"( I. It II .., " ~*I- 1 1ft -t o q '" ~LD"'" SERVICE MANUAL 71 B-FOUR / 71 C-FOUR MARINE DIESEL ENGINES and 20.0KW-60Hz/16.0KW-50Hz BED 20.0KW-60Hz/16.0KW-50Hz BEDA MARINE DIESEL GENERATORS SINGLE AND THREE PHASE PUBLICATION NO. 43317 FIRST EDITION I FEBRUARY 1998 l"'" 'WESTERBEKE j .. WESTERBEKE CORPORATION' MYLES STANDISH INDUSTRIAL PARK 150 JOHN HANCOCK ROAD' TAUNTON MA 02780-7319' TEL. 1-508-823-7677 FAX 1-508-884-9688' WEBSITE: Www.WESTERBEKECOM --- ..
CALIFORNIA PROPOSITION 65 WARNING Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm. A WARNING Exhaust gasses contain Carbon Monoxide, an odorless and colorless gas. Carbon Monoxide is poisonous and can cause unconsciousness and death.
SAFETY INSTRUCTIONS INTRODUCTION PREVENT BURNS - FIRE Read this safety manual carefuUy. Most accidents are caused by failure to foUow fundamental rules and precautions. Know when dangerous conditions exist and toke the necessary precautions to protect yourself, your personnel, and your machinery. The foUowing safety instructions are in compliance with the American Boat and Yacht Council (ABYC) standards. A WARNING: Fire can cause Injury • Prevent flash fires.
SAFETY INSTRUCTIONS ACCIDENTAL STARTING TOXIC EXHAUST GASES A WARNING: Accidental starting can cause Injury A WARNING: carbon monoxide (CO) Is a deadly gas! 01 death! • Ensure that the exhaust system is adequate to expel gases discharged from the engine. Check the exhaust system regularly for leaks and make sure the exhaust manifolds are securely attached and no warping exists. Pay close attention to the manifold, water injection elbow, and exhaust pipe nipple.
SAFETY INSTRUCTIONS ABYC, NFPA AND USCG PUBLICATIONS FOR INSTALLING DIESEL ENGINES • 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. Read the following ABYC, NFPA and USCG publications for safety codes and standards.
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.
TABLE OF CONTENTS DC Wiring Diagram (engine) .................................... .48 DC Wiring Schematic (engine) ................................ .49 Generator Information ..............................................50 BE Generator .............................................................51 Generator AC Voltage Connections .. .......................52 Voltage Regulator Adjustments ...............................54 Internal Wiring Schematics ......................................
INTRODUCTION CUSTOMER IDENTIFICATION CARD PRODUCT SOFTWARE Product software (tech data, parts lists, manuals, brochures and catalogs) provided from sources other than WESTERBEKE are not within WESTERBEKE'S control. /..-v-IWES I ERBEKE I .
TESTING FOR OVERHAUL HOW TO DETERMINE ENGINE OVERHAUL PERIOD Precautions for Disassembly and Reassembly Cause of Low Compression When servicing an engine, keep in mind the following precautions. 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.
ENGINE TROUBLESHOOTING Note: The engine s electrical system is protected by a 20ampere manual reset circuit breaker. The preheat solenoid is mounted on the same bracket. The following troubleshooting table describes certain problems relating to engine service, the probable causes of these problems, and the recommendations to overcome these problems. PROBLEM HARD STARTING LOW OUTPUT VERIFICATION/REMEDY PROBABLE CAUSE LOW CRANKING SPEED 1. Engine oil viscosity too high. 2. Run-down battery. 3.
ENGINE TROUBLESHOOTING LOW OUTPUT (cDnt.) EXCESSIVE OIL CONSUMPTION VERIFICATION/REMEDY PROBABLE CAUSE PROBLEM OVERHEATING 1. Low coolant level. 2. Loose V-belt. 3. Incorrect injection timing. 4. Low engine oil level. 1. 2. 3. 6. OIL LEAKAGE 1. Defective oil seals. 2. Broken gear case gasket. 3. Loose gear case attaching bolts. 4. Loose drain plug. 5. Loose oil pipe connector. 6. Broken rocker cover gasket. 7. Loose rocker cover attaching bolts. 1. Replace oil seals. 2. Replace gasket. 3.
ENGINE TROUBLESHOOTING PROBLEM SMOKY EXHAUST (cont.) ABNORMAL SOUND OR NOISE ROUGH OPERATION PROBABLE CAUSE VERIFICATION/REMEDY WHITISH OR PURPLISH (cont.) d. Worn valve stem and valve guide. e. Low engine oil viscosity. f. Excessive oil pressure. 3. Injection timing is too late. 4. Insufficient compression. d. Replace. e. Replace. f. 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.
ENGINE TROUBLESHOOTING PROBLEM KNOCKING PROBABLE CAUSE VERIFICATION/REMEDY ENGINE KNOCKS WITHOUT MUCH SMOKE 1. Main engine troubles. a. Overheated cylinder. a. See OVERHEATING; LOW OUTPUT. h. Carbon deposits in cylinder. 2. Too early injection timing. 3. Too high injection pressure. 4. Improper fuel. h. Clean. 2. Correct. 3. Correct. 4. Replace with proper fuel. KNOCKING WITH DARK SMOKE 1. Poor compression. 1. See LOW COMPRESSION; HARD STARTING. 2. Injection pump malfunctioning. a. Worn plunger.
ENGINE DISASSEMBLY GENERATOR \ 3. Remove engine heat exchanger and engine cooler. If possible, leave one end of each hose connection attached to the part being r e m o v e d . ' 4. Remove starter motor. Disconnect the AC wiring, unplug the DC wiring harness at the control panel and remove the speed sensor from the bellhousing. Carefully support and then unbolt the generator back end from the engine. For generator maintenance and service, refer to the GENERATOR SECTION of this manual. S.
12. Remove the thennostat housing and the thennostat. Leave temperature sending unit in place. 13. Remove the coolant circulating pump. 14. Remove the air intake silencer. 15. Remove all the high pressure injector lines from the injection pump to the injectors. Leave the two upper line clamps in place. NOTE: Cap the ends of the lines and the connections at the injection pump and at the injectors to prevent entry of foreign material. 16. Remove the intake manifold. 17.
ENGINE DISASSEMBLY 21. Remove the injection pump. Scribe the mating marks on the pump body flange and the timing gear case k:l before removing. I~ '. . I . I REMOVING THE· CRANKSHAFT PULLEY i . / SCRIBED { MATING MARKS .' II' !. I .... ~ ilNJECTION (PUMP . NOTE: Remove the crankshaft pulley bolt with the aid ofa a. Remove the cover and the lock nuts. 38 mm socket and draw the pulley off the front crankshaft. b. Loosen the two injection pump hold down nuts. Do not remove entirely.
ENGINE 'DISASSEMBLY 'INJECTION 27. Thrn the engine over and remove the oil pan. 28. Loosen the set screw, then remove the oil pump assembly. 29. Remove the camshaft carefully. Insure that all the pushrod tappets are seated into the engine block prior to attempting to remove the camshaft from the block. 30. Remove the timing gear ~~ from the front of the engine block. Discard the old gasket. / llOLER GEAR 'J TIMING ~EARS OIL PAN: ! ~ REMOVING THE INJECTION PUMP GEAR \.'.~ .. ~~..: .... •• 0 .
ENGINE DISASSEMBLY 31. Remove the rear oil seal. 32. Remove the connecting rod bearing caps. 33. Remove the piston and connecting rod assemblies from the top of the cylinder block. 34. Remove the main bearing caps. 38. Disassemble the piston assembly. a. Using the piston ring remover, remove the piston rings. b. Remove the wrist pin snap rings. 'c. Using a nylon drift, drive the wrist pin from the piston and rod. NOTE: Mark the bearing caps to insure properr~~sembly. 35. Remove the crankshaft.
ENGINE INSPECTION CYLINDER HEAD 1. Visual Inspection. Check the cylinder head for cracks or any other damage and, if necessary, repair or replace it. 2. Distortion Inspection. Measure the cylinder head surface distortion with a straight edge and the thickness gauge. Take 6 measuring positions as shown in the diagram. IT the distortion exceeds permissible limit, replace the cylinder head. (The head has no allowance for planing and must be replaced, not renewed.
ENGINE INSPECTION 2. Dimension L. Check the protruding length of the valve stem, if it exceeds the specification, correct it as follows: Dimension L Standard 71 Bn1 C 48.0 mm (1.890 in) a. When dimension L becomes large 0 - 0.5 mm (00.0202 in) from the standard, it is possible to use both the valve and the cylinder head. g.
ENGINE INSPECTION VALVE SPRING VALVE GUIDE 1. Free Length Check. Measure the free length of the valve spring and if free length is less than the limit, replace it. 1. Inspecting clearance between valve and guide. Set a dial gauge with a magnet and check the clearance between the valve stem and the valve guide. If the clearance is more than the limit, replace the valve or valve guide. Valve Spring Limit 71 B Inner spring Outer spring 71C Inner spring Outer spring 42 mm (1.654 in) 43.6 mm (2.083 in) 43.
ENGINE INSPECTION ROCKER ARM TAPPET 1. Visual Inspection. Check each component part of rocker arm assembly for cracks or other damage. Check if the oil passages of the rocker arm and shaft are clogging and, if necessary, repair or replace it. 1. Visual inspection. Check the tappet for cracks and "AT RETAINING RING....... ~-JAMNUT BRACKET _ _ _ ~ other damage and, if damaged replace the tappet.
ENGINE INSPECTION CYLINDER LINER PISTON AND PISTON RING 1. Wear Inspection. Measure the liner bore at three positions of upper, middle and lower portions with a cylinder gauge in X-X and Y-Y directions as shown. If wearing exceeds the limit, replace the liner. Cylinder Liner Bore 71 Bn1 C 88.925 - 88.950 mm (3.5010 - 3.5020 in) Wear Limit 0.20 mm (0.008 in) 1. Visual Inspection Check the sliding surface and ring groove of the piston for wear, scratches or any other damage. a.
ENGINE INSPECTION ~SMALL END BUSHING PISTON PIN OIL HOLE PISTON PIN LARGEEND-- : CLEARANCE 0.0005 - 0.0015 mm (0.012 - 0.039 in) OIL HOLE BUSHING~,~~~=~!=~r~~~ 4. Small end bushing replacement. Using a press, press out the bushing. Align the oil passages of the connecting rod and the small end bushing; press in the bushing to the connecting rod bore. After a small end bushing has been replaced, ream the bushing bore to obtain the specified clearance between the small end bushing and the piston pin.
ENGINE INSPECTION CRANKSHAFT 5. Inspecting piston ring end gap. Position the piston ring into the bottom of the cylinder liner. Measure the piston ring end gap and, if it exceeds the limit, replace the ring. 1. Visual Inspection. Check the crankshaft for cracks or other damage. If cracking is suspected, thoroughly clean the crankshaft and perform a color test on the shaft, or run a candle flame over the crankshaft and look for oil seepage from cracks. If any cracks are detec~, repl~ce the crankshaft.
ENGINE INSPECTION For the measurement on both the crank pin and the main journal, measure them at vertical and horizontal directions on front and rear places. b, When refinishing the crankshaft, it's finish to Rl mm as shown in the diagram. c, Refer to the chart for refinishing dimensions of the crankshaft where an undersize bearing is used. 8, I Oil Clearance ~1-=-3.71~.~3.~gg~m~m~e!IJ==~~~~~~ 71 B Standard: 0.059 - 0.090 mm (0.0020 - 0.0040 in) Limit: 0.12 mm (0.005 in) 71C Standard: 0.040 - 0.
ENGINE INSPECTION 4. Inspecting camshaft oil clearance. Check the oil clearance of the camshaft by measuring the camshaft bore in the cylinder block and camshaft journal diameter. If the oil clearance is more than the limit, replace the camshaft or cylinder block. 71 ani C Oil clearance limit: 0.145 mm (0.0057 in) 5. Inspecting camshaft runout. Check the camshaft runout and, if it exceeds the limit, replace the camshaft. 71 ani C Runout limit: 0.08 mm (0.003 in) 6. Camshaft front bearing replacement.
ENGINE INSPECTION PUSH ROD REAR OIL SEAL 1. Visual Inspection. Check the push rod for damage on 1. Inspecting oil seal. Check the oil seal lip for wear or other damage and, if necessary, replace it. 2. Oil seal replacement. Upon inspection, finding the existing seal worn or frayed, pick the old seal halves out of their grooves and thoroughly clean the half-housings. a.
ENGINE REASSEMBLY Take the following precautions: ENGINE ASSEMBLY • Be careful no.t to. mix bo.lts and nuts. Metric and S.A.E. bo.lts are used o.n vario.us engine assemblies. • During assembly, recheck clearances and insure that parts are being assembled in their pro.per o.rder and facing in the co.rrect directio.n in relatio.n to. the engine blo.ck, such as, pisto.ns, pisto.n rings, bearings and bearing caps. • Apply lubricating o.il to. mo.ving parts during assembly. Insure that mo.
ENGINE REASSEMBLY 4. Install the crankshaft. NOTE: Do not apply oil to the backsides of the main bearing shells. PLACE A HEAVY HAMMER AND GENTLY PRESS DOWN WITH THE FORCE OF YOUR HAND. THE ENTIRE SURFACE SHOULD BE COATED WITH FRESH LUBE OIL a. Fit the main bearings on the cylinder block and the bearing caps respectively. Check that the oil ways align perfectly with those in the block. h. Fit the thrustwashers to the cylinder block so that the oil grooves on thrustwashers face to crankshaft side. c.
ENGINE REASSEMBLY h. Install the oil deflector on the crankshaft. 11. Install the timing gear cover. a. Install the bearing housing cover on the timing gear cover. b. Install the injection pump drive gear cover on the timing gear cover. c. Install the timing gear cover and tighten the timing gear cover attaching nuts and bolts after the crankshaft pulley has been installed temporarily to center the seal. Timing Gear Cover Tightening Torque 71 an1C 1.6 - 2.4 m-kg (11.6 -17.4 ft-lb) 10. Install each gear.
ENGINE REASSEMBLY 17. Install the flywheel. Install the flywheel onto the rear end of the crankshaft. 18. Install the tabwasher plate and the flywheel bolts. Torque the bolts. Bend the tabwasher to lock the bolts in place. Tightening Torque ,71Bn1C 15.5-16.3 mkg (112 - 118ft-lh) 25. Tighten the cylinder head bolts. Tighten the cylinder head bolts evenly in the sequence shown. Tightening Torque 71 B 11.8 - 12.5 m-kg (85 - 90 ft-lh) 71 C 11.0 -11.
ENGINE REASSEMBLY 28. Install 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 sendor and reconnect their wires. c. Install a new thermostat and gasket (the old thermostat can become a spare). When installing the new thermostat and gasket, apply a thin coat of sealant to both sides of the gasket. d.
ENGINE REASSEMBLY 43. Install the alternator and drive belt. A CAUTION: Connect the aiternator PfDptlr/y. Should the polarity be revelSlld, a powerful current would flow from thB battery into the alternator, damaging the diodes and wiring harness. a. Install the alternator support bolt through the alternator leg (underside) into the engine casting. 50. Install new hose connections and clamps for COOling system. 51. Marine Engine. Reinstall the marine transmission and fill with ATF Dextron ill.
EXHAUST MANIFOLD I HEAT EXCHANGER EXHAUST MANIFOLD Check the manifold pressure cap. Open the valve by pulling it and make sure it closes when released. Make certain the upper and lower seals are in good condition. If any doubt, replace the cap. The exhaust manifold, which was disassembled from the cylinder head, should be inspected before reassembly. 1. Remove the exhaust elbows from the lower surface of the manifold. Clean and inspect for cracks and defects. Replace as needed. 2.
FUEL INJECTION PUMP SPEED ADJUSTMENT (PROPULSION ENGINE) The fuel injection pump is the most important component of the diesel engine and, therefore, calls for the utmost caution in handling. Speed (hertz) and timing are the only adjustments the service dealer can perform on the injection pump. Other types of adjustments or repairs must be performed by a qualified injection service shop. Early Models without Electronic Governing 3. Inspecting and adjusting the injection pump timing. a.
FUEL INJECTION PUMP/FUEL LIFT PUMP FUEL LIFT PUMP (Early Models) 4. Turn the crankshaft in the direction of normal rotation until the No.1 piston is at IDe by referencing the indicator on the valve stem. The Fuel Lift pump should be cleaned and repainted. Install a new filter as illustrated and clean the ground wire end terminal. a. The measuring device indicator needle should move 1.00 mm from the zero setting. Beginning of Static Injection 71 an1C Cam lift 1.00 mm (0.
FUEL INJECTORS REMOVING THE INJECTORS. Start to Injection 1. Disconnect the high pressure lines from the injectors and loosen the lines at their attachment to the injection pump and move them out of the way of the injectors. Avoid bending the lines. 2. Remove the fuel return line in its entirety from the top of the injectors. Take care not to lose the two sealing washers and banjo bolt that attaches the fuel return line to each injector.
FUEL INJECTORS INSPECTING SPRAY PATTERN ASSEMBLING 1. Operate the hand lever of the nozzle tester at intervals of one stroke per second to check if the fuel is injected correctly in its axial direction. A nozzle is defective if it injects fuel in an oblique direction or in several separate strips. Also, a spray in the fonn of particles indicates a defect. These defects may sometimes be caused by clogging with dust and, therefore, all parts should be carefully cleaned before reassembly.
GLOW PLUGS DESCRIPTION Re-install the plugs in 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. The glow plugs are wired through the preheat soleniod. When PREHEAT is pressed at the control panel this solenoid should "click" on and the glow plug should begin to get hot.
ENGINE ADJUSTMENTS VALVE CLEARANCE ADJUSTMENT 1. Warm the engine to normal operating temperature. 2. Pull off the air breather pipe from the rocker cover, and take off the rocker cover bolts and the rocker cover to expose the rocker shaft and valve assembly. 3. Remove the glow plugs from each of the cylinders to enable the engine to be easily rotated by hand to position each cylinder for valve adjustment.
ENGINE ADJUSTMENTS If a weak cylinder is flanked by healthy cylinder, the problem is either valve or piston related. Check the valve clearances for the weak cylinder, adjust as needed and test again. If the cylinder is still low, apply a small amount of oil into the cylinder to seal the rings and repeat the test. If compression comes up - the rings are faulty. Abnonnally high readings on all cylinders indicates heavy carbon accumulations, a condition that might be accompanied by high pressures and noise.
COOLANT CIRCULATING PUMP DISASSEMBLY '\ APPLYATHINCOATOFOIL , TO SPRING LOADED SEAL 1. Remove the PUlllP pulley boss by using a support and press. 2. Remove the bearing shaft from the impeller and bearing housing by using a support block and press. 3. Remove the snap ring with snap ring pliers and press out the water pump shaft from the bearings. INSPECTION Inspect the shaft, bearings and impeller. Look for cracks and damage. Check the housing gasket and inspect the rear seals an,d small end gaskets.
LUBRICATING OIL PUMP INSPECTION 1. Visually check the disassembled parts and replace faulty parts. Check the sliding surface of pump cover. with special care and replace the cover if the surface has steps or excessive streaks. (Minor steps streaks may be repaired by rubbing them with a compound on a surface plate.) 4. Clearance between outer rotor and pump body. Check the clearance between the outer rotor and pump body with a feeler gauge. If the clearance exceeds the limit, replace the rotor or pump body.
OIL PRESSURE SWITCH/OIL PRESSURE OIL PRESSURE SWITCH/SENDER OIL PRESSURE When performing an engine overhaul, replace the oil pressure switch and the oil pressure sender. When installing the new parts apply a teflon sealant to the threaded ends being careful not to close off the oil hole in the sender. Oil Pressure Sender and Switch Torque 71 ani C To test the oil pressure, remove the oil pressure sender, then install a mechanical oil pressure gauge in it's place.
RAW WATER PUMP PUMP OVERHAUL 6. Inspect all parts and replace those showing wear or erosion. \ Disassembly L The pump, as removed from the engine, will have hose attachment nipples threaded into its inlet and outlet port. They may be left in place or removed if they interfere with the pump disassembly. Note the port location and positioning if removed. 1. Loosen the set screw with an allen wrench and remove the water pump pulley from the shaft 2.
71 STARTER MOTOR DESCRIPTION No-Load Test The starter can be roughly divided into the following sections: • A motor section which generates a drive power. • An overrunning clutch section which transmits an armature torque, preventing motor overrun after starting. 1. Connect the ammeter, voltmeter, and battery to the starter as illustrated. 2. When the switch is closed, the pinion must protrude and the starter must run smoothly (at 3000 rpm or more).
71 STARTER MOTOR 4. Return test:. With a battery connected to the solenoid terminal M (-) and to the starter body, manually pull out the pinion fully. The pinion must return to its original position when released from holding by hand. IAnRACTION TEST :BATTERY. 3. Holding test. With a battery connected to the solenoid terminal S (+) and to the starter body, manually pullout the pinion fully, The pinion must remain at that position even when released from holding with your hand.
STARTER MOTOR STARTER INSPECTION Solenoid Inspect the solenoid for continuity between tenninals Sand M and between tenninals S and body. No continuity should be found between Sand M. Continuity should be found between S and the body and M and the body. Brush and Brush Holder Inspection 1. Check the brushes. If worn out beyond the service limit, replace the brushes . .Brush Height Standard 17 mm (0.669 in) Limii 6 mm (0.236 in) CONTINUITY CHECK BRUSHES Inspecting The Armature NEW 1.
il STARTER MOTOR Field Coil Inspection 2. Greasing. Whenever the starter has been overhauled, apply grease to the following parts: .' 1. Check for insulation between one end (brush) of the coil and yoke. a. Armature shaft gear and reduction gear. 2. Check for continuity between both ends (brushes) of the coil h. All bearings. 3. Check the poles and coil for tightness. d. Bearing sleeves. c. Bearing shaft washers and snap rings. e. Pinion. f. Sliding portion of lever.
TACHOMETER TACHOMETER/HOURMETER Tachometer Inaccurate a. With a hand-held tach on the front of the crankshaft pulley retaining nut or with a strobe-type tach, read the front crankshaft pulley rpm. Set the engine with a hand or strobe tach at 1S00-1800 rpm. The tachometerlhourmeter used in propulsion engine instrument panels contains two separate electrical circuits with a common ground. One circuit operates the hourmeter and the other the tachometer.
ALTERNATOR TESTING 1. Start the Engin~ DESCRIPTION 2. After a few minutes of running measure the starting battery voltage at the battery terminals using a multi-meter set on DC volts. The voltage should be increasing toward 14 volts. If it is, your alternator is working. 3. Turn to step 5 on the next page. The charging system consists of an alternator with a voltage regulator, an engine DC wiring harness, a mounted DC cir- , cuit breaker and a battery with connecting cables.
ALTERNATOR TESTING e. Now check the voltage between the alternator output tenninal (B+) and ground. If the circuit is good, the voltage at the alternator should be the same as the battery, or if an isolator is in the circuit the alternator voltage will be zero. If not, a problem exists in the circuit between the alternator and the battery. Check all the connections -look for an opening in the charging circuit. Alternator is Working 5. Check the voltage of the service battery.
PROPULSION ENGINE WIRING DIAGRAM #039144 "0 It D tlof ,,111: r~' I _..I''~ MOO£UJ I 0 ,.------ ,:~: I~ I I +.rLcfl ~"'=" o MIW!l. ;; NOTE ,: An on-off switch should be installed in this circuit to disconnect the starter from the battery in an emergency and when leaving the boat. Twelve volt diesel engine starters typically draw 200 to 300 amps when cranking.
PROPULSION ENGINE WIRING SCHEMATIC #039144 + nAn II YOC 14L. r-' ~-------4I~'-I~-----'~M~-------------+ I I ""------------ UFT ~_+~4_----_+__{P -----, 'UN' FUlL '_I:I .--+-+--+----........~·V '.!.IE!! 0.'. SEIDEl . ... .A'•n ADMIRAL PANEL 'FACIIOMETEI n. c [J ' ALARM "., CAPTAIN PANEL TO II @pRfSIOI I IE 72 AMP 114 T. 8 @ UN I yfRSAL PROPULS ION PRESIOIIIE 51 OPTIONAL Wll• • M IIPI' ALTERNAIORS® .i,''' ',.....,cIY.., WT'~t;!J'T"OUD • ,wn_, ' ....
GENERATOR INFORMATION USE OF ELECTRIC MOTORS Generator Frequency Adjustment 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 start, under similar circumstances, than other types.
THE BE GENERATOR SINGLE AND THREE PHASE DESCRIPTION CIRCUIT BREAKER 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.
GENERATOR AC VOLTAGE CONNECTIONS DESCRIPTION .The regulator is equipped with seven numbered terminals (0 to 6) and their related brass jumpers. The illustrations show connection points and jumpers for the 3 phase configuration of the generator. The sensing leads connect between pin #1 and pin #2 on the AC terminal block and connection #2 and #0 on the voltage regulator board.
GENERATOR Ae VOLTAGE CONNECTIONS· AC VOLTAGE CONNECTIONS Generator Frequency ,NOTE: The frame ground wire (white/green) must be prop· erly positioned when changing the AC output configuration of the AC terminal block. For making connections to the AC terminal block, use terminal ends for 1/4 inch studs that will accept multi strand copper wire sized for the amperage rating from the hot lead connection. The frame ground wire is white or white with a green strip.
VOLTAGE REGULATOR ADJUSTMENTS Description .Amp-Hertz The voltage regulator is an advanced design which ensures optimum AC alternator performance. It is equipped with complete protection circuitry to guard against operating conditions that could be detrimental to the AC alternator. These two adjustments are used in conjunction with 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.
INTERNAL WIRING SCHEMATICS SINGLE PHASE r------------, EXCITER STATOR RED r-----~----------, I I I I I I I I I EXCITER ROTOR FIELD RED 1-------1 I~: ROTOR I I i'M . : II I I _ I I I I I I I STATOR, I RED RED I I AUX ® ® U1 l.. _ _ _ _ _ ~------~---J ________ J l.._ W2 REGULATOR W ::> -' CD RED :::g ..J W' >- BLACK o ~ ~~: ~ i ~ . ~ V1 GREEN RED Hertz Amp stab BLUE Voll c..
BE TROUBLESHOOTING NOTE: AC GENERATOR TROUBLESHOOTING MUST BE PERFORMED WITH ENGINE OPERATING AT 60 BER1Z. PROBABLE CAUSE FAULT No AG voltage output at no load. 1. Short or open in the main stator winding. 2. Shorted pozi-resistor on exciter rotor. 3. Four or more shorted or open diodes on exciter rotor. 4. Short or open in exciter stator winding. 5. Short or open in rotating field winding. Flesidual voltage produced at no load 15 - 20 volts AG. 1. Blown 6 AMP buse fuse auxiliary circuit feed to AVR.
ELECTRONIC GOVERNOR ELECTRONIC GOVERNING SYSTEM The system is composed of three basic components: 1. Controller - Mounted inside the instrument panel box. 2. Sensor - Installed on the generator stator housing 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. • SPEEDm Controller Adjustments GAIN i\J 1. Speed. - This adjustment is used to raise or lower engine speed to the desired hertz. 2.
TROUBLESHOOTING THE ELECTRONIC 'GOVERNOR Problem System appears dead (Engine runs at idle.) Probable cause VerificationJR_edy 1. Low battery voltage at controller. 1. Check wiring for cause. Check battery 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 should be 2.5 volts or greater. 4. Check Actuator - depress PREHEAT and check for battery voltage between negative black lead at terminal block. a.
SHORE POWER TRANSFER SWITCH 120 VOLT/60 HElm THREE WIRE CONFIGURATION SHORE POWER CONNECTIONS (60 HERR) Generator I N G1 '"G2 • Notice the repositioning of the white wire ground load on the terminal block to the generator case. l' NOTE: Diagram shows connections for a two .. wire. 120-Volt system. For a three-wlr. system t 1<--__ ' "_58 dotted lines tor the other hot leg. I I 1'..... - - " L-----t
GENERATOR WIRING DIAGRAM #039422 "'LT[RNATOR 51 ... LIFT PUMP II" 'I~ pup PUR ~" [l<'---'" Pu" -----l----, .""L ~ 0,\ D-~) .....ro/PUR ';v ""~ FUEL SOLENOID WATER TEMP. SENDER ~ .i'" SPEED ACTUATOR ..-----'~ GLOWPLUGS ~0 ~D "BAT~RY SWITCH ~ ~ J ·".ED -".ED "OPUIVREa NOTE 2: ~--~--~-----JO~ill~~~~ ~~ ,\..2 I ; STAR!ER " ~14.BAIIEB'l" " ~~ .. z " ...'" OIL PRESsURE SW. ·s· "Q~-..- ~ GROUND TO BLOCI( "'ULU OIL PRESS."~ SENDER ...- ,010A C.B• '.12.£0 .,....
GENERATOR WIRING SCHEMATIC #039422 + 12VDC r -1 BATTERY : START SOL. : SWITCH L _, STARTER +-__________..;.r-1----I--....' _ _ _- i M )..----4 L.. ___ ..I PREHEAT SOL. , ,, GLOWPLUGS r----- ... ,, ,, L.. ____ J .r ' '20A ,:L . ,ie.B. _J START SWITCH r----j 0 -1 STOP iSWITCI:\ K LIFTPUMP O.P. SW. -, P W.T. SW. FUEL SOl... K I.
SPECIFICATIONS WESTERBEKE 20 KW BEDA GENERATOR SPECIFICATIONS Engine Type FUEl SYSTEM Diesel, four-cycle, four-cylinder, fresh water-cooled Vertical, in-line overhead valve mechanism (33 hp at 1800 rpm maximum). General Open flow, self priming - 1 bleed point Fuel No.2 diesel oil (cetane rating of 45 or higher) Aspiration Naturally aspirated.
SPECIFICATIONS WESTERBEKE 20 KW BEDA GENERATOR ELECTRICAL SYSTEM Starting Battery 12-Volt, (-) negative ground Battery Capacity 400 - 600 Cold Cranking Amps (CCA) DC Charging Altemator 51 Amp rated, belt-driven Starter 12-Volt, Reduction Gear, 3 KW Starting Aid Glow plugs, sheathed type DC No-Load Current ± 2% of rated Amps DC Cranking Current 250 - 300 Amps (engine cold) AC GENERATOR (3 Phase) AC GENERATOR (SINGLE PHASE) General - Single Phase Brushless, four-pole, revolving field Sealed lu
SERVICE DATA I TOLERANCES AND LIMITS 20 KW 60Hz Generator/16KW 50 Hz Generator 71 I-FOUR 71 C-FOUR VALVE TIMING Intake Valve Opens BTDC ClosesABDC Exhaust Valve Opens BBDC ClosesATDC Compression Pressure Standard Limit Limit Differences Between Cylinders Valve Clearance (cold) Intake Exhaust 17" 47" 51 0 130 30.0 kglcm2(4271b/in2) 200 rpm 27.0 kglcm2 (3841b/in2) 200 rpm 17" 47" 51 0 130 30.0 kglcm2 (427 Ib/in2) 200 rpm 27.0 kglcm2 (3841b/in2) 200 rpm 3.0 kglcm2 (431b/in2) 3.0 kglcm2(431blin2) 0.3 (0.
SERVICE DATA I TOLERANCES AND LIMITS 20 KW 60Hz Generator/16KW 50 Hz Generator 71 I-FOUR 71 C-FOUR VALVE GUIDE, VALVE AND VALVE SPRINGS Valve Face Angle (Intake) (Exhaust) Rear Oil Seal Insert Limit Valve Spring Squareness Limit (Inner) (Outer) Free length of Valve Spring (Inner) Standard (Outer) Valve Spring Constant Limit Standard Limit (Inner) (Outer) 45° 30" 30" 6.35 - 7.62 (0.250 - 0.300) 1.25 (0.049) 1.37 (0.054) 43.6 (1.717) 42.0 (1.654) 55.7 (2.193) 52.9 (2.083) 2.02kglmm (1131b/in) 2.
SERVICE DATA I TOLERANCES AND LIMITS 20 KW 60Hz Generator/16KW 50 Hz Generator 71 B-FOUR 71 C-FOUR CYLINDER BLOCK, PISTON AND PISTON PIN Piston Diameter (Diameter measured at 9(f to pin mm (in) mm (in) 88.872 - 88.898( 3.499 - 3.5(0) 88.880 ± 0.013 (3.4989 ± 0.(005) 0.044 - 0.070 (0.0017 - 0.(028) 0.054 - 0.080 (0.0021 - 0.(031) 2.433 - 2.543 (0.096 - 0.1(0) 2.423 - 2.443 (0.095 - 0.096) 4.793 - 4.813 (0.1887 - 0.1895) 2.363 - 2.383 (0.093 - 0.094) 2.363 - 2.383 (0.093 - 0.094) 4.743 - 4.763 (0.
SERVICE DATA I TOLERANCES AND LIMITS· 20 KW 60Hz Generator/16KW 50 Hz Generator 71 I-FOUR 71 C-FOUR ROCKER ARM AND ROCKER ARM SHAFT Bore in Rocker Arm Rocker Arm Shaft Diameter Oearance in Rocker Arm Standard Limit mm(in) 15.876 - 15.896 (0.625 - 0.626) 15.835 - 15.860 (0.623 - 0.624) 0.016 - 0.061 (0.0006 - 0.0024) 0.07 (0.003) TAPPET Outer Diameter Bore in Cylinder Block Oearance in Cylinder Block Standard Limit mm(in) 14.224 - 14.249 (0.560 - 0.561) 14.288 - 14.319 (0.563 - 0.564) 0.039 - 0.095 (0.
TORQUE SPECIFICATIONS 20 KW 60Hz Generator/16KW 50 Hz Generator 71 B.
71 Bn1 C ENGINE SPECIFICATIONS ENGINE SPECIFICATIONS Engine Type FUEL SYSTEM Diesel, four-cycle, three-cylinder, fresh water-cooled, vertical in-line overhead valve mechanism (71 Hp at 3600 rpm maximum). General Open flow, self bleeding - 1 bleed point Fuel No.
STANDARD HARDWARE TORQUES NOTE: Unless stated otherwise for a specific assembly, use the following torque values when tightening standard hardware. Grade 4 6mm bolt head/nut Grade 7T, 8T and 8.8 Pitch Ib-II kg-m 1 2.9-5.1 0.4-0.7 6mm bolt head/nut Pitch Ib-II kg-m 1 5.S-S.7 0.S-1.2 1.25 14.5-21.7 2.0-3.0 Smm bolt head/nut 1.25 7.2-11.6 1.0-1.6 Smm bolt head/nut 10mm bolt head/nut 1.25 13.7-22.4 1.9-3.1 10mm bolt head/nut 1.25 2S.9-39.S 4.0-5.5 10mm bolt head/nut 1.5 13.0-21.
METRIC CONVERSIONS INCHES TO MILLIMETERS MILLIMETERS TO INCHES mm mm Inches mm Inches mm Inches 381.00 1 1 25.40 15 0.0394 15 0.5906 2 508.00 2 50.80 20 0.0787 20 0.7874 635.00 3 76.20 25 3 0.1181 25 0.9843 4 101.60 762.00 4 0.1575 1.1811 30 30 5 127.00 889.00 0.1969 1.3780 35 5 35 10 254.00 40 1016.00 10 0.3937 40 1.5748 10 MILLIMETERS =1 CENTIMETER, 100 CENTIMETERS =1 METER =39.37 INCHES (3.3 FEET) Inches INCHES TO METERS METERS TO INCHES Meters Inches Meters Meters Inches Meters Inches 0.1778 0.1 1 0.
INDEX AC Voltage Connections .................52, 53 Alternator Inspection ...................... 047 Alternator Testing ........................ 046 Alternator Troubleshooting ................. 046 Block - Cylinder .......................... 16 Camshaft ................................20 Circuit Breaker - Generator ..................51 Connecting Rod .......................... 18 Coolant Circulating pump .................. .37 Crankshaft .............................. .19 Crankshaft Bearing Assembly ......
INDEX Spindle - Idler Gear ........................21 Starter Motor ............................ .41 Starter Motor - Solenoid ................... .41 Starter Motor - Adjustment and Repair ........ .41 Switch - Oil Pressure ....................... 39 Tappet - Inspection ........................ 16 Testing for Overhaul ........................3 Thermostat Assembly ...................... 27 Timing Gear Case ......................... 11 Timing Cover ............................ 22 Timing Gear ..................
WESTERBEKE WESTERBEKE CORPORATION -AVON INDUSTRIAL PARK AVON.
