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INTRODUCTION
Read this safety mariual iarefirlly. Mast accidents are caused by failure tofollow fundarnerztal rules andprecastions.
Know when dangerous conditiorzs exist and take the necessary precautions to protect yoprse(l; yourper.sonrre1, and your rnachirtery.
The followirrg safe0 irtstrrrctiorts are in compliance with the
Arnerican Boat and Yacht Council (ABYC) standards.
PREVENT ELECTRIC SHOCK
A
Do not touch AC electrical connections while engine is running, or when connected to shore power. Lethal voltage is present at these connections!
enclosures and covers in place.
Shut off electrical power before accessing electrical equipment.
Use insulated mats whcnevcr working on clectrlcal equipment.
(particularly shoes) when handling electrical equipment electrical equipment.
Do not connect utility shore power to vessel's AC circuits. except through a ship-to-shore double throw transfer switch. Damage to vessel's AC generator may result if this procedure is not followed.
Electrical shock results from handling a charged capacitor
Discharge capacitor by shorting terminals together.
PREVENT BURNS
-
A
Do not touch hot engine parts or exhaust system components.
A
running engine gets very hot!
Always check the engine coolant level at the coolant recovely tank.
A
Steam can cause injury or death!
In case of an engine overheat, allow the engine to cool before touching the engine or chccking the c(x)lant.
PREVENT BURNS
-
A
Fire can cause injury or death!
Prevent llash lires. Do not smoke or permit flames o r sparks to occur near the carburetor, fuel line, filter. fuel pump, or other potential sourccs of spilled fuel or fuel vapors. Use a suitable container to catch all fuel when removing the fuel linc, carburetor, or fuel filters.
B
Do not operate with a Coast Guard Approved flame arrester removed. Backfire can cause severe injury o r death.
Do not opcratc with the air clcancrlsilencer removcd.
Backfire can cause severc injury or death.
Do not smoke or pcrmit flames or sparks
KI occur near the fuel system. Keep the compartment and the enginelgener- ator clean and free of debris to minimize the chances of lire. Wipe up all spillcd fuel and engine oil.
Be aware
-
PREVENT BURNS
-
a
Explosions from fuel vapors can cause injury or death!
hatches closed when fueling. Open and ventilak cabin after fueling. Check below for fumeslvapor before running the blower. Run the blower ibr four minutes before starc ing your enginc.
All fuel vapors are highly cxploslve. Use extreme care when handling and storingfuels. Store fuel in a well-ventilamd area away from spark-producing equipment and out of the reach of children.
Do not till the fucl tank(s) while the engine is running.
Shut off thc fucl service valve at the enginc when servicing the fuel system. Take care in catching any fuel that might spill. D O NOT allow any smoking, open flames. or other sources of lire near the fuel system or engine when servicing.
Ensure proper ventilation exists when servicing the fuel system.
Do not alter or modify the fuel system.
Be certain fuel linc fittings arc adequately tightened and free of leaks.
Make sure a lire extinguisher is installed nearby and is
Extinguislicrs rated ABC by the NFPA are appropriate for all applications encountcrcd in this environment.
WWESTERBEKE
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Engbes
&
Generators
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SAFETY INSTRUCTIONS
TOXIC EXHAUST GASES ACCIDENTAL STARTING
A
Accidental starting can cause injury or death!
A
Carbon monoxide (EO) is a deadlygas!
~ i ~ ~ ~ ~ generator. Remove the negative lead first and reconnect it last.
Make certain all personnel are clear of the engine before staning.
Make certain all covers, guards, and hatches are re- installed before starting the engine.
BATTERY EXPLOSION
A
Battery explosion can cause injury or death!
w
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 manifold1 water-injected elbow is securely attached.
Be sure the unit and its surroundings are well ventilated.
Run blowers when running the generator set or engine.
Don't run the generator set or engine unless the boat is equipped with a functioning marine carbon monoxide detector that complies with ABYCA-24. Consult your boat builder or dealer for installation of approved detectors.
For additional information refer to ABYC T-22
(educational inforination on Carbon Monoxide).
Do not smoke or allow an open flame near the battery being serviced. Lead acid batteries emit hydrogen, a highly explosive gas, which can be ignited by electrical arcing or by lit tobacco products. Shut off all electrical equipment in the vicinity to prevent electrical arcing dur- ing servicing.
Never connect the negative
(-) battery cable to the posi- live (+) connection terminal of the starter solenoid. Do not test the battery condition by shorting the terminals together. Sparks could ignite battery gases or fuel vapors.
Ventilate any compartment containing batteries to prevent accumulation of explosive gases. To avoid sparks, do not disturb the battery charger connections while the battery is being charged.
Avoid contacting the terminals with tools, etc., to prevent bums or sparks that could cause an explosion. Remove wristwatch, rings, and any other jewelry before handling the battery.
Always turn the battery charger off before disconnecting the battery connections. Remove the negative lead first and reconnect it last whenservicing the battery.
BATTERY ACID
A
Sulfuric acid
in
batteries can cause severe injury or death!
When servicing the battery or checking the electrolyte level, wear rubber gloves, a rubber apron, and eye protec- tion. Batteries contain sulfuric acid which is destructive.
If it comes in contact with your skin, wash it off at once with water. Acid may splash on the skin or into the eyes inadvenently when removing electrolyte caps.
Do not service the engine while it is running. If a situation arises in which it is absolutely necessary to make operat- ing itdjustinents, use extreme care to avoid touching mov-
v
ing parts and hot exhaust system components.
>
.
,
I
A
Carbon monoxide (GO) is an invisible odorless gas. Inhalation produces flu-like symptoms, nausea or death!
k
Do not can diesel exhaust Diesel
Exhaust sulfur causes rapid deterioration of copper tubing resulting in exhaust/water leakage.
Do not install exhaust outlet where exhaust can be drawn through portholes, vents, or air conditioners. If the engine: exhaust discharge outlet is near the waterline, water could' enter the exhaust discharge outlet and close or restrict the flow of exhaust. Avoid overloading the craft.
w
Although diesel engine exhaust gases are not
as
toxic as exhaust fumes from gasoline engines, carbon monoxide gas is present in diesel exhaust fumes. Some of the symptoms or signs of carbon monoxide inhalation or poisoning are:
Vomiting
Dizziness
Headache
Inability to think coherently
Throbbing in temples
Muscular twitching
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Nausea
AVOID MOVING PARTS
Weakness and sleepiness
I
A
Rotating parts can cause injury or death! o
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Engines & Generators
SAFETY INSTRUCTIONS
Do not wear loose clothing or jewelry when servicing equipment; avoid wearing loose jackets, shirts, sleeves, rings, necklaces or bracelets that could be caught in moving parts.
Make sure all attaching hardware is properly tightened.
Keep protective shields and guards in their respective places at all times.
Do not check fluid levels or the drive belts' tension while the enginelgenerator is operating.
Stay clcar of the drive shaft and the transmission coupling when the engine is running; hair and clothing can easily be caught in these rotating parts.
HlUARDOUS NOISE
A
WARNING:
High noise levels can cause hearing
IOS!
Never operate a generator without its muffler installed.
Do not run an engine with the air intake (silencer) removed.
Do not run engines or generators for long periods with their enclosures open.
A
WARNING:
Do not work on machinery when you are mentally or physically incapacitated by fatigue!
OPERATORS MANUAL
Many of the preceding safety tips and warnings are repeated in your Operators Manual along with other cautions and notes to highlight critical information. Read your manual carefully, maintain your equipment. and follow all safety procedures.
GASOLINE ENGINE AND GENERATOR
INSTALLATIONS
Preparations to install a gasoline engine or generator should begin with a thorough examination of the American Boat and
Yacht Council's (ABYC) standards. These standards are from a combination of sources including the USCG and the NFPA.
Sections of the ABYC standards of particular interest are:
H-2 Ventilation
H-24 Gasoline fuel systems
P- l Exhaust systems
P-4 Inboard engines
E-9 DC Electrical systems
All installations must comply with the Federal Code of
Regulations (FCR).
ABYC, NFPA AND USCG PUBLICATIONS FOR
INSTALLING GASOLINE AND DIESEL ENGINES AND
GENERATORS
Read the following ABYC. NFPA and USCG publications lor safety codes and standards. Follow their recommenda- tions when installing your WESTERBEKE enginelgeneralor.
ABYC (American Boat and Yacht Council)
"Safety Standards for Small Craft"
Order From:
ABYC
3069 Solomon's Island Rd.
Edgewater. MD 21037
NFPA (National Fire Protection Association)
"Fire Protection Standard for Motor Craft"
Order From:
NFPA
1
Batterymarch Park
P.O. Box 9101
Quincy, MA 02269-9 101
USCG (United States Coast Guard)
"USCG 33CFR183"
Order From:
U.S. Government Printing Office
Washington,
D.C.
WESTERBEKE
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Engines
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Generators
INSTALLATION
When installing
WESTERBEKE engines and generators it is important that strict attention be paid to the following information:
CODES AND REGULATIONS
Strict federal regulations,
ABYC guidelines, and safety codes must be complied with when installing engines and generators in a marine environment.
SIPHON-BREAK
For installations where the exhaust manifold/water injected exhaust elbow is close to or will be below the vessel's waterline, provisions must be made to install a siphon- break in the raw water supply hose to the exhaust elbow. This hose must be looped a minimum of
20" above the vessel's waterline. Failure to use a siphon-break when
the exhaust manifold injection port is at or below the load waterline will result in raw water damage to the engine andpossibleflooding of the 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:
A siphon-break requires periodic inspection and cleaning to etrsure proper operation. Failure to properly maintain a siphon-bmak can result in catasrrophic engine damage. Consult the siphon-break manufacturer for proper maintenance.
EXHAUST SYSTEM
The cxhaust hose must be certified for marine use. The system must be designed to prevent water from entering the exhaust under any sea conditions and at any angle of the vessels hull.
A detailed
40
page Marine Installation Manual covering gasoline and diesel, engines and generators, is available from your WESTERBEKE dealer.
TABLE OF CONTENTS
Introduction
.............................................................
2
Wiring Diagram (#44780)
..................................
84
Testing for Overhaul
............................................
3
Remote Instrument Panel Wiring(#44392)
.......
86
Engine Troubleshooting
.......................................
4
Wiring Diagram (#44781)
..................................
87
Angular Tightening Methods
...............................
8
Engine Troubleshooting
.....
.:
....................
.
Standard Torque Specifications
..........................
An extensive troubleshooting chart
.
Engine Disassembly
...........................................
10
Important Measurements
..................................
1 1
Disassembly Steps
.............................................
12
Inspectionmepair
Cylinder
Head
Inspectionmepair
..............................................
.............................
l 6
....................................
.
BE Generator
...................................................
112
Voltage Regulator
...........................................
Generator Information
.....................................
AC Voltage Connections
.................................
Internal Wiring diagram
..................................
Electronic Governor Adjustments
...................
113
114
115
116
117
Refer to the index for specific items in this section
Torque Data
............................................
such as: pistons. flywheel. crankshaf. valves. push rods. camshafr. etc
.
Assembly
...................................................
35
9
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46
Troubleshooting the Electronic Governor
......
118
BE Troubleshooting
.........................................
119
Generator Maintenance
..................................
120
Refer to the index for spec#c items in this section such as: mcker arms. oil cooler; engine timing. etc
.
Lubricating System
Cooling System
..................................................
49
65 BED Generator Specifications
Raw Water Pump
Turbocharger
............................................
47
45 BED Generator Specifications
....................
55 BED Generator Specifications
...............................................
52
95 BED Generator Specifications
.....................................................
53
EON4 Engine Specifications
...........................
121
....................
....................
123
....................
124
125
Engine Adjustments
...........................................
55
llOT4 Engine Specifications
Fuel System
.............
:
56
120N6 Engine Specifications
.........................
127
Tachometer
........................................................
62
170T6 Engine Specifications
.........................
128
Alternator
..............................................
63
-
69
Lay-up and Recommissioning
...........................
Complete tesring and breakdown of the Mando
51A
alternator:
Starter Motor
.............................................
70
-
83
Complete testing and breakdown of the starter moto,:
Metric Conversions Data
.................................
Special Tools
....................................................
131
Index
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P W E S T E R B E K E
1
Englnes & Generators
INTRODUCTION
PRODUCT SOFTWARE
Product software. (technical data, parts lists, manuals, brochures and catalogs), provided from sources other than
WESTERBEKE are not within WESTERBEKE'S control.
W
E
STERBEK
E
CANNOTBE RE
S
P O
N
S
IBLE F
OR THE
CONTENT O F SUCH S O m A R E . MAKES NO WAR-
RANTIES O R REPRESENTATIONS WITH RESPECT
THERETO, INCLUDING ACCURACK TIMELINESS O R
COMPLETENESS THEREOFAND WILL IN NO EVENT
B E LIABLE FOR ANY TYPE O F D A M A G E OR INJURY
INCURRED IN CONNECTION WITH O R ARISING O U T
O F T H E FURNISHING O R USE O F SUCH SOFTWARE.
WESTERBEKE customers should keep in mind the time span between printings of WESTERBEKE product software and the unavoidable existence of earlier WESTERBEKE product software. The product software provided with products' whether from
Or other suppliers, must not and cannot be relied upon exclu- sively as the definitive authority on the respective product. It not only makes good sense but is imperative that appropriate representatives of WESTERBEKE or the supplier in question be consulted to determine the accuracy and currentness of the product software being consulted by the customer.
NOTES, CAUTIONS AND WARNINGS
As this manual takes you through the operating procedures, maintenance schedules. and troubleshooting of your marine engine, critical information will be highlighted by NOTES,
CAUTIONS, and WARNINGS. An explanation follows:
NOTE:
,411 operating procedure essenrial to note.
Customer Identification Card
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WESTERBEKE
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Engines
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Generators
MR. GENERATOR OWNER
MAIN STREET
HOMETOWN, USA
Model 55 BED
Expires 111200 1
Ser. #U0000-El02
The WESTERBEKE serial number is an alphanumeric number that can assist in determining the date of manufac- ture of your WESTERBEKE enginelgenerator. The manufac- turer's date code is placed at the end of the engine serial number and consists of a character followed by three num- bers. The character indicates the decade (A=1960s, B=1970s,
C=1980s, D=1990s E=2000s), the first number represents the year in the decade, and the second and third numbers repre- sent the month of manufacture.
SERIAL NUMBER LOCATION
The engine's serial number can be found stamped into the block just out board of the injection pump. identi- fication plate on the engine manifold also displays the engine model and serial number.
The generator serial number is stamped on the left side of the generator housing and on the flat surface above the rotary carrier bearings.
observed, can result in the damage or destruction of your engine.
ORDERING PARTS
ENGINE OVERHAUL
The following sections contain detailed information relating to the proper operation characteristic of the major components and systems of the engine. Included are disassenlbly, inspection and reassembly instructions for the guidance of suittable equipped and staffed marine engine service and rebuilding facilities. The necessary procedures should be taken only by such facilities.
Additional detailed information and specifications are provided in other sections of this manual, covering the generator, alternator, starter motor, engine adjustments,
"0ling PulnPs, etc. engine model number and serial number as they appear on the silver and black nameplate located on the manifold. You must provide us with this information so we may properly identify your engine. In addition, include a complete part description and pan number for each part needed (see the separately furnished P a s List). Insist upon WESTERBEKE packaged parts because wiNfr or generic parts are frequently not made to the same specifications as original equipment.
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WESTERBEKE
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Engines & Generators
HOW TO DETERMINE ENGINE OVERHAUL PERIOD
Cause of Low Compression
Generally, the time at which an engine should be overhauled is determined by various conditions such as lowered engine power output, decreased compression pressure, and increased fuel and oil consumption. The lowered engine power output is not necessarily due to trouble with the engine itself, but is sometimes caused by injector nozzle wear or injection pump wear. The decrease in compression pressure is caused by many factors. It is, therefore, necessary to determine a cause or causes on the basis of data produced by periodic inspection and maintenance. Oil analysis on a seasonal basis is a good means of monitoring engine internal wear. When caused by worn cylinders or piston rings, the following symptoms will occur:
1 Low engine power output
2 Increased fuel consumption
3 Increased oil consumption
4 Hard engine starting
5
Noisy engine operation
These symptoms often appear together. Symptoms 2 and 4 can result also from excessive fuel injection, improper injec- tion timing, and wear of the injectors. They are caused also by defective electrical devices such as the battery, alternator, starter and glow plugs. Therefore it is desirable to judge the optimum engine overhaul time by the lowered compression pressure caused by worn cylinders and pistons plus increased oil consumption. Satisfactory combustion is obtained only under sufficient compression pressure. If an engine lacks compression pressure, incomplete combustion of fuel will take place even if other pans of the engine are operating properly. To determine the period of engine overhaul, it is important to measure the engine compression pressureregu- larly.
At
the same time, the engine speed at which the mea- surement of compression pressure is made should be checked because the compression pressure varies with engine rpm.
The engine rpln can be measured at the front end of the crankshaft.
NOTE:
To test engine compression see the ENGINE
ADJUSTMENT section of this manual.
ASSEMBLY
1. Wash all parts, except for oil seals. O-rings, rubber sheets, etc., with cleaning solvent and dry thein with pressure air.
2. Always use tools that are in good condition and be sure you understand how to use them before performing any job.
3. Use only good quality lubricants. Be sure to apply a coat of oil, grease or sealant to pans 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 inust be installed.
TESTING FOR OVERHAUL
OVERHAUL CONOlTlONS
Compression pressure tends to increase a little in a new engine until piston rings and valve seats have been broken in.
Thereafter, it decreases gradually with the progress of wear of these parts.
When decrease of compression pressure reaches the repair limit, the engine must be overhauled.
The engine requires overhaul when oil consumption is high, blowby evident, and compression values are at minimum or sliould l ~ e
kg/cn~:
441
psi at
200
rp11. The niwriniun~ cliffereticc bet wee^^ cylirzders riiust not exceed
10%.
DISASSEMBLY
1. Before disasseinbly and cleaning, carefully check for defects which cannot be found after disassembly and cleaning.
2. Drain water, fuel and oil before disassembly.
3. Clean or wash the engine exterior.
4. Do not remove or disassemble the parts that require no disassembly.
5.
Perform disassembly in a proper order using proper tools.
Keep disassembled parls in order. Apply oil when neces- sary. Take special care to keep the fuel system parts from intrusion of dust and dirt.
6. Pais must be restored to their respective components fiom which they were removed at disassembly. This means that all pan. must be set aside separately in group?, each marked for its component, so that the same combination or set can be reproduced at assembly.
7. Pay attention to marks on assemblies, components and parts for their positions or directions. Put on marks, if necessary, to aid assembly..
8. Carefully check each part or component fore any sign of faulty condition during removal or cleaning. The part will tell you how it acted or what was abnormal about it more accurately during removal or cleaning.
ALTERNATOR INSPECTION
When rebuilding the engine, the alternator should be cleaned and inspected. The housing can be wiped off with a solvent and the alternator terminal studs should be cleaned with a wire brush. Make certain the studs are tight and clean the
- connections that connect to the wiring
Turn the rotor pulley by hand. It should turn smoothly.
Depending on when the alternator was bast serviced, the brushes may need replacing. If the alternator is at all suspect. send it to a service shop for testing and overhaul.
For additional information on alternators refer to the
ALTERNATOR and MANDO
SERVlCE in this manual.
WESTERBEKE
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Engines & Generators
ENGINE TROUBLESHOOTING
The following troubleshooting chart describes certain problems relating to engine service, the probable causes of these problems, and the recommendations to overcome
Refer also t o t h e m o r e detailed Troubleshooting section in the b a c k
of
this manual.
NOTE:
TIE engine's electrical system is protected by a
20-
the need for an engine overhaul.
PROBLEM
HARD STARTING
PROBABLE CAUSE
LOW CRANKING SPEED
1.
Engine oil viscosity too high.
2.
Run-down battery.
3. Worn battery.
4.
Battery terminals loosely connected.
5.
Defective starter.
DEFECTIVE INJECTION SYSTEM
1.
Air trapped in fuel passage.
2. Clogged fuel filter.
3. Low injection pressure.
4.
Inadequate spray.
5.
Injection pump delivering insufficient fuel.
6. Injection too early. nlounted on the same bracket.
VERIFICATIONIAEMEOY
1.
Replace engine oil with less viscous oil.
2.
Recharge battery.
3. Replace battery.
4.
Clean terminals and correct cables.
5.
Repair or replace starter.
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.
LOW OUTPUT
MAIN ENGINE TROUBLES
1.
Low compression.
a.
Incorrect valve clearance.
b. Inadequate contact of valve seat.
c. Valve stem seized.
d.
Broken valve spring.
e. Compression leaks through cylinder head gasket.
1.
Piston ring seized.
Q .
Worn piston ring and cylinder.
2.
Burnt glow plug.
3. Faulty glow plug operation.
4.
Incorrect governor lever position.
LOW COMPRESSION
a.
Adjust valve clearance.
b. Lap valve.
c. Replace valve and valve guide.
d. Replace valve spring.
e.
Replace gasket.
1.
Replace piston and piston ring.
g. Overhaul engine.
2.
Replace glow plug.
3. Correct lead wire connection.
4.
Set lever to starting position.
See
HARD STARTING
INJECTION SYSTEM OUT OF ADJUSTMENT
1.
Incorrect injection timing.
2.
Insufficient injection.
3. Low injection pressure.
INSUFFICIENT FUEL
1.
Air trapped in fuel system.
2.
Clogged filter.
3. Contaminated fuel tank.
INSUFFICIENT INTAKE AIR
1.
Clogged air cleaner.
1.
Adjust injection timing.
2.
Repair or replace injection pump.
3. Check injection nozzle and adjust pressure.
1.
Check and retighten connector.
2.
Clean or replace filter.
3. Clean tank.
1.
Clean or replace air cleaner.
(contitwed)
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Engines
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PROBLEM
LOW OUTPUT (cont.)
EXCESSIVE OIL
CONSUMPTION
EXCESSIVE FUEL.
CONSUMPTION
SMOKY EXHAUST
ENGINE TROUBLESHOOTING
VERIFICATION/REMEDY PROBABLECAUSE
OVERHEATING
1.
Low coolant level.
2.
Loose V-belt.
3. Incorrect injection timing.
4.
Low engine oil level.
OIL LEAKAGE
1.
Defective oil seals.
2.
Broken gear case gasket.
3. Loose gear case attaching bolts.
4.
Loose drain hose.
5.
Loose oil pipe connector.
6. Broken rocker cover gasket.
7. Loose rocker cover attaching bolts.
OIL LEVEL RISING
1. Incorrectly positioned piston ring gaps.
2.
Displaced or twisted connecting rod.
3. Worn piston ring.
4.
Worn piston or cylinder.
OIL LEVEL FALLING
1.
Defective stem seal.
2.
Worn valve and valve guide.
ENGINE BODY TROUBLES
1.
Noisy knocking.
2.
Smoky exhaust.
3. Moving parts nearly seized or excessively worn.
4.
Poor compression.
5.
Improper valve timing.
6. Improper valve clearance.
INSUFFICIENT INTAKE AIR
1.
Air intake obstructed.
NOZZLE TROUBLES
1.
Seized noule.
2.
Worn nozzle.
IMPROPER FUEL
FUEL LEAKS
WHITISH OR PURPLISH
1.
Excessive engine oil.
2.
Excessive rise of oil into combustion chamber.
a. Poor piston contact.
b.
Seized piston ring.
c.
Excessive piston-to-cylinder clearance.
1.
Add coolant.
2.
Adjust or replace V-belt.
3. Adjust injection timing.
6.
Add engine oil.
1. Replace oil seals.
2.
Replace gasket.
3. Retighten bolts.
4.
Retighten hose.
5.
Retighten oil connections.
6. Replace gasket.
7. Retighten attaching bolts.
1. Correct ring gap positions.
2.
Replace connecting rod.
3. Replace ring.
4.
Replace piston and rebore cylinder.
1. Replace stem seal.
4.
Replace a valve and valve guide.
1. see
KNOCKING.
2.
See
SMOKY EXHAUST.
3. Repair or replace.
4. See LOW
COMPRESSION; HARD STARTING.
5.
Adjust.
6. Adjust.
1.
Remove obstruction.
1.
Replace.
2.
Replace.
Replace with proper fuel.
Find fuel leaks.
1. Correct oil level.
a. Check.
b.
Replace or clean.
c. Replace or correct.
(cunrinued)
WESTERBEKE
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Engines & Generators
5
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PROBLEM
SMOKY EXHAUST (cant
ABNORMAL SOUND
OR NOISE
ROUGH OPERATION
ENGINE TROUBLESHOOTING
PROBABLE CAUSE
WHITISH OR PURPLISH (cont..)
d.
Worn valve stem and valve guide.
8.
L
OW engine oil viscosity.
1.
Excessive oil pressure.
3. Injection timing is too late.
4.
Insufficient compression.
VERIFICATION/REMEOY
d. Replace.
8.
Replace.
I.
Correct.
3.
Adjust.
4.
See
LOW COMPRESSION; HARD STARTING.
BLACKISH OR DARK GRAYISH
1.
Engine body troubles.
a.
Poor compression.
b. Improper valve clearance.
2.
Insufficient intake air (air cleaner clogged).
3. Improper fuel.
CRANKSHAFl AND MAIN BEARING
1.
Badly worn bearing.
2.
Badly worn crankshaft.
3.
Melted bearing.
CONNECTING ROD AN0 CONNECTING ROO BEARING
1.
Worn connecting rod big end bearing.
2.
Worn crankpin.
3. Bent connecting rod.
a. See
LOW COMPRESSION; HARD STARTING.
b.
Adjust.
2.
Clean air cleaner.
3. Replace with proper fuel.
1.
Replace bearing and grind crankshaft.
2.
Grind crankshaft.
3. Replace bearing and check lubrication system.
1.
Replace bearing.
2.
Grind crankshaft.
3. Correct bend or replace.
PISTON, PISTON PIN, AN0 PISTON RING
1.
Worn cylinder.
2.
Worn piston pin.
3. Piston seized.
4.
Piston seized and ring worn or damaged.
VALVE MECHANISM
1.
Worn camshaft.
2.
Excessive valve clearance.
3. Worn timing gear.
4.
Worn fan pulley bearing.
INJECTION PUMP SYSTEM
1.
Uneven injection.
2.
Control rack mallunctioning.
3. Worn delivery valve.
4.
Inadequate injecllon nozzle spray.
GOVERNING SYSTEM
1.
Governor lever malfunctioning.
2.
Fatigued governor spring.
1.
Rebore cylinder to oversize and replace piston.
2.
Replace piston.
3. Replace piston and rebore cylinder.
4.
Replace piston and rings.
1 .
Replace.
2.
Adjust.
3. Replace.
4.
Replace.
1.
Adjust injection or replace parts.
2.
Disassemble, check and correct injection pump.
3. Replace.
4.
Replace injection nozzle.
1.
Check governor shafl and correct operation.
2.
Replace.
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Engines
&
Generators
PROBLEM
KNOCKING
INTERMIllENT
EXHAUSTSOUND
OVERHEATING
LOW OIL PRESSURE
ENGINE TROUBLESHOOTING
VERlFlCATlONBEMEOY PROBABLE CAUSE
ENGINE KNOCKS WITHOUT MUCH SMOKE
1. Main engine troubles.
a. Overheated cylinder.
b. Carbon deposits in cylinder.
2.
Too early injection timing.
3. Too high injection pressure.
4.
Improper fuel.
a.
See
OVERHEATING; LOWOUTPUT.
b.
Clean.
2.
Correct.
3. Correct.
4.
Replace with proper fuel.
KNOCKING WITH DARK SMOKE
1. Poor compression.
2.
Injection pump malfunctioning.
3. Improper noule.
a.
Poor spray.
b.
Poor chattering.
c. Afler-injection drip.
d.
Nozzle needle valve seized.
1.
Fuel filter clogged.
2.
Water mixed in fuel
1. See
LOW COMPRESSION; HARD STARTING.
2.
AdjustFIepair
a.
Clean or replace nozzle.
b.
Repair or replace nozzle.
c.
Repair or replace nozzle.
d. Replace.
1.
Clean or replace.
2.
Replace fuel.
1.
V-belt slackening or slippery with oil.
2.
Damaged water pump.
3. Lack of coolant.
4.
Low oil level or poor oil quality.
5.
Knocking.
6. Moving parts seized or damaged.
7.
Defective thermostat.
1.
Worn Bearings.
2.
Relief valve malfunction.
3. Clogged oil cooler.
4.
Diesel dilution of the oil.
1. Adjust, replace or clean.
2.
Replace.
3. Add.
4.
Add or change.
5.
See
KNOCKING.
6. Replace.
7. Replace.
1. Engine overhaul replace bearings.
2.
Overhaul oil pump.
3. Repair.
4.
Injection pump repair.
W W E S T E R B E K E
/
Engines
&
Generators
ANGULAR NUT AND BOLT TIGHTENING METHOD
1. Carefully wash the nuts and bolts to remove all oil and gredse.
2. Apply a coat of molybdenum disulfide grease to the threads and setting filces of the nutsand bolts.
3. Tighten the nuts and bolts to the specified torque (snug torque) with a torque wrench.
CENTER LINE
6. Draw another line (F-G) on the face of each of the parts to be clamped. This line will be in the direction of the specified angle
(Q) across the center
(E) of the nut or bolt.
7. Use a socket wrench to tighten each nut or bolt to the point where the line (A-B) is aligned with the line
(F-G).
Example: Specified Angle and Tightening Rotation i
360"
One full turn
4. Draw a line (A-B) across the center of each bolt.
5. Draw another line (C-D) on the face of each of the parts to be clamped. This line should be an extension of the line
(A-B).
COINCIDING LlNE
C
IV~)-IWESTERBEKE
I
Engines & Generators
STANDARD BOLTS
/
TIGHTENING TORQUE SPECIFICATIONS
NOTE:
Tlre torque values givat it! rlreji)/lowbrg ruble slrould be applied wltere a particular torque is 1to1 s/~ecified.
kg-m
~
'
28.5 i5.7
NOTE:
Bolts 1t111rk~d
(111
asr~risli I I S P ~ I , ~ ~ , ~
. ~~.~
~?!areri(rls
( IS
ca,slil~fis.
/K~WESKRBEKE
/
Engines & Generators
ENGINE DISASSEMBLY
GENERATOR
Disconnect the AC wiring and unplug the engine's DC wiring hamess at the generator control panel. Remove the battery cables from the engine and tape over the terminals.
NOTE:
Lube1 any lines, ho.ses or cables us you separate therrr.
Separate the exhaust hose at the water injected elbow and disconnect the fuel supply and return lines.
Drain the engine oil and the coolant from the engine.
Carefully support and then unbolt the generator backend from the engine. See
SPECIAL TOOLS in this manual.
Additional generator information will be found in the
GENERATOR section of this manual.
PROPULSION ENGINE
Switch off the batteries and disconnect the battery cables from the engine and tape over the terminals.
Drain or pump out all the engine oil and drain the coolant from the engine and engine hoses.
Unplug the instrument panel wiring hamess. Drain the transmission fluid and the transmission oil cooler hoses,
Detach the oil cooler hoses and unbolt the transmission from the engine.
TRANSMISSION
If the transmission is not being rebuilt it should be visually inspected. Flush out and pressure test the oil cooler and replace the coolant hoses. Inspect and lubricate the gear shift linkage and the propeller shaft coupling. Clean and repaint the transmission and change the transmission fluid.
For transmission service and maintenance refer to your transmission manual. To rebuild a transmission contact your
WESTEWEKE
dealer or an authorized transmission service center.
DAMPER
PLATE
DRAIN
BOLTS
ENGINE DISASSEMBLY
H
Clean the exterior of the engine of any deposits of
Take the following precautions:
. dirt and oil.
B, 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 transmissiodgenerator separated from the engine, begin the following step by step procedure to disassemble the engine.
1.Remove the transmission damper plate from the engine flywheel.
2. Remove the engine oil cooler and oil hoses. Note oil hose connections from the oil cooler to the engine.
3.Remove the engine heat exchanger. If possible, leave one end of each hose connected to the palt being removed.
4. Remove the bell housing and the circuit breaker1 preheat solenoid mounting bracket.
5. Remove the engine back plate.
6.
Remove the start motor, drive belt and the alternator.
Label the wires and cables.
7.
Remove the engine mounted raw water pump, complete with its adapter mounting plate. See RAW
WATER PUMP for paris breakdown.
8. With the hoses disconnected, remove the thermostat housing and housing gasket, leaving the temperature sender in place.
9. Remove the coolant circulating pump. Refer to
C O O U N T PUMP ASSEMBLY.
10.Remove the air intake silencer and the intake manifold.
11.Remove the oil filter and the mounting bracket from the engine block.
12.Unbolt the elbows and remove the exhaust manifold in its entirety.
13.Remove the fuel injection pump. Disconnect the fuel injection pipes and fuel leak-off pipe from the fuel injection pump and nozzles.
NOTE:
P~rr plugs or cups on the openings of the injecrion pump onrl rroulc connectors. Golfrees work well asplugs.
14.Remove the fuel injection nozzle.. Loosen the fuel injection nozzles with a wrench. Remove the nozzles and gaskets from the cylinder head.
15.Pepare to disassemble the engine block.
0 .
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Engines
&
Generators
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MEASUREMENTS
PRIOR TO MAIN ENGINE DISASSEMBLY
1. Idler Gear
Measure the following points before disassembly. mm(in)
Limit
~
Idler Gear End
Play
Standard
-
~~~
0.058
-
(0.002
-
0.2
(0.008)
-
~
-~
Timing Gears
Backlash
~~
Standard
0.10
(0.004
-
-
~ rnm(in)
Limit
0.3
(0.012)
Includes the crankshaft gear, the camshaft gear, and the idler gear.
MEASURE IDLER
GEAR
END PLAY
2.
Cam Shaft
Measure the following points before disassembly. mm(in)
Limit
Cam Gear End
Play
Standard
0.050
-
(0.002 -
0.2
(0.008)
3.
Crankshaft Bearing Cap
Measure the crankshaft end play at the thrust bear- ing (center main bearing) before disassembly. mm(in)
~
Crankshaft End
Play
~
Standard
~
0.15
(0.006
-
-
Limit
0.4
(0.016)
~
MEASURE TIMING GEARS BACKLASH
,CAMSHAFT GEAR
'-----
T
H
RUST P
LA
TE
'FEELER GAUGE
MEASURE CAM SHAFT
GEAR
END PLAY
MEASURE CRANKSHAFT BEARING CAP END PLAY
WESTERBEKE
I
Engines
&
Generators
11
DISASSEMBLY
4
8
Disassembly Steps
1 . Dipstick and guide tube tube
2. Air breather
3.
Turbo adapter
4. Oil feed pipe
5.
Oil drain pipe
6.
Turbocharger
7. Gasket
8.
Starter
9.
Drive belts
10. Alternator
11. Waterpump pulley
12. Cylinder head cover
Turbocharger
Plug oil ports in turbocharger body immediately after removal o f t h e turbocharger.
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4
'7
5
WESTEREEKE
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Engines
&
Generators
12
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Disassembly Steps
1. Rubber hose
;
water by-pass
2. Rocker arm shaft assembly
3.
Push rod
4. Cylinder head bolt
5. Cylinder head assrnbly
6. Cylinder head gasket
7.
Water pump assembly
8. Tappet chamber cover
DISASSEMBLY
9. Oil pump driving pinion
10. Starting handle nut
11. Taper bushing
12. Crankshaft pulley and dust thrower
13. Timing gear cover
14. Oil thrower
15. Flywheel
'15
DISASSEMBLY
NUMBERS INDICATE
SUGGESTED ORDER
OF DISASSEMBLY
SIX CYLINDER MODEL
(SHOWN)
11
CRANKSHAFT
BEARING (LOWER) AND BEARING CAP
2
OIL PAN
(NOTSHOWN)
Disassembly Steps
1.
Oil cooler
2. Oil pan
3.
Oil pump and coupling
4. Flywheel housing
5. Piston and connecting rod
6. ldler gear
7.
Camshaft
8.
Tappet
9.
10.
Timing gear case ldler gear shaft
11. Crankshaft bearing cap
12. Crankshaft bearing (lower half)
13. Thrust bearing
14. Crankshaft
15. Crankshaft bearing (upper half)
6
GEAR
INSPECTOIL COOL
REPLACEANY PAR
SHOW EXCESSIVE
BY-PASS VALVE,
O-RING. SPRING
AND PLUG
WESTERBEKE
/
Engines
&
Generators
14
INSPECT OIL COOLER ASSEMBLY:
REPLACE ANY PARTS THAT
SHOW EXCESSIVE WEAR
OR DAMAGE.
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INSPECTIONIREPAIR
C A
R
BO
N
DEP OSITS
NUMBERS INDICATE
ORDER OFDISASSEMBLY
1.
PISTON RINGS
2. SNAP RINGS
3. PISTON PIN AND
CO N
NE
CTING
ROD
Note:
Remove any cylinder bore.
This will deposits from the upper Pa rt the
1.
Piston Rings
Use a piston remover to remove the Piston rings.
DO not attempt to use some other tool: Piston ring stretching will ring tensbon.
2, 3.
SNAP R INGS and Piston Pin
Use a pair snap ring.
,*,
T~~ the piston pin out with a hammer a nd brass bar.
~ w E S T E R B E K E
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Engines
&
Generalors
NUMBERS INDICATE THE SUGGESTED ORDER OF DISASSEMBLY
6 ,
SPLIT COLLAR
*-
7
SPRING SEAT (UPPER)
INTAKE MANIFOLD/GASKET
(SIX CYLINDER SERIES SHOWN)
3
4
SIX CYLINDER
HOUSING/GASKET
MANIFOLDIGASKEI
INSPECTION AND REPAIR
Make all necessary adjustments, repairs and part replacements if excessive wear or damage is discovered during inspection.
- i
WHEN REMOVING THE SPLIT COLLAR
USE VALVE SPRING COMPRESSOR
mWES7ERBEKE
1
Engines & Generators
"
INSPECTION/REPAIR
CYLINDER HEAD
Cylinder Head Lower Face Warpage
1. Use a straight edge and a feeler gauge to measure the four sides and the two diagonals of the cylinder head lower face.
2. Regrind the cylinder head lower face if the mea- sured values are greater than the specified limit but less than the maximum grinding allowance.
Water Jacket Water Pressure Test
Use the hydraulic gauge to check the water jacket water pressure.
(71.1 psi) three minutes,
Check the entire cylinder head for water leakage.
TESTING THE WATER
JACKET PRESSURE
If the measured values exceed the maximum grind- ing allowance, the cylinder head must be replaced.
Cylinder Head Lower Face Warpage
Standard Limit mm(in)
Maximum Grinding
Allowance
0.2 (0.008) 0.3 (0.012)
(0.002) or less
A
VALVE GUIDE
Valve Stem and Valve Guide Clearance
Measuring Method
-
I
1. With the valve stem inserted in the valve guide, set the dial indicator needle to " 0 .
2. Move the valve head from side to side.
Note the total dial indicator reading (TIR).
This value is the clearance between the valve stem and the valve guide.
If the measured values exceed the specified limit, the valve and the valve guide must be replaced as a set.
Valve Stem Clearance mm(in)
Cylinder Head Height (Reference)
Standard
89.95 (3.544)
-
1
89.65 (3.530)
Note:
depression must be checked.
MEASURE
CYLINDER
HEAD HEIGHT
!
!
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MEASURE THE VALVE STEM AND GUIDE CLEARANCE
INSPECTION/REPAIR
Valve Depression
Measuring Method
-
II
1. Measure the valve stem outside diameter.
1. Install the valve
2.
Use a caliper calibrator or a telescoping gauge to measure the valve guide inside diameter.
The difference between the valve stem outside di-
2. Use a depth gauge or a straight edge with steel r u l t to measure the valve depression from the cylinder head lower surface.
MEASURING
THE
VALVE GUIDE 1.0. ameter and the valve guide inside diameter is equal to the valve stem clearance.
If the measured value exceeds the specified limit. the valve seat insert andlor valve must be replaced.
63
If the valve is replaced, the valve guide must be also replaced. mm(in)
1
Intake and Exhaust
Valve Depression
1
; i
Standard
,0,039)
Limit
2.5 (0.098)
Valve Guide Replacement
Valve Guide Removal
Use a hammer and the valve guide remover to drive out
REMOVERIINSTALLER
The height of the valve guide top edge from the cylinder head upper face should be 14.1 mm (0.55 in).
Valve C o n t a c t W i d t h
1. Inspect the valve contact faces for roughness and unevenness.
Make smooth the valve contact surfaces.
2.
Measure the valve contact width.
If the measured value exceeds the specified limit, the valve seat insert must be replaced.
Valve Contact Width
I
Standard
I
Limit mm(in)
1
1.5 (0.059)
1
2.0 (0.078)
NTACT WIDTH i i i i
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Engines & Generators i
INSPECTlONlREPAlR
Valve Seat lnsert Replacement
Valve Seat lnsert Removal
1.
Arc weld the entire inside circumference valve seat insert
0
.
@ of the
2. Allow the valve seat insert to cool for a few minutes.
This will invite contraction and make removal of the valve seat insert easier. v a l v e Seat lnsert Correction
1. Remove the carbon deposits from the valve seat insert surface.
2. Use valve cutters (15'. 30'. or 75' blades) to remove scratches and other rough areas.
This will bring the contact width back to the stand- ard value of 90'
@ .
Remove only the scratches and rough areas. Do not cut away too much. Take care not to cut away
3. Use a screwdriver free.
@ to pry the valve seat insert
Take care not t o damage the cylinder head
@
.
I
4.
Carefully remove carbon and other foreign material from the cylinder head insert bore.
Valve Seat Installation
1. Carefully place the attachment a
(having the smaller outside diameter than the valve seat insert) on the valve seat insert a.
Note:
The smooth side of the attachment must contact the valve seat insert.
2. Use a bench press a to slowly apply pressure to the attachment and press the valve seat insert into place. (Amount of pressure needed is more than
2,500 kg)
Note: not apply an excessive of pressure with the bench press. Damage to the valve seat insert will result.
Note:
Use an adjustable valve cutter pilot.
Do not allow the cutter pilot to wobble inside the valve guide.
3. Apply abrasive compound to the valve seat insert surface.
4. lnsert the valve into the valve guide.
5. Hand lap the valve and the valve seat with a lapp- ing cup.
This will provide optimum valve and valve seat con- tact for effective gas sealing.
6. Check that the valve contact width is correct.
7. Check that the valve seat insert surfacels in contact
WESTERBEE
/
Engines & Generators with the entire circumference of the valve.
A,
-
..
\
,,
4 5 O
\
19
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INSPEGTION/REPAIR
VALVE SPRING
Valve Spring Free L e n g t h
Use a vernier caliper to measure the valve spring free length.
If the measured value is less than the specified limit, the valve spring must be replaced.
Valve Spring Tension
Use a spring tester to measure the valve spring tension.
If the measured value is less than the specified limit, th' valve spring must be replaced,
Valve Spring
11.5 (24.36)
TAPPET (Cam Follower or Valve
L i f t e r )
Inspect the tappets for excessive wear, damage and any abnormalities.
. .
.,
PIllED CRACKED
NORMAL
V a l v e S p r i n g I n c l i n a t i o n
.
.
Use a surface plate and a square to measure the valve spring inclination.
If the measured value exceeds the specified limit, the valve spring must be replaced. mm(in)
Use a micrometer to measure the tappet diameter, mm(in)
Tappet Diameter
Standard
27.97
-
(1.1020-1.1024)
Limit
27.92
(1.1000)
SPRING TENSION
20
Use a dial indicator to measure the clearance between the tappet and cylinder body tappet travelling bore. mm(in) i i i
I i
INSPECTION/REPAIR
PUSH
ROD
Use a filler gauge to measure the valve push rod run-
, out.
Roll the push rod along a smooth flat surfase lillustra- tion). mm(in)
Limit
Push Rod Run-Out 0.3 (0.012)
MEASURING THE ROCKER ARM SHAFT
Rocker Arm Correction
Inspect the rocker arm valve stem contact surfaces for ridges@ and scoring@
If the surfaces have light ridge or scoring, they may be honed with an oil stone.
If the ridge or scoring is severe, the rocker arm must be replaced.
Rocker Arm Shaft Outside Diameter
Use a micrometer to measure the rocker arm outside diameter.
If the measured value is less than the specified limit, the shaft must be replaced. mm(in)
Limit
Rocker Arm Shaft
Diameter
Standard
18.98
(0.747
-
-
18.85
(0.743)
ROCKER ARM
ROCKER ARM SHAFT AND ROCKER ARM
lnspect all disassembled parts for wear, damage and any abnormalities.
1. Use a vernier caliper to measure the rocker arm bushing inside diameter. mm(in)
Limit
Rocker Arm Bushing
Inside Diameter
Standard
19.01
(0.749
-
-
19.05
10.751)
2. Measure the rocker arm shaft outside diameter.
Replace either the rocker arm or the rocker arm shaft if the clearance exceeds the specified limit.
- - - - - - - - - - - - - -
ROCKER ARM SHAFT
4
0.0.
f mm(in)
ROCKER ARM
and Rocker Arm
Shaft Clearance
3. Check that the rocker arm oil port is free of obstruc- tions.
If necessary, use compressed air to clean the rocker arm oil port.
P W E S T E R B E K E
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Engines
&
Generators
21
INSPECTION/REPAIR
IDLER GEAR AND IDLER GEAR SHAFT
1. Use a micrometer to measure the idler gear shah outside diameter.
If measured diameter exceeds specified limit. replace the idler gear shaft. mm(in)
Outside Diameter
: holes with the mat- ing oil ports (machined on the cylinder body cam- shaft bearing fining bore).
MEASURING
IDLER GEAR SHAFT
2. Use a dial indicator to measure the idler gear inside diameter. mm(in)
1.
Use the camshaft bearing remover and installer to remove camshaft bearing from the cylinder body.
Camshaft Bearing Remover and Installer.
2. Measure the clearance between the cam journal and the camshaft bearing.
Cam Journal and Cam
Bearing Clearance
Standard
0.03
-
0.09
(0.001
-
(0.006)
REMOVER
AND INSTALLER
-
~ W E S T E R B E K E
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Engines & Generators
22
ALIGN THE
Cam Journal
f i
4. Use a micrometer to measure the cam lobe height.
If the cam lobe height is less than the specified li- mit, the camshaft must be replaced.
Standard
.%
+
MEASURING
THE CAMSHAFT
1
I
5. Place the camshaft on a measuring stand
Use a dial indicator to measure the camshaft run- out.
Note the total indicator reading (TIR).
If the measured run-out exceeds the specified limit, the camshaft must be replaced.
rnrnfinl
1
Camshafi Run-Out TIR
0.12 (0.005)
'CYLINDER BODY AND LINER
Cylinder Liner Bore Measurement
Use a cylinder indicator to measure the cylinder liner bore at measuring position shaft
@ in line with the crank-
@ and across the crankshaft
@ .
Measuring Point a
Wear Portion)
If the measured value exceeds the specified limit, the cylinder liner must be replaced.
Cylinder Liner Projection Inspection
I
1. Hold a straight edge
@ along the top edge of the cylinder liner to be measured.
2. Use a feeler gauge liner projection.
@ to measure each cylinder
I
Limit
Cvlinder Liner Proiection 10.03
-
mmlin)
I
The difference in the cylinder liner projection height between any two adjacent cylinders must not exceed 0.03 mm (0.001 in). r
Cylinder
Liner Bore
I
Cylinder Liner Replacement
Cylinder L i n e r Removal
1. Set the cylinder liner remover to the cylinder liner.
2. Check that the remover shaft ankle is firmly gripp- ing the cylinder liner bottom edge.
3. Slowly turn the remover shaft handle counterclock- wise to pull the cylinder liner free.
Cylinder Liner Remover: 9-8523-1 169-0
Cylinder Liner Remover Ankle:
For all models except 6BG1: 9-8523-2557-0
For 6BG1
NOTE:
Toke cure not to rlanlage the cylindir body upperface drrring the cylinder liner renlovul procedure.
L&~Q:"
/ mm(in)
1
Standard
1
Limit
I
Note:
The ir~sirle plated.
It
cannot be rebored or honed. Ifthe inside of the cylinder liner is scored or scurched, the cylinder liner must bc rel?Ir~ccd.
WESTEREEKE
I
Engines
&
Generators
INSPECTION/'EPAIR
Cylinder Bore Measurement
Cylinder Liner Grade Selection
The term "grade" refers to the cylinder body inside diameter and the cylinder liner outside diameter combi- nation.
Measure the cylinder body inside diameter and select the appropriate cylinder liner grade.
Loose fitting cylinder liners (the liner is too small for the cylinder bore) will adversely affect engine cooling effi- ciency and may lead to serious engine damage.
Cylinder liners which are too large for the cylinder bore will be difficult to install.
Cylinder Liner Outside Diameter
Measurement
1. Take measurements at measuring points and
0.
@.
@
Measuring Points mm(in):
0
20.0 (0.788)
105.0 (4.137)
195.0 (7.683) average value the measurements to determine the correct cylinder liner grade.
MM (IN)
CYLINDER LINER FITTING
CLEARANCE STANDARD
0.001
-
0.019
(0.00004
-
0.0007)
MEASURING THE
CYLINDER BODY I.D.
MEASURING
POINTS
Cylinder Body Inside Diameter Measurement
1. Take measurements at measuring point the positions W-W, X-X,
Y-Y, and
Z-2.
@ across
Measuring Point
2. Calculate the average value of the four measure- ments to determine the correct cylinder liner grade.
T
MEASURING
Ti
MEASURING
CYLINDER
LINERS
Y
Cylinder Bore and Cylinder Liner Outside Diame- t er
cOmt,inations
(Reference)
EON411 10T4
Grade
Cylinder Bore
105.001
-
(4.1 339
-
105.011
(4.1 343
-
-
105.021
-
(4.1347
- mm(in),
Cylinder Liner
Outside Diameter
105.011
-
(4.1343
105.021
-
(4.1347
-
105.031
-
(4.1350
-
4.1354)
120N61170T6 mm(in)
-
Grade Cylinder Bore
Cylinder Liner
Outside Diameter
I
1 107.001
1
(4.2126
-
4.2130)
1
107.011
(4.2130
-
-
1
107.011
-
(4.2130
-
i
107.021
-
107.030
(4.2134
-
4.2138)
;
107.021 - 107.030 i
107.031 - i
(4.2134
-
(4.2138
-
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WWESTERBEKE
1
Engines & Generators i i
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1
lNSPECTlON/REPAlR
Cylinder Liner Installation
1. Carefully wipe away any foreign material from the cylinder liner inside and outside surfaces and the cylinder bore.
2. Use new kerosene or diesel oil to thoroughly clean the cylinder liner and bore surfaces.
3. Use a clean rag to remove all traces of kerosene or diesel oil from the cylinder liner and bore surfaces.
Piston Grade Selection
The term "piston grade" refers to the piston diameter and cylinder liner bore combination.
Selection of the proper piston grade will ensure efficient engine operation, free from cylinder liner and piston problems.
Measure the cylinder liner bore after installing the cylin- der liner. Then select the appropriate piston grade for the installed cyl,ink
@
C Y
LINDER -
LINER
K,ooL
3
INSTALLER
,
3:
-
-
-
-
4. Insert the cylinder liner
@ into the cylinder body
@ from the top of the cylinder body.
5. Set the cylinder liner installer cylinder liner.
Cylinder Liner Bore Measurement
@
to the top of the
1, Locate the two measuring points.
Cylinder Liner Installer:
For 4 Cyl.
For 6 CYL.
9-8523-2554-0
5-8522-1 01 8-0
6. Position the cylinder body so that the installercen-
Cylinder Liner Measuring Point : 20 m m (0.788 in)
Cylinder Liner Measuring Point a
105 m m (4,173 in)
2. Measure the cylinder liner bore at measuring point
@ and
@ in four different directions (W-W,
X-X, Y-Y, and 2-73.
;::"
LINER
3. Calculate the average value of the eight measure- ments. mm(in)
Cylinder Liner Bore Total Indicator Reading
4 Cyl. 6 Cyl.
(4.0166
-
4.0181) (4.1347
-
4.1362)
Note:[! is 1~1ost inzl~ortant used. Failure to select the correct piston grade will result in piston seizurp. Always measure the cylinder bore and select
t h e a ~ ~ l ~ m ~ r i a r e ~ i s t o n j i r a d e .
7. Check that the cylinder liner is set perpendicular to the cylinder.
Check that the cylinder liner does not wobble.
8. Use the bench press to apply an initial seating force of 500 kg (1,102.5 lg) to the cylinder liner.
9.
Use the bench press to apply a final seating force of
2,500 kg (5,512.5 lb) to fully seat the cylinder liner.
10. After installing the cylinder liner, measure the cylin- der liner projection.
Refer to "Cylinder Liner Projection Inspection".
-
Piston Outside Diameter
1. Piston outside diameter vary depending on the pis- ton type to be used.
2. Measure the piston outside diameter at the measur- ing piston
@ shown in the illustration.
3. Piston Grade.
You can find steel strut on the inner surface of
C
101.975
-
(4.0148
-
104.975 mm(in)
1 piston as shown in the illustration.
1
Grade
1
4 Cyl.
1
6 CYL.
A
,
101.955
-
;
101.974 ;704.955 ~ < 7 7
(4.0140
-
(4.1321 -
-
104.994
(4.1329
-
1
Piston Ring
Gap
1. Insert the piston ring horizontally (in the position it would assume if it were installed to the piston) into the cylinder liner.
2. Use an inverted piston to push the piston ring into the cylinder liner until i t reaches either measuring point or measuring point
@
.
Cylinder liner diameter is the smallest at these two points.
Do not allow the piston ring t o slant to o n e side or the other. It must be perfectly horizontal.
Cylinder Liner Measuring Point
Cylinder Liner Measuring Point
0
10 m r n (0.39 in)
0
: 130 m m (5.12 in)
Cylinder Liner Bore and P i s t o n Clearance
1) Steel strut Built-in Type (Autothermatic Type)
For all 48.66 series
0.055
-
0.085 mm (0.0021
-
0.0033 in)
PISTON AND PISTON RING
Piston Ring a n d Piston Ring G r o o v e Clearance
Use a feeler gauge to measure the clearance between the piston ring and the piston ring groove.
Do this at several points around the piston.
I
If the clearance between the piston ring and the piston ring groove exceeds the specified limit, the piston ring must be replaced. mrn(in)
I
Standard
I
Limit
1
3. Use a feeler gauge to measure me piston ring gap.
If the measured value exceeds the specified limit, the piston ring must be replaced.
1 st Compression
Ring Gap
2nd Compression
Ring Gap
-
Oil ring Gap
I
Standard Limit
0.25
(0.0098
-
0.45
-
0.0177)
: i 1.50
(0.0591)
0.20
1
(0.0079
-
0.40
-
0.0157) i
,
1.50
(0.0591)
I
1
0.20
-
0.40
1
1.50
,
(0.0079
-
0.01 57)
;
(0.0591)
-
/
Engines & Generators
PISTON PIN
Piston Pin Outside Diameter
Use a micrometer to measure the piston pin outside diameter at several points.
If the measured piston pin outside diameter exceeds the specified limit, the piston pin must be replace.
I
Piston Pin Outside
Diameter
mmlinl
I
Standard
'
Limit
I
~ ~
I -~
35.000 -
11.3780
- i
34.95 i
11.37601
PIN HOLE
DIAMETER
If an inside dial indicator is not available, use the follow- ing procedure to check the piston pin fit.
1. Use a piston heater to heat the piston to approxi- mately 60°C (140'F).
2. Push strongly against the piston p i n with your thumbs.
The piston pin fining should feel tight.
USING A HOT PLATE TO
HEAT THE PISTON
Piston Pin and Piston Clearance
Use an inside dial indicator to measure the piston pin hole.
Piston Pin Hole Diameter
4
CYL.
mm(in)
Standard
35.000
-
(1.3780
-
6
CYL.
35.010
MEASURING PISTON
PIN HOLE 1.0.
PISTON PIN SHOULD
FIT TIGHTLY
\ /
Piston Pin and Piston Pin
Hole
Clearance
Determine the clearance between the piston pin and the piston pin hole by calculating the difference behiveen the piston pin hole diameter and the piston pin outside diameter. mm(in)
Piston Pin and Piston Pin
;
Hole Clearance
I
1
Limit
0.050 (0.002)
(%3
I
Engines
&
Generators
INSPECTION/REPAIR
CONNECTING ROD
Connecting Rod Alignment
Use a connecting rod aligner to measure the parallelisrn bemeen the connecting rod big end hole and the con- necting rod small end hole.
If either the measured parallelism exceeds the specified limit, the connecting rod must be replaced.
Connecting Rod Alignment
(Per Length of 100 mm (3.94 in)) mm(in)
Connecting R o d Bushing Removal
1.
Clamp the connecting rod in a vise.
2. Use a brass bar and a bench press or hammer tc remove the coonecting rod bushing.
CONNECTING ROD
Use the connecting rod bushing installer to install the connecting rod bushing.
Connecting Rod Bushing Installer: 9-8523-1369-0
(J-29765)
NOTE:
The connecting
rod
busl~ing
he
aligtzed with the connecting rod oil port.
3. Use a piston pin hole grinder reamer
@ fitted with a a or an adjustable pilot reamer to ream the piston pin hole. mm(in) ecting R o d Small E n d Bush- i n g Clearance
Use a caliper calibrator and a micrometer to measure the piston pin and connecting rod small end bushing clearance.
If the clearance between the piston pin and the connect- ing rod small end bushing exceeds the specified limit, replace either the piston pin or the connecting rod bushing.
Standard mm(in)
Limit
0.010
-
REAMING THE PISTON HOLES
PISTON
PIN
CONNECTING ROD
TAKING MEASUREMENTS
CLEARANCE
~ W E S T E R B E K E
I
Engines
&
Generators
Connecting Rod Bearing Inspection
1. Fit the connecting rod bearing lower half into the connecting rod bearing cap.
2. Check the connecting rod bearing lower half ten- sion.
If the tension is insufficient, the bearing must be replaced.
3. Tighten the connecting rod and the bearing cap to the specified torque.
1st step kg.rn(1b.h)
2nd step
Connecting Rod and Bearing
Cap Bolt Tightening Torque
4
(28.9)
60.+30'
0'
CRANKSHAFT
Crankshaft and Bearing lnspection
1. lnspect the crankshaft journal surfaces and the crank pin surfaces for excessive wear and damage.
2. lnspect the oil seal fining surfaces of the crankshaft front and rear ends for excessive wear and damage.
3. Replace or repair the crankshaft if any excessive wear or damage is discovered.
4. lnspect the crankshaft oil ports for obstructions.
5.
Use high pressure air to clean the oil ports if neces- sary. i
4.
Use an inside dial indicator to measure the connect- ing rod inside diameter. mmiin)
Connecting Rod Bearing
:
Nominal Diameter
64 (2.520)
Crankshaft Journal and Crankpin Outside Diarne- ter
1. Use a micrometer to measure the crankshaft journal outside diameter across points
@
-
@ and a
-
0 .
2.
Use the micrometer to measure the crankshaft iour- nal outside diameter at the two points (
@ and
@ I .
3. Repeat steps 1 and 2 to measure the crankshaft out- side diameter.
If the measured crankshaft journal diameter andlor the crankpin outside diameter are less than the standard value, the crankshaft must be reground. mm(in)
79.905 -
Diameter
/
Bearings i
(3.1464
-
3.1472)
]
!
Position at
;
Standard
Crankshaft Journal
Diameter
!
/
A,,
Bearings
!
79.905 -
(3.1459
-
WESTERBEKE
I
Engines & Generators
Crankshaft Pin Diameter
INSPECTlONlREPAlR
mm(in)
.
.
Standard
63.924
-
63.944
(2.5167
-
2.5175)
4. Measure the crankshaft journal outside diameter
(andlor the crankpin outside diameter) and the bearing inside diameters to determine the bearing clearance.
Crankshaft Journal a n d Bearing Clearances
If the bearing clearance exceeds the specified limit, the crankshaft must be reground (except for the 120N6 and
170T6) or the bearing must be replaced.
6
C YL.
.
Position at
Crankshaft Journal and Main Bearing
Clearance
Center
Bearing
Only
Other
Bearings
Standard mm(in!
Limit
0.039-0.098
(0.0015-0.0039)
0.025-0.084
(0.0010-0.0033)
0,11
(0,0043) mm(in)
Rod
Bearing
Inside
Tighten the connecting rod and the bearing cap with specified torque, and use inside dial indicator to rnea- sure the connecting rod bearing inside diameter.
1st step kg.rn(1b.h)
2nd step
Connecting Rod and Bearing
Cap Bolt Tightening Torque
4
(28.9)
60.-30'
v
Clearance
Crankpin and
Connecting Rod
Bearing Clearance
Standard
0.03-0.07 mm(in)
Limit
CONNECTING
ROD BEARING
Crankshaft Journal Bearing Inside Diameter
1. Install the main bearing cap with bearings to the cylinder body with the specified torque and facing the arrow mark on the bearing cap toward front. Place them in order of punched cylinder numbers.
2. Use an inside dial indicator to measure the main bearing diameters.
Main Bearing Cap Torque kg.m(lb.ft)
24.1
?
1
(173.5 k
7.2)
Crankshaft Run-Out
1. Mount the crankshaft o n a set of V-blocks.
2. Set a dial indicator to the center of the crankshatt journal.
3, Gently turn the crankshaft in the normal direction of engine rotation.
Read the dial indicator (TIR) as you turn the crank- shaft.
If the measured value exceeds the specified limit, the crankshaft mus rnm(in)
Main Bearing Nominal
Diameter
80
(3.150)
.
~
MEASURING CRANKSHAFT
WESTERBEICE
1
Engines
&
Generators
30
1
I
Crankshaft
Run-Out mm(in)
I
I
Model
/
Standard
I
Limit
1
6 Cyl.
1
4
Cyl.
1
I
'
0.05 (0.002)
'
1
0.40 (0.016)
1
0.30 (0.012)
I
If the crankshaft generated a crack after repair. replace the crankshaft.
The crankshafts for the
120N6
and the 170T6 engines can not be bench pressed because they are finished in the Tufftride method.
Main Bearing and Connecting Rod Bearing Ten- sion
Check to see if the bearing has enough tension, so that good finger pressure is needed to fit the bearing into position.
FITTING THE BEARINGS
Crankshaft
Regrinding Procedure (4
Cyl.)
1. Regrind the crankshaft journals and the crankpins.
2. Fillet the crankshaft journal and crankpin radious to a minimum of R3.5
There must be no stepping around the fillet area.
3. Finish the crankshaft journal, crankpin, and oil port corners to a smooth surface having a chamfer
, radius of 1 mrn (0.04 in).
Crankshaft Journal and
Crankpin Roughness
0.4
p
or less
4. Measure the crankshaft journal and crankpin clear- ance.
I
Refer to "Crankshaft Journal Clearance" and "Crank- pin and Clearance': on
5. Measure the crankshaft run-out.
Refer to "Crankshaft Run-Out':
Crankshaft Grinding Limit (4 Cyl.)
Crankshaft Regrinding (4 Cyl.)
To ensure .crankshaft reliability, pay close attention to the following items during and after the crankshaft grinding procedure. mrn(in)
Undersize Bearing
Availability
0.25 (0.010) 0.50 (0.020)
Note:
Crunkshufrs for rlre 120N6 and tire 170T6 can nor be
ground because they orefinisl~ed
No utvmpt should be made
11)
grindfitlish rhesefuces of the harden in^ rrearnre~lt).
Tllerefore, rile relder.size bearirlgs are nor prepared.
Crank Journal Diameter
Crankpin Diameter
I
79.419 (3.127)
63.424 (2.497)
Undersize bearings 0.25 mm (0.010 in) and 0.50 m m
(0.020 in) are available to compensate for excessive clearance between the crankpin bearing and the crank- shaft. Regrinding of the crantshaft to fit the undersize bearings is required.
Standard rnrn(in)
Limit
Crankpin and
Connecting Rod
Bearing Clearance
0.03-0.07
Undersize bearings 0.25 mrn (0.010 in) and 0.50 m m
10.020 in) are available to compensate for excessive clearance between the crankshaft journal bearing and the crankshaft. Regrinding of the crankshaft to fit the undersize bearings is required.
I
6B Engines Only I ~ o s i t i o n at/ Standard rnrn(in)
/
Limit
I
Crankshaft Journal and Main Bearing
Clearance
Other
!
0.025-0.084
I
Bearings 1(0.0010-0.0033)
1
(0.0043)
4B Engines Only i
Position at
i
Standard
1
Limit
Crankshaft Journal
(
All j
0.039-0.098 i
0.11 and Main Bearing
, l
WESTERBEKE
/
Engines
&
Generators
INSPECTION/REPAIR
Plastigage Clearance Measurements
This is another method to measure the crankjournal bearing clearance.
Crankshaft Journal Bearing Clearance
1. Clean the cylinder body, the journal bearing fining portions, the bearing cap, and the inside and out- side surfaces of the bearing.
2. lnstall the new journal bearing to the cylinder body.
3. Carefully place the crankshaft on the bearing.
4.
Rotate the crankshaft approximately
30'
to seat the bearing.
5. Place the Plastigage (arrow) over the crankshaft journal across the full width of the bearing.
Apply engine oil to the Plastigage to keep it from falling.
6. Install the bearing cap with the bearing.
7. Tighten the bearing cap to the specified torque.
Do not allow the crankshaft to turn during bearing cap installation and tightening.
TIGHTEN THEBEARING CAP
1. Clean the crankshaft, the connecting rod, the bear- ing cap, and the bearings.
2.
Install the bearing to the connecting rod.
Do not allow the crankshaft to move when installing the bearing cap.
3. Hold the connecting rod (with the bearing installed) against the crankshaft pin.
4.
Anach the plastigage to the crankshaft pin.
Apply engine oil to the plastigage to keep i t from falling.
5. lnstall the connecting rod bearing cap and tighten it to the specified torque.
Do not allow the connecting rod to move when installing and tightening the bearing cap.
6.
Remove the bearing cap.
7. Compare the width of the plastigage anached to'; either the crankshaft or the bearing against the scale printed on the plastigage container.
If the measured value exceeds the limit, perform the following additional steps.
1) Use a micrometer to measure the crankshaft outside diameter.
2)
Use an inside dial indicator to measure the bearing inside diameter.
3) Replace the crankshaft and/or the bearing i f the measured value(s1 exceed the limit.
8. Remove the bearing cap.
9. Compare the width of the plastigage attached to either the crankshaft or the bearing against the scale printed on the plastigage container.
If the measured value exceeds the limit, perform the following additional steps.
1 )
Use a micrometer to measure the crankshaft outside diameter.
2)
Use an inside dial indicator to measure the bearing inside diameter.
3)
Replace the crankshaft and/or the bearing if the measured valuels) exceed the limit.
~ W E S T E R B E K E
I
Engines & Generators
32
Crankshaft Tufftriding Inspection
(6
Cyl.)
lnspection
Model 120N6 and 170T6
1. Use an organjc cleaner to thoroughly clean the crankshaft. There must be no traces of oil on the surfaces to be inspected.
2.
Prepare a 10% solution of ammonium cuprous chlo- ride (dissolved in distilled water).
3. Use a spot glass rod to apply the solution t o the surface to be inspected.
Hold the surface to be inspected perfectly horizontal to prevent the solution from running.
Note:
Do not allow the solution ro cvrne in contact with the oil pons and their surrounding area.
O i l Seal W e a r
Ring
Replacement
(6 cyl.)
Removal
Use the oil seal wear ring remover to remove the oil seal wear ring from the crankshaft front end.
Oil Seal Wear Ring Remover:
FACE IN CONTACT
WITH CRANKPIN
OR JOURNAL
AMMONIUM
CUPROUS
CHLORIDE,
TEST LIQUIO SHOULD
NOTBEAPPLIED
NEAR THE OIL PORT
J
Installation
Use a brass bar and a hammer to drive the oil seal wear ring into place.
APPROX.
IOMM
Judgement
1.
Wait for thirty to forty seconds.
If there is no discoloration after thirty or forty sec- onds, the crankshaft is useable.
If discoloration appears (the surface being lesteo wlll become the color of copper), the cran~snaft replaced.
2.
Clean the surface being tested with clean water of steam immediately after completing the test.
Note:
Tile anrn~oniur~r corrosive. Because
of
this, i f is iniperalivc Illat l l ~ c being tested be cleaned itnniediatcly after cornl~letirlg t11e test.
o "
0
~
BRASS BAR
Crankshaft Gear lnspection
Visually inspect the crankshaft gear.
Replace the crankshaft gear if excessive wear or damage is discovered.
Removal
Use the crankshaft gear remover to remove the crank- shaft gear.
Crankshaft Gear Remover: 9-8521-0141
0
2
(url
I
Engines & Generators
INSPECTlONlREPAlR
Flywheel Housing O i l Seal Replacement
Removal
Use a pry bar to remove the flywheel housing oil seal. lnstallation oil seal.
Installation
Use the crankshaft gear installer to install the crankshaft gear.
FLYWHEEL AND FLYWHEEL HOUSING
(REAR OIL SEAL)
Ring Gear Inspection
Inspect the ring gear. the ring gear must be replaced.
TIMING GEAR CASE COVER
Crankshaft
Front Oil
Seal Replacement
Removal
Use an adapter and a hammer to remove the crank front end oil seal. lnstallation
Use the crankshaft front oil seal installer to instal crankshaft front oil seal.
OIL SEAL INSTALLER
REMOVING
THE
Ring Gear Removal
Strike around the edges of the ring gear with a hammer and chisel to remove it.
Ring Gear lnstallation
1. Heat the ring gear evenly with a gas burner to invite thermal expansion.
Do not allow the temperature of the ring gear to exceed 200'C (390°F).
2. Use a hammer to install the ring ge ficiently heated.
INSTALLING FRONT OIL SEAL
I i
I
WESTERBEKE
I
Engines & Generators
34
ASSEMBLY
PISTONICONNECTING
ROO
ASSEMBLY
2
PISTON
PIN
5
CONNECTING
NUMBERS INDICATE THE
SUGGESTED ORDER OF
ASSEMBLY
4. Piston Ring
1) Use a piston ring installer to install the three piston rings. lnstall the piston rings in the following order.
(1) Oil ring
(2) 2nd compression ring
(3) 1st compression ring
The marked side of the two compression rings must be facing up.
The undercut side of the second compression ring will be facing down.
As the oil ring has no any facing mark, it may face in either direction.
2) Lubricate the piston ring surfaces with engine oil.
3)
Check that the piston rings rotate smoothly in the piston ring grooves.
PISTON AND CONNECTING ROD
Important Operations
1. Piston
Use a piston heater to heat the pistons t o approxi- mately 60°C (140'F).
2. Connecting Rod
1) lnstall the connecting rod to the piston with setting the marks asillustrated.
2) Install the piston pin into the piston and the connecting rod bushing.
PISTON
PISTON
5. Connecting Rod Bearing
1) lnstall the connecting rod bearings to the con- necting rod large-end and the connecting rod cap.
2) lnstall the bearing cap to the connecting rod with semi-tightening the cap bolts.
3. Piston Pin Snap Ring
1) Use a pair of snap ring pliers to install the pis- ton pin snap ring.
2) Check that the piston moves smoothly on the piston pin.
WESERBEKE
I
Engines & Generators
35
SPRINGS
CYLINDER HEAD
ASSEMBLY
EXHAUST MANIFOLD
EXHAUST VALVES
1. Valve Stem Oil Seal
1) Lubricate the oil seals and valve stem sealing area with engine oil.
2) Use a valve stem oil seal installer to install the
3. Intake and Exhaust Valve Springs
lnstall the valve springs with their painted end (the close pitched end) facing down.
!
1) Place the cylinder head on a flat wooden sur- face.
2) Lubricate valve stems with engine oil.
3) Install the valves to the intake or exhaust guides.
Install the valves to their original lapped valve seats.
WESTERBEKE
I
Engines
&
Generators
*
~
!
!
c~
!
!
ASSEMBLY
4. Spring Seat Split Collar
1)
Use a spring compressor to push the valve spr- ing into position.
2)
Install the spring seat split collar.
3) Set the spring seat split collar by tapping lightly around the head of the collar with a rubber hammer.
SETTING
THE
SPRING
SEAT SPLIT COLLAR
5. Intake Manifold and Gasket
1) lnstall the intake manifold gasket.
The intake manifold gasket must be installed with its unchamfered corner facing up and to the front of the engine.
6. Exhaust Manifold and Gasket
1) Install the exhaust manifold gasket.
The "TOP" mark must be facing up.
4
CYL. AND 6 CYL. USE
DIFFERENT MANIFOLD GASKETS.
0
2) lnstall the exhaust manifold.
3) Tighten the exhaust manifold bolts to the speci- fied torque a little at a time in the numerical order shown in the illustration. kg.m(lb.ft)
Exhaust Manifold Bolt
Torque
2.9
k (21.0
i
@REAR
UNCHAMFERED
CORNER
2) lnstall the intake manifold.
3)
Tighten the intake manifold bolts to the speci- fied torque a little at a time in the numerical order shown in the illustration. kg.m(lb.ft)
Intake Manifold Bolt
Torque
2.6
0.5 i
3.6)
WESTERBEKE
I
Engines
&
Generators
37
INSTALL EITHER E N 0 OF THE
DISTANCE TUBE TO THE SPOT
FACING (6 CYL. ONLY)
i
I
I
1
!
~ C R A N K S H A F I
BEARING
(LOWER) AND
BEARING CAP
ASSEMBLY
THE ROCKER ARM MUST
BE INSTALLED WlTH THE
NUMBERS INDICATE SUGGESTED ASSEMBLY SEOUENCE
AND
COUPLING
CONNECTING ROD
TAPPETS
-
Important Operations
1. Oil
Jet (6
Cyl. Turbo) jet nozzles.
Oil Jet Torque
SHAFT
/
2.1
f
0.5 (15.2
i
3.6)
CASE
MAJOR COMPONENT REASSEMBLY STEPS
.$rF
Install the oil jets taking care not to damage the oil kg.m(~b.ft)
]
WlTH OIL HOLE
AN0 GROOYE (UPPER)
3
1
2.
Crankshaft Bearing (Upper Half)
3.
Crankshaft Bearing (Lower Half) and Crankshaft
Bearing Cap
The Crankshaft Bearing Configulation
Bearing Upper
Half
4
6
With Oil Groove Without Oil Groove
All Upper Halves
All Upper Halves
-
-
Bearing Lower
Half
4
6
All Lower Halves
Except C enter
Bearing
-
Center Bearing only
All Lower Halves
4.
Crankshaft
Crankshaft counterweight size will vary from engine to engine. Check your Parts Catalog Part Number listing to determine crankshaft counterweight sire for your engine.
5.
Thrust Bearing
Install the thrust bearings with the oil groove side facing the crankshaft sliding face.
4
e
i
i
I
Take care not to misinstall the bearing halves.
W W E S T E R B E K E
I
Engines
&
Generators
38
i
ASSEMBLY
8. Camshaft
Tighten the thrust plate bolts through the camshan gear hole. kg.m(lb.ft)
I
Thrust Plate Bolt Torque
1
2.6
f
0.5 (18.8 f 3.6)
1 kg.rn(1b.n)
6.
Crankshaft Bearing Cap
1) Lubricate the bearing cap bolts with engine oil.
2)
Install the bearing caps to the crankshaft.
The arrow mark must be pointing to the front of the engine.
3) Tighten the bearing cap bolts to the specified torque a little at a time in the numerical order shown in the illustration.
Crankshaft Bearing Cap
Bolt Torque
24.0 kg.m(lb.ft)
*
(173,5 7,2)
4) Check that the crankshaft turns smoothly by manually rotating it.
cANisn~
9. Idler Gear Shaft
Use the thrust collar fixing bolt as a guide to install the idler gear shaft.
1) Apply liquid gasket to the timing gear case sur- faces contacting the cylinder body.
2) Tighten the timing gear case bolts to the speci- fied torque.
10. ldler Gear
1) Install the idler gear.
Set the timing marks [A] a n d [B] as shown in the illustration.
2) Tighten the idler gear bolts seating the thrust collar to the specified torque.
The thrust collar must be installed with the chamfered side facing the f r o n t of the engine. kg.rn(1b.h)
Idler Gear Bolt Torque 5.5 1 (39.8 f
CAMSHAFT
GEAR
!
I
Engines & Generators
39
CRANKSHAFT
G E
AR
I
11. Piston and Connecting Rod
Position the piston ring gaps as shown in the illus- tration.
1) Set the piston ring gaps as shown in the illus- tration.
2) Lubricate the piston, the piston rings, and the connecting rod bearings with engine oil.
3) Position the piston front mark towards the front of the engine.
11
@
ASSEMBLY
7) Lubricate the connecting rod cap bolt threads and setting faces with Mos grease.
8) Use the angular tightening method to tightf:, the connecting rod cap bolts to the specifiec torque. kg.m(lb.ft)
1st step 2nd step
Connecting Rod Bolt Torque and Angle
4
(28.9)
60.+3w
0'
12. Oil Pump and Coupling
1) Lubricate the oil pump with the specified grade
COUPLING
4)
Use the piston ring compressor to compress the piston rings.
FRONT
MARK
2) Install the oil pump with the coupling.
3) Tighten the oil pump bolts to the specified torque.
Oil Pump Bolt Torque
1
5.3
f
1.0 (38.3 kg.m(lb.ft)
*
7.2)
'
5)
Use a hammer grip to push the piston in until it makes contact with the crankpin.
At the same time, rotate the crankshaft until the crankpin reaches its highest point.
6)
Set the bearing cap cylinder number marks and the connecting rod cylinder number marks.
The marks must be facing the exhaust manifold.
13. Flywheal Housing
1) Apply a liquid gasket to the shaded area of the illustration.
2) Install the flywheel housing.
Tighten the flywheel housing bolts to the speic- fied torque.
~ l
Bolt Torque kg.m(lb.ft)
~ h
16.1
f
~
7.2)
Inner Bolt 2.6
*
3.6)
~
CYLINDER
NUMBERS
REFER TO THE "ANGULAR TIGHTENING METHOD."
FLYWHEEL HOUSING
~
~
APPLY
LIOUID
GASKET
ASSEMBLY
MAJOR COMPONENT REASSEMBLY
14.
Oil Pan
1) Apply liquid gasket to the areas indicated by the arrows in the illustration.
2) lnstall the oil pan gasket.
3) lnstall the oil pan.
Tighten the oil pan bolts to the specified torque.
Oil Pan Bolt Torque kg.m(lb.ft)
/
2.6 f
0.5 (18.5 f
3.6)
1
Important Operations
1. Flywheel
1) Lublicate the flywheel bolt threads.
2) lnstall the flywheel.
The crankshaft rear end dowel pin and the fly- wheel dowel hole must be aligned.
3) Tighten the flywheel bolts to the specified torque in the numerical order shown in the illustration. kg.m(lb.ft)
i
j i 6 f i . 5 t i i 5 . 7 + 10.8)
15. Oil Cooler
1) Apply liquid gasket to the oil cooler gasket.
2) lnstall the oil cooler gasket to the oil cooler body case.
3) lnstall the oil cooler.
Tighten the oil cooler bolts to the specified torque.
Start from the middle and work out to either side. o
2. lnjection Pump
and
Injection Pump Gear Assembly
1) lnstall the injection pump bracket with the injec- tion pump to the timing gear case.
Dowel the injection pump bracket with the tim- ing gear case.
2)
Tighten the injection pump bolts to the speci- fied torque.
Injection Pump Bolt Torque kg.m(lb.ftJ
1
2.6 f
0.5 118.8 f
3.6)
31 Align the injection pump gear "C" timing mark with the idler gear
.,:A
'1
BY-PASS
VALVE.
OTiING,
SPRING
AND
PLUG
OIL
COOLER BOLT
TORQUE
SEQUENCE
41
!
I
!
3. Crankshaft Pulley Nut
a) Apply MoSz to the crankshaft pulley nut threads and fitting face. b) Use the appropriate wrench to tighten the crankshaft pulley nut to the specified torque.
CRANKSHAFl PULLEY NUTTOROUE
(48 SERIES)
(6B SERIES)
Kg-m
(Ib-It)
44.0k5.0 (318.1 Z36.2)
44.0k5.0 (318.1 k36.2)
ASSEMBLY
6.
Cylinder Head, Gasket, and Bolts
a) Carefully place the cylinder head gasket on the cylinder body upper surface.
The gasket "TOP" mark must b e facing up. b) Align the cylinder body dowels and the cylinder head dowel holes.
FRONT
4. Tappet Chamber Cover
a) Apply liquid gasket to the tappet chamber cover gasket. b) Install the tappet chamber cover and tighten the bolts to the specified torque.
Kp-m (Ib-n)
TAPPET CHAMBER COVER
BOLT TOROUE
2.6 k0.5 (18.8k3.6) c) Carefully place the cylinder head on the cylinder body. d) Tighten the cylinder head bolt a s follows:
1. As cylinder head bolts have t w o kinds of length, install them at the proper location. (The shorter ones
4 cyl. series: 4 bolts. 6 cyl. series; 6 bolts) must be used at the injection pump side.
2. Follow the numerical sequence shown in the illustrations.
I
TAPPET CHAMBER
5. Water Pump
Apply liquid gasket (Belco Bond No.4) to the water pump gasket before installing the water pump.
3. The cylinder head bolt tightening method vary depending on the gasket type to be used.
t
WATER
NOTE:
Refer to the Coolarrt Pleirl? .sectior~ in tlris 11m171ral,/'ir details
qf
the wutcr
I ) I N I I / I .
I'Hfl
WESTERBEE
I
Engines & Generators
42
1
~ i
I i i
For laminated steel type gasket.
Apply molybdenum disulfide grease t o the cylinder head bolt threads and setting faces.
Use the Angular Tightening Method.
14
ROCKER
ARM
2
CYLINDER HEAD BOLTS
CYLINDER HEAD
INJECTION
PUMP
7.
Rocker Arm and Rocker Arm
Shail
1) Check that the rocker arm shaft bracket lower surface oil port is free from obstruction.
2) Install the rocker arm shaft with the bracket to the cylinder head.
3)
Tighten the rocker arm bracket bolts t o the specified torque a little at a time in the numeri- cal order shown in the illustration.
4) Lubricate the rocker arm and the rocker arm shaft with engine oil.
ROCKER ARM SHAFT
THE ROCKER ARM MUST
BE INSTALLED WITH THE
OIL PARTSFACING Ufl
NUMBERS INDICATE SUGGESTED ASSEMBLY SEDUENCE
43
AN0 DUST THROWER
MAJOR COMPONENTS REASSEMBLY
NUMBERS INDICATE SUGGESTED ASSEMBLY SEQUENCE
,
5) Adjust the valve clearance.
Refer to MAINTENANCE for the valve clearance adjustment procedure.
1 i
I
ASSEMBLY
1. Cylinder Head Cover
1) Check that the rocker arms, the rocker arm shafts, and the valve springs are thoroughly lubricated with engine oil.
If required, relubricate these parts.
2) Place the cylinder head cover gasket o n the cylinder head cover.
Check the head cover gasket for looseness.
3) Tighten the cylinder head cover bolts t o the specified torque a little 'at a time i n the sequ- ence shown in the illustration.
6
CYL.
Cylinder Head Cover Bolt
Torque
2,1
0,5
kg.rn(1b.k)
*
3,6)
.
3
,
3. Oil Filter Assembly
1)Before the installation, set the special gaskets which are included within the repair kit with the two oil filter mounting bolts.
2)Apply a coat of LOCTITE 271 o n the bolt threads to seal the bolts from the crankcase as illustrated.
3)
Install the oil filter assembly a n d tighten the bolts securely.
4.
Injection Nozzle
4
CYL.
Cylinder Head Cover Bolt
Torque kg.m(lb.ft)
0,5
(7.9
+
3,6) gaskets.
Be carefull not t o damage the nozzle tips. kg.rn(1b.k)
6
CYLINDER
CYLINDER HEAD
2.
Starter
Install the starter t o the flywheel housing and tighten the bolts t o the specified torque. kg.m(lb.kl
Starter Fixing Bolts
Torque
! 8.4 (60.7)
DRIVE BELT
Adjust the drive belt tension.
Refer to MAINTENANCE for the drive belt tension adjustment.
5.
Fuel Injection Pipe a n d Fuel Leak
Off
Pipe
1) Install the fuel injection pipes
@
and tighten the bolts t o the specified torque.
Injection Pipe Torque
3.1 f
+
1.5)
2) Carefully position and set t h e clips
@
It is very important that each clip b e positioned correctly.
An improperly positioned clip w i l l result in objectionable fuel pulsing noise and injection
+ pipe breakage.
3) Install the fuel leak off pipes@
~
1 i
$ 1
I
WWESTERBEKE
/
Engines
&
Generators
44
I
ASSEMBLY
6. Fuel Pipe (Feed Pump t o F u e l Filter).
7. Fuel Pipe (Fuel Filter t o Injection Pump).
8. Fuel Return Pipe.
Install the fuel pipes and tighten the fuel pipe joint bolts to the specified torque.
Take care not to interchange the check valves and joint bolts.
Kg-m (Ib-R)
I
FUEL PIPE JOINTBOLTTORClUE
1.7f 0.1 (12.3 k0.7)
9. Intake Pipe.
Install the intake pipe and tighten the intake pipe flange bolts to the specified torque.
Kp-m (Ibd)
I
INTAKE PIPE FLANGE BOLTTOROUE
1.7 f0.1 (12.3f 0.7)
1O.lnstall the Thermostat and Thermostat Housing. a. Inspect the thermostat housing and the housing gasket. Apply some sealant to the gasket when reassembling. b. Install the temperature switch and sender and reconnect their wires.
11. Install the Oil and Water Sender and Switch.
12.lnstall the Starter Motor.
13.lnstall the Breaker Panel a n d t h e Preheat
Solenoid.
14.Reinstall the Engine Electrical harness.
15.Mount the complete Exhaust Manifold and the
Expansion Tank t o the Cylinder Head.
EXHAUST MANIFOLDIHEAT EXCHANGER
The exhaust manifold, which was disassembled from the cylinder head, should be inspected before reassembly. a. Remove the exhaust elbows from the lower surface of the manifold. Clean and inspect for cracks and defects. Replace as needed. b. Remove the exhaust nipples, elbows and plugs from the manifold and heat exchanger. c. Remove water connectors from the ends of the manifold. Be sure to note the proper location and arrangement of each for proper alignment. d. Examine all parts for defects, corrosion and wear and replace as needed. e. Flush out the manifolds interior with a liquid cleaner and rinse thoroughly with fresh water. f.Use a pipe cleaner to clear the passage that connects the coolant recovery tank tubing. g. Flush out the coolant recovery tank and its connecting tube. h. Replace the heat exchanger zinc. i.lnstall new hose connections and clamps for the cool- ing system.
16,Alternator installation. a. Put the alternator in position. Install the adjusting bolt in position to hold the alternator in position. b. Put the belt in position 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
112" deflection at the center with pressure.
MARINE TRANSMISSION
1. Assemble the damper plate t o the flywheel.
2. Reinstall t h e marine transmission and f i l l with
ATF Dextron Ill.
NOTE:
Some transnzissions, such as the Borg Warner Velvet
Drive require oil coolers. Oil coolers should be cleaned, pressure tested and repainted at engine overhaul. The transn~ission be inspected.
Refer to the text on Heat Exchangers.
3. Fill t h e engine cooling system w i t h antifreeze mixture a n d the engine o i l sump with lube oil
(A.P.I. spec. CF o r CG-4).
The engine should be test run under load prior to reinstalling. At this time readjust the valve clearances on the hot engine.
Allow the engine to cool to room temperature and re- torque the cylinder head bolts and re-check the valve clearances. See ENGINE ADJUSTMENTS.
GENERATOR
I. its control panel. Reconnect all DC wiring and reconnect all AC connections.
A
A U TI ON :
Check all AC and
oc
wiring
t
and diagrams.
2.
Fill t h e engine cooling system with antifreeze mixture a n d t h e engine oil sump w i t h lube oil
(A.P.I. spec. CF o r CG-4).
The engine should be test run under load prior to reinstalling. At this time readjust the valve clearances on the hot engine.
Allow the engine to cool to room temperature and r e - torque the cylinder head bolts and re-check the valve clearances.See ENGINE ADJUSTMENTS.
I.wlWESTERBEKE
I
Engines
& Generators
ASSEMBLY
ENGINE TUNING OPERATION
After reassembly, the engine must be tuned. This will ensure that the engine operates at its maximum efficiency.
2. Connect the electrical wiring. Refer to the WIRING
DIAGRAM.
3. Connect the air intake l i n e t o the air cleaner.
4. Connect the exhaust pipe.
5. Manually operate the f u e l feed pump t o feed fuel t o the engine.
6. Bleed the fuel lines of air.
7. Crank the engine with t h e starter (non-ignition operation) for about twenty seconds. This will pre-lubricate the engine internal components.
8. Start the engine and a l l o w it t o run at 750 t o 800 rpm f o r five minutes.
9. Remove the cylinder head cover while the engine i s running.
10.Check that the engine o i l i s continuously c i r c u - l a t i n g from the oil pump t o the valve rockers t h r o u g h the cylinder head.
If there is no oil circulation or if the oil circulation is sluggish, stop the engine and make the appropriate repairs or adjustments.
Reinstall the cylinder head cover.
1 l . l n c r e a s e the engine speed t o 1500 rpm t o d o t h e e n g i n e warming-up operation.
1Z.Check the engine f o r oil, fuel, coolant, and a i r i n t a k e leakage.
13.Check f o r abnormal noise and odor.
14.Check f o r abnormal electrical charging.
15.Check the engine fastening parts f o r looseness.
16 When t h e engine coolant temperature reaches
75'C (167°F) or more, increase the engine s p e e d t o 2000 rpm and allow it t o run f o r twenty seconds.
This will give the engine the essential run-in operating time.
17.Adjust the engine operation speed t o the specified value.
18.Stop t h e engine t o complete the tuning procedure.
Refer to the following pages for details of sub-assemblies. These sections also include: Wiring Diagrams.
Engine/Generator Specifications, Torque Diagrams. Generator Data, and a detailed Troubleshooting Section.
.
.
W W E S T E R B E K E
I
Engines & Generators
OIL SYSTEM FLOW DIAGRAM
Full flow fnlter
LUBRICATING SYSTEM
THI S G EAR TYPE O IL
PUMP IS DRIVEN BY
THE CAMSHAFT OIL
PUMP DRIVE
NUMBERS iNDlCATE
SUGGESTED ORDER
OF DISASSEMBLY
Visually inspect t h e disassembled parts for excessive wear a n d damage.
Oil Pump Drive
Gear
Use a feeler gauge to measure the clearance between the oil pump cover (oil pump case) inside surface and the drive gear.
If the clearance exceeds the specified limit, the drive gear and/or the oil p u m p cover must be replaced.
Make the necessary adjustments, repairs, and parts replacements if excessive wear or damage is indicated.
WESEREEKE
I
E n g i n e s & G e n e r a t o r s
47
LUBRICATING SYSTEM
STRAIGHTEDGE
Oil
Pump
Driven Gea
Use a feeler gauge to measure the clearance between the oil pump case cover inside surface and the driven gear.
If the clearance exceeds the specified limit, the driven gear or the oil pump cover must be replaced.
Cartridge (Spin-On) Type
Removal
Remover and Installer: Filter Wrench
1.
Loosen the used oil filter by turning it counterclock- wise with the filter wrench.
2. Discard the used oil filter.
Installation
1. Wipe the oil filter mounting face with a clean rag.
This will allow the new oil filter to seat properly.
2.
Lightly oil the O-ring.
3. Turn in the new oil filter until the sealing face is fit- ted against the O-ring.
4. Use the filter wrench to turn in the oil filter an addi- tional 314 of a turn or one turn.
5. Check the engine oil level and replenish to the spec- ified level if required.
6. Start the engine and check for oil leakage from the
NUMBERS INDICATE THE
ORDER OFASSEMBLY
1
ELEMENT
SPIN
ON
OIL FILTER-
INSPECT AND MAKE ALL
NECESSARY REPAIRS AND
REPLACEMENTS
Install the oil cooler element to the oil cooler, and tighten the cooler element fixing nuts to the speci-
Oil Cooler Element
Fixing Nut Torque kg.;n(lb.ft)
2.6
*
0.5 (18.8
k
3.6)
CHANGING THE OIL
W E S T E R E E K E
/
Englnes
&
Generators
48
i i
I
1
COOLING SYSTEM
NUMBERS INDICATE
DRDER OF DISASSEMBLY
COOLANT
PUMP
DlSASSEMBLY
SEALANT WASHER
& SEAL
1.
Impeller
Use the remover to remove the impeller.
3.
Snap Ring
Use a pair of snap ring pliers to remove the snap ring.
4.
Spindle, Bearing, and Spacer
Use a bench press and a suitable remover to pulley center.
PRESS
PULLEY CENTER
5.
Seal Unit, Washer and Seal
Use a suitable remover to remove the seal unit, the washer, and the
I
WESTEREEKE
I
Engines & Generators
49
COOLING SYSTEM
INSPECTION AND REPAIR
Make the necessary adjustments, repairs, and parts replacements if excessive wear or damage is discovered during inspection.
ASSEMBLY
7.
Spindle, Bearing, and Spacer
Lubricate the bearing with multipurpose grease.
Use a bench press to install the spindle, the bearing and the spacer.
SEALED SIDE OUTWARD
REMOVING THE BEARINGS
6.
Bearing Replaceme
Removal:
Use a bench press to remove two bearings and the spacer.
Installation:
Use a bench press to install two bearings and the spacer.
8.
Snap Ring
Use a pair of snap ring pliers to install the snap ring.
9.
Pulley Center
Use a bench press and a bar to install the pulley center.
LL BEARING
PULLEY CENTER
Use a micrometer to check the fitness at the three points shown in the illustrations.
Shaft to Pulley Center
Fitness mmfin)
0.02
-
Fitness
Shah to Impeller
Fitness
0.07
-
Pulley Center to Pulley
Fitness
-
0.14 (0.0055)
or less
10.
Seal Unit, Was
1 )
Apply a thin coat of liquid gasket to the seal unit outer periphery before installation.
2) Use a bench press and unit into the pump body. a bar to install the seal
IMPELLER
@
PULLEY CENTER
@
TAKING MEASUREMENTS
PULLEY
0
0.
~ W E S T E R B E K E
I
Engines & Generators
50
L
I
~
1
,
I
I
:
!
COOLING SYSTEM
11.
Impeller
1) Use a bench press t o install the impeller to the spindle.
2) Use a feeler gauge to measure the clearance between the impeller and the pump body. mm(in)
Clearance between
Impeller and Pump Body
0.3-0.8 (0.01 18-0.031 5)
HEAT EXCHANGER
The heat exchanger should be inspected and serviced during an engine overhaul.
1.
Disconnect the hoses and remove the hoses fittings. drain plug and zinc anode. Also, remove the end fittings and gaskets.
2. lnspect the tube (casing) for wear and dents, if a t all suspect replace the heat exchanger.
3. Clean out any zinc debris and pressure test the coolant and raw water passages.
4. When reassembling, install new gaskets and O-rings.
Apply some lubricant to the new gaskets and to t h e fittings as you install them.
5.
Install a new zinc anode.
Note:
All ofrhe above can be accomplished by sending rhe hear exchanger to a heat exchanger service shop. Tlzqy
rill
also service transmission and engine oil co<~ler,~.
6 .
Repaint the assembled heat exchanger with
WESTERBEKE heat resistant spray enamel. specified torque.
INSTALLING
THERMOSTAT
THERMOSTAT AN0 GASKET
REPLACE GASKET
THE GASKET I S GROOVED
AN0 FITS AROUND THE
OUTER EDGE OF THE
THERMOSTAT
0
REMOVE HEAT EXCHANGER
DRIVE BELT
Adjustment
1.
Inspect the cooling fan drive belt for cracking a n d other damage. Replace if suspect.
2.
Check the drive belt tension by exerting a force of lOkg (22 lb) midway between the pulley and the alternator pulley.
3. Adjust the belt tension by loosing the alternator mounting bolt and adjusting bolt and pivoting t h e alternator.
Be sure t o retighten the bolts after adjusting the belt tension.
WESTERBEKE RAW WATER
PUMP
COMPLETE OVERHAUWUMP REMOVED FROM ENGINE
DISASSEMBLE
1. Remove the six screws and lock washers, and the sealing
O-ring.
Inspect the O-ring for re-use.
NOTE:
Inspect the in~/~ellerfor if necessary.
2. Remove the impeller key.
3.
Remove the lock nut and withdraw the drive gear from the pump shaft and remove the key. [Insert a metal rod
0.19" in diameter thru the hole in the shaft to prevent it from turning while removing the lock nut].
4. Using snap pliers, remove the snap ring.
5.
Press out the shaft and bearing assembly from the pump housing. Using an arbor press, support the bearings inner race and press the shaft out of the bearings.
6. Remove the O-rings from the shaft.
7.
Remove the shaft seal from the housing.[Note the seal face position in the housing so as to re-install the new seal correctly].
8.
Remove the cam screw and sealing washer and withdraw the cam from the housing.
INSPECTION
Inspect all parts for wear and corrosion. It is also recommended that O-rings, gaskets, and seals be replaced.
Keys Part Name
PARTS LIST
Part Number
1 pump Housing
2
3
Shan
4
5
6
7
8 impeller
.
cam cover
Gear
0-Ring
KEY
--
.. .
- -
. . .
10
11
Seat
O'Ring
12
13
14
15
Snap Ring
~
O'Ring cap Screw
Nut
16
17 lockwashsr
O'Ring
44344
43.510
43506
~
43503
43500
43511
43567
43675
-
.
.
--
35972
~~~
43566
43566
43569
43570
43873
45691
~
31780
44183
18
19 screw
Washer
Cap Screw
4367.5
32889
43674
~.~
..
REASSEMBLY
Reassemble the pump in the reverse order.
Apply a small amount of petroleum jelly on the lip of the shaft seal and on the shaft itself when installing the shafthearing assembly into the pump housing.
When installing the pump cam inside the housing, apply a small amount of Permatex
#I
to the inner surface of the cam and to the securing screw threads. Remove any excess.
CAREFULLY MESH THE PUMPS GEAR
WITH THE TIMING GEAR
WHEN ASSEMBLED
I
1
1
1
2
2
..
1
1
1
1
6
I
6
I
1
1
1
Ouanlity
1
7
- ~-
~
. .
~
1
AT REASSEMBLI: APPLY A LIGHT
COAT OF SILICONE OR PETROLEUM
JELLY TO THE INNER SURFACE
OF THE HOUSING
INSPECT HOUSING FOR CRACKS b~
! t
! i i
!
1-
PUSH AND
PULL
OIL
TO
FIL
OM ROCKER COVER
TO OIL SUMP
,
-
.
TURBO CHARGER
Rotor Shaft Axial Play Measurement
1) Install a dial indicator on the turbine housing as illu- trated.
2) Use the dial indicator to measure the rotor shaft axial play with moving the shaft push and pull. Read the total indicator reading (TIR). mm(in)
Rotor Shaft Axial Play TIR
Limit
I
0.1 1 (0.0043)
3) If the measured value exceeds the specified limit the shaft must be replaced.
TURBOCHARGER
(6
C Y ~ . )
Rotor Shaft Radial Play TIR
Limit
1
0.215 (0.0085) rnm(in)
4)
If the measured value exceeds the specified limit, replace the shaft.
MAGNET
@-
TURBINE HOUSING
@
DIAL
INDICATOR
.
I$=*
.\k
-:p
PULL
facing up.
Turbocharger
E
Turbocharger Mounting Flange Gasket
Carefully position the gasket with the edged side
[m
Semitighten the turbocharger mounting nuts.
The nuts will be fully tightened atter installation of the oil pipes. kg.m(lb.ft)
Rotor Shaft Radial Play Measurement
Oil Drain Pipe
1) Turn over the turbocharger with the turbine exhaust inlet flange facing up.
1) Remove the exhaust manifold distance tube immediately beneath the turbocharger.
2) Install a dial indicator to measure the rotor shaft radial play.
This will make it easier to install the oil drain pipe.
3) Use the dial indicator to measure play. Read the TIR. mm(in)
Rotor Shaft Radial Play TIR
2) Install the oil drain pipe and tighten the oil drain pipe flange nuts to the specified torque.
Oil Drain Pipe Torque kg.milb.ft)
/
3.8 f
0.7 (27.5
+
5.1)
3) Reinstall the exhaust manifold distance tube.
~ W E S T E R B E K E
/
Englnes & Generators
53
TURBOCHARGER
FOR LEAK'
Oil
Feed
P i p e
1) Pre-lubricate the turbocharger with engine oil through the oil port shown in the illustration.
2)
Install the oil feed pipe and tighten the pipe flange bolts to the specified torque.
Oil Feed Pipe Flange
Bolt Torque kg.m(lb.ft)
2.6 f
f
3.6)
Turbo Adaptor Fixing
Bolt Torque
5.3 kg.m(lb.ft)
*
7.2)
CHECKING
1.
Check the air intake duct connections for air lea- kage.
2.
Check the intake manifold connections for air lea- kage.
3. Check the exhaust duct connections for smoke lea- kage.
4. Check the turbocharger mounting nuts for loose- ness.
5.
Check the oil feed pipe for oil leakage.
6. Check the oil return plpe joints for oil leakage.
K p m
(Ib-It)
OIL RETURN PIPE BOLTS TOR(1UE 2.1 k0.5 (15.2
k
3.6)
Turbo Adapter (6 cyl.)
1) Use a screw driver t o insert the gas sealing ring t o the turbocharger exhaust outlet port.
2) Tighten the turbo adaptor fixing bolts to the specified torque.
GAS SEALING RING
WESTERBEKE
I
Engines & Generators
' ,
ENGINE ADJUSTMENTS
INJECTION TIMING ADJUSTMENT
Bring No.
I stroke. Tum the crankshaft pulley clockwise (viewed at engine front) and align the mark on the crankshaft pulley with the TDC mark.
Remove the access cover at the front of the injection pump and check the alignment between the pointer
A
on the injection pump gear lock plate and the projected pointer
6
on the timing gear case. I f
A
and
B
are in alignment, the timing is set correctly.
I f they are in alignment, No.
I is at the TDC on the compression stroke. I f it is i n misalignment, recheck by turning the crankshaft pulley one Inore tum to repeat the procedure to make sure that i t is i n alignment.
4.
H O I ~
5.
Slowly turn the crankshaft pulley clockwise and at the same time, feed fuel to the injection pump by slowly pumping the feed pump. When the fuel stops to flow out from No.
I shaft pulley and pumping. This i s the beginning of fuel
4 CYL. SHOWN
THE 6 CYL. HAS EIGHT
TIMING NOTCH LINES
PUNCHED ON THE GEAR
CASE AND THE TDC
MARK ON THE CRANK
PULLEY
PULLEY MARK
Check the crankshaft position for the start of fuel injection.
1.
Tum the crankshaft pulley counterclockwise viewed from the engine front about 30".
2.
Remove No. I high pressure injection line.
6.
Notice which injection timing mark is aligned with the pulley mark. The timing mark in alignment with the pulley mark indicates the degrees before VDC), the start of fuel injection
7.
Blow out the remaining fuel from'the delivery valve holder. Check that there is no fuel being delivered from the priming pump.
INJECTION TIMING BCTC (4 CYL.) 14
(4 CYL. TURBO) 12
-DELIVERY VALVE
INJECTION TIMING BTDC (6 CYL.)
12
(6 CYL. TURBO) 12
INJE
3.
Remove the injection pump No. 1 delivery valve holder, delivery valve and spring and reinstall the delivery valve holder back into the pump.
DELIVERY VALVE HOLDER TIGHTENING TORQUE:
39
-
44 Nm (4
-
4.5 Kg-mR8.9
-
32.5
ll-lb)
WESTERBEKE
I
Engines & Generators
ENGINE ADJUSTMENTS
ADJUSTMENT PROCEDURES
1.
Align the pulley mark and the specified timing mark.
(Refer to the injection timing specifications.)
2. Loosen the four injection pump attachment nuts.
3.
To
advance the timing, pivot the injection pump at the pump drive shaft away from the engine.
To retard the timing, pivot the injection pump at the pump drive shaft toward the engine.
NOTE:
A lnlm misalignment benverrl tlie tiniirig nrarks pulley will correspotld to abo~rt
iri
crank angle.
4. Recheck the timing, following procedures I through 5.
5.
Tighten the four injection pump attachment nuts.
6. Again remove No. I delivery valve holder, and reinstall the delivery valve. spring and the valve holder.
INJECT1
PUMP
MARKS
INJECTION PUMP
DELIVERY VALVE HOLDER TIGHTENING TORQUE:
39
-
44
Nm
(4
-
4.5
Kg-mlL8.9
-
32.5 n-lb)
7. Reinstall the No. I high pressure injection line.
TIMING GEAR
CASE
WESTERBEKE
I
Engines & Generators
TESTING ENGINE COMPRESSION
Make certain the oil level (dipstick) is at the correct level and the air intake filter is clean. The battery and starter motor
nus st also be in good condition.
1.
Warm
the engine to normal operating temperature.
2. Move the conuol lever to a position for shutting off the fuel. (Disconnect the wires if a fuel shutdown solenoid is used).
3. Remove all the glow plugs from the engine and install the compression gaugeladapter combination to the cylinder on which the compression is to b e measured.
TESTING ENGINE COMPRESSION
Q
OIL PRESSURE
Thc cngine's oil pressure, during operation, is indicated by the oil pressurc gaugc on the instrument panel. DUI-~ng normal operation, the oil prcssure will rangc hetwccn 40 and
60 psi (2.8 and
4.2 kglcrn?).
NOTE:
A
rrewly sturtecl, ccolrl errgbrc
CUII have, rrrl oil p r ~ s s ~ r r e reading up to
60 psi (4.2 kg/criI).
A
warri~etl cat1 lrave arr oil pressure rcudirtg as low as
35 psi (2.5 kg/cm?). Tllcst, readirrgs will
vnty
deperldir~g of tl~r,
Low Oil Pressure
The specified safe minimum oil prcssure is
5
-
10
psi. A gradual loss ol oil pressurc usually indicates a worn bcarings.
For additional information on low oil pressure rcadings, scc the ENGINE TROUBLESHOOTING chart.
Testing Oil Pressure
To test the oil pressurc, removc the oil pressure sender, thcn install a mcchnnical oil pressure gauge in it's place. Aftcr warming up the engine. sct thc enginc speed at idlc and read the oil prcssure gaugc.
OIL PRESSURE 5 0 psi at
1800 rpm.
SENDER AND SWITCH TORQUE 9.13 H-lb (1.2
-
1.8 m
-
kg).
Oil pressure at
18M)
(or
1500) rpm should maintain a reading of 50 psi.
4. Clbse the raw water seacock (thru-hull).
5.
Crank the engine and allow the gauge to reach a maximum reading, then record that reading.
6. Repeat this process for each cylinder.
COMPRESSION PRESSURE
441
psi
(31.0 Kglcm? al2W rpm.
ALLOWABLE LIMIT 370PSI (26.0 Kglcm?.
MAXIMUM PERMISSIBLE DIFFERENCE BEWEEN CYLINDERS
28.44 psi
(2.0
Kglcm')
NOTE:
Ifthe readings are below the lintit, the engine rleeds at; omrhaul.
7. Re-install the glow .plugs and reset the fuel shut-off to the run position.
8. Open
the
raw water
seacock (thru-hull).
Low Compression
When low compression is found, determine the cause by applying a small amount of oil in the cylinder thru the glow plug hole. Allow the oil to settle.
Install the pressure gauge and repeat the above test. If the compression reading rises dramatically, the fault is with the rings. If the conlpression valve does not rise, the problem is with the valves.
A slight rise in compression would indicate a problenl with both the rings and the valves.
PREHEAT SOLENOID
/
OIL PRESSURE
SWITCH
,OIL GALLERY
ENGINE ADJUSTMENTS
VALVE CLEARANCE ADJUSTMENT
NOTE:
Tlle cylirlder head bolts have been tiglrtolcd with
Tilerefore, ir is ,lot tircessarv to retighten the cylirlder licrrd
Chart
shows
six
cylinder model
VALVE CLEARANCE
0.076 IN (0.40MM)
1. In order to bring No.1 or No.6 (six cyl.), No.4 piston
(four cyl.) to the top dead center in the compression stroke, align the TDC mark and the crankshaft pulley mark.
Chaarl
shows four cylinder model
4. Loosen each valve clearance adjusting screw as shown in the illustration.
5. lnsen a 0.40mrn (0.016 in) feeler gauge between the rocker arm and valve stem end.
6. Turn the valve clenrance adjusting screw until a slight drag can be felt on the feeler gauge.
7. Tighten the locknut
LOCKNUTTOR[1UE
18.8
+
3.6 It-lb (2.6
+
0.5 kpm)
8. Rotate the crankshaft 360'.
9. Realign the crankshaft pulley TDC notched line with the timing pointer.
10. Adjust the clearances for the remaining valves as shown
2. Do the adjustment on the circle marked valves in the above table where No.1 piston is in theTDC in the compression stroke. After these steps, do the adjustments on the double circle ,marked valves where the No.6 piston (six cyl.) No.4 piston (four cyl.) is on TDC in the compression stroke.
3. After adjusting the valves with piston No. l at TDC, rotate the crankshaft 360' again aligning the TDC mark and the pulley mark. This brings piston No.6 or No.4 to
FRONT
NO.l CYLINDER IS AT TDC IN COMPRESSION STROKE
~ 0 . 6 IS AT TOC INCOMPRESSION STO
K
E
FRONT
NO.l CYLINDER IS AT
TDC IN COMPRESSION
STROKE
FRONT
N0.4 CYLINDER IS AT
TDC I N COMPRESSION
STROKE
WESTERBEKE
I
Engines & Generators
58
"
LI
I
I i i
I
1
FUEL SYSTEM
'
INCOMI
C h a n g i n g the Fuel
F i l t e r
FUEL
INJECTION
PUMP
1.
Shut the fuel supply off.
The fuel injection pump is a very important component of the diesel engine, requiring the utmost care in handling.
If the fuel injection pump requires servicing, remove it and
2.
Slip a plastic bag over the fuel filter to prevent fuel spillage then loosen the fuel filter, turning take it to an authorized fuel injection pump service facility. counterclockwise with a filter wrench.
Do not attempt to disassemble and repair it.
3.
Using a rag, wipe clean the sealing face on the
N U M B E R
3RG..
BASS..
..............
1
............
.................
A
,,,,.PC
l!!!!!!
I housing bracket so the new filter can be seated properly.
4.
Lightly oil the sealing O-ring on the n e y filter. To reinstall, turn the filter assembly counterclockwise carefully until the O-ring contacts the sealing surface of the housing bracket. Turn 213 further with the filter wrenth.
NOTE:
The cartridge cuntainsfuel. Toke
cure
not
to
spill it during disassembly.
6.
Check
...
Id.ntific.Mn number
IDENTIFICATION PLATE
AND
P R O D U C T SERIAL
5.
Open the fuel supply. The filter will fill with fuel.
1.
Injection pump adjustment and repair should be made by the nearest DKKC (Diesel Kiki Co., Ltd.) or
ROBERT BOSCH Authorized Service Outlet.
2.
When you ask such authoriged service outlet the adjustment or repair, the Identification Plate and
Product Serial Number will give them a necessary clue to get technical data distributed b y the manu- facturers previously.
Without this data, the Service Outlet will be unable
FUEL
t o effectively service your injection pump.
LIGHTLY WIPE
WITH CLEAN FUEL
If you are unable to locate the data applicable to your injection pump, please contact your
WESTERBEKE dealer.
STRAINER
CLEAN WITH DIESEL FUEL
FUEL FEED PUMP
WITH FRESH FUEL
FUEL
INJECTORS
Poor fuel quality, contaminants and loss of positive fuel pressure to the injection pump can result in injector faults. Fuel injectors must be serviced in a clean room environment.
Before removing the old injector, clean the area around the base of the injector to help prevent any rust or debris from falling down into the injector hole. If the injector will not lift out easily and Is held in by carbon build-up or the like, work the injector side-to-side with the aid of the socket wrench to free it, and then lift it out.
The injector seats in the cylinder head on a copper sealing washer. This washer should be removed with the injector and replaced with a new washer when the new injector is installed.
The fuel injectors should be pressure tested after 750 operating hours.
INJECTION STARTING
PRESSURE
18.1 Mpa (2630 psi)
F u e l Feed
Pump
The fuel feed pump is an integral part of the injection pump. The fuel strainer in the pump should be serviced.
Refer to the illustration.
HOLDDOWN NUTS TORQUE
1.9+0.2 kp-m (13.5f 1.5
bib)
(.wlWESTERBEKE
I
Engines
8
Generators
59
NUMBERS INDICATE
THE ORDER OF
DISASSEMBLY
.
FUEL SECTION
.NOZZLE HOLDER
4. Injection-Nozzle
There must be no oil on the contact surfaces of t h e injection nozzle and the injection nozzle holder.
Clean these contact surfaces with diesel fuel before installation.
The nozzle dowel pin must be aligned with t h e dowel hole in the nozzle holder body.
5. Retaining N u t
ALIGN THEOOWEL
WITH THE HOLE.
kg.rn(1b.h)
Nozzle
Remove the nozzle assembly from the nozzle body.
Keep the parts separately to maintain the proper needle valve to body combination.
Push Rod Spring
Check the push rod spring for wear, weakness, and cor- rosion.
Nozzle Holder Push Rod
1. Check the nozzle holder push rod curvature.
2.
Check the nozzle holder push rod and needle valve contact surfaces for excessive wear and poor con- tact.
Injection Nozzle
1. Check the injection n o u l e needle valve, the valve seat, and the injection nozzle hole for carbon depos- its.
If carbon deposits are present, the injection nozzle and the needle valve must b e replaced.
2. Hold the nozzle body vertically.
Pull the needle valve about one-third of the way out of the nozzle body.
Release the needle valve.
Check that the needle valve falls back into the noz- zle body as far as the valve seat.
If the needle valve does not fall back into the nozzle body as far as the valve seat, the injection nozzle and the needle valve must b e replaced.
3.
Injection Pipe Connector
Nozzle Connector Torque
/
5.5
f
0.5 (38.8 kgm(1b.h)
*
3.6)
TORCIUE WRENCH
INJECTION TESTING
1.
Using the nozzle tester, check the spray pattern a n d injection starting pressure of nozzle and, if it exceeds t h e limit, adjust or replace the nozzle. W h e n
The spray injected from the nozzle is
a.lf the diesel fuel of the nozzle tester is discolored. replace it. At the same time, clean or replace the fuel filter. b.Set the nozzle tester in a clean place where there is no dust or dirt. c.Mount t h e nozzle holder on the nozzle tester. d.Use the fuel at the approximate temperature of
68'F (20%).
W W E S T E R B E K E
I
Engines & Generators
60
~
1
1
,.
8
I i
z .
i i
I i i
!
FUEL SECTION
Spray Condition Check (During Injection Nozzle Testing
Operation)
1. e. Operate the hand lever of nozzle tester several
GLOW PLUGS
times to bleed the air in the nozzle line, then move
The glow plugs are wired through the preheat solenoid. the hand lever at intervals of one stroke per second
GOOD
'.-'
I
. '
.
.
,
..
.
I
'.
..
.:
:
...
~.
.
1 -
.I
, ,
:BAD
';
When PREHEAT is pressed at the control panel this while reading the injection starting pressure.
Injection Starting Pressure Adjustment.
The lnjection nozzle injection starting pressure can be adjusted after the screw is installed.
INJECTION STARTING PRESSURE 2630 psi (18.1 MPa) (185 Ku/cm') solenoid should "click" on and the glow plug should begin to get hot.
Inspection
To inspect the plug, remove the electrical terminal con- nections, then unscrew or unclamp each plug from the
uuqliy
remove all the carbon and oil deposits. While cleaning, examine the tip for wear and burn erosion; if it has eroded too much, replace the plug.
Testing
BAD BAD An accurate way to test glow plugs is with an ohmmeter.
1
Touch one prod to the glow plug's wire connection, and the other to the body o f 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).
Tighten the cap nut.
2. Check the injection nozzle starting pressure.
3. Check the injection nozzle spray condition.
Nozzle Holder
Cap
Nut
to the touch. Be careful not to burn your fingers when
/
4.5
f
0.5 (32.5
*
3.6)
Cap Nut Torque
TESTING A
GLOW PLUG
I
INJECTION HOLDDOWN NUTS TOR(~UE 1.9+0.2 (13.7+ 1.5)
TESTING A
GLOW
PLUG
USING
A TEST LIGHT
GLOW
PLUGS
Re-install the plugs i n the engine and test them again.
The plugs should get very hot (at the terminal end) within 20 to 25 seconds. If the plugs don't heat up quickly, check for a short circuit. When reinstalling the glow plugs, use anti-seize compound on the threads.
A
Do not keep a glow plug on for more than
30
seconds.
Kp-m (Ib-It)
I
GLOW PLUG TIGHTENING TOROUE TORllUE 2.7 (19.5)
WESTERBEKE
I
Engines
&
Generators
TACHOMETER
TACHOMETES/HOUR METER
The tachorneterAiour tnetn- used in propulsion engine instru- ment panels contains two separate electrical circuits with a common ground. One circuit operates the hour meter and the
NOTE:
Currenr rilodel tacl~oiileters use a coarse udjusnircnr dial to set the /aclzonlcter
10
/he crankshafi uullev rains. The calibrating screw is tlzeri used forfnc furzing.
. volts alternator charging voltage supplied to the
(+) terminal on tlie back o i the instrument.
The tachometer circuit operates on AC voltage 6-8 volts, ied from one of the diodes in the alte~nator tachometer input terminal while the engine is running, and the alternator producing battery charging voltage 13.0-14.8 volts DC.
The following are procedures to follow when troubleshooting a iault in either of the two circuits in a tachomelerhour meter.
Hour meter Inoperative
Check for tlie PI-oper DC voltage between (+) and
(-) terminals.
1. Voltage present
- meter is defective
- repair or replace.
2. Voltage no1 present
- trace (+) and (-) electrical con- nections for fault. (lump 12 volts
DC to meler
(+) terminal to verify the operation.)
Tachometer Inoperative
Check for the propel- AC voltage between tachometer input tenninal and (-) terminal with the engine running.
1. Voltage present
- attempt adjusting meter tlxough calibra- tion access hole. No results, repair or replace meter.
2.
AC voltage not present
- check for proper alternator DC output voltage.
3.
Check fou AC voltage at tach tenninal on alternator to ground.
4. Check electrical conneclions from tachometer input ter- minal to alternator connection.
Tachometer Sticking
1. Check for proper AC voltage between "tach inp:' terminal and
(-) temiinal.
2. Check for good ground connection between metel-
(-)
CALIBRATION
TACH INP
AC VOLTAGE
TACHOMETER CHECK (New Installation)
NOTE
In a new installation having new insfrunlent panels, not always be correctly calibrated to the engine's rpnl. This calibration should be checked in all new installations.
1. Wann up the engine to normal operating temperature.
Remove any specks on the crankshafi pulley with a clean cloth and place a piece of suitable reflecting tape on the pulley to facilitate use of a photoelectric type tachometer.
2. Start and idle the engine.
3.
Aim the light of h e tachometer onto the reflecting tape to confirm the engine speed. Check the instrument panel tachometer reading. Adjust the tachometer in the panel by using the inslrumenl coarse adjustment to calibrate the instrument reading to the closest
R.P.M. that the photo tach is showing. Then use the fine calibration adjustment to bring the instrument to the exact reading as Uie photo tach.
3. Check that alternator is well grounded to engine block at alternator pivot bolt.
Tachometer Inaccurate
a.
With a hand-held tacli on h e iron1 o i the crankshaft pulley retaining nut or with a strobe-type tach, read the fiont crankshaft pulley rpni at idle. b. Adjust theiachometer with a small Phillips type screw- driver through the calibration access hole in the rear o i h e tachometer. Zero the tach and bring it to the ipm indicated by the strobe or hand tach. (Verify the ipm at idle and at high speed and adjust the tach as needed).
WESTERBEICE
/
Engines
&
Generators
WESTERBEKE 51A MANDO ALTERNATOR
DISASSEMBLY AND TESTING
REAR HOUSING
hot. Do not touch until the alternator has cooled down.
A
Before starting the engine, make certain that everyone is clear of moving parts! Keep away from sheaves and belts during test procedures. applications. Always disconnect shore power cords, isolate DC and AC converters and shut down generators
REFER TO THE
WIRING DIAGRAMS FOR THE ABOVE
WIRING HARNESS CONNECTIONS
TESTING THE OUTPUT CIRCUIT
1. Connect the positive voltmeter lead to the output terminal
B and connect the negative lead to the ground terminal
E on the alternator.
2. Wiggle the engine wiring harness while observing the voltmeter. The meter should indicate the approxim~te battery voltage, and should not vary. If no reading is obtained, or if the reading varies, check the alternator output circuit for loose or dirty connections or damaged wiring.
NOTE:
Prior to any alten~aior if~sliect heltfor excessive wenr and rqlrccc $!~rcessnr?. Also
(141r.rr for proper belt tension.
TESTING THE EXCITATION CIRCUIT
I .
Connect the positive (+) voltmeter lead to the excitation terminal R on the alternator and the negative
(-) lead to the ground terminal
E on the alteni:~tor.
3.
note :he voltmeter reading. The re:~ding should be
1.3 t o
2.5
volts (see illustration).
If
the reading is between
.75
and 1.1 volts, t h e rotor field circuit probably is shorted or grounded.
Disassemble the alternator and test the rotor as described under CLEAN AND TESTALTERNATOR
COMPONENTS
in this section.
4.
If the reading is between
6.0
and
7.0
volts, t h e rotor tield circuit probably is open. Remove the regulator and inspect it for worn brushes or dirty slip rings.
Replace the brushes if they are less than IIJin. (6 mm) long. If the brushes and slip rings are in good condi- tion, disassemble the alternator and test the rotor. 3s outlined under CLEAN AND TES7ALTERNATOR
COMPONEXTS
in this section.
WESTERBEKE
/
Engines & Generators
63
1
;
TESTlNG THE
EXCITER
LEAD
MANDO ALTERNATOR SERVICE
d ? n 9
e.
Remove the regulator cover
f. Temporarily re-install Jumper ( A ) and a11 associat- nuts. Leave Jumper (B) itistalled. g. Remove the plastic plug from the side of the regulator.
h.
Connect a jumper between the top brush lead and the ground.
5. If no reading is obtained, an open exists in the alternator-excitation lead or in tlie excitation circuit of the regulator. Disconnect the lead from exc terminal R.
Connect the positive voltmeter lead lo the excitation lead and the negative voltmeter lead to ground terminal
E. If the voltmeter now indicates an approximate.batrery voltage, the voltage regulator is defective and must be replaced. If no voltage is indicated, check the excitation circuit for loose or dirty connections or damaged wiring.
TEST VOLTAGE REGULATOR
Perform this test to determine if the voltage regulator is operating correctly. using a 0
-
20 volt DC voltmeter.
NOTE:
The battery must be fully charged to obrair~
proper
voltage reading in this test. Ifnecessary, charge tlte battery with
a
battery chargemr allow the engine to run a s~rfficier~t length of time to fully charge the battery before taking
n
reading.
1. Connect the positive (+) voltmeter lead to the positive battery terminal and the negative
(-) voltmeter lead to the negative terminal.
2. Start the engine and run it at fast idle until the engine reaches its normal operating temperature. Adjust the engine speed to 1500
-
2000 rpm and observe the voltmeter for the highest reading. 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 Phillips cover screw from the regulator cover (see illustration). c. Remove the nut from the output terrntnal and the nut from the sensing terminal. and remove Jumper
(A).
d. Remove another nut from tlie sensing terminal. :~nd the nut from the excitation terniinal.
I
CONNECT
JUMPER
\
',
WIRE
I
i. Repeat steps
1
and
2.
NOTE:
D o
r ~ u t
j. If a voltmeter reading of 14.5 volts or above is now obtained, the voltage regulator is faulty and must be replaced. If the voltmeter reading is below
14.5 volts, inspect the brushes and slip rings for wear, dirt or damage. If the brushes and slip rings is fault internally.
Disassemble the alternator and test the components. as outlined in this section.
WENERBEKE
I
Engines
&
Generators
MANDO ALTERNATOR SERVICE
REMOVE ALTERNATOR
1. Disconnect the negative
(-) battery ground cable.
2. Disconnect the wiring leads.
3. Loosen the screws. Holding the alternator, rotate i t toward the engine and lift the belt off the pulley.
4. Remove the screws and washers and remove the alternator.
10. Place an oversized V-belt around the pulley and fasten the pulley i n n vise.
11. Use a
718
in. box wrench to loosen and remove the pulley nut.
12. Remove the pulley nut, lockwasher, pulley, fan. and spacer.
PULLEY
AND
FAN COMPONENTS
DISASSEMBLE ALTERNATOR
1. Remove the terminal nuts to remove the jumper (see illustration).
2. Remove the remaining terminal nuts.
3. Remove the capacitor.
4. Remove the Phillips screw from the regulator cover.
6. Remove the nut from the terminal.
7.
Remove the jumper.
8. Remove the terminal insulators.
9. Remove the two Phillips screws and remove the bmsh/regulator assembly.
more than 1/16 in. (1.6 mm). Damage to the stator
NOTE:
Score the srato,:
and
the front and rear l~ousirlgs rhe relit may be reassembled correctly.
13. Remove the four through-bolts and carefully ply the front housing away from the rear housing using two screwdrivers.
14. Carefully push the rotor assembly out of the front
15. After removing the three bearing locking screws, care fully press the front bearing out of the housing. Press against the inner race of the bearing.
(ur7
I
Engines
&
Generators
65
MANDO ALTERNATOR SERVICE
BEARING LOCKING
2. Inspect and test the diode-trio assembly: a. Using a commercial diode tester. a 12-volt D C test lamp or an ohmmeter, check the resistance betwee each of the three diode terminals and the indicator light stud. light stud
DIODE TERMINAL
BEARING
16. Remove the rectifier assembly by removing the Phillips screw and lifting out the assembly.
RECTIFIER ASSEM
DIODE TRIO ASSEMBLY
b.
Reverse the tester leads and repent 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 the diode-rectifier bridge as follows:
a.
Using a commercial diode tester, check for continuity from each of three terminals to the ouput terminal.
RECTIFIER REMOVAL
CLEAN AND TEST ALTERNATOR COMPONENTS
1. Inspect and test the brush/regulator assembly. The brush set may be reused if the brushes are 114 in.
(6 mm) or longer. The brushes must not be oil soaked, cracked or grooved.
Test for continuity between I and 2, and 3 and 4 using a test lamp or an ohmmeter. These checks will indicate a good brush/regulator assembly: replace the complete assembly, if necessary.
GROUND-
TERMINAL DIODES b.
Reverse the tester leads and repeat Step a.
c. Continuity should exist in only one direction a n d a11 diodes should check alike.
d. Perform the same continuity checks between t h e three terminals and strap ground terminal. T h i s should show continuity in only one direction through the diodes and all diodes should check alike.
e.
If any diode appears to be defective, replace t h e rectifier assembly.
TESTING BRUSH ASSEMBLY
I
Engines &
Genera=
MANDO ALTERNATOR SERVICE
4. Cleen and inspect the front and rear housings: a. Inspect the rear housing for cracks o r breaks in the casting, stripped threads or a damaged bearing bore.
Replace the housing if my of these conditions exist. b. Inspect the front housing for cracks, stripped or' damaged threads in the adjusting ear, or an out-of- round bore in the mounting foot. If possible, correct slightly damaged threads using a tap.
Replace the housing, if necessary. c. If the housings are to be reused, clean them in solvent and dry with compressed air.
5. Clean and inspect the rotor shaft bearings:
NOTE:
Do
not use a solvent on the rear rotor benrirlg since it is serviced as a unit with the rotor:
a. The bearings should be wiped clean with a lint-free cloth containing a moderait. amount or'commrri;.,l solvent. Do not immerse a bearing in solvent, or use pressurized solvent or air. b. Check the bearings for obvious damage, looseness or rough rotation. Replace a bearing if any doubt exists as to its condition.
NOTE:
Ifthe rear rotor bearing needs replacemenr, replace the entire rotor:
6. Inspect the belt pulley for rough o r badly wom belt grooves or keyway, and for cracks or breaks. Remove minor burrs and correct minor surface damage; replace a badly worn or damaged pulley.
LAMINATIONS
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 o r indicates poor insulation between the windings and the laminations. the stator must b t replaced.
8. Check the rotor assembly as follows:
NOTE:
Ifslip rings need lo be replaced, you mlcst replace the entire roto,:
a. Visually inspect for physical defects such as dam- aged shaft threads. worn or damaged bearing areas. burned o r pitted slip rings or scuffed pole fingers. b. Measure the winding resistance across the slip rings
(A). Place the ohmmeter leads on the edges of the slip rings, not on the brush contact surfaces. The correct winding resistance at
70
-
80" F (21
-
27" C) is 4.1 to 4.7 ohms. c. Minor burning or pitting of the slip ring surfaces can be removed using a crocus cloth. Thoroughly wipe the slip rings clean after polishing, removing all grit and dust.
d. Check for a grounded slip ring or rotor winding by measuring the resistance from each slip ring to the rotor body o r pole finger
(B).
An open circuit should be indicated in both cases for a good rotor. e. If the windings are defective or physical damage cannot be corrected, replace the rotor assembly.
9.
Use a commercial capacitor checker to test the capacitor for capacity, shorts, leakase. and series resistance.
P
B
7. Test the stator windings as follows: a. Using an ohmmeter or test lamp, check ibr continuity between all three leads ( I , 2, and 3).
A low ohm reading or lit test lamp should be observed.
L2
EXC
S
E
INTERNAL CIRCUIT WIRING
P W E S T E R B E K E
I
Engines
&
Generators
67
MANDO ALTERNATOR SERVICE
2. Place the rotor (pulley end up) on the bed of an arbor press, on two steel blocks.
3. Press the front housing and bearing assembly down onto the rotor shaft. Press against the bearing's inner race only, using a sleeve driver. Take care to insure that the rotor leads clear the steel blocks.
FRONT HOUSING AND
BEARING ASSEMBLY
TESTING THE ROTOR
ASSEMBLE ALTERNATOR
1. Carefully press the front bearing into the front housing, pushing against the bearing's outer race using a bearing driver. Lock the bearing in place with screws.
TOROUE:
25
-
35 1b-in
(2.8
-
4.0 Nm)
4. lnstall the rectifier assembly into the rear housing.
5. Insert the Phillips screw and tighten it.
RECTIFIER
FRONT BEARING
FRONT HOUSING
FRONT BEARING ASSEMBLY
BEARING LOCKING
SCREWS
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 laminations aligned with the four through-bolt holes in the housing.
b. Align the scribe marks you made in the stator. and front and rear housings during disassembly. c.
Slip the rear housing into place over the rotor shaft.
FRONT BEARING
through the holes at the top of the rear housing.
d.
Install the four bolts and tighten them.
TORQUE:
35
-
65
Ib-If
(4.0
-
7.3
PlmJ
NOTE:
I f t h e frt,t~t Izorrsitzs
is
rrrn: /hi, tlrrorr,yIz-bolt
lvill
rrut be tr11>1)cd
ASSEMBLING THE BEARINGS
~ W E S T E R B E K E
I
Engines & Generators
68
MANDO ALTERNATOR SERVICE
7.
Install the spacer and the fan. Then push the pulley. lockwasher and nut onto the shaft. Turn the nut a few turns.
8. Place an oversized V-belt around the pulley and fasten the pulley in a vise.
INSTALL ALTERNATOR
1. Install the alternator, screws and washers
2.
Connect the wiring leads.
3. Put the belt on the alternator, crankshaft and coolant pump pulleys
4. Adjust the alternator belt's tension (see DRIVE BELT
ADJUSTMENT under ENGINE ADJUSTMENTS).
I
Banev Voltage
Maximum Speed
Cut in
Speed
Reg. Set Voltage
Ambient Temp.
Ground
12
Volt
13500
RPM
Max 2000
RPM (at exc.)
Max.
1500
RPM (at L2)
14.7
Volts
-20°C
-
100°C
Negative
I
9.
Use a torque wrench to the tighten the nut.
TORQUE:
35
-
50 Ib-ii
(47
-
68 Nm)
10. Carefully install the bmsh/regulator assembly on the rear housing with the two mounting screws.
11.
Install the small terminal insulators.
12.
Install the large terminal insulator.
13. Install the jumper.
14.
Install the nut on the terminal
15.
Install the bmsh/regulator assembly cover.
16.
Install the Phillips screw for the brush/regulator assembly cover.
TORQUE:
25 - 35 1b-ft (2.8
-
5.1
NmJ
17.
Install the capacitor.
18. Install the terminal nuts
19.
Install the jumper.
20. Install the last terminal nut.
WESTERBEKE
I
Engines
&
Generators
CONTROL
SWITCH
TROUBLESHOOTING
To independently test the starter it is necessary to remove it from the engine. However, before doing this, checks should be made to ensure that the problem is with the starter and not with the engine, battery, wiring or switches. When the other possible problem sources have been eliminated, then remove and test the starter. Comparison of test results with the Troubleshooting chm will aid in isolating the prob- lem within the starter to specific components. This will determine the repair or repairs needed to restore the starter to serviceability.
Battery Test
Realistic testing, as well as successful operation, requires a fully charged battery capable of supplying the current needs of the starting system. Step one in troubleshooting the start- ing system is to test the battery. Follow the battery manufac- turer's inshuctions.
Wiring and Switches
Visual Inspection
Visually inspect all wiring and switches in the starting cir- cuit for damage and loose or corroded connections. This includes all ground connections. Clean and tighten the con- nections as required. Replace damaged wiring or compo- nents.
FIGURE
1.
STARTER WIRING CIRCUIT
Continuity
Check
Disconnect the field lead on the starter from the solenoid M terminal and insulate it carefully to prevent accidental con9
Set the transmission in neutral. Use a voltmeter to check fi voltage at the solenoid S terminal while the start switch is held in the START position. If voltage is not present at the S terminal. use the voltmeter and the wiring diagram to
trace
the control circuit and locate the point of voltage loss and cor- rect it as necessary.
Starter Removal
If the battery, wiring and switches
are
in satisfactory condi- tion and the engine is known to be functioning properly, remove the starter for further testing.
Starter No-Load Test
With the starter removed from the engine, the no-load test can reveal damage that can be corrected by repair or it may indicate the need for component testing after the starter is dis- assembled. Repair and component test procedures are described in the
UNIT
REPAIR section. The no-load test is also used to test units for normal operation after repair or overhaul. Comparison of test results with the Trouble- shooting chart will indicate what corrective action, if any, is required.
I i
WWESTEFIBEKE
I
Engines
& Generators
STARTER MOTOR
Test Hook-Up (Figure 2) necting wiring. Do the following:
NOTE:
During the no-load test, close the switch and operate
Connect the starter for the no-load test as shown in the
the stanerfor cycles of 30 seconds maximum. Between
illustration using suitable instruments, battery cables and con-
C Y C ~ ~ S ,
envise overheating and damage to the starier may result.
1.
Secure the starter in a suitable test stand to check its operation.
1. Momentarily close the switch.
2. Use a momentary contact, pushbutton switch in the test circuit for a quick release if very high current surges are encountered.
a.
If there is a high current flow and the starter fails to operate (zero rpm), release the switch immediately.
Internal mechanical damage is indicated. Discontinue the test and refer to TROUBLESHOOTING.
3.
Make all connections or disconnections with the switch open and the carbon pile load turned off.
4.
If sparking or current flow in the battery circuit is noted when making the connections, the starter sole- noid switch contacts may be frozen shut (refer to
TROUBLESHOOTING). b.
If there is no current flow and the starter fails to oper- ate (zero rpm), release the switch immediately. An open circuit is indicated. Discontinue the test and refer to TROUBLESHOOTING.
c.
If there is a current flow and the starter operates, release the switch and proceed with the next step of the no-load test.
5. As the k t the negative battery cable securely to a clean metal ground on the starter frame.
6.
The carbon pile load is used to adjust the operating voltage for comparison with specifications. It may not be necessary in all cases but should be used to elimi- nate the need for interpolation of test data.
Test
Procedure
2. Close the switch and observe the voltmeter. Adjust the carbon pile load to obtain a
10
volt reading (20 volts on a
24-volt starter). Observe and record the ammeter and rpm readings. Release the switch.
3.
Compare the ammeter and rpm readings to those listed under SPECIFICATIONS at the end of this section. If the readings are outside the limits shown, refer to
TROUBLESHOOTING to determine the most likely causes. If the readings are within the limits, the starter is operating normally.
A
U T
I
ON :
Keep fingers and tools away from the opening in the
O.E.
(drive end) housing while testing.
The strong shifting action of the solenoid could cause personal injury or damage as the drive pinion moves into the cranking position and spins.
CLAMP ON
AMMETER
FIGURE
2.
STARTER NO-LOAD TEST HOOK-UP
p
I
Englnes
&
Generators
71
STARTER MOTOR
Troubleshooting
ble cause and its remedy. The problems listed i n the chart apply specifically to the no-load test and do not necessarily apply t o operation under other circumstances. t o the following
TROUBLESHOOTING
chart for the proba-
PROBLEM PROBABLE CAUSE VERIFICATION/REMEDY*
Normal current and speed.
Current flow with test circuit switch open.
Failure to operate with very low or no current.
Failure to operate with high current.
a. Starter OK.
a.
Solenoid switch contacts stuck closed. a. Open solenoid wiring.
b. Open field circuit.
c.
Open armature coil(s) or high insulation between commutator bars.
d. Broken brush spring(s) or worn brushes. a. Frozen bearing or other damage to drive train.
b. Direct ground in terminals or fields.
a. Recheck battery, switches and wiring, including battery cable loss. Check If starter operation on engine is slow or
Sluggish.
a.
Test and, if necessary, replace solenoid assembly. a. Inspect and lest solenoid assembly.
b. Inspect and lest frame and field assembly.
c.
lnspect armature. d. inspect brushes and brush springs.
a. Inspect bearings, armature, drive shaft and related drive parts.
b. Inspect and test frame and fieid assem- bly, solenoid assembly, armature and brush installations for shorts.
a.
Inspect bearing, armature, drive shaft, and gear reduction gears.
Low speed with high current.
Low speed with normal (or low) current.
High speed with high current. a. Excessive friction in bearing(s) or gear reduction unit, bent armature shaft or loose pole shoe, bent drive shaft.
b. Shorted armature.
c.
Grounded armature or fields. a. High internal electrical resistance caused by poor connections, defective leads or dirty commutator.
b. Causes listed under Failure to operate with very low or no current.
a.
Shorted fields.
b. Inspect and test armature.
c. Inspect and test frame and field coil assembly and armature. a. lnspect internal wiring, electrical connec-
'tions and armature commutator.
b.
Remedies listed under Failure to operate with v e y low
or
no current.
a. Inspect and test field and frame assembly.
*
Refer to the
UNITRE'AIR
section for required disassembly, inspeclion, test, and if necessary, repair or replacement insmdions.
STARTER REPAIR
NOTE:
Always install fasteners at their original locations.
Fir is necessary to replace fasteners, use only the correct part numbers or equivalent. Ifthe correct part nurnber is not available, me only afastener of equal size and strength. Use a torque wrench to tighten fasteners when a torque value is specified Torques specified arefor dry, ~nlubricaledfnren- ers unless otherwise specified.
Introduction
(Figure
3)
.
Figure 3 shows the starter broken down into its component lowing components which are serviced as assemblies:
Solenoid assembly (1)
Clutch Drive assembly
(2)
Brush Holder assembly (3)
Armature assembly (13)
Frame and Field assembly (19)
This section provides instructions for complete disassembly of the starter as would be the case for overhaul.
I f the starter is not due for an overhaul, and repair affecting specific parts only is required, the starter may be disassembled only to the extent necessary to gain these parts,
Parts
removed from the stmer as subassemblies or groups need not
be
di s
- assembled for such limited repa affected parts. i is to ensure that all p a s can be thoroughly cleaned and inspected.
In this section the starter is broken down by main groups.
These groups are then disassembled into individual parts and operations. To see the parts relationship o f the
conzplete
starter, refer back to Figure
3.
To begin, make a mark completely down one side o f the starter to ensure proper alignment of all its components at assembly. Use a colored pencil or marker that w i l l show on all parts.
72
STARTER MOTOR
1 SOLENOID ASSEMBLY
2. CLUTCH DRlVE
ASSEMBLY
3. BRUSH HOLDER
ASSEMBLY
4. BRUSH (GROUNDED)
5. BRUSH (INSULATED)
6. D.E. HOUSING
BUSHING
7. BRUSH SPRING
8. D.E. ARMATURE
BEARING
9.
C.E. ARMATURE
BEARING
10. CENTER SUPPORT
BEARING
11. SHIFT LEVER
12. PINION STOP
13. ARMATURE
14. C.E. FRAME
15. DRIVE SHAFT
16. ARMATURE SUPPORT
BRACKET
17. DRIVE SHAFT
SUPPORT
18. DRIVE HOUSING
19. FRAME
8
FIELD
ASSEMBLY
20. C.E. FRAME O-RING
21.
SHIFT LEVER SCREW
22.
SHIFT LEVER WASHER
23. SHIFT LEVER NUT
25.
SOLENOID SCREW
26.
PLATE (IF USED)
27.
DRIVE HOUSING PLUG
28. DOWEL PIN
29. INSULATED BRUSH SCREW
30.
WASHER (FIBER)
31.
WASHER (THIN; ONE OR
TWO MAY BE USED)
32.
WASHER (THICK)
33. FRAME SEAL
34.
BUSHING PLUG (IF USED)
35. STOP RING
36. DRIVE HOUSING BOLT (LONG)
37. DRIVE HOUSING BOLT
(SHORTER ON SOME MODELS)
39. GROUNDED BRUSH SCREW
41.
THRU BOLT
42.
BRUSH PLATE SCREW
-
Engines
&
Generators
73
34
STARTER MOTOR
General Disassembly
(Figure 4)
Remove or Disconnect:
1. The motor lead on the frame, field and brush holder group (A) from the solenoid assembly (I). Reinstall the nut on the solenoid terminal.
a.
Remove the nut on the solenoid, slip off the motor lead and reinstall the nut.
2.
3.
Brush plate screws (42).
4. C.E. frame (14) and O-ring (20).
Imporiant:
a.
In the following step, use care not to lose the small dowel pin (28) installed between the frame, field and brush holder group (A) and the gear reduction and drive group
(B).
This dowel pin is required for assembly and must be saved. If the dowel pin should be lost, it must be replaced with a 2
mm
(0.079 in.) dia. x
10 mm
cured or manufactured locally.
5. Frame, field and brush holder group (A), dowel pin (28) and frame seal (33). a. The m a t u r e assembly (13) may come off with the frame, field and brush holder group (A) or may b e retained by the gear reduction and drive group
(B).
6.
Armature assembly (13) with bearings (8 and 9). a. Do not remove the bearings from the m a t u r e assembly unless replacement is required (refer to
CLEANING, INSPECTION AND REPAIR).
7. Solenoid screws (25).
8. Solenoid assembly (I).
a.
Pivot the inside end of the solenoid assembly ( I ) out of engagement with the shiR lever in the gear reduction and drive group
(B) and withdraw the solenoid assembly.
25
I SOLENOID ASSEMBLY
8. D.E. ARMATURE BEARING
9.
C.E. ARMATURE BEARING
13. ARMATURE ASSEMBLY
14. C.E. FRAME
20. C.E. FRAME O-RING
25. SOLENOID SCREW
28. DOWELPIN
33. FRAME SEAL
41.
THRU BOLT
42.
BRUSH, PLATE SCREW
A. FRAME, FIELD
8
BRUSH HOLDERGROUP
B. GEAR REDUCTION 8 DRIVE GROUP
FIGURE
4.
ELECTRICAL GROUP
v
Engines
&
Generators
,
STARTER MOTOR
4
Disassembly of Frame, Field and Brush Holder Group
(Figure 5)
Remove or disconnect:
1.
Insulated brush screws (29).
a.
Move the brush holder assembly ( 3 ) [with the brush- es (4 and 5 ) ] away from the frame and field assem- bly (19) slightly to reach across with a screwdriver and remove the screws (29).
2. Frame and field assembly (19).
3.
Grounded brush screws (39).
4.
Brushes (4 and 5 ) . if replacement is required.
a.
Grasp the brush end of each brush spring (7) with needle nose pliers, twist the spring end away from the brush (4 o r 5 ) and withdraw the brush.
5.
Brush springs (7). if replacement is required.
a.
Grasp the brush end of each brush spring ( 7 ) with needle nose pliers, twist the spring end away from the brush socket on the brush holder assembly ( 3 ) and remove the spring.
NOTE:
At this stage of disassenrbly, all electrical com- ponents can be inspected, and ifrequired, independently tested as specified in CLEANING, INSPECTION
AND
REPAIR.
Disassembly of Gear Reduction and Drive Group
(Figure 6)
Remove or disconnect:
1. Housing bolts ( 3 6 and 37).
2. Armature support bracket (16).
ImporIanI:
a.
The washers ( 3 0 through 32) may stick to the m a - ture support bracket or to the drive shaft and clutch group ( C ) as the armature suppon bracket is removed. In either case, note the position and num- ber of each of these washers.
3.
Washers (30 through 32).
a.
Save the washers; they are to be installed in the same position and number at assembly.
4. Drive housing plug (27) and plate (26).
a.
driver.
5. Shift lever nut (23). washer (22) and screw (21).
6.
Remove the shift lever (11) and the drive shaft and clutch group ( C ) from the drive housing (18) together, then separate them. a. Do not remove the bushing plug (34) or the bushing
(6)
from the drive housing (18) unless replacement is required (refer to
C
LE ANI
N
G , INSPECTION AND
REPAIR).
39
3. BRUSH HOLDER
ASSEMBLY
4.
5.
BRUSH (GROUNDED)
BRUSH (INSULATED)
7. BRUSH SPRING
19. FRAME
& FIELD
ASSEMBLY
29' INS
U
LATED BRUSH
SCREW
39. GROUNDED BRUSH
SCREW
FIGURE
5.
FRAME, FIELD AND BRUSH HOLDER GROUP
6. D.E. HOUSING BUSHING
1 1 SHIFT LEVER
16. ARMATURE SUPPORT
BRACKET
32. WASHER (THICK)
21. SHIFT LEVER SCREW
22. SHIFT LEVER WASHER
34. BUSHING PLUG (IF
USED)
36. DRIVE HOUSING BOLT
23. SHIFT LEVER NUT
26. PLATE (IF USED) (LONG)
27. DRIVE HOUSING PLUG 37. DRIVE HOUSING BOLT
30. WASHER (FIBER)
(SHORTER ON SOME MODELS)
31. WASHER (THIN; ONE OR C. DRIVE SHAFT
8
CLUTC H
TWO MAY BE USED) GROUP
FIGURE 6. GEAR REDUCTION AND DRIVE GROUP
mWES7ERBEKE
I
Engines
&
Generators
75
I
STARTER MOTOR
Disassembly of Drive
Shaft and Clutch Group
(Figures 7 and 8)
Disassembly of the drive shaft and clutch group is not required unless it is necessary to clean, inspect or replace one or more parts of the group separately. Then proceed as follows:
Remove or disconnect:
1. Stop rings (35) and pinion stop (12). a.
Position the drive shaft and clutch group on the work bench with the internal gear end down. b. Using an open tube slightly larger than the shaft (see
Figure
8), drive the pinion stop (12) toward the clutch drive assembly (2) until it clears the stop rings
(35).
c. Using care not to scratch the drive shaft (15), pry the stop rings out of the shaft groove and slide them off the end of the shaft. d.
Inspect the edges of the shaft groove for burrs that may have been formed through repeated cranking cycles. Such burrs may make removal of the pinion stop and clutch drive assembly (2) difficult. If burrs are found, use a suitable file to carefully remove the burrs only -not the base metal. Thoroughly clean away metal filings. e. Slide the pinion stop (12) off the drive shaft (15).
Discard the old pinion stop (12) and stop rings (35).
New parts must be used at assembly.
2. Clutch drive assembly (2) from drive shaft (15).
3. Drive shaft support (17) from drive shaft (15). a. Do not remove the bearing (10) from the drive shaft
(15) unless replacement is required. (refer to CLEAN-
ING, INSPECTION AND REPAIR).
1 0
2. CLUTCH DRIVE
ASSEMBLY 15. DRIVE SHAFT
10. CENTER SUPPORT 17. DRIVE SHAFT
BEARING
12. PINION STOP
SUPPORT
35. STOP RINGS (2 PCS)
FIGURE
7.
DRIVE
SHAFT
AND
CLUTCH GROUP
%
PINION STOP (12)
DRIVE SHAFT (15)
FIGURE
8.
REMOVING PINION STOP
1 i i
WESTERBEE
I
Engines
8
Generators
!
STARTER MOTOR
CLEANING, INSPECTION. TESTING
AND
REPAIR
Cleaning
NOTE:
Do not clean or immerse starter parts in grease dis- solving solvents. Solvents will dissolve grease packed in the drive assembly and may damage fhe a m t u r e orfield coil insulation.
Clean:
1. All starter parts with a soft cloth prior to testing
Inspection
(Figure 3)
Inspection in the following steps refers to visual inspection of the starter parts and assemblies to determine their servicea- bility. Electrical tests for certain assemblies are described in
COMPONENT ELECTRICAL TESTING.
Inspect:
1. A11 parts for cracks, distortion other structural damage.
Replace parts or assemblies which are cracked, bent or otherwise damaged.
2. Threaded parts for shipped, crossed or otherwise dam- aged threads. Replace
parts
with thread damage that cannot be cleaned up Ging a suitable tap or die.
Replace any hardware items that have damaged threads.
3. The solenoid assembly (1) for a cut or tom boot. boot is damaged, replace the solenoid assembly.
If
the
4. The clutch drive assembly (2) for the following.
Replace the clutch drive assembly if damaged: a. Pinion gear tums roughly or turns in both directions. b. Pinion gear teeth broken or showing evidence of step wear. c. Deep scoring or other damage to the shift lever collar.
5.
The blush holder assembly (3) for the following.
Replace the blush holder if damaged: a. Loose riveted joints. b. Cracked or broken insulation.
6. Blushes (4 and 5) for excessive wear. a. The minimum allowable blush length is 12 mm
(0.472 in.). Replace excessively wom brushes in sets.
7.
The D.E. housing bushing (6) for scoring or other dam- age. Replace a damaged bushing (refer to REPAIR
PROCEDURES).
8. Ball bearings
(8,9
and 10) as follows: a. Hold the m a t u r e (13) or drive shaft (15) and slowly rotate the outer bearing race by hand. b.
Check that the bearing tums freely without binding or the feel of flat spots.
c.
Replace damaged bearings (refer to REPAIR
PROCEDURES).
9. Armature assembly (13) for the following:
a.
Gear teeth that are broken, or that show evidence of b. step wear or root interference.
- a No. 400 grit polishing cloth if necessary. Thoroughly clean metal dust from between the commutator bars. If the commutator surface cannot be repaired in this man- ner, replace the armature assembly. Do not turn the commutator in a lathe. c. Worn commutator. Replace the armaNre assembly if the commutator OD is less than 35 mm (1.378 in.) or if the undercut depth at any point is less than 0.2 mm
(0.008 in.). Do not undercut the insulation.
10. Drive shaft (15) for the following. Replace the drive shaft if damaged: bushing (6). b. Internal gear with teeth broken or showing evidence of step wear.
c.
Damaged spline. The clutch drive assembly must slide smoothly and easily over the full length of the spline.
P W E S T E R B E K E
I
Englnes & Generators
STARTER MOTOR
Component Electrical
(Figures 9 and 10)
Testing
Perform the following electrical tests on the solenoid assem- bly (I), armature assembly (13) and frame and field assem- bly (19) to determine their serviceability.
1. Using a suitable ohmmeter, check the windings of the solenoid assembly (I) for continuity as follows: a. Check the resistance of the solenoid pull-in and hold-in windings in series by measuring the resist- ance between the motor terminal (see Figure 9) and the solenoid case. The resistance should be approxi- mately 0.95 ohms for 12-volt starters and approxi- mately 1.75 ohms for 24-volt starters. b. An extremely high resistance reading indicates a break or fault in the winding continuity. A very low resistance reading indicates a short or ground in the winding circuit. Either condition is cause for replacement of the solenoid assembly.
2. Check the armature (13)
as
follows for shorts, opens or grounds using suitable test equipment and instruments
(test lamp must be 110 volts or less). a. Rotate the armature in a growler holding a steel ship such as a hacksaw blade against the armature.
If
a short circuit is present, the steel ship will vibrate in that area. b.
Check the armature for grounds using a test lamp or ohmmeter. There shall be no continuity between the annature shaft and any point on the commutator.
c.
Check for opens by visually inspecting the points where the armature conductors join the commutator.
A poor connection often will be indicated by signs of arcing or burning of the commutator.
d. Replace armatures which
ate
shorted, grounded or show evidence of opens.
3.
Check frame and field assembly (19) for grounds or opens using a test lamp (110 volts max.) or ohmmeter, as follows: a. Check that there is continuity (no opens) between the field terminal that connects to the solenoid, and the connection points for the insulated brushes on the field coil straps. b.
Check that there is no continuity (no grounds) between the frame and the field terminal that con- nects to the solenoid.
c.
Replace frame and field assemblies that have grounds or opens.
SWITCH
TERMINAL
BATTERY
TERMINAL
I f a
MO?OR
TERMINAL
FIGURE 9. SOLENOID TERMINALS
FIELD ASSEMBLY
FIGURE 10. FRAME AND FIELD ASSEMBLY
WESTERBEKE
I
Engines
&
Generators
STARTER MOTOR
Repair
Procedures
(Figures
3
and 11)
1. If necessary, replace the bearings (8 and 9, Figure 3) on the armature (13) as follows:
NOTE:
Ball bearings which are removed from the armature must be replaced with new bearings. The removal pmcedure causes internal damage to the bearings.
Remove or disconnect:
a.
C.E.
andor
D.E.
bearings (8 and/or 9) from the shaft of the armature (13) using a suitable bearing puller.
Install or Connect:
b.
New
C.E.
and/or
D.E.
bearings (8 andor 9) to the armature assembly (13) using a tube that bears on the bearing's inner race only. Press on the bearing until the inner race bottoms out against the shoulder on the armature shaft
2. If necessary, replace the center support bearing (10,
Figure 3) on the drive shaft (15) as follows:
NOTE:
Ball bearings which are removedfrom the drive shaft must be replaced with new bearings. The bearings.
TOPVIEW FLAT
Remove or disconnect:
a. The center support beking (10) from the drive shaft
(15) using a locally fabricated tool as shown in
Figure 11.
Install or Connect:
b.
The center support bearing (10) from the drive shaft
(15) using a locally fabricated tool (Figure 11). With the drive shaft in a suitable support fixture, place the tool bolt ends through the access holes in the wide end of the drive shaft and squarely press the bearing off of the surface on the center shaft.
3. If necessary, replace the bushing (6, Figure 3) in the drive housing (18) as follows: a. From inside the drive housing (IS), drive out the plug (34) if present. Use a file to clean away rem- nants of the old stake to allow installation of a new plug. Clean away any metal shavings.
b.
Using a suitable open tube, press out the bushing (6).
c.
Using a suitable open tube, press the new bushing
(6) into the drive housing (18) until the end of the bushing is flush with the inside of the housing.
d. Install a new plug (34), if used, to the drive housing.
Stake housing material over the plug at three places, equally spaced.
SIDE VIEW
PRESS
WIDE END OF
MATERIALS NEEDED-
-
PIECE OF FLAT METAL STOCK ABOUT 5MM (OR 3116 IN.)
THICK. AND 55 MM (OR 2 114 IN.) SQUARE OR ROUND.
-
THREE 6 MM OR 3/16 IN. BOLTS OF EQUAL LENGTH,
LONG ENOUGH TO EXTEND AT LEAST 35 MM ( I 318 IN.)
BELOW THE FLAT STOCK WHEN INSTALLED THROUGH
IT. TO USE NUTS INSTEAD OF TAPPED HOLES. USE
LONGER BOLTS TO COMPENSATE FOR NUT THICKNESS.
1. LOCATE THREE HOLES EQUALLY AROUND A 32 MM
(1.26 IN.) CIRCLE ON FLAT STOCK. DRILL AND TAP
HOLES AS NEEDED TO MATCH BOLT THREADS.
2. INSTALL BOLTS IN FLAT STOCK AND TIGHTEN. ENDS
OF INSTALLED BOLTS SHOULD PASS THROUGH
ACCESS HOLES IN END OF DRIVE SHAFT WITHOUT BINDING.
FIGURE 11. TOOL FOR REMOVING CENTER SUPPORT BEARING
WESTERBEKE
I
Engines
&
Generators
ASSEMBLY
Lubrication During
Assembly
1.
The armature bearings (8 and 9, Figure 3) and drive shaft support bearing (10) are permanently lubricated. Do not add lubricant to these bearings. Lubricate the following just before or during assembly (avoid excessive grease): a.
D.E. housing bushing (6) (in drive housing). h. The pivot hole and working surface on the ends of the shift lever (11). c. The internal gear, shaft and spline on the drive shaft
(15).
Drive Shaft and Clutch Group
(Figures 7 and 12)
1. If disassembled, position the drive shaft on the work sur- face with the internal gear end down and assemble the drive shaft and clutch group
as
follows:
Important:
a. If the center support bearing (10) is being replaced, install it on the drive shaft (15) as specified in REPAIR
PROCEDURES,
step 2, before proceeding with assemblv.
Instdl or Connect:
1. The drive shaft support (17)
to the drive shaft (15), seat- ing the bearing (10) in the support.
2. The clutch drive assembly (2) to the drive shaft (15).
3.
A
new pinion stop (12) onto the drive shaft (15). the end with the recess for the stop rings (35) up. a. Install the stop rings (35) in the groove in the drive shaft (15). b. Pick up and support the assembly under the pinion stop (12).
A
metal block, with a U-shaped cutout that will slide over the shaft between the pinion gear and the stop, can be clamped in a vise to provide support
(see
Figure 12).
c.
Make sure the stop rings (35) (in the drive shaft groove) are fully seated in the pinion stop recess and stake the upper edge of the pinion stop (12) over the stop ring (35) at four places, equally spaced. Do not allow staked metal to contact the drive shaft (15).
Assembly of Gear Reduction and Drive Group
(Figure 6)
Imporid:
If the
D.E.
install them in the drive housing (18) as specified in
REPAIR PROCEDURES,
step 3, before proceeding with assembly.
1. Lubricate the D.E. housing bushing, shift lever, and drive shaft as described under LUBRICATlON DURZNC
ASSEMBLY.
Install or Connect:
2.
The arms on the shift lever (11) with the shift collar on the drive shaft and clutch group (C).
3.
The assembled shift lever (11) and the drive shaft and clutch group ( C ) into the drive housing (18), aligning the
7) with those in the drive housing. a. Make sure that the drive shaft support is fully seated in the drive housing and that the drive shaft bearing
(10, Figure 7) remains fully seated in the drive shaft support.
4.
Shift lever screw (21), washer (22) and nut (23).
Tighten:
a. Nut to 4.5 Nm (40 lb-in.).
5. The plate (26), if used, and the drive housing plug (27) to the drive housing (18).
6.
Washers (30 through 32) in the same number and posi- tions
as
noted at disassembly.
7. The armature support bracket (16) to the drive housing
(18). aligning the mark made prior to disassembly with that on the drive housing.
8.
Drive housing bolts (36 and 37).
METAL
BLOCK
APPROX.
38 M M
(1 112 IN.)
FIGURE 12. PINION STOP SUPPORT BLOCK
STARTER MOTOR
Assembly of
Frame, Field and
(Figures 5,13 and 14)
Brush
Holder
Group
BRUSH HOLDER
ASSEMBLY
SOCKET
FIGURE
13.
BRUSH SPRING ON POST
Install or Connect:
1. Brush springs
(7).
a. Start each brush spring onto the post on the brush holder assembly (3) as shown in Figure 13, just enough to hold the inside end of the spring from turning. b. Grasp the free end of the spring with needle nose pliers and twist clockwise over the top of the brush socket.
c.
Push the spring fully onto the post and release the free end to engage the notch in the brush socket.
NOTE:
The brush l e a d may be damaged by excessive handling. Do not over-flex the leads near the clip welds or the clips may break
08
2.
Brushes
(4
and
5).
if removed.
a.
See Figure 14 for the proper installed position of all brushes. Make sure the insulated brushes (5) go into the brush sockets of the brush holder assembly (3) that are mounted on the insulation. b. To install each brush, grasp the free end of the brush spring with needle nose pliers, twist clockwise to clear the brush socket and insert the brush partly into the brush socket. c. Gradually release the spring so that its end contacts the side (not end) of the brush (see Figure 13). This will hold the brushes retracted until after the brush holder is installed over the armature commutator.
3. Grounded brush screws (39). a. Position the terminals of the grounded brush leads behind the terminal tabs on the brush holder (3) (see
Figure
13). b. Insert the brush screws (39) through the terminal tabs on the brush holder and thread them into the brush lead terminals.
Tighten:
c.
Grounded brush screws to 1.5 Nm (13 lb-in.).
INSULATED BRUSH
FIGURE
14.
SPRINGS AND BRUSHES ON BRUSH HOLDER
WWESTERBEKE
I
Engines
&
Generators
81
ASSEMBLY
4. The frame and field assembly (19) to the brush holder assembly. a. Position the brush holder assembly (3) (with installed brushes) over the terminal end of the frame and field assembly (19). b. Attach the terminals of the insulated brush leads to the conductors in the frame and field assembly with the insulated brush screws (29).
c.
The insulated brush screws to 1.5
Nm
(1
3 ib-in.).
Starter
Assembly
(Figures
4 and 15)
Support the gear reduction and drive group (B) with the pinion gear end down and proceed as follows:
Important:
If the armature bearings (8 and 9)
are
being replaced, install them on the armature (13) as specified in REPAlR PROCE-
DURES, step 1 before proceeding with assembly.
Install or Connect:
1. Solenoid assembly (1). a.
Pivot the plunger of the solenoid assembly into engagement with the shift lever in the gear reduction and drive group (B). b.
Position the solenoid assembly mounting flange and install the solenoid mounting screws (25).
Tighten:
c.
Solenoid screws to 2.8 Nm (25 lb-in.).
2. Frame seal (33).
3.
The armature assembly (13) with bearings (8 and 9) into the gear reduction and drive group (B). a. Make sure the gear teeth are aligned, then seat the bearing (8) on the armature shaft fully into the hous- ing recess.
4. Frame, field and brush holder group (A).
a.
Place the dowel pin (28) in the hole in the armature support bracket of the gear reduction and drive group
(B).
b. Position the frame, field and brush holder group over the armature assembly (13). align the hole for the dowel pin (28) and the marks made prior to disas- sembly, and seat in the gear reduction and drive group (B).
c
fiist the brush springs (7, Figure 5) away from the brushes (4 and 5, Figure S), slide the brushes in to contact the commutator on the armature (13). and release the brush springs to contact the ends of the brushes.
5.
O-ring (20).
Important:
a. The O-ring can easily he damaged during installa- tion of the C.E. frame (14). To prevent such dam- age, install the O-ring as described in the following steps. b. Install the O-ring on the frame, field and brush hold- er group (A) so that it is against the shoulder on the field frame that will abut the C.E. frame when installed. This is the normal installed position for the O-ring.
c.
Carefully roll the O-ring out of its normal installed position up onto the major O.D. of the field frame.
Allow the O-ring to remain in this position until the
C.E. frame is partially installed.
6.
C.E. frame (14) a. Align the marks on the C.E. frame and frame and field assembly (19, Figure 5) m a d e prior to disas- sembly. b. Start the C.E. frame onto the frame and field assem- bly, leaving a gap just slightly larger than the thick- ness of the O-ring (20).
7.
Brush plate screw (42). a. Use a scribe or similar tool to align the tapped holes in the brush holder assembly (3, Figure 5) with the screw holes in the C.E. frame (14).
Tighten:
b.
Brush plate screws to 2.8 Nm
(25 lb-in.). a. Install the thru bolts and tighten them by hand but do not close the gap between the C.E. frame and the frame and field assembly where the O-ring (20) goes. b.
Roll the O-ring (20) back down into its installed position between the C.E.
frame
and the kame and field assembly. c. Align the timing ribs on the edge of the C.E. frame
(14) with the timing spots on t h e frame and field assembly (A) to assure proper brush alignment.
Refer to Figure 15.
Marks
are located in 2 places on the motor but will only match o n e way.
Tighten: d .
Thru bolts (41) to 8.5 Nm (75 ib-in.).
9.
The motor lead on the h e
Figure 5). a. Remove the nut from the terminal on the solenoid, install the motor lead terminal a n d reinstall the nut.
Tighten:
b. The nut on the terminal of the solenoid assembly to
11 Nm (100 lb-in.).
*
1
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m W E S 7 € R B E K E
I
Englnes
&
Generators
STARTER INSTALLATION
Testing After
Repair or Overhaul
After repair or overhaul, the starter can be tested as speci- fied in the Starter No-Load Test found in the
TROU-
BLESHOOTING section.
After repair, overhaul, testing or replacement of the starter, reinstall it using the following torques when making the elec- hical connections to the starter.
ACAUTION:
is disconnected at the battery when making the elec- trical connections to Ule starter. Otherwise, injury may result. If a tool is shortedat the solenoid bat- tery terminal, the tool will heat enough to cause a skin burn.
C.E. FRAME
Tighten:
a
Solenoid battery (B) terminal nut to
18 Nm
(13 lb-ft.). b. Solenoid switch (S) terminal nut to 1.8 Nm
(16 1b-in.).
STARTER SPECIFICATIONS
All 12 Volt models have these No-Load Test Specifications:
AMPS
VOLTS
10
Minimum
125
ASSEMBLY
FIGURE 15. ALIGNING TIMING MARKS
Maximum
190
~
-
All 24 Volt models have these No-Load Test Specifications:
AMPS
VOLTS
20
Minimum
75
Starter Solenoid current consum~tion:
RATED VOLTAGE
Maximum
90
AMPS
PULL IN WINDING
1
VOLTS
1
OHMS
Minimum
3000
Minimum
3600
RPM
RPM
Maximum
5600
Maximum
5400
HOLD IN WINDING
I
AMPS
1
VOLTS
I
OHMS
WIRING DIAGRAM
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I
Engines
&
Generators
84
WIRING SCHEMATIC
+I44780
WWESTERBEKE
/
Engines
&
Generators
REMOTE INSTRUMENT PANEL
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Engines
& genera tors^
ALTERNATOR. 2 4 V 42A
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WESTERBEKE
/
Engines
&
Generators
87
i
WIRING SCHEMATIC
MARINE ENGINES #44781
81116RI
12.24
YPC
O P T I O N A L A L T F R N A T O R S
! m S T O L I T E
7 2 AMP.
A L T -
! i
!
Engines
&
Generators
88
DISCONXCCI JUMPER TOR
Y I I .IT" 1.0 B A l l l l k L 6 .
5 .
1 6 0 . 1 9 0
A M P . A L T .
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l.211111
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ENGINE TROUBLESHOOTING
Hard Starting
...................................................................................................
90
Starter Inoperative
................................................................................
Starter Operates but engine does not turn over
....................................
91
Engine turns over but does not start though fuel is being delivered to the injection pump
..............................................
92
Engine turns over but does not start
....................................................
93
. .
...................................................................................
94
.....................................................................................
96
Excessive Fuel Consumption
.....................................................................
99
Excessive Oil Consumption
.....................................................................
101
Overheating
..............................................................................................
102
White Exhaust Smoke
..............................................................................
103
Dark Exhaust Smoke
................................................................................
104
Oil Pressure Does Not Rise
......................................................................
105
Abnormal Engine Noise
............................................................................
106
NOTE:
Use this sectiot~
.
#I
Check Poblt
.
#2 Trouble Cause. #3 Ren~edy
.
Checkpoint
ENGINE TROUBLESHOOTING
HARD STARTING
1)
STARTER INOPERATIVE
Trouble Cause
Tlansmlrslon
neutral swltch
(lf
so equipped)
NG
Defect~ve switch
Remedy
Battery
NG
Poor connectrons due to rustlng
NG tery cable term~nals
NG
Battery doscharged or weak Recharge or replace the battery
NG
Drove belt loose o r broken
Adjust or replace t h e drive belt
OK
Starter swltch
OK
Starter motor
OK
Starter motor
NG starter relay
- rnagnetlc swltch or starter relay
NG swltch
-
Defective starter motor
- the starter relay
or
NG
Repaar or replace the starter motor
L
I
I
I
ENGINE TROUBLESHOOTING
HARD STARTING
2) STARTER MOTOR OPERATES BUT ENGINE
DOES
NOT TURN OVER
Checkpoint Trouble Cause Remedy
Banery
-
Poor connectoons due to rusttng
NG tery cable terminals
NG
Battery dascharged or weak
NG
Recharge or replace the banery
NG
Drove
belt
loose
or broken
OK
Staner motor
NG
OK
Engine
Adjust
or
replare the drwe belt
NG
Defectave magnetx swltch
-
Match
NG
Brush wear
Weak brush sprang
N G
Replace the brush andlor the brush spring
Ptston. crank bearlng seizure. or other damage
- pans
-
I
P W E S T E R B E K E
I
Engines
&
Generators
ENGINE TROUBLESHOOTING
HARD STARTING
3)
ENGINE TURNS OVER BUT DOES NOT START
FUEL IS BEING DELIVERED TO
THE
INJECTION PUMP
Checkpoint
Continued from the previous page
OK
Trouble Cause Remedy
Injection nozzle
NG pressure too low
Improper spray condition
- nozzle
OK
Injection pump
-%-
Defective fuel injection nozzle resulting in fuel drippage after fuel injection
NG
Replace the delivery valve
NG Defective injection pump control rack operation
- pump control rack
OK
I..-- lnjection pump
WE
pump)
NG injection pump plunger worn or stuck plunger assembly or other damage
NG lnjection pump governor spring seizure
NG Replace the injection pump governor spring i i
ENGINE TROUBLESHOOTING
HARD STARTING
4)
ENGINE TURNS OVER BUT DOES NOT START
Checkpoint Trouble Cause Remedy
Engine stop mechanism
Defective engine stop mechanism.
-
Replace the engine stop
-
Fuel
NG
Defective fuel cut solenoid valve
IVE pump)
- valve
FUEL IS NOT BEING DELIVERED TO THE INJECTION PUMP
Fuel tank is empty Fill the fuel tank
OK
'
Fuel piping
OK
Fuel filter
-
Loose fuel line connections
Repair or replace the fuel l i n e s
Retighten the fuel line connections
NG
- not close
-
NG
- overflow valve
Clogged fuel filter element
.
- the fuel filter cartridge filter
OK
Fuel system
NG
Air in the fuel system Bleed the air from the fuel system
Continued on the next page
Checkpoint
ENGINE TROUBLESHOOTING
UNSTABLE LOW IDLING (PROPULSION)
Trouble Cause
Low idling improperly adjusted
Remedy
Adjust the low idling Low idling
OK
.
Thronle control system
NG improperly adjusted
OK
Fuel system Fuel system leakage or blockage
NG Adjust the throttle control system
Repair or replace the fuel system
NG
Air in the fuel system
*
Bleed the air from the fuel system
OK
Fuel filter
Continued on the next page
NG
Water particles in the fuel system Change the fuel
- the fuel filter cartridge
I
n
1
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I
WESTERBEICE
/
Engines
&
Generators
ENGINE TROUBLESHOOTING
UNSTABLE LOW IDLING (PROPULSION)
Checkpoint
Continued from the prevlous page
OK
lntectlon pump
Trouble Cause
-!!?-
Defectwe governor lever operation
- lever
2
Remedy
NG
Regulator valve improperly adjusted
WE
pump only)
NG valve
NG
Broken plunger sprlng
-!!?-
Replace the plunger sprlng
NG
Worn plunger
NG
Worn camshaft (In-lme pump only)
Replace the camshaft
1 dd
NG Worn roller tappet (In lone pump only1
NG
Worn cam dtsc IVE pump only)
-
Replace the cam d~sc
I
Valve clearance
NG adjusted
NG
Adlust the valve clearance
~ W E S T E R B E K E
I
Engines
&
Generators
95
Checkpoint
Air cleaner
OK
Fuel
OK
Fuel filter
OK
Fuel feed pump
.
-
.
OK
-
~
Injection nonle
ENGINE TROUBLESHOOTING
INSUFFICIENT POWER
Trouble Cause
NG
Clogged air cleaner element element
Remedy
NG
Water particles in the fuel
-
Clogged inlet filter screen
-
Clean filter screen
NG
Defective fuel feed pump
NG pump
NG
Replace the fuel
Replace the injection nozzle
NG
Injection nozzle injection starting pressure too low
Improper spray condition
NG Adjust or replace the injection nozzle
OK
Fuel injection pipes
Continued on the next page
NG obstructed
- the fuel pipes
Checkpoint
Continued from the previous page
OK
ENGINE TROUBLESHOOTING
INSUFFICIENT POWER
Trouble Cause
Injection pump
NG
Defective delivery valve
Remedy
NG
Replace the delivery valve
I
NG
Defective timer
-!?%
Repair or replace the timer
Improper control lever operation
W
Adjust or replace the control lever
I
NG
Defective injection timing
W
Adjust the injection timing
Repair or replace the injection pump timer
NG
Weak governor spring
NG
Replace the governor spring
NG
Worn plunger
NG
Replace the plunger assembly
Continued on the next page
NG
Worn camshafl iln-line pump only)
-
Replace the camshafl
F W E S T E R B E K E
I
Engines & Generators
Checkpoint
Continued from the previous page
OK
ENGINE TROUBLESHOOTING
INSUFFICIENT POWER
Trouble Cause
Worn roller tappet
Injection pump
Remedy
Replace the roller tappet
OK
Turbocharger
-%
Exhaust gas leakage from the exhaun system
Air leakage from the intake system
NG
parts
NG
Defective turbocharger assembly
-!%
Replace the turbocharger assembly
OK
Compression pressure
OK
Valve clearance
OK
Valve spring
OK
Exhaust system
Blown out cylinder head gasket
Improper seating between the valve and the valve seat
NG
adjusted
*
Replace the rdlated parts
Adjust the valve clearance
Valve spring weak or broken
-%
Replace the valve spring
-
Exhaust pipe clogged
-
Clean the exhaust pipe
OK
Full load adjusting screw seal
NG
Open and improperly set adjusting screw seal
- screw
t,
i i
WESTEREEKE
I
Engines
&
Generators
98
Checkpoint
EXCESSIVE FUEL CONSUMPTION
Trouble Cause Remedy
1
L
!
1
I
Fuel system
OK
I
Air cleaner
OK
I
L
OW idling speed
Fuel leakage
-%--
Clogged air cleaner element
NG
Repair or replace the fuel system related parts element
.
Poorly adjusted low idle speed
-??
.
Adjust the low idle speed
OK
Injection nozzle
OK
I
Fuel injection timing
I
Injection nonle injection starting pressure too low
Improper spray condition
NG n o n l e
- adjusted the fuel injection timing
Injection pump
OK
I
-%
Defective delivery valve result- ing fuel drippage after fuel injection
-!!.!?
Replace the delivery valve
Turbocharger
I
Continued on the nen page
- intake side
Repair the turbocharger intake side
WESTERBEE
1
Engines & Generators
ENGINE TROUBLESHOOTING
EXCESSIVE FUEL CONSUMPTION
Checkpoint Trouble Cause
Continued from the previous page
OK
*
Defective turbocharger assembly Turbocharger
Remedy
Replace the turbocharger assembly
OK
Valve clearance
- adjusted
-!%
Adjust the valve clearance
OK
Compression pressure
Blown out cylinder head gasket
Worn cylinder liner
Piston ring sticking or broken
Improper seating beween the valve and the valve seat
-!%
Replace the related parts
OK
Valve spring
-!%
Valve spring weak or broken
-!%
Replace the valve spring
%
Checkpoint
ENGINE TROUBLESHOOTING
EXCESSIVE OIL CONSUMPTION
Trouble Cause Remedy
I
I
Engine ail
OK
Oil seal and gasket
OK
Air breather
NG
Too much engine oil
NG
Correct the engine oil volume
-
NG gasket
NG andlor the gasket
-
Clogged air breather
-
-
Clean the air breather
OK
Inlet and exhaust valves
Valve seals
OK
Piston rings
OK
Cylinder liners
Defective valve seals
5
guides
NG valves, and the valve guides
NG
- worn
&?-
Replace the cylinder liners
I
Engines & Generators
Checkpoint
Cooling water
ENGINE TROUBLESHOOTING
OVERHEATING
Trouble Cause Remedy
-
Insufficient antifreeze
Insufficient raw water
NG
Replenish the antifreeze
Correct raw water flow
OK
Drive belt
NG causing slippage
Replace the drive belt
OK
Raw water pump
Impeller or bearings
.
OK
Water pump
OK
Cylinder head and cylinder body sealing cap
OK
Thermostat
NG water leakage
Defective thermostat
-
OK
Cooling system
OK
I
Fuel injection timing
NG foreign material
NG
Replace the thermostat
- the cooling system
NG Fuel injection timing improperly adjusted
NG
Adjust the fuel injection timing
!
I
I
I
~
~
Checkpoint
ENGINE TROUBLESHOOTING
WHITE EXHAUST SMOKE
Trouble Cause Remedy
Fuel
,
OK
Fuel injection timing
Replace the fuel
Adjust the fuel injection timing
OK
Compression pressure
OK
Turbocharger
Blown out cylinder head gasket
Worn cylinder liner
Pinon ring sticking or broken
Improper seating between the valve and the valve seat
-
Defective turbocharger
-!??-
Replace the turbocharger
OK
I
Inlet and exhaust valves
Valve seals
OK
Piston rings
OK
Cylinder liners
-!??-
Defective valve seals
Worn valves stems and valve guides
NG valves, and the valve guides
- or improperiy installed
NG properly install
- worn
Replace the cylinder liners
WESTERBEKE
/
Engines & Generators
ENGINE TROUBLESHOOTING
DARK EXHAUST SMOKE
Trouble Cause Checkpoint Remedy
Air cleaner
OK
Injection nozzle
OK
Fuel injection timing
NG
Clogged air cleaner element
- element
Injection nozzle injection starting
-
Improper spray condition
- nozzle
-
OK
Injection pump
NG Fuel injection timing improperly adjusted
NG
Adjust the fuel injection timing
-
Defective delivery valve resulting in fuel drippage after
-%- fuel injection
Replace the delivery valve
NG
Excessive injection volume
-%-
Adjust the injection volume
!
Checkpoint
ENGINE TROUBLESHOOTING
OIL PRESSURE DOES NOT RISE
Trouble Cause Remedy
Engine oil
-
Too much engine oil
NG Replace the engine oil
Correct the engine oil volume
OK
Oil pressure gauge or rendor
Oil pressure indicator light
-
NG
OK
Oil filter
Defective ail pressure gauge or rendor
Clogged oil filter element
1
-
or
replace the oil the oil filter canridge
OK
Relief valve and by-pass valve
- by-pass valve spring
.
.
OK
~-
~
Oil pump
-%-
Clogged oil pump strainer
.
NG
Replace the relief valve andlor
7 the by-pass valve spring
NG
Clean the oil pump strainer
NG
Worn oil pump related pans parts
OK
Rocker arm shah
OK
I
Camshafl
NG
Worn rocker arm bushing
Replace the rocker arm bushing
NG Worn camshaft and camshaft bearing
NG
Replace the camshafl and the camshaft bearings
-
I
OK r
Crankshaft and bearings
NG
Worn crankshah and bearings
l%3
I
Engines &
Generators
105
the bearings
ENGINE TROUBLESHOOTING
ABNORMAL ENGINE NOISE
1.
Engine Knocking
Checkpoint Trouble Cause Remedy
Check to see that the engine has been thotoughly warmed up before beginning the troubleshooting procedure.
Fuel
OK
I
Fuel injection timing
OK
I
I
Injection noule
OK
I
Compression pressure
NG Fuel unsuitable
NG adjusted
NG pressure and spray condition
- nozzle
Replace the fuel
- the fuel ;niection timing
- plston rtng
NG
Broken ptston ring
2.
Exhaust
Leakage
Noise
-
Exhaust System
OK
I
I
Injection nozzles andlor glow plugs
Continued on the next page
NG
NG
Loosely connected exhaust or broken exhaust hose
Loose injection nozzles andlor glow plugs
Tighten the exhaust hose connect~ons
Replace the exhaust hose
NG
- andlor the glow plugs
WESTERBEKE
I
Engines & Generators
ENGINE TROUBLESHOOTING
Checkpoint
Continued from the previous
@age
OK
ABNORMAL ENGINE NOISE
2. Exhaust Leakage Noise
Trouble Cause
Exhaust mantfold
NG fold andlor glow plugs
Remedy
- connect~ons
OK
Cylinder head gasket
&.-
Damaged cyltnder head gasket
NG
3. Continuous Noise
Drwe
belt
OK
Raw water pump
OK
Water pump bearing
&.-
Readjust the drove belt tenrlon
Loosen drive belt
-
Impeller or bear~ngr
-
NG Worn
Or bearlng damaged water pump
-!%
Replace the water pump bearlng
OK
Alternator
Defective alternator
5 or replace the alternator.
OK
Valve clearance
NG Valve clearance ~mproperly adjusted
ENGINE TROUBLESHOOTING
ABNORMAL ENGINE NOISE
4.
Slapping Noise
Trouble Cause Checkpoint Remedy
1
I
Valve clearance
OK
Rocker arm
OK
Flywheel adjusted
-
Damaged rocker arm
-
Loose flywheel bolts
Retighten the flywheel bolts
OK
Crankshaft and thrust bearings
.
.
- andlor thrust bearings
OK
- the thrust bearings
Crankshafl and connecting rod bearings
- andlor connecting rod bearings
NG the connecting rod bearings
OK
Connecting rod bushing and piston pin
NG
Worn or damaged connecting rod bushing and piston pin
NG Replace the connecting rod bushing andlor the Piston Pin
OK
Piston and cylinder liner
Worn or damaged piston and
5
Foreign material in the cylinder der liner
1
!
I
TIMING GEAR CASE
/
TORQUE
DATA
Ks-m (Ib-ll)
FUEL SYSTEM
4.20.8
0.6iO.Z
U.3f
1.51
1.750.1
2.6+0.5
CYLINDER HEAD
INTAKEIEXHAUST
MANIFOLDS
WESTERBEKE
I
Engines & Generators
109
CYLINDER HEAD
TORQUE DATA
Kg-m (Ib-n)
FUEL FILTER
5.3e1.0
138.3i7.21
I31
60*5
(433.8t36.21
FLYWHEEL
22.3i2.2
4
Cyl.
5.3k1.0
(38.3f7.21
CYLINDER BODY
(6
CYL. SHOWN)
115.2t3.61
2.lf0.5
115.2t3.61
/FX?WESTERBEKE
I
Engines
&
Generators
11 0
TURBOCHARGER
I
I
TORQUE DATA
138.3f7.21
W W E S T E R B E K E
I
Engines
&
Generators
1116.7f10.51
Lubricate with sngins oil
139.8i7.21
THE BE GENERATOR
SINGLE AND THREE PHASE
DESCRIPTION
This generator is a four-pole, brushless, self-excited generator which requires only the driving force of the engine to produce
AC output. The copper and laminated iron in the exciter stator are responsible for the self-exciting feature of this generator.
The magnetic field produced causes an AC voltage to be induced into the related excitor rotor windings during rotation.
Diodes located in the exciter rotor rectify this voltage to DC and supply it to the windings of the rotating field: This creates an electromagnetic field which rotates through the windings of the main stator, inducing an AC voltage which is supplied to a load. An AC voltage is produced in the auxiliary windings of the main stator and is, in tum, supplied to a voltage regulator. The regulator produces a DC voltage to further excite the exciter stator windings, enabling the generator to produce a rated AC output. The voltage regulator senses AC voltage output and adjusts DC excitation to the exciter stator winding according to amperage load the generator is furnishing To maintain a constant voltage output.
PARAUEL OPERATION
Two or more of these generators may be run in parallel by simply adding
a
parallel device. The parallel device is added to the electrical terminal box to ensure equal output of generator voltage. Contact your
WESTEBBEKE
dealer or the
WESTERBEKE
factory for information on parallel operation.
A
EM ERGEN C Y
STOP
GENERATOR BACK-END
Prior to performing any maintenance, make certain that the generator is shut down, switches are off and the unit is at room temperature.
use liquids or water. Do not use compressed ai- interior components as this
. on any result in short circuits.
CIRCUIT BREAKER
PARALLELING DEVICE
NOTSHOWN
i
A C TERMINAL'<
* ir
~ W E S T E R B E K E
I
Englnes
&
Generators
112
~
I i
.i
VOLTAGE REGULATOR ADJUSTMENTS
Description
The voltage regulator is an advanced design which ensures optimum AC alternator performance. It is equipped with complete protection circuiuy to guard.against operating conditions that could be detrimental to the AC alternator.
red
2
green
-
r
Herh d
A ~ P
-
Slab
z
YOU
This potentiometer is used to adjust output voltage. At proper engine operating speed the output voltage should b e held at
? I % from a no-load condition to a full rated generator output and from power factor 1.0
-
0.8 with engine drive speed variations up to
-6%.
Prior to starting the engine, turn the VOLT and STAB trimmers (using
a
mini phillips screwdriver) fully in a counter clockwise (Minimum) direction until you feel them hit their stops.
Turn the
AMP and
HERTZ
uimmers completely clockwise
(Maximum) in the same manner.
With the alternator mnning'at no-load, at normal speed, and with VOLT adjust at minimum, it is possible that output voltage will oscillate. Slowly rotate the VOLTadjust clock- wise. The voltage output of the alternator will increase and stabilize. Increase the voltage to the desired value. In this situation, only the green
LED will
stay l i t
Stability
This potentiometer permits variation of the regulator's response to generator load changes so as to limit overcompensation and obtain a minimum recovery time to the normal voltage output.
In order to adjust the regulator stability the alternator must be mnning at no-load and the output must be monitored.
Turn the STAB adjust slowly clockwise until the voltage starts to fluctuate. At this point rotate the STAB adjust counterclockwise until the voltage is stable within 1 or 2 tenths of a volt.
VOLTAGE REGULATOR DIAGRAM
Amp-Hertz
These two adjustments arc used in conjunz:ion ai:h
the
two protection circuits in the voltage regulator that are indicated by the illumination of a colored
LED
lights.
1. Delayed overload protection (yellow
LED).
2. Low speed protection (red
LED).
Both systems have an intervention threshold which can be adjusted using the respective potentiometer. Each of thc 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
;I S
motor start-up or other similar load surge demands. The regulator also has a third
LED
(green), that glows during generator operation to indicate correct operation of the regulator with the generator.
WESTERBEKE
I
Engines & Generators
GENERATOR INFORMATION
USE
OF ELECTRIC MOTORS
The power required to start an electric motor is considerably more than is required to keep it running after it is started.
Some motors require much more current to start them than others. Split-phase (AC) motors require more current to stm, under similar circumstances, than other types. They are com- monly used on easy-starling loads, such as washing machines, or where loads are applied after the motor is stmed, such as small power to&. Because they require
5 to
7
be avoided, whenever possible. if the electric motor is to be driven by a small generator. Capacitor and repulsion- induction motors require from 2 to 4 times as much current to start as to run. The current required to stan any motor varies with the load connected to it. An electric motor con- nected to an air compressor, for example, will require more current than a motor to which no load is connected.
In general, the current required to s m 115-Volt motors connected
to
medium stardng loads will be approximately as follows:
-
MOTOR SIZE
(HP)
AMPS FOR
RUNNlNG
(AMPERES)
AMPS FOR
STARTING
(AMPERES)
116
114
1 I3
112
314
1
3.2
4.6
5.2
7.2
10.2
13
6.4 to
22.4'
9.2 to
32.2'
10.4 to
72.8'
14.4 to
29.2'
20.4 to
40.8'
26 to
52
NOTE:
In the above table the marimum Amps for Staning is
more for some s m l l motors thm for larger ones. The reason made in larger sizes.
Because the heavy surge of current needed for staning motors is required foc only an instant, the generator will not be damaged if it can bring the motor up to speed in a few seconds. If difficulty is experienced in starting motors, tum off all other electrical loads and, if possible, reduce the load on the electric motor.
Required Operating Speed
Run the generator first with no load applied, then at half the generator's capacity, and finally loaded to its full capacity as indicted on the generator's data plate. The output voltage should be checked periodically to ensure proper operation of the generating plant and the appliances it supplies.
If an AC voltmeter or ampere meter is not installed to monitor voltage and load, check it with a portable meter and amp probe.
NOTE:
When the vessel in which the generator
is
installed contains AC equipment of 120 volts only, it is recommended
AC ~ermrnal be configured to pm- vide one
120
wolf AC hot leg for the vrael's distribution panel. This will ensure good motor staning responsefmm the generato,:
Generator Frequency Adjustment
Frequency is a direct result of enginelgenerator speed, as indicated by the following:
When the generator is run at 1800 RPM, the AC voltage
. .
When the generator is run at 1500 RPM, the AC voltage output frequency is 50 Hertz.
Therefore, to change the generator's frequency, the generator's drive engine's speed must be changed. Along with a reconfiguring of the AC output connections at the generator, a regulator board voltage output adjustment must also be made. See
ELECTRONICGOVERNOR in the manual.
A
Prior to any cleaning or maintenance, make certain all switches are off and the generator is
at
room temperatun.
Generator Maintenance
Maintaining reasonable cleanliness is important.
Connections of tenninal boards and rectifiers may become corroded, and insulation surfaces may stvt conducting if salts, dust, engine exhaust, carbon, etc. are allowed to build up. Clogged ventilation openings may cause excessive heating and reduced life of windings.
For unusually severe conditions. thin rust-inhibiting peboleum-base coatings, should be sprayed or brushed over all surfaces to reduce rusting and corrosion. Typical materials suggested
are
Daubert Chemical Co. "Non-
Rust AC-410" and Ashland "Tectyle 506" or equivalent.
In addition to periodic cleaning, the generator should be inspected for (a) tightness of all connections, (b) evidence of overheated terminals and (c) loose or damaged wires.
The drive discs on single bearing generators should
be
checked periodically if possible for tightness of screws and for any evidence of incipient cracking failure. Discs should not be allowed to become rusty because rust may accelerate cracking. The bolts which fasten the drive disc to the generator shaft must be hardened steel SAE grade
8, identified by 6 radial marks, one at each of the 6 comers of the head.
The rear m a t u r e bearing is lubricated and sealed; no maintenance is required. However, if the bearing becomes noisy or rough-sounding, have it replaced.
Examine bearing at periodic intervals. No side movement of shaft should be detected when force is applied. if side motion is detectable, bearings are wearing or wear on shaft of bearing socket outside bearing has occurred.
Repair must be made quickly or major components will mb and cause major damage to generator.
Compressed air can
be
used to clean the generator exterior. Do not use compressed air on internal components.
'
!
p
I
Engines
&
Generators
GENERATOR AC VOLTAGE CONNECTIONS
AC VOLTAGE CONNECTIONS
The frame ground wire (whitelgreen) must be properly
~ ~ positioned when changing the A C output configuration of the AC terminal block. For makine connections to the AC
~ ~~~~~~ ~
~~-~~
- terminal black, use terminal ends for 114 inch studs that will accept multi strand copper wire sized for the amperage rating from the hot lend connection. The frame ground wire is white or white with a green strip. It connects between the neutr~l stud and the generator frame.
L1
-
L2-
Generator Frequency
1. Frequency is a direct result of enginelgenerator speed:
1800 mm
=
60 hertz: 1500 rum
=
50 hertz.
2. To change generator frequency
Configure the
AC terminal block for the desired voltage frequency as shown. Ensure that the case ground wire is connected to the correct terminal block neutral ground stud.
NOTE:
The white/green ground wire may be removed in those installarions where the
AC circuit has a separate rrenrral arid source in the vessel.
IMPORTANT
When changing from 50Hz to 60Hz the generator power and nominal vottage will increase by 20% but the current does not change from the 50Hz value.
Should voltage stay at 50Hz, then the output power may be increased by 5% due to improved ventilation.
This is accomlished by resetting the
AVR
potentiometer.
50H.2, the voltage and power values must decrease by 20% of the 60Hz value.
L2
SERIES
Y
480V/60 Hz
380V/50
Hz
4 + 5
~ 3 + 3
9
0
I O + I
fl
L1
-
PARALLEL Y
208V/60
Hz
190V/50
Hz
L2
L3
L3
8 + 9 l O + l
l
SERIES DELTA
240V/60 Hz
220V/50
Hz
4
PARALLEL DELTA
120V/60 Hz
1700V/50
Hz
-
MuS T
NOTE: F NJRIIIG FOR
50
ra
THE 60 Hz JUMPER
BE
REMO/ED FROhl ThE REGULJ TOR
-
~ W E S T E R B E K E
I
Engines
&
Generators
r - - - - - - - - - - - -
I
I
I
-,
I
A
EXCITER STATOR
1
I
I I I
INTERNAL WIRING DIAGRAM
12
WlRE
-
3
PHASE
-
RECONNECTABLE
YELLOW
THE (PO) PARALLEL DEVICE
IS OPTIONAL UP TO 320 KVA
THE LNVKPACTIVATES OR
OE-ACTIVATES THEPARALLELING
DEVICE IF IT IS PRESENT
12
WIRE 3 PHASE
SHOWING PARALLEL
y
W W E S T E R B E K E
I
Engines
&
Generators
ELECTRONIC GOVERNOR ADJUSTMENTS
TO E L E ~ O R O W I C
COlTROLLW
~ ~
DESCRIPTION
The system is composed of three basic components:
9.
Controller. Mounted in the instrument panel.
2. Sensor. Installed on the bellhousing over the flywheel ring gear.
3. Actuator. Mounted at the front of the engine and attached with linkage to the throttle arm of the injection pump.
1
! O C M W O R
I"
REFER TO WIRING DIAGRAMS
S
ENSO
R
L O C KNUT-
:iF,"EEL
Ar
RELAY
-
\
LIN
EAR
ACTUATOR
CONTROLLER ADJUSTMENT
1. Speed. This adjustment is used to raise or lower the engine's speed to the desired hertz.
2. Gain. This adjustment affects the reaction time of the actuator to the generatorlengine load changes.
NOTE:
A
high gain adjustment car1 induce an oscillati~zg of the actuatorproducing a hurztirzg nzorle. b~ such
Calibration
1. With no power to the governor, adjust the GAIN to
2. Start the engine and adjust the speed by turning the speed pot clockwise to desired speed.
NOTE:
Co~ztmllers
10
rni~zin~unz
Howeve,: fix safety, one slzould be capable ~$di.~ablirtg
3.
At no-load, turn the GAIN potentiometer clockwise until the engine begins to hunt, if t h e engine does not hunt, physically upset the governor linkage.
4. Turn the GAIN potentiometer counterclockwise until stable.
NOTE:
Tlze co~ztroller range is
+
20% (9.6VDC I2VDC 14.4VDC). Ifvoltage
INSPECTION AND ADJUSTMENT
The controller has two adjustment pods. You need a mini screw driver to adjust these. One is speed and the gain. These are noted on the drawing of the controller.
When you press the preheat switch, the actuator linkage attached to the throttle arm of the injection pump should move outward towards the injection pump and return back into the actuator in a quick motion.
Start the engine. The speed should be in the low idle range
600-700
rpm. If the engine speed is higher than this idle range, shut the engine down. Check the linkage between the actuator and throttle arm. The throttle arm stop should be about touching the open idle stop screw boss. Adjust the linkage to position the throttle lever.
The controller has an adjustment screw for speed adjustment. Turn this screw outward (counter clockwise) a few turns. Restart the engine.
NOTE:
Ythere is any oscillating ofthe actuator linkage producing hunting, adjust the gain towards zero
"0"
this hunting is removed.
Increase the engine speed slowly with the speed adjusting screw turning it inward (clockwise). In some instances this screw may need to be turned
6-10
turns before an increase in engine speed is noted. Bring the engine speed to rpm
(60 1500 (50
Momentarily push the actuator linkage towards the actuator and release. The actuator should quickly regain proper speed. If there is any hunting adjust the gain towards zero
When the gain is adjusted you may need to readjust the
Speed at no load, shut the generator down,
Push the DC exciter circuit breaker in. Start the generator.
Check speed (Hertz) set at
60
Load the generator.
If the governor is slow to react and maintain
60
Hertz adjust the gain clockwise. Again you may need to adjust the speed at no load.
You will find the governor will maintain
60 i
~ ~ n h k ~ ~ ~ ~
for the
WESTEREEKE
/
Engines
&
Generators
Problem
System appears dead
(Engine runs at idle.)
TROUBLESHOOTING THE
ELECTRONIC GOVERNOR
Probable Cause
1.
L
OW banely voltage at controller.
VerificationlRemedy
1. Check wiring for cause. Check banery state of charge.
2. stuck linkage.
3. No signal or weak signal from sensor.
(Measure AC voltage from sensor while engine is running at idle. Voltage ihould be 1.5 volts 0.r greater.
4. Check Actuator
- depress PREHEAT and check for banery voltage between negative black lead at terminal block. a. Purple lead to black.
2. Lubricate, free up linkage between controller and throttle arm.
3. Check lor improperly installed or damaged sensor in flywheel housing. Replace or adjust.
4. Replace controller if battery voltage is not present at bo~h leads.
Actuator fully extends when PREHEAT is depressed and stays extended.
Actuator hunts (oscillates) and engine running. b. Second purple to black.
5. Perform the following check between terminals at the actuator and the negative
DC lead at the controller terminal block.
(Preheat depressed). a. Low voltage (1.20-2.0VDC) at either actuator connection. b. Battery voltage at both actuator connections.
c. Banery voltage at one actuator lead but not the other.
I
.
Check controller. Lilt one of the purple actuator leads from the terminal block.
Depress PREHEAT a. Actuator fully extends. b. Actuator does not fully extend and connections.
NOTE: Release PREHEAT and reconnect the purple lead.
1. Linkage between actuator and thronle binding.
2.
Improper adjustment of GAIN on controller.
3. Inadequate DC power supply to controller, complete the following tests:
Connect a DC voltmeter across the plus and negative leads at the controller terminal block.
Lifl both purple leads from the terminal block.
Connect one purple lead to the
C pius terminal and the other to the
DC negative.
Momentarily depress PREHEAT.
The actuator should fully extend. a. Broken ac!uator laad. b. Broken actuator lead. c. Replace the actuator. a.
Sholt in lead to actuator.
b.
Replace controller.
1. Lubricatellree-up.
2. Lessen GAIN adjustment (Recalibrate the Controller).
3. If actuator does not fully extend, check the actuator leads.
If the voltage is less than specilied, check for loose or poor connections, low banery voltage, voltage drop in DC circuit due to remote panel installation and small wire sizes making connections.
DC voltage registering on the meter should be:
12
VDC System
- 9.6 vDC or higher
24 VDC System
-
19.2
VDC or higher
NOTE:
Reconnect actuator leads properly afler making this test.
3a. Check the position of the sensor.
3a. Sensor positioned marginally too far away from flywheel teeth giving erratic signal voltage to ~0ntr0ller.
-
m W E S T E R 5 E K E
I
Engines & Generators
118 i i
I
I i
~ i
',
LOW AC VOLTAGE OUTPUT AT
NO LOAD 60
-
100 VAC.
BE TROUBLESHOOTING
NOTE: AC
GENERATOR TROUBLESHOOTING MUST
BE PERFORMED WITH THE ENGINE OPERATIN AT
60 H Z
FAULT
NO AC VOLTAGE OUTPUT AT NO LOAD.
RESIDUAL VOLTAGE PRODUCED AT
NO LOAD
15
-
20
VOLTS AC.
1. Short or open in the main stator winding.
PROBABLE CAUSE
4.
Open in exciter stator winding.
5.
Open in rotating field winding.
2. Shorted pozi-resistor on exciter rotor.
3. Four or more shorted or open diodes on exciter rotor.
1.
Blown 6 AMP fuse auxiliary circuit feed to AVR.
3. Shorted or open main stator auxiliary winding.
2. Faulty voltage regulator
1. Reset voltage potentiometer.
2. Open or shorted diodes in. exclter rotor
1 to
3 diodes.
4.
AC
circuit breaker tripped.
3. Open or shorted exciter rotor winding.
4.
Faulty voltage regulator.
HIGH AC OUTPUT VOLTAGE
150
VAC OR HIGHER.
UNSTABLE VOLTAGE OUTPUT.
(ENGINE SPEED STEADY)
AC VOLTAGE DROP UNDER LOAD
60
-
100
VOLTS AC.
1. Reset voltage potentiometer.
2. Faulty voltage regulator.
1. ST6 pod on regulator needs adjustment.
1.
Diode@) on exciter rotor breaking down when load is applied (inductive)
2. Faulty voltage regulator.
W W E S T E R B E K E
I
Engines & Generators
GENERATOR MAINTENANCE
make certain that the generatoe isshutdown, switches are off and the unit is at room temperature.
CLEANING
Use compressed air to clean the exterior of the generator. Do not use liquids or water. D o not use compressed air on interior components a s this could cause short circuits.
3. Remove the seager rings with sna ring pliers.
Rotation Diode Bridge
1. Disconnect the five wires of the rotating diode bridge.
DIODE B R I O 6 6
DISASSEMBLY
If it becomes necessary to disassemble the statorlrotor assembly, use the following text as a guide.
1. Insert a suitable puller (which can be easily made) and remove the exciter.
2. Extract the rotor using a hoist with soft ropes of sufficient strength.
Carefully remove the rotor and place it on the prepared work area. It may be necessary to remove the front cover to extract the rotor due to the diameter of the fan.
REASSEMBLY
1. Heat the bearing with a special magnetic device and using insulat gloves, assemble the bearings to the shaft.
2. Put the seager rings back i
ROTORIFAN
ASSEMBLY
3. Reassemble the e making sure the d cables are turned the covers back i n place.
WESTERBEKE
I
Engines & Generator*
120
I
I
45
BED GENERATOR SPECIFICATIONS
Diesel, four cylinder, four-cycle, marine engine.
Vertical in-line overhead valve, water cooled direct injection, 70 hp @ 1800 rpm and
60 hp @I500 rmp.
Naturally aspirated.
Integral with injection pump.
4.02 x 4.65 inches (102.0 x 118.0 mm).
Fuel Injection Timing
Closed system with bleed points.
N
O
. 2 diesel oil (cetane rating of 45 or higher).
BOSCHModel A type (In-line).
14" BTDC
Full flow replaceabie.
Replaceable paper element. irection of Rotation
Clockwise, when viewed from the front.
210lt-lb
0
1500 rpm.
Width: 30.6 inches (778 mm)
Length: 62.5 inches
(1588 mm)
750-900 Cold Cranking Amps (CCA).
C Charging Alternator
51 Amp rated, belt-driven.
Intake and exhaust.
Full flow, paper element, spin-on type.
14.5 U.S. qts (13.8 liters).
&
~, lntelference Level
Brushless, four pole, revolving field,
All units adjustable to 50 or 60 He*..
Three phase. Single phase units available.
12 lead reconnectable standard
2
1% no load to full load.
Class " H , as defined by NEMA MGI-!.65
Direct drive centrifugal blower.
Within NEMA MGI-22.40 definition
- full load
Meets "CE requirements
240 120
400 230
Voltage regulator is adjustable
=
5%
~ W E S T E R B E K E
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Engines & Generators
121
Centriiugal type, metal impeller, belt-driven.
Positive displacement, rubber impeller, engine-driven.
17 USqts (16.1 liters).
~
I
!
55 BED GENERATOR SECTION
Diesel, four cylinder, four-cycle, turbocharged marine engine. Vellical in-line overhead valve, water cooled direct injection, 90 hp @ 1800 rpm and 80 hp
@
1500 rpm. integral with injection pump.
4.02 x 4.65 inches (102.0
x
118.0 mm).
202 cubic inches (4.3 liter). Piston Displacement
Direction of Rotation
Engine Torque (ma.)
Clockwise, when viewed from the front.
280 fl-lb @ 1500 rpm.
Closed system with bleed points.
No. 2 diesel oil (cetane rating of 45 or higher).
BOSCHModel A type (In-line).
Fuel Injection Timing
Fuel Filter (on engine) Full flow replaceable.
Replaceable paper element.
190 cfm.(6.2 crnm).
DC Charging Alternator 51 Amp rated, belt-driven
DC Na-load Current
12 Volt, 2.9 KW
2 2 % of rated amps
2630 psi (185 Wlcm'). intake and exhaust
0.016 inches (0.40 mm).
Operating Oil Pressure
Full flow, paper element, spin-on type.
14.5 U.S. qts (13.8 liters)
250 - 85 psi
Brushless, four pole, revolving field, power take-otl
All units adjustable to 50 or 60 Hertz..
Three phase. Single phase units available.
12 lead reconnectable
Voltage Regulation
Insulation
Cooling
Temperature Rise
Interference Level
Standard
2
1% no load to full load.
Class "H, as defined by NEMA MGI-!.65
Direct drive centrifugal blower.
Within NEMAMGI-22.40 defination
- full load
Meets "CE requirements
Voltage Oulput
Configuration
Series Star
Parallel Star
Series Della
Parallel Delta
Zig Zag
60
Hertz
L-L L-N
480 277
208 120
240 120
130
400 230
50
Hertz
L-L L-N
400 230
230 127
230 115
110
330 190
Voltage regulator is adjustable
2
5%
3 Phase amperage calculation: Amps=Watts/jVoltage
x
1.732
x
PF.]
Operating Temperature
170
-
190" F (77
- 88" C)
Centrifugal type, metal impeller, belt-driven.
Positive displacement, rubber impeller, engine-driven.
Note: The pressure differential between the outside of the engine cornpall- mentversus the inside of the engine compartment should not exceed 2 inches of water (51 mm) at full open thronle (measure with a manometer).
~ W E S T E R B E K E
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Engines & Generators
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I
1
I i
I
I
I i
65 BED GENERATOR SPECIFICATIONS
-,
Piston Displacement overhead valve, fresh water cooled direct injection. marine engine. 100 hp @ 1800 rpm and 85 hp @ 1500 rpm.
Naturally aspirated.
Integral with injection pump.
4.13 x 4.92 inches (105.0 x 125.0 mm)
396 cubic inches (6.5 liter)
1 - 5 - 3 - 6 - 2 - 4
Direction of Rotation
Clockwise, when viewed from the front.
313ft-lb@ 1500 rpm.
Dimensions - inches (mm) Height: wlout transmission Width:
34.2 inches
30.6 inches
(868 mm)
(778 mm)
Length: 74.9 inches (1903 mm)
Fuel lniection Timing
No. 2 diesel oil (cetane rating of 45 or higher).
BOSCHModel Atype (In-line).
14" BTDC
Fuel Filter (on engine)
Full flow replaceable.
Replaceable paper element.
12 Volt, 2.9 KW actuated shift
*2% of rated amps
2631 psi (185 kf/cm7).
Exhaust 45"
Intake and exhaust
Operating Oil Pressure
Full flow, paper element, spin-on type..
14.5 U.S. qts (13.8 liters)
28- 85 psi
Brushless, four pole, revolving field. power take-OH
All units adjustable to 50 or 60 Hea..
Three phase. Single phase units available.
12 lead reconnectable
Insulation
Cooling
Temperature Rise lnlerference Level
Standard
2
1% no load to full load.
Class " H , as defined by NEMA MGI-!.65
Direct drive centrifugal blower.
Within NEMAMGI-22.40 defination
- full load
Meets "CE" requirements
Voltage Output
Configuration
Series Star
Parallel Star
Series Delta
Parallel Delta
Zig Zag
GO
Hem
L-L L-N
480 277
208 120
240 120
130
400 230
50 Herlz
L-L L-N
400 230
230 127
230 115
110
330 190
Voltage regulator is adjustable
2
5%
3 Phase amperage calculation: Amps=Wansl[Voltage x 1.732 x
P.F.]
Operating Temperature
Centrifugal type, metal impeller, belt-driven.
Positive displacement, rubber impeller, engine-driven.
25 US qts (23.7 liters) merit versus the inside of the engine compartment should not exceed 2 inches of water (51 mm) at full open throttle (measure with a manometer)
~ W E S T E R B E K E
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Engines & Generators
123
95
BED GENERATOR SPECIFICATIONS
Integral with injection pump.
4.13 x4.92 inches (105.0 x 125.0 mm)
Direction of Rotation ngine Torque (max.)
1 - 5 - 3 - 6 - 2 - 4
Clockwise, when viewed from the front.
423 It-lb
@
1800 rpm.
Width:
30.6 inches (778 rnm)
Length: 75.0 inches (1903 mm) uel Injection Timing
No. 2 diesel oil (cetane rating 0145 or higher).
BOSCHModel Atype (In-line).
12" BTDC
Full flow replaceable.
Replaceable paper element.
240 cfm (6.2 cmm)
C Charging Alternator
51 Amp rated, belt-driven
12 Volt, 2.9 KW actuated shill.
OC No-load Current
2631 psi (185 kilcm').
Exhaust 45'
Intake and exhaust
Operating Temperature 170 - 190' F (77
-
88"
C)
Centrifugal type, metal impeller, belt-driven.
Coolant (Fresh Water)
25 US qts (23.71 liters)
Interference Level
Brushless, four pole, revolving field,
All units adjustable to 50 or 60 Hem..
Three phase. Single phase units available.
12 lead reconnectable
Standard
2
1% no load to full load.
Class " H , as defined by NEMA MGI-!.65
Direct drive centrifugal blower.
Within NEMA MGI-22.40 delination
- full ioad
Meets "CE requirements
L-L L-N
Operating Oil Pressure
Gear typelpressure circulation
Full flow, paper eiemed, spio-on type.
22.0 U.S. qts (20.8 liters)
25
-
85 psi (3.5 - 4.2 kglcm')
I
I
I i
I
Voltage regulator is adjustable
-+
5%
Note: The pressure differential between the outside of the engine cornpart- merit versus the inside of the engine companment should not exceed 2 inches of water (51 mm) at full open thronle (measure with a manometer).
WESTERBEKE
I
Engines
&
Generators
124
80N4 SPECIFICATIONS
Engine Type
Aspiration
Governor
Bore & Stroke
Piston Displacement
Firing Order
Vertical in-line overhead valve, water cooled direct iniection, 80 hp @ 2500 rpm.
Naturally aspirated.
Integral with injection pump.
4.02 x4.65 inches (102.0 x 118.0 mm).
262 cubic inches (4.3 liter).
1 - 3 - 4 - 2 .
Direction of Rotation
Clochise, when viewed from the front.
Engine Torque
Weight (dry)
210 ll-lb @ 1500 rpm.
Compression Ratio 17:l
Dimensions
- inches (mm) Height: 32.0 inches (813 mm) w/out transmission Width: 25.2 inches (645 mm)
Length: 47.2 inches (1168 mm)
971 ibs (440.8 kgs).
I
Compression Pressure
(Limit of difference
441 psi (31 kg/cm2) at 200 rpm
Not to exceed 28.44 psi (20.0 kglcm').
Injector Pressure
2133 psi (150 kflcm').
Valve Seat Angle
Valve Clearance
(engine cold)
Engine Speed
Intake 45"..
Exhaust 4% intake and exhaust.
0.016 inches (0.40 mm). idle: 600
-
900 rpm.
Cruise: 1800
-
2200 rpm.
Max: 2400 -2500 rpm.
General Fresh water-cooled block, thermostatically- controlled with heat exchanger.
Operating Temperature
170
-
190' F (77
-
88" C).
Fresh Water Pump
Centrifugal type, metal impeller, belt-driven
Raw Water Pump
Positive displacement. rubber impeller, engine-driven.
Coolant (Fresh Water)
System Capacity
17 US qts (16.1 liters).
Exhaust Elbow
Exhaust Hose Sue
45" elbow
4" I.D. (101.6 mm) hose
Note: The pressure diflerential between the outside ol the engine compart- ment versus the inside of the engine compartment should not exceed 2 inches of water (51 mm) at full open throttle (measure with a manometer).
General
Fuel
Fuel infection Pump
Fuel Injection l m i n g
Nozie
Fuel Filter
(on engine)
Air cleaner
Air Flow
(engine combustion)
Fuel Consumption
12 Volt, (-) negative ground.
(
Slarting Battery
Battery Capacity
DC Charging Alternator
51 Amp rated, belt-driven.
I
I I
Starling Aid
Starter
DC No-load Current
DC Cranking Current
'
Glow plugs.
12 Volt, 3
KW.
-C2% of rated amps
400 CCA.
I 1
General
I I
Oil Filter
Sump Capac'i
Gear type/pressure circulation.
Full flow, paper element, spin-on type.
14.5
U.S. ots 113.8 liters).
(not including filter)
Operating Oil Pressure
(engine hot)
Oil Gnde
25 - 85 psi.
API Specification CF or CG-4,
SAE
30,lOW-30. 15W-40.
General
Gear Ratio (Standard)
Propeller Shall
(usin0 standard transmiss~on)
Lubricating Fluid
Transmission Sump
Capacity Hurth 45
Closed system with bieed points.
NO.
2
diesel oil (cetane rating of 45 or hlgher)
BOSCHModei A type (In-line).
14" BTDC
Multi-hole
Full flow replaceable.
Replaceable paper element.
150 cfm.
4.7 U.S. gph (17.8 Iph).
Clutch
2:OO:t (Huilh 45A) or (Hurlh 63A)
Right handedstandard transmission, propel er snould ai ow the eng ne to reacn .ts l ~ l l a! ILI.
' while undeiway in forward gear.
Dextmo 111
2.13 US qts (2.0 liters) approximate.
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~ W E S T E R B E M
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Engines
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Generators
11
0T4 SPECIFICATIONS
marine engine. Vertical in-line overhead valve. water cooled direct injection, 110 hp @ 2400
Piston Displacement
Integral with injection pump.
4.02 x 4.65 inches (102.0 x 118.0 rnm).
202 cubic inches (4.3 liter).
Direction of Rotation
Engine Torque (max.)
Clockwise, when viewed from the front.
280 fl-lb @ 1500 rpm.
Dimensions
- inches (mm) Height:
32.0 inches (813 mm) wlout transmission Width: 28.3 inches
(719 mm)
Length: 47.2 inches (1168 mm)
Fuel Injection tming
Closed system with bleed points.
No. 2 diesel oil (cetane rating of 45 or higher).
BOSCHModei A lype (In-line).
12" BTDC.
Full flow replaceable,
Replaceable paper element.
750- 900 Cold Cranking Amps (CCA)
DCCharging Alternator
51 Amp rated, belt-driven
DC No-load Current
2 2 % of rated amps
Not to exceed 28.44 psi (20.0 kglcrncm').
2133 psi (150 M/cm2). intake and exhaust
0.016 inches (0.40 mm).
Idle: 600
-
900 rpm.
Operating Oil Pressure
14.5 U.S. qts (13.8 liters)
25
-
85 psi
APi Specification CF or CG-4.
SAE 30.10W-30,15W-40
Operating Temperature
Centrifugal type, metal impeller, belt-driven.
:
(Hurth 45A) or (Hurlh 63A)
Right handed-standard transmission.
Propeller Recommendations 24x18 P-2 blade or 24x16 P.3 blade
Capacity Hurth 45A
2.13 US qts (2.0 liters) approximate.
WESTERBEKE
/
Engines
&
Generators
126
!
1
120N6
SPECIFICATIONS
Engine Type
Aspiration
Governor
Bore & Stroke
Diesel, six cylinder, four-cycle, Vertical in-line, overhead valve. fresh water cooled direct injection, marine engine. 120 hp @ 2500 rpm.
Naturally aspirated. integral with injection pump.
Piston Displacement
Firing Order
296 cubic inches (6.5 liter)
1 - 5 - 3 - 6 - 2 - 4
Direction of Rotation
Clockwise, when viewed from the front.
Engine Torque
Weight (dry)
298 ft-lb @ 1500 rpm.
Compression Ratio 17:l
Dimensions
- inches (mm) Height: 32.5 inches (823 mm) wlout transmission Width: 25.2 inches (645 mm)
Length: 56.4 inches (1410 mm)
1175 lbs (534.1 kgs).
Compression Pressure
441 psi (31 kglcm') at 200 rpm
(Limit of difference
Not to exceed 28.44 psi (20.0 kglcm').
Injector Pressure
2631 psi (180 M/cm7).
Valve Seat Angle intake 45"
Exhaust 4 B
Valve Clearance
(engine cold)
Engine Speed
Intake and exhaust
0.016 inches (0.40 mm)
Idle: 600
-
900 rpm
Cmise: 1800
-
2200 rpm
M a :
2400 -2500 rpm
General Fresh water-cooled block, thermostatically. controlled witll heat exchanger.
Operating Temperature 180
-
190'
F
(77
-
88" C)
Centrifugal type, metal impeller, belt-driven.
Positive displacement, rubber impeller, engine-driven.
25 US qts (23.7 liters)
"
I.D. (101.6 mm) hose hole The pressJre dderenta' oerween the outs!de ot toe eng ne compan- lncnes of water (51 mml at 15
I open Ihrotbe (measure wth
a
manometer)
General
Fuel
Closed system with bleed points.
N
O
. 2 diesel oil (cetene rating of 45 or higher).
Fuel Injection Pump
BOSCHModel A type (In-line).
14" BTDc Fuel Injection Timing
Nonie Multi-hole
I
Fuel Filter
(on engine)
Full flow replaceable.
Air cleaner Replaceable paper element
Air Flow 240 cfm
(engine combustion)
I
Fuel Consumption
6.5 U.S. gph (24.6 iph).
I
Starting Battery
Battery Capacity
12 Volt, (-) negative ground
750-900 Cold Cranking Amps (CCA)
DC Charging Alternator
51 Amp rated, belt-driven
Starting Aid Glow plugs
Starter
12 Volt, 3 KW actuated shin.
DC No-load Current
DCCranking Current
2 2 % of rated amps
400 CCA
General
Oil Filter
sum^
Capacitv
(not includingjilter)
I
Oueraline Oil Pressure
(engine hot)
Oil Grade
Gear typelpressure circulation
Full flow, paper element, spin-on type
.
~~~~
,
25
-
.
,
-
4.2 kolcm?
API Specification CF or CG-4.
SAE30,lOW-30.15W-40
. I I
General
Gear Ratio (Standard)
Propeller Shall
(HURTH Standard Transmission) Case-hardened helical gears, hydraulically operated multiple disc clutch.
2:W:l (Hum 45A) or (Hurth 63A)
Right handed-standard transmission.
Propeller Recommendations 22x16 P-2 blade or 22x14 P-3 blade
(using standard propeller should allow the engine to reach its transmission) full rated rum (2500 t
000 -100) at lull open throttle while undelway in folward gear.
Lubricating Fluid Dexfron
Ill
Transmission Sumo
Capacity Hulth 45'
Hurth 63
2.13 US qts (2.0 liters) approximate.
4.2 US qts (4.0 liters) approximate.
1
I
Ewine Type
Aspiration
Governor
Bore &Stroke
Pislon Displacement
Flring Order
Direction of Rotation
Engine Torque (max.)
Compression Ratio marine engine. Vertical in-line overhead valve, fresh water cooled direct injection, 170 hp @
2500 rpm.
Turbocharged.
Integral with injection pump.
4.13 x 4.92 Inches (105.0 x 125.0 mm)
423 cubic inches (6.5 liter)
1 - 5 - 3 - 6 - 2 - 4
Clockwise, when viewed from the front.
423 ti-lb
4
1800 rpm.
17:l
Geneml
Fuel
Closed system with bleed points.
N
O
. 2 diesel oil (cetane rating of 4 5 or higher).
Fuei injection Pump
Fuel Injection Timing
Nonie
Fuei Filter
(on engine)
BOSCHModel A lype (In-line).
12" BTDC
Multi-hole
Full flow replaceable.
Air cleaner
Replaceable paper element
Air Flow
365 cfm.
(engine combustion)
1
Fuel consumption
9.3 U.S. gph (35.2 iph).
I
Dimensions - inches (mm) Height: wlout transmission Width:
33.5 inches
28.0 inches
(823 mm)
(711 mm)
Length: 5Z:5 inches (1410 mm)
Weight (dry) 1245 lbs (565.23 kgs).
I
Starling Banery
Battery Capacity
12 Volt. (-) negative ground
750
-
900 Cold Cranking Amps (CCA)
DC Charging Alternator
51 Amp rated, belt-driven
I
Compression Pressure
(Limit of diiierence
Injector Pressure
Not to exceed 28.44
2631 psi (185 Mlcm').
1 psi (20.0
kglcm')
Starling Aid
DC No-load Cunent
Glow plugs
12 Volt. 3 KW
2 2 % of rated amps
DC Cranking Current 400 CCA
Valve Seat Angle Intake 45"
Exhaust 45'
Valve Clearance
(engine cold)
Engine Speed
Intake and exhaust
0.016 inches (0.40 mm)
Idle: 600
-
900 rpm
Cmna 1800
-
2200 rpm
Max: 2400 -2500 rpm
General
Oil Filter
Gear typelpressure circulation
Full flow, paper element, spin-on type.
Sump Capaciy
(not including filter) 1
DpeFting Oil Pressure lenolne hot)
22 U.S. qts (20.8 liters)
25
-
85 psi
I
General
Fresh water-cooled block, thermostatically- controlled with heat exchanger.
O~erallng 180
-
190"
F
(77
-
88" C)
Fresh Water Pump
I
Raw Water Pump
Positive displacement, rubber Impeller, engine-driven.
APi Speciiication CF or CG-4,
SAE 30.10W-30 15W-40
.
.
I
--
(HURTH Standard Transmission) Case-hard- helical gears, hydraulically operated multiple disc clutch.
Coolant (Fresh Water)
System Capacity
25 US
qts
(23.7 liters)
I
General ened
Gear Ratio (Standard)
Propeller Shati
2:00:1 (Hum 45A) or (Hurth 63A)
Right hanoed.standar0 transmssion.
Exhaust Elbow
Exhaust Hose Size
]
Model
45" elbow
4" I.D. (101.6 mm) hose
1H1 RHC7
I
I
Propeller Recommenoalions 24x18 P.2 btaoe or 24x16 P.3 olade
(using standard transmission) propelier should allow the engine to reach its full rated rpm (2500
+
000 -100) at full open throttle while underway in forward gear.
Oextmn
Ill
Lubricating Fluid
Transmission Sump
Capacity Hurlh 63
4.2 US qts (4.0 liters) approximate.
I
I
I
I
Combustion Air 365 cfm
Note: The pressure differential between the oulside of the engine comparl- ment versus the inside of the engine compallmentshouid not exceed 2 inches of water (51 mm) at full open throtlle (measure with a manometer).
I
/ ~ ~ W E S T E R S E K E
I
Engines
&
Generators
I
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.
.
STANDARD AND METRIC CONVERSION DATA
LENGTH-DISTANCE
Inches (in) x 25.4
=
Millimeters (mm) x ,0394
=
Inches
Feet (It) x ,305
=
Meters (m) x 3.281
=
Feet
Miles x 1.609 = Kilometers (km) x ,0621
=
Miles
DISTANCE EQUIVALENTS
1 Degree of Latitude
=
60 Nm
=
11 1.1 20 km
1 Minute of Latitude = 1 Nm = 1.852 km
VOLUME
Cubic lnches (in" x
16.387 = Cubic Centimeters x ,061 =i< lmperial Pints (IMP pt) x ,568
=
Liters (L) x 1.76
=
IMP pt lmperial Quarts (IMP qt) x 1.137 = Liters (L) x.88
=
IMP qt lmperial Gallons (IMP gal) x 4.546
=
Liters (L) x .22
=
IMP gal lmperial Quarts (IMP qt) x 1.201
=
US Quarts (US qt) x ,833
=
IMP qt lmperial Gallons (IMP gal) x 1.201 = US Gallons (US gal) x ,833
=
IMP gal
Fluid Ounces x 29.573 = Milliliters x ,034
=
Ounces
US Pints (US pt) x ,473
=
Liters(L) x 2.113
=
Pints
US Quarts (US qt) x ,946 =Liters (L) x 1.057
=
Quarts
US Gallons (US gal) x 3.785
=
Liters (L) x ,264 = Gallons
MASS-WEIGHT
Ounces (oz) x 28.35 =Grams (g) x ,035
=
Ounces
Pounds (Ib) x
,454
=
Kilograms (kg) x 2.205
=
Pounds
PRESSURE
Pounds Per Sq In (psi) x 6.895
=
Kiiopascats (kPa) x ,145 = psi lnches of Mercury (Hg) x ,4912 =psi x 2.036
=
Hg
Inches of Mercury (Hg) x 3.377
=
Kilopascals (kPa) x ,2961
=
Hg lnches of Water (HtO) x ,07355 = lnches of Mercury x 13.783
=
HtO lnches of Water (HzO) x ,03613
= psi x 27.684
=
Hz0 lnches of Water (HzO) x ,248 = Kilopascals (kPa) x 4.026
=
H2O
TORQUE
Pounds-Force lnches (in-lb) x ,113 = Newton Meters (Nm) x 8.85 =in-lb
Pounds-Force Feet (It-lb) x 1.356
=
Newton Meters (Nm) x ,738
= ft-lb
VELOCITY
Miles Per Hour (MPH) x
1.609
=
Kilometers Per Hour (KPH) x
,621
=
MPH
POWER
Horsepower (Hp) x ,745 = Kilowatts (Kw) x 1.34 = MPH
FUEL CONSUMPTION
Miles Per Hour IMP (MPG) x .354
=
Kilometers Per Liter (KmlL)
Kilometers Per Liter (KmlL) x 2.352
=
IMP MPG
Miles Per Gallons US (MPG) x ,425 = Kilometers Per Liter (KmlL)
Kilometers Per Liter (KmIL) x
2.352
=
US MPG
TEMPERATURE
Degree Fahrenheit ("F)
=
("C X 1.8)
Degree Celsius ("C) = ("F
-
32) x ,515
+
32
LIQUID WEIGHTS
Diesel Oil
=
1
US gallon
=
7.13 lbs
Fresh Water
=
1 US gallon
=
8.33 lbs
Gasoline
=
1
US gallon
=
6.1 lbs
Salt Water
=
1 US gallon
=
8.56 lbs
~ W E S T E R B E K E
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Engines & Generators
129
METRIC CONVERSIONS,
INCHES TO MILLIMETERS
MILLIMETERS TO INCHES
~~
Inches
mm
Inches mm mm Inches mm Inches
~
1
2
25.40
50.80
15
20
381.00
508.00
1
2 0.0787 20
0.5906
0.7874
3 76.20 25 635.00
3 0.1181 25 0.9843
4 101.60 30
762.00 4 0.1575 30 1.1811
5 127.00
35
889.00 5 0.1969 35 1.3780
10
2 5 4 . 0 0
. .
40
10
-
0.3937
.
40
.
__
10
MILLIMETERS
= 1
CENTIMETER,
100
CENTIMETERS
= 1
METER
= 39.37
INCHES (3.3 FEET)
INCHES TO METERS
METERS TO INCHES lnches
1
2
3
4
5
6
Meters
0.0254
0.0508
0.0762
0.1016
0.1270
0.1524
~~- lnches
-.
7
8
9
10
11
' 2
-
Meters
0.1778
0.2032
0.2286
0.2540
0.2794
Meters
0.1
0.2
0.3
0.4
0.5
0.6
- lnches
--
3.937
7.874
11.811
15.748
19.685
23.622
~
Meters
0.7
0.8
0.9
1.0
1.1
~~
1.2
~~~~ lnches
27.559
31.496
35.433
39.370
43.307
47.244~
TO
CONVERT
MErERS
TO CENTIMETERS,
MOVE
DECIMAL
POINT
TWO
PLACES
TO THE
RIGHT
~
~~
~.
Ib
1
2
3
4
5
YARDS TO METERS METERS TO YARDS
Yards
1
2
3
4
~~
5
Meters
-
0.91440
Yards
6
Meters
.....
5.48640
Meters
1
Yards
1.09361
Meters
~ . . ~
6
Yards
6.56168
1.82880 7
6.40080 2 2.18723 7
7.65529
2.74320 8
7.31 520 3 3.28084 8 8.74891
3.65760
9 8.22960 4 4.37445
9 9.84252
4.57200
~~
lo..^-
-
9.1 4400
~
.
MOVE DECIMAL POINT FOR HIGHER VALUES
-
5
5.46807
~
~.
10
..
10.93614
-
METERS = 6,561.68 YARDS
POUNDS
TO KILOGRAMS
kg
0.454
0.907
1.361
1.814
2.268
Ib
6
7
8
9
10
~
~.
kg
2.722
3.175
3.629
4.082
4.536 kg
KILOGRAMS
TO POUNDS
...
~~
Ib
kg
~ ~
1 2.205 6
Ib
13.228
2
3
4
5
4.409
6.614
8.81 8
11.023
7
8
9
10
15.432
17.637
19.842
22.046
Gallons
~~~
1
2
3
4
5
GALLONS TO LITERS
Liters
3.79
7.57
-
Gallons
10
20
Liters
37.86
75.71
11.36
15.14
30
40
113.57
151.42
18.93
50 189.28
Liters
1
2
LITERS TO
GALLONS
Gallons
0.26
Liters
60
Gallons
~.
15.66
0.53 90
23.77
5
10
1.32
2.64
120
150
31.32
39.62
20
5.28
180 47.54
Pints
1
2
3
4
5
~~ ~
PINTS
TO LITERS
Liters
0.47
Pints
6
.
Liters
2.84
~
0.95
1.42
1.89
2.37
7
8
9
10
3.31
3.79
4.26
4.73
Liters
1
2
3
4
5
LITERS TO PINTS
Pints
Liters
2.11
4.23
6.34
8.45
10.57
6
7
8
9
10
Pints
12.68
14.79
16.91
19.02
21.1 3
TEMPERATURE
32 40 5 0 6 0
70
75 85 95 105 1 4 0 175 212
"F
I I
I
I I I
I
I I
I I
0 5
I I I I I I I I I I
1 0 15 2 0 25 3 0 35 40 6 0 8 0 100
"C
p
I
Engines & Generators
130
I
SPECIAL TOOLS
CONNECTING ROD BUSHING
INSTALLER
Y47020
CRANKSHAFT GEAR
REMOVER (470
CRANKSHAFT PULLEY SOCKET
0
54MM
4 c r L . 4 2 ~ ~
CRANKSHAFT REAR OIL SEAL
INSTALLER
Y47019
63
CYLINDER LINER INSTALLER
Y47015
/
ADAPTER GAUGE
@
Q
VALVE STEM OIL SEAL
INSTALLER
X47014
CRANKSHAFT TAPER
BUSHING REMOVER
Y47017
COMPRESSION GAUGE
CYLINDER LINER REMOVER ANGLE
(47022
Y47021
CYLINDER LINER REMOVER
VALVE SPRING COMPRESSOR
NOTE:
Nun16ers in italic a n WESTERBEKE l>urt nunz6er.s. Contact your WESTERBEKE dealerfor additiorlul tools.
PISTON RING
COMPRESSOR
INDEX
AC Voltage Connections
. . . . . . . . . . . . . . . . . . .
InspectionIRepair
. . . . . . . . . . . . . . . . . . . . .
Alternator
CleaningResting
Disassembly
Testing
.
Instrument Panel Wiring
#44329
. . . . . . . . . . . . . . . . . . . . . . . .
Introduction
. . . . . . . . . . . . . . . . . . . . . . . . . . .
Lubricating System
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance
.
:
. . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . .
Angular Nut
&
Bolt Tightening
. . . . . . . . . . . . . .
Measurements
BE Generator
Compression
-
. . . . . . . . . . . . . . . . . . . . . . . . . . .
Metric Conversion data
Engine
. . . . . . . . . . . . . . . . . . . . .
Oil Cooler
Coolant Pump
. . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Flow Diagram
Cooler
.
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Pump
Cylinder Head Torque
. . . . . . . . . . . . . . . . . . . . .
Pump
-
Coolant
. . . . . . . . . . . . . . . . . . . . . . . . . . .
Diagram
-
Wiring
#47781
. . . . . . . . . . . . . . . . . . .
Pump
Diagram
-
Wiring
#47780
. . . . . . . . . . . . . . . . . . .
Pump
-
Fuel Injection
Engine Disassembly
Drive Belt
. . . . . . . . . . . . . . . . . . .
-
14
Pump
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pump
Electronic Governor
Crankshaft Bearings
-
Oil
.
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . .
Raw Water Pump
Engine Adjustments
Engine Assembly
55
.
RepairIInspection
. . . . . . . . . . . . . . . . . . . . . .
Camshaft
Connection Rod
47
. . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
........................
28
Cylinder Head Cover
Exhaust Manifold
. . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . .
Flywheel
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Crankshaft
Cylinder Head
Injection Nozzle
.
.
Injection Pump
Oilcooler
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OilPan
PistodConnecting Rod
Piston
. . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Liner
Flywheel
Idler Gear
:
. . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
.22.
Piston
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
.15,
Piston Pin
PushRod
Rocker
Arm
........
....................
26
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
21
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
21
Rocker
Arm
Tappet
Timing Gear Case
Valves
Valve Guide
Valve Seat
Water Pump
Engine Compression
Engine Troubleshooting (Index
89)
. . . .
Valve Spring
. . . . . . . . . . . . . . . . . . . . . . .
Specifications
-
170T6
. . . . . . . . . . . . . . . . . . . . .
108
Specifications
-
120N6
Engine Tuning
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Feed Pump
. . . . . . . . . . . . . . . . . . . . . . . . . .
Specifications
llOT6
59
Specifications
80N4
Fuel Section
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Specifications
.
BED
Generator
. . . . . . . . . . . . . . . . . . . . . . . . . . .
Generator Information
. . . . . . . . . . . . . . . . . . . . .
Specifications
.
BED
114
Specifications
-
55
BED
Generator Maintenance
. . . . . . . . . . . . . . . . . . . .
Specifications
.
BED
Glow Plug Test
Heat Exchanger
. . . . . . . . . . . . . . . . . . . . . . . . . . .
Starter Motor
Disassembly
. . . . . . . . . . . . . . . . . . . . . . . . .
. . .
:
Electrical Testing
Injection Pump
Injection Nozzle
. . . . . . . . . . . . . . . . . . . . . . .
Injection Timing
Inspection/Clearing
Parts
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tmubleshooting
. . . . . . . . . . . . . . . . . . . . . . . .
(
b
1
!
P W E S T E R B E K E
1
Engines & Generators
132
I
!
~
!
I
!
!
INDEX
Tachometer
Thermostat
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Turbocharger
Testing for Overhaul
. . . . . . . . . . . . . . . . . . . . . . . .
Valve Clearance Adjustment
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Voltage Regulator Adjustments
Timing
-
Injection
Torque Data
Wiring
.
-
1 1
1 Wiring Diagram #44780
Torque Specifications
. . . . . . . . . . . . . . . . . . . . . . .
Wiring Diagram #44781
. . . . . . . . . . . . . . . . . . .
Troubleshooting BE Generator
Wiring Diagram Internal
. . . . . . . . . . . . . .
Wiring Schematic #44780
. . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . .
Troubleshooting Electronic Governor
. . . . . . . . .
Wiring Schematic #44781
. . . . . . . . . . . . . . . . . . .
Troubleshooting Engine (Index 89)
. . . .
.4.
89
-
108
m W E S 7 E R B E K E
I
Enalnes
8
Generators
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