-( I. It Ii ~ " ~ ~ ~ . 1ft ..,. ~ o q ~LD"" SERVICE MANUAL FOR THE 82B FOUR MARINE DIESEL ENGINE AND THE 25KW-60Hz BED /20KW-50Hz BED MARINE DIESEL GENERATORS SINGLE PHASE & THREE PHASE PUBLICATION NO.
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 carefully. Most accidents are caused byfailure to follow fundamental rules and precautions. Know when dangerous conditions exist and take the necessary precautions to protect yourself, your personne~ and your machinery. The following safety instructions are in compliance with the American Boat and Yacht Council (ABYC) standards.
SAFETY INSTRUCTIONS TOXIC EXHAUST GASES ACCIDENTAL STARTING A WARNING: Accidental starting can cause injury A WARNING: carbon monoxide (CO) is a deadly gas! or death! • Disconnect the battery cables before servicing the engine! generator. Remove the negative lead first and reconnect it last. • Make certain all personnel are clear of the engine before starting. • Make certain all covers, guards, and hatches are reinstalled before starting the engine.
SAFETY INSTRUCTIONS • • • • ABYC, NFPA AND USCG PUBLICATIONS FOR INSTALLING DIESEL ENGINES Do not wear loose clothing or jewelry when servicing equipment; tie back long hair and 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. Follow their recommendations when installing your engine. Make sure all attaching hardware is properly tightened.
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 Introduction ................................................................2 Engine Troubleshooting (Chart) ................................. .3 Testing for Overhaul ...................................................7 Engine I Generator Disassembly ................................8 Engine Disassembly ....................................................9 Engine Inspection ..................................................... 14 Engine Assembly ............................................
INTRODUCTION PRODUCT SOFTWARE CUSTOMER IDENTIFICATION CARD Product software (tech data, parts lists, manuals, brochures and catalogs) provided from sources other than WESTERBEKE are not within WESTERBEKE'S control. / ....
ENGINE TROUBLESHOOTING The following troubleshooting chart describes certain problems relating to engine service, the probable causes of these problems, and the recommendations to overcome these problems.This chart may be of assistance in determining the need for an engine overhaul. PROBLEM HARD STARTING NOTE: The engine's electrical system is protected by a 20ampere manual reset circuit breaker. The preheat solenoid is mounted on the same bracket.
ENGINE TROUBLESHOOTING PROBABLE CAUSE PROBLEM LOW OUTPUT (cont.) VERIFICATION/REMEDY OVERHEATING 1. Low coolant level. EXCESSIVE OIL CONSUMPTION 1. Add coolant. 2. Loose V-belt. 2. Adjust or replace V-belt. 3. Incorrect injection timing. 3. Adjust injection timing. 4. Low engine oillevel. 6. Add engine oil. OIL LEAKAGE 1. Defective oil seals. 1. Replace oil seals. 2. Broken gear case gasket. 2. Replace gasket. 3. Loose gear case attaching bolts. 3. Retighten bolts. 4.
ENGINE TROUBLESHOOTING PROBLEM SMOKY EXHAUST (coni.) PROBABLE CAUSE VERIFICATION/REMEDY WHITISH OR PURPLISH (coni.) d. Worn valve stem and valve guide. d. Replace. e. Low engine oil viscosity. e. Replace. r. r. Excessive oil pressure. Correct. 3. Injection timing is too late. 3. Adjust. 4. Insufficient compression. 4. See LOW COMPRESSION; HARD STARTING. BLACKISH OR DARK GRAYISH 1. Engine body troubles. a. Poor compression. a. See LOW COMPRESSION; HARD STARTING. b.
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. b. Carbon deposits in cylinder. b. Clean. 2. Too early injection timing. 2. Correct. 3. Too high injection pressure. 3. Correct. 4. Improper fuel. 4. Replace with proper fuel. KNOCKING WITH DARK SMOKE 1. Poor compression. 1. See LOW COMPRESSION; HARD STARTING. 2. Injection pump malfunctioning. a.
TESTING FOR OVERHAUL HOW TO DETERMINE ENGINE OVERHAUL PERIOD Cause of Low Compression OVERHAUL CONDITIONS Compression pressure tends to increase a little in a new engine until piston rings and valve seats have been broken in. Thereafter, it decreases gradually with the progress of wear of these parts. Generally, the time at which an engine should be overhauled is detennined by various conditions such as lowered engine power output, decreased compression pressure, and increased fuel and oil consumption.
ENGINE/GENERATOR DISASSEMBLY PROPULSION ENGINE GENERATOR Unplug the instrument panel wiring harness. Drain the transmission fluid and the transmission oil cooler hoses, Detach the oil cooler hoses and unbolt the transmission from the engine. Drain or pump out all the engine oil and drain the coolant from the engine and engine hoses. Disconnect the AC wiring and unplug the engine's DC wiring harness at the generator control panel. Disconnect the battery cable connections and the engine ground cables.
ENGINE DISASSEMBLY DISASSEMBLING THE MAIN ENGINE With the transmission/or generator separated from the engine, begin the following step by step procedure to disassemble the engine. NOTE: Mount the engine on a suitable stand or work bench. 1. Remove the transmission damper plate from the C engine flywheel. O~~ ~ i~O~ DAMPER PLATE BOLTS o~t~0 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.
ENGINE DISASSEMBLY f. Once loosened, remove the holddown nuts and washers and carefully withdraw the pump from the drive gear and engine so as to avoid losing the injection pump drive key inside the timing case. 16. Remove the fuel injectors, dust seals and sealing washers from the cylinder head using a 27mm deep socket. 17. Remove the glow plugs. 18. Remove the crankcase breather hose and rocker arm cover. 19. Remove the engine mounted fuel filter and fuel line to the injection pump.
ENGINE DISASSEMBLY Engine Block Disassembly 24. Lift the cylinder head off the engine and remove the cylinder head gasket. Disassemble the engine in the following order: 21. Remove the cylinder head rocker cover and gasket. , ~j ROCKER COVER ~ ® HEAD "GASKET 22. Remove the cylinder head. NOTE: Loosen the cylinder head bolts equally and gradually and in the order shown. 5 9 13 17 16 12 8 25. Disassemble the rocker arm assembly. 26. Remove each valve from the cylinder head assembly.
ENGINE DISASSEMBLY CRANKSHAFT PULLEY 27. Remove the crankshaft pulley bolt with the aid of a 38 mm socket and draw the pulley off the front crankshaft. --TIMING GEAR CASE INJECTION PUMP DRIVE GEAR TIMING GEAR COVER Remove the timing gear cover and remove the injection pump washer, injection pump friction gear and the injection pump drive gear. 29. Remove the camshaft gear. a. Wedge a clean cloth between the camshaft gear and the idler gear; remove the retaining bolt. b.
ENGINE DISASSEMBLY b. Remove the wrist pin snap rings. c. Using a nylon drift, drive the wrist pin from the piston and rod. d. Protecting your eyes with safety glasses, disengage and withdraw the snap rings. Although mechanics generally press out (and sometimes hammer out) pistons pins, these practices should be discouraged. Instead, take the time to heat the pistons, either with a heat gun or on a hot plate. Pins will almost fallout. e. While the piston is still warm, check for bore integrity. .
ENGINE INSPECTION INSPECTING .THE CYLINDER HEAD 1. Visual Inspection. Check the cylinder head for cracks or any other damage and, if necessary, repair or replace it. REMOVING THE INSERT 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. If the distortion exceeds permissible limit, replace the cylinder head. (The head has no allowance for planing and must be replaced, not renewed.
ENGINE INSPECTION NOTE: Measure the fitting pressure after compressing the spring several times. Spring Fitting Pressure Inner Fitting Length 1.49 in (37.8mm) Fitting Pressure Limit 24.92 Ib (11.3kg) VALVE GUIDE INSTALLER Outer 1.59 in (40.3mm) 66.36 Ib (30.1 kg) VALVE SPRING TESTER~ SPRING FITTING PRESSURE HEIGHT ABOVE THE SPRING SEAT 0.65 in (16.5mm) --+\---~ I VALVE GUIDE 1. Inspecting clearance between valve and guide.
ENGINE INSPECTION '/:,.,-.. _ SEAT INSERT J:HECKING VALVE STEM WEAR VALVE SEAT d. Check for contact between the valve and valve seat by applying a thin coat of Prussian Blue (or Redlead) on the valve seat contact face, then insert the valve into the valve guide and press fit the valve on the valve seat. NOTE: Do not rotate the valve! CONTACT FACE 1. Valve Seat Angle. Valve seat angle is 45° and 30° respectively for intake and exhaust sides. The standard contact width of the valve seat is 0.079 in (2.
ENGINE INSPECTION ROCKER ARM CYLINDER BLOCK 1. Visual Inspection. Check each component part of the 1. VISUal Inspection. Check the cylinder block for cracks and damage. If necessary, repair or replace it entirely. rocker arm assembly for cracks or other damage. Check if the oil passages of the rocker arm ana shaft are clogging and, if necessary, repair or replace the rocker arm. 1m-JAM NUT SPRING WASHER . _~~ ~ ~>@J ~ Q;;II A. _____ ADJ. SCREW ~-~BUSHING'~ . . ROCKER SHAFT ~ SUPPORT ~~ ~~ ~-_B:e.
ENGINE INSPECTION 2. Cylinder Liner Replacement. Hydraulic press or similar c. Measure the piston diameter at 90° (perpendicular) to the pin bore axis and 0.866in (22mm) below the piston top. SUB COMBUSTION device is needed. a. Attach the cylinder liner puller and installer to the . lower rim of the cylinder liner, then press out the liner. CHAMBER h. Check for scratches on the cylinder block side and, if any, remove them by using extremely fine emery paper with engine oil. c.
ENGINE INSPECTION CONNECTING ROD 1. Visual Inspection. Check the connecting rod for cracks PISTON PIN or other damage and, if necessary, replace it. CLEARANCE BETWEEN THE PISTON PIN AND SMALL END BUSHING 4. Small end bushing replacement. Using a press, press out the old bushing. Align the oil passages of the connecting rod and the small end bushing; press in the new bushing to the connecting rod bore.
ENGINE INSPECTION 3. Inspecting crank pin and journal. Support the crank- 6. Inspecting connecting rod bearing. Check the connecting rod bearing for peeling and thennal damage. If it is shaft on both ends using V-blocks. Measure the diameter of each crank pin and crankshaft main journal and, if the diameter is less than the limit, refinish the crank pin and main journal to size for the next undersize bearing. severe, replace the bearing. 7. Inspecting connecting rod bearing clearance.
ENGINE INSPECTION 4. Inspecting crankshaft end play. Check the end play of 3. Inspecting camshaft journal. Check the camshaft journal and, if wearing exceeds the limit, replace the camshaft. the crankshaft and, if the end play exceeds the limit, replace the thrust washer with 0.007 in (0.178 mm) oversize. Crankshaft end play is measured by setting a dial gauge on the rear end of the crankshaft and moving the crankshaft in the axial direction. Crankshaft End Play Standard: Crankshaft End play limit: No.
ENGINE INSPECTION TAPPET 1. Visual inspection. Check the tappet for cracks and other damage and, if damaged replace the tappet. Check for abnormal wear of the portion of the tappets that contact with the cam, and if anyone is abnormally worn, replace the tappet. 2. Inspecting Clearance Between Tappet and Tappet Bore. Check the clearance between the tappet and tappet bore and, if the clearance is greater than the limit, replace the tappet or cylinder block. CHECKING .CLEARANCE Clearance Limit 0.
ENGINE INSPECTION TIMING GEAR COVER OIL SEAL OIL PAN 1. Inspecting timing gear cover oil seal. Check the timing gear cover and the lip of the oil seal for any damage. If necessary, replace the cover or oil seal. 2. Oil seal replacement. To remove the oil seal, use the oil seal puller and installer and pull out the oil seal. To install, apply engine oil on the outside of a new oil seal, then press fit the oil seal with oil seal puller and installer until the installer comes in contact with the cover. 1.
ENGINE ASSEMBLY Reassembly Precautions ENGINE ASSEMBLY • Be careful not to mix bolts and nuts. Metric and S.A.E. bolts are used on various engine assemblies. 1. Install the valves in cylinder head. Using the valve spring lifter arm and pivot, assemble the valve, lower spring seat, oil deflector, inner valve spring, outer valve spring, upper spring seat and taper sleeve in this order.
ENGINE ASSEMBLY PLACE A HEAW HAMMER AND GENTLY PRESS DOWN WITH THE FORCE OF YOUR HAND. THE ENTIRE SURFACE SHOULD BE COATED WITH FRESH LUBE OIL. 4. Main Bearings and Bearing Caps. NOTE: Do not apply oil to the backsides of the main bearing shells. 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. b. Fit the thrustwashers to the cylinder block so that the oil grooves on thrustwashers face to crankshaft side. c.
ENGINE ASSEMBLY 10. Fuel Injection Pump. NOTE: It is easier to first install the injection pump to the timing gear case and the entire assembly onto the engine. Install the injection pump aligning the identification marks. Mount the injection pump on the gear case, then tighten the pump drive gear attaching nuts. Attaching Nut Torque 29 - 51 Mb (4.0 - 7.0 m/kg) ~'. ,.,-' " I TIMING GEAR COVER 13. Install the friction gear. 14. Install the camshaft gear lock bolt. 11. Install the timing gear case.
ENGINE ASSEMBLY 26. Position the cylinder head. 27. Insert the pushrod. Check if the push rod is securely set in the tappet concavity. 19. Assemble the new gasket set (lower block). a. Position the gasket ends A on the gaskets B and C. b. Apply a silicon sealing agent on the mating surfaces of the gasket and that between the cylinder block and the timing gear case. c. Install the lower block making certain the lower block gasket is perfectly aligned. Tighten the bolts evenly. .
ENGINE ASSEMBLY 31. Adjust the valve clearance. Adjust the No.1, 2,3, and 6 . valves when the No. 1 piston is on Top Dead Center (IDC) or the compression stroke. 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. Tum the crankshaft once, setting the No, 4 cylinder piston at TDC (compression) and adjust the No.4, 5, 7, and 8 valves.
ENGINE ASSEMBLY 43. Install the fuel injection nozzles and return lines. Use new sealing washers throughout, in the same order as 51. Install the raw water pump and drive belt. Insure it is in proper alignment with the crankshaft pulley. Check the belt tension. were the old washers. Injector To Head BoH (27mm deep socket) 43 - 51 f1-lb (6.0 - 7.0 m-kg) Refer to RAW WATER PUMP for pump breakdown. See FUEL INJECTORS for more details. 44. Install the glow plugs and connectors.
ENGINE ASSEMBLY MARINE ENGINEJTRANSMISSION GENERATOR 59. Assemble the damper plate to the flywheel. 59. Mount the generator back end assembly with its control panel. Reconnect all DC wiring and reconnect all AC connections. Damper Plate Torque 14·20 ft·lb (1.7 - 2.7 m-kg) 60. Reinstall the marine transmission and fill with ATF DextronIII. A CAUTION: Check all AC and DC wiring connections to WESTERBEKE wiring schematics and diagrams.
EXHAUST MANIFOLD I HEAT EXCHANGER EXHAUST MANIFOLD 3. 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 nipples, elbows and plugs from the manifold. 2. Examine all parts for defects, corrosion and wear and replace as needed.
FUEL INJECTION PUMP TESTING INJECTION TIMING 11. Remove the plug and sealing washer from the aft center of the injection pump. The plug is centrally located where the four high pressure injector lines attach to the pump. In place of the plug install the Mazda tool #49 9140 074 measuring device. Ensure the measuring device rod contacts the plunger inside the pump and then zero the gauge. 1. Remove the air intake/silencer assembly. 2.
FUEL INJECTION PUMP I FUEL LIFT PUMP CHECKING CAM LIFT FUEL LIFT PUMP (EARLY MODELS) 1. Turn the crankshaft in the direction of normal engine rotation and read the maximum value which the dial indicator pointer on the measuring device shows. This value is cam lift. . The fuel lift pump should be cleaned and repainted. Install a new filter as illustrated and clean the ground wire terminal. Amount of Cam Lin 0.08 in (2.2 mm) 2.
FUEL INJECTORS REMOVING THE INJECTORS c. Mount the nozzle and nozzle holder on the nozzle tester. NOTE: Injector must be serviced in a "clean room" environment. d. Use the fuel at the approximate temperature of 68° F (200 C). 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. e.
FUEL INJECTORS INSPECTING SPRAY PAnERN 5. Assure the needle valve, when it is pushed in the nozzle body, comes down into the valve seat by its weight about 0.7092in (18mm). If it does not, replace the assembly. If any defect is found, always replace the needle valve and the nozzle body as a unit. 6. Check that there is no flaw or other damage on mating surfaces and sliding surfaces of the nozzle body and the needle valve and, if present, replace the nozzle assembly. 1.
FUEL SYSTEM TROUBLESHOOTING PROBLEM Engine hard to start or fails to start Engine idling too low. Fuel consumption too high. PROBABLE CAUSE VERIFICATION/REMEDY 1. No fuel at injectors. 1. Check causes a through e. a. No fuel in fuel tank and/or fuel shut off. a. Fill tank. Open shutoff and bleed system. b. Fuel filter clogged. b. Replace filter and bleed. c. Fuel filter clogged. c. Bleed pump. Check fittings for suction leak on fuel supply. d. Fuel shutoff solenoid not working. d.
FUEL SYSTEM TROUBLESHOOTING PROBABLE CAUSE PROBLEM Engine output and performance poor. Large amount of black exhaust smoke. Abnormal noise from engine VERIFICATION/REMEDY 1. Purge fuel system and replace with quality fuel. 1. Contaminated or inferior fuel. 2. Fuel filter obstructed. 2. Remove and replace filter element. 3. Air in fuel system. 3. Bleed and check for source. 4. Injection pump timing incorrect. 4. Check the timing and adjust pump as needed. 5. Injector high pressure lines leaking.
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 solenoid. 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 8. Adjust each valve's clearance by inserting a 0.012in (O.03mm) feeler gauge between the rocker arm and the valve stem. Make sure to adjust all valves when the engine is cold. 1. Warm the engine to nonnal operating temperature. 2. Pull off the air breather pipe from the rocker cover. Remove the rocker cover bolts and remove the rocker cover to expose the rocker shaft and valve assembly. 3.
ENGINE ADJUSTMENTS When servicing the injection pump, the service shop must be advised if the pump is to be used in a generator application. The service shop will have to remove and replace the governor spring with a propulsion spring. Once the pump is set to propulsion specifications, the generator spring is reinstalled in the-injection pump and the pump remounted on the engine. The throttle is then set for the proper engine no-load speed (hertz).
COOLANT CIRCULATING PUMP REMOVING THE PUMP ASSEMBLY Remove in the following order: coolant (drain as needed); V-belt; water hoses; water pump attaching nuts; and water pump. Assemble the water pump in the reverse order of disassembly, using the following procedure: 1. Fill lithium grease (lithium base NLGI No.2) into the following positions. DISASSEMBLY • Ball bearings • Approximately 113 space between both ball bearings • Space between the ball bearing and water baffle plate. 2.
LUBRICATING OIL PUMP REMOVING THE OIL PUMP 3. Inspect the clearance between the inner rotor and the outer rotor. Check the clearance between the lobes of the rotors with a feeler gauge. If the clearance exceeds the limit, replace both rotors. OUTER ROTOR Remove from the engine in the following order: 1. Oil Pan; 2. Oil Pump Set Screw; 3. Oil Pipe Attaching Bolts; and 4.
LUBRICATING OIL PUMP ASSEMBLY 6. Measure the free length of the plunger spring. Check the relief valve for worn plunger and fatigued spring. . 7. Assemble in the reverse order of disassembly. NOTE: When installing the rotors into the body, be sure that the tally marks on the rotors are positioned toward the cover. PLUNGER ;SPRING PLUNGE,\ J)~ U MEASURING FREE LENGTH . Spring free Limit 1.61 in (40 mm) Cover TIghtening Torque (7/16" socket) 5.8 - 8.7 n-Ib (0.8 - 1.2 m-kg) RELIEF VALVE PLUG .
RAW WATER PUMP 5. Remove the housing assembly, releasing the shaft, bearing and seal assembly. This will allow the bearing and seal to be disassembled for inspection. PUMP OVERHAUL NOTE: Since completely rebuilding a damaged or worn pump from individually purchased parts would almost match the price of a new pump, WESTERBEKE recommends that a new pump be purchased. NOTE: It may be necessary to use a drift and arbor press to press the bearing and seal assembly from the shaft. 6.
STARTER MOTOR DESCRIPTION No-Load Test The starter can be roughly divided into the following sections: 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). If the current or starter speed is out of specification, disassemble the starter and repair it. • A motor section which generates a drive power.
STARTER MOTOR 4. Return test: With a battery connected to the solenoid 3. Holding test. With a battery connected to the solenoid terminal S (+) and to the starter body, manually pull out the pinion fully. The pinion must remain at that position even when released from holding with your hand. 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. HOLDING TEST RETURN TEST ATTRACTION TEST 7.
STARTER MOTOR STARTER INSPECTION Solenoid Inspect the solenoid for continuity between terminals S and M and between terminals S and body. No continuity should be found between S and 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. Inspecting The Armature BRUSHES 1. Check the armature with a growler tester. If it's short circuited, replace the armature.
STARTER MOTOR Field Coil Inspection 2. Greasing. Whenever the starter has been overhauled, apply grease to the following parts: a. Armature shaft gear and reduction gear. 1. Check for insulation between one end (brush) of the coil and yoke. b. All bearings. 2. Check for continuity between both ends (brushes) of the coil 3. Check the poles and coil for tightness. c. Bearing shaft washers and snap rings. d. Bearing sleeves. e. Pinion. f. Sliding portion of lever.
TACHOMETER TACHOMETER/HOUR METER Tachometer Inaccurate a. With a hand-held tach on the front of the crankshaft The tachometerlhour meter used in propulsion engine instrument panels contains two separate electrical circuits with a common ground. One circuit operates the hour meter and the other the tachometer. The hour meter circuit operates on 12 volts alternator charging voltage supplied to the (+) terminal on the back of the instrument.
ALTERNATOR TESTING DESCRIPTION 1. Start the Engine. The charging system consists of an alternator with a voltage regulator, an engine DC wiring harness, a mounted DC circuit breaker and a battery with connecting cables. Because of the use of integrated circuits (IC's), the electronic voltage regulator is very compact and is mounted internally or on the back of the alternator. 2.
ALTERNATOR TESTING Alternator is Working 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. MU LTIMETER TESTING THE STARTING BATTERY· ALTERNATOR (ENGINE RUNNING) 4.
828 FOUR MARINE ENGINE WIRING DIAGRAM #039144 " 110 It D I ,------- ,:~: ,~ I +~ ~~ . o ll..illl.U 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. A switch with a continuous rating of 175 amps at 12 VDC will normally serve this junction, but a switch must never be used to "make" the starter circuit.
828 FOUR MARINE ENGINE WIRING SCHEMATIC #039144 + II YDe START SOL. STAun +---______~r-i-I~'+_------~{M}_--------------~ r---~~--------------------~ ------1 I ALTEIUIATOI LifT 'UM' ~-;~~-------+~P tno FUEL r-+-+-t----------4..~~._e_II.!.''!.!. 0.'. IE"DEI a :'=' 1' ~ '1:; - - ~~-~~~---~ Pi=. 'I;; ;'j'1P1":i - - ,i='u":; Pi·, ,j':. n·" - '" - - - - - - ',:'i ADMIRAL PANEL TACIIOMETEI S ••• 0.', tAUG£ .w. pt., ""'I·'PI-1 CAPTAIN PANEL L. ., T[ST ow.
SPECIFICATIONS - 828 FOUR MARINE ENGINE FUEL SYSTEM ENGINE SPECIFICATIONS Engine Type Aspiration Govemor Combustion Chamber Bore &Stroke Piston Displacement Firing Order Direction of Rotation Compression Ratio Dimensions Weight Inclination Generator Power Take Off General Fuel Fuel Injection Pump Fuel Injection Timing Nozzle Fuel Filter (on engine) Air cleaner Air Flow (engine combustion) Diesel, four-cylinder, four-cycle, fresh water-cooled, vertical in-line overhead valve mechanism.
SERVICE DATA I STANDARDS AND LIMITS - 828 FOUR MARINE ENGINE Component Specified Value I Standard inches{mm) Component Repair Limit inches{mm) Specified Value I Standard inches{mm) Repair Limit inches{mm) Valve Spring (Inner) Wire Diameter ............................0.138 (3.5) Outer Coil Diameter ..................1.083 (27.5) Free Length ...............................1.736 (44.1) ......................1.654 (42.0) Fitting Length ............................1.488 (37.8) Fitting Load ...............
SERVICE DATA I STANDARDS AND LIMITS • 828 FOUR MARINE ENGINE Component Specified Value / Standard inches(mm) Repair Limit inches(mm) Component Specified Value / Standard inches(mm) Repair Limit inches(mm) MAIN BEARING CONNECTING ROD Small End Bore Piston Pin and Small End Bushing 0.005 - 0.0015 (0.012 - 0.039) 0.0020 (0.05) Bend and Twist 0.002 in 4 (0.05 in 100) Side Clearance 0.0094 - 0.0134 (0.239 - 0.340) 0.0157 (0.40) Small End Bore 1.1816 - 1.1824 (30.012 - 30.033) Clearance ..................
TORQUE SPECIFICATIONS - 828 FOUR MARINE ENGINE COMPONENT FHB (M-KG) COMPONENT FHB (M-KG) Alternator Bracket .......................... 27 - 38 (3.8 - 5.3) Injection Pipe Flare Nut ..................18 - 22 (1.6 - 3.0) Back Plate ......................................24 - 35 (3.3 - 4.8) Injection Pump Gear Locknut... ..... 29 - 51 (4.0 - 7.0) Camshaft Gear ..............................46 - 69 (6.4 - 9.5) Injector to Head ..............................43 - 51 (6.0 - 7.0) Camshaft Thrust Plate .....
STANDARD HARDWARE BOLT HEAD MARKINGS Metric bolt class numbers identify bolts by their strength with 10.9 the strongest. Bolt strength classes are embossed on the head of each bolt. Customary (inch) bolts are identifed by markings two to grade eight (strongest). The marks correspond to two marks less than the actual grade, i.e.; a grade seven bolt will display five embossed marks. NOTES: 1. Use the torque values listed below when specific torque values are not available. 2.
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.
GENERATOR CONTROL PANEL SWITCHES DESCRIPTION 3. START: The START toggle switch is a double pole, single throw switch. The switch serves two purposes: starting the engine and defeating of bypassing the engine oil pressure switch. The defeat function turns on the fuel solenoid, instrument power and alternator excitation. While the PREHEAT switch is still depressed, depressing the START switch engages the start solenoid. Panel power and the fuel solenoid will be activated.
CONTROL PANEL TROUBLESHOOTING MANUAL STARTER DISCONNECT (TOGGLE SWITCHES) NOTE: The engine control system is protected by a 20 amp manual reset circuit breaker located on the engine as close as possible to the power source. Problem Probable Cause Verification/Remedy PREHEAT depressed, no panel indications electric fuel pump and preheat solenoid not energized. cuit 1. Oil Pressure switch. 1. Check switches and/or battery connections. 2. 20 amp circuit breaker tripped. 2. Reset breaker.
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. NOTE: Series Delta requires the installation of a jumper on the regulator board between terminal B and 10.
GENERATOR AC VOLTAGE CONNECTIONS AC VOLTAGE CONNECTIONS Generator Frequency NOlE The frame ground wire (white/green) must be properly positioned when changing the AC output configuration of the AC terminal block. For making connections to the AC terminal block, use terminal ends·for 114 inch studs that will accept multi strand copper wire siW1 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. Delay¢ overload protection (yellow LED). 2.
INTERNAL WIRING SCHEMATICS SINGLE PHASE r------------, EXCITER STATOR RED RED EXCITER ROTOR 1--- - I + - --1 STATOR I I 1 RED RED _____ L_ AUX WINDINGS ~------~---J _________ J AC TERMINAL BLOCK, ® ® W2 V1 U1 RED 3 .... .... .... >o BLACK RED BLUE GREEN NOTE: This fuse may be located on the regulator. YELLOW THREE PHASE r------------, 6 WIRE RECONNECTABLE EXCITER STATOR 1.
INTERNAL WIRING SCHEMATICS 3 PHASE TWELVE WIRE RECONNECTABLE 1---- 1 I r-------., I EXCITER STATOR r - - - + - - - - - - - , ! II I I + EXCITER ROTOR II I I I ROTOR FIELD I 12 -...:1---_____: 1~ 3 L-j:r-1IiI r-+r---'::4~~:--------:' AC 4 ____+----4 87 TERMINAL I:!i:~5~;::::::==::: : I 6: : ~~~~~~~!!:::::::: 7 I I IL I I ~.--~2~-+!-------4:11 I II STATOR 8 _ _ _ _ _ .... NOTE: This fuse may be located on the regulator.
BE TROUBLESHOOTING NOTE: AC GENERATOR TROUBLESHOOTING MUST BE PERFORMED WITH ENGINE OPERATING AT 60 HER1Z. PROBLEM PROBABLE CAUSE No AC voltage output at no load. 1. Short or open in the main stator winding. 4. Short or open in exciter stator winding. 2. Shorted pozi-resistor on exciter rotor. 5. Short or open in rotating field winding. 3. Four or more shorted or open diodes on exciter rotor. Residual voltage produced at no load 15 - 20 vOlls AC. 1.
ELECTRONIC GOVERNOR Electronic Governor System • I The system is composed of three basic components: 1. 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. • I 1,--.-..,.-----, ~ ~~:-=,---, Controller Adjustment 1. Speed. This adjustment is used to raise or lower the engine's speed to the desired hertz. 2. Gain.
TROUBLESHOOTING THE ELECTRONIC GOVERNOR Problem System appears dead (Engine runs at idle.) Probable Cause VerificationJRemedy 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 SHORE POWER CONNECTIONS (60 HERTZ) 120 VOLT/60 HZ THREE WIRE CONFIGURATION Generator Notice the repositioning of the white wire ground load on the terminal block to the generator case. r N G1 4G2 • l , =- NOTE: Diagram shows connections for a twowir•• 120" Volt system. For a thr.... wire system use dotted lines ror the other hot leg. I I I I Generator r j Z I NOTE: Diagram shoWI connections for a two- ~ /~-- ... $\ -----t.
BED GENERATOR WIRING SCHEMATIC #039422 + 12VDC r -, J : BATTERY : : SWITCH START SOL. , -, STARTER I-----------+-r--I---I--.....' - - - - - - i M l - - - " ' ; L.':"' __ ,.,j PREHEAT SOL. r-----j 1-----~J~J---4----~ J 1.o. ____ .J . -, J )'20A ; . :C.B. , 0 l _J L-_~ -1 STOP K _ _ _ _~~~ 7 LIFTPUMP Pl----+ : SWITCH _J FUEL SOL.
BED GENERATOR WIRING DIAGRAM #039422 AL T""RNATOR _51 A liFT PUMP [1,----", PO"---+--. ~ FUEL SOLENOID WATER TEMP. SENDER ~ ® r-. Ii!! ..z ;! ... '''A ~ ... OIL PRESSURE SW. OIL PRESS. SENDER ~ T v~ ~Et.4P. EXHAUST ... _.u ,- SW• • ... ARM ~'n .,• ..,A/WNT [J W r- T8·2 ~ .+_-1=:1>0:..;II~ ;::t-..., '---1:020 ~ L~~wi=~~ ~ ~ ::::::- ..... I. ,J.e:!. REMOVE THIS ~1Gi0 JUMPER WHEN , (6l CONNECTING A I~~~-!=-----. REMO~P~L t~~0~~~~t=f=t----------~ 0< .-~ LL~~ ·'·"'"..,fOil-.
BED GENERATOR WIRING SCHEMATIC #039422 (WITH DUAL RELAYS) : BATTERY ! SWITCH STARTER SOLENOID r---I I I I I I I PREHEAT SOLENOID r--I I I I I L- _ STARTER M __ I GLOWPLUGS L... _ _ _ I ALTERNATOR 120 AMP ICIRCUIT jBREAKER r I I PREHEAT SWITCH L j 85 86 L I I j 0 K2 30 r T82-3 START 0 KI L __ I I STOP ! SWITCH L KI 110 AMP ICIRCUIT jBREAKER 30 START SWITCH 1 EMERGENCY IT 870 87 ~~?b FUEL PUMP OIL PRESS. SW. EXH. TEMP. SW. WATER TEMP. SW.
BED GENERATOR WIRING DIAGRAM #039422 (WITH DUAL RELAYS) ,~ - 'ltlf) OR.N .14 PUR "4 PUR 114 PUR r> 114 PUR WATER L--jl" L~MP - ill..I1.E.B. ~ tl4 PUR .~ ~ ~ ~ ~ :;;; ~QLE~Q ~ Z ~ ; BATTERY SWITCH 19 IQ :¢; I'ID 110 REI) 110 Oftlrl :rT / V-I 1.: _ _ I ~----------~ .14 PUR/WNT ~Q :'-~ ".oc ~) ~ L fJWir.AI. A.e..E..~ ~ QI" ~RE~~UBE ~L/P"' Q ACTUAIQR r ~ ~ FUE" ~Q"E~QIQ U -----"'l ~ ~~ ~~ -- \:' 'r WAlEB TEM~EBAIUBE = -- ((=f) II ..
SPECIFICATIONS WESTERBEKE 25 KW BED GENERATOR ENGINE SPECIFICATIONS Engine Type Aspiration Govemor Combustion Chamber Bore & Stroke Piston Displacement Firing Order Direction of Rotation Compression Ratio Dimensions Weight Inclination Generator Power Take Off FUEL SYSTEM General Fuel Fuel Injection Pump Fuel Injection Timing Nozzle Fuel Filter (on engine) Air cleaner Air Row (engine combustion) Diesel, four-cylinder, four-cycle, fresh water-cooled, vertical in-line overhead valve mechanism.
SPECIFICATIONS WESTERBEKE 25 KW BED GENERATOR ELECTRICAL SYSTEM Starting Battery 12-Volt, (-) negative ground Battery Capacity 400 - 600 Cold Cranking Amps (CCA) DC Charging A1temator 51 Amp rated, belt-driven Starter 12-Volt, Reduction Gear Starting Aid Glow plugs, sheathed type DC No-Load Current ± 2% of rated Amps DC Cranking Current 250 - 300 Amps (engine cold) AC GENERATOR (THREE PHASE) AC GENERATOR (SINGLE PHASE) General - Single Phase Brushless, four-pole, revolving field Sealed lubri
SPECIAL TOOLS • GENERATOR FIELD FABRICATED TOOLS Lifting Eye Tool These drawings provide a means by which simple tools can be made to assist in the removal of the generator end from the engine and in the replacement of the generator end on the engine. A local machine shop should be able to fabricate these tools at a modest price, but first check with your local WESTERBEKE dealer to see if these tools are on hand for loan.
METRIC CONVERSIONS INCHES TO MILLIMETERS Inches mm 1 2 3 4 5 10 25.40 50.80 76.20 101.60 127.00 254.00 15 20 25 30 35 40 MILLIMETERS TO INCHES mm Inches 381.00 508.00 635.00 762.00 889.00 1016.00 mm Inches mm Inches 1 2 3 4 5 10 0.0394 0.0787 0.1181 0.1575 0.1969 0.3937 15 20 25 30 35 40 0.5906 0.7874 0.9843 1.1811 1.3780 1.5748 = = 10 MILLIMETERS 1 CENTIMETER, 100 CENTIMmRS 1 METER INCHES TO METERS Inches Meters 1 2 3 4 5 6 0.0254 0.0508 0.0762 0.1016 0.1270 0.
INDEX AC Voltage Connections .................53, 63 Alternator Testing .........................50 Camshaft ................................21 Compression-Engine .......................39 Connecting Rod .......................... 19 Control Panel Troubleshooting ...............61 Coolant Circulating pump .................. .41 Crankshaft ...............................20 Cylinder Block ........................... 17 Cylinder Head Bolt Pattern .............. .27,35 Cylinder Liner ...........................
INDEX Wiring Diagram ........................73 Wiring Schematic .......................72 Glow Plugs - Testing ...................... .38 Heat Exchanger .......................... .31 Injection Pump .........................9, 10 Injection Timing ......................... .32 Injectors ............................... .32 L Dimension ............................. 15 Lubricating Oil Pump ..................... .42 Metric Conversion Chart ....................79 Oil Pressure ............................. .
~r"9Y" rWESTERBEKE ~ 1008 WMDW 12/98 WESTERBEKECORPORATION MYLES STANDISH INDUSTRIAL PARK 150 JOHN HANCOCK ROAD, TAUNTON, MA 02780-7319
