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Westerbeke Diesel W 18 Parts Manual



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         SERVICE MANUAL     DIESEL ENGINES    GENERATORS                  2CYLINDER MODELS                                            Generators  Engines                             60 Hz                          50 Hz  W13                       WMD 44                        WMD 33  W13A                      44 BCD                        33 BCD                  3CYLINDER MODELS                                            Generators  Engines                             60 Hz                          50 Hz  W18                       WMD 60                        WMD 45  W18                       60 BCD                        45 BCD  W21                       WMD 77                        WMD 58                             WMD 80                        WMD 60  W21A                      80 BTD                        60 BTD  RD60  35B THREE                  100 BTD                       75 BTD                PUBLICATION NO 43444                  1st Edition  April 1999  lrWESTERBEKE              JWESTERBEKE CORPORATION AVON INDUSTRIAL PARK               AVON MA 02322 TEL 508 5887700 FAX 508 5599323               WEBSITE                          JI9   Member National Marine                     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 WARNINGExhaust gasses cDntain CarbDn MDnDxide an DdDrless andcDIDriess gas CarbDn MDnDxide is pDisonDus and can  and death SymptDms Df CarbDn  can                     ThrDbbing in TemplesNausea                       Muscular                      Vomiting Weakness and Sleepiness Inability to Think CDherentlyIF YOU OR ANYONE ELSE EXPERIENCE ANY OF THESE SYMPTOMSGET OUT INTO THE FRESH AIR IMMEDIATELY symptoms persistseek medical attentiDn Shut dDwn the unit and dD nDt restartuntil it has been inspected and repaired                                            SAFETY                                                         PREVENT BURNS  FIRERead these safety instructions carefully Most accidents arecaused by failure to follow fundamental rules and precautions Know when dangerous conditions exist and take the                                                                     A WARNING          Fire can cause injury or deathnecessary precautions to protect yourself your personneland your machinery                                                  Prevent flash fires Do not smoke or permit flames orThe following safety instructions are in compliance with               sparks to occur near the carburetor fuel line filter fuelthe American Boat and Yacht Council ABYC standards                  pump or other potential sources of spilled fuel or fuel                                                                       vapors Use a suitable container to catch all fuel whenPREVENT ELECTRIC SHOCK                                                 removing the fuel line carburetor or fuel filters                                                                     Do not operate with a Coast Guard Approved flame                                                                      arrester removed Backfire can cause severe injury or A WARNING Do not touch AC electrical connections                     death while engine is running or when connected to shore power Lethal voltage is present at these connections              Do not operate with the air  removed                                                                       Backfire can cause severe injury or death Do not operate this machinery without electrical                   Do not smoke or permit flames or sparks to occur near the   enclosures and covers in place                                    fuel system Keep the compartment and the enginegener                                                                       ator clean and free of debris to minimize the chances of Shut off electrical power before accessing electrical               fire Wipe up all spilled fuel and engine oil   equipment                                                                     Be aware      diesel fuel will burn Use insulated mats whenever working on electrical  equipment                                                        PREVENT BURNS  EXPLOSION Make sure your clothing and skin are dry not damp  particularly shoes when handling electrical equipment Remove wristwatch and all jewelry when working on                                                                     A WARNING         Explosions from fuel vapors can cause                                                                     injury or death   electrical equipment Do not connect utility shore power to vessels AC                  Follow refueling safety instructions Keep the vessels   circuits except through a shiptoshore double throw               hatches closed when fueling Open and ventilate cabin   transfer switch Damage to vessels AC generator may                after fueling Check below for fumesvapor before run   result if this procedure is not followed                           ning the blower Run the blower for four minutes before Electrical shock results from handling a charged capacitor          starting your engine   Discharge capacitor by shorting terminals together with           All fuel vapors are highly explosive Use extreme care when   an insulated tool                                                  handling and storing fuels Store fuel in a  BURNS  HOT ENGINE                                             area away from sparkproducing equipment and out of                                                                       the reach of children                                                                     Do not fill the fuel tanks while the engine is running A WARNING Do not touch hot engine parts or                         Shut off the fuel service valve at the engine when servicing  exhaust system components A running engine gets                     the fuel system Take care in catching any fuel that might  very hot                                                            spill DO NOT allow any smoking open flames or other                                                                       sources of fire near the fuel system or engine when servic Always check the engine coolant level at the coolant                 ing Ensure proper ventilation exists when servicing the  recovery tank                                                       fuel system                                                                     Do not alter or modify the fuel system A WARNING         Steam can cause injury or death                 Be sure all fuel supplies have a positive shutoff valve                                                                     Be certain fuel line fittings are adequately tightened and In case of an engine overheat allow the engine to cool              free of leaks   before touching the engine or checking the coolant               Make sure a fire extinguisher is installed nearby and is                                                                      properly maintained Be familiar with its proper use                                                                      Extinguishers rated ABC by the NFPA are appropriate                                                                      for all applications encountered in this environment                                                          Engines  Generators                                             SAFETY  STARTING                                                     TOXIC EXHAUST GASES A WARNING Accidental starting can cause injury                         A WARNING         Carbon monoxide CO is a deadly gas Dr death                                                                         Ensure that the exhaust system is adequate to expel gases Disconnect the battery cables before servicing the engine               discharged from the engine Check the exhaust system   generator Remove the negative lead first and reconnect                 regularly for leaks and make sure the exhaust manifolds   it last                                                                are securely attached and no warping exists Pay close                                                                           attention to the manifold water injection elbow and Make certain all personnel are clear of the engine before                                                                           exhaust pipe nipple  starting                                                                         Be sure the unit and its surroundings are well ventilated Make certain all covers guards and hatches are re  installed before starting the engine                                  In addition to routine inspection of the exhaust system                                                                           install a carbon monoxide detector Consult your boatBAmRY EXPLOSION                                                            builder or dealer for installation of approved detectors                                                                         For additional information refer to ABYC T22 educa A WARNING         Battery explosion can cause injury                     tional information on Carbon Monoxide Dr death Do not smoke or allow an open flame near the battery                                                                         A WARNING       Carbon monoxide CO is an invisible                                                                         odorless gas Inhalation produces flulike symptoms  being serviced Lead acid batteries emit hydrogen a                   nausea Dr death   highly explosive gas which can be ignited by electrical  arcing or by lit tobacco products Shut off all electrical                                                                         Do not use copper tubing in diesel exhaust systems Diesel  equipment in the vicinity to prevent electrical arcing dur                                                                          fumes can rapidly destroy copper tubing in exhaust sys  ing servicing                                                                          tems Exhaust sulfur causes rapid deterioration of copper Never connect the negative  battery cable to the posi              tubing resulting in exhaustwater leakage  tive  connection terminal of the starter solenoid Do               Do not install exhaust outlet where exhaust can be drawn  not test the battery condition by shorting the terminals                through portholes vents or air conditioners If the engine  together Sparks could ignite battery gases or fuel vapors             exhaust discharge outlet is near the waterline water could  Ventilate any compartment containing batteries to prevent               enter the exhaust discharge outlet and close or restrict the  accumulation of explosive gases To avoid sparks do not                flow of exhaust Avoid overloading the craft  disturb the battery charger connections while the battery  is being charged                                                      Although diesel engine exhaust gases are not as toxic as                                                                           exhaust fumes from gasoline engines carbon monoxide Avoid contacting the terminals with tools etc to prevent             gas is present in diesel exhaust fumes Some of the symp   bums or sparks that could cause an explosion Remove                   toms or signs of carbon monoxide inhalation or poison   wristwatch rings and any other jewelry before handling                ing are   the battery                                                                           Vomiting Always tum the battery charger off before disconnecting                  Dizziness   the battery connections Remove the negative lead first   and reconnect it last when servicing the battery                       Throbbing in templesBATTERY ACID                                                                Muscular twitching                                                                            Intense headache A WARNING Splphuric acid in batteries can cause                          Weakness and sleepiness severe injury Dr death                                                AVOID MOVING PARTS When servicing the battery or checking the electrolyte  level wear rubber gloves a rubber apron and eye protec             A WARNING Rotating parts can cause injury  tion Batteries contain sulfuric acid which is destructive If         Dr death  it comes in contact with your skin wash it off at once  with water Acid may splash on the skin or into the eyes               Do not service the engine while it is running If a situation  inadvertently when removing electrolyte caps                           arises in which it is absolutely necessary to make operat                                                          Engines  Generators                                                                   ii                                            SAFETY INSTRUCTIONS    ing adjustments use extreme care to avoid touching                ABYC NFPA AND USCG PUBLICATIONS FOR    moving parts and hot exhaust system components                                                                       INSTAlliNG DIESEL ENGINES Do not wear loose clothing or jewelry when servicing                 Read the following ABYC NFPA and USCG publications  equipment avoid wearing loose jackets shirts sleeves             for safety codes and standards Follow their recommenda  rings necklaces or bracelets that could be caught in                tions when installing your    moving parts                                                       ABYC American Boat and Yacht Council Make sure all attaching hardware is properly tightened              Safety Standards for Small Craft  Keep protective shields and guards in their respective                Order From  places at all times                                                                          ABYC Do not check fluid levels or the drive belts tension while             3069 Solomons Island Road   the engine is operating                                               Edgewater MD 21037 Stay clear of the drive shaft and the transmission coupling          NFPA National Fire Protection Association   when the engine is running hair and clothing can easily            Fire Protection Standard for Motor Craft   be caught in these rotating parts                                                                        Order FromHAZARDOUS NOISE                                                           NFPA                                                                          11 Tracy Drive A WARNING        High noise levels can cause hearing                                                                          Avon Industrial Park                                                                          Avon MA 02322 loss                                                                       USCG United States Coast Guard                                                                       USCG 33CFR183 Never operate an engine without its muffler installed                                                                        Order From Do not run an engine with the air intake silencer  removed                                                                US Government Printing Office                                                                          Washington DC 20404 Do not run engines for long periods with their enclosures  open A WARNING 00 not work on machinery when you are mentally or physically incapacitated by  MANUALMany of the preceding safety tips and warnings are repeatedin your Operators Manual along with other cautions andnotes to highlight critical information Read your  maintain your equipment and follow all   to install an engine should begin with a thorough examination of the American Boat and Yacht CouncilsABYC standards These standards are a combination ofsources including the USCG and the NFPASections of the ABYC standards of particular interest are      H2 Ventilation      Pl Exhaust systems      P4 Inboard engines      E9 DC Electrical systemsAIl installations must comply with the Federal Code ofRegulations FCR                                                           Engines  Generators                                                                 iiiEngines  Generators                                                                              TABLE OF  3       Engine Adjustments 39   Product Software 3                 Tightening the Cylinder Head 39    Model Designations 3                                Adjusting Valve Clearance 39   Notes Cautions and Warnings  3                        Adjusting Fuel Injection Timing  40   Ordering PartsSerial Number Location 3                               Adjusting NoLoad Engine Speeds   Specifications 5                      Lubrication System Service 42Testing for Overhaul 6               Description  42   How to Judge Engine Overhaul Period  6                               Disassembly  42       Cause of Low Compression  6                              Oil Filter and Oil Pump  42       Measuring Compression Pressure  6                             Inspection  43   Overhaul Conditions  6                      Oil Pump 43       Disassembly  7                Reassembly  43       Reassembly  7               Testing the Oil Pressure  43Service Standards 8               Oil Pressure Switch  44Technical Data                  Generators  44     Tightening Torque  11                   Propulsion Engines  44Engine  2                 Fuel System 45Engine Parts Identification 16                    Description  45   2Cylinder Models  16               Fuel System Service 47   3Cylinder Models  17                  Disassembly  47Cylinder Head 18                  Fuel Filter  47    Construction  18                Fuel Lift Pump  47                                                                                                                      Fuel Injection Pump   47Cylinder Head Service 20                      Injector  48   Disassembly  20               Inspection  48    Inspection  20              Fuel Filter  48       Cylinder Head  20                                                                                                                      Fuel Lift Pump  48       Valve Guide  20                    Fuel Injection Pump  48       Valve Seat  20                 Nozzle  48       Valve  21                                                                                                                   Reassembly  48       Valve Spring  21                   Fuel Filter  48       Rocker Arm and Rocker Shaft  21                                Fuel Lift Pump  48    Reassembly  22                                                                                                                      Injection Pump  48       Partial Reassembly  22                                                                                                                      Installation and Adjustment of Fuel Injection Pump  49       Installation of Cylinder Head Assembly 22                                     Injector  50       Valve Clearance Adjustment  22                              Adjustment and Installation of Nozzle Holder Assembly  50Cylinder Block 23          Raw Water Cooling Circuit 52    Construction  23            Description  52Cylinder Block Service 25               Raw Water Pump Service 53    Disassembly 25              Pump Overhaul  Raw Water Pump PN 33636 53       A Models  25                  Disassembly  53       B C and D Models  25                                                                                                                      Inspection 53       Removing Piston Pin  26                                                                                                                      Reassembly 53    Inspection  26                                                                                                                  Pump Overhaul  Raw Water Pump PN 32610 54       Cylinder Block 26                      Disassembly 54       Piston Piston Pin and Piston Rings  27                                Inspection 54       Connecting Rod 27                                                                                                                      Reassembly  54       Crankshaft  28                                                                                                                  Pump Overhaul  Raw Water Pump PN 24143  55       Main Bearings and Connecting Rod Bearings  28                                           Disassembly  55       Gearcase  29                                                                                                                      Inspection 55       Timing Gears and Lube Oil Pump Gear 29                                        Reassembly  55       Camshaft  29       Fuel Injection Pump Camshaft  29                         Fresh Water Cooling Circuit 56       Ball Bearings  29               Description 56       Tappets  29         Fresh Water Cooling Service 57       Push Rods  29              Disassembly  57    Reassembly  A Models 30                         Inspection 57    Reassembly  B C and D Models  33                                   Water Pump 57Governor 37              Thermostat  57   Description 37             Reassembly  57   Disassembly 37                   Drive Belt Adjustment 57    Inspection  37       Admiral Control Panel 58       Governor Lever 37                   Description  58       Governor Spring 37                Captain Control Panel 59       Needle Bearing  37                 Description  59   Reassembly and Adjustment  37                      Control Panel  60Engine Shutoff 38               60    Engine with Manual Stop Standard  38                                 Hourmeter Inoperative  60   Optional Key Switch Shutoff D Models only  38                                         Tachometer Inoperative  60       Installing and Adjusting the Key Switch                                                                        Tachometer Sticking  60          Shutoff Solenoid 38                        Tachometer Inaccurate  60       KeyStop Solenoid System Operation                                                                         Manual Starter Disconnect Toggle Switches  61          Checking Procedure 38                        Water Temperature and                                                                                                                      Oil Pressure Gauges  61                                                                                                                                                                                                      continued                                                                                               Engines  Generators                                                                                                           1                                                                              TABLE OF  Panel Early Models 62                         Replacement of Field Coils  91    Activation by Key Switch  62                       Low Voltage Output   Service 64                    High Voltage Output  92    Description  64            Solenoid with Throttle Linkage  92    Adjustment and Repair  64                  WMD Generator AC Internal Wiring Diagrams 93        Pinion Gap Inspection  64                  WMD Generator DC Electrical System 94        NoLoad Test 64                 WMD Generator Wiring Diagram 24700  94    Solenoid  65           WMD Generator Wiring Schematic 24700  95    Starter Disassembly  65               80 BTD Generator 96    Starter Inspection  66               Description  96        Solenoid  66          80 BTD Generator  97        Inspecting the Armature  66                      80 BID Internal Wiring Schematic  97        Brush and Brush Holder Inspection  66                              80 BID Internal Wiring Schematic with Voltage        Field Coil Inspection  67                        Regulator Circuit Removed  98    Starter Adjustment and Reassembly  67                              Bridge Rectifier  100DC Electrical System 68                        Testing the Bridge Rectifier for Faults    Description  68                   with an Ohmmeter  100        Engine 12Volt Control Circuit 68                            Exciter Stator Windings  101    Charging System  68                  Exciter Rotor  102    Alternator  68                        Main Stator Windings  103        Checking for Proper Voltage  68                          Compound Transformer  103    Battery Maintenance  69                   Selector Switch  104    Glow Plugs  69               Bridge Rectifier Wiring   Service 70                        NoLoad Voltage Adjustment  105    Description 70             Optional Voltage Regulator  106    Alternator   70                           Installation  106        Testing the Charging Voltage  70                          Generator Frequency  107        Output Test  71                   Manual Check  107    Disassembly  71                   Electrical Check  107    Inspection  72            Winding Connections  108        Diode 72         100 BTD Generator 109        Checking for Short Circui  72                       Description  109        Checking for Open Circui  72                     100 BTD Generator  110        Checking Diode Trio  72                      100 BID Internal Wiring Schematic  ll0        Stator  73           Residual Voltage Check  112        Field Coil Rotor  73                  Bridge Rectifier  112        Checking Brush and Brush Spring  73                                    Testing the Bridge Rectifier for Faults        Checking the Slip Ring  73                             with an Ohmmeter  113    Regulator  73            Internal Wiring Diagram  113    Reassembly  74               Component Resistance Values   75               Component Resistance Checks  114DC Electrical System 76                        Exciter Stator Windings  114    Engine Wiring Diagram 24666 Key Switch  76                                      Exciter RotorlField  115    Engine Wiring Schematic 24666 Key Switch 77                                        Main Stator Windings  116    Engine Wiring Diagram 33685 Key Switch                                                                        Compound Transformer  116        Two Pushbuttons  78                   Selector Switch  116    Engine Wiring Schematic 33685 Key Switch                                                                      Bridge Rectifier Wiring  116        Two Pushbuttons 79                     NoLoad Voltage Adjustment  117    Engine Wiring Diagram 36844 Admiral Panel 80                                        VoltageHertz Connection Bar  117    Engine Wiring Schematic 36844 Admiral Panel 81                                         Generator Frequency  118    Engine Wiring Diagram 36467 Captain Panel 82                                        Wiring Connections  119    Engine Wiring Schematic 36467 Captain Panel  83                                    BT Generator DC Electrical System  l20    Engine Wiring Diagram 39144 Admiral                                                                          BT Generator Early Models Wiring Diagram 34651  120        Captain Panels 84                 80 BID  100 BID Generators Wiring    Engine Wiring Schematic 39144 Admiral                                                                            Diagram 36412  122        Captain Panels 85                 80 BID  100 BID Generators WiringStandard Hardware 86                      Schematic 36412  123Sealants Lubricants 86                  BC Generator 124Metric Conversions 87                  Description  124Generator Information 88                    Guide  124    Use of Electric Motors  88                 BC Generator  125    Required Operating Speed  88                       Internal Wiring Schematic With Battery Charging Circuit  125    Generator Frequency Adjustment 88                             Rotating FieldAuxiliary Windings and Diodes  126    Generator Maintenance 88                      Main Stator Windings  127    Generator   88                       Exciter Windings and Capacitors  127WMD Generator 89                 Battery Charging Circuit  129    Description 89             Generator Frequency Hertz Adjustment  130    Disassembly 89                   50 Hertz  60 Hertz Adjustment  130    Inspection 89                Engine SpeedGenerator Hertz Adjustment  130    Reassembly 89                   NoLoad Voltage Adjustment  131WMD Generator  90                         BC Generator DC Electrical System 132    No Electrical Output  90                  44 BC  60 BC Generator Wiring Diagram 35951  132    Flash Field Coils 90                44 BC  60 BC Generator Wiring Schematic 35951  133                                                                                                Engines  Generators                                                                                                            2                                                        service manual contains detailed information relating to         Differences between 2cylinder and 3cylinder engine modelsthe proper operation of the major components and systems of           are described in the disassembly inspection and reassemblythe engine or generator Included are disassembly inspection        procedures throughout the Engine section of this manualservice and reassembly instructions for the guidance of suitably equipped and staffed marine engine service and rebuild          NOTES CAUTIONS AND WARNINGSing facilities The necessary procedures should be undertaken         As this manual takes you through the service proceduresonly by such facilities and their personnel Refer also to your       maintenance schedules and  of your  parts catalog when performing an engine over               critical information will be highlighted byhaul                                                                 NOTES CAUTIONS and WARNINGS An explanation fol                                                                      lowsPRODUCT SOFTWARE                                                                      NOTE An operating procedure essential to noteProduct software tech data parts lists manuals brochuresand catalogs provided from sources other than WESTERBEKE are not within WESTERBEKES control                              A CAUTION Procedures which if not  CANNOT BE RESPONSIBLE FOR THE                               observed can result in the damage or destruction ofCONTENT OF SUCH SOFTWARE MAKES NO WAR                                your  OR  WITH RESPECTTHERETO INCLUDING ACCUR4CY TIMELINESS ORCOMPLETENESS THEREOF AND WILL IN NO EVENTBE LIABLE FOR ANY TYPE OF DAMAGE OR INJURY                                                                       A WARNING Procedures which if not properly fol                                                                       lowed can result in personal injury or loss of lifeINCURRED IN CONNECTION WITH OR ARISING OUTOF THE FURNISHING OR USE OF SUCH  customers should also keep in mind the                     ORDERING PARTSSERIAL NUMBER LOCATIONtime span between printings of WESTERBEKE product soft               Whenever replacement parts are needed for engines alwaysware and the unavoidable existence of earlier WESTER                 provide the engine model number and engine serial numberBEKE manuals In summation product software provided                 as they appear on the silver and black identification namewith WESTERBEKE products whether from WESTER                        plate located on the manifold For generators provide theBEKE or other suppliers must not and cannot be relied upon           complete generator model number engine serial number andexclusively as the definitive authority on the respective prod       generator serial number as they appear on the silver anduct It not only makes good sense but is imperative that              black decal located on the generator endappropriate  of WESTERBEKE or the supplier in question be consulted to determine the accuracy andcurrentness of the product software being consulted by  MODEL  manual contains certain descriptions procedures  that vary depending on the             The engine serial number can also be found stamped into themodel Where references to specific models are necessary             engine block just outboard of the injection pump The generfour basic model group designations are used A Models               ator serial number is stamped into the generator housing onB Models C Models and D Models                                      the side or above the rear carrier bearing         A MODELS                           B MODELS                  You must provide us with this information so we may prop       2CYLINDER                     3CYLINDER                  erly identify your  In addition include a                                                                      complete part description and part number for each part            GENERATORS                                                ENGINES                               needed see the separately furnished Parts List Also insist           60 Hz    50 Hz                  60 Hz     50 Hz                                                                      ijpon WESTERBEKE packaged parts because will fit or W13      WMD 44    WMD 33    W18       WMD 60    WMD 45        generic parts are frequently not made to the same specifica W13A     44 BCD    33 BCD    W18       60 BCD    45 BCD        tions as original equipment         C MODELS                           D MODELS                  NOTE Component locations in this manual are referenced       3CYLINDER                     3CYLINDER                  from the front of the engine which is the pulleydrive belt end            GENERATORS                       GENERATORS               Left and right sides are determined as follows imagineENGINES                         ENGINES                               straddling the engine facing in the same direction as the           60 Hz    50 Hz                  60 Hz     50 Hz                                                                      front of the engine the left side is at your left the right side W21     WMD 77     WMD 58   35B Three   100 BTD   75 BTD                                                                      is at your right          WMD 80     WMD 60 W21A    80 BTD     60 BTD RD60                                                          Engines  Generators                                                                  3                            INTRODUCTION   Owners may find it convenient to fill in the data on the decal or  shown below to provide a quick reference when using this service manual             SPECIFICATION 50 HZ                     60 HZ             MODEL               RPM               KW                KVA               VOLTS               AMPS                ENG HP                ENG SER NO              GEN SER NO              PFIPHASE                        I              WIRES                RATING                INSUL CLASS               TEMP RISE                BAITERY                CO                                  GENERATOR DECAL                    PROPULSION ENGINE IDENnFICATION NAMEPLATE                                 Engines  Generators                                         4                              SPECIFICATIONS                                     A MODELS                         B MODELS                          C MODELS                            D MODELS                                   2CYLINDER                     3CYLINDER                      3CYLINDER                        3 CYLINDER                                        GENERATORS                       GENERATORS                        GENERATORS                         GENERATORS                         ENGINES                          ENGINES                          ENGINES                              ENGINES                                      60 Hz     50 Hz                 60 Hz      50 Hz                   60HZ      50 Hz                    60 Hz     50 Hz                         W13        WMD44     WMD33      W1B     WMD60       WMD45    W21         WMD77        WMD 5B 358 Three    100 BTD   75 BTD                         W13A      44 BCD    33 BCD     W1B     60 BCD      45 BCD                WMDBO        WMD60                                                                                           W21 A       BO BTD       60 BTD                                                                                           RDSOEngine Type                           Vertical inline 4cycle OHV  with heat exchanger diesel                                 2                                                                        3Bore  Stroke             28 x 30 in 70 x 78 mm 26 x 31 in 65 x 78 mm                29 x 31 in 73 x 78 mm 31 x 31 in 78 x 78 mmTotal Displacement         366 cu in 060 liters        474 cu in 078 liters          597 cu in 098 liters        682 cu in 112  Chamber                                                        Swirl chamber  Ratio                                                                  231Injection Order                         12                                                              132Injection Timing                                  Engines 23  15 BTDC Generators 19  15 BTDCInjection Pump                                                                Bosch M typeInjection Nozzle                                                               Throttle typeGovernor                                                               Centrifugal flyweight typeFuel                                                              Diesel 2 cetane rating 45 or                                                        Forced lubrication trochoid pumpOil Filter                                               Paperelement filter full flow type 5 liter capacitySump Capacity               25 quarts 23 liters                                                  36 quarts 35 litersFresh Water Pump                                                              Centrifugal typeFresh Water  approximate       40 quarts 37 liters                                                  50 quarts 48 litersRaw Water Pump                                               Positive displacement Neoprene  Motor                                                       12 volts  16 kW reduction typeDC Alternator                                               12 volt  50 amp  internal voltage  Angle                                                  15 Continuous in all directions                                                                     20 Temporary 20  Battery                                                      12 volt 300 CCA or  Value   Standard                                                         455 psi at 280 rpm 32 kgcm2   Minimum                                                          370 psi at 280 rpm 26 kgcm2   Overhaul                                                         312 psi at 280 rpm 22                                                                  355 psi 25 kgcm2                                                              Engines  Generators                                                                        5                                            TESTING FOR OVERHAULHOW TO JUDGE ENGINE OVERHAUL PERIOD                                    5 Install a pressure gauge adapter in the first injector hole                                                                          or glow plug hole to be testedCause of Low Compression                                               6 Connect the pressure gauge to the  the time at which an engine should be overhauledis determined by various conditions such as lowered enginepower output decreased compression pressure and increasedfuel and oil consumption The lowered engine power outputin the case of diesel engines is not necessarily due to troublewith the engine itself but is sometimes caused by injectornozzle wear or injection pump wear It is most reasonable tojudge by a decrease in compression pressure The decrease incompression pressure is caused by many factors It is therefore necessary to determine a cause or causes on the basis ofdata produced by periodic  Oil                                                           MEASURING                                                                                                                   on a seasonal basis is a good means of monitoring                                                        PRESSUREengine internal wear When caused by worn cylinders orpiston rings the following symptoms will occur         Low engine power output                                       7 Crank the engine with the starter motor until the pressure         Increased fuel consumption                                       reaches a maximum value Read the engine rpm and the         Increased oil consumption                                        pressure gauge when the starter rotation has become                                                                          stable         Hard engine starting                                                                       8 Repeat the above procedure for each cylinder         Noisy engine operation                                                                       9 If the compression differs by more than 427 psi 30These symptoms often appear together Increased fuel con                 kglcm 2 at 200 rpm then determine the cause of the lowsumption and hard engine starting can result also from exces             pressure and repair as necessarysive fuel injection improper injection timing and wear ofplugs and nozzles They are caused also by defective electri           NOTE Do not guess the conditions of other cylinders rum acal devices such as the battery alternator starter and glow           result of testing one cylinder Be sure to measure the complugs Therefore it is desirable to judge the optimum engine           pression pressure for each cylinder Look for cylinders withoverhaul time by the lowered compression pressure caused                dramatically at least 20 lower compression than the averby worn cylinders and pistons plus increased oil consump              age of the other cylinders If the weak cylinder is flanked bytion In diesel engines satisfactory combustion is obtained           healthy cylinders the problem is either valve or headgasketonly under sufficient compression pressure If an engine                related or very low compression in an adjacent cylinderlacks compression pressure incomplete combustion of fuel              indicates gasket failure Abnormally high readings on allwill take place even if other parts of the engine are operating         cylinders indicate heavy carbon accumulations a  To judge the period of engine overhaul it is impor          that might be accompanied by high pressures and noisetant to measure the engine compression pressure regularly At          NOTE In case of severe vibrations detonation noise andthe same time the engine speed at which measurement of                smoky sooty exhaust have the injectors overhauled by ancompression pressure is made should be checked because the             authorized fuel injection service center Poor fuel  pressure varies with engine rpm                           contaminants and loss ofpositive fuel pressure to theThe engine rpm can be measured at the front end of the                 injection pump will result in injector                                                                        OVERHAUL  Compression Pressure                                         Compression pressure tends to increase a little in a new                                                                       engine until piston rings and valve seats have been broken inTo check the compression pressure follow this procedure              Thereafter it decreases gradually with the progressive1 Warm the engine                                                    wear of these parts2 Remove all the fuel injectors or all the glow plugs from            When decrease of compression pressure reaches the repair   the cylinder block                                                 value the engine must be overhauled3 Disconnect the fuel solenoid from the throttle arm                  The engine requires overhaul when oil consumption is high   generator models only                                            blowby evident and compression values are at minimum or                                                                       below Engine compression should be 32 kglcm 2 at 2804 Place the stop lever in the OFF position propulsion                                                                       rpm See SERVICE STANDARDS chart   models only                                                          Engines  Generators                                                                   6                                          TESTING FOR OVERHAULNOTE The SERVICE STANDARDS chart gives the values for               or replacement of the engine components Refer to            1 Prepare all parts necessary for  values and measurements during engine overhaul                                                                    2 Clean or wash the parts Apply oil on surfaces                                                             needed or specified1 Before disassembly and cleaning carefully check for             3 Carefully check gaskets packings and oil seals even if   defects which cannot be found after disassembly and                 not specified to check Replace with new ones if defec   cleaning                                                           tive2 Drain water fuel and oil before disassembly                    4 Be sure to install in proper directions and positions3 Clean or wash the engine exterior                                  pay attention to dowel pins mating marks and specified                                                                       directions Where tightening torque is not specified4 Do not remove or disassemble the parts that require no              tighten evenly to an ordinary torque Apply sealant where   disassembly                                                        specified5 Perform disassembly in a proper order using proper tools        5 After completion of the reassembly manually rotate the   Keep disassembled parts in order Apply oil when neces             engine crankshaft two complete revolutions to ensure   sary Take special care to keep the fuel system parts free          there is no binding or obstructions Prepare for starting   from the intrusion of dust and dirt                                the engine and idle the engine sufficiently for a test run                                                       Engines  Generators                                                                7                                                           SERVICE STANDARDSThese SERVICE STANDARDS specify thevalues at which the engine components will                            A MODELS                    B MODELS                    C MODELS                    D MODELSrequire REPAIR replacement is optional                           2CYLINDER                3CYLINDER                3CYLINDER                3CYLINDERor REPLACEMENT due to maximum                                            GENERATORS                  GENERATORS                 GENERATORS                       GENERATORS                                                             ENGINES                 ENGINES                     ENGINES                              wear It is important to observe                               60Hz 50Hz                   60Hz 50Hz                  60Hz 50Hz                          60Hz 50Hzthese standards for your                    W13       WMD44 WMD33 W1S          WMD60    WMD4S W21       WMD77     WMDSS    35B Three    100 STD 7S STDand to take action when necessary to main                   W13A      44 BCD    33 BCD   W1a   60 BCD   4S BCD           WMDSO     WMD60tain a high level of safety dependability                                                                              W21A   SO STD    60 STDand performance                                                                                                        RD60All measurements are in mm unless otherwise notedTo convert mm to inches multiply by 03937                                                                                                                                 REPAIR or                DESCRIPTION                                MODELS                            STANDARD VALUE                     replacement             REPLACEMENT                                                                                                                                 Required at             Required at   ENGINE COMPRESSION PRESSURE                         A                     32 kgcm 2at 320 rpm                                26 kgcm2                                                         B C D               32 kgcm2at 280 rpm                                 26 kgcm 2   INTERCYLINDER DIFFERENCE max                     A B C D               25 kgcm2   INJECTION ORDER                                     A                     1 2                                                         B C D               132   CYLINDER HEAD       Bottom surface distortion                       A B C          D      Within 005                                            01      Valve seat angle IN and EX                     A B C          D      45      Valve seat width IN and EX                     A                     10 13                                               25                                                         B C          D      13 18                                               25      Valve seat sinkage                               A B C          D      05                                                                                 1   VALVE CLEARANCE IN and EX                         A B C          D      025 when engine is cold   VALVE      Stem 00                                        A B C D               66      Stem to guide clearance           Intake                                      A   B    C     D      012                                                                           010           Exhaust                                     A   B    C     D      025                                                                           015      Valve face angle                                 A   B    C     D      45      Valve head thickness margin width              A   B    C     D      10                                                                           05   VALVE SPRING       Free length                                     A B C D               43                                                     10       Instalied loadllength                           A B C D               140 kg  07 kg36 mm                                                       15       Squareness                                      A B C D               2                                                                                  3   ROCKER ARM      Arm to shaft clearance                           A B C D               005 mm                                                                       02   CYLINDER BLOCK        Camshaft hole 10          Front bushing                                A B C D               45        Cylinder bore                                  A                     70                                                     02                  95 Replace block                                                                                                                                                          or sleeve                                                            B                65                                                     02                  95 Replace block                                                                                                                                                          or sleeve                                                                C            73                                                     02                  95 Replace block                                                                                                                                                          or sleeve                                                                      D      78                                                     02                  95 Replace block                                                                                                                                                          or sleeve        Cylinder bore oversize finish tolerance        A B C D               oto 003 for each oversize        Taper of cylinder                              A B C D               within 001NOTE Valve seats are a part of the cylinder head A machine shop can install valve seats and cut the seats to properly fit the valves                           continued                                                                          Engines  Generators                                                                                     8                                                         SERVICE STANDARDSAll measurements are in mm unless otherwise notedTo convert mm to inches multiply by 03937                                                                                                                   REPAIR or                 DESCRIPTION                             MODELS                     STANDARD VALUE                replacement    REPLACEMENT                                                                                                                   Required at    Required at   PISTON      00 skirt end                               A                  70                                                         B              65                                                             C          73                                                           0            78       Piston to cylinder clearance                  A B C 0            035  086                                  120            03       Oversize                                      A                  025 050 075 100                                                       B C 0            025 050 075   PISTON PIN      Type                                           A B C              Semifloating type                                                                  0     Fullfloating type       00                                          A B C              19                                                           0            23       Piston to pin clearance                      A B C 0            002 slight force fitheat                               008       Pin to connecting rod clearance               A B C 0            Pressfit load 500 1500 kg   PISTON RINGS                                      A B C 0            3 No1 chrome plated barrel type                                                                          No2 and No3 taper ring      Number of oil rings                            A B C 0            1 chrome plated with coil expander      Ring side clearance         Compression No1                            A   B   C    0     0812                                                      03                         No2                        A   B   C    0     05  09                                                    02                         No3                        A   B   C    0     04  08                                                    02                         Oil ring                    A   B   C    0     03  07                                                    02      Ring gap                                       A   B   C    0     15 40                                     125            15   CONNECTING ROD      Bend and distortion                            A B C 0            05                                                        015      Sideplay clearance                             A B C 0            01  035                                                  05      Smallend bushing 10                               0            23                                                        008   CONNECTING ROD BEARING      Standard Type                                  A B C 0            Kelmet metal with back metal      Oil clearance                                  A B C 0            012 025                                   05             015      Undersize                                      A B C 0            025 050 075   CRANKSHAFT      Bend                                           A B C        0     03                                                         005      End play                                       A                  00603                                                       B C        0     005 021                                   03           005       Main 00                                     A                  59                                           015        095                                                       B C        0     52                                           015        095      Conn 00                                     A B C        0     42                                           015        095      Undersize finish tolerance         Main common to all                        A B C 0            00015         Conn common to all                       A B C 0            015   MAIN BEARING      Standard type                                  A B C 0            Kelmet metal with back metal                                                                        flanged metal for center bearing only       Oil clearance                                 A B C 0            04 05                                     06           010       Undersize                                     A B C 0            025 050 075                                                                                                                                       continued                                                          I                                                                   I   Engines  Generators                                                                              9All measurements are in mm unless otherwise noted                                                         SERVICE STANDARDSTo convert mm to inches multiply by 03937                                                                                                                      REPAIR or                 OESCRIPTION                             MOOELS                   STANOARO VALUE                     replacement    REPLACEMENT                                                                                                                      Required at    Required at   CAMSHAFT      Front bearing                                  A B C 0            Lead bronze alloy with back metal      Oil clearance                                  A B C 0            004  008                                     010             015      Cam lobe height IN and EX                    A B C 0            3576                                                           10   PUMP CAMSHAFT       Front bearing                                 A B C 0            Ball bearing       Cam lobe height                               A B C 0            44                                                              10   TAPPET      00                                           A B C 0            23      Tappet to cylinder block clearance             A B C 0            01  08                                                        015   PUSH ROO       Bend                                          A B C 0            Within 03                                                                      LUBRICATION   ENGINE OIL   Oil specification        API service classification                   A B C              Class CC                                                           0            Class CF or CG4       Viscosity   above 20C                        A B C 0            SAE30 or 10W30                   5 to 20C                        A B C 0            SAE20 or 10W30                   below 5C                         A B C 0            SAE 10W30   OIL PUMP       Type trochoid                                A   B   C    0       Check valve opening pressure                  A   B   C    0     4  04 kgcm 2 at 500 rpm of pump speed       Outer rotor to body clearance                 A   B   C    0     015  02                                                       03       Outer rotor to inner rotor clearance          A   B   C    0     005  012                                                      025       Rotor to cover clearance                      A   B   C    0     003007                                                        020   OIL PRESSURE SWITCH        Contact closing pressure       Engine                                        A B C 0            4  6 psi normally open       Generator                                     A B C 0            4  6 psi normally open                                                                      FUEL SYSTEM    FUEL INJECTION PUMP       Model NOPFR2M                               A       Model MOPER3M                                   B C 0       At smoke set SS          Pump speed                                 A B          0     1500 rpm 275  10 mm3st          Pump speed                                         C          1500 rpm 38  10 mm3st       At start set MS          Pump speed                                     B              150 rpm 36  75 mm3    st          Pump speed                                 A   C 0            150 rpm 34  5 mm3    st       Difference from reference cylinder            A B C 0            Within 2 mrnsrev cylinder       Prestroke                                     A B C 0            22  01    NOZZLE       Throttle type                                 A B C 0       Model NOON4S024                             A B C 0       Injection start pressure                      A B C 0            120  10 kgcm2                                                                      Engines  Generators                                                                             10                                              TECHNICAL DATA                                                TIGHTENING TORQUE                DESCRIPTION                 MODELS             TYPEQUANTITY      TIGHTENING TORQUE kgm  CYLINDER HEAD BOLT                    A                                   6          120 130                                            B C D            M12 bolt       8       115  125 wet                                            B C D            M10 bolt       3        65  80 wet  CRANKSHAFT PULLEY NUT                 A B C D              M18                          1520  MAIN BEARING CAP BOLT                 A B C D                                           555  CONNECTING ROD CAP NUT                A B C D                                           3235  FLYWHEEL MOUNTING       8T bolt with flange            A B C    D                                        13 14       8T bolt with washer old        B C    D                                      115 125  OIL DRAIN HOSE BANJO BOLT             A B C    D                                         56  OIL FILTER                            A B C    D                                        1113  FUEL INJECTION PUMP        Delivery valve holder           A B C D                                            45  NOZZLE HOLDER        Holder mounting bolt            A B C D                                            15 2        Holder body and retaining nut   A                                                  810                                          B C D                                             68  GLOW PLUG                             A B C D                                           152Conversion factor to get Nm  ftIb x 1356  Nm                                                     Engines  Generators                                                          11                                         ENGINE  following  table describes certain                  NOTE The engines electrical system is protected by a 20problems relating to engine service the probable causes of            ampere manual reset circuit breaker located on a bracket onthese problems and the  to overcome                    the left front side of the engine The preheat solenoid isthese problems                                                        mounted on the same bracket      PROBLEM                               PROBABLE CAUSE                                         HARD STARTING              LOW CRANKING SPEED                            1 Engine oil viscosity too high                        1   Replace engine oil with less viscous oil                            2 Rundown battery                                     2   Recharge battery                            3 Worn battery                                         3   Replace battery                            4 Battery terminals loosely connected                  4   Clean terminals and correct cables                            5 Defective starter                                    5   Repair or replace starter                            DEFECTIVE INJECTION SYSTEM                            1 Air trapped in fuel passage                         1 Bleed air from fuel system                            2 Clogged fuel filter                                 2 Clean or replace filter                            3 Low injection pressure                              3 Adjust injection pressure                            4 Inadequate spray                                    4 Clean or replace nozzle                            5 Injection pump delivering insufficient fuel         5 Repair or replace injection pump                            6 Injection too early                                 6 Adjust injection timing                            MAIN ENGINE TROUBLES                            1 Low compression                                 a Incorrect valve clearance                          a Adjust valve clearance                                 b Inadequate contact of valve seat                   b Lap valve                                 c Valve stem seized                                  c Replace valve and valve guide                                 d Broken valve spring                                d Replace valve spring                                 e Compression leaks through cylinder head gasket     e Replace gasket                                 f Piston ring seized                                  f Replace piston and piston ring                                 g Worn piston ring and cylinder                      g Overhaul engine                            2 Burnt glow plug                                     2 Replace glow plug                            3 Faulty glow plug operation                          3 Check glow plugs and solenoid                            4 Incorrect governor lever position                   4 Set lever to starting position LOW OUTPUT                 LOW COMPRESSION                                         See HARD STARTING                            INJECTION SYSTEM OUT OF ADJUSTMENT                            1 Incorrect injection timing                          1 Adjust injection timing                            2 Insufficient injection                              2 Repair or replace injection pump                            3 Low injection pressure                              3 Check injection nozzle and adjust pressure                            INSUFFICIENT FUEL                            1 Air trapped in fuel system                          1 Check and retighten connector                            2 Clogged filter                                      2 Clean or replace filter                            3 Contaminated fuel tank                              3 Clean tank                            INSUFFICIENT INTAKE AIR                            1 Clogged air inlet                                   1 Clean or replace air inlet                                                                                                                                 continued                                                           Engines  Generators                                                                  12                                  ENGINE     PROBLEM                          PROBABLE CAUSE                                           OUTPUT cont   OVERHEATING                     1 Low coolant level                                      1   Add coolant                     2 Loose Vbelt                                           2   Adjust or replace Vbelt                     3 Incorrect injection timing                             3   Adjust injection timing                     4 Low engine oil level                                   4   Add engine oilEXCESSIVE OIL        OIL           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 Loose drain plug                                       4   Retighten plug                     5 Loose oil pipe connector                               5   Retighten oil connections                     6 Broken rocker cover gasket                             6   Replace gasket                     7 Loose rocker cover attaching bolts                     7   Retighten attaching bolts                     OIL LEVEL RISING                     1 Incorrectly positioned piston ring gaps                1   Correct ring gap positions                     2 Displaced or twisted connecting rod                    2   Replace connecting rod                     3 Worn piston ring                                       3   Replace ring                     4 Worn piston or cylinder                                4   Replace piston and rebore cylinder                     OIL LEVEl FALLING                     1 Defective stem seal                                    1 Replace stem seal                     2 Worn valve and valve guide                             2 Replace valve and valve guideEXCESSIVE FUEL       ENGINE BODY           1 Noisy knocking                                         1 See KNOCKING                     2 Smoky exhaust                                          2 See SMOKY EXHAUST                     3 Moving parts nearly seized or excessively worn         3 Repair or replace                     4 Poor compression                                       4 See LOW COMPRESSION HARD STARTING                     5 Improper valve timing                                  5 Adjust                     6 Improper valve clearance                               6 Adjust                     INSUFFICIENT INTAKE AIR                     1 Air intake obstructed                                  1 Clean or remove obstruction                     NOZZLE TROUBLES                     1 Seized nozzle                                          1 Replace                     2 Worn nozzle                                            2 Replace                     IMPROPER FUEL                                              Replace with proper fuel                     FUEL LEAKS                                                 Find fuel leaksSMOKY EXHAUST        WHITISH OR PURPLISH                     1 Excessive engine oil                                   1 Correct oil level                     2 Excessive rise of oil into combustion chamber due to                          a Poor piston contact                                     a Check                          b Seized piston ring                                      b Replace or clean                          c Excessive  clearance                  c Replace or correct                                                                                                                           continued                                                    Engines  Generators                                                           13                                     ENGINE     PROBLEM                             PROBABLE CAUSE                                      EXHAUST cont   WHITISH OR PURPLISH cont                            d Worn valve stem and valve guide                    d Replace                            e Low engine oil viscosity                           e Replace                             f Excessive oil pressure                            f 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 Improper valve clearance                            b Adjust                        2 Insufficient intake air                            2 Clean air intake silencer                        3 Improper fuel                                      3 Replace with proper fuelABNORMAL SOUND          CRANKSHAFT AND MAIN BEARINGOR NOISE                1 Badly worn bearing                                 1 Replace bearing and grind crankshaft                        2 Badly worn crankshaft                              2 Grind crankshaft                        3 Melted bearing                                     3 Replace bearing and check lubrication system                        CONNECTING ROD AND CONNECTING ROD BEARING                        1 Worn connecting rod big end bearing                1 Replace bearing                        2 Worn crankpin                                      2 Grind crankshaft                        3 Bent connecting rod                                3 Correct bend or replace                        PISTON PISTON PIN AND PISTON RING                        1 Worn cylinder                                      1   Rebore cylinder to oversize and replace piston                        2 Worn piston pin                                    2   Replace piston                        3 Piston seized                                      3   Replace piston and rebore cylinder                        4 Piston seized and rings worn or damaged            4   Replace piston and rings                        VALVE MECHANISM                        1 Worn camshaft                                      1   Replace                        2 Excessive valve clearance                          2   Adjust                        3 Worn timing gear                                   3   Replace                        4 Worn fan pulley bearing                            4   ReplaceROUGH OPERATION         INJECTION PUMP SYSTEMHUNTING               1 Uneven injection                                   1   Adjust injection or replace parts                        2 Control rack malfunctioning                        2   Disassemble check and correct injection pump                        3 Worn delivery valve                                3   Replace                        4 Inadequate injection nozzle spray                  4   Replace injection nozzle                        GOVERNOR SYSTEM                        1 Governor lever malfunctioning                      1 Check governor shaft and correct operation                        2 Fatigued governor spring                           2 Replace                                                                                                                          continued                                                        Engines  Generators                                                                14                             ENGINE     PROBLEM                      PROBABLE CAUSE                                               ENGINE KNOCKS WITHOUT MUCH SMOKE                1 Faulty injector                                     1 Foul exhaust  rebuild injector                2 Bent rod                                            2 Fuelish exhaust  check compression repair                3 Main engine troubles                    a Overheated cylinder                                a See OVERHEATING LOW OUTPUT                    b Carbon deposits in cylinder                        b Clean                4 Too early injection timing                          4 Correct                5 Too high injection pressure                         5 Correct                6 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 Worn plunger                                         a   Replace                     b Pinion is not in mesh with control rack              b   Correct                     c Broken delivery valve spring                         c   Replace                     d Worn delivery valve seat                             d   Replace                3 Improper nozzle                    a Poor spray                                            a Clean or replace nozzle                    b Poor chattering                                       b Repair or replace nozzle                    c Afterinjection drip                                  c Repair or replace nozzle                    d Nozzle needle valve seized                            d     1 Fuel filter clogged                                 1   Clean or replaceEXHAUST SOUND   2 Fuel pipe sucks air                                 2   Retighten pipe joints or replace pipe                3 Water mixed in fuel                                  3   Replace      1 Vbelt slackening or slippery with oil              1   Adjust replace or clean                2 Damaged water pump                                  2   Replace                3 Lack of coolant                                     3   Add                4 Faulty thermostat                                   4   Replace                5 Low oil level or poor oil quality                   5   Add or change                6 Knocking                                            6   See KNOCKING                7 Moving parts seized or damaged                      7   Replace                                                 Engines  Generators                                                        15                        ENGINE PARTS IDENTIFICATION                                         2CYLINDER MODELS                                                                                ROCKER ARM     INTAKE VALVE                                                                                ROCKER SHAFT    EXHAUST VALVE                                                                                ROCKER STAY                                                                                PISTON                                                                                CYLINDER HEAD      WATER PUMP                                                                                CYLINDER BLOCK                                                               PUSH ROD                                                              l3F TAPPET          CONNECTING ROD   iUlt11                                       CAMSHAFT                GEAR CASE fr                                                                                 PULLEY CRANKSHAFT GEAR                                                                                FLYWHEEL  BEARING HOUSING                                                                                RING GEAR      BREATHER VALVE                                                                                   ROCKER COVER         ROCKER ARM                                                               EXHAUST VALVE     INTAKE MANIFOLD                                                                                   GLOW PLUG           PUSH ROD                                                                                   INJECTOR                                                                                  CYLINDER HEAD          FUEL FILTER                                                                                  PISTON              TAPPET           CAMSHAFT         CRANKSHAFT  OIL PRESSURE SWITCH                                                 FRONT VIEW                                           Engines  Generators                                                16                                     ENGINE PARTS IDENTIFICATION                                                    3CYLINDER MODELS          WATER OUTlET FITTING                                                 COVER                                                           nbttROCKER ARM      INTAKE VALVE                                                                              ROCKER SHAFT    EXHAUST VALVE    iftlHtfH IfrfrBf CYLINDER HEADWATER PUMP PULLEY       II      WMERPUMP                                                           CYLINDER BLOCK           PISTON lftilltfrkJ                                         WHlf PUSH ROD      CONNECTING ROD    tmLJ                                                                 tff1ftHIntW CAMSHAFT           DRIVE BELT                                                                                dJ4q REAR OIL SEAL   CRANKSHAFT PULLEY JiLPr          CRANKSHAFTt                                                                                               J   FLYWHEEL                       GEAR CASE                                                                                ROCKER COVER              AIR BREATHER PIPE                              GLOW PLUG  P                                                                                                 EXHAUST MANIFOLD                INTAKE MANIFOLD                                INJECTORI11IF                     CYLINDER HEAD                                                                     tttttt       PISTON                 INJECTION PUMP HiJU                                                                                          CONNECTING ROD                                                                           1wJ1 PUSH ROD                                                                          hii TAPPET                                                                            f        CAMSHAFT                 PUMP CAMSHAFTti                 CYLINDER BLDCK iI                           lpCRANKSHAFT                               OIL PICKUP TUBE fiol                                      OIL PAN   41                                                         Engines  Generators                                                              17                                                       CYLINDER                                                           The precombustion chamber is of a swirl chamber type                                                                      Ricardo made of heat resisting steel and is press fittedThe cylinder head is of an overhead valve type made of                in the cylinder head This chamber therefore requires nohighrigidity special cast iron and has an excellent cooling                                                                       The crossflow type cylinder head provided with itsintake port on the righthand side and the exhaust pon on the         Intake and exhaust valve guides are made of sintered alloylefthand side ensures high intakeexhaust efficiency               and are commonly usable in either port The valve guides are                                                                      oilimpregnated to improve wear resistance                                                                      Valve seats when needed can be installed by a competent                                                                      and knowledgeable machine shop                                                                      The cylinder head gasket is made of carbon graphite It is                                                                      provided with stainless steel sheet grommets around the                                                                      bores for improved heat and pressure resistance The gasket                                                                      requires no sealant when assembled                                                                      Intake valves are made of heatresisting steel and have a                                                                      largediameter head to provide greater intake efficiency The                                                                      heads of the exhaust valves are protected against high tem                                                                      peratures by a special heatresisting steel facing welded to                                                                      the valve head                                               enlNOEK HEAD           Valve springs are coated with red enamel which marks the                                              3Cylinder shown        rocker arm end to aid in proper placement of the spring dur                                                                      ing assembly The spring retainer and retainer lock are com                                                                      mon to intake and exhaust valves The valve stem seal at the                                                                      top of the valve guide prevents downward seepage of oil into                                                                      the combustion chamber The high speed engines 3000 rpm                                                                      and over are provided with a valve spring seat between the                                                                      valve springs and cylinder head                                   enlNOEK HEAD                                  2Cylinder Engines                                    CYLINDER HEAD                                   CYLINDER HEAD GASKET                                                                                  VALVE GUIDE                                                                                 VALVE STEM SEAL                                                                      Rocker arm rocker shaft and stay The rocker arms are                                                                      made 9f special cast iron and are gas carbonized on the entire                                                                      surface An oil hole is on the upper side of each arm The                                                                      rocker arm shaft is a carbon steel tube the interior of which                                                                      forms a lubricant passage The rocker arm area of the shaft is                                                                       Three rocker shaft stays of aluminum     enlNOEK HEAD                                                     alloy casting are used The rearmost stay forms an oil pas    3Cylinder Engines                                                sage connected to the cylinder head The rear stay is identical                                                                      to the front stay            CYLINDER HEAD                                                           Engines  Generators                                                                 18                                                       CYLINDER HEADIntake manifold and exhaust manifold An intake manifoldwith its gasket is on the right side of the cylinder head and anexhaust manifold is on the left side of the cylinder head Theshape of each manifold depends on the engine modelThe crankcase vent system allows blowby gases produced inthe cylinder block to circulate inside the engine thus preventing them from exhausting This system leads blowby gasesfrom the cylinder block through tappet holes and push rodholes into the rocker cover and further through the airbreather pipe rubber pipe into the air intake manifold sothat blowby gases are carried into the combustion chamberand are burned during combustion                                                                                 ROCKER SHAFT                                                                                                                   ROCKER COVER              VALVE SPRING                                                                                                                    EXHAUST VALVE         ROCKER SHAFT STAY                                                                                                         GLOW PLUG                PUSH ROD                                                                        ti FUEL INJECTOR                                                   II  II       CYLINDER HEAD                                                                                           PRECOMBUSTION CHAMBER                                                             CYLINDER HEAD                                                            2Cylinder Engines                                                                         ROCKER SHAFT                                                                                                                       ROCKER SHAFT STAY              GLOW PLUG   s                                                                                    LJllffr PUSH ROD          FUEL          INJECTOR                                                           PRECOMBUSTION CHAMBER                                CYLINDER HEAD                                                               CYLINDER HEAD                                                             3Cylinder Engines                                                             Engines  Generators                                                                    19                                                CYLINDER HEAD SERVICE   DISASSEMBLY                                                             INSPECTION   1 Remove the air breather pipe Remove the water bypass      hose if provided                                                    Cylinder Head   2 Remove the fuel injection lines                                     NOTE See SERVICE STANDARDS for tolerances and                                                                           measurements   3 Remove both the intake manifold and exhaust manifold      assemblies                                                          1 Before cleaning the cylinder head check it for cracks                                                                              damage and water leaks   4 Remove the rocker cover                                                                           2 Hot tank the cylinder head to thoroughly clean all   S Remove the rocker arms and rocker shaft as an assembly                                                                              surfaces and oil passages   6 Remove the push rods                                                                           3 Check the lower surface of the cylinder head for distor   7 Remove the cylinder head assembly by loosening the                      tion using a straightedge and a feeler gauge      head bolts in the numerical order shown below             FRONT OF       ENGINE                   CYLINDER HEAD BOLTS LOOSENING SEQUENCE                              2Cylinder Engines                                                                                               CHECKING CYLINDER HEAD DISTORTION                                                                           Valve Guide                                                                           1 Check the valve stemtoguide clearance If the replace                                                                              ment value is reached replace the valve guide and valveFRONT OFENGINE                  CD           CD            CD             CD             2 To remove an existing guide press it upward with a                                                                              driver frQm under the cylinder head To install a new                                                  CD                        guide press it into the top of the cylinder head with a                                                                              driver until the specified height is obtained                   CRINDER HEAD BOLTS LOOSENING SEQUENCE                             3Cylinder Engines                                                                                                                15t D5IA MODELS                                                                                                                12t 05 B C AND b MODELS   8 Remove the cylinder head gasket   9 Partly disassemble the cylinder head assembly as      follows         a Remove the thermostat housing Remove the                                                                                                                        VALVE GUIDE            thermostat and thermostat gasket         b Remove the fuel injectorS and sealing washers         c Remove the glow plug lead wires and remove the            glow plugs                                                                                            INSTAlLlNG VALVE GUIDE         d Using a valve spring com presser compress the            spring for each valve Remove the retainer lock                Valve Seat            and then remove the retainer spring and valve Place            the removed valves and other parts in order by each            1 Check each valve seat for damage and improper contact            cylinder                                                         If necessary correct it as shown in the illustration After                                                                              correction lap the valve into the seat using lapping com         e A valve spring seat of 2mm thick for each spring is               pound            fitted on the cylinder head surface Be careful not to            lose the spring seats                                                                 Engines  Generators                                                                      20                                                CYLINDER HEAD SERVICE    NOTE Correction of a valve seat should be done after the          Valve Spring    valve guide has been checked and if necessary replaced                                                                       1 Check the valve springs for cracks and damage                                                                       2 Measure the free length and load of each spring Replace                                                                          the spring if excessively deteriorated               INTAKE SIDE           EXHAUST SIDE                       CORRECTING VALVE SEAT2 If the valve seat sinkage reaches the replacement value   see SERVICE STANDARDS install a new valve seat3 Check the valve seat sinkage by measuring the installed   length of each valve assembly When measuring the size   up to the top of the valve spring retainer include retainer   thickness at the collar of 2  025 mm                                                                                       CHECKING FREE LENGTH OF VALVE SPRING                                                                       NOTE The thickness of the valve spring retainer collar is                                               STANDARD                17  03 mm                                               VALUE                      VALVE SEAT SINKAGE                                                f t4 Check the valve seat inserts if provided for proper fit   Replace any that fit looselyValve1 Check the valve face and stem for excessive wear dam              3 Check the squareness of each spring Replace the spring   age and distortion If there is any correct or replace the            if it tilts excessively   valve2 If the replacement value of the valve head thickness is                     20rT                                                                   SQUAREMD   reached replace the valve3 Check each valve stem for wear and pitting in the areas         GAUGE            shown by the arrows in the illustration If necessary                          correct or replace the valve                     X                                                                                            CHECKING SPRING SQUARENESS                                                                       Rocker Arm and Rocker Shaft                                                                       1 Check the valve contact surface of each rocker arm for                                                                          excessive wear and damage If there is any replace the                                                                          rocker arm Check the push rod contact surface of each                                                                          adjusting screw for wear and damage If there is any                                                                          replace the screw     CHECKING VALVE                                                                       2 Measure the rocker arm JD and shaft OD If the differ                                        VALVE HEAD                        ence between them is excessive replace the rocker arm                                        THICKNESS                                                          Engines  Generators                                                                  21                                              CYLINDER HEAD  reassamble the cylinder head reverse the order of disas sembly taking care to observe the following instructions   gNTEoF                                                           Partial Reassembly1 Press in the valve guides to the specified height For the   installation procedure see VaLve Guide2 Install the valve stem seals securely on the valve guide                                               CD3 Apply oil to the valve stems and insert them into the   valve guides Install the springs retainers and retainer                            CRINDER HEAD BOLTS TIGHTENING SEQUENCE                                                                                                   3Cylinder Engines            i   locks in that order4 To assemble the rocker arms and shaft place the rocker                3 Be sure to use only new gaskets and packings Apply   shaft in such a manner that the identification mark 43                  sealant to the specified sealing points   mm hole at the front end of the shaft faces toward the   front of the engine Install the frontmost rocker arm and             Valve Clearance Adjustment   retain it with a snap ring In a similar manner install the   other rocker arms one after another Finally install the              A Models   rearmost rocker arm and retain it with a snap ring Then             With the piston of each cylinder at top dead center TDC   install the assembly on the cylinder head When tighten                of its compression stoke adjust the valve clearance to the   ing the front and rear stays be sure to install the bolt               specified value using a feeler gauge between the valve stem   seats and washers                                                      tip and the rocker arm face using the adjusting screw     IDENTIFICATION MARK                                                  B C and D Models                                                                          Position the piston in 1 cylinder at the top of its compres                                                                          sion stroke Observe the valves and timing mark on the front                                                                          crankshaft pulley TDC when doing this Adjust the valve                                                                          clearances for cylinder 1 Rotate the crankshaft 2400 in the                                                                          normal direction of rotation clockwise and adjust the valves                                                                          for the next cylinder in the engines firing order cylinder 3                   INSTALLING ROCKER ARMS ON ROCKER SHAFT                                                                          Rotate the crankshaft another 240 0 and adjust the valves for5 Tighten the glow plugs to the specified torque                        cylinder 26 Install the nozzle holders and tighten the bolts temporar             NOTE For additionaL information see Adjusting VaLve   ily After installing the high pressure injection lines               CLearance under ENGINE ADJUSTMENTS   retighten the bolts evenly to the specified torque Do not                                          ADJUSTING SCREW   reuse any sealing washers                                                                              LOCKNUT7 Install the glow plug lead wires The glow plugs are a   taper sealed type they do not require  of Cylinder Head Assembly                                                                                                                         CLEARANCE COLD 025 mm1 Install the cylinder head assembly with a new gasket The    gasket does not require any sealant                    2 Tighten the cylinder head bolts to the specified torque in   the numerical order shown in the illustration Start with a   slight torquing of the bolts and after two or three stages   of moderate torquing finally tighten to the specified torque   see TECHNICAL DAE4 Be sure to use a torque wrench   AiONTOF  ENGINE                                                                                               ADJUSTING VALVE CLEARANCE       CRINDER HEAD BOLTS TIGHTENING SEQUENCE                    2Cylinder Engines                                                                Engines                                                                            Generators                                                                     22                                                    CYLINDER                                                              The piston pins are hollow carbonized forgings When con                                                                         necting a piston to its rod a piston pin is pressfitted into theThe special iron casting cylinder block is of a full jacket              small end of the rodtype in which cylinder liners are integrated with the cylinderblock                                                                   The piston rings are made of special cast iron Each piston is                                                                         provided with three two for D Models compression rings                                                                         and one oil ring The outside surfaces of the top compression                                                                         rings and oil rings are hard chrome plated The top rings are                                                                         of the semikeystone type and the oil rings are provided with                                                                         a coil expanderThe main bearings are made of metalbacked copper sintered alloy Kelmet and an aluminum alloy To improve runin  they are coated with a leadtin alloy platingon the journal surface and tin flashplating on the journal                                                     NO1surface and tin flashplating over the entire bearing surface                                                                                           ND2Crankshaft thrust is received by the flanged center bearingOn the front bearing area of the camshaft a  copper alloy rolled bushing is pressfittedThe crankshaft is a  of carbon steel which                                                                                           3is supported by four bearings to provide high  pins and oil seal contact areas are  to improve wear resistance and durability                                                                                PISTON                                                                                                        DO                                                                                                 PISTON  PISTON RINGS                                                                         The connecting rod has an Ibeam cross section and a hori                                                                         zontally split big end to provide high rigidity                                                                         The big end bearing is made of a metalbacked special                                                                         copper alloy except some Model C engines and all Model D                                                                         engines which use a special aluminum alloy and is flash                                                                         plated all over                                         CRANKSHAFTS                                                                         The front plate and gear case The steel front plate is posi                                                                         tioned by a dowel pin located in the upper part of the                                                                         camshaft area and a dowel pin in the lower part of the injecThe flywheel is made of cast iron and the ring gear is made             tion pump area It is bolted to the cylinder block through aof carbon steel and is  to the flywheel The             gasket On the left end rear surface the lube oil pump geargear teeth are                                        bearing housing is installed together with the gear case TheThe pistons are made of an aluminum alloy to reduce engine               aluminum casting gear case is attached to the front end surweight and to decrease bearing load during highspeed opera             face of the cylinder block through the front plate The casetion Each piston forms a tapered cylinder with elliptical               houses the lube oil pump front bearing and the governorcross section contour so as to obtain the best contact with the          related parts It serves also as a camshaft and idler gear thrustcylinder bore The piston crown surface has a cavity to                  stopperimprove fuel combustion                                                           Engines  Generators                                                                    23                                                 CYLINDER BLOCK                                                                      Valve timing is as follows                                                                                                   TDC                                                                               INTAKE VALVE  VALVE CLOSES                                                                                                                                                                              ii                      The Camshaft and Timing Gears The camshaft is a high                                                                                                                                                                                                                                                                                           t Irt carbon steel forging The cam surface and journals are induction hardened to improve wear resistance The shaft is sup                                                                                                                                                                                                                                                                                                                   ported on three bearings the front bearing is a bush bearingwith the exception of a bushless bearing for engines pro                                                     EXHAUST VALVE OPENSduced in the initial period of production while the middle                                        BDCand rear bearings are in the holes cut in the cylinder blockAll bearings are lubricated by a forced lubrication systemThe camshaft rear journal has a slot for intermittently lubri                                  VALVE TIMINGcating the rocker arms through the cylinder head The rear                    Intake valve opens BTDC                 18end of the shaft is provided with an oil escape hole to let                                                                              Exhaust valve closes ATDC               18excess oil return to the oil pan                                                                              Intake valve closes ABDC                46The helical timing gears are finished by shaving and crowning to provide high durability and to reduce chattering                      Exhaust valve opens BBDC                46                                                                                                        The tappet and push rod The tubuiar type tappets are chill                                                                      hardened at the bottom and gascarbonized at low tempera                                                                      ture over the entire surface to improve wear resistance Each                                                                      tappet is offset from the cam center to prevent uneven wear                                                                      of the tappet bottom The steelbar push rods are flamehard                                                                      ened at each end                                                                              PUSH   RDDI GOVERNOR FLYWEIGHTS  GEAR                                                                          CAMSHAFT   CRANKSHAFT Ii   GEAR                                                                                                       OFFSET OF TAPPET                                                                                                               AND CAMSHAFT                           TIMING GEARS                                                                                               OFFSET                         2Cylinder Engines                                                                      The injection pump camshaft                                                                      is made of high carbon steel                                                                      Its cam surfaces are induction                                                                      hardened to improve wear                                                                      resistance The front end of                                                                      the shaft supported on a ball                                                                      bearing is connected to a gear                                                                      The rear end is provided with                                                                      an Oldhams coupling groove                                                                      for connecting to the oil pump            INJECTION PUMP CAMSHAFT                                                                                                                     3Cylinder shown                                                                      drive shaft                                                                      The highpressure oil pump is directly coupled to the injec                                                                      tion pump camshaft at the rear of the shaft mating into the                                                                      Oldhams coupling groove                                                                      The sheet metal oil sump has an oil drain hose that routes                                                                      from the lube oil drain plug to a bracket at the front side of                           TIMING GEARS                         3Cylinder Engines                           the engine                                                        Engines  Generators                                                                 24                                         CYLINDER BLOCK  Models1 For the removal of the cylinder head and related parts   refer to DISASSEMBLY under CYLINDER HEAD    SERVICE2 For removal of the injection pump water pump and elec   trical equipment refer to their respective sections3 For the removal of the oil filter and oil pump refer to   LUBRICATION SYSTEM SERVICE4 Remove the push rods then puIl the tappets upward out                                                         REMOVING THE   of the crankcase                                                                                               CRANKSHAFT                                                                                                                 2Cylinder shown5 Remove the oil pan and gasket                                                                     B Cand 0 Models6 Remove the flywheel                                                                      1 For removal of the cylinder head and related parts refer7 Loosen the crankshaft puIley nut and removethe puIley               to DISASSEMBLY under CYLINDER HEAD SERVICE   and washer                                                                     2 For removal of the water pump and electrical equipment8 Remove the gear case and gasket                                     refer to their respective sections9 Remove the oil pump gear                                         3 Pull off the push rods tlen pull out the tappets upward10 Remove the governor weight assembly then remove the             4 Remove the fuel filter    snap ring and the governor gear                                                                     5 Loosen the crankshaft pulley nut then take off the pulley11 Draw out the camshaft and gear from the crankcase                  and washer                                                                     6 Loosen the flywheel mounting bolts and remove the fly                                                                        wheel                                                                      7 Remove the back plate and rear oil seal case                                                                     8 Remove the lube oil pump gear bearing housing Remove                                                                        the gear case but first it is necessary to remove the tie                                                                        rod located at the right front beside the injection pump                                                                        of the cylinder block and to remove the stopper spring                                                                        and tierod from the injection pumps fuel rack                                                                           A      CAUTION Be sure to separate the injection                                                                           pump rack from the tierod before remoing the                                                                           gear case The front plate is bolted to the cylinder                                                                           block from inside the gear case therefore be care                                                                           ful not to drie out the gear case together with the12 Remove the sleeve crankshaft gear plate and thrust                   front plate Also be careful not to damage the    washer                                                                dowel pins13 Remove the connecting rod cap Draw out the piston and                                                                     9 Remove the fuel injection pump    connecting rod upward                                                                      10 Remove the governor weight bolts Remove the weights    Note Keep the rod caps and bearings in order near each    cylinder to ensure they will be reassembled in their              11 Remove the pump camshaft bolt    original order Mark them as needed                              12 Remove the oil filter and the oil pump assembly Then14 Remove the bearing housing from the crankcase                        pull out the injection pump camshaft15 With the crankshaft counterweight positioned in the cut           13 Remove the gears Then remove the front plate    of the crankshaft hole in the crankcase draw the crank         14 Remove the camshaft    shaft out carefully so the main bearings will not be    damaged                                                          15 Tum the engine upside down Remove the oil pan and oil                                                                          screen                                                           Engines  Generators                                                                25                                           CYLINDER BLOCK SERVICE16 Remove the nuts from the big end of each connecting rod                 DModels    and remove the cap Push the piston and connecting rod                                                                            1 Remove the snap ring from each end of the piston    assembly upward out of the cylinder block Keep the    removed parts in order for each cylinder When pushing                  2   Using a piston heater heat the piston for about 5 minutes    out the piston and connecting rod assembly put a                           in an oil bath of about 80C Then remove the piston    wooden block against the cap mating surface of the rod                      from the oil bath and pull out the piston pin    so as not to damage the metal surface                                  INSPECTION17 Remove the main bearing caps Keep the caps and bear                   Cylinder Block    ings in order for each cylinder It is necessary to measure             1 Check the cylinder block for cracks and damage If there    the crankshaft end play before removing the caps see                      is any repair or replace the block Check the camshaft    Crankshaft para 3 under CYLINDER BLOCK SER                            front journal bushing for wear and damage If there is    VICE Mark the caps and rod with a number punch 1  4                     any replace the bushing using a special tool fool    as needed                                                                 03358318 Remove the crankshaft                                                      If the journal mating part in the cylinder block is damRemoving Piston Pin                                                             aged on an engine without a bushing at the front end of                                                                                the camshaft machine the indicated dimension of theWhen separating the piston from the connecting rod use the                                                                                hole and pressfit the bushing in place For  procedures Keep the disassembled parts in order                      installation procedure see CYLINDER BLOCKfor each set Take care to prevent confusion especially for                                                                                SERVICE REASSEMBLY early engines onlyeach set of piston and wrist pinA Band C Models1 Set the piston and connecting rod assembly on the                                                                                  A    CAUTION Force out the bushing in the cylin   special tool piston pin setting tool body                                   der block using an appropriate bushing drift Be                                                                                  careful not to damage the tappet hole2 Insert the push rod of the tool into the piston pin hole   and press the pin out                                                         When machining the bushing installation hole the                                                                                  148 mm 118998 hole is to be parallel and con     A CAUTION Do not hammer a piston pin to                                     centric within 01 mm 00039 to the 145 mm                                                                                  117717 hole     remove it A stuck piston pin which requires exces     sive pulling force should be replaced Do not apply                                                                                       CYLINOER BLOCK FRONT FACE     a load of more than 3000 kg to the piston pin set                                                                          CAMSHAFT                                                                                                                                  BUSHING     ting tool                                                                                      INSTALLER                                                                                                  REMOVING CAMSHAFT BUSHING                                                 IOENTIFICATION MARK        2 Check the water jacket for scale and corrosion Clean the                                                                               block thoroughly and ensure that all oil passages are                                                                               clean ARROW  MARK                                                                      3 Check the cylinder walls for scratches dents and wear If                                                                               necessary repair by honing or boring Measure the cylin                                                                               der bore in rightangled directions A and B at three PISTON                                                                        different depths                                                                            4 When cylinder bore wear is not excessive and only the                                                                               piston rings require replacement check the upper part of                                                                               the cylinder for ridge wear If any exists ream the                                                                               cylinder bore and hone when necessary                           REMOVING PISTON PIN                                                                Engines  Generators                                                                       26                                               CYLINDER BLOCK SERVICE        E9                                                                                   WEIGHT OF RINGJFRONT                    12mm                                                                                                    SEMIKEYSTONE RING CLEARANCE                                                                                          PISTON RING SIDE CLEARANCE                                                                       4 Measure the gap of each piston ring Replace the ring if                      CHECKING CYLINDER WEAR                              its gap is excessively large To measure the ring gap                                                                          insert a ring into the least worn place of the cylinder borePiston Piston Pin and Piston Rings                                       skirt using a piston and measure the gap with a feeler                                                                          gauge1 Check the piston for seizing scratches and wear If nec    essary replace the piston2 Measure the piston OD Replace the piston if exces                                                                                                    PISTON                                                                                                    o   sively worn If the  clearance is exces   sively large machine the cylinder to an oversize bore or   replace the piston The piston OD should be measured   at the lower end of the skirt at right angles to the axis of   the piston pin hole                                                                                                     JLNG                                                                                                    RING GAP                                                                                      MEASURING PISTON RING GAP CLEARANCE                                                                       Connecting Rod                                                                       1 Using a connecting rod aligner check each connecting                                                                          rod for bending and distortion If necessary correct or                                                                          replace the rod        MEASURING PISTON 00                                                                       2 Measure the connecting rod thrust clearance with a rod                                                                          assembled on the crankshaft If the clearance is exces                                                                          sive replace the rod assembly3 Measure the side clearance between each piston ring and   its groove If necessary replace the ring    As to the semikeystone type top ring allow it to sink by    its own weight into the groove then measure its depth    from the piston surface                                                                                           CONNECTING ROD                                                                                           THRUST CLEARANCE              PISTON RING SIDE CLEARANCE                                                           Engines  Generators                                                                  27                                           CYLINDER BLOCK  Measure the crankshaft bend If excessive repair or   replace the crankshaft                                                                                   MEASURING                                                                                   CRANKSHAFT                                                                                   END PLAY                                                                    Main Bearings and Connecting Rod Bearings                                                                    Check the surface of each bearing for flaking melting seiz                                                                    ing and poor contact If any of these conditions exist replace                         CRANKSHAFT 00                            the bearing                                                                    A Models                                                                    When replacing the main bearings use the  Check the crankshaft journals and pins for damage               installer tool   seizure and other faults If excessively worn or damaged   machine to the undersize diameter At the ame time             1 Renwving the main bearing To remove the main bear   replace the corresponding main bearing or connecting rod            ing put the guide ring onto the installer body as illus   bearing with the same undersize bearing When machin               trated Remove the main bearing from the bearing   ing a crankshaft journal or pin to the undersize one be            housing by pushing from the front toward the rear Also   sure to finish its fillets to R25 mm Check that all oil           remove the main bearing from the rear of the crankcase   passages in the crankshaft are clean and open                      by pushing inward from the rear after removing the oil                                                                       seal                                                                    2 Installing the main bearing Before installing the main                                                                       bearing apply engine oil to the bearings outside surface                                                                       Be sure to use a press to install the bearing Do not ham                                                                       mer the bearing                                                                       To install the main bearing assemble the main bearing                                                                       installer body and guide ring as illustrated and then                                                                       pressin the bearing in the same direction as it was                                                                       removed                                                                      BEARING                         BEARING                                                                     INSTALLER                       INSTALLER                 FlUET RADIUS ON CRANKPIN JOURNAL                                                                                                         MARKING3 Check the crankshaft end play If the specified limit is   exceeded replace the flanged No3 main bearing To   check the end play install the main bearings crankshaft   and main bearing caps then tighten the cap bolts to the   specified torque Measure the end play with a dial gauge   held against the front end of the crankshaft                                                                          REMOVING MAIN BEARINGS          INSTALLING MAIN BEARINGS                                                          Engines  Generators                                                               28                                                CYLINDER BLOCK SERVICE The main bearing must be pressedin in such away that the                Camshaft crankcase oil hole and bearing oil hole line up The housing                                                                          Measure the clearance between the center journal and the body has a marking on its collar Set the bearing with th oil                                                                          cylinder block and between the rear journal and the cylinder hole properly aligned with this marking and then press m                                                                          block If either or both clearances are excessive replace the with the oil hole aligned with the crankcase 011 hole After                                                                          camshaft front bushing or cylinder block Replace the  setting do not turn the tool and bearing Be sure that th                                                                          camshaft if the cam surface is damaged or the cam lobe IS main bearing is pressed in with the outer area of the mam                                                                          badly worn bearing above the crankcase center B C and D Models Fit thai barings to the cylinder block and the connect  ing rod bearings to the connecting rods Tigten the bolts to  specification Measure the JD of each beanng Then mea  sure the OD of the crankshaft journals and pins to calculate  the oil clearance a plastigauge may be used If any oil clear  ance is excessive replace the corresponding bearing If an  excessive clearance still remains even after replacement of  the bearing grind the crankshaft to the undersize OD and  install the same undersize bearing                                                                                          MEASURING CAM LOBE HEIGHT                                                                          Fuel Injection Pump Camshaft                                                                          Replace the camshaft if the cam surface is excessively worn                                                                          or damaged or if the Oldhams coupling is damaged                  CONNECTING ROO BEARING 10 Gearcase Check the gearcase body for cracks and damage and the oil seal for damage Also check the governor related parts If the camshaft thrust plug pressfitted in the gearcase has been worn or damaged install a new thrust plug                                                                          Ball Bearings                         22   04                                        Check each ball bearing for excessive wear or damage and                                                                          for irregular or noisy rotation If there is any replace the                                                                          bearing                                                                          Tappets                                                                          1 Check the bottom of each tappet for cracks flaking and                                                                             nicks If any of these conditions exist replace the tappet                                                                          2 Check the clearance between each tappet and the cylinder                                     PRESSFIT HEIGHT OF                     block If any clearance exceeds the specified limit                                     CAMSHAFT THRUST PLUG                    replace the tappet                                                                          Push Rods Timing Gears and Lube Oil Pump Gear                                      1 Replace a push rod if both its ends are excessively worn Check each gear for poor contact wear and damage If there              2 Place each push rod on a surface plate and check for is any replace the gear Also check the splined bore of the                bending at the center of the rod If the bend exceeds the lube oil pump gear for faults                                              specified limit correct or replace the rod                                                            Engines  Generators                                                                     29                                              CYLINDER BLOCK   AMODELS                                                           c Set the piston connecting rod and guide as an assem                                                                                  bly on the tool body When setting insert the tool                                                                                  guide into the tool body with the cut in the guide in A CAUTION Clean each part sufficiently Clean oil                               alignment with that in the tool body and then tum the                                                                                  guide 90 Make certain the small end of the connect passages sliding surfaces and rotating parts with spe                                                                                  ing rod rests properly on the tool body Also confirm cial care                                                                                  that the front mark on the piston head and identifica Before assembling apply engine oil to all sliding rotat                       tion mark on the connecting rod face up ing and pressfit parts such as bearings and cylinder                         d Press the piston pin in under a pressure of 500 to 1500 inner walls                                                                     kg If the piston pin is easily pressed in with less pres                                                                                  sure than above or if the pin needs a greater pressure Replace gaskets packings and oil seals with new ones                           replace the connecting rod or the piston and pin Apply sealant to gaskets and packings and to the                                assembly The piston pin will be positioned in place specified sealing points                                                        by the guide After installation tum the push rod 90                                                                                  so that the cut in the guide comes in alignment with Observe tightening torque and sequence where speci                              the cut in the tool body Detach the piston and con fied For other parts tighten to the torque for ordinary                        necting rod assembly from the tool body screws or bolts as the torque table specifies Check clearances and end plays during assembly work                                                                                                                           GUIDE E                                                                                                                         1 Assemble the piston and the connecting rod using the   piston pin setting tool   8    Insert a piston pin into the push rod of thetool then         screw a guide see illustration for proper guide fully         into the push rod   b Insert the assembled push rod piston pin and guide      into the piston pin hole from the guide side and into      the small end of the connecting rod In this case both      the arrow front mark on the piston head and the      identification mark on the connecting rod are to be                                                                                               PISTON PIN SmlNG TOOL PN 033582      positioned upward Before insertion apply engine oil                                              AModels only      to the piston pin and to the connecting rod small end      hole                                                                                    A CAUTION After assembling the piston andPISTON                                                                              connecting rod make certain the connecting rod                                                                                    small end is properly positioned at the center of                                                                                    the piston pin If any excessive deviation from                                                                                    the proper pOSition is found correct it In this                                                                                    case check the piston pin setting tool also                                                                       MARK                                                                                    Each piston and its pin are matched parts and                                                  InCTlclrATIn                                                                                     therefore a set of piston and pin must not be                                                                                    confused with other pistons and pins All pistoAS                                                                                    and pins to be used in an engine must be of the                                                                                    same size same mark                                                                               Piston rings differ in shape from one another Be sure to                                                                               install them in their proper positions and directions as                                                                               illustrated and with the stamped manufacturer mark and                                                                               size mark facing up                                                                               When installing the piston ring with a coil expander                                                                               position the expander joint opposite to the ringgap                                                                               position                      INSTALLING PISTON PIN                          AModels only                                                                Engines  Generators                                                                          30                                                     CYLINDER BLOCK SERVICE                      p                                                                      5 Install the outside thrust bearing in the bearing bore in                                                                         the bearing housing then install the stopper plate crank                                                                         shaft gear and sleeve Install the stopper plate with the                                                                         chamfered side facing toward the rear of the engine                               RNO2                                    Install the crankshaft gear with the stepped side facing                                                                         toward the rear of the engine Also install the sleeve with                                                                         the chamfered square end toward the front of the engine                               3                                         iI        00                                        PISTON RINGS       PISTON RING       POSITIONS                                                                                                                                             c                                                   v                                                                                     NUT                                   RING GAP                                                                                                                                       PULLEY                                                                                   WASHER       FRONT OFp                POSITIONS                                                   SLEEVE       ENGINE                                                                                             INSTALLING CRANKSHAFT GEAR  SLEEVE                                                                       c                                                                3 Insert the crankshaft into the crankcase Apply engine oil   to the main bearings and crankshaft journals Be careful   not to damage the main bearings4 Install the bearing housing with the tongue of the inside   thrust bearing properly fitted in a notch in the bearing   housing     A CAUTION Thrust bearings inside and out     side are identical Howeer before installation               6 Temporarily install the sleeve stopper washer except for     measure their thickness to confirm that they are                    the PTO pulley and crankshaft pulley Tighten the nut                                                                         Check the crankshaft end play If the end play exceeds     within the standard size From this the crankshaft                                                                         the specified value recheck the thrust bearing Also     end play can be specified                                          check that the crankshaft gear and sleeve are properly                                                                         installed Mter checking the end play loosen the nut and                                                                         remove the pulley and washer        INSTALLING                                                                          CHECKING CRANKSHAFT END PLAY         THRUST BEARING                                                            Engines  Generators                                                                 31                                                CYLINDER BLOCK SERVICE7 Insert the piston and connecting rod assembly from                     10 Install the oil pump drive gear with ball bearing   above into the cylinder using a ring band At this time               11 Attach a gasket coated with the specified sealant to the   make certain that the piston ring ends are properly posi                  gear case then install the gear case with the governor   tioned and that the arrow mark on the piston head is                       linkage assembled to it   directed toward the front of the engine In older models   the arrow faces toward the combustion chamber After                   12 Install the crankshaft pulley Be sure to install the crank   insertion install the rod metal in proper position and                    shaft spacer stopper washer and crankshaft pulley washer   tighten the rod cap to the specified torque                           13 Install the flywheel and tighten the bolts to the specified                                                                              torque                                                                          14 Install the oil pan                                                                          15 Insert the tappet      FRONTOF                                                            16 Install the cylinder head assembly      ENGINE r                                          lJi                             17 Install the injection pump assembly                                                                                                                                6                      PISTON RING GAP POSITIONS8 Assemble the camshaft gear to the camshaft and retain it   with a key Insert the camshaft into the crankcase with   the crankshaft gear mating mark and camshaft gear mat   ing mark properly aligned as illustrated                                                                                               INSTALLING INJECTION PUMP                                                                          18 Install the oil pump and oil filter When the oil pressure                                                                              switch has not been installed yet apply sealant to its                                                                              threaded portion and install                                                        CRANKSHAFT                                                                          19 Install the fuel filter                                                        GEAR                                                                          20 Install the water pump          CAMSHAFT GEAR                                                                          21 Install the starter and alternator              TIMING GEAR MATING MARKS9 Install the governor gear Install a snap ring onto the   shaft Then install the governor weight assembly and   sliding shaft                      INSTALLING THE GOVERNOR                                                               Engines  Generators                                                                     32                                            CYLINDER BLOCK SERVICE                                                                                  265 mm t 05 mmREASSEMBLY  B C and D MODELS A    CAUTION Clean each part sufficiently Clean oil passages sliding surfaces and rotating parts with spe cial care Before assembling apply engine oil to all sliding rotat ing and pressfit parts such as bearings and cylinder inner walls Replace gaskets packings and oil seals with new ones Apply sealant to gaskets and packings and to the spec                                     PRESSFlnlNG IDLER GEAR SHAFT ified sealing points                                                    3 When replcing the dipstick guide coat the new guide Observe tightening torque and sequence where speci                         without a flange with HERMESEAL 52B sealant then fied For other parts tighten to the torque for ordinary                   pressfit into the cylinder block Pressfit to a height of                                                                             30  05 mm 11811 00197 from the cylinder screws or bolts as the torque table specifies                              block surface When installing the former type of guide Check clearances and end plays during assembly work                        which is increased in diameter at the midpoint press it in                                                                             until caught in the hole There is no difference in the                                                                             pressfit position between the former type and later type1 When the camshaft front bushing is pressed in align the                                                                             guides   bushing oil hole with the oil hole in the cylinder block   using a bushing installing tool For proper alignment   make a mark indicating the blocks oil hole position on   the front end face of the block After installing the bush   ing confirm that the oil holes are properly aligned with   each other                                                                                          LATER TYPE GUIDE                       FORMER GUIDE                                                                                             PRESSFIniNG DIPSTICK GUIDE INTO BLOCK                                                                          4 Install the main bearings to the cy Iinder block                                                                             NOTE The oil ports must be properly positioned and the              OIL HOLEI                     BUSHING SEAM                bearing fitted correctly into the block recess                                                                          5 Install the crankshaft Apply engine oil to the journals                                                                             and pins                                                                          6 Install the main bearing caps and tighten the cap bolts to the                                                                             specified torque Each cap carries an embossed arrow mark                                                                             and numeral to prevent incorrect installation of the caps                                                                             When installing the No1 and No 4 caps apply sealant to                                                                             the upper surface cylinder block mating surface                                                                                      FRONT OF ENGINE  INSTALLER      L              l    1 mm                     PRESsFITTlNG CAMSHAFT BUSHING2 When pressing in the idler gear shaft follow the align   ment and length of protrusion shown in the diagram   Failure to do so will result in low oil pressure during   engine operation                                                                                                      MAIN BEARING CAPS                                                                Engines  Generators                                                                     33                                            CYLINDER BLOCK SERVICE7 Check the crankshaft end playS Apply sealant to the outside surface of both side seals                PISTON   Press the side seals into the front and rear caps thus com   pleting the reassembly of the crankshaft                                                                                                                           InITlCII ATI   MARK                       J L       INSTAWNG       BEARING CAP       SIDE SEALS                                                                                               PISTON PIN SETTING TOOL                                                                               b Insert the assembled push rod piston pin and guide                                                                                  into the piston pin hole from the guide side and into                                                                                  the small end of the connecting rod In this case both9 Install the oil seal into the crankshaft rear oil seal case                   the arrow front mark on the piston head and the   Install the seal case to the cylinder block Remember to                       identification mark on the connecting rod are to be   install the gasket Turn the crankshaft one complete                           positioned upward Before insertion apply engine oil   revolution to ensure there is no unwanted binding                             to the piston pin and to the connecting rod small end                                                                                  hole10 Install the back plate11 Install the flywheel Tighten the bolts to the specified                                                                               c Set the piston connecting rod and guide as an assem                                                                                    bly on the tool body When setting insert the tool    torque                                                                                    guide into the tool body with the cut in the guide in12 Assemble the piston and the connecting rod                                     alignment with that in the tool body and then tum the   Band C Models                                                                    guide 90 Make certain the small end of the connect                                                                                    ing rod rests properly on the tool body Also confirm    a Use the Piston Pin Setting Tool Insert a piston pin                                                                                    that the front mark on the piston head and identifica       into the push rod of the tool then screw a guide see                                                                                    tion mark on the connecting rod face up       illustration for proper guide fully into the push rod                                                                               d Press the piston pin in under a pressure of 500 to 1500                                                                                                                             kg If the piston pin is easily pressed in with less pres                                                                                  sure than above or if the pin needs a greater pressure                                           89mm                                  replace the connecting rod or the piston arid pin                                            GUIDEF                                            Ie MODELS                          assembly The piston pin will be positioned in place                                                                                  by the guide Mter installation tum the push rod 900                                                                                  so that the cut in the guide comes in alignment with                              am                                                                                  the cut in the tool body Detach the piston and con                                                          PUSH ROD                necting rod assembly from the tool body                              GUIOE                              B MODELS             PISTON PIN SETTING TOOL                  NO ST332301                                                                 Engines  Generators                                                                      34                                                         CYLINDER BLOCK SERVICE                                                                          14 Install the piston and connecting rod assembly from the     A CAUTION After assembling the piston and                               top of the cylinder block using a ring band In this case                                                                              make certain the piston ring gaps are properly positioned     connecting rod make certain the connecting rod                          and the arrow mark on the piston faces the front of the     small end is properly positioned at the center of                        engine After insertion install the connecting rod end     the piston pin If any excessive deviation from                          halves in place and tighten the rod cap bolts to the speci     the proper position is found coect it In this                         fied torque Apply oil to the bearing surfaces before                                                                              assembly of the Cnnecting rod ends     case check the piston pin setting tool also                                                                          15 Install the front plate Remember to install the gasket and     Each piston and its pin are matched parts and                           dowel pin     therefore a set of piston and pin must not be                                                                          16 Tum the crankshaft until the No1 cylinder piston comes     confused with other pistons and pins All pistons                        to the top dead center     and pins to be used in an engine must be of the                                                                          17 Align the keyway in the crankshaft gear with the key on     same size same mark                                                   the crankshaft Install the gear on the shaft                                                                          18 Align the mating mark 1 on the idler gear with that on    DModels                                                                   the crankshaft gear install the idler gear on the idler    When assembling the piston and connecting rod for                         shaft Insert the camshaft and gear assembly into the    D Models heat the piston at 80 a C for about 5 minutes in                cylinder block so that the mating mark 2 on the    oil using a piston heater After installing the piston pin               camshaft gear aligns with that on the idler gear Then    lock with a snap ring at each end of the pin                             insert the injection pump camshaft assembly into the                                                                              cylinder block and align the mating mark 3 on the13 Piston rings differ in shape from one another Be sure to                 pump gear with that on the idler gear Finally install the    install them in their proper positions and directions as                 injection pump drive shaft gear assembly    illustrated and with the stamped manufacturer mark and    size mark facing up   When installing the piston ring with a coil expander   position the expander joint opposite to the ring gap   position                                           PISTON RINGS                                          GEAR MATING MARKS     PISTON RING     POSITIONS                                                                    19 Confirm that mating marks on the gears are in proper                                            t                                                                              alignment with each other                                                                                    RING GAP                                                                                                                             20 Fit the governor weight assembly to the injection pump                                                                              cam gear    FRONT OFA                   POSITIONS    ENGINE v                                                              S                                                                                                                            Engines  Generators                                                                     35                                                 CYLINDER BLOCK SERVICE21 Install the gear case with the governor and related parts          26 Install the cylinder head assembly see CYLINDER    previously installed and gasket When installing the gear              HEAD SERVICE REASSEMBLY    case insert the tierod and tierod stopper spring into the        27 Install the injection pump assembly see Installation and    hole in the cylinder block so to position it next to the                Adjustment of Fuel Injection Pump under FUEL    injection pump fuel rack                                               SYSTEM            INSTALLING GEAR CASE                                                                                                INSTALLING INJECTION PUMP22 Insert the crankshaft pulley Install the washer and nut    Then tighten to the specified torque                               28 Install the oil pump and oil filter see REASSEMBLY23 Install the back plate Be sure to install the gasket                  under LUBRICATION SYSTEM SERVICE When the oil24 Install the oil pick up then install the oil pan                      pressure switch and oil pressure sender with adapter has                                                                            not yet been installed apply sealant to the threaded25 Apply oil to the periphery of the tappet Insert the tappet             portion when installing    into the cylinder block Then insert the push rod properly    into the tappet hole Check to see if the tappet moves              29 Install the fuel filter    lightly                                                            30 Install the fresh water pump                                                                        31 Install the starter see  SERVICE                                                                            and alternator see                                                                             SERVICE                                                                        32 Install the raw water pump                                                  TAPPET                INSTALLING TAPPET AND PUSH ROD                                                             Engines  Generators                                                                   36                                                                                                                       3 Remove the fuel injection pump see Fuel Injection                                                                           Pump under FUEL SYSTEMThe governor keeps engine speed constant by using a balance between the centrifugal force acting on the governor               4 Remove the gear case mounting bolts and remove theweights and the tension of the governor spring                            gear case see CAUTION under DISASSEMBLY CYLIN                                                                           DER BLOCK SERVICEIf engine speed increases the governor weights will openforcing the sliding shaft forward This moves the injection             5 Remove the governor springpump fuel rack linked to the sliding shaft through the gover          6 Remove the nut washer and spring lever Remove thenor lever assembly tierod and spring in the direction that              speed control lever from the gear caseinjects less fuel into the cylinders The movement is stopped                                                                        7 Remove the nut washer and spring lever remove theat a point where the centrifugal force of the governor weights                                                                           governor lever set bolt and remove the governor leverbalances with the tension of the governor spring                                                                        8 Remove the governor weight assembly and the slidingIf engine speed is decreased by an overload the control rack                                                                           shaft from the injection pump camshaftis pushed against the smoke set spring in the direction thatinjects more fuel The Angleich mechanism restricts the                 9 Remove the tierod and spring from the governor leverincrease and quantity of fuel injection thus preventing overload saving fuel and decreasing exhaust smoke                         INJECTION PUMP                                             GOVERNOR LEVER                                             GOVERNOR WEIGHT                     h2tao1fSLIDING SHAFT                                             GEAR CASE                                             GOVERNOR SHAFT                                                                                     GOVERNOR LEVER SECTION OF GEAR CASE                                             PUMP GEAR    PUMP CAMSHAFT                                                                        INSPECTION                           c1IIDLER GEAR                                                                        1 Check the governor weights for wear and damage                                                                           Replace if defective                                                                        2 Check the sliding shaft for damage and stiff movement                                                                           Replace if defective                                      GEAR CASE                                                                        Governor Lever                                             NEEDLE BEARING             Check the sliding shaft contact area of the governor lever and                                                                        check the tierod and spring which connect the governor                                             GOVERNOR LEVER                                                                        lever to the fuel rack Replace if defective                                             GOVERNOR SHAFT            Governor Spring                                             NEEDLE BEARING             Check the spring for deterioration and breakage Replace if                         L                                                                        defective When overhauling replace the spring                                             GOVERNOR SPRING          GOVERNOR                                                      Needle Bearing                                           SPEED CONTROL LEVER          Check the needle bearing supporting the governor lever shaft                                                                        in the gear case for  Remove the drive belt see FRESH WATER COOLING                       REASSEMBLY AND ADJUSTMENT   SERVICE                                                            To reassemble the governor reverse the order of disassembly2 Remove the crankshaft pulley nut and remove the pulley              After reassembly check the governor for smooth operation                                                              Engines  Generators                                                                   37                                                  ENGINE SHUTOFFENGINES WITH MANUAL STOP Standard                                           pullin lead should be run to the heavy solenoid terminalA manual stop lever is located on the outboard side of the                    on the starter Connect the red hold lead splice into theengine block just below the fuel injection pump The damper                   R connection on the DC  is also mounted on this same lever assembly A throttle bracket is provided to attach a pushpull cable This cable          SIDEWILFILLER                                                                         REMOVE   is attached to the shutoff lever When pulled fully in the stopdirection by the cable a lever inside the cover assemblymoves the fuel rack of the injection pump to the fuel stop                                                                                               position stopping the engine Once the engine stops thecable is pushed in to return the shutoff lever back into thefuelrun position A heavy return spring on the shutoff leverassists in doing this Periodically lubricate the lever andpushpull cable to ensure free movement                                                 MANUAL STOP            KeyStop Solenoid System Operation                                                                        Checking Procedure                                                                        1 Wire the system making reference to the wiring diagram                                                  THROTTLE LEVER        2 Viewing with the tierod cover off confirm that when the                                                                           key switch is turned to the ON position before starting                                                                          the engine the solenoid energizes and brings the fuel                                                                           injection pump fuel rack to the MS STOP plate position                                                                        3 Tum the key switch to OFF and reinstall the tierod coverOPTIONAL KEY SWITCH SHUTOFF                                             4 The shutoff sequence is as follows0 Models only                                                            When the start button is depressed during the normalAn optional key switch shutoff solenoid 037100 is offered                 starting procedure the solenoid is energized by the pullfor D Models only This solenoid mounts in a boss directly                 in lead Once the engine starts and the start button isbehind and slightly below the injection pump mounting loca                released the solenoid remains energized by current to thetion This solenoid when energized by turning the key                    hold lead of the solenoid coming from the R terminalswitch on allows the injection pump fuel rack to move to the              connection on the alternator which receives  position allowing the engine to start and run When               rent once the engine starts and the oil pressure switchthe key switch is turned off the solenoid plungermoves the               closes from engine oil pressurefuel rack to the stop fuel position stopping the  and Adjusting the Key Switch                                  A       CAUTION The pullin lead draws about 810 ampsShutoff Solenoid                                                             to energize the solenoid The hold lead draws about one1 Remove the large plug or side oil filler assembly located             amp to keep the solenoid energized Should these leads   just behind the injection pump and slightly below it on               be connected incorrectly during installation the sole   the engine block                                                     noid will be damaged from excess current draw during2 Visual access to the fuel injection pump fuel rack is                 engine operation   needed To obtain this remove the shutoff lever side   cover assembly                                                      NOTE Should the solenoid fail and engine operation is3 Thread the locknut all the way onto the solenoid and                 required unscrew the solenoid as far out of the boss as pos   apply a small amount of Teflon sealant to the threads for           sible without removing it Lock it in position with the locknut   ward of the nut                                                     The engine will now start To shut the engine off use the4 Thread the solenoid into the boss on the engine block and            manual shutoff lever Disconnect the two leads red and white   observe the solenoid plunger through the side cover                  from their power source   opening Allow the plunger to contact the fuel rack and   move it fully into the shutoff position on the injection   pump Do not thread the solenoid further into the boss so   that the plunger against the fuel rack is pushed into the   solenoid5 Back the solenoid out of the boss 14 to 12 tum and   secure the solenoid in position with the locknut6 Properly connect the three electrical leads from the sole   noid The black eye lead goes to block ground The white                                                                                         KEY STOP SOLENOID                                                             Engines  Generators                                                                   38                                                     ENGINE ADJUSTMENTS    TIGHTENING THE CYLINDER HEAD                                                a Rotate the engine in the normal direction of rotation                                                                                   placing the No1 Cylinder at the top of its compres    Pull off the air breather pipe from the rocker cover and                                                                                   sion stroke Align the timing mark on the gear case   remove therocker cover Before adjusting the valve clear                                                                                   with the timing mark on the crankshaft pulley indi    ance retighten the cylinder head bolts to their specified                                                                                   cated for cylinder No1 the timing mark next to the    torque in the sequence shown in the diagram Make sure the                                                                                   three injection timing marks In this position the No    engine is cold when this is done Before applying the speci                                                                                   1 cylinder is at its top timing mark while dead center    fied torque to a bolt loosen it 14 to 12 a tum and then apply                                                                                   on its compression stroke Adjust both intake and    the torque see TECHNICAL DATA                                                                                   exhaust valve clearances for this cylinder            FRONT OF     ENGINE                                                                                                                               INJECTION                                                                                                                               TIMING MARK                    CYLINDER HEAD BOLTS TIGHTENING SEQUENCE                                2Cylinder EnginesFRONT OFENGINE                                                                                             NO3 TOP                                                                                                      TIMING MARKS                                 o            CD              CD                                                                                                  3Cylinder Engine shown                                                                                   Adjust each valves clearance by inserting a 025 mm                           CD          CD            CD                            feeler gauge between the rocker arm and the valve                                                                                   stem                     CYLINDER HEAD BOLTS TIGHTENING SEQUENCE                                3Cylinder Engines    ADJUSTING VALVE CLEARANCE   Adjust the valve clearances when the engine is cold Valves   are adjusted by cylinder in the firing order of the engine 12   for 2cylinder engines 132 for 3cylinder engines Tighten   the cylinder head bolts to the specified torque before adjust   ing the valves see TIGHTENING TORQUE chart    1 Pull off the air breather pipe from the rocker cover and      take off the rocker cover bolts and the rocker cover   2 The valve clearances must be adjusted at IDC Top Dead      Center for each cylinder when each is on its compres      sion stroke Remember the engines firing order 12 for      2cylinder engines 132 for 3cylinder engines The      valves must be adjusted in the firing order while they are      closed You may find that turning the engines crankshaft      is more easily done when the engines glow plugs are      removed before the crankshaft is turned Adjust the valve      clearances as follows           NOTE It is important to exactly align the timing mark on           the gear case with that on the crankshaft pulley if not           the valve may be pushed up by the piston depending on           the position of the cam lobe                                                                                                   ADJUSTING VALVE CLEARANCE                                                                                                     3Cylinder Engine shown                                                                   Engines  Generators                                                                        39                                             ENGINE ADJUSTMENTS       If the valves have no specified clearance adjust by              aligned with the timing mark on the front gear case The       means of the adjusting screws Remember to align the              injection timing is correct when the timing marks are       timing marks properly it not the valve may be                   aligned Refer to the SERVICE STANDARDS chart for                                                                                              pushed up by the piston depending on the position of             the injection timing for the model being checked       the cam lobe Be sure to check the valves for this       cylinder  both should be closed   h For 2cylinder engines After adjusting the valves for      cyllinder No1 place the No2 cylinder piston at the      top dead center on its compression stroke and adjust      its intake and exhaust valve clearances                                                                                     u                                                                                                                                                                                                                                                                                                                                                                                FRONT                                                                                                    CRANKSHAFT                                                                                                    PULLEY      For 3cylinder engines After adjusting the valves for      cylinder No1 turn the crankshaft clockwise 240 0 so      the IDC mark on the camshaft pulley for the No3      cylinder is approximately at the position shown in the      illustration Now adjust the intake and exhaust valve      clearances for cylinder No3 Be sure to check the      valves for this cylinder  both should be closed   c For the No2 cylinder turn the crankshaft clockwise            8 When the specified injection timing is not correct      another 240 0 to position the IDC mark on the crank               increase or decrease the shim material thickness under      shaft pulley approximately at the position shown in                the fuel injection pumps mounting flange Injection tim      the illustration Now adjust the intake and exhaust                ing varies 10 with each 01 mm increase or decrease of      valves for cylinder No2 Be sure to check the valves              shim thickness The addition of shim thickness will retard      for this cylinder  both should be closed                         the timing and reducing shim thickness will advance the                                                                         timing Shims are available in the following  FUEL INJECTION TIMING                                          2 mm 3 mm 4 mm and 8 mm Refer to your engines1 Rotate the engines crankshaft in its normal direction of             generators parts catalog for shim part numbers   rotation to position piston No1 at the beginning of its           9 Another method of checking the injection timing without   compression stroke                                                   removing the spring from under the delivery valve holder2 Remove the highpressure fuel line between the No 1                  is to disconnect the high pressure injector line from the   injector and the No 1 fuel delivery valve holder                    injector Then with the number one piston at the begin                                                                         ning of its compression stroke turn the crankshaft in the3 Remove the No 1 delivery valve holder                               normal direction of rotation and carefully watch the fuel4 Remove the delivery valve spring from the holder and                  in the end of the high pressure line The moment this fuel   reinstall the holder only                                            starts to swell and come out of the line this is the injec5 Reattach the high pressure fuel line to the delivery                 tion timing point By this method the timing is about 10   holder Fuel will flow from this line during the timing               later than the spill timing method previously discussed   check Attach it so that the end that would connect to the   fuel injector is pointing away from the engine Have a                                                                      ADJUSTING NOLOAD ENGINE SPEEDS   container under it to catch the fuel                              To adjust the engine speed on a generator adjust the linkage                                                                      between the throttle arm and the fuel run solenoid Shorten6 Move the throttle to full open and energize the fuel lift                                                                      ing the linkage increases the engine speed Lengthening the   pump Place the starter key in the ON position do not                                                                      linkage reduces the engine speed   turn the key to the START position                                                                      NOTE This adjustment is performed with the engine operat    NOTE the fuel shutoff lever must be in the RUN position         ing and at normal operations temperature with no amperage   while making the adjustment or no fuel will flow from the                                                                      being taken from the generator See the chart below   fuel injection pump7 Slowly turn the crankshaft in the normal direction of                    GENERATOR MODELS                     NOLOAD SPEED rpm   rotation and watch the fuel flowing from the injector line                 60 hertz models             1850  1880 615  620 hertz   The instant it stops is the injection timing LT point                                                                               50 hertz models             1550  1580 515  520 hertz   With the crankshaft stopped at the LT position check to   see if the timing mark on the front crankshaft pulley is                                                                      NOTE Any adjustment of the throttle on a generator is done                                                                      only with the linkage between the fuel solenoid and the                                                                      throttle lever                                                         Engines  Generators                                                                 40                                             ENGINE  Models This adjustment need only be performedafter an engine overhaul or when the governor system orinjection pump  have been performed Thisadjustment is performed after engine assembly during testingat the factory See the chart below for noload engine speed1 With the damper spring released 1y loosening the   damper spring adjusting bolt set the engine at a rpm   specified in the chart with the maximum speed set bolt   Lock the bolt at that position           ENGINES            lia rpm       A Band C Models       3110 0                                   30           D Models           3710 0                                   302 Tighten the damper spring adjusting bolt until the engine   speed is set to a  40 rpm shown in the table below as   b rpm Lock the adjusting bolt at that position with a                             DAMPER SPRING ADJUSTMENT   locknut Apply Locktight to the threads of the adjusting   bolt           ENGINES            b rpm                                                          APPROlC 1D       A Band C Models       3150 0                                   50           D Models           3750 0                                   50    a Seal the abovementioned adjusting bolt with its brass       cap and crimp it on the bolt    h Seal the maximum speed set bolt with wire and seal       ing materiaL3 Acljusting the Idling Speed Idling speed for most   engines is between 800 and 1000 rpm Set the engine to   the idling speed with the idling set bolt and lock the bolt   at that position                                                                                                              SPEED CONTROL LEVER                                                                                 DAMPER SPRING ADJUSTMENT                                                          Engines  Generators                                                                  41                                       LUBRICATION SYSTEM                                                               The cartridge type oilfilter in which the filter body is inte                                                                         gral with the filter element is easy to handle Oil from the oilThe lubrication system uses a trochoid gear pump and a full              pump is led into the filter element When a pressure differenceflow oil filter The oil pump is driven through the Oldhams             between before and after the element exceeds 142lbin 2 1coupling at the rear end of the fuel injection pump camshaft            kglcm2 due to excessive clogging of the element a bypassOil from the oil pump flows into the cartridge type oil filter           valve in the element will open an oil passage bypassing thevia the relief valve After being filtered by this filter oil is        element As a result oil flows to various engine parts  to various engine parts through oil galleries in the           filtration Therefore it is important to replace the oil filter regengine block         i                                    ularly The oil filter should be replaced after the initial 50                     OIL FILL                                            hours of operation and thereafter every 100 hours of opera                                                                         tion                                                                         The trochoid gear type oil pump is mounted on the back of                                                                         the fuel injection pump on the right side of the cylinder block     OIL PIPE                                                            The oil pump houses a relief valve If pump delivery oil pres                                                                         sure exceeds 569Ibin2 4 kglcm2 the relief valve will open                                                                         to bypass oil into the oil pan thus preventing further oil                                                                         pressure rise                                                                                                            9                                                                                                               RELIEF   VALVE                                                                                            RELIEF VALVE     I                                                                                                              OIL PRESSURE   SWITCH                                                                                                                         OIL PUMP ASSEMBLY                                                                                                                             2Cylinder Engines          LUBRICATION SYSTEM            2Cylinder Engines                                                                                                            SPRING                                                                                                      RELIEF VALVE                                                                                                                     j   I                                                                                 OIL PRESSURE                                                                                 SWITCH    OIL PUMP    OIP STICK                                                                                      DlL PUMP ASSEMBLY                                                                                                                             3Cylinder Engines                                                                         DISASSEMBLY                                                                         Oil Filter and Oil Pump                                                                         1 Remove the oil filter                                                                         2 Remove the pump cover assembly housing and gasket          LUBRICATION SYSTEM             3Cylinder Engines                                                            Engines  Generators                                                                    42                                       LUBRICATION SYSTEM                                                                     4 Pump body Oring Check the pump body Oring for                                                                                  cracks and damageOil Pump                                                                      5 Oil pressure switchsender Replace the oil pressure1 Outer rotor to body clearance Using a feeler gauge                           switch and the oil pressure sender   check the clearance between the outer rotor and body If   excessive replace the rotor assembly                                                                                   A    CAUTION Oil Pressure Switch  00 not use                                                                                   lock pliers vise grips or pipe wrenches on the oil                                                                                   pressure switch Use the correct socket which is                                                                                   available from SnapOn Proto New Britain and                                                                                   others Damage to the switch will cause oil leaks                                                                                   andor switch failure                                                                              REASSEMBLY                                                                              1 Install the oil filter and tighten fully by hand Tightening                            OUTER ROTOR TO HOUSING CLEARANCE                     torque 80 to 94 ftIb 11 to 13 kgm Before installa                                                                                 tion check for proper fitting of the Oring in the groove2 Rotor clearance Check the clearance between the outer                        and coat the Oring with a small quantity of oil   and inner rotors with a feeler gauge If excessive replace    the rotor assembly                                                       2 Install the gasket Then install the oil pump housing                                                                                 Oring rotor assembly and cover assembly in that order   Check the Oldhams coupling of the inner rotor shaft for                      Apply oil to the rotating parts   cracks damage and wear                                                                              3 With sealant applied to the threaded portion screw in the                                                                                 oil pressure switch taking care not to close the oil hole                                                                                 with sealant                                                                              4 Apply liquid teflon sealant to the threaded portion of the                                                                                 oil pressure sender Take care not to close off the oil hole                                                                                 into the sender Thread the sender into its fitting on the                                                                                 oil pumps housing                                     i99R STANDARD VALUE 01502                                                  REPLACE VALUE    01503                                                                              TESTING THE OIL PRESSURE                                                                              1 Start and warm up the engine                          OUTER ROTOR TO INNER   OUTER ROTOR                  2 Check for oil leaks at the filter and pump assembly                          ROTOR CLEARANCE                                                                              3 Remove the oil pressure sender and connect a mechanical3 Rotor to cover clearance With the outer rotor inserted in                    oil pressure gauge to the hole    the pump body insert a straightedge and check the clear                                                                              4 Set the engine speed at 3000 rpm and measure the oil    ance between the rotor and the straightedge with a feeler                                                                                 pressure It should be fairly constant at 50 Ibin 235    gauge If excessive replace either the rotor or the body                   kgcm2                                                                                  NOTE Insure that oil meets specification standards                                                                                  Class CF or CG4 or beuerSAE 30 lOW30 l5W40                               ROTOR TO COVER CLEARANCE                                                               Engines  Generators                                                                     43                                     LUBRICATION SYSTEM SERVICEOIL PRESSURE                                                                                  All generators have a twoprong oil pressure switch see                                                   ALL GENERATOR                                                                                                            which is normally open When the oil pressuredrops below 510 psi 0407 kgcm2 this switch interruptsthe circuit for the fuel run solenoid by opening shuttingdown the generator                                                                                                                                                                                                                                                                  OILPropulsion Engines                                                                       PRESSUREEarly propulsion engines have an oil pressure switch that isnormally closed This switch opens when the oil pressure ishigher than 510 psi 0407 kgcm2 see illustration whenthe oil pressure drops below 510 psi 0407 kgcm the           OIL PRESSURE  switch closes activating an alarm that emits a pulsating signal                                                                                                       EARLY PROPULSION                                                                                                           ENGINE MOOELSLater propulsion engines have a twoprong oil pressureswitch see illustration which is normally open When theoil pressure drops below 510 psi 0407 kgcm the  an alarm that emits a pulsating signalNOTE On all propulsion engines the alarm will also emit apulsating signal when the engine starts up as the oil has not                                                                                  yet reached its normal pressure a good check of the alarmIf this alarm emits a continuous signal it indicates an                                                    LATER PROPULSION                                                                                                            ENGINE MODELSengine overheat with the engine operating  2JOF 99C                                                                                               t                                                                                               OIL                                                                                         PRESSURE                                                                                                     OIL PRESSURE SWITCHES                                                         Engines  Generators                                                                 44                                                      FUEL                                                              The builtin fuel injection pump is mounted on the right sideAn  fuel lift pump draws fuel from the diesel            of the cylinder block It consists of the pump elementssupply through an ownersupplied fuel filterwater separator          plunger assemblies delivery valves tappets and smoke setto the engines primary fuel filter and on to the fuel injection        unit As the pump camshaft rotates the plungers are movedpump The pressurized fuel is then injected into the combus            up and down through a fixed stroke thus delivering pressurtion chamber through the injection pipes and nozzles Excess            ized fuel to engine cylindersfuel is returned to the fuel supply through the fuel return             Fuel injection control Fuel injection rate is dependent onpipes that connect to the top of each nozzle holder                    the relative positions of the plunger lead and barrel TheNOTE Fuei supplied to the fuel lift pump must be filtered to           plunger is rotated by the control pinion which is mounted on1025 microns by the ownersupplied fuel filterwater                 the plunger barrel This pinion meshes with the                                                               lower collar which transmits the rotation of the pinion                                                                        directly to the plunger As the engine runs the injection                                                                        pump camshaft rotates to move the control rack through the                                                                        centrifugal type governor weight governor sleeve and lever                                                                        The control rack slides to turn this pinion Rightward move                                                                        ment STOP mark side of the control rack decreases the                                                                        fuel injection rate as the rack moves to the left the fuel                                                                        increases                                                                                  TTlI SMOKE SET                                                                                                                       STOPPER                                                                                                                      CONTROL RACK                                                                        RETURN SPRING                                                                                                                   FUEL                                                                                                                   INJECTION                                                                                                                   PUMP                                                                        Smoke set unit The smoke set unit restricts the maximum                                                                        fuel injection rate of the injection pump The stopper is held                                                                        by a spring in the position shown in the illustration This                                                                        position is the smoke set position When starting the engine                                                                        propulsion models pull the throttle control lever fully          FUEL FILTER          WATER SEPARATOR           PRIMARY                             toward the maximum speed position and the tierod with                                    FUEL FILTER                         stopper spring will move the control rack in the arrowed                                                                        direction against the spring force thus causing overinjection                                                                        for easy engine start For the injection pump with the                      FUEL SYSTEM                                       Angleich mechanism overinjection requires releasing that                                                                        mechanismFuel Pump Two types of fuel lift pumps are shown in  both operate on the same  principal Earlier model engines use a lift pump with a  element This element should be changed at  intervals at every 250 hours Later modelengines use a smaller lift pump that does not require maintenance Electrical connections should be kept clean and tightwith either pumpThe primary juelfilter encloses a highly effective paper element This filter assembly is located on the engine betweenthe fuel pump and the injection pump The paper elementshould be changed at regular maintenance intervals                                                                                         SMOKE SET           OVERINJECTION                                                                                         POSITION                                                          Engines  Generators                                                                   45                                                         FUEL SYSTEMAngleich Mechanism The Angleich Mechanism restricts the                    The intercylinder injection control Fuel injection  of the smoke set plate in the narrower range                       among the cylinders is performed by the adjusting platesAngleich effect L to save fuel consumption and decrease                 one plate for A Models two plates for B Models whichemission of exhaust smoke                                                  have their own cam mechanisms These adjusting plates are                                                                            located on the opposite side of the control rack Necessary                                                                            turning of the plunger barrels required for intercylinder                                                                            injection control is attained by turning the respective adjust                                                                            ing plates This adjustment is performed on a fuel shop flow                                                                            bench only      ADJUSTING PLATE  PLUNGER BARREL                                            AN GLEICH                                            SET PLATE                                            AN GLEICH                                            SET SPRING                                                                                                      ADJUSTING PLATES                                                                                                  3Cylinder Engine shown                                          ANGLEICH                          Delivery valve operation The delivery valves function is to                                          MECHANISM                         deliver fuel to the injection pipes after the fuel pressure has                                                                            been increased sufficiently and to prevent afterdrip from                                                                            the nozzles When the fuel pressure above a plunger has                  o                                                                            decreased after injection its delivery valve piston closes the                                                                            delivery valve seat At this time the compressed fuel remain                                                                            ing in the injection pipe drips from the nozzle To prevent                                                                            this afterdrip the delivery valve piston makes a stroke to                                                                            draw back the fuel before the delivery valve reaches the seat                                                                            thus reducing the fuel pressure in the injection pipe to nearly                                                                            zero                                                          l                                              STOP         l                                                          J                                    ANGLEICH EFFECT LReleasing the Angleich Mechanism It is necessary whenstarting the engine to set the injection pump in the overinjection MS condition by moving the throttle control lever fully                DURING                                                   AFTERto the FULLOPEN position This requires the Angleich set                     INJECTION                                                INJECTIONplate to be released from its set position Usually the                                                                            Nozzle and nozzle holder Fuel from the fuel injection pumpAngleich set plate is released by pulling the throttle lever                                                                            flows through the passage in the body of each nozzle holderuntil it is caught by its stopper when stopping the engine                                                                            and is injected from the nozzle into the combustion chamberAfter starting the engine the Angleich set plate is returned                                                                            Fuel overflowing from the nozzle enters the nozzle  to the applied position during warmup running                                                                            and returns to the fuel tank through the banjo and attachedof the engine                                                                            return fuel line                                                                                                   BANJOLII                                                                                                    BOLT                                                                                               BOOY                                                                                             SPRING                                                                                               DISTANCE      RELEASING                                                                                PIECE      ANGLEICH                                                                            RETAINING NUT      MECHANISM                                                                                                             INJECTOR                                                                                                    NOZZLE                                                                  Engines  Generators                                                                       46                                              FUEL SYSTEM                                                                a Remove the delivery valve holder                                                                          b Take out the valve spring valve and OringFuel Filter                                                                          c Take out the gasket and valve seatRemove the retaining nut Oring and filter element                                                                          d Unbend the lock plate of the tappet guide pin Push theFuel Lift Pump                                                               tappet slightly in and pull out the guide pin using                                                                             needlenose pliers Then remove the tappetThe fuel lift pump requires little or no  an early fuel lift pump and change the filter                e Remove the spring and upper seatLater model fuel lift pumps require no disassembly Fuel to               f Remove the pinionthe pump must be filtered to 1025 microns Electrical connections must be clean and tight Fuel connections at the                 g Pull out the plunger barrel upward from the pumppump must be tight and without leaks                                        housing Keep the removed plunger barrels and                                                                             plungers in a set for each cylinder Do not mix                                                                             plungers and barrels of other cylinders                                      FROM ENGINE                                      PRIMARY FUEL FILTER                 h Pull off the split pin Remove the washer return spring                                                                             and smoke set stopper Draw out the control rack                                                                             Remove the Angleich set spring and plate if equipped                                                                             before taking out the control rack                                                                            A CAUTION Do not disassemble the intercylin                                                                            der injection control adjusting plate When this plate    FUEL LIFT PUMP                                                          has been disassembled it will become necessary to    LATER MODEL                                                                            adjust the intercylinder injection by a tester When                                                                            this plate requires removal remember to draw a                                                                            mating mark across the pump body and the plate                                                                                                        GASKET                                                                                                       VALVE SEAT                                                                                                                                           DELIVERYFuel Injection Pump                                                                                    PLUNGER       U                  VALVE HOLDER                                                                                                       a                                                                                                                               a1 Remove the fuel injection pipes2 Before removing the pump be sure to remove the pump   side cover and disconnect the tierod and spring from the   rack Then remove the bolts fastening the injection pump   and remove the pump assembly3 Record the thickness and number of pump adjusting                                                                                                                              1             ADJUSTING   shims to facilitate adjustment at the time of assembly                                                                                PLATE                                                                                 BANJO                                             SPRING4 When partly disassembling the fuel injection pump use                        BOLT                                                                                   the following procedure                                                                                                            DELIVERY VALVE     A    CAUTION    Do not attempt to disassemble the                                                                          PUMP HOUSING     fuel injection pump unless it is necessary Since the     adjustment of an injection pump requires a pump                        SMOKE SET                                                                           STOPPER      tester and technical disassembly reassembly and                   RETURN                                                                         SPRING                                                                                1q     adjustment of a pump should not be performed if     such a tester and technician are not available     Before disassembly close the fuel inlet and outlet                                 LOWER                                                                                          SEAT                                                                                                                      PINION                                                                                          Ia     and clean the pumps outside surfaces                                                                                                                    UPPERSEAT                                                                                                                    I     Keep disassembled parts immersed in clean                                                                                          TAPPET     kerosene and keep all parts neatly arranged in order                                                                               ANGLEICH SET PLATE     to avoid confusion                                                AN GLEICH SET SPRING                                                                                                                              UNGER                                                               Engines  Generators                                                                 47                                              FUEL SYSTEM  Disconnect the return pipe from the nozzle holder upper                                                                                        FUEL LIFT PUMP   nipple                                                                              EARLY MODEL2 Disconnect the fuel injection pipe from the nozzle holder3 Loosen the nozzle holder attaching bolts and remove the   holder assembly4 When disassembling the nozzle holder into parts use the                                                                               t                                                                       SUCTION HEAO                                                                       APPROX 500 mm   following procedure   a Holding the nozzle holder body in a vice remove the      retaining nut with a spanner wrench When holding in      the vice be sure to use an aluminum or copper plate      adapter                                                                                               TESTING THE FUEL LIFT PUMP   h Remove the shim pressure spring flange pressure      pin and distance piece                                                                      Fuel Injection Pump   c Remove the nozzle from the retaining nut If the noz      zle is hard to remove apply light taps to it with a            1 Delivery valve seat Check the contact surface of the      wooden block Be careful not to damage the nozzle                   delivery valve seat Replace if defective      needle valve                                                   2 Plunger barrel Check the plunger for seizure damage                                                                          and rust Also check to see if the plunger slides smoothly                                         BANJO BOLT                       when inserted into the barrel If defective do not repair                                                                          it but be sure to replace as a set with a new one                                                                      3 Control rack and pinion If the rack and pinion have any                                                                          worn or damaged teeth replace                                                                      4 Tappet Check the tappet OD roller and shaft for wear                           00  SHIM                                 and damage If defective replace                                   SPRING                                                                                                    Nozzle                           PIN                                    1 Check the nozzle for incorrect contact and damage                                                                         Replace the nozzle as an assembly if defective                                         DISTANCE PIECE                                                                      2 Check the pressure spring for damage           NOULEHOLDER                   NOZZLE                                                                          NOTE Also check the Angleich set plates and set springs                                                                          for wear and damage                                         RETAINING NUT                                                                      REASSEMBLY                                                                      Fuel                                                                       Install the filter element and filter cup Orings in positionFuel Filter                                                           Tighten the retaining nut securelyCheck the filter element for contamination The regular element replacement interval is 250 hours Replace the element           Fuel Lift Pumpmore frequently if necessary                                         To reassemble set the plunger plunger spring valve Oring                                                                      and washer in position in that order and as a final step fit theFuel Lift Pump                                                        retainer to prevent the abovementioned parts from poppingThe fuel lift pump operates during the start sequence when            out of position see  is depressed Simulate a start and depress PRE               Put the filter in position and fit the magnet and gasket in theHEAT The pump should produce a clicking sound indicating             cover Using a 17 mm spanner fasten up to the stopper porthe pumping piston in the pump is pumping If no clicking is          tion in such a way as to prevent air leakageheard check that there is 12V DC at the pump connectionand that the pump is properly grounded                               Injection Pump1 Checking the pump delivery Test the pump by connect                                                                      1 Insert the plunger barrel with its slots in alignment with    ing a battery and fuel line as illustrated Fuel delivery                                                                         the dowel pins projecting in the pump housing    must be 225 cc 5 pints or more every 15 seconds                                                                      2 Install the Oring in the delivery valve holder                                                            Engines  Generators                                                                 48                                               FUEL SYSTEM SERVICE3 Install the spring seat gasket and the valve assembly in                 8 Insert the tappet taking care not to drop the shim Align   the holder Tighten the delivery holder to the pump hous                   the tappet guide hole with the dowel pin hole of the hous   ing Make certain that the aring has been properly                         ing and insert the tappet guide pin Install the lock plate   installed                                                                  before inserting the tappet guide pin and bend the lock                            GASKET                                      plate after inserting the pin                         VALVE SEAT                                                        DELIVERY                           PLUNGE                     VALVE HOLDER                            8                                                                                           1            ADJUSTING                                                                                                                        INSTALLING TAPPET                                                                                                                         3Cylinder shown                                                        PLATE        BANJO                                    SPRING        BOLT       LAWI                                                      DELIVERY VALVE   PUMP HOUSING                                                                            9 Install the smoke set stopper return spring and washer                                                                               Then insert the split pin and split it On later engines                                                                               also install the Ering stopper                                                                            10 Install the Angleich set plate and spring when equipped                                    PINION                              11 Torque the delivery holder to specification 289362 ftIb                                    UPPERSEAT                                  45 kgm                                   I        RSPR                                FUEL INJECTION PUMP                                                                            Installation and Adjusbnent of Fuel Injection Pump                                                                            1 When installing the pump assembly select and install the                                                                               adjusting shim After installing the pump fit the tierod                                                                               from the governor lever to the control rack then install the                                                                               tierod spring to the control rack Make sure that the end of                                                                               the tierod spring positioned at the governor lever side has4 Install the control rack                                                                               the shorter straight wire of the two ends of the spring ForS Install the pinions with their deeproot teeth aligned with                 proper selection of shim thickness temporarily install a   the respective marks on the rack                                           shim set having the same thickness as before removal and                                                                               when adjusting fuel injection timing replace the current DEEP ROOTS                                                                    shim set with one formed by a proper combination of four                                                                               kinds of shims  02 03 04 and 08 mm in thickness                                                                               NOTE Maintaining the same shim thickness for the injec                                                                               tion pump will place the pump in the same timing with the                                                                               engine as when previously removed                  ASSEMaLiNG RACK AND PINION6 Install the spring upper seat and spring7 Put the plunger and the spring lower seat together Install   the assembly so that in the same alignment position as   mentioned in step 5 the plunger frontend lead slant   groove is positioned on the opposite side of the control   rack On former engines insert the mark L area of the   plunger collar into the control rack side                                                                                                    INSTALLING INJECTION PUMP                                                                                                         3Cylinder shown                                                            Engines  Generators                                                                       49                                                 FUEL SYSTEM SERVICE2 Install the tierod cover In the case of a damper spring          Adjustment and Installation of Nozzle   loaded cover install the cover with the tierod pressed            Holder Assembly   toward the High Speed side by the speed control lever   see illustration                                                 1 Injection Start Pressure Test Using a nozzle tste mea                                                                          sure the injection start pressure If the pressure IS dIffer                                                                          ent from the standard value adjust to the specified                                                                          pressure by increasing or decreasing the thickness of the                                            TIEROD SPRING                adjusting shim Increasing or decreasing shim thickness                                                                          by 01 mm will vary the pressure by approximately 10                                           GASKET                         kglcm 2 When replacing the shim grip the retaining nut                                                                          in a vise and remove the body with a wrench Tighten the                                           LOCKNUT                        retaining nut to the specified torque                                           ADJUSTING BOLT                                                                            INJECTION                                                                                                                               SHIM THICKNESS                                                                                                                                                                                                  PRESSURE TEST                                                                                                                                   O1mm                                                                                                                      I            O2mm                                                                                                                                   O3mm                                                                                                                                   OSmm                      INSTAUING TIEROO COVER3 Connect the fuel supply hose Preheat to bleed air from the   system4 Check damper spring adjustment and fuel injection timing   For these adjustment procedures refer to ENGINE                                                                          2 Chattering Test For the chattering test operate the tester  A CAUTION Thoroughly clean all parts with                              lever slowly If the nozzle sprays sharply and intermit                                                                          tently the nozzle is considered good The nozzle hould  kerosene Do not wipe them with rags                                                                          spray fuel straight in its axial direction A nozzle IS defec  When tightening the retaining nut on the nozzle holder                  tive if it sprays fuel in a wrong direction or in several  body be Sure to tighten it to the specified torque                    separate strips Also a spray in the form of particles indi  Insufficient torquing will cause poor compression                      cates a defect These defects may sometimes be caused  Excessive torquing will prevent the nozzle needle from                  by clogging with dust therefore all parts should be care  moving freely                                                          fully cleaned before assembly1 Install the nozzle assembly distance piece and pressure                                                                                                       pin in the retaining nut2 Install the shim spring and flange to the body Install the   retaining nut on the body and tighten to the specified                                                1   torque                                                                                                                                                                                                                                                                                                                                                                                                                                 I                                                                                                                A CAUTION When using a vice to tighten the                                                             1                                                                                                                                                                                                                                                                                                                                           I      nut be sure to hold the body side the retaining                                                            nut was held a deformed nozzle would result                             GOOD                           BAD                BAD                                                                                                   CHATTERING TEST                                                             Engines  Generators                                                                  50                                              FUEL SYSTEM SERVICE3 Afterdrip test An injection nozzle is considered defec    tive if it drips fuel accumulated oil the bottom of the noz    zle after fuel injection is stopped during the chattering    test Replace such a nozzle A very small amount of fuel    may sometimes remain on the top of the nozzle This is    due to chattering and is not detrimental                         AFTER DRIP TEST                                                     rio                                                                                                                       GOOD                    BAD                     BAD4 Injection Condition Test Operate the tester lever quickly   at a rate of 800 strokes per minute The nozzle should   inject a fine atomozed mist of fuel straight in its axial   direction A spray in the form of particles is cause for   rejection5 Install the Nozzle Holder Assembly Install the tested    nozzle holder assembly in the cylinder head Tighten    bolts to the specified torque Be sure to install the assem    bly together with new sealing washers     A CAUTION When installing the nozzle holder     assembly in the cylinder head fit the holder loosely     with two bolts temporarily tightened After fitting     the injection pipe retighten the bolts evenly to the     specified torque                                                              Engines  Generators                                                                   51                                    RAW WATER COOLING                                                           The heat exchanger functions as part of the fresh water sys                                                                     tem and the raw water system The heat exchanger is a copThe raw water cooling circuit is driven by a positive dis           per tube which encloses a number of small copper tubesplacement impeller pump This pump draws in water directly                                                                     Raw water is pumped through the small copper tubes andfrom an ocean lake or river through the seacock then to a        fresh water coolant from the engine is circulated around theraw water strainer The raw water is drawn through the                                                                     copper tubes The raw water removes heat from the freshstrainer to the selfpriming pump and to the heat exchanger                                                                     water coolant A zinc anode is located in the raw water porwhere it cools the engines circulating fresh water coolant         tion of the exchanger to help control the effects of electrolyThe raw water is then discharged into the water injected                                                                     sis This area of the exchanger should be  elbow mixing with and cooling the exhaust gases                                                                     inspected and cleaned To keep the exchanger operating effiThis mixture of exhaust gas and raw water is driven through          ciently it should be removed from the engine every 1000the exhaust system and overboard                                                                     hours to be thoroughly cleaned and pressure  oil cooler In some installations the raw wateris also used to cool the engines transmission by passingthrough a transmission oil cooler Similar to a heatexchanger the transmission fluid is cooled by the raw waterand then passes into the exhaust elbow The oil cooler shouldbe cleaned and pressure tested at about the same interval asthe heat exchanger every 1000 hours                                                                                                                        PETCOCK                                                                          CLEAN OUT DEBRIS                                                                                             HEAT EXCHANGER                        TRANSMISSION OIL COOLERS                                                                          NEW                REPLACE          REPLACE       CLEAN                                                                                                                            AND REUSE                                                                                                   ZINC ANODES                                                                     The raw water pump is  selfpriming pump with a nonfer                                                                     rous housing and a Neoprene impeller The impeller has flex                                                                     ible vanes which wipe against a curved cam plate within the                                                                     impeller housing producing the pumping action The raw                                                                     water pump should be checked every 500 operating hours for                                                                     wear Should the pump fail it can be disassembled and over                                                                     hauled Check for internal wear within the pump such as the                                                                     cover plate cam and impeller housing Replace components                                                                     that show excess wear                                                       Engines  Generators                                                                52                                        RAW WATER PUMP SERVICE                                              RAW WATER PUMP  PH 33636PUMP OVERHAUL                                                          2 Install the shaft into the bearings Support the bearings at                                                                          their center races Push the shaft into the bearings                                                                ing at the impeller drive slot end using the base of theThe pump as removed from the engine will have hose                      drive slot Push the shaft through both of the  nipples threaded into its inlet and outlet ports              flush against each other so the flatsided end of the shaftThey may be left in place or removed if they interfere with               extends beyond the second bearing center race 15 mmthe pump disassembly Note the port location and positioning              1932 in  5 mm 132 inif removed                                                                       3 Support the pump housing at the impeller side1 Remove the six cover plate screws cover plate and the                Apply a small amount of petroleum jelly to the seals   cover plate gasket                                                    inner lips and to the impeller shaft Carefully install the   NOTE Replacement of the cover plate gasket is recom                  shaft rotating it through the seals until the bearings   mended however ifyou are going to reuse i keep the                  contact the housing from the bearing end Use a pushing   gasket submerged in water until the pump is reassembled               tool that will push this shaft and the bearing assembly   If its allowed to dry the gasket will shrink and not be              into the pump housing by applying pressure against the   reusable                                                              outer bearing race Push the assembly into the housing                                                                          until the bearings seat fully in the housing Install the2 Remove the impeller with its drive screw from the pump                 retaining ring   housing                                                                       4 Position the cam in the housing and secure it in place3 Remove the screw and sealing washer and remove the                     with the screw and sealing washer   cam from the pump housing                                                                           NOTE Use a small amount of Permatex 1 on the inner4 Remove the retaining ring                                              cam surface and screw threads Remove any excess from5 Support the pump housing at the mounting flange end                   the impeller housing   on an arbor press and with a drift press out the shaft and        5 Apply a light film of silicone or petroleum jelly to the   bearings from the pump housing                                        inner surface of the housing for the impeller6 With the pump housing supported push the seals out of                  NOTE Coat only the surface do not overapply Install   the pump housing Push the impeller side seal out the                   the impeller with the drive screw Push the assembly into   impeller side then lift the spacer out Then push the                  the housing with the drive screw mating in the slot of the   bearing side seal out the bearing side                                 drive shaft7 Supporting the bearings inner race push the shaft out of          6 Install the cover gasket and cover and secure them with   the bearings                                                          the six cover                                                              7 Reposition and tighten the hose nipples Assemble the                                                                          pump to the engine and attach the hosesInspect all parts and replace those showing wear or  Install the seals and spacer in the pump housing Push the   impeller side seal into the housing Rotate the pump and   install the spacer against the seal face Push the bearing   side seal into the housing from the bearing side    NOTE The seals flat surfaces that have printing and    numbers face toward each other             GASKET         COVER                                                                                                                       PUMP HOUSING                                                                                          RAW WATER PUMP                                                                                             PN 33636                                                            Engines  Generators                                                                  53                                         RAW WATER PUMP SERVICE                                               RAW WATER PUMP           PH 32610PUMP  disassembling the raw water pump for inspection animpeller kit part 032620 should be purchased so theimpeller can be replaced with a new gasket at the time ofinspection Although the impeller is a small part it plays animportant role in the proper operation of the  the impeller at the time of the raw water  can only improve the raw water pumps pumpingability see the note below1 Remove the four cover screws cover plate and the cover   plate gasket2 Remove the rubber impeller and the wear plate3 Remove the rubber Oring4 Remove the cam screw and washer and the camNow the raw water pump is stripped far enough to  the pump by rotating the pumps drive shaft If thereis excessive play or if it sounds rough or is frozen replacethe entire pumpSince rebuilding a damaged or worn pump from  pieces would almost match the price of a newpump we recommend that a new pump be purchased insteadof rebuilding one                                                                  COVER                                                                                     When reassembling the raw water pump with a newimpeller kit wipe a little petroleum jelly around the impellerThis ensures that when the engine is started the impeller willnot run dry until raw water reaches the impeller as it drawsa prime                                                           Engines  Generators                                                                   54                                         RAW WATER PUMP SERVICE                                               RAW WATER PUMP  PN 24143Pump 24143 has been replaced by pump 33636 Complete                      ment bushing chill the bushing in a freezer for 1 hour to24143 pumps are no longer assembled but their component                    reduce its size Prepare the pump housing on a press toparts are still available                                                  accept the bushing                                                                        2 Apply some light oil to the housing boss that the bushingPUMP OVERHAUL                                                              will be pressed into Using an appropriate drift push theDisassembly                                                                bushing into the housing so that it is flush with theRemove the pump from the engine The pump body is a                        impeller housings inner surfacebronze cast unit Its inlet and outlet hose connections are part        3 Using an appropriate installer install the impeller shaftof the pump housing casting                                               seal Ensure that the seal seats properly in the housing1 Remove the six cover plate screws along with the cover                  and that the lip seal is positioned correctly   plate and gasket                                                    4 Place the slinger ring in the housing against the impeller2 Using an appropriate drift push the impeller drive shaft               seal   and impeller out of the pump housing                                5 Install the impeller shaft oil seal into the housing so it is3 Using circlip pliers remove the outer circlip from the                 flush with the housing surface Again ensure that the lip   impeller drive shaft then remove the impeller from the                 seal is positioned correctly   shaft                                                               6 Install the inner circlip on the impeller drive shaft and4 Remove the key from the shaft and the inner circlip                   install the impeller key in the shaft5 Remove the screw holding the cam in the pump housing                7 Apply some light oil to the shaft and with a rotating   and remove the cam                                                     action slide it into the shaft bushing from the impeller                                                                           side and rotate it through the impeller seal Locate the6 Using an appropriate puller withdraw the outer and inner                                                                           slinger ring and rotate the shaft through it Continue   shaft seals along with the slinger ring from the pump                                                                           rotating the shaft and slide it through the housing oil seal   body                                                                        8 Install a new cam Apply some sealant to the cam retain7 Support the pump on a press and with a lubricated drift                                                                           ing screw and thread it into the cam through the housing   push the carbon shaft bushing out of the pump housing                                                                           and tighten it securely   Note the position of the shaft bushing in the housing   prior to removal                                                    9 Apply a small amount of petroleum jelly on the housings                                                                           inner circumference then install the impeller onto theInspection                                                                 shaft and into the housing Install the outer circlip on theExamine all components and replace worn or damaged parts                  shaftIf the pump housing is worn internally and requires replace                NOTE The set of the impeller blades is of no concernment we recommend that the pump assembly be replaced                       Once the pump is installed on the engine and the enginewith the current production pump It is available in a replace             rotated the blades will take the correct positionment kit Part 037431                                                 10 Install the housing cover and gasket Tighten the cover                                                                            screws  The carbon shaft bushing is a slight force fit into the   pump housing To aide in the installation of the replace                                                                          IMPELLER                                                                                                                            COVER                        SLINGER                        RING                                                                                                RAW WATER PUMP                                                                                                   PN24143                                                           Engines  Generators                                                                   55                                     FRESH WATER COOLING                                                             The water temperature switch and the water temperatureThe fresh water cooling circuit consists of a circulatory belt        sender are both mounted in the thermostat housing Thedriven water pump a thermostat and thermostat housing                water temperature switch normally open in a propulsionheat exchanger engine manifold and all associated hoses             engine when activated will close and sound an alarm The                                                                       water temperature switch normally closed in a generator                                                                       drive engine when activated will opeh and interrupt DC                                                                       Voltage to the fuel run solenoid and shut the drive engine                                                           IMPELLER    down The water temperature sender is a variable resistor                                                                       affected by heat Voltage from the water temperature gauge is                                                                       grounded through the sender to the block Depending on the                                                                       resistance through the sender effected by coolant heat the                                                                       gauge will indicate a temperature reading                                                                       Change of Coownt Over a long period of engine                                                                 scale will be deposited and rust formation will occur in the                                                                       water jacket and heat exchanger causing progressive deterio                                                                       ration in cooling system efficiency For this reason flush the                                                                       cooling system every 500 hours of engine operation             FRESH WATER PUMP                                          Antirust and Antifreeze To protect the cooling system                                                                       against corrosion and freezing always use a known brand of The water pump is a centrifugal impeller type and is                  antifreeze compatible with aluminum cooling system compo mounted on the front upper part of the cylinder block The            nents The use of an antifreeze mixture of 5050 is recom pump shaft is supported on  greasefilled           mended for yearround use Use antifreeze that is compatible doublerow radial ball bearings                                      with aluminum components and never mix different brands                                                                       of antifreeze Do not use plain water this can be detrimental                                                                       to the cooling system components                                                                       NOTE Look for the new  long lasting                                                                       antifreeze that is now available                                                                       Antifreeze mixtures will protect against an unexpected freeze                                                                       and they are beneficial to the engines cooling system They                                                                       retard rust and add to the life of the circulating pump seal                                                                                           ANTIFREEZE PROTECTION                                                                        Antifreeze concentration      23      35         50     60                                                                                                      14F      4F     40F     58F                                                                        Freezing temperature        10C   20C   40C   50C    COOLANT    TEMPERATURE    SE             TYPICAL             THERMOSTAT             ASSEMBLY ThermosllJt A thermostat housing is located on the cylinder                                      COOLANT RECOVERY TANK head water outlet Enclosed is a wax pellettype thermostat The valve opening temperature is not affected by variations of pressure in the cooling water passages                                                          Engines  Generators                                                                  56                                      FRESH WATER COOLING                                                             Thermostat1 Drain the cooling water A drain plug for draining the              Visually check the thermostat for damage Then put it in   engine block is located on the side of the engine block             water and raise the water temperature to test its valve open   just right of the lube oil filter A drain plug for draining        ing temperature Replace if defective   the heat exchanger is located on the heat exchanger2 Disconnect the water hose from the pump                                                                        A   CAUTION The wax pellettype thermostat remains    NOTE Generator models are equipped with belt guards                closed if its heatsensing part is defective Leaving this    that will need to be removed                                                                        uncorrected would cause the engine to overheat3 Remove the pump drive belt4 Disconnect the bypass hose when equipped                           REASSEMBLY5 Remove the water pump assembly                                     To reassemble the cooling system reverse the order of disas6 If necessary remove the water pump adapter when                    sembly When adjusting the drive belt tension use the fol   equipped                                                           lowing procedure7 On an engine with a thermostat remove the water outlet             Drive Belt Adjustment   fitting bolts in the front of the cylinder head and remove   the thermostat                                                                        A WARNING Never attempt to adjust the drive belt                                                                         tension while the engine is operating                                                                        A CAUTION Excessive water pump drive belt                                                                        tension can cause rapid wear of the belt and reduce                                                                        the service life of the fresh water pumps bearings                                                                        Excessive slack or the presence of oil on the belt                                                                        can cause belt slipping resulting in high operating                                                                        temperatures                                                                       Adjust the alternator position so that the belt may deflect 38                                                                       to 12 9 to 12 mm deep when depressed at the middle                                    WATER PUMP ASSEMBLY                point between the alternator and crankshaft pulleys After                                                                       adjustment securely tighten the support bolt and brace boltINSPECTION                                                             If any clearance is found between the gear case and alternator                                                                       fitting part insert a suitable shim inside the support on theWater Pump                                                             back of the alternator before tightening the bolts Reinstall1 Check every part for cracks damage and water leaks                belt   Replace if defective    NOTE No rebuilding kits are available for the fresh water    circulation pump2 Check the impeller and shaft for rotating condition If   they make noise or rotate irregularly replace as an   assembly                                                                                    BELT TENSION                                                            Engines  Generators                                                                  57                                              ADMIRAL CONTROL                                                                                  When the engine is shut down with the key switch turned off                                                                                            the water temperature and oil pressure gauges will continueThis  control panel is equipped with a                                                                                            to register their last readings before the electrical power wasKEY switch and RPM gauge with an ELAPSED TIME                                                                                            turned off When the electrical power is restored both gaugesmeter which measures the engines running time in hours and                                                                                            will once again register true readingsin 110 hours The panel also includes a WATER TEMPERATURE gauge which indicates water temperature in degrees                                    A separate alarm buzzer with harness is supplied with  an OIL PRESSURE gauge which measures the                                        Admiral Panel The installer is responsible for  oil pressure in pounds per square inch and a DC                                   connecting the buzzer to the fourpin connection on thecontrol circuit VOLTAGE gauge which measures the sys                                       engines electrical harness The installer is also  voltage All gauges are illuminated when the key                                      for installing the buzzer in a location where it will be dry andswitch is turned on and remain illuminated while the engine                                 where it will be audible to the operator should it sound whileis in operation The panel also contains two rubberbooted                                  the engine is running The buzzer will sound when the  one for PREHEAT and one for START                                             tion key is turned on and should silence when the engine has                                                                                            started and the engines oil pressure rises above 5 psi                                WATER TEMPERATURE GAUGE THIS GAUGE IS                                                     OIL PRESSURE GAUGE THIS GAUGE IS GRADU                                GRADUATED IN DEGREES FAHRENHEIT AND IS                                                     ATED IN POUNDS PER SQUARE INCH PSI AND IS                                ILLUMINATED WHILE THE KEY SWITCH IS                                                        ILLUMINATED WHILE THE KEY SWITCH IS                                TURNED ON THE ENGINES NORMAL OPERATING                                                   TURNED ON THE ENGINES NORMAL OPERATING                                TEMPERATURE IS 170190 F 77SS0C                                                     OIL        RE RANGES BETWEEN 3060 PSIRPM GAUGE REGISTERS REVOLUTIONSPER MINUTE OF THEENGINE AND CAN BERECALIBRATED FORACCURACY FROMTHE REAR OFTHEPANEL                                                                                                                                                   KEY SWITCH PROVIDESHOUR METER REGIS                                                                                                                                                   POWER ONLY TO THETERS ELAPSED TIME                                                                                                                                                   INSTRUMENT PANELAND SHOULD BE USED                                                                                                                                 CLUSTERtAS A GUIDE FOR                                                                                                                                                    DC VOLTMETER                                                                                                                                                   INDICATES THE AMOUNT                                                                                                                                                  THE BATTERY IS BEINGPREHEAT BUnON WHEN PRESSED ENERGIZES                                                                                                             CHARGED SHOULDTHE ALTERNATORS REGULATOR THE FUEL LIFT                                                                                                          SHOW 13VTO 14VPUMP AND THE ENGINES GLOW PLUGS IT BY                                                              AUTOMATIC AlARM SYSTEMPASSES THE ENGINES PROTECTIVE OIL PRES                                                             HIGH WATER TEMPERATURE ALARM AN ALARM BUZZER HASSURE ALARM SWITCH IN ADDITION THIS                                                                  BEEN SUPPLIED WITH THE INSTRUMENT PANEL IF THE ENGINESBUTTON ENERGIZES THE START BUnON                                                                     FRESH WATER COOLANT REACHE210 F 9SC THIS SWITCH                                                                                                      WILL CLOSE SOUNDING THE ALARM WHICH WILL EMIT A CON                                                                                                      TINUOUS SIGNAL                                                                                                                                                              LOW OIL PRESSURE AlARM A LOW OIL PRESSURE ALARMSTART BUnON WHEN PRESSED ENERGIZES                                                                  SWITCH IS LOCATED OFF THE ENGINES OIL GALLERY THISTHE STARTERS SOLENOID WHICH CRANKS THE                                                                                           I                                                                                    I                 SWITCH MONITORS THE ENGINES OIL PRESSURE SHOULD THEENGINE THIS BUTTON WILL NOT OPERATE                                                                                                                                                       I                         ENGINES OIL PRESSURE FALL TO 5 10 PSI THE SWITCH  UNLESS THE PREHEAT BUTTON                                                         CLOSE SOUNDING THE ALARM IN THIS EVENT THE ALARM WILLIS PRESSED AND HELD AT THE SAME TIME                                                                 EMIT A PULSATING SIGNAL                                                                  Engines  Generators                                                                                        S8                                                    CAPTAIN CONTROL                                                                     OIL PRESSURE or high WATER TEMPERATURE The                                                                               RPM gauge is illuminated when the KEY switch is turned onThis  control panel is equipped with a                                                                               and remains illuminated while the engine is in operationKEY switch an RPM gauge PREHEAT and START buttons an INSTRUMENT TEST button and three indicatorlamps one for ALTERNATOR DISCHARGE one for lowOIL PRESSURE and one for high ENGINE  It also includes an alarm buzzer for low                                                                               ALARM THE ALARM WILL SOUND IF THE ENGINES OIL PRESSURE                                                                               FALLS BELOW 15 PSI IN THIS EVENT THE ALARM WILL EMIT A                                                                               PULSATING SIGNAL THE ALARM WILL ALSO SOUNO IF THE WATERRPM GAUGE REGISTERS REVOLUTIONS PER                                           TEMPERATURE IN THE FRESHWATER COOLING CIRCUIT RISES TOMINUTE OF THE ENGINE AND CAN BE RECALI                                        205F IN THIS EVENT THE ALARM WILL EMIT A CONTINUOUS SIGNALBRATED FOR ACCURACY FROM THE REAR OF                                           NOTE THE ALARM WILL SOUND WHEN THE KEY SWITCH IS TURNEDTHE PANEL                                                                     ON THIS SOUNDING IS NORMAL ONCE THE ENGINE STARTS AND THE                                                                               ENGINES OIL PRESSURE REACHES 15 PSI THE ALARM WILL SILENCE                                                                                                                               TEST BUTTON WHEN                                                                                                                               PRESSED TESTS THE                                                                                                                               ALTERNATOR THE OIL                                                                                                                               PRESSURE AND THE                                                                                                                               WATER TEMPERATURE                                                                                                                               CONTROL CIRCUITS                                                                                                                               WHEN PRESSED THE                                                                                                                               ALTERNATOR THE OIL                                                                                                                              PRESSURE AND THE                                                                                                                               WATER TEMPERATURE                                                                                                                               INDICATOR LIGHTS IL                                                                                                                               LUMINATE IN ADDITION                                                                                                                               TO SOUNDING THE                                                                                                                               ALARM BUZZER                                                                                                                               KEY SWITCH PROVIDES                                                                                                                               POWER ONLY TO THE IN                                                                                                                               STRUMENT PANEL CLUSTER                                                                                               PREHEAT BUTTON WHEN PRESSED ENERGIZES                                    START BUTTON WHEN PRESSED ENERGIZES                      THE ALTERNATORS REGULATOR THE FUEL LIFT                                    THE STARTERS SOLENOID WHICH CRANKS THE                    PUMP AND THE ENGINES GLOW PLUGS IT BY                                    ENGINE IT WILL NOT OPERATE ELECTRICALLY                   PASSES THE ENGINES PROTECTIVE OIL PRES                                    UNLESS THE PREHEAT BUTTON IS PRESSED AND                   SURE ALARM SWITCH IN ADDITION THIS                                    HELD AT THE SAME TIME                                     BUTTON ENERGIZES THE START BUTTON                                                               Engines  Generators                                                                      59                                   CONTROL PANEL                                                      Tachometer Inaccurate  The  used in propulsion engine instru             1 With a handheld tach on the front of the crankshaft pul  ment panels contains two separate electrical circuits with a              ley retaining nut or with a strobetype tach read the front  common ground One circuit operates the hourmeter and the                 crankshaft pulley rpm Set the engine with a hand or other the tachometer The hourmeter circuit operates on 12                strobe tach at 15001800 rpm   volts alternator charging voltage supplied to the  terminal         2 Adjust the tachometer with a small Phillips type screw  on the back of the instrument                                            driver through the calibration acess hole in the rear of theThe tachometer circuit operates on AC voltage 68 volts fed                tachometer Zero the tach and bring it to the rpm set byfrom one of the diodes in the alternator and supplied to the                the strobe or hand tach Verify the rpm at idle and attachometer input terminal while the engine is running and                  high speed 30003600 rpm Adjust the tach as neededthe alternator producing battery charging voltage 130148volts DC Use the following procedures when  a fault in either of the two circuits in a                                                                       COARSE Hounneter Inoperative                                               AOJUSTMENT Check for the proper DC voltage between  and  terminals                                                                                                                        TERMINAL 1 Voltage present  meter is defective  repair or replace                                                                                                              lDAfIl TERMINAL 2 Voltage not present  trace  and  electrical con    nections for fault Jump 12 volts DC to meter                                                                ralnMCD INPUT    terminal to verify the operation                                                                                   AC VOLTAGE                                                                                             CURRENT TACHOPttETER Tachometer Inoperative Check for the proper AC voltage between tachometer input terminal and the  terminal with the engine running 1 Voltage present  attempt adjusting the meter through the    calibration access hole If no results repair or replace the    meter2 AC voltage not present  check for proper alternator DC   output voltage3 Check for AC voltage at the tach terminal on the alterna   tor to ground 4 Check the electrical connections from the tachometer    input terminal to the alternator  Sticking 1 Check for proper AC voltage between the tachometer                                      EARLY MODEL TACHOMETER                                                                                                                                         GROUND    input terminal and the  terminal2 Check for a good ground connection between the meter    terminal and the alternator3 Check that the alternator is well grounded to the engine   block at the alternator pivot bolt                                                                                                                                GROUND                                                                                                                                    TERMINAL                                                                                                                                 TACHOMETER INPUT                                                                                                                                 AC VOLTAGE                                                                                             EARLY MOOEL TACHOMETER                                                           Engines  Gerators                                                                    60                                      CONTROL PANEL                                         MANUAL STARTER DISCONNECT TOGGLE SWITCHES                     NOTE The engine control system is protected by a 20 amp manual reset circuit breaker                     mounted on a bracket at the top rear of the engine near the PREHEAT solenoid             PROBLEM                                       PROBABLE CAUSE                                             PREHEAT depressed no panel indications    1 Battery switch or power not on                         1 Check switch andor battery connections    fuel solenoid electric fuel pump and    preheat solenoid not energized          2 20 amp circuit breaker tripped                         2 Reset breaker If opens again check preheat sole                                                                                                           enoid circuit and run circuit for shorts to ground START SWITCH DEPRESSED no starter          1 Connection to solenoid faulty                          1 Check connection    engagement                                             2 Faulty switch                                          2 Check switch with ohmmeter                                             3 Faulty solenoid                                        3 Check that 12 volts are present at the solenoid con                                                                                                            nection                                             4 Loose battery connections                              4 Check battery connections                                             5 Low battery                                            5 Check battery charge state START DEPRESSED panel indications OK      1 Poor connections to fuel solenoid Defective fuel run   1 Check mechanical positioning of the fuel solenoid    Start solenoid OK Fuel solenoid not        solenoid PN 2304                                      for plunger and throttle arm    functioning                                                                                                        2 Manually check movement of the fuel run solenoid                                                                                                           plunger and throttle arm NO IGNITION cranks does not start Fuel   1 Faulty fueling system                                  1 Check for fuel to generator system    solenoid energized                                                                                                        2 Check for air in the fuel system                                                                                                           Allow system to selfbleed                                                                                                        3 Full lift pump faulty ENGINE STOPS                                1 Switch and wiring                                      1 Inspect all wiring for loose connections and short                                                                                                           circuits NOT CHARGING BATTERY                        1 Alternator drive                                       1 Check the drive belt and its tension Be sure the                                                                                                           alternator turns freely Check for loose connections                                                                                                           Check the output with a voltmeter Ensure 12V are                                                                                                           present at the regulator terminal BATTERY RUNS DOWN                           1 Oil pressure switch                                    1 Observe if the gauges and panel lights are activated                                                                                                           when the engine is not running Test the oil pressure                                                                                                           switch                                             2 High resistance leak to ground                         2 Check the wiring Insert sensitive 025 amp meter                                                                                                           in battery lines Do not start engine Remove con                                                                                                           nections and replace after short is located                                             3 Low resistance leak to ground                          3 Check all wires for temperature rise to locate the                                                                                                            fault                                             4 Alte rnato r                                           4 Disconnect alternator at output after a good battery                                                                                                           charging If leakage stops Remove alternator and                                                                                                           bench test Repair or replace                           WATER TEMPERATURE AND OIL PRESSURE GAUGESIf the gauge reading is other than what is normally indicated                      If both of the above gauge tests are positive the gauge isby the gauge when the instrument panel is energized the first                     undoubtedly OK and the problem lies either with the constep is to check for 12 volts DC between the ignition B                         ductor from the sender to the gauge or with the senderand the Negative B terminals of the gauge                                     If either of the above gauge tests are negative the gauge isAssuming that there is 12 volts as required leave the instru                    probably defective and should be replacedment panel energized and perform the following steps                             Assuming the gauge is OK check the conductor from the1 Disconnect the sender wire at the gauge and see if the                         sender to the sender terminal at the gauge for continuity     gauge reads zero which is the normal reading for this                       Check that the engine block is connected to the ground     situation                                                                   Some starters have isolated ground terminals and if the2 Connect the sender terminal at the gauge to ground and                         battery is connected to the starter both plus and minus   see if the gauge reads full scale which is the normal                         terminals the ground side will not necessarily be connected   reading for this situation                                                     to the block                                                                       Engines  Generators                                                                             61                                   CONTROL PANEL  EARLY  BY KEY SWITCH                                                overheat condition exists and the operating temperature of                                                                        the engine reaches 205F and sounds the alarm TheTurning the ignition switch ON activates the instrument                                                                        tachometer will register the engine speed as it takes impulsespanel The oil and water temperature gauges will zero the                                                                        from the alternator as it charges If the alternator does notvoltmeter will indicate battery voltage and the hourmeter                                                                        produce a charge the tachometer will not operate Thewill start to record time The alarm buzzer should sound The                                                                        hourmeter will continue to record time The hourmeter is onelectric fuel pump will start to operate                                                                        a separate 12 volt circuitPushing the key will activate the preheat circuit This closes a                                                                        The circuit is protected by a circuit breaker located on thesolenoid on the engine with an audible click and supplies 12                                                                        engine Whenever excessive current flows the circuit breakervolts to the engine glow plugs Preheat as needed for weather                                                                        will trip This is a manual reset breaker which must be  A noticeable voltage drop will indicate on the                                                                        before the engine will operate electrically againvoltmeter when the preheat circuit is  to preheat turn the key to START This energizesthe starter and turns the engine over Once the engine starts           A CAUTION The builderowner must ensure that therelease the keyswitch It should spring back to the ON posi             instrument panel wiring and engine are installed so thattion and pop out of the preheat position                                electrical devices cannot come in contact with seaThe voltmeter should indicate a charge from the alternator of            water135  145 volts The oil pressure and the alarm buzzershould shut off Oil pressure opens the oil pressure switch in          The latest information regarding your engines electricalthe alarm circuit shutting off the alarm The water tempera            system is included on the wiring diagram shipped with theture switch operates the opposite way it closes when an                engine Be sure to study this wiring diagram and all notes                                                                        thereon           EARLY PROPULSION ENGINE MODELS                                        LATER PROPULSION ENGINE MODELS  INTRUMENT       PANEL ASSEMBLY                                          INSTRUENT PANEL ASSEMBLY     RfAR VIIW      o          OP G          WT G                                            REAR VICW                                                                            f0oiLllrfS3Ulr Wri    0            CD I                                                                             I                                           I                                                                                                                                       I                                                                             I                                           HOUII                                                                                                                              tTDt                                                                                         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             r           INTRU  ENT PANL A5BLY    vw                          1                  OPe      TG f2 r                                            1                                    rVL7                                                                               frl 1             OOI                                                                 I    I   1   I                                                                                   I J Tl                                                                                             1                I                                                                                             I                1                                                                                          I                I                                                                                             I                                                                                             I                 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                                         1             r                                                                                             I    I                                                                                                  1                                                                1                                                                1                                                                1                                                                                         rJ                                                        RCOT     CONTROL PANL                                Engines  Generators                                       63                                                                                                              ADJUSTMENT AND REPAIRThe starter can be roughly divided into the following sections            If any abnormality is found by the following tests the starter     A motor section which generates a drive power                       should be disassembled and repaired     An overrunning clutch section which transmits an arma               Pinion Gap Inspection      ture torque preventing motor overrun after starting                                                                           1 Connect a battery 12V between the starter terminal S     A switch section solenoid which is operated when                      and the starter body and the pinion drive should rotate      actuating the overrunning clutch through a lever and                    out and stop      which supplies load current to the motorThe starter is a new type small lightweight and is called ahighspeed  starter Its differences in con              A CAUTION Never apply battery voltage for overstruction from conventional starters are as follows                        10 seconds continuously    In conventional starters the pinion slides on the motor             2 Lightly push the pinion back and measure the return      shaft armature shaft In the new type of starter the pin            stroke called pinion gap      ion shaft is separate from the motor shaft the pinion      slides only on the pinion shaft                                     3 If the pinion gap is not within the standard range 05 to                                                                              20 mm adjust it by increasing or decJeasing the number     A reduction gear is installed between the motor shaft and               of shims on the solenoid The gap is decreased as the      the pinion shaft                                                       number of shims increases     The pinion sliding part is not exposed outside the starter      so that the pinion may slide smoothly without becoming      fouled with dust and grease     The motor shaft is supported at both ends on ball bear      ings The lever mechanism switch and overrunning      clutch inner circuit are identical to conventional ones                              SOLENOIO                                                                           NoLoad Test                                                                           1 Connect the ammeter voltmeter and battery to the starter                                                                              see illustration                                                                           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 disas                                                                              semble the starter and repair it                                         t   CLUTCH     REAR                                         I            FRONT BRACKET                                                                                                                   BATTERY     BRACKET                       CENTER               ARMATURE            BRACKET                           STARTER                                                                                                                                          M                                                                                A CAUTION Use thick wires as much as possible                                                                                and tighten every terminal securely This is a sole                                                                                noid shifttype starter which makes a rotating sound                                                                                louder than that of a directdrive type starter When                                                                                detecting starter rotation at the pinion tip be care                                                                                ful not to come in contact with the pinion gear when                                                                                it protrudes                                         STARTER WIRING                                                                 Engines  Generators                                                                      64                                                                                                          3 Holding test With a battery connected to the solenoid                                                                            terminal s and to the starter body manually pull outPerform the following tests If any test result is not satisfac            the pinion fully The pinion must remainat that positiontory replace the solenoid assembly                                        even when released from being held by hand1 Disconnect the wire from terminal M2 Attraction test Connect a battery to the solenoids termi    nal S for  and M for  Have a switch in the  lead                                                                                                             T    and close it The pinion drive should extend fully out                                                                                             CONNECTOR OFF     A CAUTION Do not apply battery current for     more than 10 seconds when testing the solenoid                                                                              HOLOING TEST                        RETURN TEST                                                                        4 Return test With a battery connected to the solenoid ter                                                                            minal 1 and to the starter body manually pull out the                               ATTRACTION TEST                              pinion fully The pinion must return to its original posi                                                                            tion when released from being held by handSTARTER DISASSEMBLY                                                     7 Pull out the reduction gear lever and lever spring from                                                                           the front bracket1 Disconnect the wire from the solenoid terminal M                                                                        S On the pinion side pry the snap ring out and pull out the2 Loosen the two screws fastening the solenoid Remove                                                                           pinion and pinion shaft   the solenoid assembly                                                                        9 At ach end of the armature remove the ball bearing3 Remove the two through bolts and two screws fastening                   with a bearing puller It is impossible to replace the ball   the brush holder Remove the rear bracket                              bearing pressfitted in the front bracket If that bearing4 With the two brushes pulled away from the armature                     has worn off replace the front bracket assembly   remove the yoke and brush holder assembly Then pull   the armature out5 Remove tije cover pry the snap ring out and remove the   washer6 Unscrew the bolts and remove the center   bracket At the same time the washers   for the pinion shaft end play                                                                             BRUSHES   adjustment will come off                                                                                 BRUSH HOLDER                                                                                        ASSEMBLY         LLJ                                                                                                   i  c                                                            Engines  Generators                                                                   65                                           SERVICE                                                                                                            CLEANING THE   the solenoid for continuity between terminals S andM and between terminals S and body No continuity shouldbe found between Sand M Continuity should be foundbetween S and the body and M and the body                                        CONTINUITY CHECK                                                                              Brush and Brush Holder Inspection                                                                              1 Check the brushes If worn out beyond 10 mm replace                                                                                        the brushes                                                                                             The Annature1 Check the armature with a growler tester If its short cir                                              NEW            USED   cuited replace the armature Also check for insulation                                                                              2 Check the brush spring tension A weak or defective   between the communicator and its shaft If poorly insu                                                                                 spring will cause excessive brush wear replace the   lated replace the armature                                                                                 springs if suspect                                                   ARMATURE                                                   CHECK                                                                              3 Check for insulation between the positive brush holder                                                                                 and holder base If poorly insulated replace the holder                                                                                 assembly Also check the brush holders for proper staking2 Measure the commutator 00 and the depth of undercut   Repair or replace it if the service limit is exceeded Also   check the commutator outside surface for dirtiness and   roughness If rough polish the commutator with a fine   crocus cloth                             Commutator 00 1260 in 320 mm                               Commutator 00 service limit 1230 in 312 mm                             unudercut 0030 n 196 omO                                                           ms  038                                                                               ndercut service Imit 1 In mm                                                                                                                                             1                                   COMMUTATOR 00                  WESTERBEICE                                                                   Engines  Generators                                                                       66                                         SERVICEField Coil Inspection1 Check for insulation between one end brush of the coil   and yoke2 Check for continuity between both ends brushes of the   coil3 Check the poles and coil for tightness                                                                      2 Greasing Whenever the starter has been overhauled                                                                         apply grease to the following parts          FIELD COIL TEST                                                                         8   Armature shaft gear and reduction gear                                                                         b All bearings                                                                         c Bearing shaft washers and snap rings                                                                         d Bearing sleevesSTARTER ADJUSTMENT AND REASSEMBLY                                        e Pinion                                                                         f Sliding portion of lever A     CAUTION Before instaling thoroughly clean the  starter flange and mounting surfaces remove all oil  old paint and rust Starter performance largely                            A   CAUTION Never smear the starter fitting sur  depends on the quality of the wiring Use wire of suffi                    face tenninals brushes Dr commutator with  cient size and grade between the battery and starter                        grease  and fully tighten to the tenninal                                                                      3 After reassembly check by conducting a noload test                                                                          the starter assembly in the reverse order of disassembly making sure of the following1 Pinion shaft end play adjustment Set the en play    thrust gap to between 05 to 2 mm by inserting an    adjusting washer between the center bracket and the    reduction gear    8   Fit the pinion shaft reduction gear washer and snap         ring to the center bracket    b  Measure the end play by moving the pinion shaft in         the axial direction If the end play exceeds 05 mm         increase the number of adjusting washers inserted                                                          Engines  Generators                                                                 67                                                    DC ELECTRICAL SYSTEM     DESCRIPTION                                                               NOTE An isolator with a diode a solenoid or a battery                                                                               selector switch is usually mounted in the circuit to isolate the     The DC Circuit functions to start operate and stop the                   batteries so the starting battery is not discharged along with     engine The circuit is best understood by reviewing the DC                the house batteries If the isolator is charging the starting     ELECTRICAL SYSTEM WIRING DIAGRAMS                                                                               battery but not the house battery the alternator is OK and     The engines DC wiring is designed with three simple basic                the problem is in the battery charging circuit     circuits prehea start and run or stop     Engine 12Volt Control Circuit                                              A WARNING Shut off the engine battery switch or dis     The engine has a 12 volt DC electrical control circuit that is              connect from the battery when working on the engine     shown in the wiring diagrams Refer to these diagrams when                  electrical system      or when servicing the DC electrical system     on the engine                                                                               Checking for Proper Voltage                                                                               If you suspect the alternator has failed perform the following       A       CAUTION To avoid damage to the battery charg                  tests with the engine off       ing circuit never shut off the engine battery switch                   1 Using a voltmeter connect the voltmeter red wire clip to       while the engine is running Shut off the engine battery                   the output terminal B       switch however to avoid electrical shorts when                        2 Connect the voltmeter negative wire to any ground on the       working on the engines electrical circuit                                engine                                                                               3 Check the battery voltage If the battery is in good condi     CHARGING SYSTEM                                                              tion it should read 12 to 125 volts     The charging system consists of an alternator a voltage                  4 Check the voltage between the alternator  positive     regulator an engine DC wiring harness an enginemounted                    terminal B and any engine ground If the circuit is good     DC circuit breaker a battery and connecting wires Because                  the voltage at the alternator should be the same as the     of the use of integrated circuits ICs the electronic voltage              battery unless theres an isolator in the circuit then the     regulator is very compact and is mounted internally or on the                reading would be zero     back of the alternator     ALTERNATOR                                                   A    CAUTION To avoid damage to the battery charg     If you suspect that the alternator is not producing enough                  ing circuit never shut off the engine battery switch     voltage to charge the engines battery check the following                when the engine is running       A WARNING A failed alternator can become very       hot Do not touch until the alternator has cooled down                   A WARNING Before starting the engine make cer                                                                                 tain that everyone is clear of moving parts Keep away     o       Make certain your alternator is securely mounted                   from sheaves and belts during test procedures     o       Check the drive belts for proper tension     o       Inspect for loose or disconnected wires at the alternator                                                                               5 Start the engine                                                                               6 The voltage reading for a properly operating alternator                                                                                  should indicate between 135 and 145 volts If your                                                                                  alternator is over or uncercharging have it repaired at a   14 BLACK                                                                                  reliable service shop                                                                                   NOTE Before removing the alternator for repair use your                                                                                   voltmeter to ensure that 12 volts DC excitation is present14 PURPLE                                                                         at the EXC terminal if the previous test showed only bat                                                                                   tery voltage at the B output terminal                 MANDO                  51 AMP ALTERNATOR                                                                  Engines  Generators                                                                          68                                           DC ELECTRICAL SYSTEMBATIERY  the manufacturers  and then establish a systematic maintenance schedule for your engines                                                                       A WARNING These glow plugs will become very hot                                                                        to the touch Be careful not to burn your fingers whenstarting batteries and house batteries                                                                        testing plugso   Monitor your voltmeter for proper charging during    engine operation                                                                      Reinstall the plugs in the engine and test them again Theo   Check the electrolyte level and specific gravity with a           plugs should get very hot at the terminal end within 20 to    hydrometer                                                       25 seconds If the plugs dont heat up quickly check for ao   Use only distilled water to bring electrolytes to a proper        short circuit    level                                                            When installing the glow plugs use antiseize compound ono   Make certain that battery cable connections are clean             the threads    and tight to the battery posts and to your engineo   Keep your batteries clean and free of corrosion                   A CAUTION Do not keep glow plugs on for more                                                                        than 30 seconds A WARNING Sulfuric acid in lead batteries can cause severe burns on skin and damage clothing Wear protective gearGLOW PLUGSThe glow plug is a small heater installed in each precombustion chamber They run off the engine starting battery andbecome red hot when activatedThe glow plugs are wired through the preheat solenoidWhen PREHEAT is pressed at the control panel this solenoidshould click on and the glow plug should begin to get hotGlow plugs can be checked by unscrewing and holding themagainst a good ground engine block and turning them onThe tip should glow red hot You can also use an ammeter totest the power drain 8 to 9 amps per plug or an ohmmeterto test resistance 11 to 12 ohms                                 TYPICAL GLOW PLUG                                                         Engines  Generators                                                                 69                                                                                                   NOTE The alternator connections and color coding described                                                                          on the following illustrations may vary from earlier WESTThe alternator serves to keep the battery constantly charged                                                                          ERBEKE engines Always refer to the wiring diagrams inIt is driven from the pulley at the end of the crankshaft by a                                                                          this manual and also make a quick sketch of your  The type of alternator used is ideal for high speed                                                                          wiring before disconnecting for serviceengines having a wide range of engine speeds It containsdiodes that convert AC to DC and an IC regulator that keepsthe generated voltage constant even when the engine speedchanges  A        CAUTION Do not use any highvoltage tester such  as a megger Otherwise damage to diodes will result  During highspeed running of the engine do not discon  nect the positive or negative tenninal of the battery  from terminal B of the alternator If this is done diode  failure will result  With altemators having Ie regulators absolutely avoid  a short circuit between tenninals Band L This would  allow current to flow in the diode trio and damage it  Do not start the engine with the lead disconnected from                         MITSUBISHI                                                                              50 AMP ALTERNATOR                                                                                                                        MANOO                                                                                                                   51 AMP ALTERNATOR  terminal B of the alternator Otherwise damage to the  voltage regulator will result                                          ALTERNATOR   When charging the battery with a quick charger be                      If you suspect that the alternator is not producing enough  sure to disconnect the battery tenninals to prevent                     voltage to charge the engines battery check the following  damage to diodes                                                       o   Make certain your alternator is securely mounted                                                                          o   Check the drive belts for proper tension                                                                          o   Inspect for loose or disconnected wires at the alternator                                                    FAN                                                                           A WARNING A failed altemator can become very                                                                           hot Do not touch until the altemator has cooled down                                                          PULLEYREAR                                                                      Testing The Charging VoltageBEARING                                                            SHAFT         If you suspect the alternator has failed perform the following                                                                          tests                                                                          1 Using a voltmeter connect the voltmeter red wire clip to                                                           FRONT             the output terminal B                                                           BEARING                                                                          2 Connect the other voltmeter wire to any ground on the                                                                              engine                                                                          3 Start the engine and record the voltmeters readings                                                                            A CAUTION To avoid damage to the battery charg                                                                            ing circuit never shut off the engine battery switch                                                                            when the engine is running                                                            Engines  Generators                                                                     70                                    SERVICEThe voltage reading for a properly operating alternator                     NOTE If the screwdriver is inserted too deep the statorshould be between 135 and 145 volts If your alternator is                coil might be damagedover or undercharging have it repaired at a reliable service          2 Hold the rotor in a vise and remove the pulley nut Thenshop or continue with the following tests                                remove the pulley fan spacer and seal Next remove theNOTE Before removing the alternator for repair use your                  rotor from the front bracket and remove the sealvoltmeter to ensure that 12 volts DC excitation is present at           3 Unsolder the rectifier from the stator coil lead wires andthe R EXC terminal if the previous test showed only battery              remove the stator  at the B output terminal                                                                            NOTE Make sure that the solder is removed quickly in                                                                           less than five seconds If a diode is heated to more than                                                                            150C 310F it might be damaged                                                                        4 Remove the condenser from terminal B                                                                        5 Unsolder the plates Band L from the rectifier assembly                                                                        6 Remove the mounting screw and B terminal bolt and                                                                           remove the electronic voltage regulator and brush holderOutput Test                                                                The regulator and brush holder cannot be sepearated1 Disconnect the battery ground cable                                 7 Remove the rectifier assembly2 Disconnect the wire from terminal B on the alternator                S Brush and brush spring replacement   and connect an ammeter between B and this wire                                                                            When only a brush or brush spring is to be replaced it can3 Connect a voltmeter between terminal B  and ground                be replaced without removing the stator etc With the brush4 Connect to the P terminal                                               holder assembly removed unsolder the pigtail of the brush5 Reconnect the battery ground cable to the  terminal              NOTE If the terminals Land B of the rectifier assembly are    The voltmeter should indicate the battery voltage                  bent damage might result to the rectifier Therefore the                                                                        plates Band L should be gently bent at the center6 Connect B to the R terminal regulator7 Start the engineS Tum on 12 volt accessories equaling the amperage output                                                                             PLATE B    7    of the alternator accelerate the engine to the specified   speed 2000 to 3000 rpm and measure the output cur   rent The output current should be close to the alterna   tors maximum ouput                                                      RECTIFIER                                    REGULATOR 8                                                                             ASSEMBLY                                     BRUSH HOLDER   Output Current      1300 rpm      2500 rpm      5000 rpm                                                            PLATE L        Hot            16 amp         41 amp        48 amp                                                                                                                     STATOR       Cold            24 amp         50 amp    NOTE rpm is that of the alternator The pulley ratio    alternator vs crank pulley is 1 78 to 1 all readings are    at 135 volts                                                                                                                                  REAR                                    OUTPUT TEST SETUP                                                                                                                                         Mter removing the three assembly throughbolts insert a   screwdriver between the front bracket and stator While              SPACER     ROTOR   prying i remove the front bracket and rotor                                                           Engines  Generators                                                                   71                                   SERVICEAn alternate method for removing the stator winding brush             regukaor unit and the Ie diode rectifier assmblyfrom the rear bracket With the front bracket and rotor               Diodeassembly separated from the rear half of the alternator              Diode troubles are classified as opencircuit and shortcircuit1 Insert a flatbladed screwdriver between the stator core           When the diode is opencircuited no current flows In the   and the edge of the rear bracket on the same side as the           shortcircuited diode current flows in both directions   brushholder Raise this side of the stator core away from   the bracket so as to open a gap of about 12 inch                 Checking for Short Circuit   NOTE Be careful not to allow the screwdriver blade to             Check for continuity between the  heat sink and the stator   enter far enough to touch the stator winding                      coil lead joint terminal and between the  heat sink and the                                                                      said terminal If each test shows current flow in both direc2 Maintaining the 12 inch gap insert the screwdriver                                                                      tions the diodes are shortcircuited Replace the rectifier   between the stator core and the bracket on the rectifier                                                                      assembly   side and move the stator laterally toward the brushholder   for a distance of 12 to 34 of an inch without lifting it   from the bracket3 Insert a 2 Phillips screwdriver through this opening and   remove the two screws holding the rectifier                                                                      Checking for Open Circuit4 Remove the nut anchoring the B terminal bolt and the               To check for an open circuit in the diodes which have passed   capacitor mounted thereto on the outside rear of the               the shortcircuit test disconnect the diode leads and check   bracket Then remove the third Phillips screw holding the          with your ohmmeter between the diode lead and the body   brush holder to the bracket                                       reversing the leads If no continuity is found the diode is5 Carefully withdraw stator brush holder and rectifier from         open   the rear bracket as one loosely connected unit                                                                      Checking Diode Trio   With the bracket out of the way it is easy to unsolder the   stator winding leads from the rectifier quickly to avoid           Check each of the three diodes for continuity If any diode   heat damage to the diodes and IC chips It is also easier        allows current flow in both directions or does not allow   to renew the brushes because there is no need to bend the          current to flow in one direction replace the rectifier assembly   connecting plates between the brush holder and the   rectifier and possibly damage the rectifierWhen reversing this procedure make sure that the statorwinding leads are gently pushed back from possible contactwith the rotor body after seating the stator into the rearbracket                                                           Engines  Generators                                                                 72                                    SERVICE                                                                                                                                                                                                                                     the stator lead wires from the coil and check forcontinuity between the three leads with a circuit tester If no                                                           continuity is found the stator windings are open Next checkfor insulation between each lead and the core If continuity is                                                                                                                        found replace the stator                                                                       Checking Brush and Brush Spring                                                                       Replace the brush if it has worn to the replacement value                                                                       Check the brush spring force Also confirm that the brush                                                                       moves smoothly in the brush holder                                                                                                      Standard      Replacement                                                                                                        Value       Required at                                                                           Brush Length mm             18              8                                                                           Brush Spring Farce g      37060           210                                                                       Checking the Slip Ring                                                                       Because the slip ring wears very little the diameter must be                                                                       measured with a micrometer Replace the rings rotor                                                                       assembly when wear reaches the replacement value                                                                                                   Standard         Replacement                                                                                                     Value          Required atField Coil Rotor                                                         Slip Ring 00           33 mm             322 mmCheck resistance between the slip rings The resistance must               Runaut               003 mm or less        02mmconform to the specified value               Resistance Value 387Q  10                           The slip ring must be smooth with no surface oil If neces                                                                       sary clean and polish with a fine crocus cloth                                                                       REGULATOR                                                                       The regulator consists of a voltage regulator and a lamp                                                                       relay their wires are gathered into a connector The voltage                                                                       regulator is used to always keep the alternator output con                                                                       stant regardless of alternator speed and to cut off the flow of                                                                       current to the field coil when necessary The lamp relay is                                                                       used on the Captain panel only to illuminate the panel light                                                                       indicating no alternator charge The 50A alternator has a                                                                       builtin IC regulator During alternator operation field cur                                                                       rent is controlled automatically by the IC regulator                                                                       1 Connect an ammeter approx 60A rating between the                                                                          battery positive terminal and its cable                                                                       2 Connect a voltmeter between he generator terminal LCheck fr continuity between the slip ring and the core If             and the ground In this case the voltmeter must indicatethere is continuity it means that the coil or slip ring is               0 If otherwise indicated a defective alternator orgrounded Replace the rotor assembly                                     faulty wiring is suspected                                                           Engines  Generators                                                                  73                                   SERVICE3 Tum the starting switch key to the ON position and the           REASSEMBLY   voltmeter will indicate a value considerably lower than   the battery voltage If the indication is near the battery   voltage a defective generator is possible                        A CAUTION Connect the alternator properly Should4 With the ammeter shortcircuited start the engine                the polarity be reversed a powerful current would flow                                                                      from the battery into the alternator damaging the                                                                      diodes and wiring harness     A CAUTION If the ammeter is not shortcir     cuited a large starting current will bum out the     ammeter coil                                                   1 Install the alternator support bolt through the alternator                                                                         leg underside into the engine casting                                                                     2 Swing the alternator into position on the adjusting5 Increase the engine spled to between 2000 and 3000 rpm                                                                        bracket and fasten Lightly tighten   and read the ammeter6 If the ammeter reading does not exceed 5A read the               3 Adjust belt tension   voltmeter at that state 20003000 rpm The voltmeter            4 Tighten both bolts and recheck belt tension   reading is the regulated voltage                                    Torque values7 If the ammeter reading exceeds 5A continue charging                   Support bolt           20  24 Nm 15  18 ftIbs   the battery until the ammeter reading drops to 5A or                   Adjusting bracket bolt 12  14 Nm 9  10 ftIbs   below or replace the battery with a fullycharged one or           NOTE Make certain the belts are perfectly aligned with   connect a 14Q 25W resistor in series to the battery to            the alternator and engine pulleys If not insert or remove   restrict charging current                                           spacers as needed to align the alternatorS The Ie regulator is of the temperature compensation type   and therefore regulated voltage varies with temperature   It is necessary to measure the temperature of the rear   bracket surrounding the regulator and to use the   measurement for correction of regulated voltage                                              AMMETER                CHECKING THE IC REGULATOR VOLTAGE                                                         Engines  Generators                                                                74                                                   uses a variety of marine transmissions madeby wellknown marine manufacturers such as HURTH ZFBORG WARNER PARAGON and others If you  parts repair work or an overhaul we recommend contacting the transmission manufacturer directly forinformation on the locations of authorized service facilities                                                                               Itv                                                                                iWJj                                                                                                                                                                                     iJ                                                                                                                                                                                                                                                                                                1                                                                                                   Iooi                                                        Engines  Generators                                                                 75                                                                         DC ELECTRICAL SYSTEM                                                                          ENGINE WIRING DIAGRAM 24666                                                   Sf NOTE                     KEY SWITCH       WTtR TPT                                            wTSNOER                     R       SWITCH             OIL PItSURe                       ITCH                                                               ALTERNATOR              b   t                 ALARM                                           I                I                I                I                        fUEL   SOL W8W52W70WIOO                I               I                I               I               1                I                L                                                                                                                                                                                                                                     PREHEAT SOL           SEtNOTe      OPSENOER                           PREHETER                                               aLII   NOT USCD                                      R                                                                                            EEttOTE14                                                                                                                      111                                                                                                                               0                          SERIES I ALTERNATOR                           t2VOLT OAMP                                                                  34           594           AlJcRNArO I2V 501t            I                                                                  33          7       I    PANEl JESS rfoSnUMcNTS       I                                                                  JZ          eeo           PANtt COMPLEre                                                                                             KEY SWITCH                                                                                                                                                   I                                                                                                                                    11                                                                                              ALAtM                                                                                        4    011 PReSS SiN        NC                         I                                                                  28                                                                  27                    I                                                                                              WAre12 r5MPr Sw NO                                                                                              PIiiL LIFT PUMP                                I                                                                         JIS      I        AMM         opnONL                           I                                                                   25 20G54                   SPlirrEIZ OPIOVA                                                                   24 1452                 GLOW PtUGS          W30fW6 4AJ                                                                  123 11530                 GOW PLUGS              W40        1                                                                  2   2                 NEUTRA SAF4     sw PAeAfCII  1                                                                   21 23433                 NErA sAETY  WlJRNEe   I                                                                   20 i4628                  PANE iESS INSrRGlHENrs        I                                                                   If e 660                 PANeL        COMPLEre                     1                                                                   8 11532                  SuPPRESSIO tr Atr           I                                                                   17    2959                                                                    e Z4G84                                                                                              TACH Klr A7ERNAoli                                                                                              ALrERNAIo1f  Sf A                                                                                                                                 I                                                                                                                                                                                                       15     23571             SENOE WAre 7IP                 I                                                                                                                                       14     24338                                                                          2 32                                                                                              SONOID        ueL                                                                                             SENDEJ OIL PRe sCle                                                                                                                     WS8                                                                                                                                  I                                                                                                                                  I                                                                    II 24a8                 PREHeAT4                       4                                                                   11     243f              SOLNOIO pleHAr                                                                                 to     24683               CIlCIT lREAK6e 20AHI I                                                                         IG2              SrArR     IwfAeNe GNCINI     I                                                                    8     30032              HAINeSS tN6INS                        I                                                                    7                                                                    G                                                                          30148                                                                          19           G                                                                                             HARNeSS PIINEI                                                                                             KEY SWITCH                                 I                                                                                             VOLrMErEI2                                                                  c4                                                              I                                                                                                                                                                                                         I                                                                          itt                                                                           I                                                                               17                                                                                        S                                                                                             SWITCH PItHeAT                                                                                             OIL PIPErstlIilE GAUGE                                                                                             wlree rsJIp GAUGE                                                                                             TACHOMETSR                                                                                                                                    I                                                                                                                                    I                                                                                                                                                                                                    ITEM PART NO                    DESCRI PTION                   OTY ASS TfN                                                                                                  Engines  Generators                                                                                                           76                DC ELECTRICAL SYSTEM               ENGINE WIRING SCHEMATIC 24666                         KEY SWITCH                      12vDC tRY                BAnERY RtTURN                                                                             PRtHEAT                          10                                                      I                                                      L                                                 FUEL LIFT PUMP                                                                                                            ALARM     eI OP SW                                                  A                                        I                 Jr                                                              WTSW                                         NOrcS ON 8UllDcliOWNERJ      AN ONOFF sWITCIi MUSr as J      iAll   N     I 141 TO DtSoNNllcr      rHE srAr6 CIACUlr FOiIA rHE SATTERY  AN EIvIEteGENCI       WHEN     letllN rHe SoAT J2vqLr DIESel ElltIWG SrAllrERS TYPICALLY DeAW     200 To 300 AMPS WHEN CRAHIfN rNE Du TTOItI OF NDWDUAL CAKINQ     CCLES SJIOuLD NOr EXCED 30 SECONDS A SWI1C WITH CDNl1NUOUS     eATNt OF I7SAMPS Ar 12vDC WILL NOH SEevE mGS UN7TfNS     aur SuCH A SWITCH MtlSr NV1A12 tfJE USD ro MAKE H THE srAree CIItCUlr     OTHeR Nores     WARNING SENDel CONNECTION               CONrAcr wml B MAY DAMAGE SENDER    ALI   IErUIHS ARE THROUGH ENGINE eLOC     FOIt WIIG OF AUILLAIiY AtrEIiNATOIiS SEE THE FOLLOWING DIAGRAHS      HoroeoLA     B AM 1232      MOTOROlA        IZO AMP I   1123 1      LEECE NEVlIIE 53 AMP 535      ggCeNevILLE lOS AMP lGt14     IF AODrtOIVAI PReSSURE SWITCHES Ae tREiiD TO srAeT      eOAr ACCESSOie A JLEXISLI HOSE Musr BE RUN FloM      THE OIL PIESSIJiiS MANIFOLD To A NE41 eUlJHEAD AND      ALi PIESSURE WIFCHES MOiNTED AT TIle BUlIIHEAI      APPLY illASTle O n6HT WOUND PtllirlCSPtlCE ElECTHCAL      TAPE AOLlN CONHECrOliS CONNECTED     CAunON                 TfIIS PR0I IS PROTECTED BY II MAWUAL RESET       cUlr alieAJte tocrD      NEAP 71 SroRTE AND AS CIOsE      TO   THE SotNeE of CueENr AS PosSIBLE      EXCESSIVE CUICENr DIAH ANYWllees IN TN INS7RUMENr PANEL      WigNt PC FHIie WJ4 AlliE THE SIIEAIIEg ro nIP IN THis VINr      MQsr tliiIS MQDGlS WilL SHlIr DOW BGCAUSE THtr OPENED       Ie A R bISCtJNIVErs     Elii  EL SIJPPL  HERE DE fIe               OWNER MUST SE SUIiE THAr          71   lNSrlUMENT PANEL      WIIG AND ENaIN AIE INJrALLeb TO peEVENr CON1i4cr      BETWEEN ELgCrlflCAL DeVICeS AND SALT WArEIZfj ITII4S 4 G 9          f 20 WERE USED     WtTI PeEVOUS         IESltSN                                   Engines  Generators                                            77                                                                   DC ELECTRICAL SYSTEM                                                                    ENGINE WIRING DIAGRAM 33685                                                                   KEY SWITCH  TWO PUSHBUTTONS                                                           Ol WWZW70WIOO                           p                     fUEL                                 ruel Lin ru   t                                 CwUwl1wl7Wll tI                                  wtWIOO                                                                                                                                                                                                                                                      PREHEAT SOL           saNOTt       oPSENDER                     i     PREHETER                                               81K1ONOT USED                                                                                       ON                           SERIES I ALTERNATOR                            12OLT OAMP                                                                   a                sw fir SCfAC2                                                                   305                                                                                                7it                                                                                5           VI                                                                                                                                                        24lJ             F      IFL                  PIMP                                                                                                                             W                                                                                     r                     u                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                D A                Oti                                                                                                               74iff         WS8       4                                                                                                 UI                              20AHA                                                                                                                        1                                                                                                       Vi                                                                                      IS   1                                 GAuGIS                                                                                     w                       fiip G AUGS                                                                                                                                     ITE IPARTNo                     PTiN                                  IQ   I TboN                                                                                                Engines  Generators                                                                                                                 78                                              DC ELECTRICAL SYSTEM                                              ENGINE WIRING SCHEMATIC 33685                                              KEY SWITCH  TWO PUSHBUTTONS     12 VDC BATTERY                   BATTERY RETURN                                          TARTER                                                                                                                                                   PREHEAi       PREHEATER                                                                                                        NoreS ON BUllOEIOWNERf RESPONSIBILITY                                                                            AN ONOF SWITCH MtJsr eE IWALItP IN nilS IINE TO DSCONNEcr                                                                            nuz srAreR CIIClIlr FIOM rHE BATTERY Iff AN IiMEiGENCr                                 ALTERNATOR                                 lEAVING ruE BOAT I2VOLT DIESeL ENCIIVE srAIiIiS TYPICALlY OtAVI                                                                          zoo To 300AMP WilEN CAKIN nlE DuRiOAl OF INDIVlDUAL CFiANKNC                                                                           CYCLES SNOULI NOT EXCEED o SECONDS A SWlrCIl WITH CONTlNGlOUS                                                                           eATING OF 175 AMIS AT 2 VDC WILL IIOIMAlLI SEVG TiltS JIINC17DN                                                                           BUT SUCH A SWlrcH MUsr NEVGI2 BE cJSeD ro MAKe 7HE STASree CIRCUli                                                                           OTHER NoreS                        01                                                                          WARNING SeNOR CONNECTToN                                                                                        CONrAcr WITH     8 MAY AMAE     sENP             PREHEAT             w                                                                           ALL   ErURNS AIE rHROUGH eNGINe 3LOG                                                                           FOR WIRING OF AuxILLAY ALrEtNAros SCE rHI FOLLOWING DIAGRAMS                            I                                              MOTOOLA     es  MP t 1232             START   SWI                                                 MoTOROLA     120 AMP I 1123 I                                                                           LE6CE NEVIUS 53 AMP IG53S                                                                           LEECeNEVILLE lOS AMP lGt4                                         I                              IF ADDITIONAL PRESRE SWtrcHttS ARe eD TO srA2r                                          I                                             L                                                                             BOAr ACCESSOF A JEXBLe HOSE Musr BE RUN FROM                                                                           nlE OIL PSSSUIE MANrOLl 70 A NEAIY BUIKHGAD AND                                                                           Ll PRESSRE SWITCHES MQlINTcD AT TIle BGlll4ffeAO 1                       oT                                    rUEL LIFT PU  P                                    ALARM                                      Ar                                                   OPW                                                                                                                                                                                                                                                                          APPLY SILAsrlC OR riGHT WOllND pLASrlcSPIICE lEcrRICAL                                                                           rAPe AROUND CONNCrORS CONNECrED                                                                            CAunON                                                                                     nils PROlC IS ptOTeCrID BY A AMIAI RESEr                                                                            lfcUlr EREAK toCrD NEAR 7714 srARTER AND AS CIOSE                                                                            TO rHI SCl OF CURReNr A1 POSSleLc                                               WTSW                     EXCESSIVe CUReErlr DIAII AWYWHeRE IN rH NSrRVMGNr PArlE                                                                            WIRING OR Erfirle WU CAUSE rHE 8IEAKJ To TlIP IN THIS EvcNT                                                                            MosT ENGINe MODElS WIll SHUT DOWN aGCAUSG THS OpeNED                                                                             R A       JISCONNecrs   ttl L SUPPI  HEREFOle 7JI                                                                            6UfUcL OWNeR Musr se SURe TlAr THG lNsrRUMENr PANEL J                                                                            WIPING AND ENN AilE INJrALlil ro PIVENr CONrAci                                                                            BETweeN ELECilCAl DeVICe AND SALT WArEIZ                                                                                                                               Engines  Generators                                                                       79                                                                 DC ELECTRICAL SYSTEM                                                                 ENGINE WIRING DIAGRAM 36844                                                                        ADMIRAL PANEL                                                                                                                 19   ORED                                                                                                WATER                GLOWPLIJGS                                                                      TEMP                234OR6                                                                      SWITCH                    DEPENDI KG OK                    NUMBER OF                                                                                                                    0                                    18     17                    CYliNDERS                                                                                                                 16   14 LT BlUE                PREHEAT                SOLENOID                                                                                                                                                                                       v                                                                                  2                                                                                                                                                                                                                                                                                                                                                                                        I2YEL1E               1                                                                                                         USED ON SOME MODELS                                                                                                                                                                                FUEL       I      L           I           I          oJ                                                                                                                                OIL                                                                                                                                RE                                                                                                                                                                                                       USED ON SOME MODELS                                                                     GROUND TO                                                                     ENGINE                                                                                                                                                                                                                                                                                                                            0                                                                     BLOCK                        fUSED ON SOME HOCELSI                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                   z                    z                                                                                                   Ii                                                                                                                                                                  SZ                                                                                                                                                                                                  P2                                          z                                          i                                                i w                                                     z                                                           e                                                                     z                                                 0                                                  2  2                                                                                                                                                                                 0                                                                                                                                                                                                                                                                                                            14 LT BLUE                                                                                                                                                                                     r                I                                                                                                                                          ALTERNATOR  51 A                                                                                                                                                           USED ON SOME tOOElS                I                I                                                                                                                                    MALE CONNECTOR ON                                                                                                                                                                                                   LTBWEEI                                                                                                                                                                                                             17 lTBIUE                I                                                                                                                     flI4rJ                                                                                                                                                                                                                                                                                                      THIS SlOE                                                                                                                                                      WH                        ECTORON              LBN                I                                                                                                                                          D                I                                                                                                                                                                 B                                                                                                                                                                                  OK                                                                                                                                                                                 1481                I                                                 VOLTMETER                I                I                I                L                                         0                                     BLK                                                                                                                                          ADMIRAL                                                                                                                                     PANEL                                                                                               Engines  Generators                                                                                                           80                                     DC ELECTRICAL SYSTEM                                     ENGINE WIRING SCHEMATIC 36844        12 VDC                              ADMIRAL PANEL                                                             START              STARTER                                                                      SOL                                                                                       GLOvlPLUGS                                                     PREHEAT SOL          C8                                    C8          lOA                                    lOA                                                                                                  UFT PUMP                                                                                                       P                                                                              I                                                                              I          I        FUEL SOL                      NEUTRAL                                                                              I                                                                              L                                                                                           L    F                       SI                     Op                                                 O P SNDR                                               SW                                                                                                       vIT SNDR                                                                                                      WT SW51              SI           SI          SI     S2      S2    52   51   SI       SI                PI           PI          PI     PI            P2    PI   PI       PI                                                                                                         TACH                                                                                              5                                                                                                        VOLTS                          START                          SW                                                                                                          OP                                                                                                         rIT         PREHEAT SvI                     NOTES                     I THIS PRODUCT IS PROTECTED BY A MANUAL RESET CIRCUIT BREAKER LOCATED NEAR THE                      STARTER EXCESSIVE CURRENT DRAIN WILL CAUSE THE BREAKER TO TRIP AND THE ENGINE                      WILL SHUT DOWN THE BUILDEROWNER MUST BE SURE THAT THE INSTRUMENT PANEL                      WIRING AND ENGINE ARE INSTALLED TO PREVENT CONTACT BETWEEN ELECTRICAL DEVICES                       AND SALTWATER                     2 AN ONOFF SWITCH SHOULD BE INSTALLED BETWEEN THE BATTERY AND STARTER TO                      DISCONNECT   THE BATTERY IN AN EMERGENCY AND WHEN LEAVING THE BOAT A SWITCH                      WITH A CONTINUOUS RATING OF 175AMPS AT 12VDC WILL SERVE THIS FUNCTION THIS SWITCH                      SHOULD NOT BE USED TO MAKE OR BREAK THE CIRCUIT                     3 GRAY WIRE AT PLUG 2   IS UNUSED AND SHOULD BE INSULATED                                                         Engines  Generators                                                                81                                                                         DC ELECTRICAL SYSTEM                                                                          ENGINE WIRING DIAGRAM 36467                                                                                  CAPTAIN PANEL                                                                                                                                                                         fk                                                                                                                                                                                                                  1                                                                                                                                                                                                                 I                                                                                                                                                                                                                 I                                                                                                                       WATER                                                                                                                       TEMP                                                                                                                                                                                                                 I                                   GLOWPLUGS                                   Z34OR 6                                                                         SWITCH                                                                                    I                                      DEPENDING ON                                            OPTIONAL                                                                                                          1                                      NUMBER OF                                      CYLINDERS                                                                                              WITH INST                                                                                              PANEL                                                                                                                                                                             4                                                                                                                                                                                                                                                                                                                                                                                                                              I                                                                                                                                         Ie    14 LT BLUE                                                      1                                                                                                                                                                                                                 I                                   PREHEAT                                                                                                                                                                                                               I                                   SOLENOID                                                                                                                                               14 LT BLUE                                                  1                                                                                                                                         OIL                                                                  I                                                                                                                                         PRESSURE                                                     1                                                                                                                                         SWITCH                                              I                                                                                                                                                                                                      1                                                                                                                                               SEME MODEs                          1                                                                                                                                                                                                                       Ii     FUEL SOLENOID      rt                                                                                                                                                 OIL                                I       USED ON SOME rIOOELS                                                                                                                                                                                  i                                                                                                                                                 PRESSURE      l                                                                                                                                                  SENDER                                                                                                                                                        OPTIONAL WITH                                                                                           GROUND TO                                                     INSTRUMENT                                                                                           ENGINE                                                             PANEL                                                                                           BLOCK                                                                                                                                                                                        LIFT                                                                                                                                                                                        PUMP                                             fuSED OM SOME MODELSI                                                                                                                                                                                                                                                                                                                                                                                            z                                                                                                                                              Z                                                                            w                                     i5    0                                                                                                                        l                                                              SI                                   52                                                                                                                                                                                                                                                              pfo                    1BJ                                                                                                    P2                                                                                                                                                                                                                                             I IJ                                                                                     z                                                                                                                                            Ii  S                                                                                                                                                                                                                                                                               8                                                                                                           z                                                                                                                                                                                                                                                                                         z                                                               S                                                                    g                                                                                                                                                                                                                            22                                                                                 P   2                                                                                                                                                                                                                                                                                                                                                                                                                                                         i         0                                                                                                                                                                                             AlTERNATOR5IA                                                                                                                                                                                            USED ON SOME MODELS                                                                         r                                                                                                                                                                                 iO14LT BUJE    MOLD                                                                                                                                                                                 TO ENG BLOCk   I                                                                                                                                                                                                                                                                            SoItN                  S ORN      r                f 1                                    IUE                                                                               2valal                                                                                     DU      I                           LAIM                                                                                                                                                   FUEL SOLENOID WIRING                                                     Ie    0                                                                                                                                                                                                               W20B TWO W30BTIoIREEJ      I                     ri                                         ALT                                                                                                                                            r9                                                                          LAMP      I                                                    START                     IBlk               Dz                                                                                                                                                                          TEST SWITCH                                                                                                    5      I                                                                              14etU                                                                                                        Do      i              fl                                                 AP          1411Jc                                                                                                                                              0      01      I                                                                                                                                     4BLK              n                                                                                                                                                                                                                        7r                                                                                                                                                                         CAPTAIN                                                                                                                                                                         PANEL      I      I                             1                                                                                       4ED                                                           PREHEAT                                                                           WpC                                                                          LAMP                                                                                                                                              TACHOMETER                        KEYSWITCH                                                    t4BLUE      I                                                    SWITCH                                                                          8 ILK      I                                                                   18 aLK      I                                                                   189 Ie      I                                                                   OLk      I                                                                                                            Engines  Generators                                                                                                                       82                               DC ELECTRICAL SYSTEM                               ENGINE WIRING SCHEMATIC 36467                                        CAPTAIN PANEL             IZVOC              CB               ZOA                                                                                     I                                                                           fo                                                                                     I          FUEL SOlENOIO                           I                                                                     OPsNOP                      j                      IJ NTRl               OPSW                                                                                                                              511                                                                                                                                                   IITsNOR                                                                                                                                                                                                                                                                          iT SW        51        PI                      1                      PI                                     51                                     PI   PI     Pl        PI                                                                52                                                                PZ                                                                     51   51   SZ                                                                               PZ                                                                                                 TACH                                                                                                             51                                                        TZ                                                        05      T6        01                                                                                                                       LAMP                                                      T3                                                                     04                                                                                                                  f   TEST                                                                                                                       slIlTCH                                                                          OZ                T4                                                                T5                                                                                           03                                                                               T7               PREHEAT SIIITCH                                               ALARMSTART I TURN KEY TO ON POSITION THE ALARM WILL SOUND OIL PRESSURE AND          BATTERY CHARGE INDICATORS WILL LIGHT        2PUSH PREHEAT SWITCH FOR IS TO 60 SECONDS AS REQUIRED ALARM WILL STOP        3WHI LE CONTINUING TO PUSH PREHEAT SWITCH PUSH THE START SWITCH ALSO          WHEN THE ENGINE STARTS RELEASE THE START SWITCH ONLY        4WHEN THE OIL PRESSURE                  INDICATOR LAMP GOES OUT RELEASE THE          PREHEAT SWITCHSTOP    TURN THE KEY TO TH E OFF POSITIONI THIS PRODUCT IS PROTECTED BY A MANUAL RESET CIRCUIT BREAKER LOCATED NEAR   THE STARTER EXCESSIVE CURRENT DRAIN WILL CAUSE THE BREAKER TO TRIP AND THE   ENGINE WILL SHUT DOWN THE BUILDEROWNER MUST BE SURE THAT THE INSTRUMENT   PANELWIRING AND ENGINE ARE INSTALLED TO PREVENT CONTACT BETWEEN ELECTRICAL   DEVICES AND SALTWATER                                2 AN ONOFF SW ITCH SHOULD BE I NSTALLED BETWEEN THE BATTERY AN D STARTER TO   DISCONNECT THE BATTERY IN AN EMERGENCY AND WHEN LEAVING THE SOAT A SWITCH   WITH A CONTINUOUS RATING OF 175 AMPS AT 12VDC WILL SERVE THIS FUNCTION THIS   SWITCH SHOULD NOT BE USED TO MAKE OR BREAK THE CIRCUIT3 PINK WIRE AT PLUG Z IS UNUSED AND SH OULD BE INSULATED                                               Engines  Generators                                                             83                                                                         DC ELECTRICAL SYSTEM                                                                         ENGINE WIRING DIAGRAM 39144This diagram illustrates the                                               ADMIRAL  CAPTAIN PANELS12 VDC negative  circuit Two  panels are also                                                                                                                   GRshown the Captains Panel and the Admirals Panel                                                                                                                                 IIIK                                                                                                                                                                  r11                                                                                                                                                                  I                                                                                                                                                                  I I                                                                                                                                                                C         II   ON                                                                                                                                                                         MODELS                 SEE NOT 2                              III                           1       J                               1                               1                                                                                                      12 VDC                                                                                                     0                              llllBl                                                                                                                                                    I                                                                                                            NOTE             AN ONOFF SWITCH                                                                                                 SHOULD BE IN             STALLED BETWEEN             THE BATTERY AND             STARTER TO DIS                                                                                                                  m                                                                                                                                                                                                                                                                                                                                                                         C                                                                                                                              ALARM                                                                                                                              euzzElt                                                                                                                                                  ADMIRAL                                                                                                                                                  PANEL             CONNECT THE BAT             TERY IN AN EMER             GENCY AND WHEN                                                                                                                                        I             LEAVING THE BOAT            A SWITCH WITH A             CONTINUOUS             RATING OF 175             AMPS AT 12 VDC             W1LL SERVE THIS             FUNCTION THIS             SWITCH SHOULD             NOT BE USED TO             MAKE OR BREAK             THE CIRCUIT                                                                                                   110 Ito                                                                 1                                                                                                                                                                                                                                                                                                   CAPTAIN                                                                                         o                                                                                                                                           PANEL                                                                                                                   r                                                                                                                                    l                                                                                           IIII                                                                                             IU                           l                                                                                                                LiilLL                                                                                           I III                                                                                              Engines  Generators                                                                                                             84                                                                     DC ELECTRICAL SYSTEM                                                                   ENGINE WIRING SCHEMATIC 39144    12 VDC             STAIIT                                                                      ADMIRAL  CAPTAIN PANELS                        SOL               STUTn                    r             I M 4iiti                                 I                                                                                                                                                     I                                                                                                     I                                                                                                     I                                                                                                     I                                                                                                     I                                                                                                     I                                              ALTEIUIATOII                                          I                                                        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liBjNT                                                                                              ADMIRAL                                                        TACHOMETER                                                                                           PANEL                                                                                                             NOTES                                                                                                             I THIS PRODUCT IS PROTECTED BY A MANUAL RESET CIRCUIT BREAKER LOCATED NEAR THE                                                                                                                STARTER EXCESSIVE CURRENT WILL CAUSE THE BREAKER TO TRIP AND THE ENGINE WILL                                                                                                                SHUT DON THE BUILDERONER MUST BE SURE THAT THE INSTRUMENT PANEL WIRING AND                                                                                                                ENGIHE AU INSTALLED TO PREVENT CONTACT BETWEEN ELECTRICAL DEVICES AND SE ATER                                                                                                             2 AN ONOFF SITCH SHOULD BE INSTALLED BETEEN THE BATTERY AND STARTER TO                                                                                                                DISCONNECT THE BATTERY IN AN EMERGENCY AND HEN LEAVING THE BOAT   A SITCH                                                                                                                WITH A CONTINUOUS RATIN6 Of 175 AMPS AT 12 VDC WILL SERVE THIS fUNCTION THIS                                                                      0                                      SWITCH SHOULD NOT BE USED TO MAKE OR BREAK THE CIRCUIT                                                                      utE                                                                                                          3 THE PINK IRE AT PLUG      IS UNUSED AND SHOULD BE INSULATED CAPTAIN PANEL ONLY                                                                                                               THE GRAY IRE AT PLUG 2 IS UNUSED AND SHOULD BE INSULATED ADMIRAL PANEL ONLY                                                 nlI                                                                                          CAPTAIN                                                                                          PANEL                                                                       LAM                                                                       rUT                                                                                                                                                                                                                      II LT BLU                                                                                                                                                 PINK                                              51 AMP                  ALTERNATOR                                              STANDARD ALTERNATOR ON THE                                                                                                                       PRESTOLITE        72 AMP      AIT                                              maIJiClffl il                      IlI   82B        IlIt                                                                                                                                        114 BRN                                                                                                                       I   GRA                                                                                                                       I I  PINK                                                                                                                 I       LT BL                                                                                                               UNIVERSAL PROPULSION                                                                                                                 PRESTOLITE 51 AMP              ALT                        OPTIONAL ALTERNATORS     AVAllAIIlC O INC   J5 cAtiOto   pas a                 ONLY                                                                                                         Engines  Generators                                                                                                                       85                                                         STANDARD HARDWAREBOLT HEAD MARKINGS                                                                                Metric bolt class numbers identify bolts by their strength with 109 the                                                                                strongestNOTES 1 Use the torque values listed below when specific torque values are not available            2 These torques are based on clean dry threads Reduce torque by 10 when engine oil is used            3 Reduce torques by 30 or more when threading capscrews into aluminum    STANDARD BOLT  NUT TORQUE SPECIFICATIONS                                            METRIC BOLT  NUT TORQUE SPECIFICATIONS                       SAE Grade 5        SAE Grade 67       SAE Grade 8 Capsrew Body Size       Torque              Torque              Torque           Boll                  Grade 46      Grade 48    Grade 88  98 Grade 109 Inches  Thread    FHbNm            FILb Nm          FILb Nm        Dia    Wrench Size    FILb Nm     FHbNm        FILb Nm    FILb Nm      14  20              8 11            10 14            12 16           28             10 14                               14 19          M3       55mm         03 05      05 07       1 13       15 2                                                                                  M4        7mm          08 11       1 15         2 3        3 45     5116 18              17 23            19 26            24 33          M5        8mm          15 25         2 3         45 6       65 9          24              19 26                               27 37      38 16              31 42            34 46            44 60         M8        10mm            3 4        4 55        75 10       11 15          24              35 47                               49 66         M9        13mm           7 95       10 13        18 25        35 26     716 14              49 66            55 75            70 95         M10       16mm           14 19       18 2pl        37 50        55 75           20             55 75                               78 106      12 13             75 102            85 115          105 142        M12       18mm           26 35        33 45        63 85       97 130           20            85 115                              120 163        M14       21 mm          37 50        55 75       103 140     151 205                                                                                 M16       24mm           59 80       85 115       159 215     232 315     9116 12            110 149           120 163          155 210          18            120 163                              170 231                                                                                 M18       27mm          81 110      118 160       225 305     321 435      518 11            150 203           167 226          210 285        M20       30mm          118160      166 225       321 435     457 620          18            170 231                              240 325        M22       33mm          159 215     225 305       435 590     620 840      34 10            270 366           280 380          375 508          16            295 400                              420 569        M24       36mm          203 275     288 390      553 750     789 1070                                                                                 M27       41 mm         295 400     417 565     811 1100     1154 1565      78  9            395 536           440 597          605 820        M30       46mm          402 545     568 770     1103 1495    1571 2130          14            435 590                              675 915        1 8             590 800           660 895          910 1234       M33       51 mm         546 740    774 1050     1500 2035    2139 2900         14             660 895                              990 1342       M36       55mm          700 950    992 1345     1925 2610    2744 3720                                                  SEALANTS                                                                  Use LIQUID TEFLON for sealing pipe plugs and fillings that connect coolant                                                                                passages o not use tape sealantsOil based PERMATEX 2 and its HIGH TACK equivalent are excellent allpurpose sealers They are effective in just about any joint in contact with     BOLTS   raw water oil Or fuel                                                                                Lightly oil head bolts and other fasteners as you assemble them Bolts andA light coating of OIL or LIQUID TEFLON can be used on rubber gaskets          plugs that penetrate the water jacket should be sealed with PERMATEX 2 orand Orings                                                                    HIGH TACKLOCTITE hydraulic red sealant should be used on oil adapter hoses and the oil   When assembling the flywheel coat the bolt threads with LOCTITE bluefilter assembly                                                                                Antiseize compounds and thread locking adhesives such as LOCTITE protectCoat both surfaces of the oil pan gasket with high temp RED SILICONE sealer    threaded components yet allows them to came apart when necessaryWhen installing gaskets that seal around water coolant passages coat both    LOCTITE offers levels of locking according to the jobsides with WHITE SILICONE grease                                               LITHIUM based grease is waterproof ideal for water pump bearings and  ADHESIVE SPRAYS are useful for holding gaskets in position dur     ing boxesing assembly                                                                                Heavily oil all sliding and reciprocating components when assembling  gasket sealers such as HYLOMAR work well in applications requir    use clean engine alling nonhardening properties HYLQMAR is particlarly effective oncopper cylinderhead gaskets as it resists fuel oil and water                                                           YIVWESTERBEICE                                                                    I Engines  Gentrators                                                                             86                                    METRIC CONVERSIONS              INCHES TO MILLIMETERS                                     MILLIMETERS TO INCHESInches             mm              Inches           mm             mm         Inches           mm           Inches   1            2540                    15        38100           1          00394          15           05906   2            5080                    20        50800           2          00787          20           07874   3            7620                    25        63500           3          01181          25           09843   4           10160                    30        76200           4          01575          30           11811   5           12700                    35        88900           5          01969          35           13780  10           25400                    40       101600          10          03937          40           15748                                      10 MILLIMETERS 1 CENTIMETER 100 CENTIMETERS                    1 METER 3937 INCHES 33 FEET                   INCHES TO METERS                                         METERS TO INCHESInches         Meters              Inches          Meters         Meters      Inches          Meters        Inches   1           00254                     7        01778         01           3937          07          27559   2           00508                     8        02032         02           7874          08          31496   3           00762                     9        02286         03          11811          09          35433   4           01016                    10        02540         04          15748          10          39370   5           01270                    11        02794         05          19685          11          43307   6           01524                    12        03048         06          23622          12          47244       TO CONVERT METERS TO CENTIMETERS MOVE DECIMAL POINT TWO PLACES TO THE RIGHT                   YARDS TO METERS                                          METERS TO YARDSYards          Meters              Yards           Meters         Meters       Yards          Meters         Yards   1           091440               6             548640          1         109361           6           656168   2           182880               7             640080          2         218723           7           765529   3           274320               8             731520          3         328084           8           874891   4           365760               9             822960          4         437445           9           984252   5           457200              10             914400          5         546807          10          1093614           MOVE DECIMAL POINT FOR HIGHER VALUES                  eg 6000 METERS  656168 YARDS              POUNDS TO KILOGRAMS                                       KILOGRAMS TO POUNDS  Ib            kg      Ib     kg                                  kg         Ib      kg                      Ib   1              0454                   6         2722           1           2205           6           13228   2              0907                   7         3175           2           4409           7           15432   3              1361                   8         3629           3           6614           8           17637   4              1814                   9         4082           4           8818           9           19842   5              2268                  10         4536           5          11023          10           22046                  GALLONS TO LITERS                                         LITERS TO GALLONSGallons           Liters           Gallons         Liters         Liters      Gallons         Liters        Gallons   1            379                10              3786           1             026         60           1566   2            757                20              7571           2             053         90           2377   3           1136                30             11357           5             132        120           3132   4           1514                40             15142          10             264        150           3962   5           1893                50             18928          20             528        180           4754                     PINTS TO LITERS                                         LITERS TO PINTS Pints            Liters            Pints          Liters         Liters          Pints       Liters         Pints   1              047                6             284           1           211             6           1268   2              095                7             331           2           423             7           1479   3              142                8             379           3           634             8           1691   4              189                9             426           4           845             9           1902   5              237               10             473           5          1057            10           2113                                                   TEMPERATURE   32        40          50         60        70     75      85        95    105 140          175 212         OF       I      I            I         I        I       I       I         I     I           I     I      I       I      I            I         I        I       I       I         I     I           I     I      I       0      5          10         15        20     25      30        35    40       60       80 100         C                                                     Engines  Generators                                                             87                                           GENERATOR INFORMATIONUSE OF ELECTRIC MOTORS                                                   GENERATOR FREQUENCY ADJUSTMENTThe power required to start an electric motor is considerably            Frequency is a direct result of  speed asmore than is required to keep it running after it is started            indicated by the followingSome motors require much more current to start them thanothers Splitphase AC motors require more current to start                                                                         o   When the generator is run at 1800 rpm the AC voltage                                                                             output frequency is 60 hertzunder similar circumstances than other types They are commonly used on easystarting loads such as washing                       o   When the generator is run at 1500 rpm the AC  or where loads are applied after the motor is start               output frequency is 50 hertzed such as small power tools Because they require 5 to 7               Therefore to change the generators frequency the generatimes as much current to start as to run their use should be            tors drive engines speed must be changedavoided whenever possible if the electric motor is to bedriven by a small generator Capacitor and repulsioninduc              GENERATOR  motors require from 2 to 4 times as much current to start           o   Maintaining reasonable cleanliness is importantas to run The current required to start any motor varies with               Connections of terminal boards and rectifiers maythe load connected to it An electric motor connected to an                  become corroded and insulation surfaces may startair compressor for example will require more current than a                conducting if salts dust engine exhaust carbon etcmotor to which no load is connected                                         are allowed to build up Clogged ventilation openingsIn general the current required to start 115volt motors con               may cause excessive heating and reduced life of windnected to medium starting loads will be approximately as                     ingsfollows                                                                 o   For unusually severe conditions thin rustinhibiting                    AMPS FOR RUNNING       AMPS FOR STARTING                 petroleumbase coatings should be sprayed or brushed  MOTOR SIZE HP      AMPERES              AMPERES                      over all surfaces to reduce rusting and corrosion                                                                             Typical materials suggested are Ashland Tectyle 506        16                 32                 64  224                  and Daubert Chemical Co NonRustAC410        14                 46                 92322                o   In addition to periodic cleaning the generator should be        13                 52                104 728                   inspected for a tightness of all connections b evi                                                                             dence of overheated terminals and c loose or dam        12                 72                144  292                   aged wires        34                102                204  408               o   The drive discs on single bearing generators should be         1                 130                 2652                        checked periodically if possible for tightness of screws                                                                             and for any evidence of incipient cracking failure DiscsNOTE In the above table the maximum Amps for Starting                    should not be allowed to become rusty becauSe rustis more for some small motors than for larger ones The rea                 may accelerate cracking The bolts which fasten theson for this is that the hardest starting types splitphase are            drive disc to the generator shaft must be hardened steelnot made in larger sizes                                                    SAE grade 8 identified by 6 radial marks one at each                                                                             of the 6 corners of the headBecause the heavy surge of current needed for startingmotors is required for only an instant the generator will not           o   The rear armature bearing is lubricated and sealed nobe damaged if it can bring the motor up to speed in a few                    maintenance is required However if the bearingseconds If difficulty is experienced in starting motors turn               becomes noisy or roughsounding have it replacedoff all other electrical loads and if possible reduce the load         o   Examine the bearing at periodic intervals No sideon the electric motor                                                      movement of the shaft should be detected when force is                                                                             applied If side motion is detectable the bearings areREQUIRED OPERATING SPEED                                                     wearing or wear on the shaft of the bearing socket outAlthough individual units may vary slightly the normal volt                side bearing has occurred Repair must be made quicklyage and frequency of typical 60 50 hertz enginedriven                     or major components will rub and cause major  described in this manual are approximately as                     to the  run first with noload applied then at half the                o   Examine the control box at periodic intervals to  capacity and finally loaded to its full capacity as             cracks from engine and generator vibration If cracks inindicated on the generators data plate                                     the box are seen engine vibration may be severeThe output voltage should be checked periodically to ensure                  requiring bracing in the box for additional strength toproper operation of the generating plant and the appliances it               resist                                                                          GENERATOR                                                                          A complete and illustrated text on  and                                                                         servicing the WMD BT and BC generators is furnished in                                                                         the following pages                                                              Engines  Generators                                                                    88                                                                    WMD                                                                                 as well The housing with field coils is heavy Once the                                                                                           housing has cleared the armature shaft it should be supThe WMD model generator is a selfexciting and selfregu                                                                                           ported and slowly drawn over the armature Try not tolating brush style generator requiring only a driving force to                                                                                           drag it over the  voltage It is four lead reconnectable for 115 volts or115230 volts and has a four pole revolving armature with                             INSPECTIONno DC brushes or commutator It has a solid state bridge rec                          1 Inspect the bearing and replace as needed If the unit istifier in the exciter circuit AC slip rings a dripproof con                           going through a major overhaul bearing replacement isstruction and a single bearing design Voltage regulation is                             recommended7 noload to fullload and frequency regulation is 34                                                                                       2 Check the field coils resistance values Remove the fieldhertz noload to fullload It is in insulation class F as                                                                                          coils from the housing Note and mark each field coilsdefined by MEMA MGI165 and its temperature rise is                                                                                          position in the housing Do not mix them up Each coil haswithin MEMA MGI2240 definition when operating at full                                                                                          a different part number and a specific position in the housload Its  blower fan is direct connected to                                                                                          ing Incorrect assembly will cause low voltage outputthe armature shaft for cooling Capacitors across the hot legand neutral minimize radio interference within the limits of                           3 Unbolt the armature from the flywheel Test the armaturemost commercial and civilian applications The armature is                                with an ohmmeter Clean the slip rings and polish using abalanced laminated steel double dipped and baked The field                              crocus clothring is thick hot rolled steel with a welded bearing supportbracket machined as an assembly for precise bearing align                                                                                       REASSEMBLY                                                                                       Reassemble in reverse orderment The rear carrier bearing is prelubricated double sealedwith an antirotation lock                                                            NOTE When assembling the housing onto the generator arma                                                                                       ture be sure to properly align the antislip groove in the bear                    WMD GENERATOR SPECIFICATIONS                                                 347 amp at 115 VAC                                                                                       ing with the hole in the housing and install a new lock pin        WMD44         115 VAC        WMD 60        115 or 1151230 VAC        257 amp at 230 VAC                   The fan on the back end plays an important part in moving        WMD77         115 or 1151230 VAC        335 amp at 230 VAC        WMD BO        115 or 1151230VAC         340 amp at 230 VAC                   air through the generator for cooling In installations where        Frequency 60 Hz Standard 50 Hz available at reduced rating                  surrounding air is limited outside air should be ducted to the        RPM 180060 Hz 15050 Hz                                                   area of the screened endbell inlet to provide this needed air        VOLTAGE Normal                    115 VAC       230VAC                   Maximum no load       132 VAC       264 VAC                                                                                       for cooling and combustion as well                   Minimum full load     108 VAC       216 VAC                       The security of the generator fan hold down nut should be        Excitation Voltage 115 VAC output voltage supplied to rectifier        Field Excitation Voltage 190 VDC approximate                                checked at installation commissioning at the initial 50hour                                                                                       servicing of the generator unit and periodically                                                                             200300 hours The cooling fan securing nut should be tight                                                                                       enough so that when force is applied to rotate the fan by1 Lift and support the back end of the engine so that the                             pushing on the outer edge and blades with the palm of your   generator is not resting on its isolators                                          hand protect the hand with a cloth or a glove you should2 Remove the generator endbell cover This exposes the fan                            be able to tum the generator and engine without the fan slip   and brush rig assembly Remove the fan assembly with                                ping on the shaft If properly torqued and the fan still slips   its hardware                                                                       replace the lockwashers3 Remove the brush rig assembly This can be done in two                              Recirculation of generator cooling air through the generator   half assemblies Unbolt the two halfmoon assemblies                                must be avoided The generator compartment ventilation   from the frame attachment and lift the two halves away                              must be sufficient to prevent generator air recirculation   from the slip rings Mark the polarity of the two leads on                          Insure that the screened endbell inlet and the screened dis   the bridge rectifier that go to the field coils and unplug                          charge slots at the flywheel are not obstructed preventing   these from the bridge rectifier The two halfmoon brush                            good air circulation through the generator while it is running   assemblies can be removed from the generator by remov   ing the heavy output leads GI G2 G3 and G4 from their   attachment point on each brush holder Make a rough                                   OUTSIDE                                                                                         MAR                                                                                                     QFAN                                                                                                         1                                                                                          ti   sketch as to where each of these leads attaches on each   assembly half There are 8 leads that are paired in the   control panel to provide four reconnectable leads Inspect   and replace components in the brush rig as needed Do                                                       IE   not totally disassemble as this is not needed                                          NUT     FLAT WASHER STARWASHER4 Remove the control panel from the top of the generator   housing Mark all leads as needed for proper assembly5 Unbolt the generator housing from the bellhousing A   puller may be needed at the bearing end to assist in pulling   the housing with or without the bearing off the armature   Some gentle prying at the bell housing end will be needed                                                                                                                                                                                                                 Engines  Generators                                                                                  89                                WMD GENERATOR  ELECTRICAL OUTPUT                                                       5 If no voltage is produced check the static capacitors                                                                              that it is not shorted to ground If one is found faulty1 Remove the load from the generator and verify no output                    remove the connection from the output terminal at the   directly at the generator output leads with a voltmeter                   brush rig and repeat Step 32 Check for proper electrical connections Refer to the   INTERNAL WIRING DIAGRAMS                                               FLASH FIELD COILS   NOTE The generator armature slip rings and brush rigs                  1 Units may lose their residual magnetism from extended   are numbered from inboard at the windings or flywheel                      storage or rough handling during installation or disas   end outward toward the rear support bearing                               sembly and assembly for installation etc requiring the                                                                              field coils to be excited with 6 to 12 volts DC to restore                                                                              the magnetism to the generator This is done in the fol                                                                              lowing manner                                                                               Stop the engine and remove the generator endbell Cover                                                                               This will expose the cooling fan brush rig assembly anq                                                                               rectifier Check internal wiring see diagram The posi                                                                               tive  lead from the field coils is connected to the posi                                                                               tive marked terminal on the rectifier and the negative                                                                                lead from the field coils is connected to the opposite                                                                               unmarked terminal on the rectifier Using jumper leads                                                                               with insulated alligator clips connect 6 to 12 volts DC                                                                               battery positive to the positive of the rectifier arid nega                                                                               tive to the unmarked terminal of the rectifier for approxi                                                                               mately 10 seconds This should restore magnetism to the3 For a residual voltage check disconnect the field leads                    stationary field coils   from the bridge rectifier Note the position of the leads on   the rectifier  to  and  to  Operate the genera   tor and check the AC output no load on generator                                                                                A CAUTION Be careful not to connect DC voltage                                                                                to the AC terminals on the rectifier as this will dam   Measure the voltage between the neutral lead and the hot   leads 3 and 4 wire unit  25 volts AC each hot lead                      age the rectifier    to neutral approximate    If the residual voltage checks OK you can assume the                      Remove the alligator clip connections replace the end   rotating armature and brush rig are OK The generators                    bell cover and operate the generator and check AC output    problem lies in the rectifier andor the field coils                     voltage    If residual voltage is not present Check the brush rig and    the static capacitors Check the rotating armature resis                   i23Ovi    tance values and the continuity check found under Flash    Field Coils            5 VOLTS AC            25 VOLTS AC   25 VOLTS AC                                                                                                             INTERNAL WIRING DIAGRAM                                                                                                                   BASIC 4 WIRE                                                                                                                                       612 Volt                                                                                                                                   DC Battery          HOT      NEUTRAL      HOT        NEUTRAL        HOT           2 WIRE UNIT                  3  4 WIRE UNITS4 Test the operation of the generator by bypassing the   bridge rectifier Apply 12 volts DC to the field leads on   the bridge rectifier  to  and  to  Run the gen                         Annature   erator noload Measure the voltage output at the gener   ator leads Generator output with 12 volts DC excitation   to the field coils should be 50 to 70 volts AC If 50 to 70   volts AC is produced this should indicate that the gener   ator is OK and that the bridge rectifier is defective                                                                 Engines  Generators                                                                      90                                  WMD GENERATOR  Check for a short or open in the rotating armature or in   the stationary field coils               ROTATING ARMATURE RESISTANCE VALUES     WMD 44 2WIRE 1 OHM OR LESS SLIP RING TO SLIP RING     WMD 44 3WIRE 1 OHM OR LESS BETWEEN SLIP RINGS 1  3     WMD 60 77 80 1 OHM OR LESS BETWEEN SLIP RINGS 1  3 AND 2  4   NOTE 4wire units there should be no continuity found   between slip rings 12 23 and 34 If continuity   is found an internal short exists between these windings                                                                                                                                      and the armature should be replaced    NOTE There should be no continuity found between any    of the slip rings and the armatures central steel shaft If                          j                                         I                                                                                                                                        continuity is found the windings are shorted to the shaft                                                                                              and the armature should be replaced    Rotating armature slip rings are numbered from inboard    of the generator flywheel end outward to the rear support                             II                                                                                                                                                                                                                       f                                                 i    bearing When referring to 2 3 and 4wire units these    are the number of generator output leads being connected    to the load You will find on the WMD models that there    are 3 to 4 leads coming from the brush rig These are                         I                                                     combined to produce the voltage output wanted see the                         RAIL                                                   RAIL    WMD wiring diagrams in this section The number of    wires can also be related to the number of slip rings on                                                                                                         912 VOLT    the rotating armature                                                                               BATTERY DCREPLACEMENT OF FIELD COILS1 Field coils are connected in series and the resistance                                         TESTING THE FIELD COILS   value given in this text is the total of the four field coils   To determine the resistance value of one divide by four                       b Using a 3inch iron bolt or its equivalent place this   Each field coil has a mounting position on the generator                           bolt between each adjoining field coilshoes It should   housing and cannot be interchanged with another field                              be held in place by the magnetic attraction set up   coil                                                                              between the coilshoes by the 912 volts excitation of                                                                                      the field coils Should this fail to happen between any    When installing a replacement field coils the installer                        of the four adjoining coilsshoes then an incorrect coil    must ensure that the coil is correct for the mounting posi                       is installed and must be removed and the correct one    tion in the housing and will have the correct polarity                            installed otherwise the generator when assembled    when excited with 912 volts DC                                                  will not produce proper voltage    The field coil shoes that hold the coil securely to the    generator housing are held in place by bolts that must be                  LOW VOLTAGE OUTPUT    properly tightened when the coil and shoe are installed to                 1 Verify the voltage output at the generator output leads    the generator housing When connecting the coils in                           with load applied to the generator cJteck the noload con    series ensure the butt connections are good and secure                        dition also Check the voltage at the load Check the rat    and positioned away froni rotating parts                                     ing for the generator and verify the load with an amp   To ensure the field coils have been positioned properly in                     probe at the output leads Check all connections to ensure   the generator housing and will have the correct polarity                      they are clean and secure Ensure that the wire size carry   the following test must be made before reassembly of the                       ing the voltage to the load is of sufficient size so as not to   generator                                                                     produce a voltage drop    a Connect a 912 volt DC battery to the leads off the                         NOTE Beware of motor starting loads and the amperage       coils that would normally be connected to the  and                       draw placed on the generator from these types of loads        connectors of the bridge rectifier These leads are                     Generally the amperage draw of a motor at startup will       unmarked and the polarity in their connection to the                        be 35 times the amperage needed when running       DC battery is not important                                                Ensure that the engine noload speed is producing    NOTE When removing the leads from the battery and                             125132 250264 volts from the generator Lower    reconnecting them to the bridge rectifier you should                          noload voltage can result in low output voltage at rated    maintain the same polarity as used in this test plus lead                     amperage output    to  on rectifier and negative to unmarked  connec    tion to rectifier                                                                 Engines  Generators                                                                          91                                  WMD GENERATOR  Check the generator with a Hertz meter                              5 Insufficient cooling of the generator Ambient air entering   NoLoad Hertz               61615 51515                           the generator should not exceed 104F 40C Operating   NoLoad Voltage             130132 volts generator cold              efficiency of the generator decreases as the ambient air   NoLoad Voltage             126130 volts generator hot               temperature entering the generator endbell increases                                                                           above 104F Generators in confined areas may require3 Test the Bridge Rectifier The bridge rectifier may be                  the ducting of cool outside air into the compartment   faulty and should be checked as follows                                directed toward the inlet at the generator endbell   The field excitation rectifier is a fullwave bridge rectifi        6 Check the condition of the brushes for wear and contact   er This type of rectifier has four terminals two AC a                with the slip rings on the armature Ensure that the brush   DC positive and a DC negative The rectifier is tested in              es are not sticking in the holders   the following manner Connect one ohmmeter lead to the   positive DC terminal and the other lead to each of the              7 Condenser Testing Condensers are built into the genera   AC terminals in turn A high or low resistance reading                  tor circuit to minimize radio interference during opera   will be obtained Reverse the meter leads and an oppo                 tion If a condenser shorts out it shorts the generator out   site reading sliould be observed Now check from the                    put To determine whether a condenser is shorted stop   negative terminal to each of the AC terminals using the                the generator disconnect the lead wire from the brush   same procedures as above Check each terminal to the                    holder tq which the condenser is connected start the gen   case and no resistance reading should be observed                     erator and check the output If the generator then pro                                                                           vides power the condenser was at fault and should be   If a batterypowered test light is used follow the proce              replaced If the generator did not provide power after the   dures described above If the rectifier is good the light              lead wire was disconnected the problem was not caused   will come on in one direction only                                    by that condenser Reconnect the lead wire   If the rectifier fails any of the above tests it should be              NOTE There should be no continuity found between the   considered defective and replaced                                       lead end from the condenser and the metal case of the                                                                            condenser If so the condenser is shorted                                                                        HIGH VOLTAGE OUTPUT                                                                        1 Verify the voltage at the generator output leads                                                                            NoLoad Voltage             126130 volts generator hot                                                                                                        615620 hertz     TESTING THE                                                        2 Check the internal wiring of the generator leads attached     BRIDGE RECTIFIER                                                                           to the brush rig and the leads from the brush rig feeding                                                                           AC to the bridge rectifier One connection is from a hot                                                                           brush rig and the other must be from a neutral brush rig                                                                        SOLENOID WITH THROTTLE LINKAGE                                                                        The solenoid plunger must move smoothly and rapidly into                                                                        the solenoid when the solenoid is electrically energized                                                                        drawing with it the engine throttle arm into the set speed run                                                                        position Failure of the solenoid plunger to bottom in the                                                                        solenoid will result in a failed solenoid             BLACK  d2J             TEST LEAD4 Check the field coil resistance as per the following speci   fications                                                                              THRomE        FIELD COIL RESISTANCE TOTAL                                         ADJUSTMENT      WMD44        325 OHMS       5                                       LINKAGE      WMD60        315 OHMS       5      WMD7780    225 OHMS       5                                                                                        FUEl SOLENOID                                                            Engines  Generators                                                                   92      WMD GENERATOR Ae INTERNAL WIRING DIAGRAMS       60 Hz2 WIRE                                             60 Hz  3 WIRE RECONNECTABLE                                                                  r2il60 Hz  4 WIRE RECONNECTABLE                                    60 Hz  4 WIRE RECONNECTABLE                                                                 j  5V i                               50 Hz  2 WIRE RECONNECTABLE                                       Engines  Generators                                           93                                                                                  DC ELECTRICAL SYSTEM                                                                         WMD GENERATOR WIRING DIAGRAM 24700                               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                      Engines  Generators                                                                                                                94                                                DC ELECTRICAL SYSTEM                                             WMD GENERATOR WIRING SCHEMATIC 24700                      r                      4                              I                    1        1          I                    I         I   PREHEAT              I I                    I   0                    LlJ                      I                                                        1                                                        I I                                                        I I                             IZVDC    BATTERY                BATTERY RETURN         r 1                                                  I     11fll1        I     I I       Erl             1                I                                                     tJ    I        I   START        I       I I                                                             PREHEATER       LL J                        I       I I     M r      IE                         STOP          I       I I    I LfJ                               I       I I                                                                                            10             I L                            I       I I                  L     li I                     I                                                I       I I I IIZOAMP                                                                   CB                                                                                                                                                                   I   I     I       I L                                                         I                     L                                                              r 1                PANEl                  PREHEAT 501                        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        I EENOTEH                            LJ Httt                     FUEl IIFT PUMP                                         L                         L  1 I                                                             I                   STOP          J                                                            I               ElCH TEMP SW                                                            I                                                                                                                                               OP GAGE                                                            I                                                                                                                                                                                     I                                                            L                                                                                   wC                                                                                                                              OP SENDER                                                                                                    ttO tt      WT SENDER                                                                    Engines  Generators                                                                            95                                                 80 BTD                                                               A circuit breaker is installed on all current WESTERBEKE                                                                         generators This circuit breaker will automatically disconnectThis generator is a brushless selfexcited generator which              generator power in case of an electrical overload The  only the driving force of the engine to produce AC                                                                         breaker can be manually shut off when servicing the generaoutput The copper and laminated iron in the exciter stator are           tor to insure that no power is coming into the  for the selfexciting feature of this generator Themagnetic field creates an  field which rotates            NOTE This circuit breaker is available as a  the windings of the main stator inducing AC voltage             addon kit for earlier model generators contact yourwhich is supplied to a load A transformer is connected in               WESTERBEKE DEALERparallel to the AC output of the main stator An AC voltage isproduced in the auxiliary windings of the transformer andmain stator and is in tum supplied to a fullwave bridge rectifier The rectifier produces a DC voltage to further excitethe exciter stator windings enabling the generator to producea rated AC output as the generator speed reaches its set hertzrpmAn optional solidstate voltage regulator is available to workin tandem with the transformer regulator to produce a morestable AC output                                                                                                         CIRCUIT BREAKER                                                                                                         AND CONNECTIONS                                                                                                                                      CIRCUIT                                                          BT GENERATOR                                                                                                                        RIVE                                                                                                        OPTIONAL                                                                                                                        PTO                                                                                                                       INSTALLATION                                                          Engines  Generators                                                                   96                            80 BTD GENERATOR   guide will give you insights into prob                     NOTE Do not always rely on the vessels instruments forlems which may be encountered with the WESTERBEKE                                accurate readings bring your own instruments for testing80 BID brushless transformer regulated generator Most                         Before attempting any repairs get as clear an explanation ofpotential problems are covered in the text of this guide                       the problem as possible preferably from an individual witOwing to the simplicity of the equipment and controls thIS                      nessing the problem In some cases this may bring to light  is relatively easy once the relationship                        problem which is related to the method of operation ratherbetween cause and effect is understood                                          than an equipment faultKeep in mind that a basic fundamental knowledge of elec                         Bring basic repair parts with you on the initial trip to thetricity is required for this  and always                         problem equipment such as a regulator board when  that lethal voltages are present in the circuitry                      diodes and a bridge rectifier so that if the problem should betherefore extreme caution is essential when working on or                       found in one of these easily replaceable parts the  a generator                                                     can be remedied early and  a few basic tools are necessary for diagnosis and repair                   The internal and external wiring diagrams are important toolsThese are hand tools an amp probe and a quality volt ohm                       in  this generator or any generator model Bemeter capable of reading less than one ohm due to the preci                     sure to have both with you and be sure they are for the spesion required in reading component winding resistances                          cific model you will be working on                                                           r                       r                                                                                                                      I                                                                     c                                                                                                    I                                                                                             I                                                                                                     D                                                                                                                    I                                                                                    I                      I                                                                                                                           6                                                                                                                           5                                                                                                                                      AC                 A                                                                                                         9           T                                                                                                                          10          E                                                                                                                           3           R                                                                                                                           2          M                                                                                                                           7           I                                                                                                                         8           N                                                                                                                      BLACK WHrrE                                                                                                                                      A                                                                                                                      GREEN WHrrE                                                                                                                                      L                                                                                                                                      8                                                                                                                                      L                                                                                                                      YELLOW WHITE                                                                                                                                      0                                                                      Q                                                               C                                  Ft        G                                                                      w                                                                                                                                     K                          L     VEUOW  WHITE                                                                                                                                                                          A VR                                                                                                                          BLUE WHITE                                                                                                       BLUE WHITE                                                                                                                                                                                                                                                                                                                                                                                                 S                                      BLACK  WHITE                PLUG                                                              T                                                                                                                                      U                                                                                                                                      0                          RED  WHITE   r               J              0                                          KJ                                                                          F2        G      GREEN WHITE                          it            VEL LOW  WHITE                                        BLACK  WHITE                                                                             AVR                                                                    PLUG                                                80 BTD INTERNAL WIRING SCHEMATICA EXCITER STATOR WINDINGS 1  2                                                 D COMPOUND TRANSFORMER   F1 Exciter Stator Windings                                                     1 Compound Transformer Windings     Selector in COMP position                                                    2 Compound Transformer Windings   F2 Exciter Stator Windings                                                     3 Compound Transformer Auxiliary     Selector in Electronic                                                          WindingsB EXCITER ROTOR                                                                 F SELECTOR SWITCH   1 Auxiliary Windings abc                                                          1 Compound   2 Diodes 6                                                                          2 Electronic and Compound   3 Rotating Field Windings                                                    G BRIDGE RECTIFIER   4 PoziResistor                                                                                 AVR Automatic Voltage Regulator Plug 12 prongC MAIN STATOR   1 Main Stator Windings   2 Main Stator Windings   3 Main Stator Auxiliary Windings                                                               Engines  Generators                                                                      97                      80 BTD GENERATOR                                                              r                                                                 AC     r                                        I          C            I                                                                                                                                   6                                                                                                                                        TO                                                                                                                                        E                                                                                                                                   5    R                                                                                                              i 9           1      AooB                                                       1                                                                                                                                        M                                                                                                                                        I                     4 3                                                      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      o                                                           I                                                           I                                                                                        Z                                                                                         C                                                                                         II                                                                                                                WHT IGREEN             S                                                                                                                                        T                                        ORANGE                                                                                AC BLACK                                                                        U                                                                                                                                        D                       KI                          AC                     GREEN                                YELLOW                                                80 BTD INTERNAl WIRING SCHEMATIC                                             WITH VOLTAGE REGULATOR CIRCUIT REMOVEDA EXCITER STATOR WINDING                                             D COMPOUND TRANSFORMER   Resistance Value 100 Ohms                                            1 Compound Transformer WindingsB EXCITER ROTOR  FIELD                                                 2 Compound Transformer Windings   1 Auxiliary Windings abc                                         3 Compound Transformer Auxiliary   2 Diodes 6                                                            Windings   3 Rotating Field Windings                                         G BRIDGE RECTIFIER   4 PoziResistorC MAIN STATOR                                                        The removal of the voltage regulator circuit simplifies the   1 Main Stator Windings                                            wiring circuitry in the 12 stud BT generators exciter circuit   2 Main Stator Windings                                            Resistance readings and voltage checks can be easily gotten   3 Main Stator Auxiliary Windings                                  for the components in the exciter circuit A G C3 and D3                                                                      by locating the colorcoded wires at the connection points                                                                      shown on the above schematic When checking winding                                                                      resistance value be sure to lftboth of the components                                                                      electrical connections                                                                                                                                                                                                                                  J                                                      BATTERY                                          f                                                                       DC  RED                      CONNECTION                                                NOTE KEEP EXCITER CIRCUIT           POLARITY CORRECT DC  TO  LED           AND DC  TO THE CASE GROUND                                                   EXCITING THE GENERATOR WITH 12 VDC                                                                 Engines  Generators                                                                      98                                   80 BTD GENERATOR  The amount of noload voltage produced by the generator                              The fault lies in one or more of the following components in   can be an indicator of where in the generator the                                    the exciter circuit   problemfault may lie                                                                  A Exciter Stator A1  A2   Residual Voltage 1822 voltsAC This voltage is theAC                                   B Bridge Rectifier G   voltage produced by the generator from magnetism in the   exciter stator field This voltage is measured between the                              C Selector Switch F   neutral and hot legs with no load on the generator with                              D Main Stator Auxiliary Windings C3   it running at its rated rpm                                                                                           E Compound Transformer Auxiliary Winding D3   The presence of residual voltage is an indication that the                                                                                        2 Twelve 12 volt DC excitation of the exciter stator wind   following generator components are OK                                                                                           ings should cause the generator to produce between        1 Exciter Rotor B1  B2                                                       125135 volts AC between each hot lead and the neutral        2 Rotating Field B3                                                            Twelve volts DC is applied between the lifted  and                                                                                            leads of the bridge rectifier  to  and  to        3 Main Stator C1  C2                                                          Correct voltage produced with twelve volts DC excitation       4 Compound Transformer D1  D2                                                 indicates the fault is in one or more of the above listed                                                                                           components B D or E If the generator does not produce                                                                                           125135 volts AC then include A and C                                  NOTE The following is a list of faults with the generator operation on                                  compound COMP transformer regulation no A lIR installed                FAULT                                        CAUSE                                                    CORRECTION Correct voltage at NIL and loss of voltage   1 Selector switch in wrong position             1 Place selector switch in COMP position as load is applied No loss of engine speed and hertz High voltage at NIL 125  135 volts with   1 Generators engine speed rpm high at NIL 1 Check NIL speed and adjust NIL voltage correct voltage when loaded 115 120 volts High voltage at NIL and Fl                 1 Generators engine speed rpm is too high 1 Check NIL rpm and adjust NIL voltage                                              2 Short in compound transformer auxiliary        2 Check continuity and connections of 03 windings                                                 windings 03 low voltage at NIL 0  5 volts with        1 Main stator windings shorted C1 C2         1 Check continuity and resistance values of C1 C2 windings growling noise from generator and loss of                                                         and connections engine speed when load is applied Generator does not excite voltage is        1 Generators engine speed rpm is slow        1 Adjust the engines speed and adjust NIL voltage ovolts at NIl                                              2 Short in the main stator windings or           2 Check main stator and transformer winding resistances                                                 in transfomer                                    Artificially excite the generator and note the results                                              3 Shorted posiresistor                         3 Check resistor low voltage at NIL when load is applied    1 Oiodess in rotating exciter B2           1 Check B1 and B2 in rotating exciter voltage drops                               2 Bridge rectifier defective                    2 Follow test procedure for bridge rectifier                                              3 Auxiliary windings B1 shorted                3 Check the continuity and resistance values                                              4 Auxiliary windings 03 andlor C3 open        4 Check the continuity and resistance values of windings and                                                                                                   connections low voltage at NIL and FIL 50  70 volts    1 Exciter stator windings A1 and A2 are        1 Check continuity and resistance values of A1 and A2 windings                                                 open                                              2 Generators engine speed rpm is low         2 Check generator NIL rpm and adjust NIL voltage Voltage correct at NIL but not at Fll        1 Generator overload                            1 Check data plate and monitor load on generator with with loss of engine rpm hertz                                                                   ampprobe                                              2 low power factor load motor loads           2 Check type of load applied Consider use of optional regulator                                                                                                   board Unstable voltage                            1 Engines rpm fluctuating                      1 Check engine operation and fuel system                                                                                                                                                       continued                                                                       Engines  Generators                                                                               99                                    80 BTD GENERATOR  following is a list of faults with the generator operating on electronic ELEC regulation Selector switch is in the ELEC position with an AVR installed               FAULT                                           CAUSE                                                      correct at NIL and loss of voltage      1 Diode in exciter rotor B2 shorted             1 Check diodes see EXCITER ROTORat FILHigh voltage at NIL with no adjustment          1 Regulator board defective                      1 Replace regulator board Adjust NIL voltage with  regulator potentiometer                                                                         then switch to ELEC and adjust with AVR  voltage at NIL and FIL No adjustment       1 Regulator board defective                      1 Replace regulator board and adjust voltage as abovefrom regulator board potentiometer             2 Exciter stator winding A1 open                2 Check resistance values of C3 and 03 windings and their                                                                                                      connectionsLow voltage at NIL 0  50 volts with          1 Main stator windings shorted C1 C2         1 Check continuity and resistance values of C1 and C2growing noise from generator and loss                                                                 windings and their connectionsof engine speed when load is  does not excite 0 volts at NIL      1 Diodes in exciter rotor shorted B2        1 Check diodes in exciter rotor see EXCITER ROTOR                                                2 Generators speed is low                       2 Check the engines speed hertzLow voltage at NIL and voltage drops            1 Diodes in exciter rotor shorted B2          1 Check diodes in exciter rotor see EXCITER ROTORfurther as a load is applied                   2 Auxiliary windings in exciter rotor             2 Check resistance values and continuity to ground                                                   shorted B1Voltage OK at NIL and low at FL               1 Auxiliary windings in the exciter rotor         1 Check resistance values and continuity to ground                                                   B1 shorted                                                2 Exciter stator winding A2 is open             2 Check continuity and connection of windings                                                3 Auxiliary winding 03 or C3 open              3 Check continuity and connection of windingVoltage unstable                               1 Defective regulator board                      1 Check stability of DC voltage from regulator to exciter stator                                                                                                      windings Operate unit on COMPo Replace regulator board                                                2 Engine is hunting                              2 Check engine operation and fuel system                                                3 Electrical connections                         3 Check for clean and secure  RECTIFIER                                                                              2 3 and 5 No deflection of the needle should occur                                                                                              showing no continuityThe bridge rectifier is supplied AC voltage from the  in the generator stator C3 and the compound                                  3 Remove the  lead from point 4 and connect the transformer 03 The AC voltage measured across the AC                                    lead to point 4 and with the  lead  of the rectifier during engine operation is as follows                           touch points 1 2 and 3 The needle of the meter                                                                                            should deflect showing a passage of meter voltage           120 Volts                         120240                                        through the diodes in the rectifier           NL FL                           NIL FL                                     4 Touch point 5 with the  lead No deflection of the           1121 voltsAC                     1121 voltsAC                                                                                            needle should occurDiodes in the rectifier convert this AC voltage to DC and                                                                                         S Place the  lead of the meter on point 1 and the  onsupply it to the windings Al and A2 of the exciter stator                                                                                            point 3 No deflection of the needle should occurto induce a field through which the exciter rotor revolves                                                                                            infinite resistance Reverse the connections and theThe DC voltage measured across the  and  terminals of                                                                                            same should occurthe bridge rectifier during engine operation is as follows                                                                                         Should the rectifier fail any of the above tests it is defective           120 Volts                         120240                                     and should be replaced           NLFL                            NLFL                                      Resistance values  at 70F 21C Simpson Meter 260           817 volts AC                     817 volts AC                                                                                         ModelFailure of the bridge rectifier will result in no strong fieldbeing produced by the exciter stator windings A weak fieldis present due to the magnetism in the exciter stator whichwill cause the generator to produce residual voltage as discussed earlierTesting the Bridge Rectifier for Faultswith an Ohmmeter1 Set the ohmmeter scale on RXI DC Zero the meter2 Connect the  lead from the meter to point 4 With the    lead from the meter momentarily contact points 1                                                                        Engines  Generators                                                                                100                                     80 BTD GENERATOR  STATOR WINDINGS1 A Windings 1  2 Exciter windings A 1  2   Compound Fl 8590 ohm Reading taken between   positive  and negative  leads lifted off the bridge   rectifier with the seleector switch in the COMP position   Either of the two leads should have no continuity to the   caseground2 A Winding 1 Exciter windings AI ElecF2 300305   ohm Selector switch in the ELEC position with read   ings taken between the yellow  white and black    whitestriped wire leads at the regulator plug3 A Winding 2 Exciter windings AI ElecF2 125130   ohm Reading taken between positive  and negative    leads lifted off the bridge rectifier                                                                                                                                                                            D       I                                                                                                                                                                                                                                                   I                                                                                                             1IIIiI                       l                                                                                                                                                   AC                                       B                                                                                                           T           A                                                                                                                                                   E                                                    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                                                  A                                                                                                                                                 I                                                                   I                           I         I                                                                                               I                          I                C                                                                                                              BlACK WHrTE                                                             I                                                                            L                                                         VELtOWr1                                                                                                                                GREEN  WHITE       no                   1             z              e e            x           AEDWIlITE                                                                     BLACK    I              3            I                                                                                                         cl111                                                                                                         I 2                                                                                                   RED  WHITE                                                                                                                 3   I                                                                                                                                                       B       Ee                                                                                       oJ                                                                                  II                                                               L                                                                                                                                                   o                               J                                                                                                                               YELLJoN  WHITE       LX                                                                                                                                                   e                                1                                                c                                                                C                         1                      G        GREEtU WHilE                                                                                                                                                              K                                     F1                                           K                         T                    YEL10W WHITE                                                                                                                                                      AVA                                                                                                                                BlUE  WHITE                                                                                                                                BLUE  WHITE                                                                                                                                                   s                                              BLACK  WHITE                    pLUG                                                                T                                                                                                                                                    U                                                                                                                                                    D                          AEDfHITE                                 I                                                                                              F2              G     GREEN  WHITE                        M                                                       YELLOW  WHITE                                               BLACK  WHITE                                                                                                                                                                                                                                      AVA                                                                                PLUG                                                                                                               Terminal Block 12 Stud                                                                                                             Showing Electrical Connections                                                                                                                   from Generator                                                                               Engines  Generators                                                                                      101                              80 BTD GENERATOR  ROTOR                                                       When leads are put across the diode as illustrated voltage                                                                    passes through the diode allowing the headlight to glow1 Auxiliary windings 1012 ohm Readings taken                  brightly   between each pair of windings ab bc ca Winding                                                   HIGH BEAM 12 VOLT BULB   connections can be left soldered at their connection                                                    GLOWS BRIGHT   points If the readings are believed to be incorrect unsol   der the connections and recheck for resistance readings2 Diodes Six diodes are mounted on the exciter rotor they   rectify the AC voltage produced by the three groups of   auxiliary windings to DC voltages and supply this DC   voltage to the rotating field windings                       RESISTANCE VALUE       11 OHMS THROUGH THE DIODE       INFINITE BLOCKING                          RESISTANCE                             Reverse the leads across the diode The diode should block  II                                                                    voltage passing through it and the headlight should not glow                                                                    or it may glow faintly                        INFINITE                                                                                                                   HIGH BEAM 12 VOLT BULB                                                                                                                DOES NOT GLOWIS VERY FAINTThe diodes can be easily checked in place with the use of acommon automotive 12volt high beam headlight bulb somejumper leads and the generators 12 volt starting battery seethe next pageA short or an open in a diode can easily be found with theabove without having to unsolder and isolate each diode tocheck it with an ohmmeterNOTE Attempting to check diodes in place with an ohmmeterwill give erroneous readings on the diodes due to the auxiliary windings connections                                             a Should the bulb not glow with leads connected in both                                                                           directions the diode is open internally                            Red  While                                                                        b Should the bulb glow bright with the leads connected                                                                           in both directions the diode is shorted internally                                                                        In both a and b above the diode should be replaced                                                                        Check the resistance values of the rotating field windings                                                                        and the integrity of the posiresistor connected between                                                                        the field windings                                                                    3 Rotating Field Windings 7080 ohms Readings taken                                                                        between the two red and white wires connected to the                                                                         and  terminals of the exciter rotor as shown in the                                                                        illustration                                                                        NOTE These terminals are not marked  and  there                                                                        should be no continuity to the rotors shaft                                                                    4 Posiresistor Infinite readings between both yellow                                                                        leads lifted from terminals  and  on the exciter                                                                        rotor                                                                        NOTE A shorted posiresistor will destroy the rotating                                                                        field and cause theAC output voltage to drop to zero                          EXCITER ROTOR                                                          Engines  Generators                                                                  102                             80 BTD GENERATOR  STATOR WINDINGS                                                   b Serial 1041 and up A  terminal                                                                          strip was added to this circuit located just below the1  2 Main stator windings 2022 ohm                                   AC terminal block at the lower left Isolate the three1 Group 1 Measured between lead 6 at the AC terminal                  numbered 1 2 and 3 red  whitestriped wires   block and lead 4 at the junction block Lift both leads              coming onto each of the three terminals Lift the black   along with lead 5 at the terminal block to totally isolate             white and green  white leads off their connections   group 1                                                              on the AC terminal block Measure the resistance2 Group 2 Measured between lead 3 at the AC terminal                  value between the 1 red  white lead lifted from the   block and lead 1 arthe junction block Lift both leads               terminal strip and the black  white lead lifted from   along with lead 2 at the terminal block to totally isolate            the AC terminal block   group 2                                                                                     RED       RED           RED    NOTE The junctipn block for connections 4 and 1 from                          WHITE      WHITE          WHITE    the main stator windings and to the transformer windings    is found just below and to the left of the compound                                                           3    transformer                                                                      MAX         MID          LOW3 Main Stator Auxiliary Windings 1518 ohm   Measured between the double leads on the AC terminal   of the bridge rectifier unplugged from the rectifier and                                                                                     000   the double lead central prong connection of the regulator   plug    No continuity should be found between either of these                                              RED    three winding groups or to the generators case                                                   WHITE                                                                                     TERMINAL STRIPCOMPOUND TRANSFORMER1  2 Compound Transformer Windings 019021 ohm                                                                       NOTE The addition of the  terminal strip1 Group 1 Measured between lead 10 at the AC terminal               is for the increase or decrease offullload voltage output    block and lead 4 at the junction box Lift both leads             Should fullload voltage fall below J08 volts selecting a    along with lead 9 at the terminal block                          higher number terminal strip lead to connect the lead2 Group 2 Measured between lead 8 at the AC terminal                red  white that is routed to the regulator plug and the   block and lead 1 at the junction box Lift both leads              exciter circuit will supply a higher AC voltage to the   along with lead 7 at the terminal block                           exciter circuit during fullload conditions bringing the                                                                       output voltage of the generator up3 Transformer Auxiliary Windings 4045 ohm                                                                       Noload voltage should be properly adjusted by shim    a Serial 10011040 These very early models trans              ming the compound transfomer 121124 volts at       former auxiliary windings resistance value is mea             615620 hertz Note that the above should not be used       sured between the black and white wire lifted from                                                                       as a means of compensating for incorrectly adjusting the       the AC terminal block and the red and whitestriped            generators noload voltage       wire at the regulator plug To totally isolate these       windings for the above measurement lift also from       the AC terminal block the green and whitestriped       wire                                                          Engines  Generators                                                                 103                                 80 BTD GENERATOR  SWITCH                                                                  r                                          SELECTOR SWITCH                                          IN COMPOUND                                                                               o   0                                                                  r                                                                                 o   0                                          SELECTOR SWITCH                                          IN COMPOUND                                          WITHAVR                                                                                                                                                                                                                                                            RED  WHITE                                        GREEN  WHITE                                                                           4             1              SELECTOR SWITCH              WIRING                        YEllDW  WHITE                                            BLACK  WHITE                                                                           5                                           YEllDW  WHITE                                               BLACK  WHlTEI                                                                           6BRIDGE RECTIFIER WIRING                                                                                                                                                                                                   f                                                                                                     l                                                              RED  WHITE                     RED  WHITE                            t          AC                                                                      t          AC                                                    0                                                                                        0                                      0                                                                                        0                         0                                                                                       il                          AC              t                                                                  AC               tl                                                                                                                                                                                                                    I                                                                                                                                                                                                                                                                                                                       GENERATORS 1001 TO 1040                                                               GENERATORS 1041 AND UP                                                                           Engines  Generators                                                                                   104                              80 BTD GENERATOR  VOLTAGE ADJUSTMENT                                             be accomplished by gently tapping the top of the                                                                       laminated steel bar to reduce the air gap between theVoltage adjustment is made with the generator regulation                                                                       existing shims and the transformer corebeing governed by the compound transformer1 The selector switch must be in the COMP position2 Operate the generator and apply a moderate load momen               A CAUTION Under no circumstances attempt to   tarily and remove it Note the voltage output from the                increase the noload lIoltage by increasing the gap   generators 120 volt legs 110 volt 50 hertz The no              between the laminated steel bar and the transformer   load voltage should be between 121124 volts at 61562               core without the use of shims MagnetiC forces   hertz 111113 volts at 515 52 hertz                                                                         created within the transformer during generator   NOTE The noload voltage should be adjusted to the volt             operation may close the air gap and reduce noload   age produced by the generator once started and a   momentary load applied to excite the transformer and                  lIoltage output   then removed The voltage produced by the generator   after this momentary load is removed is noload voltage      4 To remove the laminated steel bar remove the two upper3 To raise or lower the voltage shims of varying thickness        securing bolts from the Compound transformer and lift the   nonconductive material are placed or removed from             bar from the transformer The addition of shim thickness   under the steel laminated bar on tol of the compound            will raise the noload voltage and conversely the removal   transformer The material used for shimming should not           of shim thickness will lower the noload voltage   soften at temperatures in the 176F 80C range A small           Varying shim thickness by 001 in 0025 mm will   reduction in noload voltage 1 at 3 volts can sometimes           change the noload voltage by 4 to 6 volts                                                                                             Voltage Adjustment                                                                                             Shim Location                                                                               NOTE Illustration    shows 8 BT with    voltage regulator    circuit    early models                                                                                      Regulator                                                                                      Plug                                                                     BlueWhitelue White                                                                     G      W ht            ellowBlack                                                                      reen      Ie             ed  White                                                                     Yellow  White           Black  White                                                       Engines  Generators                                                               105                               80 BTD GENERATOR  VOLTAGE REGULATOR Early Models                                     adjusted with the selector in COMP position following                                                                              procedures for noload voltage adjustmentAn optional solid state voltage regulator board 34410 isavailable for use with the BT generator When this board is             4 With generator noload voltage adjusted to  and the regulation switch is moved to the ELEC                   volts move the selector switch into the ELEC  the regulator works together with the standard com              Adjust the regulator board potentiometer to set noloadpound transformer regulator to regulate generator voltage                  voltage at 120 volts 61562 hertz 110 volts 51552output Refer to the wiring diagram                                       hertz Generator voltage output should be within t5                                                                           from noload to fullrated generator  The regulator is mounted using existing tapped holes in                    NOTE 1 The frame ground wire must be moved when   the generator case Use two 2 M4 x 07 mm screws                                                                              changing from 110 volts 50 hertz to 110220 volts 50   each 15 mm long with lockwashers to mount the regula                                                                              hertz For making connections to the A C terminal block   tor board                                                                              use terminal ends for 10 studs that will accept 6 multi                                                                              strand wire when the generator is wired for J 20 volts or2 Plug the 6prong generator plug into the receptacle on the                 use 8 when the generator is wired for J 20240 volts   regulator board                                                           Use an approved cable clamp to protect and secure the   NOTE The plug is shaped so it will only engage in the                     wire from chafing where it exits the generator housing   regulators receptacle in one direction Check this and                   NOTE 2 The neutral and frame ground    which are   insert correctly                                                          normally combined can be separated for those systems3 Before moving the selector switch to ELEC make sure                       requiring a separate neutral from common ground The   the noload voltage produced by the generator is properly                  generators frame must be connected to the vessels                                                                              common ground for safety reasons                                         120V60Hz                             120240V 60Hz                                         0                      TO FRAME III                                                  o   o                                         o                                         o        o   o                                         o                                         N                                       L1                            110V50Hz                         220V50Hz                     110220V 50Hz                           aD               0              ao       0                  aD       0                           0         0        0              0     0     0                  0                       TO FRAME                                                              0    ao                  0                       N           TO FRAME Iljrr                      L1                                                 a                                     N                             N     L1                                                          AC VOLTAGE CONNECTIONS                                                              Engines  Generators                                                                  106                              80 BTD GENERATOR  FREQUENCY                                                    Manual Check1 Frequency is a direct result of  speed             Check the operation and bottoming of the fuel solenoid   1800 rpm 60 hertz 1500 rpm 50 hertz                             plunger by manually doing the following2 To change generator frequency follow these steps                      a Connect an ohmmeter across the positive  terminal    a Connect the AC output leads to the AC terminal                         and vacant auxiliary terminal of the back of the fuel       block following the illustrations under 4 above                     solenoid see illustration    b Adjust the engines speed to obtain the frequency                   b With the fuel solenoid in the STOP position 01       corresponding to the voltage selected                                 ohms resistance should be found across these two                                                                              terminals    c Adjust the noload voltage if it is needd by the       compound transformer                                               c Manually moving the throttle arm into the RUN                                                                              position and bottoming the fuel solenoid plunger a    d Load the generator to the new amperage rating and                      resistance of about 1530 ohms should register on the       reposition the loaded voltage tap to position X Y or Z                meter indicating that the plunger has bottomed       as needed to maintain exceptable voltage output at full                against the internal switch deenergizing the pull of       rated amperage output                                                 the windings       NOTE Volts x Amperage  Watts                                         Failure to manually make sure that the fuel solenoidEngine speed is increased or decreased by adjusting the                       operates as described above will result in the failure oflength of the linkage between the throttle arm and the                        the solenoid when operated electrically The fuelsolenoid plunger with the plunger completely bottomed in                     solenoid may fail within 30 seconds if the plungerthe solenoid                                                                 does not bottom when electrically energized                                                                                                                    AUXILIARY                                                                                                                    TERMINAL         THROmE                                                                              INTERNAL                                                                                              NC SWITCH   I         ADJUSTMENT                                                                                         I                                                                                          l           LINKAGE                                                                                                                OHMMmR                   FUEL SOLENOID                                                                       Electrical Check                                                                       When operated electrically by use of the PREHEAT switch                                                                       on the instrument panel the fuel solenoid plunger should                                                                       move smoothly and rapidly into the solenoid with no binding A CAUTION Failure of the solenoid plunger to                         or hesitation drawing the throttle arm into the RUN position                                                                       with the plunger bottoming in the solenoid bottom in the solenoid will result in a failed solenoid                                                                       Slow or hesitant movement of the solenoid plunger into the                                                                       solenoid when energized can be the result of linkage bindingTo avoid failure of the solenoid make sure the solenoid               misalignment andor a possible voltage loss at the  bottoms in the solenoid Check the solenoids opera           Remove startstop panels when wired into the generatortion at the initial startup Periodically lubricating the linkage     panel with inadequate wire size for the distance run canjoints between the solenoids plunger and the throttle arm             produce this effect Check the voltage at the solenoids posiwill eliminate binding                                                tive  terminalNOTE The solenoid plunger must move smoothly and rapidly              With the solenoid operating properly when energized by theinto the solenoid when the solenoid is electrically energized         PREHEAT switch the generator can then be started and thedrawing the engines throttle arm into the SET SPEEDRUN               linkage adjusted so the engines speed will have the                                                               producing the correct noload voltage and hertz The linkage                                                                       can then be secured                                                             Engines  Generators                                                                     107         80 BTD GENERATOR                         WINDING CONNECTIONSN11 L1 50Hz     6      5           4 4                9         10N   11 L1                                           50Hz     6      5           4 4                 9        10                                                          120V   60 Hz                                                          240V   60 Hz          Winding Connection to Obtain the          Voltage and Related Frequency                              Engines  Generators                                  108                                               100 BTD                                                               A circuit breaker is installed on all current WESTERBEKE                                                                         generators This circuit breaker will automatically disconnectThis generator is a brushless selfexcited generator which              generator power in case of an electrical overload The  only the driving force of the engine to produce AC              breaker can be manually shut off when servicing the generaoutput The copper and laminated iron in the exciter stator are                                                                         tor to insure that no power is coming into the  for the selfexciting feature of this generator Themagnetic field creates an  field which rotates            NOTE This circuit breaker is available as a  the windings of the main stator inducing AC voltage             addon kit for earlier model generators contact yourwhich is supplied to a load A transformer is connected in               WESTERBEKE DEALERparallel to the AC output of the main stator An AC voltage isproduced in the auxiliary windings of the transformer andmain stator and is in tum supplied to a fullwave bridge rectifier The rectifier produces a DC voltage to further excitethe exciter stator windings enabling the generator to producea rated AC output as the generator speed reaches its set hertzrpmAn optional solidstate voltage regulator is available to workin tandem with the transformer regulator to produce a morestable AC output                                                                                                          CIRCUIT BREAKER                                                                                                          AND CONNECTIONS                                                                   DISC PLATE                                                          BT GENERATOR                                                          Engines  Generators                                                             109                                      100 BTD GENERATOR                                                                                          NOTE Do not always rely on the vessels instruments for                                                                                         accurate readings bring your own instruments for testing                                                                                         Before attempting any repairs get as clear an explanation of                                                                                         the problem as possible preferably from an individual wit                                                                                         nessing the problem In some cases this may bring to light a                                                                                         problem which is related to the method of operation rather                                                                                         than an equipment fault                                                                                         Bring basic repair parts with you on the initial trip to the                                                                                         problem equipment such as a regulator board when installed                                                                                         diodes and a bridge rectifier so that if the problem should be                                                                                         found in one of these easily replaceable parts the problem                                                                                         can be remedied early and efficiently                                                                                         The internal and external wiring diagrams are important                                                                                         guides in  this generator or any generator                                                                                         model Be sure to have both with you and be sure they are                                                                                         for the specific model you will be working on                                                                                                                                        AC TERMINAL                                                                                                                                           BLOCK                   r                                                                                        6           2        5                                              8                                                                                5          A      I                                                                                                                                8                               rIIIIOO  c                                                    b                                                                       2                                                                           I 2           11                                                                                                                     i                                                                                                              1                                                                                                                                   3                                                                                                                                2                                                                                                                                7                                                                                                                                            6                                                                                                                                            3                                                                                                                                                      7                                                                                                                                                      8                                                                                         I         I                 I      1        2    1     2     3                                                                                                                                                               I                                                                                                                                                                                1                                                                                                       7P          I                                                                                                                     I                                                                                        I         I                 I                                                                       t 3     J          I   3       J                                                                       z                                                                                      11111011                           RED                      Ji        ffi                    YELLOW  RED                                                                                                                                                                                                                                    trI                                                                                                                  f                  REDfKJ AC             BLACK                  RED                                         5         6                                                            s              GREEN              N                  AC      g                                                                                                                                                 w                                                                                                                                                                                                          w                       F           GREEN                                                                                   3         3                                                                                                                                                              cc        cc          YELLOW                                                           I YELLOW                                               GREEN                                                                                                                           8          BLACK                                                                                          I                                           BLACK                                                           BLACK                                                              BLACK                                                                       BLUE                                  1 AVRI                                     BLUE                                                                                                                           t        60 eye                                                                                                                                    so eye                                   YELLOW                                      PLUG                                                           INTERNAL WIRING SCHEMATIC  MODEL 100 BTDA EXCITER STATOR WINDINGS I  2                                                         D COMPOUND TRANSFORMER   AI and A2 Exciter Stator Windings                                                      1 Compound Transformer Windings   Selector in COMP position                                                              2 Compound Transformer WindingsB EXCITER ROTOR                                                                            3 Compound Transformer Auxiliary   1 Auxiliary Windings abc                                                               Windings with VoltageHertz Connection Bar   2 Diodes 6                                                                         E SELECTOR SWITCH   3 Rotating Field Windings                                                               FI Compound   4 Poziresistor                                                                         F2 Electronic and CompoundC MAIN STATOR                                                                           F BRIDGE RECTIFIER WIRING   1 Main Stator Windings                                                                                         AVR Optional Automatic Voltage Regulator Plug 6 prong   2 Main Stator Windings   3 Main Stator Auxiliary Windings                                                                               Engines  Generators                                                                                   110                                 100 BTD GENERATOR        NOTE The following is a list of faults with the generator operation on compound COMP transformer       regulation no A vR installed               FAULT                                         CAUSE                                                    CORRECTIONLow Voltage 70 volts at NIL and loss of     1 Selector switch in wrong position             1 Place selector switch in COMP  as load is applied no loss of enginespeed and hertzHigh voltage at NIL 125 135 volts with     1 Generators engine speed rpm high at NIL 1 Check NIL speed and adjust NIL voltagecorrect voltage when loaded115  120 vOltsHigh voltage at NIL and FL                  1 Generators engine speed rpm high           1 Check NIL rpm and adjust NIL voltage                                              2 Short in compound transformer auxiliary        2 Check continuity and connections of 03 windings                                                 windings 03Low voltage at NIL 0  5 volts with         1 Main stator windings shorted C1 C2         1 Check continuity and resistance values of C1 C2  noise from generator and loss of                                                          and connections Excite unit with 12 VDCengine speed when load is applied            2 Compound transformer windings shorted          2 Check continuity and resistance values of 01 02 windings                                                 0102                                          Excite unit with 12 VDCGenerator does not excite voltage is         1 Generators engine speed rpm is slow        1 Adjust the engines speed and adjust NIL voltageovolts at NIL                                              2 Short in the main stator windings or           2 Excite the unit with 12 VDC Short will appear as a                                                 in transformer                                   load on the engine growling of the generator                                              3 Failed diodes on exciter rotor                3 Check the diodes on the exciter rotor Four or more                                                                                                   failed diodes will terminate the rotating field                                              4 Shorted poziresistor                         4 Visually examine the poziresistor on the exciter rotor The                                                                                                   shorted resistor will be bumt This will short out the rotating                                                                                                   field Remove and test runLow voltage at NIL 10  20 volts when      1 Diodess in rotating exciter B2 shorted   1 Check B1 and B2 in the rotating exciter as explained inload is applied voltage drops                                                                    this manual                                              2 Bridge rectifier defective                    2 Follow test procedure for the bridge rectifier                                              3 Auxiliary windings B1 shorted                3 Check the continuity and resistance values                                              4 Auxiliary windings 03 andlor C3 open        4 Check the continuity and resistance values of windings and                                                                                                    correct at NIL but not at FIL with   1 Selector switch in ELEC position              1 Place selector switch in COMPloss of engine rpm hertz                                              2 Exciter stator windings A1 and A2            2 Check continuity and resistance values of A2 windings                                                 are open                                              3 Generators engine speed is low               3 Check generator NIL rpm and adjust NIL voltageVoltage correct at NIL but not at FIL with   1 Generator overload                            1 Check data plate and monitor load on generator withloss of engine rpm hertz                                                                        ampprobe                                              2 Low power factor load motor loads           2 Check type of load applied Consider use of optional                                                                                                   regulator boardUnstable voltage                             1 Engines rpm fluctuating                      1 Check the engine operation and the fuel systemLow voltage at NIL and voltage drops          1 Diodes in exciter rotor shorted B2         1 Check the diodes in the exciter rotor as  as a load is applied                                                                      in this manual                                              2 Auxiliary windings in exciter rotor shorted    2 Check the resistance values and continuity to ground                                                 B2Voltage OK at NIL and low at FIL             1 Auxiliary windings in the exciter rotor       1 Check resistance values and continuity to ground                                              2 Exciter stator compound windings A2           2 Check continuity and connection of windings                                                 is open                                              3 Auxiliary windings 03 or C3 open            3 Check continuity and connection of  unstable                             1 Defective regulator board                     1 Check stability of DC voltage from regulator to exciter stator                                                                                                   windings Operate unit on COMP Replace regulator board                                              2 Engine is hunting                             2 Check engine operation and the fuel system                                              3 Electrical connections                        3 Check for clean and secure connections                                                                       Engines  Generators                                                                               111                           100 BTD GENERATOR  VOLTAGE CHECK                                                        failed components that can produce this same novoltage                                                                              output are the poziresistor in the exciter rotor and 4 or1 Residual Voltage 1014 voltsAC                                                                              more failed diodes in the exciter rotor   NOTE The amount of noload voltage produced by the                        a Apply 12 volt DC excitation to the exciter stator   generator can be an indicator of where in the generator                                                                                 windings as explained in paragraph 2 A fault in the   the problemfault may lie                                                                                 main stator andor compound transformer windings   This voltage is the AC voltage produced by the generator                      such as a short will cause the generator engine to load   from magnetism in the exciter stator field This voltage is                   down and the shorted windings to eventually produce   measured between the AC neutral and hot legs with no                       smoke as the excitation is continued   load on the generator running at 60 hertz                                                                          4 Voltage output greater than residual and less than rated   The presence of residual voltage is an indication that the                output 25100 volts indicates a fault in the exciter   following generator components are OK                                    rotorfield B1 B2 B3 Excitation of the generator as      1   Exciter Rotor B1 a b  C  B2                             explained in paragraph 2 should produce a partial rise in      2   Rotating Field B3                                              voltage output and when removed the voltage will      3   Main Stator C1  C2                                           return to the original low output      4   Compound Transformer D1  D2                                                                          BRIDGE RECTIFIER   The fault lies in one or more of the following compo                                                                          The bridge rectifier is supplied AC voltage from the auxiliary   nents in the exciter circuit                                                                           windings in the generator stator C3 and the compound      A    Exciter Stator A1  A2                                      transformer D3 The AC voltage measured across the AC      B   Bridge Rectifier G                                            terminals of the rectifier during engine operation is as follows      C   Selector Switch F      D   Main Stator Auxiliary Windings C3                                                                                           120 Volts                  120240      E   Compound Transformer Auxiliary Winding D3                                   NL FL                    NL FL                                                                                          1020 volts AC              1020 volts AC2 Twelve 12 volts DC excitation of the exciter stator   windings should cause the generator to produce between                 Diodes in the rectifier convert this AC voltage to DC and   140150 volts AC between each hot lead and the neutral                supply it to the windings A1 and A2 of the exciter stator   Twelve volts DC is applied between the lifted  and                 to induce a field through which the exciter rotor revolves    leads of the bridge rectifier  to  and  to                  The DC voltage measured across the  and  terminals of   Correct voltage produced with twelve volts DC excitation               the bridge rectifier during engine operation is as follows   indicates the fault is in one or more of the above listed                              120 Volts                  120240   components B D or E If the generator does not produce   140150 volts AC then include A and C                                                NLFL                     NLFL                                                                                          1020 volts AC              1020 volts AC3 The absence of any voltage from the generator indicates   a fault with the main stator windings C1 and C2 andor               Failure of the bridge rectifier will result in a weak field being   the compound transformer windings D1 and D2 Other                   produced by the exciter stator windings A weak field is pre                                                                          sent due to the magnetism in the exciter stator which will                                                                          cause the generator to produce residual voltage                                                                                                                                                                                                                                                      J                                          f                                  BATTERY                                    CONNECTION                                                                                                                                                                   DC J RED                                                                                                BRIDGE RECTIFIER                                                             Engines  Generators                                                                     112                                   100 BTD GENERATOR  the Bridge Rectifier for Faults with                                    NOTE Different stylemodel meters may produce oppositean Ohmmeter                                                                     results from the above tests1 Set the ohmmeter scale on RX1 DC Zero the meter                         Should the rectifier fail any of these tests it is defective and                                                                                should be replaced2 Connect the  lead from the meter to point 4 With the    lead from the meter momentarily contact points 1   2 3 and 5 No deflection of the needle should occur   showing infinite resistance3 Remove the  lead from point 4 and connect the    lead to point 4 and with the  lead momentarily   touch points 1 2 and 3 The needle of the meter   should deflect showing a passage of meter voltage   through the diodes in the rectifier4 Touch point 5 with the  lead No deflection of the   needle should occurS Place the  lead of the meter on point 1 and the  on   point 3 No deflection of the needle should occur infi   nite resistance Reverse the connections and the same                                                                          POINT5                                                                                                                                   RECTIFIER   should occur                                                                                                                   MOUNTING HOLE                                                               INTERNAL WIRING DIAGRAM                               NOTE The AC terminal block has studs for 14 inch wire terminal ends Multistrand                               copper wire should be used and sized for the amperage rating of the generator                                                                 rl            ril                                ACTERMINAL                                                                                 I       I                  I                           BLOCK               rl                                             I       I                  I                                                                      1 111                                                                                                                              6                  aoo                                                                                                                                       2        5                                    8                                                                                         5     A                                                                                     1                                          8                                                                                                                                       6        7                I                                                 Ii                                                                                                                              3                                                                                                                              2                                             4                                                              I                                                                                             IIIIIII 7                                                                                                    2                                          b                                                                                         3        8                                                                                 I       I          2                12                     3                                        F               1                               I               I       l                  I                                                                      3         1       1 2       3       I                                                                 1    I       l1      rJ                                                                               IIIIII                 RED                                                      YELLOW  RED                                                                                                I              REDYL AC                               BLACK                RED         GREEN                                         rr r           AC g               F 1                                                                                                              w                                                         ul                                  GREEN                                                                                                 3                                                                                                                                            CQ    YELLOW                    I   YELLOW                                                                                      GREEN    BCK                                                      J                BLACK                                 BCK                          i          BLACK                 BLUE                                                  60 eye                                                                     AVR                              BLUE                                                                      PLUG                                                        SOeyc                               YelLOW                                                                      Engines  Generators                                                                          113                                       100 BTD GENERATOR   COMPONENT RESISTANCE VALUES  NOTE Resistance Values at 7fF 2rC  Simson Meter 260 Model  A Exciter Stator                    D Main Stator Auxiliary Windings     A1  A2 115 ohm                   C3 099 ohm     A1 494 ohm                      E Compound Transformer     A2 129 ohm                         D1 0007 ohm  B Exciter RotorField                  D2 0007 ohm     B1 105 ohm                      Transformer Auxiliary Windings     B2 87 ohm                          D3 502ohm  C Main Stator     C1 0117 ohm                                              COMPONENT RESISTANCE CHECKS     C2 0117 ohm                                                       Exciter Stator Windings                                                                         r1                      r                                                                                                                                                ACTERMINAL                                                                                                                                                    I                                                                                       C                                                                                                          I                                                                                                                                                                                                                        I                                                                                                                  D                                                                                                                                                          BLOCK                           rl                                                                                               I                                     6        2         5                                                                          i                                 I                                                 B                                                                                     5                  A                                                                                                                    8                      r               a                 a                                                                                       6         7             1                                                                          I                      I          I                                                                          I                                                              3                                                     I                                                                                        4                                                         b               11                                                                                   2                                                                                                  1 1                                                                                                                  2                                                                                                                        I i                                                                                                                                         2                                                                                                                                         7       3       8              1                                        2            1                                                                            2                                                                         I                                                                          I                                                                          I                                                                          I                                                                          I                                                                                                                                                                                                  I                                                                                                 I                                                                                                 1                                                                                                            I                                                                                                            I                                                                                                            I                                                                                                            I                                                                                                            I                                                                                                                r                                                                                                                            I                                                                                                                            I                                                                                                                            I                                                                                                                            I                                                                                                                            I                                                                                                 I          I                                                                        I                                                 I                                                                                       3                     2                                                                                                 J                                                                                                                                                                                                                     3                                                                          I                                                 I                                                                                                                         J             no                                                                                                            IIII III                      GREEN                            RED                          RED                                                                  F                                     I                                                                                                      GREEN                                                      AC                                                                                                                i                                                          ACg                                                                                                                                                    II                                                                         III                                                                          BLACK                                                                                                YELlOW  RED                                                                                                      RED                                                                                                      GREEN                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    E                                                                                                                                                      w                                                                                                                                                                                                                                                                                                            en                  YEllOW   i                                                                  I      YELLOW                                             j                                                                                                                                t                                                             BLACK                  BLACK                               i                                                                                                       BLACK                                                             BLACK                                                      BLUE                                                                                   IAVAI                              BLUE                50cyc                                       YEllOW                                 I PLUG       1A Windings 1  2                                             A Winding 1                                              A Winding 2Resistance readings for exciter windings                     Resistance reading for exciter winding                   Resistance readings for exciter windingA1 and A2 with the selector switch in                      A1 with the selector switch in the                      A2 with selector switch in the ELECthe COMP position are taken between                          ELEC position is taken between the yel                  position is taken between the green the positive  and negative  leads                      low  white striped wire and the black                   white striped wire lifted off the  terlifted off the bridge rectifier G Neither                  white striped wire at the AVR plug                 minal of the bridge rectifier G and theof these two leads should have continu                                                                               red  white striped wires lifted off theity to the generator caseground                                                                                      terminal of the bridge rectifier G                                                                                   Engines  Generators                                                                                           114                             100 BTD GENERATOR  ROTORFIELD                                                  The diodes can be easily checked in place with the use of a                                                                     common automotive 12volt high beam headlight bulb someAuxiliary windings group a b and c Locate the three                                                                     jumper leads and the generators 12 volt starting  points on the exciter rotor for these auxiliary winding groups Position the exciter rotor as shown in the illustra     A short or an open in a diode can easily be found with thetion and count off the porcelain knobs from the 12 oclock           above without having to unsolder and isolate each diode topoint either left or right to locate terminal points a band c      check it with an  the resistance value between the pairs of terminal           NOTE Attempting to check diodes in place with an ohmmeterpoints A  B B  C and C  A There is no need to                  will give erroneous readings on the diodes due to the auxilunsolder these connections unless a faulty reading appears If       iary windings  occurs unsolder and verify the winding fault There                                                                     When leads are put across the diode as illustrated voltageshould be no continuity found between any of the three                                                                     passes through the diode allowing the headlight to glowterminal points and the rotor shaftcase ground                                                                     brightly                             Red  White                                                                       HIGH BEAM 12 VOLT BULB                                                                                                               GLOWS BRIGHT                                                                                                                                                    o12 VOLT                                                                           BATIERY                                                                     Reverse the leads across the diode The diode should block                                                                     voltage passing through it and the headlight should not glow                                                                     or it may glow faintly                                                                                                                 HIGH BEAM 12 VOLT BULB                                                                                                                 DOES NOT GLOWIS VERY FAINT                          EXCITER ROTORRotating Field Windings See the illustration of the exciterrotor The field winding connections are noted as the  and connections of the red  white striped wires Measure theresistance value with your ohmmeter between these two conneCtion points These connections need not be  a faulty reading appears If this occurs unsolder theconnection and verify the resistance reading With these connections lifted there should be no continuity to the rotor              a Should the bulb not glow with leads connected in bothshaft This would indicate a short to ground with these field               directions the diode is open                                                                          b Should the bulb glow with leads connected in bothDiodes Six diodes are mounted on the exciter rotor thOey                  directions the diode is shorted  the AC voltage produced by the three groups of auxil                                                                         In both a and b above the diode should be replacediary windings to DC voltages and supply this DC voltage to                                                                         Check the resistance values of the rotating field windingsthe rotating field windings                                                                         and the integrity of the resistors connected between the                         RESISTANCE VALUE                                field windings                                                                     Rotating Field Windings   7O ohm Reading taken         11 OHMS THROUGH THE DIODE         INFINITE BLOCKING                                           between the two red  white wires connected to the  and                                                                      terminals ofthe exciter rotor as shown in the illustration                            RESISTANCE                                                                     Posiresistor Infinite readings between both yellow leads    iLlI             r                           lifted from the  and  terminals on the exciter rotor                          INFINITE                                                           Engines  Generators                                                                   115                             100 BTD GENERATOR  STATOR WINDINGS                                                                lifted off the AC terminal of the bridge rectifier G and                                                                                    the yellow  red striped lead lifted off the VoltageHertz1 Group 1 The resistance value is measured between the                           Connection Bar There should be no continuity found   lifted lead 4 from the red insulated terminal below the                                                                                    between these winding connections and the caseground   transformer and lead 6 lifted from the AC terminal                                                                                    as well as the two main stator groups   block Also lifted from the AC terminal block is lead 5   so as to totally isolate the stator windings of group 1                         NOTE The VoltageHertz Connection Bar is located   see illustration                                                              below and just to the left of the A C terminal block2 Group 2 The resistance value is measured between the                        COMPOUND TRANSFORMER   lifted lead 1 from the red insulated terminal below the   transformer and lead 3 lifted from the AC terminal                           1 Group 1 Resistance value is measured between the lift   block Also lifted from the AC terminal block is lead 2                         ed lead 1 from the red insulated terminal stud below the   so as to totally isolate the stator windings of group 2                         transformer and lead 7 lifted off the AC terminal block   see illustration                                                           2 Group 2 Resistance value is measured between the lift                                                                                    ed lead 1 from the red insulated terminal stud below the                                                                                    transformer and lead 7 lifted off the AC terminal block                                                                                    NOTE None of the lifted leads should have a continuity to                                                                                    the caseground nor should either of the groups have                                                                                    continuity to the other                                                                                 3 Transformer Auxiliary Windings Resistance value is                                                                                    measured between the yellow  white striped wires lifted                                                                                    off the AC terminal of the bridge rectifier G with the                                                                                    selector switch in the ELEC position and the 1 red                                                                                     white striped leads lifted off the VoltageHertz                                                                                    Connection Bar Off this same bar lift the 2 and 3 red                                                                                     White striped leads that come from the auxiliary wind                                                                                    ings to totally isolate these windings There should be no                                                                                    continuity found from either of these connections to the                                                                                    caseground or to either of the two transformer groups                                                                                 SELECTOR SWITCH                                                                                 Selector switch F2 ELEC electronicAVR and compound                                                                                 transformer This is the optional configuration of the exciter                                                                                 circuit with the optional AVR installed                                                                                 NOTE With the selector switch in ELEC F2 position in                                                                                 which the exciter stator windings are divided one group is                                                                                 excited through the bridge rectifier and the other group                                                                                 through the A VR                                                    YellowlWhite                                                        TOP VIEW                                                                   BlackIWhite                  BrownlYellow                                                                    YELLOWYELLOW        ENGINE SIDE                                                                                                                                                                                 YELLOW                                                                                                                                       OF SWITCH                                                                                                I                           RED                                                                                    BLACK    I                                                                                                                             I                                                                                                                      rGREEN                                                                                                                                       I                                                                                    BROWN    i                               rGREEN                                                                                    BLACK                                                                                             Y  CDMP                                                                                    YELLOW L                                                                                                                           mc                                                                                                                                                                                                                                                                                                                                                                     BEARING SIDE                 NOTE ON LATER MODELS THE WHITE STRIPE ON THE                                     OF SWITCH                 WIRE WAS REMOVED AND THE WIRE IS ASOLID COLOR   NOTE There should be no continuity found between any                         BRIDGE RECTIFIER WIRING   of the lifted stator leads and the case ground Also no                      The illustration shows the colorcoded striped wires at the   continuity should be found between the connections of                         two AC terminals and the colorcoded wires at the  and   the two groups                                                                DC terminals3 Main Stator Auxiliary Windings The resistance value                          NOTE When removing or reinstalling connections maintain   for these windings is measured between the black                             correct polarity connection on the  and  DC terminals   white and the brown  yellow d0uble lead connection                                                                    Engines  Generators                                                                           116                          100 BTD GENERATOR  VOLTAGE ADJUSTMENT                                        VOLTAGEHERlZ CONNECTION BARVoltage adjustment is made with the generator regulation          1 Locate the VoltageHertz Connection Barbeing governed by the compound transformer                       2 Refer to the illustration1 The selector switch must be in the COMP position              3 Connect the blue  white striped wire to either connec2 Operate the generator apply a moderate load momentari           tion A or B to correspond to the hertz that the genera   ly and remove it Note the voltage output from the gener         tor will be set to produce   ators 120 volt legs 220 volt 50 hertz The noload   voltage should be between 121124 volts at 61562                                             RED      RED              RED                                                                      BLUEWHITE                  WHITE      WHITE            WHITE   hertz 222226 volts at 515 52 hertz   NOTE The noload voltage should be adjusted to the volt   age produced by the generator once started and a   momentary load should be applied to excite the trans   former and then removed The voltage produced by the   generator after this momentary load is removed is no   load voltage                                                                       00000                       X           Y           Z3 To raise or lower the voltage shims of varying thickness   nonconductive material are placed or removed from                  BLUE       BLUE                RED         RED   under the steel laminated bar on top of the compound                  WHITE       WHITE                YELLOW WHITE   transformer The material used for shimming should not   soften at temperatures in the 176F 80C range A small                                                                      NOTE On some units A and B may be reversed To ensure   reduction in noload voltage 1 at 3 volts can sometimes                                                                      a proper connection be sure the blue  white striped   be accomplished by gently tapping the top of the laminat                                                                      leads coming offA or B go to the numbered terminal stud   ed steel bar to reduce the gap between the existing shims                                                                      on theAC terminal block 5 for 60 hertz and 6 for   and the transformer core                                                                      50 hertzVarying shim thickness by 001 inch 0025 mm will change                                                                      NOTE The placement of the blue  white wire from conthe noload voltage by 46 volts Adding shim thickness will                                                                      nection A to B or vice versa when converting to 50 Hzraise voltage lessening shim thickness will lower voltage                                                                      is only accomplished when the optional voltage regulator                                                                      is installed as well Disregard this wire connection                                                                      change if there is no voltage regulator installed                                                                  4 Connections X Yand Z are used to increase AC voltage                                                                     to the bridge rectifier under heavy AC amperage loads the                                                                     generator is supplying When this connection is moved                                                                     from X to Y or Z to increase AC output voltage under                                                                     load it will effect noload voltage and a noload adjust                                                                     ment using the compound transformer will be needed                                                        Engines  Generators                                                                117                           100 BTD GENERATOR                       115V 50Hz               230V 50Hz                  120V 60Hz                              120240V 60Hz                       0      0                t1    t1       II                                                                  11                       2       5               2        5                 II                           0       0                                                           o                                               6        7                6               7                            6                                                                         3               8                            3                                                                                                                                                                                               0                                         N              L1                              L1 N                                      L2 N                                                       AC VOLTAGE  The frame ground wire must be moved when changing                         Maximum voltage drop acceptablefrom 120 volts and J20240 volts 60 hertz to 220 volts 50                       atfull rated output ampshertz For making connections to the AC terminal block use                     60 hertz 108110 voltsterminal ends for li studs that will accept multistrand cop                 50 hertz 215220 voltsper wire sized for the amperage rating from the hot leadconnection                                                          Should the voltage drop below the proper rate loaded excita                                                                     tion can be increased to raise this voltage by  FREQUENCY                                                  connections on the VoltageHertz Connection Bar                                                                     Repositioning the two leads red  white and yellow 1 Frequency is a direct result of  speed                                                                     white from Z to Y or X will increase the loaded voltage out   1800 rpm 60 hertz 1500 rpm 50 hertz                           progressively in that order 2 To change generator frequency follow this procedure                                                                     NOTE Noload voltage may be effected needing readjustment    a Connect the AC output leads to the AC terminal                with the compound transformer Do not use these adjust       block following the diagrams                                ments to compensate for overload conditions being placed on    b On the VoltageHertz Bar reposition the blue  white         the  inductive motor type loads Loss of       striped lead to A or B to correspond to the hertz             generator hertz speed the result of overload will cause a       selected Note  this need only be performed when a           drop in voltage output       voltage regulator is installed                                                                                                                  G    c Start the engine monitor the voltage and adjust the       engine noload speed Adjust the diesel units by the                                                                                                                         BLACK    1         r                                                                                           a       linkage between the throttle arm and fuel solenoid                                                                                                       60 hertz noload speed 615620 hertz                                                      GREEN                                                                                                I         50 hertz noload speed 515520 hertz                                                       YEllOW    d After the noload hertz adjustment is made the no                                                                                              1I       BLACK                                                                                     load voltage may need to be readjusted In most cases       if the generator was producing the correct noload                                                                                                                                                                                                                                                                                                                               IAVR                                                                                                                                       PLUG       voltage at the previous hertz setting it would be cor       rect at the changed hertz setting                                                      INTERNAL WIRING SCHEMATIC       In the event it needs adjustment adjust the shim       thickness under the laminated steel bar of the trans                                             REOWHITE       former                                                                                           TO HERTZVOLTS BAR         60 hertz noload voltage 121124 volts                        BLUEWHITE                                                          BLACKWH ITE                                                                         TO PIN t8                                                          TO SELECTOR         50 hertz noload voltage 114118 volts                         TERM BLOCK 1                                       11 SWITCH                                    232238 volts                                                                          BLUEWHITE t                                       4 YELLOWWHITE     e Load the generator to the rated amperage output                    TO HERTZ                                                         TO SELECTOR       corresponding to the hertz speed of the generator                 VOLTS BAR                                                         SWITCH         Rated Loaded Speed                                                                              BLACKWHITE                    AVRPWG                                                                                                         TO BRIDGE RECTIFIER         60 hertz loaded speed 585590 hertz         50 hertz loaded speed 485490 hertz                     NOTE The voltage regulator was optional on early models                                                                     but is not available on later models                                                           Engines  Generators                                                                118           100 BTD GENERATOR 6 TERMINAL BLOCK                                  WIRING CONNECTIONS       Winding Connections Needed to Obtain the Proper Voltage and Frequency  NOTE Connections 1 and 4 are located on two red terminals below the compound transformer      6            5                       4 4                   8N  Ll 220V 50 Hz      6             5                       4 4                   8              C230V    N       6                    i     J7 Ll 120V 60                       5                    4 4                  8                                                                                                 Hz                                                              44          L2    240V     60 Hz                                                                   8                                G TERMIMAL BLOCK                   winding connections needed to obtain                   the voltage and frequency       NOTE Connections 1 and 4 are located on two red             terminals below the compound transformer                                       Engines  Generators                                            119                                                        DC ELECTRICAL SYSTEM                                       BT GENERATOR EARLY MODELS WIRING DIAGRAM 3451                          ARY                                                   BATTERY                                                                                       RETURN   1                     E1l  1 I                            i                                                           6ND TO BLOtK                          r                          I                            1CB                                12DA                          t1    SEE NDTNREMOVE JUMP R vtHNCONN C IN   R MOTCONTRO PANEL      Tel                 I                 I                 I                                                                                      I                                                                                      I                                                                                  I                                                                                                         I                           REMOTE CONTROL PANELeDPTloNAl                 I                 I                                           I                                           SEE                                                               I                                                               I                                    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                                                          S   r                                                                                                                                                                                                                                                                                                            kal                         4lojLIl             PREHEAT      I   STANDARD                                                                                                    INSTRUMENT                                                                                 START              WID                                                                                                    REAR VIEW                                                                                                                                                                                STOP           I                                                                                                                          continued                                                                        Engines  Generators                                                                              120                        DC ELECTRICAL SYSTEM    BT GENERATOR EARLY MODELS WIRING DIAGRAM 34651    Ali ONOFF SWITCH SHOUtD Se INSTALleD IN TillS CICUIT To DISCONNCCT Tile STFiRTIY    FRO THe ElATTERY IN AN eHeRGeNCY  WHeN LeAViNG THe BoIlT TWEWE VOL T    DIeSeL eNGINe STARTeRS TYPICALLY DRtlW zoo To 300 liMPS WileN CRANKING    Tile DURATiON OF INDIVIDuAL CRtlNKING cYCas SIIOVlD NOT eXCEeD 30 SeCONtS    A SWITCH VITII II CONTINUoll5 RIlTING o 175 IlMPS I1T 12 VO WItL NOII1llLLY    seRve THese FUNCTIONS SUT Il SWITCH I1tJST NeVER ee USED To lRKe THE    STARTeR CIRCUITo   THIS PRODUCT IS PROTeCTeD BY A IIRNIJAl RESET CIRCUIT BReAKeR LOCATeD    NepR THE STARTER AND AS CLOSE TO THE SOURI OF CURReNT AS PaSSleLE    EXCESSIVe CURRENT DRlJw flNYWHeRE IN THE mSTRUHENT PANEL WIRING                   OR    ENGINe WILL CAUSE THE BREAKER To TRIP IN TillS EVeNT MOST GENERRTORS WltL    SHUT DowN aeCAUSE THE OFENEI EJRfiRKER DISCONNECTS TilE FueL SUPPLY    THeREFORE TIle BUILDeRowNER lUST BE SURE THAT THe INSTRUHeNT PlNEI    WIRING liND EIGINE ARE INSTALLED TO PREVeNT coNTIiCT 6TWeN    ELCTRICAL DeVICoE AND SALT WIlTER MOST   STARTJR SOLeNOIDS DRAW ISAHPS THeREFORE THE VOLTAGE DROP IN THIS    CONDUCTOR lUST ae NO GREATER THfiN 10IN Tile AlTH FRo THE STANDf1Rt    START SowlTCII TO flNV ReMOTE SWITcHES ANt BACk To Till STANDARD STIITE SWTClI    IF TIllS REQUlRES  UlRGe CONDUCTORS Til EN f1 RELAY 111Y BE liDDED    To CONTROL TIfE STIIRTep SOLENOIO ITSelF                                   GENERATOR OPERATION                        PREHEAT DEPRESS PREHEAT SWITCH FOR 15 TO 60                                  SECONDS AS REQUIRED                        STARTDEPRESS BOTH PREHEAT AND START SWITCHES                          PREHEAT ALSO OVERIDES LOW OIL PRESSURE                                 SHUTDOWN CIRCUIT                                 WHEN GENERATOR STARTS RELEASE START                                 SWITC H ONLY CONTINUE HOLDING PREHEAT                                 SWITCH FORA FEW SECONDS UNTIL OIL                                 PRESSURE REACHES 20 PSI                        STOP DEPRESS STOP SWITCH UNTIL Tli E GENERATOR                          STOPS COMPLETELY                         WIRING SIZES TO REMOTE CONTROL PANEL     TERMINALS            o 16      1620    20 25   2532   32 40   4050   5065 1     TSI TO TS31        2        fO        10     9       8      7             T612 TO T632         14         12         12      10       10       I        6     T61   TO TB35       12         10         10       9        8        7              T614 TO T634         16         16         16      16       16       16        16     T521 TO T641         16         16         16      16       16       16        16     T82S TO T642         16         16         16      16       16       16         16                                            Engines  Generators                                                121                                  DC ELECTRICAL SYSTEM                     80 BTD  100 BTD GENERATORS WIRING DIAGRAM 36412                                                                                                                                                                                                                                                                1141U                                                                                                   114 REDIPUR                                                                                                                                           P                rVEL SOlEHOI                                                                                                                                                                                                                                                                                                         o                                                                   GROUND TO                                                                     ENG I NE                                                                                                                                                                                                                                                                                         OILdHHUR                                                                      BLOCK                                                                        1                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                BATTERT SWITCH r     L                                                                                                                                                                                                                                                                   LV                          112 TELIRED                                                                                                                                                                                                                                                                                                                        N                                                                                                                                                   EIWfII                                    114 TAM                                    I  BLU                                    114 BRM                                                                                                                                                                           114 PURIM                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                        REMOVE THIS                                                            JUMPER WHEM                                                            CONNECT I NG A                                                            REMOTE PANEL                                                                                                                                                                                                                                            N                                                                                                                                                                                                                                                                                               14 lUi                                                10  OWKT                                                II                                                 tl4 OIUl                      rl                      I                                                                                                                                            I                                                                                                                                                                                                                  41                                                                                                                                             i                                              140111                      I                                 IcnL                                                                                        lED                                                                               10 lED                                                                                                                                                                                                                                                            eAT                                                                                                                                                                                                                                                                                 sTCH                                                 WA                                                  loP                                                    o                                                                                                                                                                                                                          eMA                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                       START                                                                                                                                sTCH                                                                                                  A                                                                                                                                                                                                                                                               10 DInT                                                  YCllT                                          MEnR                       L                                                                                                                                        J                                                        Engines  Generators                                                               122                                  DC ELECTRICAL SYSTEM                     80 BTD  100 BTD GENERATORS WIRING SCHEMATIC 36412                                                  STARTER     BATTERY                                    SOLENOID                    STARTER      SWITCH                                     r     I    I                                                 L    I                                PREHEAT                               SOLENOID                                           GLOWPLUGS                               rI                               L    I                                                                                  ALTERNATOR                                                                                     B                                                              r                                                              1     10 AMP                                                                   I CI RCU IT   120 AMP    I CIRCUIT     BREAKER                                                                    BREAKERI                              START                             SWITCHr   I EMERGENCYI   I STOPI   I SWITCH                r    1 PREHEAT                I       SWITCH                                                                 FUEL PUMP                I     r   II     STOP    I SWI TCHI   I                                                                                     FUEL SOLENOID                          EXHAUST TEMP         WATER TEMP           OIL PRESSURE                             SWITCH               SWITCH                 SWITCH                                                                                  VOLTMETER    HOURMETER                OIL                         WATER                PRESS                      TEMP                SENDER                      SENDER                                                     Engines  Generators                                                         123                                                     Be                                                           meter capable of reading less than one ohm due to the preci                                                                     sion required in reading component winding resistances andThe Be generator s a self exciting self regulating brushless      a nine volt dry cell battery with two jumper leads to use intype unit These three features help make the Be a basic unit        exciter field excitationto understand and troubleshoot Frequency and voltage output depends directly on the  speed                  NOTE Do not always rely on the vessels instruments forTherefore proper adjustment and maintenance of the internal         accurate readings bring your own  action is of prime importance                              Before attempting any repairs get as clear an explanation of                                                                     the problem as possible preferably from someone who  GUIDE                                                witnessed the problem In some cases this may bring to lightThis  guide is designed to solve problems             a problem which is related to the method of operation ratherwhich may be encountered with the Westerbeke Be single               than an equipment faultand dual capacitor brushless generators Most potential              Bring basic repair parts with you on your initial trip o theproblems are covered in this guide Owing to the simplicity          problem equipment such as a regulator board when mstalledof the equipment and controls the  is relative      diodes and bridge rectifier so if the problem should be foundly easy once the relationship between cause and effect is          in one of these easily replaceable parts the problem can beunderstood                                                          remedied early and  in mind that a fundamental knowledge of electricity is          The internal and external wiring diagrams are important toolsrequired for this  and always remember that          in  this generator or any generator modellethal voltages are present in the circuitry therefore extreme     Make sure the wiring diagram you use is for the  is essential when working on or  a            model you are working  a few basic tools are necessary for diagnosis and repairThese are hand tools an ampprobe and a quality voltohm                                                           Engines  Generators                                                                   124                       Be GENERATOR                                                                        o                       r                                                                                                 DC                                  ACCHARGE                                  AC       f                                     IC      I     I     I                                          BRIDGE                                  INTEGRAL     I                 I                       RECTIFIER                               CONTROLLER     I                 I     I                 I     I                 I                                          DIO                     01                      I     I     I                                                  TI             BALLAST RESISTOR     I                                                  EI     I                                  R     I                                                  M                                          60HZ            DC     I     I                              021                                        N                                                                                                         r   CHARGE     I                        u3AA  Il                            o4 L                    B                                          IC                                                        B                                                        L                                          INTEGRAL     I                                                                                                 CONTROLLER     I     IDIODE                                             8                       EARLIER MODELS     I                        osK     I     I                        06     I                  I               rJ                                     1         4        3     I                  I                          I                                    000     I                  I                          I     I             I                                                                                        S          2       6                        I     I     L  JI    I                                                               000                        I                        I                              c                           TERMINAL BLOCK                        7                         I                            CPACITOpRS                         tCAPAICITOR   t                                 L    11                        I               I                                                 I         L                     I                               60 BCD                                44 BCD                       INTERNAL WIRING SCHEMATIC WITH BAnERY CHARGING CIRCUIT                                   COMPONENTS                                  A Rotating Field and Diodes                                  B Main Stator Windings                                   C Exciter Windings and Capacitors                                  D Battery Charging Circuit                                              Engines  Generators                                                       125                                         Be GENERATOR                  FAULT                                      CAUSE                                                CORRECTION No AC output at noload                    1 Main stator winding open or shorted        1 Excite unit with 12VDC                                                                                            2 Check stator windings Residual voltage 46 volts at NIL          1 Faulty capacitor                           1 Perform capacitor check                                             2 Faulty electrical connections              2 Check all electrical connections to ensure they are clean                                                                                               and tight                                             3 Engine speed is too slow                   3 Adjust engine speed to correct NIL hertz                                             4 Faulty exciter winding                     4 Check winding resistance value Check winding residual                                                                                               voltage output High noload AV voltage output             1 Engine speed is too fast                   1 Adjust engine speed to correct noload hertz                                             2 Noload voltage tap at capacitor           2 Change tap to lower number Correct noload voltage Load applied       1 Faulty diode                               1 Isolate diodes and check for short voltage drops to 6080 volts                                             2 Rotor windings                             2                                             3 Poor governor reaction                     3 Check engine speed under load Adjustrepair governor                                                                                               as needed                                             4 Overload on generator                      4 Check engine speed Monitor amperage draw with ampprobe Correct noload voltage but high voltage   1 Engine speed is too fast                   1 Check engine speed Adjustrepair governor as needed output when load applied Unstable voltage output                    1 Poor governor reaction                     1 Check govemor Adjust or repair as needed                                             2 Loose electrical connections               2 Check the security and cleanliness of electrical connections lIoisy generator                          1 Repair support bearing faulty              1 Inspect rear bearing                                             2 Unbalanced load 120240 wired            2 Monitor amperage draw from each leg using ampprobe                                             3 Generator rotor connection to engine        3 Check rotor security                                                is loose                            A WARNING Lethal IIoltage is present at an operating generator When making                                   connection changes or checking connections always stop the  FIELDAUXIUARY WINDINGS                                                    NOTE The shield in front of the diode can be bent carefully                                                                                    outboard to improve access to the diodeAND DIODES                                                                                    With the diode removed both leads for the first group ofTwo sets of windings are found on the rotating field An                                                                                    rotating fieldauxiliary windings will be isolated with noelectrical field is produced around these windings by the                                                                                    interference from a posibly faulty diodepassing of DC voltage through them As these windingsrotate this field passes through the main stator windings                         Check the resistance value of the rotating windings by placinducing an AC voltage that is available at the terminal                           ing the ohmmeters leads across the two exposed leadsblock to be directed to a load A separate group of windings                        Also verify that no continuity exists between these windingsfor the battery charging circuit is effected by this rotating                       and the rotor shaft by leaving one ohmmeter lead attached tofield These windings produce an AC voltage that is directed                        the winding lead and the other ohmmeter lead touching theinto the bridge rectifier that converts it to DC voltage for the                    shaft no continuity should exist If continuity is found abattery charging controller                                                        short exists1 Rotating FieldAuxiliary Windings                                                Repeat this same check on the second group of windings    Single Capacitor               Dual Capicator                                   Rotate the engines crankshaft 180 to position the second       38 ohms                      40 ohms                                       diode and connections at 1200 oclockTo check the resistance values rotate the engines crankshaftto position the diodes on the rotors shaft at 1200 oclockTo make a quick check of these windings presume the diodeis OK and place one of the ohmmeters leads on the connection at the top of the diode and the other lead at the connection at the base of the diode Compare readings with thevalue above If a distinct difference is noted in the ohm                                                                                      DIODEvalue carefully unsolder the lead on the top of the diode andremove the diode from the rotor using a thin walled deepwell 11 mm 716 socket                                                                                                                  REAR CARRIER                                                                                                                                           BEARING                                                                     Engines  Generators                                                                            126                                             Be GENERATOR     2 Diodes                                                                Residual voltage measured between line to neutral will be       8  95 ohm approximate                                            46 volts AC between each pair of leads at the terminal       Use a 260 Simpson Analog Meter                                       block This would be an indication that the stator windings                                                                             are OK Check exciter windings and artifically excite the       To check the diode unsolder the connection from the top              generator       of the diode Place one ohmmeter lead on the connection       at the top of the diode and the other ohmmeter lead to the            Group 1  Measure the resistance value between the                                                                             terminal with lead 1 and the terminal with lead 3 Check       diodes base Then reverse the position of the ohmmeter       leads                                                                that there is no continuity of Group 1 windings to the case                                                                             ground       A low resistance should be found with the leads in one                                                                             Group 2  Measure the resistance value between the       direction and infinite resistance blocking in the other                                                                             terminal with lead 4 and the terminal with lead 6 Check       direction                                                                             that there is no continuity of Group 2 windings to the case       Diode Rating 1600 volts 26 amps                                      ground       The diodes rating is far in excess of the circuits require         Check for a possible short between the two groups of stator       ments A diode failure could result from an overspeed or              windings by placing one lead of the ohmmeter on the termi       load surge or a manufacturing defect                                nal with stator lead 3 and the other ohmmeter lead on the                                                                             terminal with stator lead 6 There should be no continuity                                                                             between the two groups of stator windings                               r                               C                               e                                            EXCITER WINDINGS AND CAPACITORS                               a                               m                               en                               n                                            Single Capacitor Unit 19 ohm                                                                          Dual Capacitor Unit 22 ohm                                                              z                               m                                                                                                                                                        I                                                                                                                                                                                                    I                                                                                            I                                                                                            I                                                                                            I 50                    DIODE                                                                   IHz                               J                                                            I                                                                                            I                                                                                                                                                                                        I                                                                                                   tirCITOrrt    MAIN STATOR WINDINGS                                                                    1 I    Single Capacitor Unit            Dual Capacitor Unit   BCAModel          An AC voltage is induced in these windings by the rotating         06 ohm                          04 ohm           03 ohm          field Checking the residual voltage output from this winding    To check the main stator winding values at the AC terminal               can determine the condition of the winding when    block first remove all AC output leads the ground connec                  tion and all brass interconnects from the terminals on the                   Single Capacitor Model 1014 volts AC    block This will isolate the 6 leads on the terminal block                    Dual Capacitor Model 1416 volts AC    which make up the two main stator groups                                                                                                                An AC voltage can be measured across the capacitors while    NOTE The numbered leads on the terminal block are not in               the generator is operating This voltage may be as high as    any particular numerical order They are as shown below                450 to 500 volts AC This voltage buildup is accomplished as                                                                            the exciter windings charge the Q8pacitors and the capaci      r                                                    tors discharge back into the exciter windings This AC volt             001                                                    age reading is taken between the 60 hertz connector and the                                                                             connection plugged into the capacitors while the genera                                                                            tor is operating at its rated hertz 6L5620                                                       1    4     3                                                      0     0     0          This flow of saturating AC voltage in the exciter windings                                         2                                                       5    2     6                                                                             produces a phaseimbalance type of field that effects the                                         3                                   rotating auxiliary windings a beneficial result that produces                                                      0     0     0                                         4                                   good motor starting  for this type of generator                                                       TERMINAL BLOCK        To measure the resistance value of the exciter windings                                                                             locate the 9 and the 50 hertz capacitor connections             105                                                       NOTE Three numbered capacitor connections exist 7 8             06      L               J                                                                             and 9 and two hertz connections 50 and 60                                                                             Unplug any other connections from the capacitors noting                                                                             their position on the capacitor                                                                   Engines  Generators                                                                        127                                   Be GENERATOR  one lead of the ohmmeter on plug connection 9 and               NOTE The older single capacitor models used a 250the other lead on plug connection 50 hertz Measure the               microfarad capacitor All new model single  value of the exciter windings Check to make sure           units now have a 35 microfarad capacitor Whenthere is no continuity to the  case from               replacing a capacitor in either an early model or a latereither of the two leads Also check that no continuity exists          mode ensure that the correct rated capacitor isbetween either the 50 hertz plug or the 9 plug and any of            installed The capacitor rating is marked on the housingthe main stator winding leads on the AC terminal block see            of the capacitorMAIN STATOR WINDINGS If continuity is found here a                  250 Microfarad Capacitor  PN 035985fault exists between these two winding groups                         35 Microfarad Capacitor  PN 0359781 Field Testing the Capacitors                                   3 12 Volt DC Excitation low or no AC output voltage    With a capacitor meter test the capacitor following the            The generator can be excited using 12 volts DC taken    instructions found with the meter and compare the                  from the engines starting battery This voltage is applied    results with the value shown on the capacitor                      across the 50 and 9 leads of the exciter circuit wind    When a capacitor meter is not available follow this                ings with any other numbered leads unplugged from the    simple field test                                                  capacitors The generators reaction during flashing will                                                                        help determine its fault    a Unplug connections from the capacitor NOTE Mark       on the connections so they can be reintalled       correctly                                                                                              12 VDe                                                                                           FIELD TESTING CAPACITORS                                                                                    12 VDe    b With a jumper short across the two connections on       each capacitor that the two leads in step a above       were unplugged from This will make sure the       capacitor is discharged as it should be at shutdown    c With your ohmmeter set on the high R scale place its       plus  lead on one capacitor connection and the neg                                                                                              ative  lead on the other capacitor connection A       resistance should be read and should rise slowly as the       meter attempts to charge the capacitor This indicates       a presumably good capacitor                                     During 12 Volt Excitation    d Indications of a defective capacitor                            Output voltage normal range       1 Zero resistanceno rise in resistance value shorted           Single Capacitor Unit     Dual Capacitor Unit          capacity                                                        2226 VAC                 2428VAC       2 Infinite resistance  open capacitor                       8   A slight rise in output voltage with a loading of the       3 No continuity should be found between the capaci                  engine andor a growling noise from the generator end          tors connections apd the capacitors case or base                will indicate a fault in the main stator windings2 Capacitor Ratings Capacitor Meter                                  b No rise or a very slight rise in the output voltage will    Note Ratings are found on the capacitor case                         indicate a fault in the exciter windings Check the                                                                           ohms values for the exciter windings    Single Capacitor Units 250 microfarads UiF 5                                                                         c Normal output voltage as specified above check    Dual Capacitor Units 315 microfarads UiF 5                                                                            exciter circuit capacitors                                                           Engines  Generators                                                                 128                                   Be GENERATOR  CHARGING CIRCUIT                                                    c Remove the positive  lead from point 4 and con                                                                              nect the negative  lead to point 4 and with theNOTE This circuit is totally separate from the A C output of                 positive  lead from the meter momentarily touchthe generator TheAC output of the generator affects this cir                points 1 2 and 3 The needle should deflect showcuits output but not the reverse                                           ing passage through the diodes in the rectifier1 Bridge Rectifier                                                        d With the negative  lead still attached to point 4   Normal AC voltage to rectifier engine operating at 1800                   touch point 5 with the positive  lead The needle   rpm This voltage is measured across the two AC con                      should not deflect   nections on the bridge rectifier                                       e Placethe positive  lead of the meter on point 1   AC voltage to the bridge rectifier approximate                          and the negative  lead on point 3 The needle                                                                              should not deflect infinite resistance Reverse the   8   Noload off generator  160 volts AC                                 leads to 1 and 3 Again there should be no deflec   b FuIlload off generator  175 volts AC                                 tionIf the rectifier fails any of the above tests 8   Normal DC voltage out of rectifier This voltage is                        through e the rectifier is defective and should be   measured across the two DC connections on the bridge                       replaced   rectifier                                                             NOTE Test meter polarity may be reversed If so the test   DC Voltage from the rectifier approximate                           results will be reversed   8   Noload off generator170 volts DC                            3 Ballast Resistor 03 ohm   b FuIlload off generator  185 volts DC                             Early model integral controllers have a ballast resistor                                                                          installed along the DC plus  lead running from the2 AC Stator Winding 014 ohms                                           bridge rectifier to the integral controller This coiltype   Lift the two AC leads off the bridge rectifier and measure             resistor functions to suppress high amperage draw   the resistance value between these two leads with an                   coming from the controller when it is trying to charge a   ohmmeter This measurement should register 014 ohms                  discharged starting battery   No continuity should exist between either of these two   leads and the ground                                                             BALLAST RESISTOR                                                        DC                                              60 Hz             DC                                                                                                                         CHARGE                                                                                                                IC                                                                                                             INTEGRAL                                                                                                            CONTROLLER   To test the bridge rectifier if it is believed to be faulty   follow the test directions below                                      Early controllers having this resistor in the DC charging                                                                          circuit are of the threelead type These threelead types   8   Set the ohmmeter scale on RX1 DC Set the meter                consist of either three spade plugs in connections or        to zero                                                          three wire leads coming from the controIler   b Connect the positive  lead from the meter to point               The resistance value of the ballast coil is measured      4 With the negative  lead from the meter                      between the lifted  lead at the bridge rectifier and the      momentarily contact points 1 2 3 and 5 The                   60 hertz connection unplugged from the controller that      needle should not move showing infinite resistance                is controllers having plugs in the connector                                                                          Controllers with three leads coming from the controller                                                                          measure resistance between the unplugged 60 hertz con                                                                          nection at the bridge rectifier and the brown lead connec                                                                          tion on the coil resister terminal block                                                                       4 Integral Controller IC                                                                          The integral controller is an encapsulated solid state unit                                                                          that supplies a DC charging voltage to the generators                                                                          starting battery while the generator is operating                                                                                Charging Voltage 130 140 volts DC                                                                                Charging Amperage 0  10 amps DC                                                             Engines  Generators                                                                   129                                   Be GENERATOR    A separate group of stator windings supplies AC voltage   to a bridge rectifier that converts the AC current to DC   current to supply the integral controller unit The integral                                                                        A CAUTION Failure of the solenoid plunger to                                                                        bottom in the solenoid will result in a failed solenoid   controller unit senses the starting batterys needs and sup   plies a DC charge as needed If the integral controller is   believed to be faulty resulting in a low starting battery   check the charging circuit components D and all con           To avoid failure of the solenoid make sure the solenoid   nections in the circuit and to the battery for cleanliness       plunger bottoms in the solenoid Check the solenoids   and for tightness including the ground before replacing          operation at the initial startup Periodically lubricated link   the integral controller unit                                    age joints between the solenoid plunger and the throttle arm                                                                    will eliminate binding   NOTE When first started the integral controller unit will   produce a low charging rate This charging rate will rise        NOTE The solenoid plunger must move smoothly and rapidly   as the unit is operated                                         into the solenoid when the solenoid is electrically energized                                                                    drawing the engines throttle arm into the SET SPEEDRUN   New fourwire controllers eliminate the ballast resistor   circuit since the ballast resistors function is now handled     position   internally Whenever replacing an early style controller         50 Hertz  60 Hertz Adjustment   with the newer fourwire model remove the ballast resis        When increasing the length of the throttle adjustment link   tor and its wiring                                              age this increased length moves the throttle arm into a                                                                    slower speed range to be adjusted and secured in the 50 hertz                                                                    noload range Conversely shortening this throttle adjustment                                                                    linkage moves the throttle arm into a faster speed range to be                                                                    adjusted and secured in the 60 hertz noload range                                                                    NOTE On some models the solenoid attachment bracket is                                                                    slotted at its attachment to the engine to allow movement of                                                                    the bracket with the solenoid to make speed adjustments                                                                    Engine  Hertz Adjustment                                                                    The BC model generator is capable of 60 or 50 hertz opera                                                                    tion with corresponding AC output voltage The following                                                                    steps must be followed when changing the generators hertz                                                                    rating and corresponding AC voltage output                                                                    1 Terminal Block HertzAC Voltage            OUTPUT OC VOLTS ItHl2            ADJUSTMENT POD                                                To make the desired hertz and AC voltage change             OR  2 VDC                                                                          properly connect the AC terminal connection to the                                                                          generators terminal block see illustration Note the                                                                          positioning of the copper connectors between terminals   NOTE White  green negative  and white  black   ground are  Later model controllers   have solid color wires no white ie red yellow green   and blackGENERATOR FREQUENCY HERTZ ADJUSTMENTTo increase or decrease the speed of a diesel enginedriven                                                                                                                   26generator adjust the linkage between the throttle arm and thesolenoid plunger with the plunger completely bottomed inthe solenoid                                                                                                          1043       THROmE       ADJUSTMENT                                                                                         526       LINKAGE             FUEL SOLENOID                                                         110v50Hz                                                         Engines  Generators                                                                  130                                  Be GENERATOR  Capacitor Hertz Connections                                         4 Speed A4justment  Hertz   8   Single capacitor models One connection on the                    8   Adjust the linkage between the throttle arm and the        capacitor corresponds to the hertz speed of the gen                 fuel solenoid to produce the correct noload hertz        erator These connections are labeled 60 60 hertz              b Adjust the throttle arm against its stop to produce the        and 50 50 hertz Unplug the hertz connection that                 correct noload hertz        needs to be changed and plug in the hertz connection        required for the desired hertz rating                         NoLoad Voltage Adjustment                                                                       If the generator was producing the correct noload voltage                                                                       before the hertz change this adjustment may not be neces                                                                       sary In the event a noload adjustment is needed proceed as                                                                       follows                                                                       1 Shut off the generator                                      NOTE THE 7 PLUG                                      IS SHOWN CONNECTED                                                                           A WARNING DO NOT attempt to make a noload                                      TO THE CAPACITOR                                      ONLY AS AN EXAMPLE                                                                            voltage adjustment while the generator is operating                                                                            The capacitor can hold a 450500 volt charge                                                                            Touching any wiring can result in a severe electrical                                                                            shock In addition attempting to make a noload         A CAUTION Make sure the insulating covers                         voltage adjustment when the generator is operating         on the unused leads are in place and that the                      can cause fingers to be caught in the generators         leads never come in contact with each other or                     rotor         come in contact with the case                                                                       2 Refer to the illustrations before making any adjustments   b Dual capacitor models The capacitor on the left side               Note that there are three plugs grouped for the right      of the generator end contains the connections corre                capacitor terminal 7 8 and 9 If the generators no      sponding to the hertz speed produced by the genera               load voltage is low then disconnect the lower numbered      tor These connections are labeled 60 60 hertz and               plug and connect the plug with the next higher number If      50 50 hertz Unplug the hertz connection that needs              the generators noload voltage is high then disconnect      to be changed and plug in the hertz connection                      the higher numbered plug and connect the plug with the      required for the desired hertz rating                              next lower number Note that the plug presently con                                                                          nected to this terminal may be anyone of the three plugs                                                                          available         60Hz    50Hz LEAD    LEAD                                                                                                               NOTE THE 7 PLUG                                                                                                               IS SHOWN CONNECTED                                            NOTE THE 7 PLUG                                                  TO THE CAPACITOR                                               IS SHOWN CONNECTED                                                 ONLY AS AN EXAMPLE                                            TO THE CAPACITOR                                            ONLY AS AN EXAMPLE    A CAUTION Make sure the insulating covers on     the unused leads are in place and that the leads     never come in contact with each other or come in     contact with the case3 Integral Controller 3 Wire   Early model integral controllers of the 3 wire type had a   60 or 50 hertz connection The plugin type had a 60 or                                                      NOTE THE 117 PLUG                                                                                                                 IS SHOWN CONNECTED   50 lead plugged into the controller that corresponded to                                                     TO THE CAPACITOR                                                                                                                 ONLY AS AN EXAMPLE   the hertz produced Change this connection when chang   ing the generators hertz rating                                                           Engines  Generators                                                                 131                                         DC ELECTRICAL SYSTEM                           44 BC  60 BC GENERATOR WIRING DIAGRAM 35951                            WATER TEMP                                 SENDER                                        BlKtIl4                                                                                             FUEL                                                                                             SciLENOID                                                                                                                                                   q                                                                          z                                                                          ili                                                                                                                  OIL PRESSURE                                                                                                                                                                                                  01 L PRESSURE              BATTERY                                                                                                           CHARGER                   EMERGENCY STOP SWITCH                                                                  aJTPUT                                                                                                           r                                                                                                           r                                                                                                                     EQiER                                                                                                                     ALTERNATOR                                                                                                          EXHAUST                                                                                                          TEMP SWITCH SEENOTE        IT       21fl          I          I                    I     GROUND TO BLOCK        BATTERY                                                                                                                                                                                                                                                           PREHEAT                                                                                                                                                STANDAR   INSTRUMENT PANELJ                                                    Engines  Generators                                                        132                               DC ELECTRICAL SYSTEM         44 BC 60 BC GENERATOR WIRING SCHEMATIC 35951                                                    LJ                    SEE                     NOTE 2                                      START SOL              STARTER                                       r          M                                                                              OJ                 GLOWUGS                                                                 CB            L j20A                      PHSOL                                                                                      BATTERY                                                                                      CHARGER                                                                        EXHT SIN     OJ SW      WTSW            r lsTOP             I             I   J                    SW                                                   1                                                       J                                                   START SW                              PHSW                                              WT                                                                                        WTSNOR                                               oP tr4                                                                                         oPSNDR                                              VOLTS                                               HOURS           IINSTRUMiIL PANELSTARTING AND STOPPING  PUSH PREHEAT SWITCH FIRST HOLD FOR 15 TOGO SECONDS AS REOUIRED       2WHILE CONTINUING TO PUSH PREHEAT SWITCH PUSH START SWITCH       3 WHEN GENERATOR STARTS RELEASE START SWITCH ONLY       4WHEN OIL PRESSURE REACHES APPROXIMATELY 20PSI RELEASE PREHEAT SWITCH        THE PRElEAT SWITCH OVERIDES THE LOW OIL PRESSURE SHUTDOWN CIRCUIT        PUSH AND HOLD THE STOP SWITCH UNTIL THE GENERATOR STOPS COMPLETELYI THIS PROOUCT IS PROTECTED BY A MANUAL RESET CIRCUIT BREAKER LOCATED NEAR THE STARTER AND AS CLOSE TO THE SOUCE OF CUENT AS POSSIBLE EXCESSIVE CURRENT DRAW ANYWHERE IN THE INSTRUMENT PANEL OR ENGINE WIRING WILL CAUSE THE BREAKER TO TRIP IN THIS EVENT MOST GENERATORS WILL SHUT DOWN BECAUSE THE OPENED BREAKER DISCONNECTS THE FUEL SUPPLY THEREFORE THE BUILDEROWNER MUST BE SURE THAT THE INSTRUMENT PANEL AND ENGINE WIRING ARE INSTALLED 10 PREVENT CONTACT BETWEEN ELETRICAL DEVICES AND SALT WATER2AN ONOFF SWITCH SHOULD BE INSTALLED IN THIS CIRCUIT 10 DISCONNECT THE STARTER FROM THE  BATTERY IN AN EMERGENCY AND WHEN LEAVING THE BOAT TWELVE VOLT DIESEL ENGINE STARTERS TYPICALLY DRAW 200 TOO AMPS WillEN CRANKING THE DURATION OF INDIVIDUAL CRANKING CYCLES SHOULD NOT EXCEED 30 SECONDS A SWITCH WITH A CONTINUOUS RATING OF 175 AMPS AT 12VDC WILL NORMALLY SERVE THESE FUNCTIONS BUT A SWITCH MUST NEVER BE USED 10 MAKE THE STARTER CIRCUIT3MOST STARTER SOLENOIDS DRAW 15 AMPS THEREFORE THE VOLTAGE DROP IN THIS CONDUCTOR MUST BE NO GREATER THAN IOtON THE PATH FROM THE STANDARD START SWITCH TO ANY REMOTE SWITCHES AND BACK 10 THE STANDARD START SWITCH IF THIS REQUIRES IMPRACTICALLY LARGE CONDUCTORS THEN A RELAY MAY BE ADDED TO CONTROL THE STARTER SOLENOID ITSELF                                               Engines  Generators                                                           133               Engines   499

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