Westerbeke 10.0 KW-60Hz SBEG, Service Manual

Page 1: ... 0KW 60Hz 12 0KW SOHz BTDC Single and Three Phase MARINE DIESEL GENERATORS PUBLICATION NO 45100 FIRST EDITION March 2001 WESTERBEKE WESTERBEKE CORPORATION MYlESSTANDISH INDUSTRIAL PARK 150 JOHN HANCOCK ROAD TAUM ON MA 02780 7319 TEL 508 3 76n FAX 508 884 9688 WEBSITE www WESTERBEKE COM Al ANA Member National Ma rine Mall1 faclurus AsJ ocUJliol l ...

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Page 3: ...near the carburetor fuel line filter fuel pump or other potential sources of spilled fuel or fuel vapors Use a suitable container to catch all fuel when removing the fuel line carburetor or fuel filters Do not operate with a Coast Guard Approved flame arrester removed Backfire can cause severe injury or death Do not operate with the air cleaner silencer removed Backfire can cause severe injury or ...

Page 4: ...ter Acid may splash on the skin or into the eyes inadvertently when removing electrolyte caps TOXIC EXHAUST GASES A WARNING Carbon monoxide CO is a deadlygas Ensure that the exhaust system is adequate to expel gases discharged from the engine Check the exhaust system regularly for leaks and make sure the exhaust manifolds are securely attached and no warping exists Pay close attention to the manif...

Page 5: ...anual along wilh olher cautions and notes to highlight critical information Read your manual carefully mainlain your equipment and follow all safely procedures ENGINE INSTALLATIONS Preparations to instaJl an engine should begin wilh a thor ough examination of the American Boat and Yacht Council s AB YC slandards These slandards are a combination of sources including the USCG and the NFPA Sections ...

Page 6: ...is at or below the load waterline will result in raw water damage to the engine and possible flooding ofthe boat If you have any doubt about the position of the water injected exhaust elbow relative to the vessel s waterline under the vessel s various operating conditions install a siphon break NOTE Asiphon break requires periodic inspection and cleaning to ensure proper operation Failure 10 prope...

Page 7: ...0KW 60Hz 12 0KW 50Hz BTDC Single and Three Phase MARINE DIESEL GENERATORS PUBLICATION NO 45100 FIRST EDITION March 2001 WESTERBEKE WESTERBEKE CORPORATION MYLES STANDISH INDUSTRIAL PARK 150 JOHN HANCOCK ROAD TAUNTON MA 02780 7319 TEL 1 508 823 7677 FAX 1 508 884 9688 WEBSITE WVtW WESTERBEKE COM NMMA Member National Marine Manu acturers Association ...

Page 8: ...che o Throbbing In Temples o Muscular TWitching o Vomiting o Weakness andSleepiness o Inability to Think Coherently IF YOU OR ANYONEELSE EXPERIENCEANYOF THESE SYMPTOMS GETOUTINTO THE FRESHAIR IMMEDIATELY Ifsymptoms persIst seek medicalattention Shut down the unit and do not restart until It has been Inspected andrepaired This WARNING DECAL is provided by WESTERBEKEandshould be fixed to a bulkhead ...

Page 9: ...ernor 38 Fuel Injection Timing 39 Fuel Injectors 40 Glow Plug Testing 41 Starter Motor 42 Generator Wiring Schematic 70 Remote Panel Schematic 71 Specifications Generator 72 BT Generator Single Three Phase 76 12 Stud Internal Wiring Schematic 77 Component Resistance Values 77 Internal Wiring Schematic 6 Stud 78 Raw Water Pump 46 BT Generator Voltage Regulator 79 Engine Adjustments 47 BT Generator ...

Page 10: ...IONAL V ORIVE TRANSMISSION ILLUSTRATED RIGHT SIDE OIL FRONT DC ALTERNATOR RAW WATER UNIT 1 0_ START PRESSURE CAP THERMOSTAT WATER HEATER FRONT OIL FILL COOLER AIR INTAKE AIR FILTER _F REfIEAT SOLENOIO LIFT PUMP ffB i FUEL FILTER REAR HEAT EXCHIANGER LEFT SIDE ATF DRAIN Engines Generators 2 ...

Page 11: ...LEFT SIDE OIL PAN RIGHT SIDE OIL PRESSURE GENERATOR EMERGENCY STOP SWITCH CONNECTION TO _o nu BREAK qt EXHA UST ELBOW r S rART SOLENOID MANIFOLD PRESSURE CAP UULA I FILL STAF TER MOTOR REAR OIL FILL ASSEMBLY AIR INTAKE SILENCER FILTER PUMP OIL FILL ENGINE BLOCK DRAIN PLUG OIL DRAIN HOSE FILTER Engines Generators 3 ...

Page 12: ...ld You must provide us with this information so we may properly identify your engine In addition include a complete part description and part number for each part needed see the separately furnished Parts List Insist upon WESTERBEKE packaged parts because will fit or generic parts are frequently not made to the same specifications as original equipment CustDmer IdentificatiDn Card L WESTERBEKE I E...

Page 13: ...ean terminals and correct cables 5 Repair or replace starter 6 Check clutch for disengagement 1 Bleed air from fuel system 2 Clean or replace filter 3 Adjust injection pressure 4 Clean or replace nozzle 5 Repair or replace injection pump 6 Adjust injection timing a Adjust valve clearance b Lap valve c Replace valve and valve guide d Replace valve spring e Compression leaks through cylinder head ga...

Page 14: ...ng gap positions 4 Displaced or twisted connecting rod 4 Replace connecting rod OIL LEVEL FALLING 1 Defective stem seal 1 Replace stem seal 2 Worn valve and valve guide 4 Replace avalve and valve guide EXCESSIVE FUEL ENGINE BODY TROUBLES I CONSUMPTION 1 Noisy knocking 1 See KNOCKING 2 Srnoky exhaust 2 See SMOKYEXHAUST 3 Moving parts nearly seized or excessively worn 3 Repair or replace 4 Poor comp...

Page 15: ...NECTING ROO ANO CONNECTING ROO BEARING I 1 Worn connecting rod big end bearing 1 Replace bearing 2 Worn crankpin 2 Grind crankshaft 3 Bent connecting rod 3 Correct bend or replace PISTON PISTON PIN AND PISTON RING 1 Worn cylinder 1 Rebore cylinder to oversize and replace piston 2 Worn piston pin 2 Replace piston 3 Piston seized 3 Replace piston and rebore cylinder 4 Piston seized and ring worn or ...

Page 16: ...ozzle c After injection drip c Repair or replace nozzle d Nozzle needle valve seized d Replace INTERMITIENT 1 Fuel filter clogged 1 Clean or replace EXHAUST SOUND 2 Fuel pipe sucks air 2 Retighten pipe joints or replace pipe 3 Water mixed in fuel 3 Replace fuel OVERHEATING 1 V belt slackening or slippery with oil 1 Adjust replace or clean 2 Damaged water pump 2 Replace 3 Lack of coolant 3 Add 4 Lo...

Page 17: ... coat of oil grease or sealant to parts as specified 4 Be sure to use a torque wrench to tighten parts for which torques are specified 5 Ant time the engine is assembled new gaskets and O rings must be installed OVERHAUL CONDITIONS Compression pressure tends to increase a little in a new engine until piston rings and valve seats have been broken in Thereafter it decreases gradually with the progre...

Page 18: ... any deposits of dirt and oil Be careful not to damage the disassembled parts Arrange parts in the order of disassembly Mark or label parts as needed to insure proper mating and reassembly Keep parts clean Mount the engine on a suitable engine stand for disassembly With the transmission separated from the engine begin the following step by step procedure to disassemble the engine l Remove the tran...

Page 19: ...embly a Remove the bolts that hold the rocker stays in position and remove the rocker shaft assembly b Remove the valve caps DISASSEMBLING THE ROCKER SHAFT ASSEMBLY 21 Disassemble the rocker shaft assembly Put idcntifica tion on each rocker arm as to its location on the rocker shaft 22 Remove the cylinder head bolt Loosen the cylinder head bolts In two or three steps in the sequence shown NOTE If ...

Page 20: ...th with facilitate removal NUMBERS INDICATE THE SUGGESTED ORDER OF DISASSEMBLY ORDER OF DISASSEMBLY 27 Remove the rear plate The rear plate is doweled in position Pull the plate as straight as possible when removing it 28 Remove the oil seal case Remove the bolts that hold the oil seal case in position Remove the case from the cylinder block with a screwdriver A CAUTION Do not cause damage to the ...

Page 21: ...AR ENGINE DISASSEMBLY TIMING GEARS ORDER OF DISASSEMBLY 14INJECTION PUMP CAMSHAFT REMOVE 10 THRU 12 I AS AN ASSEMBLY I I I e 12 FUEL INJECTION PUMP CAMSHAFT GEAR 15 OIL PUMP GEAR 11 CAMSHAFT 7T1MING GEAR CASE CRANKSHAFT PULLEY Engines Generators 13 16 FRONT PLATE ...

Page 22: ...earing journals when removing the camshaft 35 Remove the fuel injection pump camshaft a Remove the stopper bolt b Tap the rear end of the camshaft with a copper bar to push it out of the front side of the cylinder block 36 Remove the gear when required To remove the gears from the camshaft and fuel injection pump camshaft lise an arbor press 37 Remove the oil pump Remove the bolts that hold the oi...

Page 23: ...or so that it will touch the end of the crankshaft and measure the end play If the end play exceeds the limit replace the flanged bearing CRANKSHAFT END PLAY STANDARD 0 00197 0 00689 in 0 050 0 175mm LIMIT 0 01969 in 0 500 mm 45 Remove the main bearing cap a Lay the cylinder block with its bottom oil pan side up b Remove the bolts that hold the main bearing caps in position Remove the caps c Remov...

Page 24: ...he illustration If warpage exceeds the limit reface the bottom face with a surface grinder WARPAGE CYLINDER HEAD BOTTOM FACE STANOARD 0 0020 in 0 05mm MAXIMUM LIMIT 0 0039in 0 10mm INSPECTING THE CYLINDER HEAD BOTTOM FOR WARPAGE 2 Rocker arms and rocker shaft Measure the bore in the rocker ann for the rocker shaft and the diameter of the rocker shaft to find the clearance between the ann and the s...

Page 25: ...a Measure the diameter of the valve stern as shown in the i11ustration If the stern is worn beyond the limit or it is abnonnally worn replace the valve VALVE STEM DIAMETER NDRMAl SIZE 0 260 in 6 6mm INLET AND EXHAUST INLET VALVE STANDARD 0 25846 0 25905 in 6 565 6 580mm LIMIT 0 25591 in 6 500mm EXHAUST STANDARD 0 25709 0 25787 in 6 530 6 550mm LIMIT 0 25591 in 6 500mm 0 o MEASURING 1 0 OF THE VALV...

Page 26: ...he valve margin valve lip thickness exceeds the limit replace the valve VALVE MARGIN LIP THICKNESS STANDARD 0 039 in 1 0mm LIMIT 0 020 in 0 5mm 8 If the valve sinkage the dimension from the top of a closed valve to the face of cylinder head exceeds the limit recondition the valve seat or replace the cylinder head assembly VALVE SINKAGE STANDARD LIMIT 0 020 0 0098in 0 5 0 25mm 0 059 in 1 5mm GOOD B...

Page 27: ...alve against the seat and rotate it only a part of a turn then raise the valve off its seat rotating it to a new position Press the valve against the seal for another part of a turn Repeat this operation until the compound wears and loses its cutting property c Wash the valve and valve seat with dry cleaning solvent d Apply engine oil to the valve and lap it in the seat e Check the valve face for ...

Page 28: ...ISE SPINNING ANOWEAR GEARS CHECK TEETH FOR WEAR BURRS OR CHIP S GASKET REPLACE CAMSHAFT CHECK FOR BEND OR DAMAGE TO THE LOBES r TIMING GEAR CASE INSPECT FOR CRACKS DISTORTION o GASKET OIL SEAL FOR DAMAGE AGING FLYWHEEL CHECK CONTACT FACE FOR SCORING OR RIDGES CHECK GEAR FOR OAMAGE _ OR WEAR TO TEETH Engines Generators 20 ...

Page 29: ... and base circle as shown in the illustration Subtract the base circle from the lobe height to find the lobe lift If the lobe lift exceeds the limit replace the camshaft LOBE HEIGHT OF CAMSHAFT STANDARD 1 4063 in 35 72mm LIMIT 1 3669 in 34 72mm 1 A EASURING _ VDIRECTION MEASURING THE LOBE HEIGHT OF THE CAMSHAFT 11 Fuel injection pump camshaft Measure the lobe height and base circle as shown in the...

Page 30: ...d side foremost REMOVING THE RING GEAR 15 Pistons piston rings and piston pins a Measure the diameter of the piston at its skirt in a direction transverse to the piston pin with a micrometer as shown in the illustration If the diameter exceeds the limit replace the piston Select a new piston so that the difference between average weight of all pistons in one engine does not exceed the standard OIA...

Page 31: ... INSPECT GEAR TEETH FOR DAMAGE MAIN BEARINGS INSPECT FOR SCRATCHES LOSS OF OVERLA CYLINDERS INSPECT FOR CRACKS OvUNCO OR RIDGES AT TOP OF o RING TRAVEL CYLINDER BLOCK CHECK FOR WARPAGE ON TOP FACE INSPECT FOR PLUGGED OIL HOLES CHECK FOR DAMAGE TO PLUGS OR DOWElS CRANKSHAFT Engines Generators 23 CHECK JOURNALS AND CRANKPINS FOR WEAR CRACKS AND BENDS INSPECT FOR CLEAR OIL HOLES DO NOT USE THIS CRANK...

Page 32: ...IAMETER OF THE PISTON PIN NOMINAL SIZE 0 91 in 23mm STANDARD 0 90527 0 90551 in 22 994 23 000mm CLEARANCE BETWEEN THE PISTON PIN AND PISTON STANDARD 0 00024 0 0071 in 0 006 0 01Bmm LIMIT 0 00197 in 0 050mm f Check the connecting rod for bend or twist as follows 1 Measure C and k If C exceed 0 0020 in O OSmm per 3 94 in 100mm of Q straighten the connecting rod with a press BENDING OR TWIST OF CONNE...

Page 33: ...98 in O 5Omm 0 0197 in or 0 75mm 0 0295 in undersize and use a undersize connecting rod bearing CRANKPIN UNDERSIZES 0 25mm 0 0098 in FINISH 47 75 C 050 mm 1 8799 O_QO J in 0 50mm 0 0197 in FINISH 47 50 o oso mm 1 8701 0 00 17 in 0 75mm 0 0295 in FINISH 47 25 _O GSO mm 1 8602 o o m in A CAUTION Grind all the crankpins of one crankshaft to the same undersize Finish the crankpin fillets to a radius o...

Page 34: ...or crankshaft is defective 7 Installation of the crankshaft gear Install the key in position on the crankshaft Install the gear in position with its keyway in alignment with the key 17 Cylinder Block 3 Measure the bore at the top middle and bottom points on axes A and B with a cylinder bore gauge If any one of the cylinders exceeds the limit hone out all the bores for oversize pistons PISTON AND P...

Page 35: ...SURFACES WITH ENGINE OIL f CONNECTING ROO CAP NUTS TORQUE TO 3 55 0 25 Kg m 34 8 2 5 Nm OIL PAN COAT THE ENTIRE SURFACE WITH HI TACK GASKET SEALER o CAMSHAFT APPLY ENGINE OIL TO JOURNALS AND LOBES Engines Generators 27 BEARINGS LUBRICATE THE INSIDE SURFACES WITH ENGINE OIL OIL PAN BOLTS CAP NUTS TORQUE TO 3 55 0 25 Kg m 34 8 2 5 Nm ...

Page 36: ...sen the bolts holding the main bearing caps once and tighten them again 4 Side seal installation a Coat the side seals with Loctite Ultra Blue b Insert the side seals between the cylinder block and the front and rear caps and push them in by hand as far as possible with their rounded side toward the outside of the cylinder block c Using a fiat plate push the seals into position taking care not to ...

Page 37: ...d of the connecting rod is put into position over the crankpin Then turn the crankshaft 1800 while pushing on the top of the piston b Install the lower half of the connecting rod bearing in the connecting rod cap making sure the tab in the back of the bearing is in the notch of the cap c Install the bearing cap to the connecting rod NOTE Make sure the number on the cap is the same as the number on...

Page 38: ...SEMBLY TIMING GEARS AND FLYWHEEL NEW GASKET CAMSHAFT NEW GASKET APPLY ENGINE OIL TO JOURNALS AND LOBES GASKET REPLACE GASKET Engines Generators 30 BACK PLATE BOLT IIJ IIJI TO 6 5 1 Kg m 64 10 Nm OIL SEAL APPLY ENGINE OIL TO SEAL LIP tiJ 0 o C FLYWHEE B O L T TORQUE TO 13 5 0 5 Kg m 132 5Nm ...

Page 39: ...er gear with engine oil h Install the idler gear in position with its 3 2 and 11 marks in alignment with the the 33 mark on the fuel injection pump camshaft gear the 22 mark on the camshaft gear and the 1 mark on the crankshaft gear respectively c Check the backlash of the gears Make reference to Timing gear backlash measurement 17 Timing gear case installation a Coat the gasket with adhesive and ...

Page 40: ...red with engine oil and thoroughly clean the face REMOVING THE CYLINDER HEAD GASKET WHITE ENAMEL INSTALLING THE VALVE SPRING I 25 Valve stem seal installation Install the valve stem seal in position in the valve guide After installation make sure the seal is in its correct position NOTE Improper stem seal installation can cause a failure to seal against downward flow ofoil along the stem 26 Instal...

Page 41: ... exhaust manifold to the specified torque TORQUE 13 4 2 5Ib ft 1 85 0 35 Kgf m 37 Fuel injection nozzle installation a Put the gasket on the nozzle h Put the nozzle assembly in position in the cylinder head and tighten it to the specified torque TORQUE 40 4 Ib ft 5 5 0 5 Kgf m 38 Put the fuel injection pump in position on the cylinder block and tighten the bolts that hold the pump to the specified...

Page 42: ...ition on the pulley Move the alternator away from the engine to make an adjustment to the belt c Tighten the bolts d Make sure the tension of the belt is correct about 1I2 deftection at the center with pressure a Remove the tie rod cover b Coat the threads of the stop solenoid with thread sealant TIrree Bond 1212 Coat the length of the threads to be turned in the governor case c Temporarily instal...

Page 43: ...nt of all the parts This should be done in three steps Manifold Mounting Bolls Torque Values 20 24 ft Ib 2 7 3 3 m kg c Reinstall the exhaust connections and plugs into the manifold using Loctite Anti Seize on the threads Check the manifold pressure cap Open the valve by pulling it and make sure it closes when released Make certain the upper and lower seals are in good condition If any doubt repla...

Page 44: ...rom the housing NOTE When replacing the plungers and barrels or delivery valves do nOlloosen the adjusting plates between the pumping elements After these parts have been replaced the injection quantity mLlst be measured A Pump Tester Cam Box is neededfor the measurement ofthe injection quantity Keep the disassembled injection pump parts in clean diesel fuel 5 CHECK TAPPET 3 I 9 FOR WEAR UI 8 SEQU...

Page 45: ...ified torque A CAUTION Do not overtighten the delivery valve holders This can put end force on the barrels resulting in a failure of the plungers to move freely If the holders are not tightened to the specified torque engine oil would leak in the injection pump DELIVERY VALVE HOLDER TORQUE 4 5 0 5 Kg m 44 5 Nm 6 Inspection after assembly 3 After the injection pump has been assembled check to see i...

Page 46: ...ith the engine at a standstilL a Remove the tie rod cover h Move the speed control lever to the high idle position and hold it there c Pull the tie rod in the direction of arrow head to the point where a slight resistance is encountered In this position the tie rod does not pull on the governor spnng d Turn in the torque spring set while lightly pulling the tie rod until the line mark on the contr...

Page 47: ...ee end of the injection pipe and at that instant check the position of the IT mark with respect to the mark on the gear case This timing is approximately I retarded Take this I retardation into account when making a shim adjustment Adjustment a If the fuel injection timing is incorrect change the thickness of shims under the fuel injection pump An increase or decrease of the shims by 0 1mm 0 004 i...

Page 48: ...recautions A CAUTION The spray injected from the nozzle is of such velocity that it maypenetrate deeply into the skin of fingers and hands destroying tissue If it enters the bloodstream it may cause blood poisoning Y2 7 i 1 l tI I b V i GOOD NOZZLE RECONDITION REPLACE a If the diesel fuel of the nozzle tester is discolored replace it At the same time clean or replace the fuel filter b Mount the no...

Page 49: ...tion and the other to the body of the glow plug as shown A good glow plug will have a 0 4 0 6 ohm resistance This method can be used with the plug in or out of the engine You can also use an ammeter to test the power drain 5 6 amps per plug A WARNING These glow plugs will become very hot to the touch Be careful not to burn your fingers when testing the plugs c Re install the plugs in the engine an...

Page 50: ...on gap 3 If the pinion gap is not within the standard range 0 0197 0 0788in 0 5 to 2 0mm adjust it by increasing or decreasing the number of shims on the solenoid The gap is decreased as the number of shims increases GENTLY PUSH BACK _ r I 0 5 2 0 mm PINION GAP No Load Test 1 Connect the ammeter voltmeter and battery to the starter as illustrated 2 When the switch is closed the pinion must protrud...

Page 51: ...nd remove the center bracket At the same time the washers for the pinion shaft end play adjustment will come ofr Inspect lor wear chipping STARTER MOTOR PINION 4 Retum test With a battery connected to the solenoid ter minal M and to the starter body manually pull out the pinion fully The pinion must return to its original position when released from holding by hand RETURN TEST 7 Pull out the reduc...

Page 52: ...vice limit is exceeded Also check the commutator outside surface for dirtiness and roughness If rough polish the commutator with fine crocus cloth COMMUTATOR 0 0 COMMUTATOR OUTSIOE DIAMETER STANDARD 1 26 in 32 mm LIMIT 1 22 in 31 mm Brush and Brush Holder Insllec1lion 1 Check the brushes If worn out beyond the service limit replace the brushes BRUSH 4 SERVIIGE LIMIT 2 Check the brush spring tensio...

Page 53: ...d fully tighten to the terminal Reassemble the starter assembly in the reverse order of disassembly making sure of the following 1 Pinion shaft end play adjustment Set the end play thrust gap to between O 5 to 2mm by inserting an adjusting washer between the center bracket and the reduction gear a Fit the pinion shaft reduction gear washer and snap ring to the center bracket h Measure end play by ...

Page 54: ... each other SHAFT 2 Install the shaft into the bearings Support the bearings at their center races Push the shaft into the bearings push ing at the impeller drive slot end using the base of the drive slot Push the shaft through both of the bearings flush against each other so the flat sided end of the shaft extends beyond the second bearing center race 19 32 in 15 mm 1132 in 5 mm 3 Support the pum...

Page 55: ...ston is at top dead center on the intake or exhaust stroke In such a case turn the crankshaft 3600 in the direction of engine rotation again No 1 piston is now at top dead center on the compression stroke g Loosen the locknut for the adjusting screw With a feeler gauge inserted between the rocker arm and valve cap adjust the valve clearance by turning the adjusting screw Make certain to adjust all...

Page 56: ... 42 7 psi 3 kgf cm2 NOTE Ifthe readings are below the limit the engine needs repair g Re install the glow plugs use anti seize compound on the threads and reset the fuel shut off to the run position h Open the raw water seacock thru hull TESTING ENGINE COMPRESSION LOW COMPRESSION ADAPTER hen low compression is found determine the cause by applying a small amount of oil in the cylinder thru the glo...

Page 57: ...tle arm against these stop bolts to either increase or decrease engine no load speed to adjust the Hertz produced 3 To arrive at the appropriate frequency either monitor the speed of the engine generator with a tachometer or monitor the frequency with a frequency meter the latter method being the more precise of the two FUEL RUN SOLENOID The fuel run solenoid is mounted in a threaded hole on the e...

Page 58: ... oil pressure sender then install a mechanical oil pressure gauge in it s place After warming up the engine set the engine speed at 1800 rpm and read the oil pressure gauge OIL PRESSURE 50 psi at 1800 rpm SENDER AND SWITCH TORQUE 9 13 ft Ib 11 2 1 8 m kg OIL PREi SUFIE SENDOR OIL SSIUR mH I o o1 SWITCH OIL OIL PRESSUIRE VALVE OIL OIL FLOW DIAGRAM OIL DRAIN HD IE LOW OIL PRESSURE SUMP The specified...

Page 59: ...ive belts must be properly tensioned Loose drive belts will not provide proper alternator charging and will eventually damage the alternator Drive belts that are too tight will pull the alternator out of alignment andJor cause the alternator to wear out prematurely Excessive drive belt tension can also cause rapid wear of the belt and reduce the service life of the coolant pump s bearing A slack b...

Page 60: ...0 20 0 30 gear and oil pump gear 0 0028 0 0079 0 0118 Lobe height of camshaft 35 72 1 4063 34 72 13669 Component ENGINE COMPONENTS Lobe height of fuel injection Standard mm inches Repair Limit mm inches pump camshaft 44 1 73 43 1 3669 Flatness of flywheel 0 15 0 0059 max 0 50 0 0197 Clearance between tappet and cylinder block 0 15 0 0059 Clearance between camshaft lournal and bushing 0 15 0 0059 C...

Page 61: ...nimum Brush length wear limit line Brush 3 0 kgf spring 6 6Ibf tension 29AN Runout of commutator 0 03 0 0012 Diameter of commutator 32 1 26 Undercut of mica 0 5 0 020 1 8 kgf 4 0 Ibl I7 7N 0 10 0 0039 31 1 22 0 2 0008 Component THREAD PARTS Sealant Mating Part Stop solenOid loctite 587 Ultra Blue Governor case Water drain joint loctite Gasket Sealer 2 Cylinder block or High Tack Gasket Sealer Oil ...

Page 62: ... INSTALLER 033583J FOR REMOVING AND INSTAlliNG THE FRONT CAMSHAFT BUSHING 039254 033583 THE ABDVE TODLS ARE AVAILABLE FROM YOUR WESTERBEKE OR MITSUBISHI DEALER NOTE IN ADDiTION TO THESE TOOLS THE FOLLOWING ADDiTIONAL TOOLS WDULD BE NEEDED BEARING PULLER VALVE SEAT CUTTER TOOL PROPER DIAL GAUGES VALVE GUIDE INSTAllER TOOL VALVE SPRING COMPRESSOR SNAP RING PLIERS ETC ALSO REFER TO SPECIAL TOOLS GENE...

Page 63: ...0 5 28 9 36 2 39 18 Glow Plug M10 1 25 12 60 1 75 0 25 12 72 17 2 2 5 Glow Plug Connection Plate M4 0 7 8 0 125 0 025 0 9 0 2 1 2 0 2 Intake Manifold 1 6 2A 12 17 16 2 Main Bearing Cap Bolt M10 1 25 17 81 5 25 0 25 38 2 51 5 2 5 Oil Filter M20 1 5 1 2 0 1 8 7 0 7 12 1 Oil Pan Bolt M8 1 25 12 25 2 8 0 3 20 3 2 2 27 5 3 Oil Pan Drain Plug M14 1 5 22 10 4 0 0 5 29 4 39 5 Oil Pressure Sender 1 2 1 8 9...

Page 64: ...IID SIiOULIl BE UISUlAT Il CA TAlJl AII l DilLY TilE n n WIR AT LU 2 IS UIIU I AIID SIIOULD 11 IIiSUlAT D ADIU_Al fAIiEL DilLY l f c 1I0T WIRE rOR UTTER ATTATCIIMCJlT Iflll IlEED TO liE U UADED TO AM a GAUGE fRO I 10 GAUtI r I I LIFT P MP I mM I I H ITSUB SH I 50 AMp Al T P U l nt_ S e u _ sMt r f SUDER 11 1 1 1 U I fUEL I I I SOL I I I6LS2J 1 I ZORO itO NuLQNI Y I L ________ _ SWITCH 1 1 114 GRA ...

Page 65: ...ency and when leaving the boat Twelve volt engine starters typically draw 200 to 300 amps when cranking A switch with acontinuous raung of 175 amps at 12 vae will normallyserve this function but aswitch mustneverbe used to make the starter circuit WIRING DIAGRAM 39144 tl0 O Engines Generators 57 ADM i RAL PANEL CAPTAIN PANEL j 1 LLU o l I I I I ...

Page 66: ...neral Fuel Fuel Injection Pump Fuel Injection Timing Nozzle Fuel Filter Air cleaner Air Flow engine combustion Fuel Lift Pump Starting Battery Battery Capacity DC Charging Altemator Starting Aid Starter General Operating Temperature Fresh Water Pump Raw Water Pump System Capacity Fresh Water General Oil Filter Sump Capacity not including fliter Operating Oil Pressure engine hot Oil Grade Engines G...

Page 67: ...Nozzle Fuel Filter Air cleaner Air Flow engine combustion Fuel Lift Pump FUEL SYSTEM Open flow self priming No 2 diesel oil cetane rating of 45 or higher In line plunger type BOSCH 0 TOC Top Dead Center Throttle type Spin on replaceable PN 024363 Replaceable paper filter cartridge 140 cfm 3 9 cmm at 3600 rpm 12 volt DC lift capacity of 5 1 5 mm solid state ELECTRICAL SYSTEM Starting Batter Batter ...

Page 68: ...ING When testing with a multimeter IDC andAC circuits are often mixed together in marine applications Always disconnect a shore power cord I isolate DC andAC converters and shut down the engine i before performing DC testing No AC tests should be I made without a proper knowledge ofAC circuits 1 Start the engine 2 After the engine has run for a few minutes measure the starting battery voltage at t...

Page 69: ...ver shut off the engine battery switch while the engine is running Shut off the engine battery switch however to avoid electrical shorts when working on the engine s electrical circuit BATTERY The minimum recommended capacity of the battery used in the engine s 12 volt DC control circuit is 600 900 Cold Cranking Amps CCA Checking the Service Battery Check the voltage of the service battery This ba...

Page 70: ...from sheaves and belts during test procedures A WARNING Multimeters and DC Circuits DC and AC circuits are ofter mixed together in marine applications Always disconnect shore power cords isolate DC andAC converters and shut down generators before performing DC testing No AC tests should be made without proper knowledge ofAC circuits REFER TO THE WIRING DIAGRAMS FOR THE ABOVE WIRING HARNESS CONNECT...

Page 71: ...g The reading should be between 13 7 and 14 7 volts 3 If the reading is high check for a loose or dirty alternator ground lead connection If the connection is good the voltage regulator is faulty and must be replaced Be sure to disconnect the battery cables before attempting to remove the alternator 4 If the reading is low a Stop the engine and remove the alternator wiring connections b Remove the...

Page 72: ...10 Place an oversized V belt around the pulley and fasten the pulley in a vise 11 Use a 7 8 in box wrench to loosen and remove the pulley nut 12 Remove the pulley nut lockwasher pulley fan and spacer PULLEY FAN PULLEY AND FAN COMPONENTS A CAUTION DO NOT insert screwdriver blades more than 1 16 in 1 6 mm Damage to the stator winding could result from deeper penetration NOTE Score the stator and the...

Page 73: ...nd the indicator light stud light stud DIODE TRIO ASSEMBLY h Reverse the tester leads and repeat the resistance checks c A very low resistance should be indicated in one direction and a very high resistance should be indi cated in the other direction if the diodes are normal d If any diode appears to be defective replace the complete assembly Do not attempt to replace an individual diode 3 Test th...

Page 74: ... and 3 A low ohm reading or lit test lamp should be observed b Check the resistance from each lead 1 2 and 3 to the laminations 4 There should be no continuity if the insulation is good c Inspect the stator windings for signs of discoloration A discolored winding should be replaced d If a winding shows a high resistance or an open circuit between any two of the three winding terminals or indicates...

Page 75: ...s SLEEVE ORIVER FRONT HOUSING AND BEARING ASSEMBLY ROTOR INSTALLING THE FRONT HOUSING ON THE ROTOR ASSEMBLY 4 Install the rectifier assembly into the rear housing S Insert the Phillips screw and tighten it RECTIFIER ASSEMBLY 6 Assemble the front and rear housings as follows a Put the stator winding in the front housing with the stator leads away from the front housing and the notches in the stator...

Page 76: ... nut on the terminal 15 Install the brushlregulator assembly cover 16 Install the Phillips screw for the brush regulator assembly cover TORQUE 25 351b 1t 2 8 5 1 Nm 17 Install the capacitor 18 Install the terminal nuts 19 Install the jumper 20 Install the last terminal nut INSTALL ALTERNATOR 1 Install the alternator screws and washers 2 Connect the wiring leads 3 Put the belt on the alternator cra...

Page 77: ...circuft MO o n l ll ltD I I RElIOv JU PH EH COIU CTI G A SECOHO RO OH PAMEl GENERATOR WIRING DIAGRAM 44735 i Ll 0 WATER Sls04tllA URf n j h r P d oW WG5 40 Qq 1 IIDm R ll MlJ ll TfMPE TUBf ll 1 1 Qj 0 o ZOA CIRCUIT f f E Kf I l l2111T AUX Oil H SSURE SfilCH I R K QI TU d J s Q Bg H II au to I ro 11 I 0 v o I u C UK 11 Tn OR Lw w GROUMO I TUMIUL or PREHEAT SOUMOIO ON jV SYSTEM OMU I rl a ill 1 IWII...

Page 78: ...T P SWITCH Oil PUSS r ______ _tst tSr ______t tvH _____ _SH TCH I _____________ _ EL PUMP X RUN RELAY 86 KI START RHAl aso u AUX O ITCH OIL PRES SEMDC TBI j T61 161 5 la I TB1 S WATER T S O R ral II AHR TEMP GAUGE I l 1 1 S If PREHEAT SWITCH L_ START 5WI TeN OJ L j TYPICAL REWO START STOP PA El CO ECTIONS tQ j Oil PRESS GAUGE QRO OH CQN C10R PINS 116 eRN AS Ilj BRH All HUG S ON INsaUNENl PH l fER ...

Page 79: ... P N 44336 44329 9 W r u PREKEAT SWITCH I I I I I 122 R D G ty I I I I I I r c o I I PREHEAT SWITCH I I I I Engines Generators 71 STOP SWITCH c START SWITCH 1 16 REDfVL 16 elK ttl6 RED WHT I t 16 WH 16 WHTIREO 16 HLJRED 2 5 I f lJ z V r r0 C2 CDCD0 S MALE CABLE CONNECTOR REAR VIEw ...

Page 80: ...Seat Angle Valve Clearance engine cold 427 psi 30 kg cm at 280 rpm 384 psi 27 kg cm 17 spill 45 17 BTDC 1991 71 0 psi 140 5 0kgf cm Intake 45 Exhaust 30 0 25mm 0 0098in LUBRICATION SYSTEM General Oil Filter Sump Capacity not including filter Operating Oil Pressure engine hot Oil Grade Pressure fed system Full flow paper element spin on type 3 9 U S qts 3 7 liters 50 60 psi 3 5 4 2 kg cm API Specif...

Page 81: ...s Brushless four pole revolving field Pre lubricated single bearing design Reconnectable single phase transfonner regulation optional solid state voltage regulation 120 or 1201240 Volts 60 Hertz 220 Volts 50 Hertz 5 no load to full load 3 Hertz 5 no load to fuUload 120 Volts 1201240 Volts 220 Volts 66 Amps 66133 Amps 27 Amps 175 200 efm 4 95 5 66 emm NOTE Increase air supply 15 for 50 Hertz operat...

Page 82: ...ator Starting Aid Starter 12 Volt negative ground 400 600 Cold Cranking Amps CCA 51 Amp rated belt driven Glow plugs sheathed type 12 Volt reduction gear General Fuel Fuel Injection Pump Nozzle Fuel Filter Air cleaner Fuel Lift Pump General Operating Temperature Fresh Water Pump Raw Water Pump System Capacity Fresh Water Raw Water Flow at 1800 rpm Measured before discharging into exhaust elbow Eng...

Page 83: ...ps Amperage High Voltage WYE 22 Amps 3phase 50 Hertz DELTA 39 Amps Generator Compartment 104 F 40 C maximum Ambient Temperature Recommendations NOTE Forced ventilation should be provided to maintain generator compartment temperatums below t04 F 40 C SPECIFICATIONS 12 5KW BTOB AC GENERATOR Single Phase AC GENERATOR 3 Phase Single Phase Brushless four pole revolving field Three Phase Brushless six p...

Page 84: ...nd the main stator and is in turn supplied to a full wave bridge rec tifier The rectifier produces a DC voltage to further excite the exciter stator windings enabling the generator to produce a rated AC output An optional solid state voltage regulator is available to work in tandem with the transformer regulator to produce a more stable AC output OPTIONAL AVR AVR A circuit breaker is installed on ...

Page 85: ...DINGS 10 0Q 8 AUXILIARY ROTOR WINDINGS A 8 C __1 0 1 2Q DIODES 6 11Q infinite ROTATING FIELD WINDINGS 7 0 8 0Q POSI RESISTOR infinite C MAIN STATDR WINDINGS 20 22Q MAIN STATOR AUXILIARY WINDlNGS_1 5 1 8Q o COMPOUND TRANSFORMER WINDlNGL 019 021Q COMPOUND TRANSFORMER AUXILIARY WINDINGS 4 0 4 5Q G BRIDGE RECTIFIER BRIDGE RECTIFIER AC TERMINAL BOARO CONNECTION 1 2 3 VOLTAGE HERTZ CONNECTION Y WESTERBE...

Page 86: ... position B EXCITER ROTOR and FIELD 1 Auxiliary Windings a b c 2 Diodes 6 3 Rotating Field Windings 4 Posi Resistor C MAIN STATOR 1 Main Stator Windings 2 Main Stator Windings 3 Main Stator Auxiliary Windings D COMPOUND TRANSFORMER 1 Compound Transformer Windings 2 Compound Transformer Windings 3 Compound Transformer Auxiliary Windings Resistance readings and voltage checks can be accessed easily ...

Page 87: ...er Each of the two circuits are able to cause an adequate reduction in excitor voltage to safeguard the excitor windings and prevent their overheating The overload protection system has a delay which permits temporary overloading of the generator during times such as motor start up or other similar load surge demands The regu lator also has a third LED green that glows during genera tor operation ...

Page 88: ...the method of operation rather than equipment fault Bring basic repair tools with you on the initial trip to the problem equipment such as diodes and bridge rectifier so that if the problem should be found in one of these easily replaceable parts the problem can be reme died early and efficiently NOTE l Vhen fault finding troubleshoot components in the order indicated below COMPONENT CHECKS REFER ...

Page 89: ...d transformer windings such as a short will cause the generator engine to load down and the shorted windings to eventually produce smoke as the excitation is continued 4 Voltage output greater than residual and less than rated output 25 100 volts indicates a fault in the exciter rotor field B 1 B 2 or B 3 Excitation of the generator as explained in paragraph 2 should produce a partial rise in volt...

Page 90: ...enerators are used on models rated lower than the capabilities ojthe generator However the generator is rated according to the capabilities of the drive engine since horsepower produces kilowatts COMPONENT RESISTANCE CHECKS Exciter Stator Windings 1 Windings A I and A 2 Resistance readings for exciter windings A I and A 2 with the selector switch in the COMP position are taken between the positive...

Page 91: ...nsulated tenninal stud below the transformer and lead 7 lifted off the AC terminal block NOTE No continuity should be found between either of these lifted leads or to the generator case ground TWO AVR PLUG TWO Ktt Nl J 5 TWO BLA CI t N 3 Transformer Auxiliary Windings Resistance is measured between the yellow wire lifted off the AC ter minal block of the bridge rectifier G with the selector switch...

Page 92: ...es can be easily checked in place with the use of a common automotive 12 volt high beam headlight bulb some jumper leads and the generator s 12 volt starting battery A short or an open in a diode can easily be found with the above without having to unsolder and isolate each diode to check it with an ohmmeter 11 OHMS THROUGH THE DIODE _11 OHMS RESISTANCE VALUE INFINITE r ki I BLOCKING LI __ INFINIT...

Page 93: ...nd to the Hertz the unit is operating at the regu lator will sense incorrect voltage and cause the generator to produce abnormally high output voltage CURRENT MODELS REPOSITION THIS WIRE FOR 50Hz TO 60Hz TERMINAL VOLTAGEJHERTZ CONNECTION BAR EARLY MODELS BlUEJWHITE Je L2 BT Generator Six Stud AC Voltage Connections NOTE The frame ground wire must be moved when changing from 110 volts and 1101220 v...

Page 94: ...HERTZ BAR YELLOW TO SELECTOR SWITCH TO BRIDGE RECTIFIER 5 4 4 8 L 2 mmr 7 llOooooOOOO0L J 0000000 1 I 00000000000 L 0600000 6 44 8 4 12 240V 60Hz A V R Plug and Connections Terminal Block Wiring Connections NOTE The frame ground wire must be moved when changing from 115V150Hz to 230v 50Hz The frame ground wire connects betvveen the neutral stud and the generator frame Wiring connections needed to ...

Page 95: ...7 I 1 l I 6 I a I I I b l PI V I 2 I C I 6 11 I I I 4 I I 1 I 1 DIODES I 1____ 1 5 I I ____ILJ___t 1 1 I I 3 1 1 I I L r L _____ J EVOLTAGE REGULATOR YELLOW RESISTANCE VALUES A EXCITER STATOR 17 9 ohm B EXCITER ROTOR WINDINGS abc 0 6 ohm C ROTATING FIELD 2 49 ohm D MAIN STATOR WINDINGS 0 05 ohm AUXILIARY WINDING 1 2 ohm E VOLTAGE REGULATOR F AUXILIARY CIRCUIT FUSE Engines Generators 87 ...

Page 96: ...auxiliary circuit AVR 2 Faulty voltage regulator 1 Open or shorted diodes in exciter rotor 1 to 3 diodes 2 Shorted exciter rotor winding 1 Faulty voltage regulator 1 STB pod on regulator needs adjustment 1 Diode s on exciter rotor breaking down when load is applied inductive 1 3 diodes 4 Open in exciter stator winding 5 Open in rotating field winding 3 Shorted or open main stator auxiliary winding...

Page 97: ...d rolled Steel Lifting Eye Tool This tool allows a mechanic to safely remove the generator end from the engine by attaching this Generator End Lifting Eye to the four screw holes located under the control panel To use this Lifting Eye remove the generator s control panel and screw the Lifting Eye to the generator end Disk Alignment Tool 1 1 4 31 75 mm 5i1 15 9 mm 4 HOLES 1 4 6mm Center lifting eye...

Page 98: ...440 597 605 820 14 435 590 675 915 M27 41 mm 295 400 417 565 811 1100 1154 1565 M30 46mm 402 545 568 770 1103 1495 1571 2130 1 8 590 800 660 895 910 1234 14 660 895 990 1342 M33 51 mm 546 740 774 1050 1500 2035 2139 2900 M36 55 mm 700 950 992 1345 1925 2610 2744 3720 NOTE Formula to convert Ft Lbs to Nm Newton Meters mulnply Ft Lbs by 1 356 SEALANTS LUBRICANTS GASKETS SEALANTS Oil based PERMATEX 2...

Page 99: ...s g x 035 Ounces Pounds Ib x 454 Kilograms kg x 2 205 Pounds PRESSURE Pounds Per Sq In psi x 6 895 Kilopascals kPa x 145 psi Inches of Mercury Hg x 4912 psi x 2 036 Hg Inches of Mercury Hg x 3 377 Kilopascals kPa x 2961 Hg Inches of Water H20 x 07355 Inches of Mercury x 13 783 H20 Inches of Water H20 x 03613 psi x 27 684 H20 Inches of Water H20 x 248 Kilopascals kPa x 4 026 H20 TORQUE Pounds Force...

Page 100: ...2 1 82880 7 6 40080 2 2 18723 7 7 65529 3 2 74320 8 7 31520 3 3 28084 8 8 74891 4 3 65760 9 8 22960 4 4 37445 9 9 84252 5 4 57200 10 9 14400 5 5 46807 10 10 93614 MOVE DECIMAL POINT FOR HIGHER VALUES e g 6 000 METERS 6 56 1 68 YARDS POUNDS TO KILOGRAMS KILOGRAMS TO POUNDS Ib kg Ib kg kg Ib kg Ib 1 0 454 6 2 722 1 2 205 6 13 228 2 0 907 7 3 175 2 4 409 7 15 432 3 1 361 8 3 629 3 6 614 8 17 637 4 1 ...

Page 101: ...ge Rectifier 81 Compound Transformer 83 Exciter Rotor Field 84 Main Stator Windings 83 Voltage Hertz Adjusting 85 Voltage Regulator 79 Glow Plug Testing 41 Governor 38 Hear Exchanger 35 Idle Speed Adjustment 51 Injection Pump 36 37 Injection Timing 39 Injectors Fuel 40 Inspection 16 34 Introduction 4 Mando Alternator Service 62 Metric Conversions Chart 91 92 Oil Pressure 50 Parts Identification 2 ...

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Page 104: ... WESTERBEKE Engines Generators 1042 WM DW 112001 ...