crankshaft

a

thickness

main

is

Tighten

8. 5 kg-m

crankshaft

unusual

occurs.)

connecting

as

follows:

connecting-rod

into

surface

Then

the

matching

aligned

rod.

bearing

out

binding

cap

oi

1

install

of

(3)

(61.463

(1)

to

of

with

end

gauge.

if

spe-

main

to

to or

rod

and

the the

the mark mark

a

Engines & Generators

40

b.

Tighten clamping

s.s

kg-m

connecting

nuts

(39.771

to

ENGINE

a

torque

lb-ft)

ASSEMBLY

rod

of

7.

(NOTE:

Install

gaskets a.

Install external bearing

with

inside

b.

Apply

cement pan

to that tely

(A)

Rotate

the

as

follows:

retainers

peripheries

caps

the

gasket crankcase.

the

attached

in

of

good

on

the

flange

the

both

gasket

the

retainers

No.1

case.

quality

(2)

in

caps.

crankshaft.)

(l)

to

of

and

facing

gasket

sides

and

the

attach

Make

is

of

complegrooves

main

No.

sure

and

the

3,

the

oil

it

c.

Apply

ends

·and cap.

gasket

of

insert

rubber

the

cement

packing

to

both

(3)

into

8.

d.

Install end clean internal

(1}

(2}

aligner.

e.

Apply

tip

into holes Tighten torque lb-ft}.

Install

follows:

a.

Apply

sides packing packing crankcase. plate pump

(2).

of

(15. 2 lb-ft}.

sleeve

of

engine

and

secure

by

gasket

of

bolts

the

in

the

gasket

of

to

(1)

fastened

The

the

onto

crankshaft.

oil

surface

it

using

four

the

of

the

and

the

tightening

bolts

an

cement

(3}

through-bolt

bearing

bolts

0.4kg-m

front

cement

front attach

front

Secure

with

by

is

ENGINE

the

Apply

to

of

oil

with

as

bolts

oil

to

they

to

plate

to

plate

face

front

injection

two

bolts

torque

2.1

ASSEMBLY

rear

the

seal seal

the fit

cap.

a

(2.9

as

both

the

of

kg-m

b •

c.

Apply

the bushings.

install engine

HeaHhe betWeen and

fit

gear

a

camshaft

150 C and

to

the

shaft.

ligh~

the

block.

gear

on a hot

180

C (

film

journals

Then

camshaft

plate

to

342 F-396

of

oil

carefully

into

i=)

to

and

42

d.

Tighten plate

access and

machined

gear.

to

crankcase,

to

securing

holes

camshaft

the

thrust

bolts

in

ENGINE

ASSEMBLY

thrust

ga1n1ng

plate

through

camshaft

9.

10.

Install follows:

a.

Install

rna

tching

each

Install as

follows:

a.

Install

the hole mesh with gear.

b.

Install strainer bearing piece both. of

(4)

the

by

the

gear.

the

oil

in

the

(3)

Install

stay

bolts

idler

the

timing

oi

1 pump

oil

pump

the

pump

camshaft

one

end

stay

cap

inserted

to

(5).

gear

assembly

(1)

installation

crankcase

drive

pump

of

(2)

to

with

the

oil

distance

other

strainer

mark

into

and

gear

drive

the

oil

No.

between

end

as

by on

2

Timing

each

gear

other 1-Camshaft

2-Crankshaft 3-Idler 4-Injection

match

gear

marks

gear

pump

meeting

gear

11.

Install pan

bolts

the

oil

to

pan

0.

7

lb-ft).

and

kg-m

torque

(5

.1

Engines & Generators

43

12.

c.

13.

Install

flywheel

a.

Install

crankshaft

block.

b.

Position

engine dowel

block.

Position

shaft pin.

flywheel tightening torque (61.5

Reassemble

follows: a.

Press

cylinder

in

illustration

the

as

backplate

follows:

dowel

end

back

block

pins

fitting

and

flywheel

using

bolt 8.5 ± 0.5

the

valve

cylinder

head

aligning

Unit~

guide

(1)

pins

and

plate

bolt

on

kg-m (lb--ft)

± 3.6)

head

(2)

as

on

and

in

engine

to

over

to

crank-

dowel

as

into

shown

right.

8

Valve

Install

valve

the

guide b.

Install spring

in spring

to securely. when assembly.

c.

Install holders, exhaust cylinder

guide.

breast

groove.

this

install

guide

installation

stem

of

valve

(5)

order.

with

installing

thermostat,

glow

manifold

head.

55

seal

(3)

Completely

the

seal

(4),

and

retainer

Compress

a

valve valve Install

rocker

plugs

tool

to

in

lifter

cotter

caps ( 8)

nozzle

to

the fit the

valve

(6)

the

(7)

shaft

and

the

1-Cylinder 2-Valve

A-Valve

B-As

installed

head

guide guide

installer

1 9

CylinGer

1-Cylinder

4-valve

cotter

head

5-valve

8-valve

2-valve spring

cap

length:

head

9-combustion

18

mm

asembly

guide

6-Retainer

(0.709

3-stem

chamber

in,)

seal

7-valve

jet

Engines & ·Generators

44

ENGINE

14.

Install assembly

a.

Lay

the with the correctly marked side UP. Install the two guide studs (4) (12mm x 1.50 x 2 inches)

b.

to hold the gasket in position and place the cylinder head (3) onto the block.

Tighten

bolts

(86.8

and

intake shown bolt tion

the

as

new

cylinder head gasket (1) (no sealant required) onto the block (2) surface

to lb-ft)

10.5

side in tightening

cylinder

follows:

the a

cylinder

torque

at

kg-m

in

the

of

exhaust

(76

lb-ft)

the

cylinder

illustra-

12

sequence

.•

EXHAUST

BOLTS

tOto

17

ASSEMBLY

head

kg-m

side

at

head

15.

CYLINDER

Install rocker

a.

Insert

into

b.

Install sembly

c.

Insert pipe

pipe

rocker

porarily

bracket head.

d.

Temporarily

three

pipe

tor.

i/NTAKE

HEAD

the

shafts

the

as

0-rings

(2)

to

threads

union

BOLTS

BOLT

TIGHTENING

as

the

tappets.

rocker

follows:

and

the

shafts.

install

to

nut

1

to

push

follows:

push

(3)

connect

front

the

tighten

on

9 ·

SEQUENCE

rods

shaft

into

the

and

Then

each

cylinder

two

the

and

connec-

and

(1)

as-

oil

oil rear tem-

or

oil

.

e.

Secure brackets bolts sides of

1.5

Tighten

fir

st.

tne

by

at

the

uniformly

kg-m

the

preinstalled

tightening

front

to

(10.85

long

bolts

four

and

rear

a

torque lb-ft)

(4)

Engines & Generators

45

16.

f.

Connect clearance valves

Adjust

in

valve

oil

pipe

to

cold

clearance

ENGINE

to

0.25mm setting.

as

ASSEMBLY

connector

(O.Olin.)

follows:

securely.

for

both

Then

intake

adjust

and

the

exhaust

valve

The

(0.0098in.) mes perature checking

a.

valve

that

Rotate

to

bring

cylinder

(TDC)

accomplished

rocker cylinder. crankshaft,

valve cylinder

the

intake-valve begins exhaust-valve

come clearance of

No.

valve

clearance

for

the

engine

difference

and

the

crankshaft

the

piston

to

Top

•

rocker

crankshaft

up

1

of

This

arms

As

rises:

to

go

all

in

the

cylinder,

No. 3 cylinder.

both

adjusting

Dead

by

you

the

arm

stop

just

rocker

down

rocker

the

usual

specification

intake

is

at

throughout

slowly

in

No.

Center

can

observing

of

turn

way.

No.4

exhaustof

turning

after

arm

manner

intake

and

normal

1

be

the this when

arm has

Under

valve

for

exhaust

temperature,

the

procedure

on

body

this

the

intake

of

No. 2 cylinder,

this

valves.

there

of

is

condition,

and

engine

This

the.·

exhaust

value

being

engine.

as

adjust

and

is

no

follows:

valve

valves

exhaust

0.2Smm assu-,

tem-

The

17.

18.

b.

Turn

there.

No.

valve

Install gasket.

Insfal)..

assembly a.

Install

b.

Install ween below

NOTE:

the

crankshaft

Adjust

4

cylinder,

of

No. 3 cylinder.

the

the as

the

Early

rocker

fresh

follows:

water

the

bypass

manifold

thermostpt.

extruded I assembled

the

pump

one

clearance

exhaust

cover

water

assembly. hose

and

manifolds

complete

valve

and

pump

bet-

tee

_

only.

on

intake

of

rotation

No.

2

(360")

and

exhaust

cylinder,

Coolant

and

by-pass

hold

valves

intake

it o·f

hose

1....-IWES'TERBEKE

(Engines

& Generators

46

19.

20.

Install

(1)

to perly. behind prevent

Install

ey.

front slipping and

througl:l£

the

Use

the

head

oil

front

Take

care

crankshaft

pulley

timing front

sealing

of

leaks.

crankshaft

not

onto

the

·fr,ant

ENGINE

gear

plate

washers

bolt

seal

(2)

pull-

~,0

damage

crankshaft

seal.

ASSEMBLY

case pro-

to

when

Torque:

21. alternator mount

22.

Install as

a.

b.

23.

Install

24.

Install lube

25.

Install

26.

Propulsion: in

Install

follows:

Attach

pulley.

Adjust

to a slack

oil

reverse

295-292

lb-ft

the

mounting

the

alternator:

alternator

fan

the

starting

the

oil

cooler

transmission

Install

order

fan

of

DC

belt

12mm

filter

with

the

of

(39.5-40.5

charging

bracket

drive

to

belt

tension

(l/2in.)

motor.

"all

drive

bell

removal.

Kg-m)

and

belt

the

mounting

..

housing

.

adaptor,

hoses.

to

along

the

filter,

flywheel.

with

transmission

oil

lines

and

27.

Generator:

28.

Install

29.

Install

30.

Install

heat

rear new

Install

exchanger

lifting

senders

the

eye

and

. .

31.

Reconnect

to

all

NOTE:

sealing

32.

Use

and

Propulsion:

Generator:

generator Install

propulsion

reinstalling

the

propulsion

engine

di-electric

corrosion

Install

and

all

new

engine

in

components

grease

protection.

mounting

new

engine

vessel.

mounting

fluids

transmission.

generator with

new

with

switches

harness

and

secure

on

all

brackets

isolators

and

filters

components

cooling

attached·components.

as

needed.

to

all

control

push

brackets.

Bleed

Engines & Generators

on

the

on

and

the

fuel

in

hoses

components.

electrical

mounting

box

new

drive

system

as

isolators.

47

the

reverse

needed.

to

AC

connections

rails

engine

as

order

Reconnect

generator

and

attach

..

New

needed

generator

end.

to

.fluid

to

test

of

removal.

provide

rails

in

run

harness

to

the

prior

to

Two

styles

of

injection

ENGINE

FUa

pumps

ASSEMBLY

INJECTION

were

PUMP

used

with

this

engine.

Early

-

This

Later

The

-

T~is

injection secured,to washers.

Inst'alling

a.

Rotate at

b.

Rotate

12:00

c.

Carefully guide drive

q When

in

pump

DPA

iJ3942F490(PN#034378)

type

DPA

type

had a tapered/keyed

#J

3942F580·

had a splined

the

Early

12:00

pump

front

engine

o'clock.

is

Model

so

injection

o'clock.

slide

the

tapered

gear.

drive

gear

shaft

by

(PN#036169)

drive

mounted

plate

by

Injection

as

.

to

pump

Insert

pump

onto

drive

is

positioned

threading

protruding

drive

shaft

to

the

three

Pump

position

drive

woodruff

the

shaft

raw·

from

shaft.

with

engine

studs

(PN#034378)

with

..

keyway

shaft

key

in

engine

with

in

the

water

the

pump drive

a

to

master

front

.11-mm

in

position

spline.

plate.

pump

hex

drive

nuts

keyway

keyway.

mounting . flange . and

woodruff

drive

key

gear,

tang

into

secure

onto

gear.

It

gear

is

and

at

the

e.

Snug

three mark cover.

MOVE

FLANGE

DOWN

AS

ILLUSTRATION.

SHOWN

the

securing

on

the

Tighten

12:00

I

PLATE

SCRIBE

ON

THE

injection

nuts

pump

MARK

ATTACHED

flange

the

pump

and

three

up

washers.

in

line securing

to

with

the

Posit

nuts.

the

front

ion

scribe

plate

the

on

23

with

•

the

scribe

front

Engines & Generators

48

ENGINE

ASSEMBLY

FUEL

INJECTION

PUMP.

Installing

a.

Remove

b.

Locate

c.

Carefully

drive

d.

snug tion

Tighten

Late

and

locate

splines

to

correspond

injection

flange,

gear,

up

the

injection

pump

Model

drive

Injection

tang

scribe

for

master

spline

to

pump

slide

drive

the

centering

and

engage

on

the

injection

pump

flange

the 3 securing

MASTER SCRIBE

plate

mark on

spline

on

scribe

shaft.

injection

the

master

the

so

as

with

the

nuts.

SPLINE

Pump (PN#036169)

from

injection

front

face

on

injection

mark

of

gear

pump on

pump

spline

with

two.

pump's

to

timing

align

three

the

scribe

injection

that

pump drive

drive

onto

the

securing

23"

scribe

on

pump

designates

drive

shaft

gear

engine

scribe

nuts

on

the

.drive

shaft.

and by

mark on

and the

front

gear

mating

position rotating

mounting

the

rotate

injec-

cover.

Verifying

a.

Injection

Locate

front pointer the

10:

when crank

timing

gear

is

located

00-o'clock

viewing

shaft

pulley.

Pump

cover.

Timing

pointer

at position

the

on

This

about

front

Engines ~ Generators

49

FRONT

PULLEY

b.

The cumference center

marks

represent

c.

Rotate position on Continue

align

crankshaft

timing

d.

On

pump plate, by together. lock and gasket.

front

and

its

the

body

two

wire,

cover

crankshaft

from

(BTD)

pl9ce

....

:23;

the

pointer

mounted

engine

the

compression

rotating

···~·

.Pulley

side

is

screws

Cut

remove

plate,

0 •

in

five-degree a

number

the

23."

mark

and

of

the

an

to

the

that

the

including

pulley

top

dead

visible

by

hand

one

stroke.

engine

on

with

stop.

injection

oval

pump

are

connecting

the

ENGINE

FUEL

has

center

mark

to

piston

to

the the

cover

body

wired

screws

the

ASSEMBlY

INJECnON

timing

increments.

halfway

PUMP

marks

(TDC)

between

embossed

to

40 •

Locate

before

the

two

on 20"

its

top

and

points

cirdead

25"

to

(NOTE: Some

from

cover

to

e.

Inside rotor with align not

rotate with engine.

side

bolts.

(NOTE:

Reattach Connect

and

inside

is

catch

the

body

the

with

align,

the

cover

injectors.

fuel

the

pump when

removed.

it

in a container.)

opening

of

the

Letter

the

top

loosen

injection

circlip

Secure

Do

not

fuel

high-pressure

the

and

gasket

over-tighten

supply

Do

will

Be

in

pump.

~

flat

flat.

pump

not

be

prepared

the

stamped

surface

the

injection

pump

and

body

The

to

and

return injector cross

lost

this

injection

The

above

pump

its

lock

the

or

rotor

of

up

or

is

mounting

wire

side

lines

mix

body

it.

the

pump

down

now

cover

up

pump

has The

circlip.

securing

to

statically

flange,

the

attaching

to

and

between

these

is

a

scribe

align

side

from

the

lines.

a

circlip

scribe

If

nuts

replace

cover

mark

the

and

the

scribe

timed

bolts.)

injection

and

mark

the

attaching

the

on

should

does

gently

mark

to

the

pump

pump.

pump

it

Engines & Generators

50

1.

2.

Lube

A

strainer then crankcase. various camshaft.

through

Oil

trochoid

the

Pump

Circulation

rotary

and

delivers

cleaned

From

parts

The

which

the

LUBRICATION·

pump

oil

of

oil

it

is

the the filter

is

draws

under

forwarded

gallery,

engine.

is

forced.

oil

pressure

a

SYSTEM

from

replacable

into

the

The

the

to

the

oil

pump

oil

pan

through

a

full-flow

oil

gallery

is

distributed

is

driven

cartridge-type

oil

inside

from

the

oil

filter,

the

to

the the

element,

The crankcase.

the

2.1

Disassembly a.

b.

c.

d.

pump

camshaft.

Loosen

securing to

the

cover To

outer oil

Drive gear

remove main main

Drive

(7)

(

6)

facilitate

pump

shaft shaft

and and

is

and

oil

from

rotor

case

out

taper

drive

out

separate outer

located

Its

main

remove strainer

pump

oil

(5),

the

oil pin gear

(

4)

from

inner

(3),

pump

removal

upside

pump

•

Pull

pump

inner

rotor

inside

shaft

the

case.

turn

down.

(2) (1)

out

case.

rotor

(

5)

is

(11),

and

the

drive

and

from

the

rotor

from

the

driven

four

gasket

separate

of

right-hand

from

capscrews

(12),

the

14 13

"==I

rear

the

and

strainer,

skew

oil

portion

gear

washers

pump

gasket,

4

of

formed

(9,10)

cover

3

the

to

(8)

and

11

51

2. 2 Inspection a.

Running

outer

rotor

clearance

and

inner

LUBRICATION.SYSTEM

between

rotor.

using

the

a

feeler

clearance positions. exceeds replace

Item

Clearance between

inner rotor and outer rotor

b.

Sliding

rotors

This

not

0 • lSmm ( 0 • 0 0 0 5

this

off

body

the

both

Specifications

(0.00051 - 0.0059)

clearance

and

clearance to

limit

the

mating

to

reduce

0.013-0.15

cover.

be

is

ance.

Specifications

Item

Clearance between

rotors and cover (0.0016

O.D4-0.09

gauge,

at

If

the

service

rotors.

Standard

is

greater

91

exceeded

face

Standard

-0.0035)

Unit:

required

in

the

Unit:

check

various

reading

limit,

mm

(in.)

Service

limit

0.25

(0.0098)

between

than

• ) I f grind

of

the

clear-

mm

(in.)

Repair

limit

0.15

(0.0059)

Checking

rotor-to-rotor

rotor-to.

cover

clearance

c.

Radial

outer Insert

tween

the checked limit, part.

Clearance rotor in body

Item

rotor

the

body.

of

outer

clearance

and

a

feeler

outer

If

is

greater

replace

Specifications

Standard

0.2-0.28

{0.0079-0.0110)

pump

the

between body.

gauge rotor

clearance

than

the

Unit: mm

Repair

limit

{0.020)

Engines & Gener.«ors

beand

the

worn

(in..)

0.5

Checking

rotor-to-body

clearance

52

d.

2.3

Reassembly

a.

Rotor

Inspect damage, wear

Shaft

Diameter.

the

and

by

~easuring

micrometer.

available

shaft

the

micrometer

the

service

of

clear

exceeded

in

badl:v-damaged

replace~ent

Install shaft

with

in

inner

clearance

the

pump

liiJrl t in

artce

or

if

is

pin.

shaft

check

Determfne

body

readings;

I

value

the

shaft

condition,

necessary.

rotor

to

LUBRICATION·SYSTEM

Specifications

for

it

for

~ith

the

of

the

from

if

terms

is is

pump.

a

Item

Rotor shaft

diameter

Shaft to body clearance

Standard

12.6~:~

0

0024

+0. +0.0016

(0 496

0.040...:.0.085

(0.00157-0.00335)

Unit: mm (in.)

Service

..

)

limit

b.

Place case. gear

c.

Place

case, cover and

(NOTE:

gear pin ling

on

d.

After

check match

indexed. the to not the be correctly

oil

has

hole

through

the

sure

pump

to

the

outer

and

complete

strainer.

If

pump

been

must

shaft.)

replacing

to

marks

wrong

case,

draw

bolts

shaft

Install

shaft

install

shaft

replaced,

be

the'

be

certain

If

the

position

in

after

that

matched.

rotor

with

made

gear

are

the

oil.

the

in

pump

with

in

pump

gasket

or

by

mounted

the

cover,

that

correctly

cover

relative

pump

Tighten

checking

marks

pump drive pin.

pump

case

drive a new

dril-

the

is

in

will

to

are

,

·Fitting.

cover-to-case

by

m~t?_t

.:ng

marks

e.

After

the

make

reassembling

strainer

certain

in that

the

a

pool the

pump

of

pump

complete

oil

and

is

capable

run

with

the

of

its

drive

sucking

strainer,

gear

oil

by in.

immerse

hand

to

I"Wj'!;!~!';~!';~

53

3.

Oil

Filt.er

LUIIRlCATION

SYSTEM

The

its the tion tial

(14.

the

filter

center

filter

of

the

pressure

2±2·

8psi)

inlet serviced actuates

The

oil

relief

the

filter

valve response discharge starts

relieving

pressure

(43~4.3psi),

the

excess and oil gallery

3.1

Disassembly

1.

limiting

reaching

to a constant

Remove

valve bracket·

is

mounted

part.

is

actually

element.

1 when

side

regularly

bypass

to

the

pressure.

rises

thereby-

oil

the

filter

(2)

·(3).

The

This

across

the

to

or

valve.

has

a

operating

oil

This

when

to

3+0.

to

the

pressure

engine

level.

(1)

and

from

on

the

oil

bypass

a

relief

valve

the

valve

the

outlet

before

built-in

pump

valve

3kg/cm2

bleeding

oil

relief

filter

right-hand

valve is

filter

opens,

the

in

the

pan

of

oil

valve

set

side.

filter

side

for

located

to

rises

the

oil

becomes

of

letting

open

The

the

in

when

to

flows

filter

so

crankcase

the

oil

the

center

the

differen-

l.0+0.2kg/cm2

directly

must

dirty

that

at

bypass

por-

from

be it

3. 2 Inspection The

engine

·

replaced engine

and

break-in.

filter

operation. Being

filter

affect

engine

A

follow is

being

consc:;:ious

changes on

wear.

-

........

good

preventative

every

to

take a sample

removed spectrographic oil.

wear

This

is

accumulates Service

Analysts,

2450

Hassell

Hoffman

800-222-0071

oil

after

every

the

engine

'*''

~

third

(6-8

will

taking

operating

Facility:

Inc

Road

Estates,

and

oil

the

first

Then

100

about

should

replace

hours

regular

have a beneficial

in

maintenance

of

fourth

of

ounces)

analysis

show what

place

as

hours.

Sample

IL

60169

1-w"IWESIEHBEKE

filter

50

must

hours

the

of

engine

oil

reducing

step

oil

change

the

engine

and

have

performed

type

the

engine

kits

of

are

f Engines & Generators

be of oil

and

internal

to

oil

a

on

the

internal

available

from them.

54

COOLING

(FRESH AND

SYSTEM

RAW

WATER)

1.

Fresh

Refer

culated

mounted

The heat thermostat, cylinder opening block/head.

The manifold oil heater

it

TO HOT

Water

to

through

on

circulating

exchanger

head,

and

coolant

to

cooler.

flow

is

finally

WAT~R

TANK

Circuit

the

illustration

the

located

controls

closing

passes the

The

controller

cooled

the

front

pump

and

lower

circuit of

draws

moves

in

to

through

discharge

coolant

and

by

above.

by

the

engine

coolant

it

through

a

housing

the

operating

regula.te

the

then

into

the

raw

the

block.

from

at

coolant

opened

of

the passes the

engine's

water

Fr~~l'!

water

belt-¢lriven

the

discharge

the

engine

the

top

temperature

flow

thermostat

manifold

through

heat

circuit.

INCOMING

coolant

fresh

block/head.

forward

of

through

and

through

the

domestic

exchanger,

part

the

RAW

WATER

water

side

engine

the

is

cirpump

of

engine

exhaust

the

lube water where

the

The

the

by

Engines & Generators

55

2.

Raw

neoprene the heat exchanger around

illustration.}

Water

water

pump.

exchanger

the

Circuit

is

drawn

impeller

This

and

removes

outside

into

type)

raw

where

COOLING

the

raw

by

the

water

of

it

heat

the

is

pumped

passes

from

tubes.

SYSTEM

water

suction

to

through.

the

(Refer

pump

action

the

fresh

(positive

of

raw

water

the

to

tubes

water

the

displacement-

the

impeller

inlet

inside

coolant

cooling

in

of

the the

flowing

system

The

be the cooling pushed

3.

Thermosta~

The

designed

operating

170"-190"F.

3.1

Disassembly

b.

4.

Fresh

The

gal

pump.

4.1

Disassembly

raw

directed

exhaust

thermostat

a.

Remove

by bolts

Remove

gaskets

from

Water

water

type. lubricated bearing zerk

fitting

water

to

injection

them

overboard

loosening

engine

grease

as

#024688

to

temperature

(77"-88"C).

thermostat

(1)

and thermostat

(4)

Pump

pump

Its

by

on

is

then

the

transmission

this

by

exhaust

is·

a wax

maintain

and

washer.

and

block

#034370

is

the

bearings

water

applied

the

side

discharged elbow

mix

engine

between

cover

removing

spacer

(6).

centrifu-

thru

of

falls

gas

type,

(2)

(3),

(5)

are

pump

the the

from

oil

to

be

into

pressure.

~·

U

~

the

exchanger

cooler.

mixed

'

~~-

the

'\_

with

exhaust

It

the

1

then

exhaust

muffler

and

passes

V\

·-2

3

~~~t==~

~;;;:;;;;~~-4

9

1 -Bolt 2-Cover

5

3-lmpeller 4-llnit 5-Spacer

2

10

seol

then

into

gases,

and

3

6-Snap ring

7-Bearing

a-Shaft 9-Bearing

10-Housing

may

is

a.

Loosen

shaft remove and

Remove loosening attaching

and

nut

water

woodruff

pump

and bolts

remove and

lock

pump

key.

cover

removing

(1).

water

washer;

pump

pulley

(2)

cover

Engines

by

& Generators

56

c.

To port and

remove

the

unscrew

impeller

shaft

impeller.

COOLING

(3),

with

a

sup-

stand

SYSTEM

(NOTE:

mounted

thread

d.

Remove

shaft the

e.

Remove the case.

f.

Pull

pulley

and

(9)

The

on

is

space.r

at

pump

snap

pulley

shaft

side

remove

from

impeller

the

right-handed.)

the

pulley

case.

ring

side

of

bearings

the

shaft.

(5)

{8)

the

is

of

pump

thread-

from

side

(6)

the

off

(7)

The

the

of

from

pump

the

case

and

4.2

Inspection

a.

Examine by the tion, bearings.

b.

Visually

a

defective

such

case

replaced

c.

Check

is

slowly

pump

rubbing

or

the

badly

the

replace

pump

rotating

is

erratic

check

impeller.

cover,

with

condition

worn

operation

the

is

new

or

damaged.

it.

in

bearings.

impeller

evident,

if

found

ones.

of

rota-

Also

the

If

for

check

damaged

unit

I""'(WESTERBEKE

Engines

& Generators

corrosion

check

the

seal.

for

cause.

due

or

breakage.

signs

to

rubbing,

Replace

of

The

rubbing.

impeller

the

seal

Replace

must

if

If

and

be

it

57

d.

Check

shaft

e.

Check

fitted pump condition.

the

pump

if

the

assembly)

for

surfaces

excessive

shaft

journals

if

of

wear

those

COOLING

bearing

are

excessively

the

surfaces

pump

or

journals

damage.

SYSTEM'

for

wear.

worn. case on

where

Replace

the

case

the

are

Replace

bearings

case found

(or

in

the

are the bad

(NOTE:

4.3

Reassembly

a.

b.

c.

d.

e.

pulley,

signs

Install

shaft shaft

Install pump

Install seal and the

impeller Install Install

pulley position the

install shaft; to washer nut.

Upon

making

of

binding.)

(1)

in

case

(7)

smaller

impeller

side

shaft

the

shaft

and

assembling

certain

bearings

and

pump

snap

on

pulley

larger

in

half

(8);

onto

cover

spacer

of

the

woodruff

the

pulley

fasten

water

(2)

install

case

ring

half

the

of

the

shaft.

(9)

(3)

the

keyway,

the

with

pump

that

on

(4).

(5)

side.

of

pump

seal

screw

onto

the

pump

the

unit case

the

the shaft, key

and

the

pulley

lockshaft

water

pump

in

5

in

1

3

2

in

pump,

rotation

turn

it

is

by

smooth

means

without

of

the any

f.

Rotate that

interfere

g.

Apply

(1.2

the

water

cubic

shaft

impeller

with

cover.

pump

inches).

to

does

grease

Do

check

not

thru

not

the

overfill.

58

zerk

fitting.

Capacity-20cc

5.

Raw

Water

Pump

(PN:016423F .

COOLING

SYSTEM

The pump

a

5.1

Disassembly

a.

b.

c.

d.

e.

is

a

positive

replaceable

Remove

and

washers

front

(11.)

With a pair positioned

impeller the and

Remove cam

Remove key (3) from

impeller

Supper t the arbor and

(2)

the

cover

impeller

out

(8)

press push and

pump

neoprene

front

(13) & (14) and

(12)

of

180"

(10),

of

the

screw

out

of

shaft

pump

or

the

bearings

housing

cover

with

screw

apart

carefully

from

impeller

the

pump

(7) and the

pump.

(2).

base

similar

(4)

(6).

impeller.

body.

rep.lacement.

screws gasket

drivers

on

the pry

shaft

take

the

in

an

press

shaft

out

of

type

pump,

engine

driven,

with

f.

g.

5.2

Inspection

a.

b.

c. d.

Properly

some those

Push

(Note

correctly).

Visually

impeller

suspected.

Visually

any

the Check Check

cations

disassembly,

cases,

seal

placement

indication inner

cam (8)

bearings

support

(9) from

examine

blades.

examine

surface.

of

damage.

of

for

(4)

bearings

the

inner

of

seal

impeller

Material

cover

wear

wear.

and

(4) and remove from housing housing.

in

(10).

(12)

or

grooving

Replace

rotate.

may

inner

remain

and

housing

Look

should

surface.

as

Look

push

be

from

needed.

in

(seal

for

flexible.

the

for

pump

bearings

lip)

any

cracked

Replace impeller

binding

shaft

housing.

out.

to

Replace

if

and

(2).

reinstall

or

there

turning

any

indi-

In In

worn

if

is

on

IW'IWESTERBEKE

l Engines & Generators

59

6.

e.

Visually

journals

worn

f.

Visually

areas where

Raw

Water

a.

Care mounting

to The shaft should

tang slotted should each pump cause pump

tang

examine

and

or

damaged.

examine

of

the

impeller

Pump

must

the

mounting

slotted

of

the

fit

from

drive

not

other

is

secured.

undue

bearings

gear.

the

Engine

be

raw

drive

sea

onto

the

be

forced

when

stress

shaft

area

pump

shaft

Mounting

taken

water

the

engine.

and

the

This

and

the

COOLING

(2)

for

of

seal

housing

bearing

turns

the

raw

in.

when pump

flange.

in

the

pump

drive

The

tang

against

water would

on

the

drive

SYSTEM

wear

(8)

outer

Lock

(9)

Washer

in contact.

for

journals

SeaWater

Pump

the

any

areas

wear

of

Replace

or

damage

and

housing

Sea

Water

Pump

Mounting

Stud

the

bearing

if

badly

in

area

the

b.

Alignment

water the the with

timing

engine.

the snuggly. position, pump 9f

will

the

tightening

(NOTE:

water

·the

HEAT

The heat exchanger should be inspected and serviced during

an

engine 'overhaul.

1.

Disconnect the hoses and remove the hose

petcock, drain plugs and zinc anode. Also, remove the

end fittings and gaskets.

2.

Inspect the tube (casing) for wear and dents, if at all suspect replace the heat exchanger.

3. Have the exchanger professionally cleaned and pressure tested by a radiator shop.

4. When reassembling always use new end cover gaskets

. and

pump

NOTE:

Inspect

sea

water

pump.

EXCHANGER

"0"

rings.

pump

driving

pump,

This

pump

Replace

is

just

as intentionally cover

To

and

assure

tang, With crank

align

up

as

on

the

w~th

it

its

procedure

is

removed

the

drive

tang

each

season

ifwom.-

critical

fuel

engine

the

aligns

four

must

that

fits

or

when

has

the

mounting

that

install

lever

drive

during

hold-down

or

into

the

removing

-

fittings,

as

no

the

on

for

be

loosened

·

the

drive

pilot

flange

pump

the

pump

the

a few

tang.

cranking.

nuts.

followed

HEAT

EXCHANGER

clearance.

because

vary

shaft

is

with injection seconds,

Visually

any

for

the

when

axial

its

gasket(s)

pump

so

verify

Secure

time

any

location

bolted

(centered)

in

the

raw

movement

the

raw

reason.)

The

the

water

pump

raw

of

to

just

.Q!!

by

s.

Install a new zinc anode. Do Not use

its threads.

any

sealant on

·Engines. & Generators

60

NOTE:

All

of

the

above

can

the

heat exchanger to a radiator

service

transmission

and

be

accomplished

engine

shop.

oil

They

coolers.

by

will

sending

also

1.

Fuel Description

Injection

FUEL

Pump (DPA).

SYSTEM

The

DPA

distributor

sisting fuel

pumping

buting

vance,

control

built

weight

ally,

of

ing

into pump

this

pumping

and

injection

type

of

a

plunger,

device,

mechanical

linkage,

a

housing.

pump

plungers

delivering

pump

transfer

automatic

governor

which

compact,

features

for

fuel.

21

is

con-

pump,

distri-

adand are

light-

Function-

a

pair

meter-

20

19

a

DPA

Fuel

18

17

16

15

Injection

14 13

12

Pump

11

3

1-Drive 2-Governor 3-Drive 4-Thrust

5-Pump 6-Automatic 7-Cam

housing

advance

(NOTE:

drive with

master

hub

weight

shaft

sleeve

Ref

shaft;

1

seal

advance

screw

DPA

:ft:

3

spline.)

2

S-Head 9-Shut-off

10-End 11-Transfer 12-Head & rotor 13-Hydraulic 14-Rotor

Fuel

Drive later

locating

plate

Injection

Shaft

pumps

Engines & Generators

4 5 6

stud

solenoid

(regulating

pump

assembly

head

Pump -

-

earlier

had

7 8

valve

valve)

Sectional

a

splined

15-Metering 16-Plunger 17-Cam 18-Governor 19-Governor 20-Governor 21-Shut-off

View

pumps

9

roller

had

drive

10

valve

spring

arm

shaft

a

keyed shaft

bracket

61

2.

Fuel

Filter

#0243

63

FUEL

SYSTEM

The

a

manual

a.

Servicing Remove

housing be the

(NOTE: height, removed, servicing.

installed. fuel

to carefully of

a

turn the prime

ignition

the

(NOTE: used the prime

to

ignition

the

fuel

filter

priming

the

with

taken

to

filter.

In

inseallations

to

prevent

shut

Turn

Install

the

sealing onto once

key

filter

The

manual

accomplish

key

filter.)

the

pump.

filter

the

catch

fuel

the

filter sealing

ON

and

priming

this

ON.

is

fuel the

gasket

to

vent

a

spin-on

element

aid

any

with

fuel

OFF

back

new

housing.

activate

any

same

(It

of

a

fuel

syphoning

at

the

ON,

filter

of

gasket

air

pump

function

takes

type.

by

unscrewing

small

that

filter

may

tanks

tank

once

simply

the

filter

Tighten

contacts

the

fuel

from

on

the

without

approximately

Its

be

located

when

shut-off

a new

it.)

filter

mounting

it

from

wrench.

spilled

while

above

the

filter

during

filter

by

applying

and

screwing

approximately

the

housing.

pump.

This

housing having

20

housing

the

Care

engine

has

may

to

pumps

has

filter should

removing

is

this

been

some

it

3/4 Turn will

be

turn

to

ELECTRIC LIFT PUMP

INCOMING FUEL

CARTRIDGE

THROTTLE CONNECTION

INJECTOR PUMP

FUEL

SYSTEM

3.

Fuel

This

{transistor

fuel motion controlled circuit.

Disassembly

Because

the

Using

Then,

from

Check

and

To

plunger valve

Wash

taminants

Pump

is

pump.

of

cover,

a 17-mm

the

cover

remove

(9),

these

#301385

a

solenoid-opera

type)

The

the

by

a

and

this

transistorized

filter

wrench,

cover

pump

body

cover thoroughly.

the

plunger,

tube

(12) plunger parts

using

12-Volt

reciprocating

pump

plunger

transistorized

Reassembly

and

plunger remove

gasket

(5).

gasket,

•

Then

spring

in

clean

compressed

ted

of

the

{ 2) ,

magnet ( 3)

Replace

and

if

first

remove

(10)

diesel

air.

DC

5

is

the

4

3

2

Electric

fuel

assembly

cover

the

damaged,

remove

and

oil

pump

require

{1).

·and

filter

replace

the

washer

plunger

and

11) Cover

Cover gasket

(2}

(3)

Magnet

(4)

Filter

(5}

Body

( 6) Spring retainer

<

7l

w"""

. ( 8) 0-ring 6 ·

(

9)

Valve

(I

0)

Plunger spring Plunger

(11) (12) Plunger tube

Fuel

is

Pump

totally

cleaning.

{See

filter

as

illustration)

(

needed.

it.

spring

retainer

(7) , O-r

(11)

remove

from

the

oil

1 \

~

for

enclosed,

4)

can

Clean

ing

inside

and

10

9

Cleaning

be

the

(6)

from

seal

the

other

only

removed

magnet

the

(8),

tube.

con-

CAUTION

1)

To

(

and retainer.

(2)

Install cover of

Checking

Turn

on

produce

sound, supplied the

pump

assembly.

circuit

(free

fuel

tion

pump pump

The careful parts. being

assemble,

washer,

the

ignition

a

clicking

check

to

still

breaker,

flow)

should during

plunger

dented

the

and

slotted

Electric

with

the

is

not

Carefully

install

in

filter

tighten

stop.

switch

sound.

a

pump.

does

If

12

electrical

225cc

maintain

engine

tube

to

deform

or

that

element,

Fuel

.

DC

voltmeter

If

not

Volts

(.

operation.

{ 12}

has

the

tube

handle

otherwise

the

order,

damaged.

plunger,

and

the

cover

Pump

(for a generator,

If

the

pump

to

12

Volts

make

is

any

not

present

connections

4 8

pints)

a

positive

very

during

the

plunger

secure

then

with

the

a 17-mm

does

determine

is

being

operating

every

fuel

small

assembled

magnet

use

PREHEAT).

not

supplied

sound,

at

the and 15

switch.

seconds.

inlet

wall

removal

to

spring,

wrench

produce

that

pump,

pressure

thickness.

of

the

prevent

valve,

parts

and

gasket

to

The

any

12

Volts

to

the

replace

check

Fuel

The

to

plunger

it

from

O-r

with

in

the

pump

should

operating

is

being

pump

the

delivery electrical the

injec-

Be

ing

the

ends

and fuel unit

63

.1.

Idling

and

Maximum

No-Load

FUEL

Speed

SYSTEM

Adjustments

2.

These

testing.

the counterclockwise out, 700-850

This

ations used. adjusted

factory

(2).

neutral

tamper

(NOTE:

hold 2900-3000 throttle, ward

Any

is

Fuel

adjustments

ptop

to

may

RPM

with

engine

gear.

time

correct

Injection

To

lower

RPM.

vary

and

No-load

and

with

full

is

Propeller

underway,.and

RPM

with

adjust

screw

reduction

8-mm

open

3220

this

RPM,

is

Nozzles

are

initially

idle.

(1) . clockwise

to

lower

(8

nun

stop

with

sealed

RPM.

adjustment.

speed

questionable,

engine

install-

speed

at

stop

throttle

load

full

speed

spe.ed,

idle

screw)

gears

is

the

screw

in

Do

not

should

between

open

in

for-

before

made

loosen

speed;

ensure

at

the

factory

the

8~mm

to

increase

normal

that

attempting·other

idle

tachometer

during

locknut

idle

speed

adjustments.

engine

and

·adjust

speed,

is

between

is

between

calibration

or

a.

Description The

.vides

fuel, pressure pump, chamber. oil of The nozzle tance precision-finished be

The adjusted washer. thickness

increase and, pressure,

injection

a

delivered

into

in

finely-atomized

mating

piece

oil

tight.

injection

hence,

means from

a

holder

by

Increasing

of

the

and

the

The

conical

surfaces

and

the

spring the

vice

the

precombustion

nozzle

an

nozzle

of

spraying

under

injection

pattern

droplets.

body,

nozzle

to

pressure

adjusting the

washer

tens injection versa.

pro-

sprays

of

the

dis-

are

will

ion

is

l-Retaining

2-Nozzle 3-Distance 4-Pressure 5-Spring 6-Washer 7-Nozzle 8-Gasket 9-Nut

Inspection

8

1

nut

tip

piece pin

holder

Nozzle -Sectional

7

6

4

2

View

1....-IWESTERBEKE

f Engines & Generators

64.

b.

Removal

1.

Removal

a. b. c. d.

e.

2.

Installation,Sequence Follow

val

and·Installation

•

Sequence

Connectors

Fuel Fuel Fuel

(nuts

Fuel

assemblies

Feed return leak-off

(5) 4 pes)

injection

the

sequence.

(1)

pipes

pipe

reverse

(4

Pes)

(2)

(3)

(4)

nozzle

of

FUEL

remo-

CAUTION

SYSTEM

Fuel injection nozzle tightening torque .

Unit:

kg·m (lb-ft)

5 ± 0.5

(36.2 ± 3.6)

After connected

cylinder

c.

Disassembly

(NOTE:

by

jection), the

cleaning,

with

l.

removing

ends

head

and

Before

testing

spray

manner

and

care

Disassembly

a.

b. c. d. e. f. g.

to

Retaining it

in a vise) Nozzle Nozzle

Distance Pressure Spring Washer

injection

of

to

prevent

Reassembly

disassembly,

it

for

pattern

already

reassembly

protect,

Sequence

nut

holder tip

(3)

piece

(6)

(7)

nozzles,

injection

entry

injection

and

described.

work,

in

particular,

(hold

(1)

•

(2)

(

4)

(5)

be

pipes

of

dirt.

collect

pressure

internal

Throughout

handle

certain

and

oil-tightness,

the

nozzle

data

(beginning

the

each

nozzle

5

on

to

cover

holes

the

disassembly,

tip.)

dis-

in

nozzle

of

in-

all

in

assembly

@---8

i==:

1----_7

Disassembling

Nozzle

Holder

!-Retaining 2-Nozzle 3-Nozzle 4-Distance 5-Pressure 6-Spring 7"JWasher 8-Nu·t 9-Gasket

Injection

65

nut

holder

tip

piece pin

Nozzle

Assembly -Disassembled

6

View

2.

Reassembly

FUEL

Sequ~nce

SYSTEM

-.

(NOTE:

placed, of

plastic:

proper

needle

d.

Inspection

Needle

1.

2.

3.

Follow

If

be

kerosene

by

valve

Immerse sene,

back without

injection defective.

Visually

having Inspect

seating the

pressure

the

sure

wash

stroking

needle

insert

and

a

the

part

reverse

needle

to

after

off

the

stem

forth

evidencing

power

bore.)

and

nozzle

valve

the

to

nozzle

examine

of

needle

and

pin.

of

dis-assembly

v.alve

wash

removing

rust

needle

body

and

valve

be

sure

any

must

the 4

or

valve

for

the

nozzle

wear

and

nozzle

repla-cement.

their

preventive

valve

nozzle

in

to

that

excessive

be·

replaced

5. for

of

sequence.

proper

protective

back

body

the

body,

the

sliding

body

distortion

its

end

have

parts.

oil

from

and

in a pool

and

clearance.

if

the

with

a

face

to

·be

in.

a

films

the

nozzle

forth

contact

magnifying

or

of

move

fit

damage

in

contact

in

clean

The

re-

pool

of

the

is

kero-

valve smooth entire

found

glass

at

its

with

4.

Poor

condition against the

nozzle Nozzle Check

Determine with by

Pressure

1.

2.

Leak-off

If

replace

the

an

abnormally

Replace otherwise carefully

Inspect pressure

the

seating

must

holder

the

use

spring

each

pipe

packing it.

has

the

seat

faces.

be

and

fit

quality

of

red

and

any

spring

pressure

defective,

for

pressure

packing

is

contact

not

distance

between

high

these

advanced

with

replaced.

of

lead

rate

pressure

and

found

may

a

If

this

piece.

nozzle

the

paste:

of

spring

and

out

defects.

the

other

to

be

coat

fit

return

pin.

for

be

corrected,

too

far,

of

does

holder

from

defective

that

of

square.

wear

for

in

by

clean

not

and

contact

oil

(leak-off)

is

at

its

needle

a

deteriorated

if

lapping

lube

help,

distance

patterns

fit

will

broken,

Inspect

end

valve.

the

oil

the

faces,

defective

the

applied

injection

piece.

obtained

be

obvious

flow.

cracked

each

spring

one

condition,

valve

to

or

for

lwiWES7ERBEKE

l Engines & Generators

66

3.

Testing

and

Adjustment

FUEL

SYSTEM

,

Injection

The

pressure

the

o~ning

however,

manual.

and a.

b.

force

adjusted

Install

operate

times

Move pressurize

tion

spray,

injection

Pressure

-of pl'.'essure

it

The

the the

to

prime

the

of

the

at

which

the

will

value as

follows:

injection

manual·

lever

the

test

pressure.

Item

Injection

pressure

the

pressure

or

be

referred

of

this

pumping

the

nozzle.

in

an

injection

pressure

deflected

12o+

needle

spring

beginning-of-injection·

pressure

nozzle

up-and-down

nozzle,

gauge

Specifications

Standard

1

g (1706.4+

to

as

handle

gauge.

14

valve

is

.injection

is

in

cycle

while needle

Unit: kg/cm2 (psi)

2

)

5·

unseats

referred

specified;

the

As

nozzle

of

the

of

observing

the

will

Repair

limit

ll 0 (1564.2)

max

itself

to

.EE,essure

it

tester,

tester

one

per

the

nozzle

indicate

against

as

valve

pressure,

in

is

checked

several

second

indica-

begins

this

and

to

the

c.

If thickness Increasing the stock ranging

in Spray The

thrqttle needle

.

fuel each portions;

the

increments

Pat

injection

during slug

indicator

injection

for

tern

type.

valve

of

initial

of

the

adjustment

from

nozzles

begins

the

sprayed

reading

the

washer

pressure

l.Omm

of

o.osmm

Some

to

initial

fuel

throttled

is

washer

thickness

by

purposes

(0.0394in.)

(0.0020in.)

used

throttling

unseat,

stage

may

spray

below

used

about

in

the

action

limiting

of

be

regarded

1 2 3 4 5 6

1111

the

on

by

lmm

l0kg/cm2

is

available

up

each.

present

each

and

terminating

Ill

the

to

the

fuel

llUJ

limit,

pressure

(0.04in.)

(l42psi).

in

l.95mm

engine

tak.es

as

place

amount

i~jection.

comprised

'

/

increase

spring.

increases

20

(0.0768in.),

are

when

of

sprayed

main

spray.

/i\

i!

\,

the

Washer

sizes,

the the

Thus,

of

two

'}f'

Jjl·\)

~

Checking

on

nozzJ.e

injection

tester

pressure

1-Good

67

2-Spray 3-0ff

cone

center

Possible

too

spray

large patterns

4-After-dr 5-fissured 6-\-Jhirling of

spray

ibble

spray spray

FUEL

SYSTEM

When

these occurs minute when cycles-per-second.

a.

b.

tested

two

when

(up

the

Initial

When

generally of

after-dribble,

All

pintle

While

for

chattering

if

so,

tendency.

washing

Evidence cates

Terminating

on

spray

the

and

lever

Throttle

the

these

protruding

the

then

and

of

that

nozzle

poor

the

nozzle types tester

down

is

and

are

nozzle

the

due

in

the

needle

If

not,

then

off-center

injection

Main

tester,

for

visual

lever

in

one

operated

Spray

is

producing

the

pattern

fuel from

is synchronism

re-tested.

Spray

dribbling

to

the

producing

valve

the

nozzle

spray

nozzle

the

inspection.

is

operated

second);

rapidly

this

is

injected

valve.

this

with

is

and

or

injection

at

terminating

at

spray

straight

after

free

directionally-erratic needs

injection,

fuel

spray,

the

cyclic

from

needle

thorough

Initial

a

rate

a

only,

then

being

check

any

valve

nozzle

rate

motion sticking

cleaning.

can

throttled

of

60

main

the

atomization

conical.

is

throttled

the

of

must

be

reproduce

cycles-per-

spray

of

4

Evidence

also

present.

needle

the

or

hitching

cleaned

spray,

spray

occurs

to

by

the

valve

lever;

indi-

6

is

by

With

second, spray

The

finely-atomized atomized

terminate Seating An

injection

duce a good

it

passes

With pressure exceeding

valve there

such

seat the

must

entire

(NOTE:

hours haul

the

main

Tightness

this

the

evidence

injection slowly

will should

be

or

tester

the

under

spray

fuel

with

nozzle,

spray

final

the

set

not

unseat.

be

is

repaired

injection

Check

and

remove

replace

initial

this

fuel

particles

no

pattern,

to

pressure

no

evidence

noted,

injection

lever

condition

should

particles

dribble

tested

test:

nozzle

100

Hold

the

by

lapping

nozzle

carbon

as

needed.)

operated

throttle

be a

without

or

and

may

be

seating

mounted

or

110kg/cm2

of

120kg/cm2

the

of

contactlng

must

nozzle

deposits

spray

may

good

without

dripping

adjusted

re-used

tightness

on

pressure

fuel

oozing

in

the

be

replaced.

for

at

any

a be

manner

around

rate

is

minimally

regarded

straight

any

large

fuel

as

above,

in

the

test.'

the

nozzle

(1422

(1706psi),

and

observe

out

faces

spray

of

pattern

nozzle

of

4

to

as

cone,

large

at

or

to

previously

droplets,

the

tip.

and

engine,

tester, 1564psi),

so

form a

the

needle

tip.

6

cycles-per-

visible.

main

consisting

and

found

provided

raise

that the

every

the

nozzle

dribble.

valve

suggested

1200

Over-

The

spray.

of

finely-

should

to

prothat

the

without

needle

tip;

If

and

or

68

·TIGHTENING

TORQUE

SPECIFICATIONS

Important bolts and nuts

Secured part or component

Cylinder head Main bearing cap Connecting Flywheel Camshaft thrust plate Front Timing gear case Crankshaft pulley Rear plate Idler thrust plate Rear oil seal Oil pan Oil pan drain plug Rocker shaft bracket Injection

holders Nozzle holder retaining

plate

pump

rod

bearing cap

delivery

valve

nuts

Diameter - Pitch

12 12

10

.

12

8 8

24 10

10

8

18

Threads

-

8

-

6

-

8 -

1.75

1.0

1.25

1.5

1.25

1.0

1.25

1.5

1.25

kg-m

Tightening torque

12

(86)

8.5

(61)

5.5

(40)

8.5

(61)

1.8

(13)

(7)

1.0

(7)

40

(288)

3.5

(25)

3.5

(25)

0.4

(3)

0.7

(5)

10.0

(72) (11)

1.5

3.0

(22)

5.0

(36)

(lb-ft)

General bolts and nuts

Screw thread

dia.

8

10

12

14

16

18

pitch

1.0

1.25

1.5

1.25"

1.75

1.5

2.0

1.5

2.0

1.5

2.5

Tightening torque

With spring washer Without spring washer

kg-m

1.8

3.6

3.4

6.5

6.0

10.4

9.8

15.8

15.0

22.9

20.7

lb-ft

13

26 25

47 43

75 71

114 108

166 150

kg-m

2.2

2.1

4.2

4.0

7.6

7.1

12.2

11.5

18.6

17.6

26.9

24.4

lb-ft

16 15

30 29

55 51

88 83

135 127

195 176

69

STARTER

MOTOR

ATTRACTION

3.

HOLDING

STARTER

1.

2.

3. Remove the two long through bolts and two screws

4. With the brushes pulled away from

5. Remove,the cover, pry the snap ring out, and remove the

6. Unscrew the bolts

TEST

Holding test. With a battery connected to

minal S ( pinion fully.

when released from holding with your

+)

and

to the starter body, manually pull

The

pinion

must

remain

the

solenoid

out

at

that position even

hand.

TEST

DISASSEMBLY

Disconnect the wire from the solenoid tenninal M (-). Loosen the

the solenoid assembly.

fastening the

remove the yoke .and brush holder assembly. the armature

washer.

same time, the washers adjustment will

two

screws fastening the solenoid.

brush

holder. Remove the rear bracket.

out

·and

remove the center

for

the pinion shaft

come

off.

Remove

the armature,

Then

bracket

end

play

ter~

the

pull

At

the

4. Return test:. With a battery connected to the solenoid

min:al

M (

~)

and to the starter body, manually pull out pinion fully. The pinion must return to its original position when released from holding by hand.

RETURN

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

8.

On the pinion side, pry the snap ring out. and pull out pinion and pinion shaft.

9.

At

each end a bearing puller. It is impossible to replace the ball bearing press-fitted

off, replace the front bracket assembly.

SOLENOID

of

the armature, remove the ball bearing with

iil

the front bracket.

TEST

If

that bearing

has

ter~

the

worn

INSPECT

FOR

WEAR & CHIPPING

STARTER

MOTOR

1-w"IWESTERBEKE

f Engines & Generators

70

'

~,

'··-·· '

NOTE:

inspect,

if

necessary

solenoid,

following pages.

brush,

armature,

clean

commuter,

and

etc.

replace

See

the

STARTER

MOTOR

STARTER

INSPECTION

Solenoid

Inspect

the solenoid for continuity between terminals S

M and between terminals S and body.

be found between

between

S

~

CONTINUITY

Inspecting

1. Check the armature with a growler tester.

· circuited, replace

between the communicator and its shaft. insulated, replace

S

the

body

The

Annature

and

M.

and M

CHECK

the

armature.

the

armature.

Continuity should

and

No

continuity should

the

body.

Also

check for insulation

be

If

it's

If

poorly

found

short

and

Brush

and

Brush

1. Check the brushes.

replace the brushes.

Brush Height

Standard !J

Limit-6

mm

mm_

(o.669 in)

(0.236

BRUSHES

2.

Check the spring will ifsuspect.

brush

cause

Holder

in)

spring tension. A weak

excessive brush wear; replace the springs

Inspection

If

worn out beyond the service limit,

NEW

USED

or

defective

·

2.

Measure

Repair or replace check the

roughness.

crocus

COMMUTATOR

the commutator

commutator

If

cloth.

0.0.

O.D.

and

the

it

if

the service limit is

outside surface for dirtiness and

rough,

polish the commutator with fine

Commutar

Standard:

...

Service limit: -1.0

"'""""""""''

ARMATURE

CHECK

depth

of

undercut

exce¢ed.

O.JJ.

Standard

38.7

Also

mm

(1.523 in)

(-0.039 in)

BRUSH

HOlDER

ASSEMBlY""

~·~.........,

3. Check for insulation between the positive brush holder

and holder base. assembly.

Also

If

poorly insulated, replace

check

the brush holders for proper staking.

the

holder

·.

71

STARTER

MOTOR

Field

Coil

Inspection

1.

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

2. Check for continuity between both ends (brushes) of

the coil

3. Check the poles and coil for tightness.

FIELD

COIL

TEST

STARTER

ADJUSTMENT

AND

REASSEMBLY

of

MULTIMETER

the

2. Greasing. Whenever the starter has been overhauled, apply grease to the following parts:

a.

Annature shaft gear and reduction gear.

b.

All bearings.

c. Bearing shaft washers

d. Bearing sleeves.

e. Pinion.

f..

Sliding portion

A

CAUTION:

terminals,

3. After reassembly, check again.

SNAP

RING

Never

brushes,

and

of

lever.

smear

the

or

commutator

by

conducting a no-load test

GEAR

snap rings.

starter

fitting

with

surface,

grease.

A

CAUTION:

starter

·old

paint, depends cient

size

and

tully

Reassemble the starter assembly in the reverse order disassembly, making sure

1.

Pinion shaft end play adjustment. Set the end play (thrust

gap)

to

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 end play by moving the pinion shaft in the

axial direction.

increase the number

nange

and

on

the

and

tighten

between

Before

and

mounting

rust.

starter

quality

grade

to

the

0.5

If

installing,

of

between

thoroughly

surfaces,

remove

performance

the

wiring.

the

Use

battery

clean

all

largely

wire

of

and

starter

terminal.

of

the following:

to 2

mm

by

inserting an adjusting

the end play exceeds 0.5 mrn,

of

adjusting washers inserted.

the

oil,

suffi-

of

PINION

SHAFT

END

PLAY

Engines & Generators

72

DESCRIPTION

The alternator serves to

It

is

driven

from

V-belt.

The type of alternator used

engines having a wide

diodes

that convert AC

the

generated voltage constant even

changes.

A

CAUDON:

as a megg111.

During nect

the

from

terminal

failure

With

altematotS

a

short

allow

current

Do

not terminal roltage

When

sure

to

damage

Bthiii'Wise,

high-speed

PDSitlve

B of

will

teSIIII.

cimllit

to

start

the

B

of

the

regulator

charging

disconnect

to

diodes.

keep

the

pulley

range

to

Do

not

running

or

negati1111

the

hafling

between

flow

in

engine

alternator.

wiiii'IJSII/1.

the

battery

the

DC, and

DSe

altemator.

IC

lelminals

the 'lliDIIe

with

battery

ALTERNATOR/REGULATOR

NOTE:

on

the battery

at the end

is

of

engine speeds.

an

any

hlgh·voltage

damage

of

the

tennlnal

tegulatotS,

the

lead

Otherwise,

constantly

of

the

crankshaft

ideal

for

high

JC

regulator

when

the

engine

to

diodes

will

engine.

II

of

this

do

the

Is

done,

absolutely

Band

L.

This

11

trio

and

disDDnnected

damage

charged.

speed

It

contains

that

speed

tester

result.

not

dlscon·

baltery

diode

avoid

would

damage

to

by

a

keeps

such

it.

from

the

the following

ERBEK.E

this

manual and

wiring before

SERVICE

The alternator

engines. Always

disconnecting

ALTERNATOR

with a

quit:k

tenninals

charger,

to

be

prevent

If you suspect that voltage

to

charge

0 Make certain

0 Check

0 Inspect

the

for

connections

illustrations also

make a quick

may

refer

for

and

vary

to

the

sketch

service.

color

coding described

from

earlier

wiring

diagrams

of

your alternator

TROUBLESHOOnNG

the

your

drive

loose

alternator

engine's

alternator

belts

or

disconnected

for

is

not

battery,

is

proper

producing

check

securely

tension.

wires

the

at

WEST-

enough .

following:

mounted.

the

alternator

in

SUP

RING

A

WARNING:

hot.

Do

not

Testing

SHAFT

Engines & Generators

If you suspect the tests.

1.

2.

3.

The

Using a voltmeter,

the output Connect the other

engine.

Start the engine

A

CAUnON:

lng

circuit,

when

the

73

A

failed

touch

until

Charging

alternator

terminal

and

To

never

shut

engine

is

altel'llafor

the

alternator

Voltage

has

connect

B.

voltmeter

record

avoid

damage

o"

the

running!

failed,

the

voltmeter

wire

the

voltmeter's

to

engine

can

has

perform

to

any

the

battery

become

t:DDied

the

red

wire

ground

readings.

battery

switch

very

down.

following

clip

to

on

the

charg·

ALTERNATOR/REGULATOR

SERVICE

The voltage reading should be between

over- or undercharging, shop, or continue

NOTE:

Before removing the alternator for

voltmeter to ensure that

· the R (EXC) termitzal voltage at the

for a properly

13.5

with

B output

operating alternator

and

14.5 volts. If your alternator

have

it

repaired at a reliable service

the

following tests.

repair,

12

volts

DC excitation is present

if

the

previous tesi showed only battery

terminal.

+

Output

1. Disconnect

2. Disconnect

3. Connect a voltmeter

4. Connect to

5.

6. Connect B+

7.

8. Tum on 12 volt accessories equaling

Test

the

battery

ground

cable.

the

wire

from

terminal B

and

connect

Reconnect

The

voltmeter should itulicate

Start the engine.

of the alternator, accelerate

speed rent. The output current should be close to the alternator's maximum ouput.

Output

Hot

Cold

an

the

to

(2000

to

Current

ammeter between B

between

P terminal.

battery

the R terminal

3000

1300

16

amp

24amp

ground

rpm)

rpm

terminal

the

and

on

the

and

this wire.

B (+)and ground(-).

cable

to

the(-)

the

battery voltage.

(regulator).

the

amperage output

engine

to

the specified

measure the output cur-

2500rpm

41amp 50

amp

use your

alternator

terminal.

5000

rpm

48amp

is

at

NOTE:

If

the

screwdriver

coil

might

be

damaged.

2.

Hold

the

rotor

in a vise

remove

the

pulley,

rotor

from

the

front

3.

Unsolder remove

NOTE:

less

150°C

4.

Remove

5.

Unsolder

6.

Remove remove The

7.

Remove

8.

Brush When

be

holder

NOTE:

bent,

damage

plates B and L should

RECTIFIER ASSEMBLY

the

Make

than

five

(310°F),

the condenser

the

regulator

the rectifier and only a brush

replaced

assembly

If

the

terminals L

rectifierfrom

stator

sure

seconds).

it

plates B and L from

mounting

electronic

and

brush

without

might

and

fan,

spacer

bracket

assembly.

that

the

If a diode

might

be

from

screw

voltage

brush

assembly.

spring

replacement:

or

brush

removing

removed,

and B of

result

to

be

gemly

is

inserted too

remove

and

the

stator

solder is removed

damaged.

terminal

and

regulator and

holder

cannot be sepearated.

spring

the

unsolder

the

rectifier.

bent

deep,

the

pulley

seal.

Next,

remove

coil

is heated

B.

the rectifier assembly.

B terminal

is

to

be

stator,

etc.

the

pigtail

rectifier

Therefore,

at

the

center.

the

nut.

remove

the

seal.

lead

wires

quickly

to

more

bolt

brush

replaced, With

the

of

the

assembly

REGULATOR& BRUSH

stator

Then

and

(in than

and

holder.

it

brush

brush.

are

the

HOLDER

the

can

NOTE:

rpm is

that

of

the

(alternator vs at i 3.5 volts.

alternator.

cratlk

pulley)· is 1.78 to 1; all readings

The pulley ratio

DISASSEMBLY

1.

After removing

screwdriver

prying it, remove

the

three assembly through-bolts,

between

the

front

bracket and stator. While

bracket

and

rotor.

are

msert

a

--

..

Engines & Generators

74

An

alternate method for

removing holder regullltor unit and the from the

assembly separated from

. 1. Insert a flat-bladed

2. Maintaining

3.

rear

bnu:ket.

and

the

edge

of brush-holder. the bracket so

NOTE:

Be

enter

for enough

between side and for a distance from

the

Insert a #2 Phillips

remove

Raise

as

careful not

the

stator

move

·the

of

bracket.

the

two

With

the

screwdriver

the

rear

this

to

open

to

touch

1/2

inch core stator

1/2

to

screwdriver

screws

bracket

side of

allOw

and

3/4

holding

ALTERNATOR/REGULATOR

the

Sllllor

winding,

I.C.

diode

rectifier

the

front

bracket

rear

half

of

between

on

the

a gap of

the stator

gap,

laterally

about

the screwdriver blade to

insert

the

bracket

toward

of

an

inch

through the

the

alternator: the

the

same

stator

core

1/2

winding.

the

screwdriver

on

the

without

this

rectifier.

and

the

brush

IUS(!mbly

rotor

stator

core

side

as

the

away

from

inch.

·

rectifier

brush-holder

lifting

it

opening

and

INSPECTION

Diode

Diode When

short-circuited

Checking

Check coil

lead

said

terminal. If tions, assembly.

SERVICE

troubles are classified as

the

diode

is

open-circuited,

diode,

far

Stunt

for continuity

joint

terminal

each

the

diodes

are

open-circuit

cu~nt

flows

Circuit

between

test

short-circuited.

and

shows

the ( +)

between

current

and

oo

current

in

both directions.

heat

sink

the

(-)

heat

flow

Replace

the

short-c.ircuit •

flows.

In

and

the

sink and

in

both direc-

rectifier

the

stator

the

4. Remove the

capacitor mounted bracket. Then brush holder

S.

Carefully withdraw the rear bracket as one

With

stator winding leads

heat damage to the to

renew the brushes

connecting plates

rectifier and possibly

When

reversing this

· winding leads are gently with

the rotor body) after

bracket.

nut

to

the

bracket out of

anchoring

ren:~ove

the

between

procedure,

thereto

the

bracket.

stator,

loosely

the

from

diodes

because

damage

pushed

seating

the B terminal

on

the

outside

third

Phillips

brush

holder

connected

way,

it

is

easy

the

rectifier

and

I.C.

chips.

there

is

the

brush

holder

the

rectifier:

make

sure

back

(from

the

stator

bolt

rear

screw

and

uniL

to

quickly

It

no

need

that

the

possible

into

and

of

the

holding

rectifier

unsolder

to

avoid

is

also to

bend

and

the

stator

contact

the

rear

the

from

the

easier

the

Checking

To

check for

the

short-circuit

with

your ohmmeter

reversing

open.

the

Checking

Check

each

allows

current

to

flow

fir

Open

an

open

test,

leads. If

Diode

of

the flow

in

Circuit

circuit disconnect between

no

Trio

three

diodes

in

both

one

direction,

in

the

diode

continuity

for

directions

replace

diodes

which

diode

leads

lead

is

found,

continuity.

or

does

the

rectifier

have

and check

and

the

diode

If

any

not

allow

passed

body,

is

diode

assembly.

Engines & Generators

75

Stator

Disconnect continuity between the continuity for insulation between found,

the

stator lead

is

found, the stator windings

replace

the

stator.

three

each

ALTERNATOR/REGULATOR

wires

from

the

coil

and

check for

leads

with a

circuit

tester.

If

no

are

open.

Next,

check

lead

and

the

core.

If continuity is

SERVICE

Field

CoB

(Rotar)

Check resistance conform to the specified

Check

for continuity

is

there

grounded. Replace the rotor

continuity, it

between

Resistance

between means

the

value.

Value:

slip rings.

3.87Q

the slip ring

that

the coil or

assembly.

The

resistance must

:!::

10%

and

the

slip

ring

core. If

is

Checking

Replace the brush if it Check the brush spring force. Also confirm that the brush moves

Checking

Because

measured with a micrometer. assembly) when wear

The slip ring

sary

Brusb

smoothly

Brush

length

Brush

Spring

the

Sip

the slip ring wears

Slip

Ring

0.0.

Runout

must

clean

and

polish with a

and

Brusb

has

in

the brush

(mm) Force

(g)

Ring

reaches

be smooth

worn

holder.

very

Standard

Yalue

33mm

0.03

mm

fine

Spriag

to

the replacement value.

Standard

Yalue

18

37fF!O

little, the diameter must

Replace

the

replacement value.

or

less

with

no

crocus cloth.

Replacement

Required

8

210

the rings (rotor

Replacement

Required

32.2mm

0.2mm

surface

oil. If

at

neces~

REGULATOR

The regulator consists

relay; their wires are gathered regulator is stant regardless current

used indicating built-in lC regulator. During alternator rent is controlled automatically

1.

Connect battery positive terminal

2. Connect a voltmeter between and the ground. "O".If faulty wiring is suspected.

used

to

the

field

on

the Captain panel only

no

alternator charge.

an

otherwise indicated, a

of a voltage

into a connector. The voltage

to

always keep

of

alternator

coil when

ammeter (approx.

In

this

speed

necessary.

to The

by

and

case,

regulator

the

alternator output

and·

illuminate the panel light

SOA

the IC

60A

its

cable.

the

vo\tmeter

defeCtive

and

a lainp

con~

to

cut off the flow of

The lamp relay

alternator has a

operation,

regulator.

rating) between the

generator terminal L

field

must

indicate

alternator or·

cur-

·

be

is

IW'IWESTEIIBEICE

l

Englne_s

& Generators

76

ALTERNATOR/REGULATOR

3.

Tum the starting switch voltmeter will indicate a value considerably lower than

the battery voltage. If the indication is near the battery ·

voltage, a defective generator is possible.

4. With the ammeter short-circuited, start the engine.

A

CAUTION:

culled, a large ammeter

5. Increase the engine and read the ammeter.

6.

If

the ammeter reading does not exceed 5A, read the voltmeter at that state reading is the regulated voltage.

7.

If

the ammeter reading exceeds SA, continue charging the battery until the ammeter reading drops to below; connect a 1/40 (25W) resistor

restrid charging current.

8.

The and, therefore, regulated voltage varies with temperature.

It

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

t:Dil.

or

replace the battery with a fully-charged one;

IC

regulator is

key

to the

ON

position, and the

lithe

ammeter

starting

t:llrrent

s~ed

(2000-3000 rpm).

of

the temperature compensation type

is

IIIJt

short·t:ir·

will

bum

out

to

between 2000 and 3000 rpm

The

voltmeter

in

series

to

the battery to

of

the rear

to

use the

of

regulated voltage.

the

5A

or

SERVICE

REASSEMBLY

A

CAUTION:

the

polarity

from

the

diode$

and

1. InstaJI the alternator support bolt through the alternator

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.

lighten Torque values:

Support bolt: Adjusting bracket

NOTE:

Make certain the alternator and spacers as

Connect

be

reversed, a powerful

battery

into

wiring

the

alternator,

harness.

altematDr

current

damaging

properly.

both bolts and recheck belt tension.

20-

24

Nm

(15-

bolt:

needed,

the

engine

to

align

12-14

belts

pulleys.

are

the

alternator.

Nm

(9-

perfectly

If

not,

would

10 ft-lbs)

aligned

insert

Should

flow

the

18 ft-lbs)

with

or

remove

CHECKING

THE

IC

REGULATOR

(OPTIONAL)

VOLTAGE

90

AMP

LINE!

ALTERNATOR. ( WIRING)

Engines & Generators

77

WHITE

EXCITATION

LINE

fl

LINE

i2

cOUTPUT

#10

RED·

CHECKING

12.2 -12.SV

12.2 -l2.8V IGN OFF

ENGINE RUNNING

ALTERNATOR

0

NOT

·--:--

#14

PlNI{

'----!~TO:

NOTE:

It voltage nected

directly to

the

positive battery not·be

connected

connectioQ the

alternator

properly.

AFTER HOOK-UP

-

3.0

-

IGN

ON

RUNNING

12.8V

s.ov

NOT

12.2

12.2 -12.8V

ENGINE

BATTERY+

is

mandatory

sensing

being

charged,

pafnt.

TERMINAL

to

physically

to

any

Otherwise,

not

-

15.0V

-

15.0V

RUNNING

(1500

for

be

It

other

operate

RPM)

wire and terminal

will

14.0

14.0 -15.0V ENGINE

of

ONLY

this con-

the

must

BORG

WARNER

VELVET

OPTIONAL

TRANSMISSION

DRIVE

TRANSMISSION

FROM

COOLER

CONNECTION

SHIPMENT

For safety reasons, the transmission is not filled with transmission fluid during shipment and the selector lever is temporarily attached to the actuating shaft.

Before leaving the undergoes a test run, with fluid. The residual fluid remaining in the transmission after draining acts

against corrosion for at least one year

TRANSMISSION

Check the transmission fluid level on the dipstick. transmission has not been filled, fill with continue

operation, keep a lookout for any leakage at the bell housing, output shaft and transmission cooler. This fluid should changed after the first 25 hours and approximately every 300 operating hours thereafter and/or at winter lay-up.

A

and starting

to

CAUTION:

the

correct

the

WES1ERBEKE

Dextran III ATF transmission

as

a preservative and provides protection

FLUID

use this fluid. During the first 25 hours

Be

certain

size

cooler

engine.

plant, each transmission

if

the

transmission

is

properly

BORG

WARNER

VELVET

.

TRANSMISSION

properly stored.

If

the

Dextran III and

of

is

filled

installed

before

DRIVE

be

SHIFT

The gear shift control mechanism and linkage must position the actuating lever on the transmission exactly in Forward

(F), Neutral (N), and Reverse (R) shifting positions. A detent

ball located behind the transmission lever must work freely to center the lever in each position. The gear shift positions at the helm must be coordinated with those actuating lever through shift mechanism adjustments. An

• improperly adjusted shift mechanism can cause damage the transmission. The shifting mechanism and transmission actuating lever should be free ensure proper operation.

Shifting

Place the gear shift in Neutral before starting the engine. Shifting from one selector position to another selector position may order. Shifts should be made at the lowest speed. Start the engine and set the throttle at idle speed; allow the transmission fluid to warm up for a

LEVER

POSITION

of

the Velvet Drive

of

dirt and well lubricated to

Into

Gear

be

made at any time below 1000 rpm and in any

practical engine

few

to

minutes .

Neutral

Move the gear shift lever to the middle position. feel the detent. This centers the actuating lever on the transmission. With the control in this position, hydraulic power completely interrupted and the output shaft sion does not tum.

NOTE:

Some transmissions switch. aligned

Unless

in

neutral,

the

transmission actuating lever

the

are

equipped with a neutral safety

engine starter will not

You

of

the transmis-

is

peifectly

activate.

should

Forward

Move the gear shift lever feel the detent. The actuating lever-on the transmission is in

the forward position. The output shaft and the propeller shaft

move the boat in a forward direction.

to

the forward position.

You

should

Reverse

Move the gear shift lever to the reverse position.

feel the detent. the reverse position. The output shaft and the propeller should move the boat in a reverse direction (astern).

NOTE:

Moving Position always away from the

gear shift control engine! of

the

actuating lever

to

Forward

This

The

actuating lever on the transmission is in

the

transmission actuating lever

is

the

problem

always toward

engine.

in

may by

If

the

forward position, shut off

be a result

the

gear shift

the

boat moves

of

incorrect movement

lever.

You

from

engine.

backwards

should

Neutral

Reverse

with

the

is

Engines & Generators

78

FORWARD

TRANSMISSION

DAILY

OPERATION

BORG

NEUTRAL

ACTUATING

WARNER

LEVER

POSITIONS

VELVET

REVERSE

0 Check the transmission fluid.

0 Visually check the gear shift linkage and transmission.

0 Start the engine in neutral. Allow a

for the fluid to wami.

NOTE:

Too

low

an

idle

speed will

noise

from

the

transmission gear and damper

such

cases

the

idle

speed should

.

0 Shift into

gear.

few

produce

be

increased.

minutes

a chattering

plate.

at

idle

In

DRIVE

TRANSMISSION

0 Clean off the transmission and properly dispose of the

used

fluid.

0

Refill

the transmission with quantity will vary depending on the transmission model and the installation angle. Fill through the dipstick

DEXTRON

Ill

ATF.

The

hole.

0 Check the dipstick for the proper fluid level.

0 Replace the oil filler cap and dipstick. (Press the dipstick

into place and turn clockwise until finger·tight.)

0 Run the engine, shutdown and recheck the

A

WARNING:

engine

is

running.

hole.

This

Oil

Capacity

Approximately 2.5 quarts (2.36liters) will fill most transmis· sions to the oil level have a direct relationship to the will be required to angle of installation will make a difference oil

required to

Never

Hot

could

cause

fill

the transmission .

pull

out

the

dipstick

fluid

will

splash

severe

burns.

mark

on

the dipstick. Many variables

oil

capacity. Additional

the

oil

.cooler and the cooler lines. The

fluid

while

from

the

in

the quantity

level.

the

dipstick

oil

of

.

A

CAUTION:

cause

damage throttle on

back

the

transmission

Shifting

to

the

to

Idle

gears

engine

when

and

the

above

damper

shifting

damper

1000

rpm

can

plate.

Pulling

gears

will

save

plate~·

the

wear

INSPECTION

0 Visually check for oil leaks at the hydraulic connections.

Check for wear on the hydraulic lines and replace worn.

0 Lubricate the detent ball and shift cable attachments. 0 Inspect the shift linkage. 0 Inspect the transmission bolts; retorque

A

CAUTION:

s/on

shift

positions.

CHANGING

After the initial 50 hour change, the transmission fluid should be changed at every 300 operating hours thereafter or at win· ter haul·out. However, the fluid must be changed whenever it becomes contaminated, changes color, or smells rancid.

Clutch

failure

lever

does

not

fully

THE

TRANSMISSION

will

engage

if

occur

If

the

detent

FLUID

necessary.

the

0 Remove the oil filler cap and dipstick.

0 Remove the

drain into a container.

oil

cooler return line and allow the oil to

0 Reconnect the oil cooler return line.

0 Use a suction pump to remove the transmission oil

through the filler cap/dipstick hole.

if

transmls·

ball

FLUID

FULL

(88°C}

8.4 kg·cm

LEVEL

is

recom·

oil

be

installed at

tempera·

in

forward

2

and

)

DIPSTICK·-

MAKE

CERTAIN RUBBER SCREWED TIGHT

HANDLE

Oil

Temperature

A maximum oil temperature mended. Discontinue operation anytime sump ture exceeds 230°F (ll0°C}.

PRESSURE

An

optional mechanical pressure gauge can the control panel to constantly monitor the pressure of the transmission gear should indicate constant.

SEAL

TO

THE

IS

THE

.

GAUGE

fluid.

of

190°F

A normal reading at 2000 rpm

95-

120 lb·in2 (6.7-

be

BORG

WARNER

VELVET

DRIVE

TRANSMISSION

MAINTENANCE

Transmission maintenance is minimal.

fluid

housing clean, check the

and

routine, Periodically inspect the transmission

and corrosion. Make certain the air vent checking the (fluid will appear

change the

fluid

level look for signs of water contamination

as

strawberry cream).

level

fluid

every 300 operating hours.

Keep

the

exterior

as

part of your regular

and

the

cooler for leaks

is

clear

and

when

Lay-up/Winterize

Storage requires special care. Follow these procedures:

0 Drain the water from the transmission oil cooler

replace it

NOTE:

raw

0 Clean

(use heat resistant paint).

with

a proper mixture of antifreeze coolant.

This

operation will usually occur

water cooling system is properly winterized.

up

the

transmission and touch-up unpainted areas

when

0 Fill the transmission with Dextran III ATF

prevent internal corrosion. (Extended storage 12

months or more).

0 Loosen attaching hardware froin the transmission

output

flange

and propeller shaft coupling

removing the boat from the

and spray

0 Inspect

Look for corrosion of the end fittings, cracks or cuts

the conduit,

all moving parts.

NOTE:

(twelve nwnths or

fluid

before putting

with

lubricant.

the

gear shift cable, linkage,

and

bending

If

the

transmission is

more),

to

prevent intemal corrosion. Reduce

the

engine back

water.

of

the

actuator

to

be

it should

into

Separate the flanges

and

attachments.

rods.

stored for a long time

be

topped

service.

the

fluid

only,

flange

Lubricate

off

the

fluid level

and

to

with

engine

before

in

WARRANTY

Service dealer.

For

assist2~1ce,

Richmond and 1208 Liberty, Tel.:

BORG

placed ation or fully reversing of Therefore torque loads made

at

caused

A

CAUTION:

occur resulting BORG related

If

any

problems occur

TRANSMISSION TROUBLESHOOTING in

NOTES

manuals

WARNER

on

low

by

at

WARNER

torsional

are available from your BORG

contact:

Old Norris

SC

29657

(80())

583-4327

is

its

gears

as

engine speeds. If it

a shock

load,

System-related

low

engine

in

damage

is

vibration

Velvet

Drive

Road

aware of the shock loads that

the

result of mechanical propeller

the

propeller blades

and

directional changes should

is

found

that a failure

any

warranty claim

noises

or speeds to

not

which

the

engine

responsible

of

this

with

the transmission,

can

cause

and/or

for

total

type.

WARNER

can

be

oper-

while

shifting.

be

was

will

be

denied.

vibrations

gear

can

rattle

transmission.

system-

see

this

manual.

OIL

COOLERS

The continued time, erode the inside of the cooler causing cross leaks occur.

These internal cooler leaks

following two problems:

1.

Transmission

and be discharged overboard through

A loss

fail.

2. The raw water

ing

fluid

will eventually

Either case requires

1.

Install a new oil cooler.

2. Refill the transmission with DEXTRON III

flow

of raw water through

fluid

will leak into the

of

transmission fluid will cause

will

leak into the transmission

an

increase

will appear

in

transmission

as

strawberry cream.

fail.

an

immediate response:

will

fluid.

the

cooler will, in

cause one of the

flow

of

raw

water

the

engine exhaust.

the

transmission

fluid

This contaminated

The

transmission

ATF.

If

water

has

needs

to

caus-

Engines & Generators

take Check your dipstick each time until mission the

If need

A transmission cooler some waters, maintenance,

WESTERBEKE recommends having a spare cooler aboard.

be

several

fluid.

fluid

lines that connect

the

transmission fails

the attention of a qualified transmission service

circumstances, depending

80

contaminated the

cleaned out

fluid

changes

Change the transmission filter

may

etc.

fluid,

the

and

replaced

to

get lid of

to

the

to

shift properly, it

last ten years or more but,

it

might only last half that

it appears

cooler.

on

operating

with

transmission

fresh

fluid.

the

contamination.

as

pure trans-

and

clean out

will

most likely

hours,

fluid

It

will

facility.

in

tropical

time.

OPERATION A

pressure

mounted

on

V-drives

culating

stay and

the

ficient

on

pump.

until

engine

RPM

pressure.

approximately

speed Extended when

V-drive,

may

between go

below

may

trolling,

stay

on

2PSI.

cruising

even

6

when

insufficient

causes level and

the

normal corroded

lit,

v-dr

The

of

should while oil

level

cruising

connections.

the

449

ive , (see

switch

installed

be

replaced.

checked

for

necessary.

on

other

models

drop

the

equipped

the

speed

for

This

1200

vary

by

is

though

lit.

to

12PSI.

the

oil

pressure

immediately

running

is

pressure

illustration)

can

in

its

If

blockage.

The

WALTER

warning

instrument

with

The

warning

boat

the

normally

RPM,

as

at

not

Normal

oil

Loss

level

the

normal

speed,

easily

place. the

pump

(not

gets

increases

pump

but

much

low

harmful

the

warning

operation

The

pressure

of

are

drop.

boat,

and

the

If

drop

be

If

pressure

The

is

standard

available

V-DRIVE

light

panel

an

oil

light

under

to

occurs

the

as

RPM,

light

oil

the

be

restored, the the

wiring

the

switch, ,

should

removed

the

pump

cir-

will

way

to

suf-

maintain

actual

400

RPM.

such

to

the

light

will

drops

and/or

major

The

oil

unit light

wiring

which

and

pressure

is

below

should

on

the

TRANSMISSION

is

on

at

as

is

,jt49

PRESSURE

DROP SWITCH

should

stays

should

is

be

an normal,

the

RV-10).

checked

be lit

be

correct

is

mounted

accurate

is

normal,

be

inspected

RV-48

checked

when

checked

and

for

the

and

an

the

for

the

on

proper

oil

the

oil

and

optional

WATERLINE

for

leaks.

boat

loose

light

t~e

side

operation.

pressure

switch

lines

replaced

reaches

and/or

remains

of

gauge

should

feature

If

the

be if

A

clatter

riding

of

Although

the

idle

The

o'iL

especially

WATER

For pipe

housing

of

DRAIN

'protection

plugs

marked

the

water

disconnected

FLANGE

When

V-drive

should rubber

proper

AND

the

to

be

mounts

alignment

or

rattle

the

propeller

~nnoying,

s~eed

level

on

V-drives

and/or

should

from

(located

Water

lines

to

drain

ENGINE

boat

the

REALIGNMENT

is

launched

propeller

rechecked

may

sag

in

the

during

it

is

not

tuning

be

without

freezing

diagonally

Drain

going

the

(see

into

water.

after

shaft

and

corrected

must

V-drive

the

harmful.

up

the

checked

pumps

during

opposite)

illustration)a

the

being

flange

be

at

compression

It

engine

several

winter

water-cooled

in

and

if

necessary.

raised

with

low

RPM

may

,for

times

lay-up,

on

the

drydock,

the

adjustments

is

stroke

be

reduced

smoother

during

remove

front

On

the

bottom

the

engine

some

·

due

of

operation.

and

RV-10

cover

line-up

to

engines

or

to

the

by

the

back

only,

the

shims

the

over-

engine.

adjusting

season,

small

of

the

one

must

of

the

V-drive

with

for

be

Engines & Generators

81

OIL

CHANGE

AND

WALTER

JOINT

LUBE

V-DRIVE

"(RANSMISSION

After

500

hours

up

the

plug

strainer.

from

the

strainer

reconnect the

two located ners

The

they

val.

of

plugs

are

Touch

metallic

screwdriver.

reinstall. plugs main are

not

housing. magnetic. be

Refill proper OIL

FILL). external greased

OIL

FILL

Pull

screw

out

the

V-drive

.

through

RV-10

only,

removing

cover.

approximate amount installation. be

checked

fully

inserted proper marks

on

tube

disulfide),

each tion

V-drive

against

parts.

the

breather

·

has

been

necessary.

the

first

thereafter,

V-drive

in

Reinstall

i43S

and

the

magnetic

on

diagonally-opposite

the

main

can

magnetic

the

object,

Usually,

in

the

removed

with

SAE

level

The Z erk

universal

with

the

breather

with

the

breather the

the

See

oil

varies

with

level

is

the

of

Molykote

which

Additional

run

to

the

strainer

clean

oil

housing.

be

inside

bottom

Only

The

(see 30

(see

a

light

oil

level

SAE

oil

plug

table

capacities.

with

The

the

in

between

gauge.

for

extra

scoring

cap.

and

100

hours

the

operating

:It

6B

bottom

after

(leave

the

outside

hose.

plugs

checked

only

after

face

such

Clean

them

there

part

two

other

illustration).

motor

oil

INSTALLATION

fitting

joint

alemite

gauge.

cap

and

30

motor

elbow.

may

be

in

the

below

the

oil

the

angle

level

level unit. the

Add a

(molybdenum

is

supplied

lubrication

or

galling

Molykote

The

oil

allowed

of

oil

should

temperature.

draining.

the

Unscrew

that

cor-

to

see

remo-

with

as

are

four

of

these

two

need

to

on

should

lub

Un-

fill

·the oil

On

the

added

top for

The

should

gauge

The

H

and

2-ounce

with

after

level

to

sit

operation

cover

elbow

surface.

are

if

a a

and

the

be

by

of

L

and

of

gears,

break-in

should

for

be

changed.

Turn

that

Disconnect

on

the

Reinstall

10

1CHOUSING

STANDARD PLUG

(NOT

'12A

BREATHER

ELBOW

break-in.

bearings

i!

~e

about

and

is

every

Run

off

the

opposite

the

season

the

engine.

oil

strainer).

the

strainer

MAGNETIC)

"12

BREATHER CAP WATER DRAIN

{UNSCREW FOR

OIL

FILL)

WATER

LINE

It

provides

and

other

not

required.

rechecked

a

minute.

after

boat

the

hose

Unscrew

Reinstall

the

Add

and/or

to

warm

Remove

t 43S

leading

and

OIL

LEVEL

GAGE

(PULL

REMOVE)

protec-

moving

unit

oil

the

UP TO

if

Oil

capacity

(Approx.}

RV-10 1

pint

RV-20

2

pints

82

RV-30

pints

3

RV-40

pints

4

RV-48

4

pints

ZF

MARINE

TRANSMISSIONS

DESCRIPTION

The information below the TRANSMISSION TROUBLESHOOTING SECTION applies to all models.

CONNECTION

ZF recommends a flexible connection between the · transmission gearbox and the ·propeiiershattTfthe engine flexibly mounted, in order to compensate for angular deflections. The installation bearing is not required, since the propeller thrust will be taken by the transmission bearing, provided the value

specified under However, the output shaft should additional loads. Special care should torsional vibration. When using a universal joint shaft, make certain to observe the manufacturers instructions.

Even with the engine solidly mounted, the use of flexible coupling or

gearbox bearings caused by hull distortions, especially in

· wooden boats output flange and stem gland

"DRIVESAVER" will reduce stress in the

or

is

specific to the

OF

GEAR

BOX

of

a special propeller thrust

SPECIFICATIONS is not exceeded.

where the distance between transmission

is

less than about 800mm.

ZF

Trans~issions,

WITH

PROPELLER

be protected from

be

taken to prevent

is

NOTE:

shifting is

Bowden cable sheaves, too small a bending radius, etc. In order support

pillar nuts

shift lever. Refer to the model's parts list.

CONTROL

The transmission is suitable for single lever remote control.

Upon loosening the retaining screw, the actuating lever can be moved to any position required for the control elements (cable or rod linkage). Make certain that the shift lever does not contact the actuating lever cover plate: the minimum distance between lever and cover should be

TI1e the actuating shift lever when in the neutral position. The

neutral position should coincide with the neutral position

The shifting travel, as measured at the pivot point actuating lever, between the neutral position and end positions

30mm

When installing the transmission, make certain that

not

impeded by restricted movability

or

rod linkage, by unsuitably positioned guide

bracfcet

for

located

shift cable to secure

o~

the transmission housing above the

of

the

to

mount a

to,

use the threaded

CABLES

0.5mm.

control cable or rod should be arranged at right angle to

of

the operating lever on the control console

of

this lever.

of

the

A and 8 should be at least

for the inner pivot point.

of

A greater amount detrimental and is recommended. However, if the lever travel is shorter, proper clutch engagement might be impeded which, in tum, would mean premature wear, excessive heat generation and clutch plate failure. This would be indicated by slow clutch engagement or no engagement at

NOTE

Check

for

shift lever travel is in no way

proper lever travel

.FORWARD

A

35mm

for the outer and

ail.

at

least each season.

NEUTRAL

N

REVERSE

B

A

CAUTION:

the

actuating

shift

lever

travel

this

mechanism

transmission

warranty

The

lever

from

is

position

is

in

any

of

the

factory-adjusted

neutral

will

position

way

tampered

be

void.

mechanism

to

to A and

with,

behind

ensure

B.

the

equal

If

Engines & Generator.:

SHIFT lEVER

0.5mm

MINIMUM

0

-.

COVER

DISTANCE

83

ZF

MARINE

TRANSMISSIONS

INITIAL

All the engine at the factory prior to delivery. For safety reasons

the fluid is drained before shipment.

Fill the gearbox with Automatic Transmission Fluid

(DEXRON up to the index mark

just insert the dipstick,

into the case after the fluid level is checked and tighten. not forget the sealing ring under the hexhead Check for leaks and change the fluid after the first 25 hours, also make a visual inspection hoses, and shift cables.

VENT

OPERATION

ZF

marine transmissions are test-run on a test stand with

IT

or

DEXTRON

on

ill). The fluid level should be

the dipstick. To check the fluid level,

do

not screw it in. Screw the dipstick

of

the dipstick.

of

the coupling, oil cooler and

KEEP

\lENT

CHECKING FLUID

FLUID

LEVEL

OPENING

CLEAR

TRANSMISSION OPERATING

Do

LOCKING

Locking required: use the gear shift lever position opposite your

direction in the position corresponding to the direction

boat.

WHEN

Rotation is being sailed, being towed, operation charging the battery), will have no detrimental effects on the

transmission

DAILY

THE

PROPELLER

of

the propeller shaft

of

travel for this purpose. Never put the gear shift

UNDER

SAIL

of

the propeller without load, such as when the boat

of

the engine with the propeller stopped (for

OR

BEING

by

an additional brake is not

of

travel

TOWED

or

anchored

in

a river, as well as

OPERATION

of

the

0 Check the transmission fluid.

D Visually check the gear shift linkage and transmission.

0 Start the engine

idle to

wann

D Shift into gear.

NOTE

:

Too

low

from the transmission

the idle speed should

For additional information refer to the following text in this Transmission Section:

MAINTENANCE TROUBLESHOOTING.

in

neutral, allowing a few minutes

the fluid.

an

idle

speed

gear

be

increased

SHAFT

AND

TRANSMISSION

will proquce a chattering noise

and

damper.plate. In such cases

COUPliNGS,

at

FLUID

Change the fluid for the first time after about 25 hours operation, then every 250 operating hours year

Removing

Push a suction pump hose the allows, use the transmission drain). Remove the drain plug from the bottom drain into a container, then reinstall the plug with its sealing washer. Wipe down the transmission and properly dispose the used fluid. After running the engine, shut down and recheck the fluid level.

CHANGE

or

when you change engine oil.

the

fluid

down

through the dipstick hole to

boqom

DRAIN

NOTE

drain this sealing washer.

A

engine dipstick

of

the housing and suck out the fluid. (If space

of

the transmission and allow the fluid to

PLUG

TORQUE

20 • 25

Mbs

: When changing the fluid, take care not to lose the

plug

sealing washer. The drain

WARNING:

is

hole.

Never

running.

This

Hot

fluid

could

pull

cause

out

will

plug

the

dipstick

splash

severe

will leak without

from burns.

of

at least once a

while

the

of

ZF

TRANSMISSIONS

General

Gear

Ratio

{optional)

Note:

There

are a variety

of

gear

ratios

available.

Only

a

few

are

listed.

Fliud

Quantities

(approximate)

Lubricating Propeller

Direction

Fluid

Shaft

of

Rotation

SPECIFICATIONS

(ZF

Standard hardened servo-operated

ZF

25M

ZF

25MA

ZF

30M

ZF

25M • 1.58

ZF

25MA-

ZF

30M-

ATFRight-hand

listed.

Transmission)

helical

(1.88:1

(2.22:1

(2.14:1)

1.58

1.90

Type A or

rotation

pints pints

gears,

with

multiple

disc

or

2.27:1

or

2.73:1)

(0.75

pints

(0.75

(0.90

Dextran -II

for

above

Case

a

clutch

or

2.73:1)

litres)

or

Ill

models

Engines & Generators

84

THE

BT

DESCRIPTION

The BT generator is a four-pole, brushless, self-excited

generator which requires only the driving force to produce AC output. The copper and laminated iron in the exciter stator are responsible for the self-exciting feature this generator. The magnetic field produced causes an AC voltage to

during this voltage to DC and supply it to the windings

· rotating field. This creates an electromagnetic field which rotates through the windings an AC voltage which is supplied transformer is connected in parallel main stator.

windings

tum, supplied to a full-wave bridge rectifier. The rectifier

produces a DC voltage to further excite the exciter stator windings, enabling the generator

AC

be

induced into the related exciter rotor windings

rotat~on.

output.

Diodes located in the exciter rotor rectify

An

AC

of

the transformer and the main stator and is, in

of

the main stator, inducing

to

a load. A step down

to

the

voltage is produced in the auxiliary

to

produce a rated

.~

··

AC

of

the engine

of

the

output

of

the

GENERATOR

The generator's data plate gives the voltage, current frequency rating

of

affixed lo the inside end. A diagram provided on the decal. These diagrams are also illustrated in this manual.

VOLTAGE

A solid state voltage regulator that works in tandem with the transformer regulator

available

' ·

of

the generator.

of

lhe louvered cover

of

the various

REGULAmR

(AVR)

to

produce a more stable

An

AC

wiring decal is

allhe

generaloJ

AC

voltage connections is .

AC

and

output is

BT[&

STUD]

W/OPTIONAL

AVR

SELECI'OR

SWITCH

DErAIL

Engines & Generators

85

VOLTAGE/HERTZ CONNECTION

BAR

BT

GENERATOR

TROUBLESHOOTING

CHARTS

PREUMINARY

Before electrical testing check for proper engine speed/hertz adjustment. Low engine speed will output, high engine speed-high AC output.

Before testing, get a clear explanation exists, be certain it relates to generator components.

CHECKING

cause

low

of

the problem that

AC

voltage

TROUBLESHOOTING

The

bald letters and numbers refer to the components

· · schematics and also to LOW

TEST COMPONENTS IN THE FOLLOWING ORDER:

F Selector Switch

B Exciter Rotor:

the

component resistance charts in the following pages

VOLTAGE (60·100 VOLTS.AC/60Hz ·115·200VOLTSI50Hz)

(6

stud only)

2 Diodes (6}, 3 Field Windings, 1 Exciter Windings

to

the simplicity

Due is relatively simple accomplished with basic tools and repair include the following:

quality

A than

Basic stripper/crimper, terminals connectors, etc.

Repair

rectifier, etc.

multimeter (multitester) capable

one

ohm

and

electrical

parts

such

of

the generators design troubleshooting

and

field testing and repairing can be

parts which should

with a specific diode testing function.

tools including cutters, soldering iron, wire

as diodes, suppressors, fuses, bridge

SEQUENCE

of

the internal wiring

abc

of

reading less

A Exciter Stator Windings 1·1+2

NO

AC

VOLTAGE OUTPUT (EXTREMELY

TEST COMPONENTS

C Main Stator Windings 1 +2 B Thermister 4

2 Diodes (4-6 open/shorted} D Compound Transformer Winding 1+2 B Rotor Field Winding 3

RESIDUAL

TEST

A Exciter Stator Windings 1-1+2 G Bridge Rectifier D Transformer Aux. Winding 3 C Main Stator Aux. Winding 3

Cbeck

to the connections

VOLTAGE

COMPONENTS

Also:

IN

THE FOLLOWING ORDER:

IN

THE

FOLLOWING ORDER:

Circuit connections from the transformer

on

the Bridge Rectifier.

LOW

VOLTAGE

1·5

VOLTS)

INTERNAL

WIRING

SCHEMAnC

(&

STUD)

BT

GENERATOR

REFER

TO

THE

GREEN

W/OPTIONAL

TROUBLESHOOTING

CHART

ON

PAGE 3 FOR

C

MAIN

i----·--..;.·-i

VOLTAGE

REGUWOR

THE

RECOMMENDING

. D

STATOR

WINDINGS

I : I 6

1 I l ' .

RED

COMPONENT

COMPoUND

WlliDIIiGS '-..

i-----.----

TESTING

TRANSFORMER

-.

STUD

SEQUENCE

TERMINAL

BLOCK

AC

I

YElLOW

BLACK

SELECTOR

SWITCH

f

I

'

F

"

A EXCITER

1 and 2 .... 11.5 0

1 ... .49.4 0

2 ....

B EXCITER

1 a b c

C!!-!>.!:iJiary

.a-b

... 1.5 2 Diodes

3 Rotor Field Windings .... 9.7

4 Thermister ... .Infinite

EXCITER

Voltages measured across the

AC

into

Bridge Recitifier: No Load 20

DC

out of Bridge Recitifier: No Load 8 VDC - Full Load 18

\YELLOW

I

..__

___

YELLOW

STATOR

12.90

ROTOR

(6)

.... 0/lnfiiiite · .

CIRCUIT

WINDINGS

AND FIELD WINDINGS

windings

0,

b-e .... 1.5

VOLTAGES

AC

and DC connections

BLACK

__::;=;.:__--""-1

+

r--4---..__,

-

·(AYR).

PLUG

·

.

COMPONENT

are_m~asured

0,

c-a

.... 1.5 0

0

(NOMINAL)

VAC

- Full Load 55

in pairs:

on

the

Bridge Rectifier

Y.AC

VDC

GREEN

BLACK

1----------...::::Bl~U:::.E

1-------

E'

AUTOMATIC

.VOLTAGE

BLUE

__

.....;..;:;___

•REGULATOR

RESISTANCE

C MAIN STATOR WINDINGS.

D COMPOUND TRANSFORMER WINDINGS

Rote: Resistance readings

accessed easily

A,

the connection When checking winding resistance values

both

(IN

OHMS)

1 and 2 ....

3 Main Stator Aux. Windings .... 1.3 0

1 and

Compound Transformer Aux. Windings 3 ...

E Voltage Regulator (optional)

F

Selector

G Bridge Rectifier

G,

C-3

of

0.40

2:

... 0.4 n

Switch

for

the components in the exciter circuit

and

D-3

by

locating the color coded wires

points

the component's electrical connections.

shown

--'

50

Hz

and

voltage checks can be

on

the above schematic.

be sure

."4.3

at

to

Q

lift

Engines & Generators

87

MEASURING

RESIDUAL

VOLTAGE

No-LOAD

The amount

.

be

an indicator

may lie.

Residual Voltage 1

This magnetism in the exciter stator field. between the

generator running

The

following generator components

Exciter Rotor

VOLTAGE

of

no-load voltage produce<t of

voltage is the

AC

presence

of

B-1

by

the generator

where

in

the

generator the problem/fault:

0-14

Vol.ts

[6

Stud] .

AC

voltage produced by the generator from

This

voltage is measured

Neutral

residual voltage is an indication that the

at

60 hertz.

8nd

Hot

leg(s) with no-load

are OK.

a, b, & c and

B-2

Rotating Field B-3

Main Stator

Compound Transformer

The fault lies in one components in the exciter circuit.

Exciter Stator

c-1

A-1

and c-2

or

more

[and A-2

0-1

and 0-2

of

the following

if

applicable] Bridge Rectifier G Selector Switch Main Stator Auxiliary Windings

·pf

applicable]

C-3

Compound Transformer Auxiliary Winding

0-3

on

the

Correct voltage produced with 12 volts excitation indicates

9an

the fault is

G, C-3

If

the generator does

with excitation, then also include the rotor components

150V

as possible faults.

generator and C·2 and/or the compOund transformer windings 0·1 and

D-2 or possibly a

Apply 12 volt

as illustrated. A fault

transformer windings such engine produce smoke

Voltage output greater than residual and' less than rated output 35-100 volts indicates a fault or

B-3. Excitation

rise in voltage return

BRIDGE

The

~lustration

AC

terminals

tenninals,

·Hole: When removing

correc(polarity connection

in

one

or

more

of

the above listed components

or

D-3 •

not

produce the correct voltage [140-

The

Absence

indicates a fault with the main stator windings

shortedthermister.

DC

excitation to the exciter stator windings

in

the main stator and/or compound

to

load

down

and

as

the excitation is continued.

of

the generator should produce a partial

output

and,

to

the

original

RECTIFIER

and

below

the

low

WIRING

shows

color

or

of

any voltage from the

as

a short will cause the generator

the shorted windings to eventually

in

the exciter rotor/field

when removed, the voltage will

our;:;~.

the

color

cod~d

wires at the two

coded wires

reinstalling connections, maintain

on

the ( +) and (-) DC terminals.

at

the ( +) and (-)

c-1

B-1,

B-2

DC

12

VOLT

EXCITATioN

Twelve (12) volt windings should

140-150

(Normal Excitation

voltsAG·m~ured

SOLENOID

EXCfll~GTHE

.

DC(+)

to

Keeping

LED

and

the

EXCITER

DC

cause

excitation

the generator

8-9

volts

.

STARTER

GENERATOR

CJC{-)

to

CIRCUIT

applied

between

DC

no

to

the exciter stator

to

produce

the

Line

load)

r--::l

\

'I

\

I

\

MOTOR

wri"H

9;ound. .

polarity conect.

\

12

vdLT$

.I

between

and

Neutral.

FRAME

{6S11JD)

WIRE

CONNECTIONS

TWO

GREEN

A +

TESTING

&STUD

STATOR

WINDINGS

EXCITER

STATOR

WINDINGS

SELECTOR

WINDINGS

Resistance readings for exciter windings the selector switch in the COMP position are taken betwe'en the positive ( +) and negative (-) leads lifted rectifier. Neither the generator

A·1

AND

A-2

of

these two leads should

ease/ ground

..

TESDNG

A-1 & A-2

RESISTANCE

A-1

and

A-2

Witi;I

off

the

bridge

h~ve

continuity to

...,.

11.5 0

·.

TWOGREEN

BRIDGE RECTIFIER

RED

WINDINGS

Resistance readings for exciter stator windings selector switch yellow wire and the black wire at the AVR plug.

A-1

TESDRG

in the ELEC position is

RESISTANCE

ta~n

between the .

A.:.1

A.-1

with the

.::..

53.0

SWITCH

..

0.

TESDNG

1. Set the meter on .Ohins scale and connect the positive lead

to point #4. Take the negative lead and momentarily touch point#1,#2,#3

· registered

2.

negative lead The Ohm meter should register an arbitrary value at each point it touches.

3. Leave the negative lead on

the positive lead. The meter should register no

4. Place on Reverse these connections

an,Ohm value.

If

the rectifier fails any

is defective.

Note:

bridge rectifiers but +

THE

BRIDGE

and 15. There should

on

the meter.

Remove the positive lead from point #4 and connect the

to

it. Momentarily touch points #t, #2

the

positive

point

#3.

The

AC-DC

REcnFIER

PQint

lead

on

point #1

meter should register

and

of

these tests replace the rectifier

terminals

location

and-

are clearly marked.

(meter·

be

#4, touch point

the meter

may

FLUKE

no Ohm value

Ohm value.

and

the

negative

and

Ohm

should

vary

on

multimeter)

and

fl5

with

val~e.

reg1ster

as

some

#3.

lead

it

AVRPLUG

WINDINGS

Resistance readings for exciter winding

switch in the ELEC position is

lifted the red rectifier.

Note:

has been changed

colors, lwwever, remain the same. ·

A-2

TEmNG

off

the negative(-) terminal

Wires

lift~.

off the positive (

RESISTANCE

A-2- 13.5 0 ·

The

white striped wiring on earlier

to

solid colors on current generators, the

A-2

with the selector

taken between the green wire

of

the bridge rectifier and

+)

terminal

model

of

the bridge

generators

BRIDGE RECTIFIER

Note:

will always

Engines & Generators

89

The

AC & DC

be

clearly marked.

terminal locations

may

vary . The

DC

+

TESTING

REFER

TO

THE

WIRING

B

AUXIUARY

1

:1·.

I I

I .

I

I · l

L

.::L-:::..

L---·~-

-------

SCHEMATICS

ROTOR

WINDINGS

.-

...

N:

-yr

. ...... 1

TROUBLESHOOTING

..

~----;

--~

EXCITER

i

J

ROTOR

WINDINGS

AELD

..

.ROTOR

GUIDES

AND

COMPONENT

WINDINGS

RESISTANCE

CHARTS

IN·THIS

MANUAL

1'ESnll

AUXIUARY

WINDINGS

1

abandc

Locate.

the

~terminal

auxiliary

in

12

I,

tenninal points a & unsolder

If

should tenninal points and the rotor shaft/case ground.

Auxiliary

TES'DNI

Refer to the illustation The connections

resistance

connection points. These

unless

connection and verify connections lifted, there

shaft. This

windings.

winding groups. Position the exciter rotor as shown

the illustration and count

o'clock point either left

band

c.

Mea8ure

th~

connections unless a faulty reading appears.

this

occurs,"

tinsolder and verify the winding fault. There

be

no continuity found between any•m the three

windings

&Stud-1.50

ROTOR

field

winding cminections are noted as the

of

the

value with your ohmmeter between theSe two

a faulty reading appears.

would

Field

Windings

points on the exciter rotor for these

off

the porcelain knobs from the

or

right to locate tenniri.al points

the resistanCe value between the pairs

b,

b & c

and

c &

a.

There is no need to

1-a,

b

and

c

FIELD

WINDINGS

or

diagram

red_&

white

striP.ed

connections need not be unsoldered

tlle

resistance reading. ·With

Should

be

indicate a short to ground with these field

3

of

the exCiter

wires.

If

this occurs unsolder the

oo

continuitY.

· ··stlld-9.7 a

of

.~r.

(+")iand

M~itte

these

tQ

the rotor

(-)

the

.

ILLUSTRAnON-AND

DIAGRAM

OF

THE

EXCITER

ROTOR

l"''IY'lWESTERBEKE

l Engines & Generators

90

.

REFER

INFINITE

TO

THE

WIRING

BLOCKING

TESDNG

SCHEMATICS

OHMS

THROUGH

====f<}==

TROUBLESHOOTING

THE

DIODE

INFINITE

DIODES

AND

GUIDES

THERMISTER

AND

COMPONENT

RESISTANCE

.

CHARTS

IN

THIS

MANUAL

12VBA1TERY

TES11NG

Six diodes are mounted AC voltage produced by windings to rotating field windings.

The diodes can be easily checked colllDl.On jumper leads

A short

above without having check it with an ohmmeter.

Nata:

will

winding's

When leads are put across

passes through the diode allowing

brightly.

DIODES

DC

voltages

automotive 12-volt high

and

the

generator's 12

or

an

open

in

a diode can easily be

to

Anempting

give

erroneous

connections.

to

check diodes in place with an ohmmeter

readings

on

the exciter rotor; they rectify the

the

three

and

'supply

unsolder

on

the

diode,

groups

this

in

place

beam

headlight

volt

starting

and

isolate

the diodes

as

illustrated, voltage

the

headlight

of

DC

with

found

due

the

auxiliary

voltage

the

battery.

each

to

use

bulb,

with

diode

the

glow

to

the

of

a

some

the

to

auxiliary

Reverse voltage passing through or

1.

2.

In both

the resistance value

integrity

connections

TESnNG

The between resistance: Infinite.

The changes reduce

operation when Should rotating field winding

the

it

may

glow faintly.

Shogld directions,

Should directions,

1.

and 2. above, the diode should be replaced. Check

of

thermistor

the + and

Thennister

take

light

amperage

the

voltage

Will be prOduced ..

leads

across

the

bulb

not

the

diode

the

bulb

glow

the

diode

of

the rotating field winding and the

the tnermister connected across

of

the rotating field winding.

THE

THERMimR

is

located

- connection for the rotating field winding

·

is

a voltage absorber when amperage

place with

flicker

if

open

of

the

generator

load

changes

thennister

the

diode.

The

diode should block

it,

and

the

headlight should not glow,

glow

with leads connected in both

is

open

intemally.

with leads connected in both

is

shorted internally.

the+

on

the

Exciter Rotor and connects

the

generator

circuited,

other

short

it

will negate the

on

the

stator windings and no AC output

to

help preventl

it

has

no

affect on the

than a flicker in the lights

take place not occurring before.

affects

and-

load

or

of

the

When

exciting of a very thermister. growling is thennister area

removed

light

low

from

allowed

of

the

and

flicker until a replacement

1-.-v-#WESIEHBEKE

I Engines & Generators

91

the

generator

or

no

AC

There

will

the

AC

to

continue

and

some

electrical smell/smoke visible in the

rotor

rear

the

generator operation restored other than for

in

an

effort

to

locate the cause

output

and the cause is a shorting·

be

no

loading

generator. However as the excitation

the

short

ca.trier bearirig.

of

the drive engine. No

will

produce

The

themiister can be.

is

installed.

heat

in

the

MAll

STATOR

Whidings

between Post

below

terminal

lift

lead

.\

TESDNG

VERY

REFER

TO

THE

WIRING

AND

COMPONENT.

MAIN

STATOR

WINDINGS

WIND.GS

Group

G-1:

lifted #4 from Junction Terminal or Red Isolation

the transformer and lead

Block.

#5 off

To

totally isolate this winding group. Also ,

the

~rminal

C ..

The resistance value

16

lifted off

Bl~k

is

measured

STATOR

LOW

VOLTAGE,

SCHEMATICS

RESISTANCE & CHARTS

:the

AC

WINDINGS

OR

NO

VOLTAGE

TROUBLESHOOTING

IN

THIS

FROM

TERMINAL

.

·MAIR

Resistance is measured

connection on the bridge rectifier

connection on the Voltage/Hertz

c.tinuftY

these leads to the case/ground or croups.

_

BOARD

STATOR

'¥ain

stator auXiliary

Test:

GUIDES.

MANUAL

AUXII.IARY

No

continuity should

WINDINGS

between

windings

the

and

Bar.

to

lifted

the

c-3 6

be

either

t:-3

double

lifted

found

of

(6

STUD)

black

double

Stud-

from either

the

transformer

AC

red

1.30

of

FROM

t

TERM/~

f~

-

rt . 1

W"mdings

be~ween

Isolation

AC

Lift

Main

Group

the

Post

Terminal

lead

#2 off

stator

lifted lead 11 from

winding_s.

BOARD

.

G-2:

below

the transformer and lead #3 lifted off the

Block.

To

the

terminal Block.

AC

R~l

The resistance value is measured

totally isolate this winding group.

c-1 """0.40

TERMINAL1

~~P~T

,.,

the

Junction Terminal or

c-2-

0.40

BLOCK

(6

Stud

J

(6

Stud)

Red

OLTAGEIHERTZ

!

\NNECOON

-

..

.

BAft

.

Engines & Generators

92

REFER

TO

THE

WIRING

SCHEMATICS

COMPOUND

TROUBLf;SHOOTING

TRANSFORMER

GUIDES

AND

COMPONENT,

RESISTANCE & CHARTS

IN

THIS

MANUAL

COMPOUND

MEASURIII

Windings

lifted

lead

AC

tenninal

Windings

lifted

lead

AC

tenninal

C8llllnally

of

these

tran.sfor:mer

TRANSFO-EI_l.

RESISTANCE

&roup

D-1:

#4

from

block

Grolgt.

D-2:

#1

from

block.

Compound

~1

&D-2-0.40

Test

.

No

lea.dS

to the case/ground or

groups.

TRANSFORMER

~~

~

:

~

I

·I::

==#=·I

·1

.2

3;

Resistance off

the

AC

switch

in

the

Voltage/Hertz

#2

and

#3

totally

isolate these windings.

TransformerAuxiliarv

~~~~·H~P~

D

:{9

Si\JD)

. ·

Resistance value is measured between

the

isolation post and lead #&lifted off the

..

(illustrated below) .

Resistance value is measured between

the

isolation post and lead

Transformer

continuity should be found from either

Windings Resistance

to

~#?lifted

·

either

of

the,

.

. .

off the

ConUnaiiJ

of

these

leads

trrinsjormer

AUXILIARY

value

is

measured·

·tenninal of the bridge rectifier (with the selector

the

ELBC

position) and the

connection bar. Off this same bar, lift the

red leads that come from the auxiliary windings to

D-3-4.3

Test

groups.

n

No

continuity should be

to

the

caselgrowui or

WINDINGS

between the yellow wire lifted

#1

Windings

to

g.;3

red

lead lifted off

Resistance

found

either

of

·

(6

from the

STUD)

eitlle.r

~·

Sl

/''W¥'1WESIERBEICB

l Eng/IJIIS & Generators

93

VOLTAGEADJUSniENTS

NO-LOAD

Voltage

being

l.

The

2.

to

3.

·

..

VOLTAGE

adjustment

governed

selector switch

position

confirm momentary voltage

load

output

hertz). volts

To

raise

(non-conductive under transformer. soften reduction

be

accomplished

steel the transfonner core. Varying the shim thickness by inch (0.025mm) will change the No Load voltage

no-load voltage, start the generator and apply a

produced by the generator after

is

removed

from the generators

The

at 615-62 hertz (232-236 volts at 515-52 hertz).

or lower the voltage, shims

the

steel

at temperatures in the

in no-load voltage

bar

to

Fli'LL·LOAD

The

three

red

can

be

used

lower

it

by

1noVinithe single/double red connection on the

other

side

from

or

#3

to

decrease. increase to

the

excitation

reCtifier

ADJUSTMENT

is

made

with the generator regulation

by

the compound transfonner. ·

[if

applicable] must be in the comp

(moderate)

no-load voltage should be between 121-124

laminated bar on top

The material used for shimming should not

reduce the

VOLTAGE

connections coming into these two components

to

increase

#3

will

load to excite the transformer. The

the

momentary

is

no-load voltage. Note the voltage

120

volt leg(s) (230 volt 50

of

varying thickness

material)

by

are

placed

or

removed from

of

the compound

176°

(80°

C)

range. A small

(1

to

3 volts) am sometimes

gently

tapping the top

gap

]Jetweetf1he existing shims and

of

ihe laminated

ADJUSTMENT

AC

voltage to the bridge rectifier or

to

12 or

#1

to increase and from #l.to 12 ·

Increasing AC voltage to the rectifier

and

theAC output. Decreasing AC voltage

lower excitation. and the AC

,001

byA-6.Y.Olts.

Output.

Tliese

will

Connects

to

1,

2,

or

3,

ted

increase

THREE

RED

'

VOLTAGEIHERTZ

CONNEcTION

.connections

full

amperage load the acceptable levels Note:

·

need

ltGta:

overload

are generaliy used to increase excitation when at

Hertz!Speed

to be adjusted when these connections are moved.

Do

not

cqndltions being placed

(inductive-motor

the

result

of

BAR.

6STUD

EARUER

At

108

volts-

drop

use

these adjustments

type

loads).

this

type

of

MODELS 6 STUD

output

60 hertz or 210

is not the issue, No-load voltage may

Loss

overload, will cause a

or

of

the generator fails below

to

compensate for

o.n

the

of

generator

decrease

6

generator/engine

AC

voilage

volts-

hertz/speed,

drop

to

.

50 hertz.

in

voltage

output.

CHANGING

When changing generator Frequency/Herq in the

the models Operator Manual or Service Manual for the proper procedures. on

the many different generator

FREQUEICYIHERTZ

Thes~

procedures will vary greatly depeiiding

ni'odels.-

field

refer to

AVR

SELECTOR

This

'SWitch

optio_l;llll

position.

SWITCH

is

norhlally set

AVR

is installed, the switch is toggled to the ELEC

YElLOW

AND

COINECTIOIIS

in

the COMP position;

·

~

·~

"i

...

.....

J

SWITCH

If

an

~

AND

PLUG

Nate:

stator bridge

A.V.R.

Nate:

The colors will,

wires.

CONNECTIONS

Wfth

the

selector switch

windings

rectifier·

PI..UG·AitD

are

and

·(s

STUD)

in

ELEC divided, the

other

one

group

through

COIIIECDONS

position

is excited

the

through

A.V.R.

Striped wires were used on early motkl generators.

however,

matchup to the cu"ent solid color

exciter

the

BT

GENERATOR

VOLTAGE

REGULATOR

ADJUSTMENTS

(3

PHASE)

Description

The

voltage regulator is an advanced

optimum

~omplete

conditions

This engine

±1% and variations VOLT driver) until

HERTZ

same normal possible VOLT stabilize. situation,

AC

generator performance. It is equipped with

protection circuitry to guard against operating

that

could

be

detrimental

potentiometer is used to adjust output voltage. At proper

operating speed the output voltage should

from

a no-load condition

from

power factor 1.0 - 0.8 with engine drive speed

up

to -6%. Prior to starting

and

STAB

trimmers (using a mini phillips

fully in a counter clockwise (Minimum) direction

you

feel them

trimmers completely clockwise (Maximum)

manner.

speed, and with VOLT adjust at minimum, it

that output voltage will oscillate. Slowly rotate

adjust clockwise.

Increase tlte voltage to the desired value. In

only

bit

their stops.

With the

the green LED will

ge~erator

The

voltage output will increase

design

which

to

the

AC

generator.

to a full

rated generator output

the

engine, turn

Thrn

the

AMP

running at no-load, at

stay

lit.

be

screw-

Stability

This

potentiometer response pensation voltage

In running

Turn

starts

te~lockwise

a

to

and

output.

order

to

adjust the ragulator stability the generator

at no-load and the

the

sru adjust slowly clockwise until the voltage

to

fluctuate.

volt.

VOLTAGE

_permits

generator load changes

obtain a minimum

At

until the voltage is stable within 1 or 2

REGULATOR

vari~on

o~tput

this point rotate the

of

so

as

recovery

must

DIAGRAM

the

regulator's

to

limit

time

be

monitored.

.STAB

overcom-

to

adjust

ensures

held

the

and

in

is

this

the

normal

must

coun-

tenths

the

at

and

be

of

Amp-Hertz

These

two

adjustments are used in

protection circuits in the voltage regulator

by

the illumination

of

colored

1. Delayed overload protection (yellow LED).

2.

Low

speed protection (red LED).

systems

Both adjusted using the respective potentiometer. circuits voltage overheating.

The

overload protection system has a temporary overloading motor start-up or other similar load lator

also

tor operation

the generator.

with

Setting

In

order

be

must

·1. Load the generator

the engine by hertz

2. Rotate the AMP adjustment counterclockwise until it hits

stop.

its put of should

3.

Slowly output voltage increases age yellow

4.

Return

and

Should this not happen, repeat

NOTE:

remove

Setting

NOTE:

jumper

two

60

setting,

1.

To

lower (54

2. Rotate the Hertz adjustment counterclockwise the the

3. Increase the engine speed . The red "LED" light

put

With the

tion

normally.

have

an

intervention

are

able to cause

to

safeguard the excitor windings

has

a third

to

indicate correct operation of

the

Overload

to

set the

loaded to its full output rating.

10.10% (54 Hertz

on

50

hertz units). ·

Wait about 15-20 seconds

the

generator should drop and

come

on.

rotate the

output at the start of the adjustment.

LED

light should come

to

nominal speed, the yellow

the

generator voltage will rise to

When

changing

the

60

hertz jumper bar

the

Underspeed

If

the.

unit is

strap

is

in

Hertz

terininals.

the

generator should

adjust

the underspeed

the

engine speed at

hertz

on

60 hertz

generator's same

time the red "LED" light

will

return

above

adjustments made, the

an

· ·

of

the generator

LED

(green), that

Protection

AMP

overload

to

its

AMP

adjustment

from

operating

place

on In

units,

AC

output voltage

will

to

normal.

conjunction

LED

lights.

threshold

adequate

rating, then

to

60

reduction

surge

protection,

on

approximately

on.

the

hertz

to

from

Protection

at

60

Hertz

the

regulator

order

to

adjust

be

running

(low

frequency)

90%

of

its

45

hertz

to

its

normal

go

out

and

with

that

are

which

Each

in

and

prevent

delay

which

during

times

demands.

glows

during

the

decrease

60

hertz

units,

after

which

the

yellow

clockwise

97%

At

this

LED

will

its

normal

adjustment.

50

hertz

the

regulator

e.nsure

board

the

underspeed

at

no-load.

protection

normal

running

on

50

hertz

starts

to

decrease

co~es

on.

speed

the

AC

regulator

the two

indicated

can be

of

the

two

excitor

their

pemrlts

such

The

regu-

genera-

regulator

generator

the

speed of

45

the

AC

LED

until the

Df

the

point

turn off

value.

operation,

board.

that

the

between

circuit,

speed

units.

slowly

and

(frequency)

voltage

should

out-

func-

out-

light

volt-

the

the·

until

as

at

.

I...,IWE&TERBEKE

f

Engines & Generators

95

AC

TERMINAL

BLOCK

CO.NNECnORS

AND

WINDING

DIAGRAMS

AC

TERMINAL

BLOCK

1201240V-80Hz.IQ;;b4Jj

L1

L2

CONNEC'nONS

L

(6

STUD)

~r;~t230V-50Hz

N L ·

,WINDING

N

NGI'ES

The

winding diagrams show the connections

. obtain the correct voltage and frequency.

The

Ground Wire that connects from the

Generator Frame must

the

11

5V-50Hz to

For

Output

. ends for

for the rating from the hot lead connection.

*When

lead connections.

*"

wiring

DIAGRAM

230V-SOHz.

Leads

from

studs

that

120160hz.

the

.accept

a

jumper

(6

STUD)

~~~,_~L2

•

necessary

be

moved

AC

Terminal

multi-strand copper wire

Neutral

when

changing

Block use terminal

is

required

between

'!laY. 50

'240V 80Hz

to

Stud to

from

the

Hz

sized

Engines

& Generators

96

BT

GENERATOR

r-------------.

I I

I ' A

I I

I

I 1 I I

EXCITER

STATOR

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

I 1 I C l

: :

_________

EX'TER

I I I 6

I I

I I 2

I I

I I 4

I I

3

PHASE

I

:

ROTOR

FJElD

.J

TWELVE

10

: S

INTERNAL

WIRING

WIRE·RECONNECTABLE

,-------,

1

-,.,

<.:1

·s

ca

DsTATDR

ffi

"'

I

11

9

7

5

1

3

BT

GENERATOR

NOTE:

NO

AC

VOLTAGE

RESIDUAL NO

LOAD

15 • 20

AC generator

FAULT

OUTPUT

VOLTAGE

PRODUCED

VOLTS

BLUE

YELLOW

TROUBLESHOOTING/3

troubleshooting

AT

NO

AC.

LOAD.

AT

must

be

performed

with

1.

Short

or

main

stator

2.

Shorted on

exciter

3.

Four

or

open

diodes

1.

Blown 6 AMP auxiliary

PHASE

the engine

open

in

the

winding.

suppressor

rotor.

more

shorted

on

exciter

fuse

circuit

AVR.

RED

operatin

at

60Hz,

PROBABLE

or

r.oto.r.

GREEN

CAUSE

4.

Open stator

5.

Open

field

3.

Shorted

stator

RESISTANCE

A.

EXCITER

B.

EXC~:t"ER

C.

ROTATING

D.

MAIN AUXILIARY

E.

VOLTAGE-REGULATOR

F.

AUXILIARY

in

exciter

winding.

in

rotating

winding.

or

open

auxiliary

VAWES

STATOR ROTOR

FIELD

STATOR

WINDINGS

WINDING

CIRCUIT

main

winding.

(17.9

WINDINGS

(2.49

(1.2

FUSE

ohm)

(0.05

ohm)

-

a b c

ohm}

(0.6

ohm)

_

LOW

AC

VOLTAGE

NO

LOAD

HIGH

AC

150

VAC

OR

UNSTABLE

AC

VOLTAGE

60

·100

VOLTS

60

·100

OUTPUT

HIGHER.

VOLTAGE

DROP

AC.

OUTPUT

AT,

VAC.

VOLTAGE

OUTPUT.

UNDER

LOAD

2.

Faulty

voltage

regulator

1.

Open

or

shorted

exciter

2.

Shorted

1.

Faulty

voltage

1.

STB

pod

needs

adjustment.

1.

Diode(s) breaking applied

Engines & Generators

diodes

rotor 1 to 3 diodes.

exciter

rotor

winding.

regulator.

on

regulator

on

exciter

down

(inductive)

rotor

when

1-3

load

97

ln.

is

diodes.

3.

2.

Faulty

voltage

regulator.

1

•.

regulator.

GENERATOR

AC

VOLTAG,E

(3

,CONNECTIONS

PHASE)

VOLTAGE THREE

.

The

(0

to

shown

figuration

REGULATORS

PHASE

regulator

6)

and

connection

CONNECTIONS

is equipped

their related

of

the

generator.

brass

·points

betw.een_pin_#Land_pin_#2

connection

NOTE:

the

#2

Series

regulator

and

Delta

board

170

#0

on

requires

between

-270V

with

seven

jumpers.

and jumpers

The

sensing

numbered

The

for

leads

terminals

illustrations

the 3 phase

connect

on._the_AG.tenninal_block

the

voltage

the

terminal B and

regulator.board.

installation 'of a jumper

0.

and

·

con-

on

AC THREE

l-N

-120

L

-N

·110

TERMINAL

PHASE

VAC

10

VAC

10

CONNECTIONS 12

PARALLEL

60

HZ

5ii

\Hz

WIRE

WYE

L

·l·

L

-l-190

(STAR)

208

VAC VAC

30

60HZ

50

HZ

l·l-450VAC L

-N • 265

USE

#10

AWG

JUMPER

WIRES

REPOSITION GROUND

AS

l2,

THE

SHOWN

L

l3

VAC

FOR

·L • 240

-N

-120

30

10

VAC VAC

60HZ

60

30 10

SERIES

HZ

. L

~ERIES

60

HZ

60HZ

WYE

(STAR)

L·l·380VAC

-N -230

DELTA

L

·l-

L2,

L3

·N

VAC

1

230

·115

30

10

1

L2

L3

N

VAC

50HZ

50

30

10

HZ

50 50

HZ HZ

Engines & Generators

98