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Century 170 T6 Technical Manual



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   SERVICE MANUAL
            80N4 and 11OT4
           120N6 and 170T6
 MARINE DIESEL ENGINES
 45KW  60Hz                          35KW  50Hz BED
 55KW  60Hz                          45KW  50Hz BED
 65KW  60Hz                          55KW  50Hz BED
 95KW  60Hz                          80KW  50Hz BED
MARINE DIESEL GENERATORS
                 PUBLICATION NO.47069
                    FIRST EDITION
                    JANUARY 2002



  l~ rWESTERBEKE
       j    WESTERBEKE CORPORATION. MYLES STANDISH INDUSTRIAL PARK
          150 JOHN HANCOCK ROAD TAUNTON MA 02780-7319 TEL. (508)823-7677
           FAX (508)884-9688 WEBSITE: WWW.WESTERBEKE.COM


                -
              ~ M~mbu Nalional Marine Manujacturur AssocIation
  CALIFORNIA PROPOSITION 65
            WARNING
Exhaust gas from diesel and
gasoline engines (and some of
its constituents) are known to
the State of California to cause
cancer, birth defects, and other
reproductive harm.




                   AWARNING:
Exhaust gasses contain Carbon Monoxide, an odorless and
colorless gas. Carbon Monoxide is poisonous and can cause
unconsciousness and death. Symptoms of Carbon Monoxide
exposure can include:
-Dizziness                   - Throbbing in Temples
-Nausea                      - Muscular Twitching
-Headache                    - Vomiting
- Weakness and Sleepiness -Inability to Think Coherently

IF YOU OR ANYONE ELSE EXPERIENCE ANY OF THESE SYMPTOMS,
GET OUT INTO THE FRESH AIR IMMEDIATELY. If symptoms persist,
seek medical attention. Shut down the unit and do not restart
until it has been inspected and repaired.




A WARNING DECAL is provided by WESTERBEKE and
should be fixed to a bulkhead near your engine or
generator.
WESTERBEKE also recommends instal/ing CARBON
MONOXIDE DETECTORS in the living/sleeping quarters
of your vessel. They are inexpensive and easily
obtainable at your local marine store.
                                                      WARNING
                                                     Geneoators Produce CAABON MONOI:'.0::: -:::::;-:.:~1. 0.0.
                                                                                                  ROCKER ARM SHAFT                   T
                                                                                                                                        mm(in)
       ROCKER ARM                                                                                               Standard              Limit
                                                                                                                                 !
       ASSEMBLY                                                                                                                  I
                                                                                  Rocker Arm Bushing
                                                                                                               0.01 - 0.05              0.2
                                                                                  and Rocker Arm                                 I
                                                                                                           (0.0004 - 0.0020)         (0.0079)
                                                                                  Shaft Clearance                               I
                                                                                  3. Check that the rocker arm oil port is free of obstruc-
                                                                                     tions.
                                                                                     If necessary, use compressed air to clean the rocker
                                                                                     arm oil port.


                                                                       WESTERBEKE
                                                                       Engines & Generators

                                                                            21
                                             INSPECTION/REPAIR
IDLER GEAR AND IDLER GEAR SHAFT
1. Use a micrometer to measure the idler gear shaft                                          CAM BEARING
   outside diameter.                                                                                                  II
   If measured diameter exceeds          specified     limit,
   replace the idler gear shaft.
                                                     mm(in)
                             Standard              Limit
~---------------r-----------
Idler Gear Shaft                                   44.9          3. Align the camkshaft bearing oil holes with the mat-
Outside Diameter                                  (1.768)             ing oil ports (machined on the cylinder body cam-
                                                                      shaft bearing fitting bore).

    MEASURING
    IDLER GEAR SHAFT




 2. Use a dial indicator to measure the idler gear inside
    diameter.
                                                    mm
                                                                     4. Use a micrometer to measure the cam lobe height.
                              Standard             Limit
                                                                            If the cam lobe height is less than the specified li-
 Idler Gear and Idler                               0.2                     mit, the camshaft must be replaced.
 Gear Shafft Clearance                            (0.008)
                                                                                                                           mm(in)
                                                                                                     Standard         Limit
                                                                     Cam Lobe Height (C-D)         7.71 (0.304)    7.21 (0.284)

       MEASURING                                                     Cam Journal
       IDLER GEAR                                                                                  56.0 (2.205)    55.6 (2.189)
                                                                     Diameter A"B
       1.0.



CAMSHAFT
 1. Use the camshaft bearing remover and installer to
    remove camshaft bearing from the cylinder body.
    Camshaft Bearing Remover and Installer.

 2. Measure the clearance between the cam journal
    and the camshaft bearing.
                                                    mm(in)            I
                                                                       I
                              Standard             Limit
 Cam Journal and Cam
 Bearing Clearance
                             0.03 - 0.09
                           (0.001 - 0.004)
                                                   0.15
                                                  (0.006)
                                                                sE&.  1'-
                                             REMOVER
                                             ANO INSTALLER
                                                                                                     MEASURING THE CAMSHAFT




                                                      Engines & Generators

                                                                22
                                                      INSPECTION/REPAIR
    5. Place the camshaft on a measuring stand.                             Cylinder Liner Projection Inspection
        Use a dial indicator to measure the camshaft run-
        out.
                                                                             1. Hold a straight edge      CD
                                                                                                           along the top edge of the
                                                                                cylinder liner to be measured.
        Note the total indicator reading (TIR).
                                                                             2. Use a feeler gauge        @    to measure each cylinder
        If the measured run-out exceeds the specified limit,                    liner projection.
        the camshaft must be replaced.
                                                                                                                                       mm(in)
                                                    mm(in)
                                                                                                                           Limit
                                                   Limit
I Camshaft Run-Out TIR                        0.12 (0.005)
                                                                             'Cylinder Liner Projection       0.03 -   0.10 (0.001 -   0.004)

                                                                                The difference in the cylinder liner projection height
i   CYLINDER BODY AND LINER                                                     between any two adjacent cylinders must not
                                                                                exceed 0.03 mm (0.001 in).
    Cylinder Liner Bore Measurement
    Use a cylinder indicator to measure the cylinder liner
    bore at measuring position        CD
                                   in line with the crank-
                                                                                                                                        o
                                                                                                                                        STRAIGHT
                                                                                                                                        EDGE
    shaft @ and across the crankshaft         .
    Measuring Point      CD     mm (in): 20.0 (0.79) (Maximum
    Wear Portion)
    If the measured value exceeds the specified limit, the
    cylinder liner must be replaced.


                                                                            Cylinder Liner Replacement
        CD                                                                  Cylinder Liner Removal
                                                                             1. Set the cylinder liner remover to the cylinder liner.
                                                                             2. Check that the remover shaft ankle is firmly gripp-
                                                                                ing the cylinder liner bottom edge.
                                                                             3. Slowly tur:n the remover shaft handle counterclock-
                                                                                wise to pull the cylinder liner free.
                                                                                Cylinder Liner Remover: 9-8523-1169-0
                                                                                Cylinder Liner Remover Ankle:
                                                                                  For all models except 6BG1; 9-8523-2557-0
                                                                                  For 6BG 1                  ; 5-8523-1004-0

                                                                            NOTE: Take care not to damage the cylinder body upper face
                                                                            during the cylinder liner removal procedure.




                                                                                              REMOVER
                                                                                              TOOL
                                                              mm(in)                                 ~
                                  I        Standard          Limit
     Cylinder                     ! 102.021 - 102.060        102.20
                       4 Cyl.
     Liner Bore                   i (4.017 - 4.018)          (4.024)
     Total Indica-                1105.021 - 105.060         105.20
                       6 Cyl.
     tor Reading                     (4.135 - 4.136)         (4.142)

    Note: The inside of the dry type cylinder liner is chrome
    plated. It cannot be rebored or honed. If the inside of the
    cylinder liner is scored or scorched, the cylinder liner must
    be replaced.




                                                               Engines & Generators

                                                                       23
                                              INSPECTION/REPAIR
Cylinder Bore Measurement                                             Cylinder Liner Outside Diameter Measurement
Cylinder Liner Grade Selection                                        1. Take measurements at measuring points                 CD, ,
                                                                         and @.
The term "grade" refers to the cylinder body inside
diameter and the cylinder liner outside diameter combi-                     Measuring Points mm(in):
nation.                                                                      CD       20.0 (0.788)
Measure the cylinder body inside diameter and select                         (2) 105.0 (4.137)
the appropriate cylinder liner grade.                                        (3) 195.0 (7.683)
Loose fitting cylinder liners (the liner is too small for the         2. Calculate the average value of the 6 measurements
cylinder bore) will adversely affect engine cooling effi-                to determine the correct cylinder liner grade.
                                                                                                              MM(IN)
ciency and may lead to serious engine damage.
Cylinder liners which are too large for the cylinder bore                 CYLINDER LINER FITTING          0.001 - 0.019
will be difficult to install.                                             CLEARANCE STANDARD              (0.00004 - 0.0007)




  MEASURING THE                                                                                                           MEASURING
  CYLINDER BODY 1.0.                                                                                                      POINTS




                  lr'J\
Cylinder Body Inside Diameter Measurement
                                                                      Cylinder Bore and Cylinder Liner Outside Diame-
 1. Take measurements at measuring point           CD   across        ter Combinations
    the positions W-W, X-X, V-V, and Z-Z.
     Measuring Point   CD: 115 mm (4.531     in)                      (Reference)
                                                                      80N4/110T4                                                 mm(in)
 2. Calculate the average value of the four measure-                  -
                                                                                                                     Cylinder Liner
    ments to determine the correct cylinder liner grade.                  Grade   I       Cylinder Bore
                                                                                                                    Outside Diameter


                                        fT
                                                                                        105.001 - 105.010           105.011 - 105.020
                             !              MEASURING
                                                                            1
                                                                                        (4.1339 - 4.1343)           (4.1343 - 4.1346)


                            I               POINT 1                         2
                                                                                        105.011 - 105.020           105.021 - 105.030

                                           ~
                                                                                        (4.1343 - 4.1346)            (4.1347 - 4.1350)
                             I                                                          105.021 - 105.030           105.031 - 105.040
                                                                            3
                                                                                        (4.1347 - 4.1350)            (4.1350 - 4.1354)
MEASURING
CYLINDER                                                              120N6/170T6                                                mm(in)
LINERS                      i        0'-                                                                             Cylinder Liner
                P           I                                             Grade   I
                                                                                  i
                                                                                          Cylinder Bore
                                                                                                               I    Outside Diameter
                                                                                  I     107.001 - 107.010           107.011 -107.020
                                                                            1     !
                                                                                  i     (4.2126 - 4.2130)      I     (4.2130 - 4.2134)
                                                                      ~-
                                                                                  !
                                                                                        107.011 - 107.020           107.021 - 107.030
                                                                            2
                                                                                  i     (4.2130 - 4.2134)
                                                                                                               ,
                                                                                                                    (4.2134 - 4.2138)
                                                                                  !
                                                                                        107.021 - 107.030       ,
                                                                                                                    107.031 - 107.040
                                                   y                        3     !
                                                                                  I     (4.2134 - 4.2138)           (4.2138 - 4.2142)




                                                        Engines & Generators

                                                                 24
                                                  INSPECTION/REPAIR
Cylinder Liner Installation                                             Piston Grade Selection
 1. Carefully wipe away any foreign material from the                   The term "piston grade" refers to the piston diameter
    cylinder liner inside and outside surfaces and the                  and cylinder liner bore combination.
    cylinder bore.                                                      Selection of the proper piston grade will ensure efficient
 2. Use new kerosene or diesel oil to thoroughly clean                  engine operation, free from cylinder liner and piston
    the cylinder liner and bore surfaces.                               problems.
 3. Use a clean rag to remove all traces of kerosene or                 Measure the cylinder liner bore after installing the cylin-
    diesel oil from the cylinder liner and bore surfaces.               der liner. Then select the appropriate piston grade for
                                                                        the installed cylinder liner.



      (!)CYLINOER-
          LINER
                         r;=t=l(--\.:3.~ INSTALLER
                         ~                        TOOL
                                                                                                                       :0
                                                                                                                       I       I
                                                                                                                                   CYLINDER
                                                                                                                                   LINER
                                                                                                                                   BORE
                                                                                                                       I       I




                                        fUNDER  BODY
                                           /

 4. Insert the cylinder liner   CDinto the cylinder body
       from the top of the cylinder body.                              Cylinder Liner Bore Measurement
 5. Set the cylinder liner installer   @       to the top of the         1. Locate the two measuring points.
    cylinder liner.
                                                                           Cylinder Liner Measuring Point CD: 20 mm (0.788 in)
    Cylinder Liner Installer:                                              Cylinder Liner Measuring Point (2) : 105 mm (4.(173 in)
      For 4 Cyl.                       9-8523-2554-0
                                                                        2. Measure the cylinder liner bore at measuring point
      For 6 CYL.                       5-8522-1018-0
                                                                            CD and      in four different directions (W-W,
 6. Position the cylinder body so that the installer cen-                  X-X, V-V, and Z-Z).
    ter @ is directly beneath the bench press shaft
                                                                        3. Calculate the average value of the eight measure-
    center @.
                                                                           ments.
                                                                                                                      mm(in)
                                         4 PRESS SHAFT
                                                                                 Cylinder Liner Bore Total Indicator Reading
 'NSTALLER
                                                                                     4 Cyl.
                                                                             102.021 - 102.060
                                                                                                        1
                                                                                                        I
                                                                                                                      6 Cyl.
                                                                                                              105.021 - 105.060
                                                                             (4.0166 - 4.0181)          !     (4.1347 - 4.1362)


                                                                        Note:lt is most important that the correct piston grade be
                                                                        used. Failure to select the correct piston grade will result in
                                                                        piston seizure. Always measure the cylinder bore and select
 7. Check that the cylinder liner is set perpendicular to               the appropriate piston grade.
    the cylinder.
    Check that the cylinder liner does not wobble.
 8. Use the bench press to apply an initial seating force
    of 500 kg (1,102.5 Ig) to the cylinder liner.
 9. Use the bench press to apply a final seating force of
    2,500 kg (5,512.5 Ib) to fully seat the cylinder liner.
10. After installing the cylinder liner, measure the cylin-
    der liner projection.
    Refer to "Cylinder Liner Projection Inspection".




                                                           Engines & Generators

                                                                   25
                                                    INSPECTION/REPAIR
Piston Outside Diameter
 1. Piston outside diameter vary depending on the pis-
    ton type to be used.
 2. Measure the piston outside diameter at the measur-
    ing piston       0
                 shown in the illustration.
 3. Piston Grade.
       ~       Steel Strut Built-in Type (Autothermatic Type)
               You can find steel strut on the inner surface of                                                          "-,,-
                                                                                                    ~
               piston as shown in the illustration.                                                                              "FEELER GAUGE
                                                                           Piston Ring Gap ~-:::-~-----!:::::::::.---
                                                             mm(in)
                                                                            1. Insert the piston ring horizontally (in the position it
 Grade i                 4 Cyl.                    6 CYL.                      would assume if it were installed to the piston) into
r-                                                             ---
                                                                               the cylinder liner.
                  101.955 - 101.974           104.955 - 104.974
   A                                                                        2. Use an inverted piston to push the piston ring into
                  (4.0140 - 4.0147)           (4.1321 - 4.1328)
                                                                               the cylinder liner until it reaches either measuring
           i      101.975 - 101.994           104.975 - 104.994                point CD or measuring point (f). Cylinder liner
   C
                  (4.0148 - 4.0155)           (4.1329 - 4.1336)
                                                                               diameter is the smallest at these two points.
                                                                                Do not allow the piston ring to slant to one side or
                              /STEEL STRUT                                      the other. It must be perfectly horizontal.
                                                                                Cylinder Liner Measuring Point CD: 10 mm (0.39 in)
                                                                                Cylinder Liner Measuring Point (f) : 130 mm (5.12 in)


                                                                                                                o
                                                                                                                          '
                                                                                                                                 PISTON




                                                                                                                        r
                                                                                                                                 PISTON RING




                                                                                                                         ~
Cylinder Liner Bore and Piston Clearance
                                                                             3. Use a feeler gauge to measure tne piston ring gap.
 1) Steel strut Built-in Type (Autothermatic Type)
    For all 4B, 6B series                                                        If the measured value exceeds the specified limit,
    0.055 - 0.085 mm (0.0021 - 0.0033 in)                                        the piston ring must be replaced.
                                                                                                                                                     mm(in)
                                                                                                                                          ,
PISTON AND PISTON RING                                                                                             Standard               I        Limit
                                                                             1st Compression                      0.25 - 0.45    I                  1.50
Piston Ring and Piston Ring Groove Clearance                                 Ring Gap                          (0.0098 - 0.0177) i                (0.0591 )
Use a feeler gauge to measure the clearance between                          2nd Compression               I     0.20 - 0.40    I                   1.50
the piston ring and the piston ring groove.                                  Ring Gap                      ! (0.0079  - 0.0157)                   (0.0591 )
                                                                                                           i
Do this at several points around the piston.                                                               I       0.20 - 0.40   :                  1.50
                                                                             Oil ring Gap
If the clearance between the piston ring and the piston                                                        (0.0079 - 0.0157) i                (0.0591)
ring groove exceeds the specified limit, the piston ring
must be replaced.
                                                 mm(in)
                                      Standard              Limit
                                    0.085 -   0.110       0.20
 1st compression ring
                                  (0.0033 -   0.0043)   (0.0079)
                                    0.030 -   0.055       0.15
                                                                           MEASURING PISTON
 2nd compression ring                                                      RING GAP
                                  (0.0012 -   0.0022)   (0.0059)
                                    0.030 -   0.070       0.15                                                                                o
 Oil ring
                                  (0.0012 -   0.0028)   (0.0059)
                                                                                                                                     o

                                                              Engines & Generators

                                                                      26
                                            INSPECTIONJREPAIR
PISTON PIN
Piston Pin Outside Diameter                                                                                             PIN HOLE
                                                                                                                        DIAMETER
Use a micrometer to measure the piston pin outside
diameter at several points.
If the measured piston pin outside diameter exceeds the
specified limit, the piston pin must be replace.
                                                      mm(in)
                      I      Standard              Limit
 Piston Pin Outside       35.000 - 35.005         34.95             If an inside dial indicator is not available, use the follow-
 Diameter             I (1.3780 - 1.3781) I       (1.3760)           ing procedure to check the piston pin fit.
                                                                      1. Use a piston heater to heat the piston to approxi-
                                                                         mately 60C (140F).
                                                                      2. Push strongly against the piston pin with your
                                                                         thumbs.
                                                                         The piston pin fitting should feel tight.

                                                                                                               USING A HOT PLATE TO
                                                                                                               HEAT THE PISTON




Piston Pin and Piston Clearance
Use an inside dial indicator to measure the piston pin
hole.
                                                       mm(in)
 Piston Pin Hole Diameter    I          Standard
                                   35.000 - 35.008
           4 CYL.
                             I    (1.3780 - 1.3783)

           6 CYL.            I
                             I
                                   35.010 - 35.018
                             I
                             I
                                  (1.3783 - 1.3787)

                                                                                     PISTON PIN SHOULD
                                                                                     FIT TIGHTLY
MEASURING PISTON
PIN HOLE 1.0.




Piston Pin and Piston Pin Hole Clearance
Determine the clearance between the piston pin and the
piston pin hole by calculating the difference between
the piston pin hole diameter and the piston pin outside
diameter.
                                                       mm(in)
                            I             Limit
  Piston Pin and Piston Pin'
                                     0.050 (0.002)
  Hole Clearance            I




                                                        Engines & Generators

                                                                27
                                                 INSPECTION/REPAIR
    CONNECTING ROD                                                       Connecting Rod Bushing Removal

    Connecting Rod Alignment                                              1. Clamp the connecting rod in a vise.
                                                                          2. Use a brass bar and a bench press or hammer to
    Use a connecting rod aligner to measure the parallelism
                                                                             remove the connecting rod bushing.
    between the connecting rod big end hole and the con-
    necting rod small end hole.
    If either the measured parallelism exceeds the specified                              BENCH
    limit, the connecting rod must be replaced.                                           PRESS

    Connecting Rod Alignment                                                                                       CONNECTING ROD
    (Per Length of 100 mm (3.94 in))                       mm(in)                                                  SMALL END
                       I    Standard                  Limit                        OLD BUSHING
                       I

                           0.05 (0.0020)               0.20
     Parallelism
                              or less                (0.0079)
                                                                         Connecting Rod Bushing Installation
                                                                         Use the connecting rod bushing installer to install the
CONNECTING                                                               connecting rod bushing.
ROD ALIGNER                                                              Connecting Rod Bushing Installer: 9-8523-1369-0
                                                                                                           (J-29765)

                                                                         NOTE: The connecting rod bushing oil port must be aligned
                                                                         with the connecting rod oil port.


                                                                          3. Use a piston pin hole grinder CD fitted with a
                                                                             reamer ~ or an adjustable pilot reamer to ream
                                                                             the piston pin hole.
                                                                                                                                 mm(in)
                                                                                                                 Standard
    Piston Pin and Connecting Rod Small End Bush-
                                                                          Connecting Rod Bushing              35.017 - 35.025
    ing Clearance
                                                                          Inside Diameter                    (1.3786 - 1.3789)
    Use a caliper calibrator and a micrometer to measure
    the piston pin and connecting rod small end bushing                                                                        ...
    clearance.
    If the clearance between the piston pin and the connect-
    ing rod small end bushing exceeds the specified limit,
    replace either the piston pin or the connecting rod
    bushing.
                                                           mm(in)


                                                                                                                      P~:~:>
                                   Standard               Limit
                                                                                                                                     ALIGN OIL
     Piston Pin and Connec-                                                                                   SOLID                  PORTS
                              0.010 -      0.030          0.05
     ting Rod Small End
                            (0.0004 -      0.0012)      (0.0020)          REAMING THE PISTON HOLES
     Bushing Clearance




       ~      PISTON PIN       CONNECTING ROD
                                                        MEASURING SMALL
                                                        END BUSHING
                                                        CLEARANCE


                   TAKING MEASUREMENTS




                                                              Engines & Generators

                                                                    28
                                           INSPECTION/REPAIR
Connecting Rod Bearing Inspection                                  CRANKSHAFT
1. Fit the connecting rod bearing lower half into the              Crankshaft and Bearing Inspection
   connecting rod bearing cap.
2. Check the connecting rod bearing lower half ten-                 1. Inspect the crankshaft journal surfaces and the
   sion.                                                               crank pin surfaces for excessive wear and damage.

   If the tension is insufficient, the bearing must be             2. Inspect the oil seal fitting surfaces of the crankshaft
   replaced.                                                          front and rear ends for excessive wear and damage.

3. Tighten the connecting rod and the bearing cap to               3. Replace or repair the crankshaft if any excessive
   the specified torque.                                              wear or damage is discovered.
                                                                   4. Inspect the crankshaft oil ports for obstructions.
                                              kg.m(lb ft)
                                1st step     2nd step              5. Use high pressure air to clean the oil ports if neces-
                                                                      sary.
Connecting Rod and Bearing         4              60o+3~:
Cap Bolt Tightening Torque       (28.9)



                      FITTING THE LOWER
                      BEARING




                                                                   Crankshaft Journal and Crankpin Outside Diame-
 4. Use an inside dial indicator to measure the connect-           ter
    ing rod inside diameter.
                                                                    1. Use a micrometer to measure the crankshaft journal
                                                     mm(in)
                                                                       outside diameter across points CD - CJ) and ~
 Connecting Rod Bearing                                                -~.
                                     64 (2.520)
 Nominal Diameter
                                                                    2. Use the micrometer to measure the crankshaft jour-
                                                                       nal outside diameter at the two points (@ and
                                                                       @).
                                                                    3. Repeat steps 1 and 2 to measure the crankshaft out-
                                                                       side diameter.
                                                                      If the measured crankshaft journal diameter and/or
                                                                      the crankpin outside diameter are less than the
                                                                      standard value, the crankshaft must be reground.
                                                                                                                        mm(in)
                                                                         (6 Cyl.)         Position at   i       Standard
                                                                                         Center         1 79.905 -    79.925
                                                                    Crankshaft Journal ' Bearing Only   I   (3.1459 - 3.1467)
                                                                                                                            --
                                                                    Diameter           I Other          !    79.919 - 79.939
                                                                                         Bearings       i   (3.1464 - 3.1472)

                                                                                                                        mm(in)
                                                                         (4 Cyl.)         Position at  I        StClndard
                                                                                                     --r--------------~
                                                                    Crankshaft Journal   All B      i 79.905 - 79.925
                                                                    Diameter                  earmgs ! (3.1459 - 3.1467)




                                                      Engines & Generators

                                                              29
                                              INSPECTION/REPAIR
                                                        mm(in)
                                         Standard
                                      63.924 - 63.944
 Crankshaft Pin Diameter
                                     (2.5167 - 2.5175)

 4. Measure the crankshaft journal outside diameter
    (and/or the crankpin outside diameter) and the
    bearing inside diameters to determine the bearing
    clearance.



Crankshaft Journal and Bearing Clearances

If the bearing clearance exceeds the specified limit, the
crankshaft must be reground (except for the 120N6 and                  Connecting Rod Bearing Inside Diameter
170T6) or the bearing must be replaced.
                                                                       Tighten the connecting rod and the bearing cap with
                                                        mm(in)         specified torque, and use inside dial indicator to mea-
      6 CYL.         Position at      Standard          Limit          sure the connecting rod bearing inside diameter.
                   Center                                                                                              kg.m(lb ft)
                                     0.039-0.098
Crankshaft Journal Bearing         (0.0015-0.0039)                                                      1st step       2nd step
                                                         0.11
and Main Bearing Only                                                   Connecting Rod and Bearing         4
Clearance          Other             0.025-0.084
                                                       (0.0043)
                                                                        Cap Bolt Tightening Torque       (28.9)
                                                                                                                        60 o -   3   g:
                   Bearings        (0.0010-0.0033)
                                                                                                                            mm(in)
                                                       mm(in)            Connecting Rod Bearing
      4 Cyl.        Position at       Standard      1 Limit              Nominal Diameter

Crankshaft Journal


                                                                                 EI3
                   All               0.039-0.098 I I  0.11
and Main Bearing
                   Bearings        (0.0015-0.0039) 1("0.0043)
Clearance
                                                                        MEASURING
                                                                        CONNECTING
                                                        mm(in)          ROD BEARING
                              Standard               Limit              1.0.
Crankpin and
                              0.03-0.07               0.10
Connecting Rod
                           (0.0012-0.0028)          (0.0039)
Bearing Clearance
                                                                       Crankshaft Run-Out
                                                                       1. Mount the crankshaft on a set of V-blocks.
Crankshaft Journal Bearing Inside Diameter
                                                                       2. Set a dial indicator to the center of the crankshaft
 1. Install the main bearing cap with bearings to the                     journal.
    cylinder body with the specified torque and facing                 3. Gently turn the crankshaft in the normal direction of
    the arrow mark on the bearing cap toward                              engine rotation.
    front. Place them in order of punched cylinder
    numbers.                                                              Read the dial indicator (TIR) as you turn the crank-
                                                                          shaft.
 2. Use an inside dial indicator to measure the main
    bearing diameters.                                                    If the measured value exceeds the specified limit,
                                                                          the crankshaft must be replaced.
                                                    kg.m(lb.tt)
                                         24.1  1
  Main Bearing Cap Torque:
                                       (173.5  7.2)

                                                       mm(in)
Main Bearing Nominal                         80
Diameter                                  (3.150)




                                                         Engines & Generators

                                                                  30
                                                           INSPECTION/REPAIR
                                                                    mm(in)
                                                                                       Crankshaft Regrinding Procedure (4 CyL)
                         Model           Standard                 Limit
                     .
                     I             i
                                                       r,---------
                                                           i
                                                                                        1. Regrind the crankshaft journals and the crankpins.
 Crankshaft          I 6 Cyl.     I.                       I   0.40 (0.016)             2. Fillet the crankshaft journal and crankpin radious to
                      ~---~'            0.05 (0.002)                     --
 Run-Out             I   4 Cyl.   I                        .   0.30 (0.012)                a minimum of R3.5  0.2.

    If the crankshaft generated a crack after repair,                                     There must be no stepping around the fillet area.
    replace the crankshaft.                                                             3. Finish the crankshaft journal, crankpin, and oil port
   The crankshafts for the 120N6 and the 170T6 engines                                     corners to a smooth surface having a chamfer
   can not be bench pressed because they are finished in                                   radius of 1 mm (0.04 in).
   the Tufftride method.
                                                                                         Crankshaft Journal and
Main Bearing and Connecting Rod Bearing Ten-                                                                                       0.4 11 or less
                                                                                         Crankpin Roughness
sion
                                                                                        4. Measure the crankshaft journal and crankpin clear-
Check to see if the bearing has enough tension, so that
                                                                                           ance.
good finger pressure is needed to fit the bearing into
position.                                                                                 Refer to "Crankshaft Journal Clearance" and "Crank-
                                                                                          pin and Clearance': on
                                  FITTING THE BEARINGS                                  5. Measure the crankshaft run-out.
                                                                                          Refer to "Crankshaft Run-Out':


                                                                                       Crankshaft Grinding Limit (4 CyL)
                                                                                                                                                        mm(in)
                                                                                                                                       Limit
                                                                                         Crank Journal Diameter                    79.4 19 (3.127)
Crankshaft Regrinding (4 CyL)
                                                                                         Crankpin Diameter                         63.424 (2.497)
To ensure crankshaft reliability, pay close attention to
the following items during and after the crankshaft                                    Undersize bearings 0.25 mm (0.010 in) and 0.50 mm
grinding procedure.                                                                    (0.020 in) are available to compensate for excessive
                                                                     mm(in)            clearance between the crankpin bearing and the crank-
   Undersize Bearing                                                                   shaft. Regrinding of the crankshaft to fit the undersize
                                       0.25 (0.010)    !       0.50 (0.020)            bearings is required.
   Availability
                                                                                                                                                         mm(in)
Note: Crankshafts for the 120N6 and the 170T6 can not be                                                           ,
                                                                                                                          Standard                      Limit
reground because they are finished in the Tufftride met/wd.
                                                                                        Crankpin and               I      0.03-0.07               0.10
No attempt should be made to grindfinish these faces of the                             Connecting Rod
                                                                                                                       (0.0012-0.0028)          (0.0039)
journals and crankpins as they are Tufftrided. (special                                 Bearing Clearance          I
hardening treatment).
77lerefore. the undersize bearings are not prepared.                                   Undersize bearings 0.25 mm (0.010 in) and 0.50 mm
                                                                                       (0.020 in) are available to compensate for excessive
                                                                                       clearance between the crankshaft journal bearing and
                                                                                       the crankshaft. Regrinding of the crankshaft to fit the
                                                                                       undersize bearings is required.
                                                                                                                                      mm(in)
                                                                            ..,
                                                                            00


                                                                            :z:          6B Engines Only        Position at I      Standard         ! Limit



                                                                tj;  n..~ ~
                                                                     .
                                                                    ~ '     -'
                                                                                        and Main Bearing Only
                                                                                        Clearance
                                                                                                                Cent~r

                                                                                                            Other
                                                                                                                     I 0.039-0.098
                                                                                        Crankshaft Journal Beanng 1(0.0015-0.0039)
                                                                                                                     i
                                                                                                                     !
                                                                                                                     i  0.025-0.084
                                                                                                          ! Bearings ,(0.0010-0.0033) i
                                                                                                                                          0.11
                                                                                                                                        (0.0043)



                                                                                         4B Engines Only    i   Position at:       Standard         !    Limit
                                                                                        Crankshaft Journal i All
                                                                                        and Main Bearing ! B     .
                                                                                                                           1 0.039-0.098          0.11
                                                                                        Clearance             eanngs            (0.0015-0.0039) (0.0043)




                                                                          Engines & Generators

                                                                                  31
                                           INSPECTION/REPAIR
Plastigage Clearance Measurements
This is another method to measure the crankjournal
bearing clearance.                                                                                               PlASTIGAGE SCALE
Crankshaft Journal Bearing Clearance
 1. Clean the cylinder body, the journal bearing fitting
    portions, the bearing cap, and the inside and out-
    side surfaces of the bearing.
 2. Install the new journal bearing to the cylinder body.
 3. Carefully place the crankshaft on the bearing.
 4. Rotate the crankshaft approximately 30 to seat the
    bearing.                                                    Crankshaft Pin Bearing Clearance
 5. Place the Plastigage (arrow) over the crankshaft             1. Clean the crankshaft, the connecting rod, the bear-
    journal across the full width of the bearing.                   ing cap, and the bearings.
   Apply engine oil to the Plastigage to keep it from            2. Install the bearing to the connecting rod.
   falling.                                                         Do not allow the crankshaft to move when installing
                 o
                                                                    the bearing cap.
                                                                 3. Hold the connecting rod (with the bearing installed)
                                          /PlASTIGAGE               against the crankshaft pin.
                                                                 4. Attach the plastigage to the crankshaft pin.
                                                                    Apply engine oil to the plastigage to keep it from
                                                                    falling.
                                                                 5. Install the connecting rod bearing cap and tighten it
                                                                    to the specified torque.
                                                                    Do not allow the connecting rod to move when
             o          o                                           installing and tightening the bearing cap.
                                                                 6. Remove the bearing cap.
6. Install the bearing cap with the bearing.
                                                                 7. Compare the width of the plastigage attached to
7. Tighten the bearing cap to the specified torque.                 either the crankshaft or the bearing against the
   Do not allow the crankshaft to turn during bearing               scale printed on the plastigage container.
   cap installation and tightening.                                 If the measured value exceeds the limit, perform the
                                                                    following additional steps.
                                      TIGHTEN THE BEARING CAP        1) Use a micrometer to measure the crankshaft
                                                                        outside diameter.
                                                                     2) Use an inside dial indicator to measure the
                                                                        bearing inside diameter.
                                                                     3) Replace the crankshaft and/or the bearing if the
                                                                        measured value(s) exceed the limit.



8. Remove the bearing cap.
9. Compare the width of the plastigage attached to
   either the crankshaft or the bearing against the
   scale printed on the plastigage container.
   If the measured value exceeds the limit, perform the
   following additional steps.
    1) Use a micrometer to measure the crankshaft
       outside diameter.
    2) Use an inside dial indicator to measure the
       bearing inside diameter.
    3) Replace the crankshaft and/or the bearing if the
       measured value(s) exceed the limit.




                                                      Engines & Generators

                                                            32
                                                 INSPECTION/REPAIR
Crankshaft Tufftriding Inspection (6 Cyl.)                            Oil Seal Wear Ring Replacement (6 cyl.)
Inspection
Model 120N6 and 170T6                                                 Removal
 1. Use an organic cleaner to thoroughly clean the                    Use the oil seal wear ring remover to remove the oil
    crankshaft. There must be no traces of oil on the                 seal wear ring from the crankshaft front end.
    surfaces to be inspected.                                         Oil Seal Wear Ring Remover:
 2. Prepare a 10% solution of ammonium cuprous chlo-
    ride (dissolved in distilled water).                                   OIL SEAL WEAR
 3. Use a spot glass rod to apply the solution to the                      RING REMOVER
    surface to be inspected.
    Hold the surface to be inspected perfectly horizontal
    to prevent the solution from running.
Note: Do not allow the solution to come in contact with the
oil ports and their surrounding area.


                                            TEST LIQUID SHOULD
               AMMONIUM                     NOT BE APPLIED            Installation
               CUPROUS                      NEAR THE OIL PORT
               CHLORIDE                                               Use a brass bar and a hammer to drive the oil seal
                        ~                   Jt                        wear ring into place.
 FACE IN CONTACT
 WITH CRANKPIN
 OR JOURNAL




Judgement
 1. Wait for thirty to forty seconds.
    If there is no discoloration after thirty or forty sec-
    onds, the crankshaft is useable.
    If discoloration appears (the surface being tested will
    become the color of copper), the crankshaft must be               Crankshaft Gear Inspection
    replaced.
                                                                      Visually inspect the crankshaft gear.
 2. Clean the surface being tested with clean water of                Replace the crankshaft      gear   if   excessive   wear   or
    steam immediately after completing the test.                      damage is discovered.
Note: The ammonium cuprous chloride solutio/l is highly
                                                                      Removal
corrosive. Because of this. it is imperative that the surfaces
being tested be cleaned immediately after completing the lest.        Use the crankshaft gear remover to remove the crank-
                                                                      shaft gear.
                                                                      Crankshaft Gear Remover: 9-8521-0141-0




                                                         Engines & Generators

                                                                 33
                                            INSPECTION/REPAIR
                                                                   Flywheel Housing Oil Seal Replacement
                                                                   Removal
                                                                   Use a pry bar to remove the flywheel housing oil seal.
                                                                   Installation
       o                                                           Use the oil seal installer to install the flywheel housing
                                                                   oil seal.


Installation
Use the crankshaft gear installer to install the crankshaft
gear.



FLVWHEEL AND FL VWHEEL HOUSING
                                                                      INSTALLING
(REAR OIL SEAL)
                                                                      THE OIL
Ring Gear Inspection                                                  SEALER
Inspect the ring gear.
                                                                   TIMING GEAR CASE COVER
If the ring gear teeth are broken or excessively worn,
the ring gear must be replaced.                                    Crankshaft Front Oil Seal Replacement
                                                                   Removal
                                                                   Use an adapter and a hammer to remove the crank
                                                                   front end oil seal.

                                                                   Installation
                                                                   Use the crankshaft front oil seal installer to instal
                                                                   crankshaft front oil seal.




    REMOVING THE
    RING GEAR



Ring Gear Removal
Strike around the edges of the ring gear with a hammer
and chisel to remove it.                                                  INSTALLING FRONT OIL SEAL
Ring Gear Installation
 1. Heat the ring gear evenly with a gas burner to invite
    thermal expansion.
    Do not allow the temperature of the ring gear to
    exceed 200C (390F).
 2. Use a hammer to install the ring gear when it is suf-
    ficiently heated.




                                                     Engines & Generators

                                                              34
                                                               ASSEMBLY
                                                                                        SNAP RING
                                                                                        PLIERS

                                                                                             ~
                          ~~~~~_4                       PISTON RINGS
PISTON/CONNECTING
ROD ASSEMBLY                                     ~3SNAPRING

 2 PISTON PIN



       ~~
                                                  1 PISTON                  4. Piston Ring
                                                                                1) Use a piston ring installer to install the three
                                                                                   piston rings.


                                                                                  Install the piston rings in the following order.
                                                                                  (1) Oil ring
                                                                                  (2) 2nd compression ring
  2 CONNECTING_                                                                   (3) 1st compression ring
    ROD               - - - - l.....


                                                                                  The marked side of the two compression rings
                                                                                  must be facing up.
5 CONNECTING                                                                      The undercut side of the second compression
  ROO BEARING~                                                                    ring will be facing down.
                                                                                  As the oil ring has no any facing mark, it may
                                                                                  face in either direction.
                                                                                2) Lubricate the piston ring surfaces with engine

                ~                                 NUMBERS INDICATE THE
                                                  SUGGESTED ORDER OF
                                                     ASSEMBLY
                                                                                   oil.
                                                                                3) Check that the piston rings rotate smoothly in
                                                                                   the piston ring grooves.


                                                                                                                   ~   _         1STCOMP.
  PISTON AND CONNECTING ROD
                                                                                                                Y- f
                                                                                                                   _
                                                                                                                       _
                                                                                                                       _         2NDCOMP.
  Important Operations


                                                                                                                   ) cJ
                                                                                                           ..   ~

   1. Piston                                                                   PISTON
      Use a piston heater to heat the pistons to approxi-                                                                        OIL
      mately 60C (140F).

   2. Connecting Rod                                                                                              PISTON RINGS
        1) Install the connecting rod to the piston with
                                                                            5. Connecting Rod Bearing
           setting the marks as illustrated.
                                                                                1) Install the connecting rod bearings to .the con-
        2) Install the piston pin into the piston and the
                                                                                   necting rod large-end and the connecting rod
           connecting rod bushing.
                                                                                   cap.
                                                              PISTON
                                                              HEAD
                                                                                2) Install the bearing cap to the connecting rod
                                                                                   with semi-tightening the cap bolts.
                                               FRONTMARK@                       3) Lubricate the bearing with engine oil.




                                       USING A PISTON
                                       HEATER                    /\


   3. Piston Pin Snap Ring
       1) Use a pair of snap ring pliers to install the pis-
          ton pin snap ring.
       2) Check that the piston moves smoothly on the
          piston pin.

                                                                Engines & Generators

                                                                       35
        6 SPRING SEAT       ~
           (SPLIT COLLAR)               /T            ASSEMBLY
                        5 SPRING SEAT
                            UPPER
               4INTAKE/EXHAUST -------c~~
                                                        10 INTAKE MANIFOLD      1 VALVE STEM
                  SPRINGS                                                 ~OILSEAL
                      3 SPRING SEAT                                                            CYLINDER HEAD
                        (LOWER)
                                                                                               ASSEMBLY




7THERMOSTAT.                                                                                           EXHAUST MANIFOLD
  HOUSING                                                                                              AND GASKET
  & GASKET



8 THERMOSTAT----;~~

    9 WATER----,~~~


                                           -
      PIPE




                                         !
      OUTLET



                                                2
                                                            ~
                                                    INTAKE AND
Important Operations                     ,-'        EXHAUST VALVES

 1. Valve Stem Oil Seal
    1) Lubricate the oil seals and valve stem sealing
       area with engine oil.
    2) Use a valve stem oil seal installer to install the
       oil seal.


          INSTALLER



                                                                 3. Intake and Exhaust Valve Springs
                                                                     Install the valve springs with their painted end (the
                                                                     close pitched end) facing down.




2. Intake and Exhaust Valves
    1) Place the cylinder head on a flat wooden sur-
       face.
    2) Lubricate valve stems with engine oil.
    3) Install the valves to the intake or exhaust
       guides.                                                                                          PAINTED PORTION

       Install the valves to their original lapped valve
       seats.




                                                     Engines & Generators

                                                            36
                                                      ASSEMBLY
                                                                     TORQUE
                                                                     ORDER
SPRING
COMPRESSOR




4. Spring Seat Split Collar
   1) Use a spring compressor to push the valve spr-
      ing into position.
   2) Install the spring seat split collar.                           6. Exhaust Manifold and Gasket
   3) Set the spring seat split collar by tapping lightly                 1) Install the exhaust manifold gasket.
      around the head of the collar with a rubber                               The 'TOP" mark must be facing up.
      hammer.


                                                                                                  4 CYL. AND 6 CYL. USE
                                                                                                  DIFFERENT MANIFOLD GASKETS.
 SETTING THE SPRING                                                                               6CYL. SHOWN
 SEAT SPLIT COLLAR




                                                                          2) Install the exhaust manifold.
                                                                          3) Tighten the exhaust manifold bolts to the speci-
                                                                             fied torque a little at a time in the numerical
                                                                             order shown in the illustration.
                                                                                                                       kg.m(lb.ft)
                                                                       Exhaust Manifold Bolt
 5. Intake Manifold and Gasket                                                                         2.9  0.5 (21.0  3.6)
                                                                       Torque
    1) Install the intake manifold gasket.
        The intake manifold gasket must be installed                 SIX CYL.
        with its unchamfered corner facing up and to                                                                         ----,
        the front of the engine.                                 G~-                                                                       I

                                                                 I
                                                                                                                                  11   I
                                                                 I                                                                         I
                                                                 9
                                                                 1                                                               12 :
                                                                 '--                                                                   J




         ::lREAR                   UNCHAMFERED
                                    CORNER                           FOUR ~YL . __ ._______- -__
    2) Install the intake manifold.                                               6
    3) Tighten the intake manifold bolts to the speci-
       fied torque a little at a time in the numerical
       order shown in the illustration.
                                                                          1   5
                                                  kg.m(lb.ft)
 Intake Manifold Bolt
                                  2.6  0.5 (18.8  3.6)
 Torque
                                                                                                              INSTALL EITHER END OF THE
                                                                         =~~iiiiiiii~iiiiiiiiiiii~t~r-DISTANCE   TUBE TO THE SPOT
                                                                                                       FACING (6 CYL. ONLY)



                                                       Engines & Generators

                                                                37
                                                      ASSEMBLY
             5 CRANKSHAFT                             ~                         THE ROCKER ARM MUST
                BEARING (LOWER) AND BEARING CAP ~~                              BE INSTALLED WITH THE
                                                                                OIL PARTS FACING UP.



                                                           '12l"':.A-o~~~~~
                                                                                                                            20lL PUMP
                                                                                                                             AND COUPLING
NUMBERS INDICATE SUGGESTED ASSEMBLY SEDUENCE          '"




   14 OIL PAN
      (NOT SHOWN)                                                                                                           ,
                                                                                                                            1 OIL



                                                                                                                            ~
                                                                                                                             JET




   8 CAMSHAFT



                       1010LER:::a-"?                                                          1   OIL COOLER
                        GEAR  ~~
                             ~(jJ"    9
                           ~       IDLER GEAR
                                   SHAFT

                                 MAJOR COMPONENT REASSEMBLY STEPS
Important Operations
                                                                           WITH OIL HOLE


                                                                          ~DJiJ
1. Oil Jet (6 Cyl. Turbo)
   Install the oil jets taking care not to damage the oil
   jet nozzles.
                                                 kg.m(lb.ft)
  Oil Jet Torque                  2.1  0.5 (15.2  3.6)     I
2. Crankshaft Bearing (Upper Half)
 3. Crankshaft Bearing (Lower Half) and Crankshaft
    Bearing Cap
                                                                    4. Crankshaft
                                                                                  ~NO             OIL GROOVE
                                                                                               (LOWER)
                                                                                                                ~D   HOLE

The Crankshaft Bearing Configulation
                                                                      Crankshaft counterweight size will vary from engine
                       With Oil Groove Without Oil GroovE             to engine. Check your Parts Catalog Part Number
                                                                      listing to determine crankshaft counterweight size
 Bearing Upper 4       All Upper Halves         -                     for your engine.
 Half          6       All Upper Halves         -                   5. Thrust Bearing
                       All Lower Halves
                                        Center Bearing                 Install the thrust bearings with the oil groove side
 Bearing Lower 4       Except Center                                   facing the crankshaft sliding face.
                                        Only
 Half                  Bearing
                 -
                   6         -            All Lower Halves

    Take care not to misinstall the bearing halves.



                                                      Engines & Generators

                                                               38
                                                     ASSEMBLY
                                                                    8. Camshaft
                                                                       Tighten the thrust plate bolts through the camshaft
                                                                       gear hole.
                                                                                                                     kg.m(lb.ft)
                                                                     Thrust Plate Bolt Torque         2.6  0.5 (18.8  3.6)     I
                                                                                                                     kg.m(lb.ft)
                                                                     Camshaft Gear Bolt
                                                                     Torque

6. Crankshaft Bearing Cap
    1) Lubricate the bearing cap bolts with engine oil.
    2) Install the bearing caps to the crankshaft.
       The arrow mark must be pointing to the front of
       the engine.
    3) Tighten the bearing cap bolts to the specified
       torque a little at a time in the numerical order
       shown in the illustration.
                                                 kg.m(lb.ft)
  Crankshaft Bearing Cap
                                 24.0  1 (173.5  7.2)         9. Idler Gear Shaft
  Bolt Torque
                                                                      Use the thrust collar fixing bolt as a guide to install
                                                                      the idler gear shaft.
    4) Check that the crankshaft turns smoothly by
       manually rotating it.                                          The oil port must be facing the camshaft.




                                                                    10. Idler Gear
                                                                         1) Install the idler gear.
                                                                            Set the timing marks [A] and [B] as shown in
                                                                            the illustration.
                                                                         2) Tighten the idler gear bolts seating the thrust
                                                                            collar to the specified torque.
                                                                            The thrust collar must be installed with the
 7. Timing Gear Case                                                        chamfered side facing the front of the engine.
     1) Apply liquid gasket to the timing gear case sur-                                                             kg.m(lb.ft)
        faces contacting the cylinder body.
                                                                      Idler Gear Bolt Torque           5.5  1 (39.8  7.2)        I
    2) Tighten the timing gear case bolts to the speci-
       fied torque.
                                                 kg.m(lb.ft)    INJECTION
                                                                PUMP GEAR

                                                                                                                               CAMSHAFT
                                                                                                                               GEAR
                                                                      C-MARK




                                                      Engines & Generators                                    GEAR

                                                               39
                                                  ASSEMBLY
" . Piston and Connecting Rod                                        7) Lubricate the connecting rod cap bolt threads
   Position the piston ring gaps as shown in the illus-                 and setting faces with Mos grease.
   tration.                                                         8) Use the angular tightening method to tighten
     1) Set the piston ring gaps as shown in the illus-                the connecting rod cap bolts to the specified
        tration.                                                       torque.
                                                                                                          kg.m(lb ft)
     2) Lubricate the piston, the piston rings, and the
        connecting rod bearings with engine oil.                                                  1st step       2nd step
     3) Position the piston front mark towards the front         Connecting Rod Bolt Torque            4          60 o + 3g:
        of the engine.                                           and Angle                         (28.9)


                                                                , 2. Oil Pump and Coupling
    PISTON RING
    ALIGNMENT                                                        1) Lubricate the oil pump with the specified grade
                                                                        of engine oil.




    4) Use the piston ring compressor to compress
       the piston rings.

                                                                    2) Install the oil pump with the coupling.
                                                                    3) Tighten the oil pump bolts to the specified
                                                                       torque.
                                                  FRONT                                                          kg.m(lb.ft)
                                                  MARK
                                                                  Oil Pump Bolt Torque           5.3  1.0 (38.3  7.2)        I
                                                                , 3. Flywheel Housing
                                                                    1) Apply a liquid gasket to the shaded area of the
                                                                       illustration.
                                                                    2) Install the flywheel housing.
    5) Use a hammer grip to push the piston in until it
       makes contact with the crankpin.                                Tighten the flywheel housing bolts to the speic-
                                                                       fied torque.
       At the same time, rotate the crankshaft until the
       crankpin reaches its highest point.                                                                       kg.m(lb ft)
                                                                 Flywheel Housing   Outer Bolt    16.1  1 (115.7  7.2)
   6) Set the bearing cap cylinder number marks and              Bolt Torque        Inner Bolt     2.6  0.5 (18.8  3.6)
      the connecting rod cylinder number marks.
       The marks must be facing the exhaust manifold.




   CYLINDER
   NUMBERS


                                                                                                             ~APPLY LlaUID     GASKET



  REFER TO THE "ANGULAR TIGHTENING METHOD. "
                                                                                 FLYWHEEL HOUSING



                                                   Engines & Generators

                                                           40
                                                             ASSEMBLY
    14. Oil Pan                                                               MAJOR COMPONENT REASSEMBLY
          1) Apply liquid gasket to the areas indicated by
             the arrows in the illustration.                                 Important Operations
          2) Install the oil pan gasket.
                                                                              1. Flywheel
          3) Install the oil pan.
                                                                                  1) Lublicate the flywheel bolt threads.
               Tighten the oil pan bolts to the specified torque.
                                                                                  2) Install the flywheel.
                                                          kg.m(lb.ft)
       Oil Pan Bolt Torque              2.6  0.5 (18.5  3.6)        I               The crankshaft rear end dowel pin and the fly-
                                                                                      wheel dowel hole must be aligned.
                                                                                  3) Tighten the flywheel bolts to the specified
                                                                                     torque in the numerical order shown in the
                                                                                     illustration.
                                                                                                                                kgm(lb.ft)
                                                                              Flywheel                       116      1.5 (115.7      10.8)
                                                                              Bolt Torque                    22.3  2.2 (161.2  15.9)


                                                                    LUBRICATE WITH ENGINE OIL

    15. Oil Cooler
          1) Apply liquid gasket to the oil cooler gasket.
          2) Install the oil cooler gasket to the oil cooler
             body case.
          3) Install the oil cooler.
               Tighten the oil cooler bolts to the specified
               torque.
               Start from the middle and work out to either
               side.                                                          2. Injection Pump and Injection Pump Gear Assembly
                                                  kg.m(lb.ft)                     1) Install the injection pump bracket with the injec-
       Oil Cooler Torque                   2.6  0.5 (18.5  3.6)       I            tion pump to the timing gear case.
                                                                                      Dowel the injection pump bracket with the tim-
    OIL COOLER                                                                        ing gear case.
    ASSEMBLY                                                                      2) Tighten the injection pump bolts to the speci-
                                                                                     fied torque.
3 ELEMENT __                                                                                                             kg.m(lb.ft)
                                                                             I Injection Pump Bolt Torque I 2.6  0.5 (18.8  3.6) I
                                                                                   3) Align the injection pump gear "C" timing mark
                                                                                      with the idler gear "C" timing mark.


                                                                               INJECTION~~
                                                                               PUMP



                       ''-1 BY-PASS VALVE, O-RING,
                            SPRING AND PLUG




                                                                            INJECTION
                                                                            PUMP GEAR--



               OIL COOLER BOLT                                WESTERBEKE
                                                              Engines & Generators
               TORQUE SEQUENCE
                                                                        41
                                                          ASSEMBLY
3. Crankshaft Pulley Nut                                              6. Cylinder Head, Gasket, and Bolts
   a) Apply MoS2 to the crankshaft pulley nut threads                    a) Carefully place the cylinder head gasket on the
      and fitting face.                                                     cylinder body upper surface.
   b) Use the appropriate wrench to tighten the                             The gasket "TOP" mark must be facing up.
      crankshaft pulley nut to the specified torque.
                                                                         b) Align the cylinder body dowels and the cylinder
                                                Kg-m (Ib-H)                 head dowel holes.
 CRANKSHAFT PULLEY NUT TORQUE        44.0  5.0 (318.1  36.2)
 (4B SERIES)
 (6B SERIES)                         44.0  5.0 (318.1  36.2)                 TOP
                                                                               MARK




                                                                               P
                                                                           FRONT
                                                        SOCKET
                                                        WRENCH

                                                                         c) Carefully place the cylinder head on the cylinder
                                                                            body.
                                                                         d) Tighten the cylinder head bolt as follows:

4. Tappet Chamber Cover                                                     1. As cylinder head bolts have two kinds of length,
                                                                               install them at the proper location. (The shorter
   a) Apply liquid gasket to the tappet chamber cover                          ones 4 cyl. series: 4 bolts, 6 cyl. series; 6
      gasket.                                                                  bolts) must be used at the injection pump side.
   b) Install the tappet chamber cover and tighten the                      2. Follow the numerical sequence shown in the
      bolts to the specified torque.                                           illustrations.
                                     Kg-m (lb-H)
 TAPPET CHAMBER COVER         2.6  0.5 (18.8  3.6)
 BOLT TORQUE


                                                                        +-
                                                                      FRONT

                                   TAPPET CHAMBER
                                   COVER                                                     TORQUE SEQUENCE




5. Water Pump



                                                                              3. The cylinder head bolt tightening method vary
                                                                                 depending on the gasket type to be used.




NOTE: Refer to the Coolant Pump sectioll ill this manual for
details of the water pump.



                                                           Engines & Generators

                                                                 42
                                                               ASSEMBLY
           For laminated steel type gasket.
                                                                               14   ROCKER ARM
           Apply molybdenum disulfide grease to the                                 ASSEMBLY   
           cylinder head bolt threads and setting faces.
           Use the Angular Tightening Method.
                                                            kg.m(lb.ft)
                     1st step           2nd step           3rd step                                                                1 CYLINDER
                                                                                                                                     HEAD
     Bolt Torque     7.0 (50.6)      9.0O.5 (65.1 3.6)    90o+3~:


           For steel-asbestos sandwich gasket.
           Apply engine oil to the cylinder head bolt
           threads and setting faces.
                                                            kg.m(lb.ft)
                         1st step                   2nd step
                                                   New bolt
                                                9.5o.5 (68.63.6)
     Bolt Torque         7.0 (50.6)
                                                 Reused bolt
                                               11.5o.5 (83.1 3.6)
                                                                        I

    7. Rocker Arm and Rocker Arm Shaft
        1) Check that the rocker arm shaft bracket lower
           surface oil port is free from obstruction.
        2) Install the rocker arm shaft with the bracket to
           the 'cylinder head.
        3) Tighten the rocker arm bracket bolts to the
           specified torque a little at a time in the numeri-
           cal order shown in the illustration.
        4) Lubricate the rocker arm and the rocker arm
           shaft with engine oil.                                                                                                   8 TAPPET
                                                            kg.m(lb.ftl                                                               CHAMBER
     Rocker Arm Shaft Bracket                                                                                                   ~COVER
                                         3.1  0.5 (22.4  3.6)
     Bolt Torque

                                                                                                                              '@~     Q;i




                         2               3          7
                             ROCKER ARM
                             ASSEMBLY
                                 4                               4 BRACKETS                         NUMBERS INDICATE SUGGESTED ASSEMBLY SEQUENCE




               2             3                                                            5) Adjust the valve clearance.
                                                                                             Refer to MAINTENANCE for the valve clearance
 ROCKER ARM SHAFT                                                                            adjustment procedure.

 THE ROCKER ARM MUST
 BE INSTALLED WITH THE
 OIL PARTS FACING UP                                    3 ROCKER ARMS



                                                                 Engines & Generators
NUMBERS INDICATE SUGGESTED ASSEMBLY SEQUENCE
                                                                          43
                                                           ASSEMBLY
 1. Cylinder Head Cover
                                                                          3. Oil Filter Assembly
        1) Check that the rocker arms, the rocker arm
                                                                             1) Before the installation, set the special gaskets
           shafts, and the valve springs are thoroughly
                                                                                which are included within the repair kit with the
           lubricated with engine oil.                                          two oil filter mounting bolts.
           If required, relubricate these parts.                             2) Apply a coat of LOCTITE 271 on the bolt
        2) Place the cylinder head cover gasket on the                          threads to seal the bolts from the crankcase
                                                                                as illustrated.
           cylinder head cover.
                                                                             3) Install the oil filter assembly and tighten the
           Check the head cover gasket for looseness.                           bolts securely.
        3) Tighten the cylinder head cover bolts to the                                                                   kg.m(lb.tt)
           specified torque a little 'at a time in the sequ-           Oil Filter Assembly
           ence shown in the illustration.                             Mounting Bolt Torque

6 cn.                                               kg.m(lb.tt)
  Cylinder Head Cover Bolt
                                     2.1  0.5 (15.2  3.6)
  Torque

4 cn.                                               kg.m(lb.tt)        4. Injection Nozzle
  Cylinder Head Cover Bolt                                                Install the injection nozzles with the injection nozzle
                                     1.1  0.5 (7.9  3.6)
  Torque                                                                  gaskets.
                                                                          Be carefull not to damage the nozzle tips.
                                                                                                                           kg.m(lb.tt)


                                 e
                                 2
                                     -                                                                    1.9  0.2 (13.7  1.5)




        6 CYLINDER



    CYLINDER HEAD
                                                                       NOZZLE /:...L...c..+--.~,,~
    COVERS
                                                                       GASKET


                                                                       5. Fuel Injection Pipe and Fuel Leak Off Pipe
                                             4 CYLINDER
                                                                            1) Install the fuel injection pipes         and tighten
                                                                               the bolts to the specified torque.
                                                                                                                           kg.m(lb.tt)
 2. Starter                                                             Injection Pipe Torque             3.1  0.2 (22.4  1.5)         I
    Install the starter to the flywheel housing and tighten
    the bolts to the specified torque.                                      2) Carefully position and set the clips   CD
                                                                                It is very important that each clip be positioned
                                                        kg.m(lb.ttl
                                                                                correctly.
  Starter Fixing Bolts
                                           8.4 (60.7)                           An improperly positioned clip will result in
  Torque
                                                                                objectionable fuel pulsing noise and injection
                                                                                pipe breakage.
DRIVE BELT                                                                  3) Install the fuel leak off pipes
Adjust the drive belt tension.
Refer to MAINTENANCE for the drive belt tension
adjustment.




                                                            Engines & Generators

                                                                  44
                                                            ASSEMBLY
6. Fuel Pipe (Feed Pump to Fuel Filter).                                    16. Alternator installation.
7. Fuel Pipe (Fuel Filter to Injection Pump).                                   a. Put the alternator in position. Install the adjusting
8. Fuel Return Pipe.                                                            bolt in position to hold the alternator in position.
   Install the fuel pipes and tighten the fuel pipe joint                       b. Put the belt in position on the pulley. Move the
   bolts to the specified torque.                                               alternator away from the engine to make an
                                                                                adjustment to the belt.
   Take care not to interchange the check valves and
   joint bolts.                                                                 c. Tighten the bolts.
                                                                                d. Make sure the tension of the belt is correct, about
                                                   Kg-m (lb-ft)                 1/2" deflection at the center with pressure.
I FUEL PIPE JOINT BOLTTORQUE   1.7  0.1 (12.3  0.7)
9. Intake Pipe.                                                             MARINE TRANSMISSION
   Install the intake pipe and tighten the intake pipe                      1. Assemble the damper plate to the flywheel.
   flange bolts to the specified torque.                                    2. Reinstall the marine transmission and fill with
                                                                               ATF Dextron III.
                                                  Kg-m (lb-fI)
 INTAKE PIPE FLANGE BOLT TORQUE       1.7  0.1 (12.3  0.7)                NOTE: Some transmissions, such as the Borg Warner Velvet
1 O.lnstall the Thermostat and Thermostat Housing.                          Drive require oil coolers. Oil coolers should be cleaned,
    a. Inspect the thermostat housing and the housing                       pressure tested and repainted at engine overhaul. The
       gasket. Apply some sealant to the gasket when                        transmission oil cooler hoses should also be inspected.
       reassembling.                                                        Refer to the text on Heat Exchangers.
    b. Install the temperature switch and sender and                        3. Fill the engine cooling system with antifreeze
       reconnect their wires.                                                  mixture and the engine oil sump with lube oil
11.lnstall the Oil and Water Sender and Switch.                                (A.P.1. spec. CF or CG-4).
12.lnstall the Starter Motor.                                                  The engine should, be test run under load prior to
                                                                               reinstalling. At this time readjust the valve
13.lnstall the Breaker Panel and the Preheat                                   clearances on the hot engine.
    Solenoid.
                                                                               Allow the engine to cool to room temperature and re-
14.Reinstall the Engine Electrical harness.                                    torque the cylinder head bolts and re-check the
15. Mount the complete Exhaust Manifold and the                                valve clearances. See ENGINE ADJUSTMENTS.
    Expansion Tank to the Cylinder Head.
                                                                            GENERATOR
EXHAUST MANIFOLD/HEAT EXCHANGER                                             1. Mount the generator back end assembly with its
The exhaust manifold, which was disassembled from the                          control panel. Reconnect all DC wiring and
cylinder head, should be inspected before reassembly.                          reconnect all AC connections.
a. Remove the exhaust elbows from the lower surface
    of the manifold. Clean and inspect for cracks and
    defects. Replace as needed.                                                 A CAUTION: Check al/ AC and DC wiring
b. Remove the exhaust nipples, elbows and plugs from                            connections to WESTERBEKE wiring schematics
    the manifold and heat exchanger.                                            and diagrams.
c. Remove water connectors from the ends of the
    manifold. Be sure to note the proper location and
    arrangement of each for proper alignment.                               2. Fill the engine cooling system with antifreeze
                                                                               mixture and the engine oil sump with lube oil
d. Examine all parts for defects, corrosion and wear                           (A.P.1. spec. CF or CG-4).
    and replace as needed.                                                     The engine should be test run under load prior to
e. Flush out the manifolds interior with a liquid cleaner                      reinstalling. At this time readjust the valve
    and rinse thoroughly with fresh water.                                     clearances on the hot engine.
f.Use a pipe cleaner to clear the passage that                                  Allow the engine to cool to room temperature and re-
    connects the coolant recovery tank tubing.                                  torque the cylinder head bolts and re-check the
g. Flush out the coolant recovery tank and its                                  valve clearances.See ENGINE ADJUSTMENTS.
    connecting tube.
h. Replace the heat exchanger zinc.
Llnstall new hose connections and clamps for the cool-
    ing system.




                                                                  Engines & Generators

                                                                       45
                                                ASSEMBLY

ENGINE TUNING OPERATION                                      10.Check that the engine oil is continuously circu-
                                                                 lating from the oil pump to the valve rockers
After reassembly, the engine must be tuned. This will            through the cylinder head.
ensure that the engine operates at its maximum
efficiency.                                                      If there is no oil circulation or if the oil circulation is
                                                                 sluggish, stop the engine and make the appropriate
1. Mount the engine on a test bench.                             repairs or adjustments.
2. Connect the electrical wiring. Refer to the WIRING            Reinstall the cylinder head cover.
    DIAGRAM.
                                                             11.lncrease the engine speed to 1500 rpm to do the
3. Connect the air intake line to the air cleaner.               engine warming-up operation.
4. Connect the exhaust pipe.                                 12.Check the engine for oil, fuel, coolant, and air
5. Manually operate the fuel feed pump to feed fuel              intake leakage.
    to the engine.                                           13. Check for abnormal noise and odor.
6. Bleed the fuel lines of air.                              14.Check for abnormal electrical charging.
7. Crank the engine with the starter (non-ignition           15. Check the engine fastening parts for looseness.
    operation) for about twenty seconds. This will
    pre-lubricate the engine internal components.            16 When the engine coolant temperature reaches
                                                                 75C (167F) or more, increase the engine speed
S. Start the engine and allow it to run at 750 to SOO            to 2000 rpm and allow it to run for twenty
     rpm for five minutes.                                       seconds.
9. Remove the cylinder head cover while the engine               This will give the engine the essential run-in
     is running.                                                 operating time.
                                                             17.Adjust the engine operation speed to the
                                                                 specified value.
                                                             1S. Stop the engine to complete the tuning
                                                                  procedure.


      Refer to the following pages for details of sub-assemblies. These sections also include: Wiring D!agrams,.
      Engine/Generator Specifications, Torque Diagrams, Generator Data, and a detailed Troubleshooting Section.




                                                  Engines & Generators

                                                        46
                                                                      LUBRICATING SYSTEM
OIL SYSTEM FLOW DIAGRAM
                               Full flow filter                                                    Oil pressure
                r - - - - - - - - - -         - -    - - - - -,                                    and oil filter            I Starter
                I          ~---
                           I
                               ~y.pass ",'
                                                      n <~l-':,--------'--f----1
                                                              I
                                                                                                   warning light
                                                                                                                             ,switch
                                                                                                                                    -.J
                                                                                                                                            Battery
                                                                                                                                            I   J             TURBO ONLY
                                                                                                                                       11 f-. - 1 ~
                                                                                                                                                                 j
                I     -
                               valve  V"'"                                                                                          -
                      -,                              LJ      I                                                                                          ~
                           I          IValve opening ~
                                       pressu re 1 kg/cm 1
                                                                                                  OL'I-------"t h                                     ----:_________ .
                                                                                         ~L...::....,....:p::..r..::.e.:..:ss..::.u-,re-,sw~,.:..:c-'--_ _ _ _ _i--_ _ _ _ _-,   I



                                                                                                                                                        ,~


                                                                                                                                       Ini            .8~      Oiling
                                                                                                                                       pump             5'"     iet
                                                                                                                                                       1-'
                                                        6BD1T only
                                          r--              --,
                                          I                       I
                                          I         Partial
                                                       I
                                          I            I Valve opening                   Oil
                                          I filter     I pressure 4.5kg/cm'              relief                                                                 Pisto
                                          I            I
                                          L _ _ _ _ _ .J                                 valve



                                                                                                                                                  I
                                                                                                                                                  I
                                                                                                                                                  I

                                                                                                                                                 :             I
                                                                                                                                                 ~ _________ J                       /
                                                                              Oil pan

    OIL PUMP                                                                              Visually inspect the disassembled                                              parts           for
 THIS GEAR TYPE OIL                                                                       excessive wear and damage.
 PUMP IS DRIVEN BY
 THE CAMSHAFT OIL                                                                         Oil Pump Drive Gear
 PUMP DRIVE
                                                                                          Use a feeler gauge to measure the clearance between
                                                                                          the oil pump cover (oil pump case) inside surface and
 NUMBERS INDICATE
                                                                                          the drive gear.
 SUGGESTED ORDER                                                                          If the cle'arance exceeds the specified limit, the drive
 OF DISASSEMBLY                                                                           gear and/or the oil pump cover must be replaced,
                                                                                                                                                                                     mm(in)
                                                                                                                                                                     Limit
                                                                                              Oil Pump Cover and Oil Pump
                                                                                                                                                              0.18 (0.0071)
                                                                                              Drive Gear Clearance




4DRIVEN
  GEAR
                                                                        DRIVE SHAFT                OIL PUMP COVER                                                    FEELER GAUGE
                                                                        & GEAR




6 DRIVEN GEAR
  SHAFT - - - -           ...J-<;;;~.-j




2 SUCTION PIPE                                                                           Make the necessary adjustments, repairs, and parts
                                                                                         replacements if excessive wear or damage is indicated,



                                                                             Engines & Generators

                                                                                        47
                                          LUBRICATING SYSTEM
                                                                         Cartridge (Spin-On) Type
                                                                         Removal
                                                                         Remover and Installer: Filter Wrench
                                                                          1. Loosen the used oil filter by turning it counterclock-
                                                                             wise with the filter wrench.
                                      .....~I ...___
                                     __                STRAIGHTEDGE       2. Discard the used oil filter.

                                                                         Installation
                                                FEELER GAUGE              1. Wipe the oil filter mounting face with a clean rag.
                                                                             This will allow the new oil filter to seat properly.
Oil Pump Driven Gear    '
                                                                          2. Lightly oil the O-ring.
Use a feeler gauge to measure the clearance between
                                                                          3. Turn in the new oil filter until the sealing face is fit-
the oil pump case cover inside surface and the driven
gear.                                                                        ted against the O-ring.
                                                                          4. Use the filter wrench to turn in the oil filter an addi-
If the clearance exceeds the specified limit, the driven
                                                                             tional 3/4 of a turn or one turn.
gear or the oil pump cover must be replaced.
                                                                          5. Check the engine oil level and replenish to the spec-
                                                          mm{in)
                                                                             ified level if required.
                                               Limit
                                                                          6. Start the engine and check for oil leakage from the
  Oil Pump Body and Driven                                                   oil filter.
  Gear Clearance       ---------
                                                                                          1 ELEMENT
                                                                         OIL COOLER
                                                                      NUMBERS INDICATE THE
                                                                      ORDER OF ASSEMBLY
SPIN DN OIL FILTER ~




                                                                                                             INSPECT AND MAKE ALL
     D-RING                                                                                                  NECESSARY REPAIRS AND
                                                                                                             REPLACEMENTS



                                                                         Install the oil cooler element to the oil cooler, and
                                                                         tighten the cooler element fixing nuts to the speci-
                                                                         fied torque.                                       .
                                                                                                                         kg.m(lb.tt)
                                                                            Oil Cooler Element
                                                                                                            2.6  0.5 (18.8  3.6)
                                                                            Fixing Nut Torque



     DRAIN



   CONTAINER -~~u




                                                  CHANGING THE OIL




                                                            Engines & Generators

                                                                   48
                                             COOLING SYSTEM

1 COOLANT PUMP                                          NUMBERS INDICATE
  PULLEY                                                ORDER OF DISASSEMBLY

                                                                                         2 COVER AND GASKET
                                                                                                  f\

                                                                       3IMPELLER~




    COOLANT PUMP
    DISASSEMBLY


                                                                                                       SNAP RING




                                                                       3. Snap Ring
                                                                         Use a pair of snap ring pliers to remove the snap
    1. Impeller                                                          ring.

        Use the remover to remove the impeller.                        4. Spindle, Bearing, and Spacer
                                                                          Use a bench press and a suitable remover to
                                         REMOVER                          remove the spindle, bearing, and spacer.

                                                       ___ PUMP
                                              ------       BODY




                                               VISE
   2.
        Use a bench press and a suitable rod to remove the
        pulley center.


                                                                       5. Seal Unit, Washer and Seal
                                                                          Use a suitable remover to remove the seal unit, the
                                      PULLEY CENTER
                                                                          washer, and the seal.




                                                           Engines & Generators

                                                                  49
                                                   COOLING SYSTEM
  INSPECTION AND REPAIR                                                ASSEMBLY
  Make the necessary adjustments, repairs, and parts                   7. Spindle, Bearing, and Spacer
  replacements if excessive wear or damage is
  discovered during inspection.                                          Lubricate the bearing with multipurpose grease.
                                                                         Use a bench press to install the spindle, the bearing
                                                                         and the spacer.



                                      REMOVING THE BEARINGS
                                      AND SPACER


                                                                                                         SMALLER BEARING
                                                                                    LARGE BEARING
6. Bearing Replacement
                                                                       8. Snap Ring
  Removal:
                                                                          Use a pair of snap ring pliers to install the snap
  Use a bench press to remove two bearings and the                        ring.
  spacer.
                                                                       9. Pulley Center
  Installation:                                                           Use a bench press and a bar to install the pulley
  Use a bench press to install two bearings and the                       center.
  spacer.

                                                                                                              PRESS & BAR

                                                                             PULLEY   CENTER-----'~



  Use a micrometer to check the fitness at the three
  points shown in the illustrations.
                                              mm(in)
                  Shaft to Pulley Center       0.02 - 0.06
                  Fitness                   (0.0008 - 0.0024)        10. Seal Unit, Washer and Seal
                                                            --
                  Shaft to Impeller            0.07 - 0.11                 1) Apply a thin coat of liquid gasket to the seal
     Fitness
                  Fitness                   (0.0028 - 0.0043)                 unit outer periphery before installation.
                  Pulley Center to Pulley     0.14 (0.0055)
                  Fitness                        or less                   2) Use a bench press and a bar to install the seal
                                                                              unit into the pump body.




                     SHAFT                        IMPELLER




                   ~
                  PULLEY CENTER
                                                 
                                                   PULLEY


                    @                            o
                                                 V
                             TAKING MEASUREMENTS




                                                             Engines & Generators

                                                                  50
                                                    COOLING SYSTEM
    11. Impeller                                                           HEAT EXCHANGER
         1) Use a bench press to install the impeller to the              The heat exchanger should be inspected and serviced
            spindle.                                                      during an engine overhaul.
         2) Use a feeler gauge to measure the clearance                   1. Disconnect the hoses and remove the hoses fittings,
            between the impeller and the pump body.                          drain plug and zinc anode. Also, remove the end
                                                                             fittings and gaskets,
                                                           mm(in)
                                                                          2. Inspect the tube (casing) for wear and dents, if at all
     Clearance between                                                       suspect replace the heat exchanger.
                                       0.3-0.8 (0.0118-0.0315)
     Impeller and Pump Body                                               3. Clean out any zinc debris and pressure test the
                                                                             coolant and raw water passages.
                                       * - - - - BENCH PRESS              4. When reassembling, install new gaskets and O-rings.
                                                                             Apply some lubricant to the new gaskets and to the
                                                                             fittings as you install them.
                                                                          5. Install a new zinc anode.
       FEELER ----;.~~~::::=?:::::::
       GAUGE            t-
                                                                          Note: All of the above can be accomplished by sending the
                                                                          heat exchanger to a heat exchanger service shop. They will
                                \("                                       also service transmission and engine oil coolers,
    12. Pulley                    \I
                                                                          6. Repaint the assembled heat exchanger with
        Install the pulley and tighten the pulley bolts to the               WESTERBEKE heat resistant spray enamel.
        specified torque.
                                                      kg.m(lb.ft)
   I Pulley Fixing Bolts Torque I
      INSTALLING
      THE PULLEY




    THERMOSTAT
                                                                    ZINC ANODE
    Disassemble and inspect both halves of the thermostat           ALSO SERVES AS A
    housing looking for cracks and deterioration, replace if        DRAIN FOR RAW WATER
    necessary. Install a new thermostat and gasket.


INSPECT THE THERMOSTAT HOUSINGS F O
CRACKS OR DAMAGE INSTALL A NEW   ~
                                  '. R
                                     '. . b . /. .~,
                                         . ' ":C-' .. '\
THERMOSTAT AND GASKET         i~~!', \
                             /,j(                     , '
                                                                                                     TO REMOVE HEAT EXCHANGER




     REPLACE GASKET
                                          1                                DRIVE BELT
                                                                           Adjustment
                                                                           1. Inspect the cooling fan drive belt for cracking and
                                                                           other damage. Replace if suspect.
                                                                           2. Check the drive belt tension by exerting a force of
                                                                              10kg (22 Ib) midway between the pulley and the
                                                                              alternator pulley.
                                                                           3. Adjust the belt tension by loosing the alternator
   THE GASKET IS GROOVED                                                      mounting bolt and adjusting bolt and pivoting the
   AND FITS AROUND THE                                                        alternator.
   OUTER EDGE OF THE
   THERMOSTAT                                                                Be sure to retighten the bolts after adjusting the belt
                                                                             tension.



                                                             Engin~ s   & Generators

                                                                     51
                                   WESTERBEKE RAW WATER PUMP
                        COMPLETE OVERHAUL/PUMP REMOVED FROM ENGINE
DISASSEMBLE                                                           INSPECTION
1. Remove the six screws and lock washers, and the sealing            Inspect all parts for wear and corrosion. It is also
   O-ring. Inspect the O-ring for re-use.                             recommended that O-rings, gaskets, and seals be replaced.
NOTE: Inspect the impeller for cracks or stiffness and replace
if necessary.                                                                                           PARTS LIST
2. Remove the impeller key.                                           Key #            Part Name              Part Number                        Quantity
3. Remove the lock nut and withdraw the drive gear from                                Pump Housing           44344
   the pump shaft and remove the key. [Insert a metal rod              2               Shan                   43510
   0.19" in diameter thru the hole in the shaft to prevent it          3               Impeller               43506
                                                                   ----       ._---   ------
   from turning while removing the lock nut].                          4               Cam                    43503
                                                                       5               Cover                  43509
4. Using snap pliers, remove the snap ring.
                                                                       6               Gear                   43511
                                                                   ----                            ..
S. Press out the shaft and bearing assembly from the pump              7
                                                                              ------~----




                                                                                       O-Ring                 43567
   housing. Using an arbor press, support the bearings inner           8               Key                    43675                              2
   race and press the shaft out of the bearings.                       9               Bearing                35972                              2
                                                                                                            -----            ---_.. -   ------   -

6. Remove the O-rings from the shaft.                                 10               Seal                   43566                              1
                                                                      11               O'Ring                 43568
7. Remove the shaft seal from the housing.[Note the seal
                                                                      12               Snap Ring              43569
   face position in the housing so as to re-install the new                   - - ---     --                ------- -- ---
                                                                      13               O'Ring                  43570                             1
   seal correctly].
                                                                      14               Cap Screw               43673                             6
8. Remove the cam screw and sealing washer and withdraw               15               Nut                     45691                             1
                                                                                                                                          ------
   the cam from the housing.                                          16               Lockwasher              317BO                             6
                                                                      17               O'Rlng                 44183
                                                                      18               Screw                  43675
REASSEMBLY
                                                                      19               Washer                 32869                              1
Reassemble the pump in the reverse order.                                              Cap Screw              43674.                             1
Apply a small amount of petroleum jelly on the lip of the
shaft seal and on the shaft itself when installing the
shaftlbearing assembly into the pump housing.                                 CAREFULLY MESH THE PUMPS GEAR
                                                                              WITH THE TIMING GEAR
When installing the pump cam inside the housing, apply a                      WHEN ASSEMBLED
small amount of Permatex #1 to the inner surface of the cam
and to the securing screw threads. Remove any excess.                                                   6




              USE PERMATEX #1 ON
              THE SCREW THREADS
              AND THE INNER CAM




                                                                                                 INSPECT HOUSING FOR CRACKS




         AT REASSEMBLY, APPLY A LIGHT
         COAT OF SILICONE OR PETROLEUM
         JELLY TO THE INNER SURFACE
         OF THE HOUSING
                                                           Engines & Generators

                                                                 52
                                               TURBOCHARGER
                                                                                                                          mm(in)
                                                                                 (6 Cyl.)                      Limit
                                                                     Rotor Shaft Radial Play TIR          0.215 (0.0085)

                                                                    4) If the measured value exceeds the specified limit,
                                                                       replace the shaft.


                                                                                             MAGNET
                                                                                             BASE




                           TURBO CHARGER
     TO OIL SUMP -+-



Rotor Shaft Axial Play Measurement
                                                                      Turbocharger Mounting Flange Gasket
 1) Install a dial indicator on the turbine housing as illu-
    trated.                                                           Carefully position the gasket with the edged side
                                                                      facing up.
2) Use the dial indicator to measure the rotor shaft
   axial play with moving the shaft push and
   pull. Read the total indicator reading (TIR).
                                                      mm(in)
                                           Limit
  Rotor Shaft Axial Play TIR          0.11 (0.0043)

3) If the measured value exceeds the specified limit                  Turbocharger
   the shaft must be replaced.                                        Semitighten the turbocharger mounting nuts.
                                                                      The nuts will be fully tightened after installation of
                                                                      the oil pipes.
                                                                                                                       kg.m(lb.ft)
                                                                    Turbocharger Mounting
                                                                    Nut Torque




     PULL
          t-rr-=::...~
     PUSH AND
                                            t-
                                            PUSH AND
                                            PULL




Rotor Shaft Radial Play Measurement
                                                                      Oil Drain Pipe
 1) Turn over the turbocharger with the turbine exhaust
    inlet flange facing up.                                             1) Remove the exhaust manifold distance tube
                                                                           immediately beneath the turbocharger.
 2) Install a dial indicator to measure the rotor shaft
    radial play.                                                           This will make it easier to install the oil drain
                                                                           pipe.
3) Use the dial indicator to measure play. Read
   the TIR.                                                             2) Install the oil drain pipe and tighten the oil drain
                                                      mm(in)               pipe flange nuts to the specified torque.
           (4 Cyl.)                        Limit                                                                    kg.m(lb.ft)
  Rotor Shaft Radial Play TIR         0.19 (0.0075)                  Oil Drain Pipe Torque            3.8  0.7 (27.5  5.1)         I
                                                                        3) Reinstall the exhaust manifold distance tube.


                                                       Engines & Generators

                                                               53
                                              TURBOCHARGER



                                                                FIXING BOLTS

 Oil Feed Pipe                                                                                                              kg.m(lb.ft)
 1) Pre-lubricate the turbocharger with engine oil                   Turbo Adaptor Fixing
                                                                                                       5.3  1.0 (38.3  7.2)
     through the oil port shown in the illustration.                 Bolt Torque
 2) Install the oil feed pipe and tighten the pipe
    flange bolts to the specified torque.

                                                kg.m(lb.ft)
                                                                 CHECKING
Oil Feed Pipe Flange                                               1. Check the air intake duct connections for air lea-
                                2.6  0.5 (18.8  3.6)                kage.
Bolt Torque
                                                                   2. Check the intake manifold connections for air lea-
                                                                      kage.

                                                                   3. Check the exhaust duct connections for smoke lea-
                                                                      kage.
                                                                   4. Check the turbocharger mounting nuts for loose-
                                                                      ness.

                                                                   5. Check the oil feed pipe for oil leakage.

                                                                 6. Check the oil return pipe joints for oil leakage.
                                                                                                             Kg-m (Ib-It)
                                                                   lOlL RETURN PIPE BOLTS TORQUE   2.1  0.5 (15.2  3.6)


  Turbo Adapter (6 cyl.)
   1) Use a screw driver to insert the gas sealing ring
      to the turbocharger exhaust outlet port.
   2) Tighten the turbo adaptor fixing bolts to the
      specified torque.




                                         GAS SEALING RING




                                                       Engines & Generators

                                                              54
                                                   ENGINE ADJUSTMENTS
INJECTION TIMING ADJUSTMENT                                                 4. Hold the fuel control lever at the fully open position.
Bring No. I piston to the top dead center on the compression                5. Slowly tum the crankshaft pulley clockwise and at the
stroke. Tum the crankshaft pulley clockwise (viewed at                         same time, feed fuel to the injection pump by slowly
engine front) and align the mark on the crankshaft pulley                      pumping the feed pump. When the fuel stops to flow out
with the TOC mark.                                                             from No. I delivery valve holder, stop turning the crank-
                                                                               shaft pulley and pumping. This is the beginning of fuel
Remove the access cover at the front of the injection pump
                                                                               injection.
and check the alignment between the pointer A on the
injection pump gear lock plate and the projected pointer B on                                                        4 CYL. SHOWN
the timing gear case. If A and B are in alignment, the timing
                                                                                                                     THE 6 CYL. HAS EIGHT
is set correctly.                                                                                                    TIMING NOTCH LINES
If they are in alignment, No.1 cylinder is at the TOC on                                                             PUNCHED ON THE GEAR
the compression stroke. If it is in misalignment, recheck by                                                         CASE AND THE TOC
                                                                                                                     MARK ON THE CRANK
turning the crankshaft pulley one more tum to repeat the                                                             PULLEY
procedure to make sure that it is in alignment.

                                                 TIMING GEAR
                                                 CASE


                                                                                                                   PUllEY MARK




                                                                            6. Notice which injection timing mark is aligned with the
                                                                               pulley mark. The timing mark in alignment with the
                                                                               pulley mark indicates the degrees before (TOC), the start
                                                                               of fuel injection
Check the crankshaft position for the start of fuel injection.              7. Blowout the remaining fuel from'the delivery valve
                                                                               holder. Check that there is no fuel being delivered from
1. Tum the crankshaft pulley counterclockwise viewed from
                                                                               the priming pump.
   the engine front about 30.
2. Remove No. I high pressure injection line.                                  INJECTION TIMING BCTC (4 CYL.) 14
                                                                                                    (4 CYL. TURBO) 12

                                        ......--DELIVERY VALVE
                                                  HOLDER                       INJECTION TIMING BlDC (6 CYL.) 12
                                                                                                    (6 CYL. TURBO) 12



                                             -SPRING

                           m::=;:ij,~   _ _ _ DELIVERY
                                               VALVE




3. Remove the injection pump No.1 delivery valve holder,
   delivery valve and spring and reinstall the delivery valve
   holder back into the pump.
   DELIVERY VALVE HOLDER TIGHTENING TORQUE:
   39 - 44 Nm (4 - 4.5 Kg-m/28.9 - 32.5 ft-Ib)




                                                                 Engines & Generators

                                                                       55
                                                 ENGINE ADJUSTMENTS
ADJUSTMENT PROCEDURES
1. Align the pulley mark and the specified timing mark.
   (Refer to the injection timing specifications.)
2. Loosen the four injection pump attachment nuts.                     LOOSEN FOUR NUTS
3. To advance the timing, pivot the injection pump at the              (80TH SIDES)
   pump drive shaft away from the engine.
   To retard the timing, pivot the injection pump at the
   pump drive shaft toward the engine.
   NOTE: A 1mm misalignment between the timing marks
   on the crankshaft pulley will correspond to about 2 in
   crank angle.
4. Recheck the timing, following procedures 1 through 5.
5. Tighten the four injection pump attachment nuts.
6. Again remove No.1 delivery valve holder, and reinstall
   the delivery valve, spring and the valve holder.
   DELIVERY VALVE HOLDER TIGHTENING TORQUE:
   39 - 44 Nm (4 - 4.5 Kg-m/28.9 - 32.5 ft-Ib)
7. Reinstall the No.1 high pressure injection line.
                                                                                          TIMING GEAR
                                                                                          CASE




                                                          Engines & Generators

                                                               56
                                             ENGINE ADJUSTMENTS
TESTING ENGINE COMPRESSION                                               OIL PRESSURE
Make certain the oil level (dipstick) is at the correct level            The engine's oil pressure. during operation, is indicated
and the air intake filter is clean. The battery and starter motor        by the oil pressure gauge on the instrument panel. During
must also be in good condition.                                          normal operation. the oil pressure will range between 40 and
                                                                         60 psi (2.8 and 4.2 kg/cm).
1. Warm the engine to normal operating temperature.
2. Move the control lever to a position for shutting off the             NOTE: A newly started, cold engine call have an oil pressure
    fuel. (Disconnect the wires if a fuel shutdown solenoid              reading up to 60 psi (4.2 kglcm2). A warmed engine can have
    is used).                                                            an oil pressure reading as low as 35 psi (2.5 kgIc171 2). These
3. Remove all the glow plugs from the engine and install                 readings will vary depending upon the temperature ()f the
                                                                         engine and the rpm.\'.
    the compression gauge/adapter combination to the
    cylinder on which the compression is to be measured.
                                                                         Low Oil Pressure
                                                                         The specified safe minimum oil pressure is 5 - 10 psi. A
                                                                         gradual loss of oil pressure usually indicates a worn bearings.
                                                                         For additional information on low oil pressure readings, see
 TESTING ENGINE COMPRESSION                                              the ENGINE TROUBLESHOOTING chart.

                                                                         Testing Oil Pressure
                                                                         To test the oil pressure, remove the oil pressure sender, then
                                                                         install a mechanical oil pressure gauge in it's place. After
                                                                         warming up the engine. set the engine speed at idle and read
                                                                         the oil pressure gauge.

                                                                         OIL PRESSURE      50 psi at 1800 rpm.
                                                                         SENDER AND SWITCH TORQUE          9 -13 fI-lb (1.2 - 1.8 m - kg).

                                                                         Oil p~ure at 1800 (or 1500) rpm should maintain a reading
                                                                         of 50 pSI.
4. Close the raw water seacock (thru-hull).
5. Crank the engine and allow the gauge to reach a
   maximum reading, then record that reading.                                                             PREHEAT SOLENOID
6. Repeat this process for each cylinder.
    COMPRESSION PRESSURE 441 psi (31.0 Kg/em') at 200 rpm.
    ALLOWABLE LIMIT    370PSI (26.0 Kg/em').
    MAXIMUM PERMISSIBLE DIFFERENCE BETWEEN CYLINDERS                                                                            20A BREAKER
    28.44 psi (2.0 Kg/em')
NOTE: lfthe readings are below the limit, the engine needs an
    overhaul.
7. Re-install the glow .plugs and reset the fuel shut-off to the
   run position.
S. Open the raw water seacock (thru-hull).
Low Compression
When low compression is found, detemline the cause by
applying a small amount of oil in the cylinder thru the glow
plug hole. Allow the oil to settle.
Install the pressure gauge and repeat the above test. If the
compression reading rises dramatically, the fault is with the
rings. If the compression valve does not rise, the problem is
with the valves.
A slight rise in compression would indicate a problem with                                                             I
both the rings and the valves.                                                                          Oil PRESSURE
                                                                                                        SWITCH




                                                             Engines & Generators

                                                                    57
                                                              ENGINE ADJUSTMENTS
VALVE CLEARANCE ADJUSTMENT
NOTE: The cylinder head bolts have been tightened with
the "Angular Tightening Method" shown ill this manual.                                                 ADJUSTING
Therefore. it is not necessary to retighten the cylinder head                                          SCREW
bolts before adjust!ng the valve clearances.                                                                                                 VALVE CLEARANCE
Chart shows six cylinder model                                                                                                               0.076 IN (0.40MM)

       Cylinder No.             1         2         3         4         5         6
       Valve arrangement    I       E I       E I       E I       E I       E I       E
       When No.1 cylinder
       is at TDC in the     00 0                        0 0             0
       compression stroke
       When NO.6 cylinder
       is at TOC in the                       0 0             0 0             00               4. Loosen each valve clearance adjusting screw as shown in
       compression stroke                                                                         the illustration.
                                                                                               5. Insert a 0.40mm (0.016 in) feeler gauge between the
1. In order to bring No.1 or No.6 (six cyl.), No.4 piston                                         rocker arm and valve stem end.
   (four cyl.) to the top dead center in the compression                                       6. Turn the valve clearance adjusting screw until a slight
   stroke, align the TDC mark and the crankshaft pulley                                           drag can be felt on the feeler gauge.
   mark.                                                                                       7. Tighten the locknut
Chart shows four cylinder model                                                                   LOCKNUT TORQUE         18.8  3.6 Hlb (2.6  0.5 kgm)
       Cylinder No.             1         2         3         4                                8. Rotate the crankshaft 360.
       Valve arrangement    I       E I       E I       E I       E                            9. Realign the crankshaft pulley TDC notched line with the
       When No.1 cylinder                                                                          timing pointer.
       is at TOC in the   0 0         0                 0                                      10. Adjust the clearances for the remaining valves as shown
       compression stroke
                                                                                                   in the illustrations.
       When NO.6 cylinder
       is at TOC in the                       0 0           0 0
       compression stroke


2. Do the adjustment on the circle marked valves in the
   above table where No.1 piston is in the TDC in the
   compression stroke. After these steps, do the adjustments
   on the double circle ,marked valves where the No.6                                                        NO.1 CYLINDER IS AT TOC IN COMPRESSION STROKE
   piston (six cyl.) No.4 piston (four cyl.) is on TDC in the
   compression stroke.
3. After adjusting the valves with piston No.1 at TDC,
   rotate the crankshaft 360 again aligning the TDC mark
   and the pulley mark. This brings piston No.6 or No.4 to
   TDC, then adjust the remaining valves.



                                                                                                                     FRONT


                                                                                                       NO.1 CYLINDER IS AT
                                                                                                       TOC IN COMPRESSION
                                                                                                       STROKE              '-1~I"""~_.a....==---t=.......:;:,,~=-'




                                                                                                                     FRONT   ~~~=~=:::,--==..-~




                                                                                                       NO.4 CYLINDER IS AT
                                                                                                       TOC IN COMPRESSION
                                                                                                       STROKE



                                                                              Engines & Generators

                                                                                          58
                                                           FUEL SYSTEM

    FUEL INJECTION PUMP                                                  Changing the Fuel Filter
    The fuel injection pump is a very important component                1. Shut the fuel supply off.
    of the diesel engine, requiring the utmost care in handling.         2. Slip a plastic bag over the fuel filter to prevent
    If the fuel injection pump requires servicing, remove it and            fuel spillage then loosen the fuel filter, turning
    take it to an authorized fuel injection pump service facility.          counterclockwise with a filter wrench.
    Do not attemJ)t to disassemble and repair it.
                                                                         3. Using a rag, wipe clean the sealing face on the
                                                                            housing bracket so the new filter can be seated
                                                                            properly.
                                                                         4. Lightly oil the sealing O-ring on the new filter. To
              ]                                                             reinstall, turn the filter assembly counterclockwise
                                                                            carefully until the O-ring contacts the sealing
                                                                            surface of the housing bracket. Turn 2/3 further
                    o I                         I    0
                                                                            with the filter wrench.
                       3RG .....
                       Pump No. 101                          NOTE: The cartridge contains fuel. Take care not to ~pill it
                  NpPE SA95 ..............
                        (LICENCE BOSCH)
                                                                         during disassembly.
                                                                         5. Open the fuel supply. The filter will fill with fuel.
                        @ ... ldentificetion number                         Check for leaks.
                                                                         6. Run the engine to make certain there are no leaks.

   IDENTIFICATION PLATE AND PRODUCT SERIAL
   NUMBER
     1. Injection pump adjustment and repair should be
        made by the nearest DKKC (Diesel Kiki Co., Ltd.) or
        ROBERT BOSCH Authorized Service Outlet.
    2. When you ask such authoriged service                outlet the
       adjustment or repair, the Identification            Plate and
                                                                                                                         LIGHTLY WIPE
       Product Serial Number will give them a              necessary                                                     WITH CLEAN FUEL
       clue to get technical data distributed by          the manu-
       facturers previously.                                             TO LlFTPUMP
                                                                         AND
        Without this data, the Service Outlet will be unable             FUEL
        to effectively service your injection pump.

        If you are unable to locate the data applicable to
        your injection pump, please contact your                                                                           PREFILL
        WESTERBEKE dealer.                                                                                               . WITH FRESH FUEL

                                                                         FUEL INJECTORS
          FEED PUMP-                                                     Poor fuel quality, contaminants and loss of positive fuel
          KNOB                                                           pressure to the injection pump can result in injector
                                                                         faults. Fuel injectors must be serviced in a clean room
                                                                         environment.
                                                                         Before removing the old injector, clean the area around
                                                                         the base of the injector to help prevent any rust or
                                                                         debris from falling down into the injector hole. If the
                                                                         injector will not lift out easily and is held in by carbo.n
                                                                         build-up or the like, work the injector side-to-side with
                                                                         the aid of the socket wrench to free it, and then lift it
                                                                         out.
                                                                         The injector seats in the cylinder head on a copper
STRAINER                               FUEL FEED PUMP                    sealing washer. This washer should be removed with
CLEAN WITH DIESEL FUEL - -                                               the injector and replaced with a new washer when the
                                                                         new injector is installed.
                                                                         The fuel injectors should be pressure tested after 750
                                                                         operating hours.
                                                                             INJECTION STARTING
                                                                             PRESSURE                    18.1 Mpa (2630 psi)

    Fuel Feed Pump
    The fuel feed pump is an integral part of the injection                  HOLDDOWN NUTS TORQUE        1.9  0.2 kg-m (13.5  1.5 fHb)
    pump. The fuel strainer in the pump should be serviced.
    Refer to the illustration.




                                                                        59
                                                       FUEL SECTION
        5 NOZZLE
          .HOLDER
           PUSH RO                                                      4. Injection- Nozzle
                                                    ,NOZZLE HOLDER         There must be no oil on the contact surfaces of the
                                                     CAP NUT               injection nozzle and the injection nozzle holder.
                                                                           Clean these contact surfaces with diesel fuel before
                                                    CAP NUT                installation.
                                                    GASKET
                                                                           The nozzle dowel pin must be aligned with the
  NUMBERS INDICATE                                                         dowel hole in the nozzle holder body.
  THE ORDER OF
  DISASSEMBLY.
                                                    NOZZLE
                                                    ADJUSTING                                                            ALIGN THE DOWEL
                                                    SCREW                                                                WITH THE HOLE.

                                                                         5. Retaining Nut
                                                                                                                             kg.m(lb.ft)
                                                   PUSH ROD                Nozzle Retining Nut
                                                   SPRING                                                    7  1
                                                                           Torque
6 RETAINING NUT

      Nozzle                                                                     INJECTOR~

      Remove the nozzle assembly from the nozzle body.
                                                                                               /1                TORQUE WRENCH
      Keep the parts separately to maintain the proper
      needle valve to body combination.

      Push Rod Spring
      Check the push rod spring for wear, weakness, and cor-            INJECTION TESTING
      rosion.                                                           1. Using the nozzle tester, check the spray pattern and
                                                                           injection starting pressure of nozzle and, if it
                                                                           exceeds the limit, adjust or replace the nozzle. When
     Nozzle Holder Push Rod                                                using nozzle tester, take the following precautions:
       1. Check the nozzle holder push rod curvature.
       2. Check the nozzle holder push rod and needle valve
          contact surfaces for excessive wear and poor con-
                                                                             A CAUTION: The spray injected from the nozzle is
          tact.
                                                                               of such velocity that it may penetrate deeply into
                                                                             the skin of fingers and hands, destroying tissue. If
     Injection Nozzle                                                        it enters the bloodstream, it may cause blood
                                                                             poisoning.
       1. Check the injection nozzle needle valve, the valve
          seat, and the injection nozzle hole for carbon depos-
          its.                                                                                                       _ NOZZLE INJECTION
                                                                                                                       TESTER
          If carbon deposits are present, the injection nozzle
          and the needle valve must be replaced.
       2. Hold the nozzle body vertically.
          Pull the needle valve about one-third of the way out
          of the nozzle body.
          Release the needle valve.
          Check that the needle valve falls back into the noz-
          zle body as far as the valve seat.
          If the needle valve does not fall back into the nozzle
          body as far as the valve seat, the injection nozzle               a.lf the diesel fuel of the nozzle tester is discolored,
          and the needle valve must be replaced.                               replace it. At the same time, clean or replace the
                                                                               fuel filter.
                                                                            b. Set the nozzle tester in a clean place where there
       3. Injection Pipe Connector                                             is no dust or dirt.
                                                        kg.m(lb.ft)         c. Mount the nozzle holder on the nozzle tester.
         Nozzle Connector Torque        5.5  0.5 (38.8  3.6)     I        d. Use the fuel at the approximate temperature of
                                                                               68F (20C).




                                                           Engines & Generators

                                                                   60
                                                         FUEL SECTION
    e. Operate the hand lever of nozzle tester several                      GLOW PLUGS
    times to bleed the air in the nozzle line, then move
    the hand lever at intervals of one stroke per second                    The glow plugs are wired through the preheat solenoid.
    while reading the injection starting pressure.                          When PREHEAT is pressed at the control panel this
                                                                            solenoid should "click" on and the glow plug should
 Injection Starting Pressure Adjustment.                                    begin to get hot.
 The Injection nozzle injection starting pressure can be                    Inspection
 adjusted after the screw is installed.
                                                                            To inspect the plug, remove the electrical terminal con-
 INJECTION STARTING PRESSURE   2630 psi (18.1 MPa) (185 Kg/em')             nections, then unscrew or unclamp each plug from the
                                                                            cylinder head. Thoroughly clean each plug's tip and




.JJl.lW.,                                            W
                                                                            threads with a soft brush and cleaning solution to
                                                                            remove all the carbon and oil deposits. While cleaning,
                                                                            examine the tip for wear and burn erosion; if it has
                                                                            eroded too much, replace the plug.
                                                                            Testing
 GOOD              BAD                                " BAD '..             An accurate way to test glow plugs is with an ohmmeter.
                                                                            Touch one prod to the glow plug's wire connection, and
                                                                            the other to the body of the glow plug, as shown. A
                                                                            good glow plug will have a 0.4 - 0.6 ohm resistance.
 Spray Condition Check (During Injection Nozzle Testing                     This method can be used with the plug in or out of the
 Operation)                                                                 engine. You can also use an ammeter to test the power
 1. Tighten the cap nut.                                                    drain (5 - 6 amps per plug).
 2. Check the injection nozzle starting pressure.
 3. Check the injection nozzle spray condition.
 Nozzle Holder Cap Nut
                                                                             A WARNING: These glow plugs will become very hot
                                                                              to the touch. Be careful not to burn your fingers when
                                                         kg.m(lb.tt)
                                                                              testing the plugs.
   Cap Nut Torque                  4.5      0.5 (32.5      3.6)   I

                                                                                      TESTING A GLOW PLUG
                                                                                      WITH AN OHMMETER
                                                                                        KEY/PREHEAT-fl/:J.




                                                                                                                                             +
                                                Kg-m (Ib-II)                                                                 TESTING A GLOW PLUG
  INJECTION HOLDDOWN NUTS TORQUE     1.9 0.2 (13.71.5)                                                                     USING A TEST LIGHT




                                                                                                             GLOW PLUGS
                                                                       FROM PREHEAT
                                                                       TERMINAL

                                                                            Re-install the plugs in the engine and test them again.
                                                                            The plugs should get very hot (at the terminal end)
                                                                            within 20 to 25 seconds. If the plugs don't heat up
                                                                            quickly, check for a short circuit. When reinstalling the
                                                                            glow plugs, use anti-seize compound on the threads.


                                                                              A WARNING: Do not keep a glow plug on for more
                                                                              than 30 seconds.

                                                                                                                            Kg-m (Ib-II)
                                                                             I GLOW PLUG TIGHTENING TORQUE TORQUE         2.7 (19.5)




                                                               Engines & Generators

                                                                       61
                                                      TACHOMETER
TACHOMETER/HOUR METER                                                  NOTE: Current model tachometers use a coarse adjustment
                                                                       dial to set the tachometer to the crankshaft pulley IpI11S. The
The tachometer/hour meter used in propulsion engine instru-
                                                                       calibrating screw is then usedfor fine tuning.
ment panels contains two separate electrical circuits with a
common ground. One circuit operates the hour meter and the
other the tachometer. The hour meter circuit operates on 12
volts alternator charging voltage supplied to the (+) terminal
on the back of the instrument.                                                                                        JUMPER WIRE

The tachometer circuit operates on AC voltage 6-8 volts, fed
from one of the diodes in the alternator and supplied to the
tachometer input terminal while the engine is running, and
the alternator producing battery charging voltage 13.0-14.8                                                                    (+) TERMINAL
volts DC.
The following are procedures to follow when troubleshooting
                                                                     COARSE                                                (-) TERMINAL
a fault in either of the two circuits in a tachometer/hour           AOJUSTMENT
meter.
                                                                                                                       TACH INP
Hour meter Inoperative                                                                            CALIBRATION          AC VOLTAGE
Check for the proper DC voltage between (+) and (-)
telminals.                                                             TACHOMETER CHECK (New Installation)
1. Voltage present - meter is defective - repair or replace.           NOTE: In a new installation having new instrument panels,
                                                                       the tachometer may 170t always be correctly calibrated to the
2. Voltage not present - trace (+) and (-) electrical con-
                                                                       engine's rpm. This calibration should be checked in all new
   nections for fault. (Jump 12 volts DC to meter (+)
                                                                       installations.
   telminal to verify the operation.)
                                                                       1. Warm up the engine to nonnal operating temperature.
Tachometer Inoperative                                                     Remove any specks on the crankshaft pulley with a clean
Check for the proper AC voltage between tachometer input                   cloth and place a piece of suitable reflecting tape on the
tenninal and (-) tell11inal with the engine running.                       pulley to facilitate use of a photoelectric type tachometer.
1. Voltage present - attempt adjusting meter through calibra-          2. Start and idle the engine.
   tion access hole. No results, repair or replace meter.              3. Aim the light of the tachometer onto the reflecting tape to
2. AC voltage not present - check for proper alternator DC                confinn the engine speed. Check the instrument panel
   output voltage.                                                        tachometer reading. Adjust the tachometer in the panel by
                                                                          using the instrument coarse adjustment to calibrate the
3. Check for AC voltage at tach telminal on alternator to
                                                                          instrument reading to the closest R.P.M. that the photo tach
   ground.
                                                                          is showing. Then use the fine calibration adjustment to
4. Check electrical connections from tachometer input ter-                bring the instrument to the exact reading as the photo tach.
   minal to alternator connection.
Tachometer Sticking
1. Check for proper AC voltage between "tach inp."
   tenninal and (-) telminal.
2. Check for good ground connection between meter (-)
   terminal and alternator.
3. Check that altemator is well grounded to engine block at
   alternator pivot bolt.
Tachometer Inaccurate
a. With a hand-held tach on tile front of the crankshaft
   pulley retaining nut or with a strobe-type tach, read the
   front crankshaft pulley rpm at idle.
b. Adjust the tachometer with a small Phillips type screw-
   driver through the calibration access hole in tl1e rear of
   the tachometer. Zero tile tach and bring it to the rpm
   indicated by the strobe or hand tach. (Verify tile rpm at
   idle and at high speed and adjust the tach as needed).




                                                             Engines & Generators

                                                                  62
                                 WESTERBEKE 51A MANDO ALTERNATOR
                                              DISASSEMBLY AND TESTING

                                                                      A WARNING: A failed alternator can become very
                                                                      hot. Do not touch until the alternator has cooled down.

                                                 REAR HOUSING

                                                                      A WARNING Before starting the engine, make
                                                                      certain that everyone is clear of moving parts! Keep
                                                                      away from sheaves and belts during test procedures.

  FAN
                                                                      A WARNING Multimeters and DC Circuits
                                                                      DC and AC circuits are ofter mixed together in marine
                                                                      applications. Always disconnect shore power cords,
                                                                      isolate DC and AC converters and shut down generators
                                                                      before performing DC testing. No AC tests should be
                                                                      made without proper knowledge of AC circuits.




    EXCITER
    TERMINAL R
                                                   TACHOMETER
                                                   TERMINAL P

REGULATOR;------1H-1----II-. .I------iiiio~          CAPACITOR
COVER


 SENSING
 TERMINAL S

        GROUND                                                    REFER TO THE
        TERMINAL E                                                WIRING DIAGRAMS FOR THE ABOVE
                                                                  WIRING HARNESS CONNECTIONS
               JUMPER B
                                                                  TESTING THE EXCITATION CIRCUIT
 TESTING THE OUTPUT CIRCUIT                                        1. Connect the positive (+) voltmeter lead to the excitation
 1. Connect the positive voltmeter lead to the output                terminal R on the alternator and the negative (-) lead to
     terminal B and connect the negative lead to the ground          the ground terminal E on the alternator.
     terminal E on the alternator.                                2. Turn the ignition switch to the on positiul! and note the
 2. Wiggle the engine wiring harness while observing the             voltmeter reading. The reading should be 1.3 to 2.5
     voltmeter. The meter should indicate the approximate            volts (see illustration).
     battery voltage, and should not vary. If no reading is       3. If the reading is between .75 and 1.1 volts, the
     obtained, or if the reading varies, check the alternator        rotor field circuit probably is shorted or grounded.
     output circuit for loose or dirty connections or                Disassemble the alternator and test the rotor as
     damaged wiring.                                                 described under CLEAN AND TEST ALTERNATOR
                                                                     COMPONENTS in this section.
 NOTE: Prior to any altemator testing, impect the entire
 altemator system wiring for defects. Check all conllections      4. If the reading is between 6.0 and 7.0 volts, the rotor
 for tightness and clealliiness. particularly battery cable          field circuit probably is open. Remove the regulator
 clamps and battery tenninals. Inspect the altemator drive           and inspect it for worn brushes or dirty slip rings.
 belt for excessive wear and replace if necessary. Also adjust       Replace the brushes if they are less than 1I4in. (6 mm)
 for proper belt tension.                                            long. If the brushes and slip rings are in good condi-
                                                                     tion, disassemble the alternator and test the rotor, as
                                                                     outlined under CLEAN AND TEST ALTERNATOR
                                                                     COMPONENTS in this section.

                                                          WESTERBEKE
                                                          Engines & Generators

                                                                 63
                                      MANDO ALTERNATOR SERVICE
                                                                         e.    Remove the regulator cover.
TESTING THE EXCITER LEAD
                                                                         f.    Temporarily re-install Jumper (Al and all associated
                                                                               nuts. Leave Jumper (B) installed.
                                                                         g. Remove the plastic plug from the side of the
                                                                            regulator.
                                                                         h. Connect a jumper between the top brush lead
                                                                            and the ground.




                                                                          JUMPER A



 5. If no reading is obtained, an open exists in the                    REGULATOR - - U - - L
    alternator-excitation lead or in the excitation circuit of          COVER
    the regulator. Disconnect the lead from exc terminal R.
    Connect the positive voltmeter lead to the excitation              SENSING                                                       OUTPUT
    lead and the negative voltmeter lead to ground terminal            TERMINAL                                                      TERMINAL
    E. If the voltmeter now indicates an approximate. battery
    voltage, the voltage regulator is defective and must be
                                                                                   GROUND/
    replaced. If no voltage is indicated, check the excitation
    circuit for loose or dirty connections or damaged wiring.
 TEST VOLTAGE REGULATOR
 Perform this test to determine if the voltage regulator is                               CONNECT    \
 operating correctly, using a 0 - 20 volt DC voltmeter.                                   JUMPER WIRE \
                                                                                                       \
 NOTE: The battery must be fully charged to obtain a proper                                             \
                                                                                                                           BRUSHES
 voltage reading in this test. If necessary, charge the battery
 with a battery chargeror allow the engine to run a sufficient                                                        /
 length of time to fully charge the battery before taking a                   REGULATOR
 reading.
 1. Connect the positive (+) voltmeter lead to the positive
    battery terminal and the negative (-) voltmeter lead to
    the negative terminal.
 2. Start the engine and run it at fast idle until the engine
    reaches its normal operating temperature. Adjust the                        PLASTIC PLUG
                                                                                                             ,TOP LEAD
    engine speed to 1500 - 2000 rpm and observe the                                                          FROM BRUSH
    voltmeter for the highest reading. The reading should
    be between 13.7 and 14.7 volts.
 3. If the reading is high, check for a loose or dirty                   i.    Repeat steps 1 and 2.
    alternator ground lead connection. If the connection is              NOTE:    Do /lot let Ihe \'()Itage exceed   16   1'011.1.
    good, the voltage regulator is faulty and must be
                                                                         j.    If a voltmeter reading of 14.5 volts or above is
    replaced. Be sure to disconnect the battery cables before
                                                                               now obtained, the voltage regulator is faulty and
    attempting to remove the alternator.
                                                                               must be replaced. If the voltmeter reading is below
 4. If the reading is low:                                                     14.5 volts, inspect the brushes and slip rings for
    a. Stop the engine and remove the alternator wiring                        wear, dirt or damage. If the hrushes and slip rings
         connections.                                                          are good, the alternator is fault internally.
    b. Remove the Phillips cover screw from the regulator                      Disassemble the alternator and test the components,
         cover (see illustration).                                             as outlined in this section.
    c. Remove the nut from the output terminal and the
       nut from the sensing terminal, and remove Jumper
        (A).
    d. Remove another nut from the sensing terminal. and
       the nut from the excitation terminal.



                                                          Engines & Generators

                                                                  64
                                       MANDO ALTERNATOR SERVICE
  REMOVE ALTERNATOR                                                    10. Place an oversized V-belt around the pulley and fasten
                                                                           the pulley in a vise.
  1. Disconnect the negati ve (-) battery ground cable.
                                                                       11. Use a 7/8 in. box wrench to loosen and remove the
  2. Disconnect the wiring leads.                                          pulley nut.
  3. Loosen the screws. Holding the alternator, rotate it              12. Remove the pulley nut, lockwasher, pulley, fan, and
     toward the engine and lift the belt off the pulley.                   spacer.
  4. Remove the screws and washers and remove the alternator.




                                                          TERMINAL
                                                          NUTS

     PHILLIPS,                                                                                                             FAN
     SCREWS                                               CAPACITOR
REGULATOR
                                                                                 PUllEY AND FAN COMPONENTS


                                                                         A CAUTION:      DO NOT insert screwdriver blades
                                                      OUTPUT             more than 1/16 in. (1.6 mm). Damage to the stator
                                                      TERMINAL           winding could result from deeper penetration.


                                                                       NOTE: Score the stator, and the front alld rear housings so
                                                                       the llnit may be reassembled correctly.
                                                                       13. Remove the four through-bolts and carefully pry the
  DISASSEMBLE ALTERNATOR                                                   front housing away from the rear housing using two
                                                                           screwdri verso
  1. Remove the terminal nuts to remove the jumper (see
      illustration).
                                                                                                                         REAR HOUSING
  2. Remove the remaining terminal nuts.
  3. Remove the capacitor.
  4. Remove the Phillips screw from the regulator cover.
                                                                      SCREW DRIVER
  5. Remove the brush/regulator-assembly cover.
  6. Remove the nut from the terminal.
  7. Remove the jumper.
  8. Remove the terminal insulators.
  9. Remove the two Phillips screws and remove the                     14. Carefully push the rotor assembly out of the front
     brush/regulator assembl y.                                            housing and rear housing.




                                                                       NOTE: If [he bearing is removed from [he hOllsing. (/ nell'
                                                                       bearing mltst be installed.
                                                                       IS. After removing the three bearing locking screws, care
                                                                           fully press the front bearing out of the housing. Press
   REMOVAL                                                                 against the inner race of the bearing.

                                                            WESTERBEKE
                                                            Engines & Generators

                                                                 65
                                   MANDO ALTERNATOR SERVICE
                                                                  2. Inspect and test the diode-trio assembly:
                                                                     a. Using a commercial diode tester, a 12-volt DC test
                                                                        lamp or an ohmmeter, check the resistance between
                                             BEARING LOCKING            each of the three diode terminals and the indicator
                                             SCREWS                     light stud.

                                                                                                               light stud
                                          FRONT BEARING




         BEARING
         DRIVER

                                                                                        DIODE TRIO ASSEMBLY

                                                                  h. Reverse the tester leads and repeat the resistance
          FRONT
          BEARING                        FRONT HOUSING               checks.
                                                                  c. A very low resistance should be indicated in one
16. Remove the rectifier assembly by removing the Phillips           direction and a very high resistance should be indi-
   screw and lifting out the assembly.                               cated in the other direction if the diodes are normal.
                                                                  d. If any diode appears to be defective, replace the
                                                                     complete assembly. Do not attempt to replace an
                                                                     individual diode.
                                                                  3. Test the diode-rectifier bridge as follows:
                                                                     a. Using a commercial diode tester, check for
                                                                         continuity from each of three terminals to the
                                                                         ouput terminal.




                    RECTIFIER REMOVAL                                        GROUND                               RECTIFIER
                                                                             TERMINAL                             DIODES


CLEAN AND TEST ALTERNATOR COMPONENTS                                 h. Reverse the tester leads and repeat Step a.
                                                                     c. Continuity should exist in only one direction and
1. Inspect and test the brush/regulator assembly. The
                                                                        all diodes should check alike.
   brush set may be reused if the brushes are 1I4 in.
   (6 mm) or longer. The brushes must not be oil soaked,             d. Perform the same continuity checks between the
   cracked or grooved.                                                  three terminals and strap ground terminal. This
                                                                        should show continuity in only one direction
   Test for continuity between I and 2, and 3 and 4 using
                                                                          through the diodes and all diodes should check
   a test lamp or an ohmmeter. These checks will indicate
                                                                          alike.
   a good brush/regulator assembly: replace the complete
   assembly, if necessary.                                            e.   If any diode appears to be defective, replace the
                                                                           rectifier assembly.




            TESTING BRUSH ASSEMBLY



                                                     Engines & Generators

                                                             66
                                      MANDO ALTERNATOR SERVICE
4. Clean and inspect the front and rear housings:
   a. Inspect the rear housing for cracks or breaks in the
      casting, stripped threads or a damaged bearing bore.
      Replace the housing if any of these conditions exist.
   b. Inspect the front housing for cracks, stripped or
      damaged threads in the adjusting ear, or an out-of-                   LAMINATIONS
      round bore in the mounting foot. If possible,
      correct slightly damaged threads using a tap.                b. Check the resistance from each lead (1, 2, and 3) to
      Replace the housing, if necessary.                                 the laminations (4). There should be no continuity
   c. If the housings are to be reused, clean them in                    if the insulation is good.
      solvent and dry with compressed air.                            c. Inspect the stator windings for signs of discoloration.
S. Clean and inspect the rotor shaft bearings:                           A discolored winding should be replaced.
   NOTE: Do not use a solvent on the rear rotor bearing               d. If a winding shows a high resistance or an open
   since it is serviced as a unit with the rotor.                        circuit between any two of the three winding
                                                                         terminals or indicates poor insulation between the
   a. The bearings should be wiped clean with a lint-free                windings and the laminations. the stator must b~
      cloth containing a moderale amount of commerc :,.1                 replaced.
      solvent. Do not immerse a bearing in solvent, or
      use pressurized solvent or air.                              8. Check the rotor assembly as follows:
   b. Check the bearings for obvious damage, looseness                NOTE: If slip rings need to be replaced, you must
      or rough rotation. Replace a bearing if any doubt               replace the entire rotor.
      exists as to its condition.                                     a. Visually inspect for physical defects such as dam-
       NOTE: If the rear rotor bearing needs replacement,                aged shaft threads, worn or damaged bearing areas,
       replace the entire rotor.                                         burned or pitted slip rings or scuffed pole fingers.
6. Inspect the belt pulley for rough or badly worn belt               b. Measure the winding resistance across the slip rings
   grooves or keyway, and for cracks or breaks. Remove                   (A). Place the ohmmeter leads on the edges of the
   minor burrs and correct minor surface damage; replace                 slip rings, not on the brush contact surfaces. The
   a badly worn or damaged pulley.                                       correct winding resistance at 70 - 80 F (21 -
                                                                         27 C) is 4.1 to 4.7 ohms.
                                                                    c. Minor burning or pitting of the slip ring surfaces
    FRONT
                                                                        can be removed using a crocus cloth. Thoroughly
    HOUSING ----->..J                               FRONT               wipe the slip rings clean after polishing, removing
                                                    BEARING             all grit and dust.
                                                                    d. Check for a grounded slip ring or rotor winding by
                                                                        measuring the resistance from each slip ring to the
                                                                        rotor body or pole finger (B). An open circuit should
                                                     EAR HOUSING        be indicated in both cases for a good rotor.
                                                                    e. If the windings are defecti ve or physical damage
                                                                        cannot be corrected, replace the rotor assembly.
                                                                 9. Use a commercial capacitor checker to test the
                                                                    capacitor for capacity, shorts, leakage, and series
                                                                    resistance.

                                                                                                                          P
                                                                                                                          B
                                                                                                             L   O.S"F
                                                                                                             "=" (REG.)
                                                                                                                          Lz
                                                                                                                          EXC
7. Test the stator windings as follows:                                                                                   S
   a. Using an ohmmeter or test lamp, check for                                                                   F
      continuity between all three leads (1, 2, and 3).
       A low ohm reading or lit test lamp should be                                                                       E
       observed.
                                                                                      INTERNAL CIRCUIT WIRING



                                                        Engines & Generators

                                                              67
                                           MANDO ALTERNATOR SERVICE
                                                                      2. Place the rotor (pulley end up) on the bed of an arbor
                                                                         press, on two steel blocks.
                                                                      3. Press the front housing and bearing assembly down
                                                                         onto the rotor shaft. Press against the bearing's inner
                                                                         race only, using a sleeve driver. Take care to insure that
                                              POLE FINGERS               the rotor leads clear the steel blocks.


                                                                           SLEEVE DRIVER.

                                                                                                                     FRONT HOUSING AND
                                                                                                                     BEARING ASSEMBLY
SLIP RINGS




                                                                          ROTOR




                                                                      INSTALLING' THE FRONT HOUSING ON THE ROTOR ASSEMBLY
ASSEMBLE ALTERNATOR                                                   4. Install the rectifier assembly into the rear housing.
1. Carefully press the front bearing into the front housing,
                                                                      5. Insert the Phillips screw and tighten it.
    pushing against the bearing's outer race using a bearing
    driver. Lock the bearing in place with screws.
    TORQUE: 25 - 35 /b-in (2.8 - 4.0 Nm)


      BEARING                                                            RECTIFIER
      DRIVER                                                             ASSEMBLY
             '"                               FRONT BEARING

       OUTER
                                                 FRONT HOUSING
       RACE
                                             /
                                                                      6. Assemble the front and rear housings as follows:
                                                                          a. Put the stator winding in the front housing with the
                   FRONT BEARING ASSEMBLY                                    stator leads away from the front housing and the
                                                                             notches in the stator laminations aligned with the
                                                                             four through-bolt holes in the housing.
                                                                          b. Align the scribe marks you made in the stator, and
                                                                             front and rear housings during disassembly.
                                                  BEARING LOCKING         c. Slip the rear housing into place over the rotor shaft.
                                                  SCREWS                      Align the mounting holes and put the stator leads
                                                                             through the holes at the top of the rear housing.
                                                                          d. Install the four bolts and tighten them.
                                                                              TORQUE. 35 - 65 Ib-ft (4.0 - 7.3 Nm)
                                                                              NOTE: If the front housing is lIeH', the through-holt
                                              FRONT BEARING                   \Vill not be tapped.



                  ASSEMBLING THE BEARINGS

                                                          Engines & Generators

                                                                 68
                                          MANDO ALTERNATOR SERVICE
7. Install the spacer and the fan. Then push the pulley,           INSTALL ALTERNATOR
   lockwasher and nut onto the shaft. Turn the nut a few
                                                                   1. Install the alternator, screws and washers.
   turns.
8. Place an oversized V-belt around the pulley and fasten          2. Connect the wiring leads.
   the pulley in a vise.                                           3. Put the belt on the alternator, crankshaft and coolant
                                                                      pump pulleys.
                                                                   4. Adjust the alternator belt's tension (see DRIVE BELT
                                                                      ADJUSTMENT under ENGINE ADJUSTMENTS).
                                                  OVERSIZED
                                                  V-BELT                  MANDO ALTERNATOR SPECIFICATIONS
                                                                    Battery Voltage       12 Volt
                                                                    Maximum Speed         13500 RPM
                                                                    Cut in Speed          Max. 2000 RPM (at exc.)
                                                                                          Max. 1500 RPM (at L2)
                                                                    Reg. Set Voltage      14.7 Volts
                                                                    Ambient Temp.         -20C - 100C
                                                                    Ground                Negative



        INSTALLING THE PULLEY AND THE FAN NUT
9. Use a torque wrench to the tighten the nut.
   TORQUE: 35 - 50 Ib-ft (47 - 68 Nm)
10. Carefully install the brush/regulator assembly on the
    rear housing with the two mounting screws.
11. Install the small terminal insulators.
12. Install the large terminal insulator.
13. Install the jumper.
14. Install the nut on the terminal.
15. Install the brush/regulator assembly cover.
16. Install the Phillips screw for the brush/regulator
    assembly cover.
    TORQUE: 25 - 351b-ft (2.8 - 5.1 Nm)
17. Install the capacitor.
18. Install the terminal nuts.
19. Install the jumper.
20. Install the last terminal nut.




                                                         Engines & Generators

                                                              69
                                                  STARTER MOTOR

                                                                                        START
                                                                                       SWITCH


                                BATIERY



                                                                                                                  CONTROL
                                                                                                                   SWITCH



                 -


                                           FIGURE 1. STARTER WIRING CIRCUIT

TROUBLESHOOTING                                                         Continuity Check
To independently test the starter it is necessary to remove         Disconnect the field lead on the starter from the solenoid M
it from the engine. However, before doing this, checks              terminal and insulate it carefully to prevent accidental contact.
should be made to ensure that the problem is with the starter       Set the transmission in neutral. Use a voltmeter to check for
and not with the engine, battery, wiring or switches. When          voltage at the solenoid S terminal while the start switch is
the other possible problem sources have been eliminated,            held in the START position. If voltage is not present at the S
then remove and test the starter. Comparison of test results        terminal, use the voltmeter and the wiring diagram to trace
with the Troubleshooting chart will aid in isolating the prob-      the control circuit and locate the point of voltage loss and cor-
lem within the starter to specific components. This will            rect it as necessary.
determine the repair or repairs needed to restore the starter to        Starter Removal
serviceability.
                                                                        If the battery, wiring and switches are in satisfactory condi-
BaHery Test                                                             tion and the engine is known to be functioning properly,
Realistic testing, as well as successful operation, requires a          remove the starter for further testing.
fully charged battery capable of supplying the current needs            Starter No-Load Test
of the starting system. Step one in troubleshooting the start-
ing system is to test the battery. Follow the battery manufac-          With the starter removed from the engine, the no-load test
turer's instructions.                                                   can reveal damage that can be corrected by repair or it may
                                                                        indicate the need for component testing after the starter is dis-
Wiring and Switches                                                     assembled. Repair and component test procedures are
Visual Inspection                                                       described in the UNIT REPAIR section. The no-load test is
                                                                        also used to test units for normal operation after repair or
Visually inspect all wiring and switches in the starting cir-           overhaul. Comparison of test results with the Trouble-
cuit for damage and loose or cOlToded connections. This                 shooting chart will indicate what corrective action, if any, is
includes all ground connections. Clean and tighten the con-             required.
nections as required. Replace damaged wiring or compo-
nents.




                                                          Engines & Generators

                                                                   70
                                                  STARTER MOTOR
Test Hook-Up (Figure 2)                                                 NOTE: During the no-load test, close the switch and operate
Connect the starter for the no-load test as shown in the                the starter for cycles of 30 seconds maximum. Between
illustration using suitable instruments, battery cables and con-        cycles, allow the starter to cool for at least two minutes, oth-
necting wiring. Do the following:                                       erwise overheating and damage to the starter may result.

1. Secure the starter in a suitable test stand to check its             1. Momentarily close the switch.
   operation.                                                               a. If there is a high current flow and the starter fails to
2. Use a momentary contact, pushbutton switch in the test                      operate (zero rpm), release the switch immediately.
   circuit for a quick release if very high current surges                     Internal mechanical damage is indicated. Discontinue
   are encountered.                                                            the test and refer to TROUBLESHOOTING.
3. Make all connections or disconnections with the switch                   b. If there is no current flow and the starter fails to oper-
   open and the carbon pile load turned off.                                   ate (zero rpm), release the switch immediately. An
                                                                               open circuit is indicated. Discontinue the test and
4. If sparking or current flow in the battery circuit is                       refer to TROUBLESHOOTING.
   noted when making the connections, the starter sole-
   noid switch contacts may be frozen shut (refer to                        c. If there is a current flow and the starter operates,
   TROUBLESHOOTING).                                                           release the switch and proceed with the next step of
                                                                               the no-load test.
5. As the last step in making the test connection, ground
   the negative battery cable securely to a clean metal                 2. Close the switch and observe the voltmeter. Adjust the
   ground on the starter frame.                                            carbon pile load to obtain a 10 volt reading (20 volts on a
                                                                           24-volt starter). Observe and record the ammeter and rpm
6. The carbon pile load is used to adjust the operating                    readings. Release the switch.
   voltage for comparison with specifications. It may not
   be necessary in all cases but should be used to elimi-               3. Compare the ammeter and rpm readings to those listed
   nate the need for interpolation of test data.                           under SPECIFICATIONS at the end of this section. If
                                                                           the readings are outside the limits shown, refer to
Test Procedure                                                             TROUBLESHOOTING to determine the most likely
                                                                           causes. If the readings are within the limits, the starter
                                                                           is operating normally.
 A CAUTION: Keep fingers and tools away from the
  opening in the D.E. (drive end) housing while testing.
  The strong shifting action of the solenoid could cause
  personal injury or damage as the drive pinion moves
  into the cranking position and spins.


                                                                                                    VOLTMETER
                                                                              CLAMP ON
                                                                              AMMETER




                                                                                               SWITCH



                                                                                                                BAT.
                                                                                                                S
                                                                                                                M


                                         CARBON
                                          PILE




                                            FIGURE 2. STARTER NO-LOAD TEST HOOK-UP



                                                              Engines & Generators

                                                                   71
                                                            STARTER MOTOR
Troubleshooting                                                                     ble cause and its remedy. The problems listed in the chart
If the results of the no-load test are outside the limits, refer                    apply specifically to the no-load test and do not necessarily
to the following TROUBLESHOOTING chart for the proba-                               apply to operation under other circumstances.

                     PROBLEM                                         PROBABLE CAUSE                                    VERIFICATION/REMEDY*
 Normal current and speed.                             a. Starter OK.                                       a. Recheck battery, switches and wiring,
                                                                                                                 including battery cable loss. Check if
                                                                                                                 starter operation on engine is slow or
                                                                                                                 sluggish.
 Current flow with test circuit switch open.           a. Solenoid switch contacts stuck closed.            a. Test and, if necessary, replace solenoid
                                                                                                                 assembly.
 Failure to operate with very low or no                a. Open solenoid wiring.                             a. Inspect and test solenoid assembly.
 current.
                                                       b. Open field circuit.                               b. Inspect and test frame and field assembly.
                                                       c. Open armature coil(s) or high insulation          c. Inspect armature.
                                                          between commutator bars.
                                                       d. Broken brush spring(s) or worn brushes.           d. Inspect brushes and brush springs.
 Failure to operate with high current.                 a. Frozen bearing or other damage to drive           a. Inspect bearings, armature, drive shaft
                                                          train.                                               and related drive parts.
                                                       b. Direct ground in terminals or fields.             b. Inspect and test frame and field assem-
                                                                                                               bly, solenoid assembly, armature and
                                                                                                               brush installations for shorts.
 Low speed with high current.                          a. Excessive friction in bearing(s) or gear          a. Inspect bearing, armature, drive shaft,
                                                          reduction unit, bent armature shaft or               and gear reduction gears.
                                                          loose pole shoe, bent drive shaft.
                                                       b. Shorted  armature.                                b. Inspect and test armature.
                                                       c. Grounded armature or fields.                      c. Inspect and test frame and field coil
                                                                                                                assembly and armature.
 Low speed with normal (or low) current.               a. High internal electrical resistance caused        a. Inspect internal wiring, electrical connec-
                                                          by poor connections, defective leads or              'tions and armature commutator.
                                                          dirty commutator.
                                                       b. Causes listed under Failure to operate            b. Remedies listed under Failure to operate
                                                          with very low or no current.                         with very low or no current.
 High speed with high current.                         a. Shorted fields.                                   a. Inspect and test field and frame assembly.
* Refer to the UNIT Rl!:PAIR section for required disassembly, inspection, test, and if necessary, repair or replacement instructions.

STARTER REPAIR                                                                      This section provides instructions for complete disassembly
                                                                                    of the starter as would be the case for overhaul. If the starter
NOTE: Always install fasteners at their original locations.                         is not due for an overhaul, and repair affecting specific parts
If it is necessary to replace fasteners, use only the correct                       only is required, the starter may be disassembled only to the
part numbers or equivalent. If the correct part number is not                       extent necessary to gain access to these parts. Parts removed
available, use only a fastener of equal size and strength. Use                      from the starter as subassemblies or groups need not be dis-
a torque wrench to tighten fasteners when a torque value is                         assembled for such limited repair unless they contain the
specified. Torques specified are for dry, unlubricated fasten-                      affected parts. Total disassembly is recommended however,
ers unless otherwise specified.                                                     to ensure that all parts can be thoroughly cleaned and
Introduction                                                                        inspected.
(Figure 3)                                                                          In this section the starter is broken down by main groups.
Figure 3 shows the starter broken down into its component                           These groups are then disassembled into individual parts and
parts and assemblies. Do not attempt to disassemble the fol-                        assemblies. Illustrations accompany the text to show specific
lowing components which are serviced as assemblies:                                 operations. To see the parts relationship of the complete
                                                                                    starter, refer back to Figure 3.
     Solenoid assembly (1)
                                                                                    To begin, make a mark completely down one side of the
    Clutch Drive assembly (2)                                                       starter to ensure proper alignment of all its components at
    Brush Holder assembly (3)                                                       assembly. Use a colored pencil or marker that will show on
     Armature assembly (13)                                                         all parts.
    Frame and Field assembly (19)


                                                                      Engines & Generators

                                                                              72
                                   STARTER MOTOR




               13




                                              28
                                          j        33




                            ____   \.~i~

          30   31 32   15              1fIJ-. @
                                       /           I
                                                                  12

                                                                8;.l
                                                                         6
                                                                         ~          I
                                                                                             2223




 1. SOLENOID ASSEMBLY                10                        '7" ..!Jb,~~",- ?~
 2. CLUTCH DRIVE                                                         ~
                                                            35 ---::::::--        ..-<>-_~
    ASSEMBL Y                                                  6~               0

 3. BRUSH HOLDER                                        2       "/
    ASSEMBLY                                                    21
 4. BRUSH (GROUNDED)
 5. BRUSH (INSULATED)
 6. D.E. HOUSING                                                                        18
    BUSHING                  21.    SHIFT LEVER SCREW
 7. BRUSH SPRING                                                                                34
                             22.    SHIFT LEVER WASHER
 8. D.E. ARMATURE            23.    SHIFT LEVER NUT
    BEARING                  25.    SOLENOID SCREW
 9. C.E. ARMATURE            26.    PLATE (IF USED)
    BEARING                  27.    DRIVE HOUSING PLUG
10. CENTER SUPPORT           28.    DOWEL PIN
    BEARING                  29.    INSULATED BRUSH SCREW
11. SHIFT LEVER              30.    WASHER (FIBER)
12. PINION STOP              31.    WASHER (THIN; ONE OR
13. ARMATURE                        TWO MAY BE USED)
14. C.E. FRAME               32.    WASHER (THICK)
15. DRIVE SHAFT              33.    FRAME SEAL
16. ARMATURE SUPPORT         34.    BUSHING PLUG (IF USED)
    BRACKET                  35.    STOP RING
17. DRIVE SHAFT              36.    DRIVE HOUSING BOLT (LONG)
    SUPPORT                  37.    DRIVE HOUSING BOLT
18. DRIVE HOUSING                   (SHORTER ON SOME MODELS)
19. FRAME & FIELD            39.    GROUNDED BRUSH SCREW
    ASSEMBLY                 41.    THRU BOLT
20. C.E. FRAME O-RING        42.    BRUSH PLATE SCREW


                              FIGURE 3. STARTER ASSEMBLY




                                       Engines & Generators

                                                   73
                                              STARTER MOTOR
General Disassembly                                                  5. Frame, field and brush holder group (A), dowel pin (28)
(Figure 4)                                                              and frame seal (33).
Remove or Disconnect:                                                     a. The armature assembly (13) may come off with the
                                                                             frame, field and brush holder group (A) or may be
1. The motor lead on the frame, field and brush holder
                                                                             retained by the gear reduction and drive group (B).
   group (A) from the solenoid assembly (1). Reinstall the
   nut on the solenoid terminal.                                     6. Armature assembly (13) with bearings (8 and 9).
   a. Remove the nut on the solenoid, slip off the motor                  a. Do not remove the bearings from the armature
      lead and reinstall the nut.                                            assembly unless replacement is required (refer to
                                                                             CLEANING, INSPECTION AND REPAIR).
2. Thru bolts (41).
                                                                     7. Solenoid screws (25).
3. Brush plate screws (42).
                                                                     8. Solenoid assembly (1).
4. C.E. frame (14) and O-ring (20).
                                                                          a. Pivot the inside end of the solenoid assembly (1) out
   Important:                                                                of engagement with the shift lever in the gear
   a. In the following step, use care not to lose the small                  reduction and drive group (B) and withdraw the
      dowel pin (28) installed between the frame, field and                  solenoid assembly.
      brush holder group (A) and the gear reduction and
      drive group (B). This dowel pin is required for
      assembly and must be saved. If the dowel pin
      should be lost, it must be replaced with a 2 mm
      (0.079 in.) dia. x 10 mm (0.394 in.) long pin pro-
      cured or manufactured locally.

        42    --I/i~                                                                  25

          14
                                                                 A




         1. SOLENOID ASSEMBLY
         8.    D.E. ARMATURE BEARING                                  9
         9.    C.E. ARMATURE BEARING
        13.    ARMATURE ASSEMBLY
        14.    C.E. FRAME
        20.    C.E. FRAME O-RING
        25.    SOLENOID SCREW
        28.    DOWEL PIN
        33.    FRAME SEAL
        41.    THRU BOLT
        42.    BRUSH, PLATE SCREW
         A.    FRAME, FIELD & BRUSH HOLDER GROUP
         B.    GEAR REDUCTION & DRIVE GROUP

                                            FIGURE 4. ELECTRICAL GROUP




                                                         Engines & Generators

                                                              74
                                                    STARTER MOTOR
Disassembly of Frame, Field and Brush Holder Group
(Figure 5)
Remove or disconnect:
1. Insulated brush screws (29).
   a. Move the brush holder assembly (3) [with the brush-
      es (4 and 5)] away from the frame and field assem-
      bly (19) slightly to reach across with a screwdriver
      and remove the screws (29).
2. Frame and field assembly (19).
3. Grounded brush screws (39).
                                                                                               19. FRAME & FIELD
4. Brushes (4 and 5), if replacement is required.                    3. BRUSH HOLDER
                                                                        ASSEMBLY                   ASSEMBLY
   a. Grasp the brush end of each brush spring (7) with                                        29. INSULATED BRUSH
                                                                     4. BRUSH (GROUNDED)
      needle nose pliers, twist the spring end away from             5. BRUSH (INSULATED)          SCREW
      the brush (4 or 5) and withdraw the brush.                     7. BRUSH SPRING           39. GROUNDED BRUSH
                                                                                                   SCREW
5. Brush springs (7), if replacement is required.
   a. Grasp the brush end of each brush spring (7) with               FIGURE 5. FRAME, FIELD AND BRUSH HOLDER GROUP
      needle nose pliers, twist the spring end away from
      the brush socket on the brush holder assembly (3)
      and remove the spring.                                                                        11
    NOTE: At this stage of disassembly, all electrical com-
   ponents can be inspected, and if required, independently
   tested as specified in CLEANING, INSPECTION AND
   REPAIR.
Disassembly of Gear Reduction and Drive Group
(Figure 6)
Remove or disconnect:
1. Housing bolts (36 and 37).
2. Armature support bracket (16).
    Important:
    a. The washers (30 through 32) may stick to the arma- '
                                                             '30
                                                                0'  /

       ture support bracket or to the drive shaft and clutch
       group (C) as the armature support bracket is              31
       removed. In either case, note the position and num-            32
       ber of each of these washers.
                                                                                               6
3. Washers (30 through 32).                                                           21
    a. Save the washers; they are to be installed in the same
                                                                  6. D.E. HOUSING BUSHING
       position and number at assembly.                          11. SHIFT LEVER
4. Drive housing plug (27) and plate (26).                       16. ARMATURE SUPPORT
                                                                     BRACKET
    a. Pry out the drive housing plug using a large screw-       18. DRIVE HOUSING            32. WASHER (THICK)
       driver.                                                   21. SHIFT LEVER SCREW        34. BUSHING PLUG (IF
5. Shift lever nut (23), washer (22) and screw (21).             22. SHIFT LEVER WASHER           USED)
                                                                 23. SHIFT LEVER NUT          36. DRIVE HOUSING BOLT
6. Remove the shift lever (11) and the drive shaft and           26. PLATE (IF USED)              (LONG)
   clutch group (C) from the drive housing (18) together,        27. DRIVE HOUSING PLUG       37. DRIVE HOUSING BOLT
   then separate them.                                           30. WASHER (FIBER)               (SHORTER ON SOME MODELS)
    a. Do not remove the bushing plug (34) or the bushing        31. WASHER (THIN; ONE OR      C. DRIVE SHAFT & CLUTCH
                                                                     TWO MAY BE USED)             GROUP
       (6) from the drive housing (18) unless replacement
       is required (refer to CLEANING, INSPECTION AND
       REPAIR).                                                            FIGURE 6. GEAR REDUCTION AND DRIVE GROUP




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                                                                75
                                                 STARTER MOTOR
Disassembly of Drive Shaft and Clutch Group
(Figures 7 and 8)
Disassembly of the drive shaft and clutch group is not
required unless it is necessary to clean, inspect or replace
one or more parts of the group separately. Then proceed as
follows:
Remove or disconnect:
1. Stop rings (35) and pinion stop (12).
   a. Position the drive shaft and clutch group on the work
      bench with the internal gear end down.
   b. Using an open tube slightly larger than the shaft (see
      Figure 8), drive the pinion stop (12) toward the
      clutch drive assembly (2) until it clears the stop rings
                                                                         2. CLUTCH DRIVE               10
      (35).
                                                                            ASSEMBLY               15. DRIVE SHAFT
   c. Using care not to scratch the drive shaft (15), pry the           10. CENTER SUPPORT         17. DRIVE SHAFT
      stop rings out of the shaft groove and slide them off                 BEARING                    SUPPORT
      the end of the shaft.                                             12. PINION STOP            35. STOP RINGS (2 PCS)
   d. Inspect the edges of the shaft groove for burrs that
      may have been formed through repeated cranking                            FIGURE 7. DRIVE SHAFT AND CLUTCH GROUP
      cycles. Such burrs may make removal of the pinion
      stop and clutch drive assembly (2) difficult. If burrs
      are found, use a suitable file to carefully remove the
      burrs only - not the base metal. Thoroughly clean
      away metal filings.
   e. Slide the pinion stop (12) off the drive shaft (15).
      Discard the old pinion stop (12) and stop rings (35).
      New parts must be used at assembly.
2. Clutch drive assembly (2) from drive shaft (15).
3. Drive shaft support (17) from drive shaft (15).
    a. Do not remove the bearing (10) from the drive shaft
       (15) unless replacement is required (refer to CLEAN-
       ING, INSPECTION AND REPAIR).
                                                                          14.2 MM
                                                                          (0.56 IN.) DIA
                                                                                        -6]    _.-
                                                                                                            22MM
                                                                                                            (0.87 IN.) DlA




                                                                                                            _   OPEN
                                                                                                                TUBE




                                                                                     FIGURE 8. REMOVING PINION STOP




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                                                                 76
                                                    STARTER MOTOR
CLEANING, INSPECTION, TESTING AND REPAIR                            6. Brushes (4 and 5) for excessive wear.
Cleaning                                                                   a. The minimum allowable brush length is 12 mm
                                                                              (0.472 in.). Replace excessively worn brushes in
NOTE: Do not clean or immerse starter parts in grease dis-                    sets.
solving solvents. Solvents will dissolve grease packed in the
drive assembly and may damage the armature or field coil            7. The D.E. housing bushing (6) for scoring or other dam-
insulation.                                                            age. Replace a damaged bushing (refer to REPAIR
                                                                       PROCEDURES).
Clean:
                                                                    8. Ball bearings (8, 9 and 10) as follows:
1. All starter parts with a soft cloth prior to testing.
                                                                           a. Hold the armature (13) or drive shaft (15) and slowly
Inspection                                                                    rotate the outer bearing race by hand.
(Figure 3)
                                                                           b. Check that the bearing turns freely without binding or
Inspection in the following steps refers to visual inspection                 the feel of flat spots.
of the starter parts and assemblies to determine their servicea-
bility. Electrical tests for certain assemblies are described in           c. Replace damaged bearings (refer to REPAIR
COMPONENT ELECTRICAL TESTING.                                                 PROCEDURES).
Inspect:                                                            9. Armature assembly (13) for the following:
1. All parts for cracks, distortion other structural damage.               a. Gear teeth that are broken, or that show evidence of
    Replace parts or assemblies which are cracked, bent or                    step wear or root interference.
    otherwise damaged.                                                     b. Rough commutator surface. Polish with a No. 400
2. Threaded parts for stripped, crossed or otherwise dam-                     grit polishing cloth if necessary. Thoroughly clean
   aged threads. Replace parts with thread damage that                        metal dust from between the commutator bars. If the
   cannot be cleaned up using a suitable tap or die.                          commutator surface cannot be repaired in this man-
   Replace any hardware items that have damaged threads.                      ner, replace the armature assembly. Do not tum the
                                                                              commutator in a lathe.
3. The solenoid assembly (1) for a cut or torn boot. If the
   boot is damaged, replace the solenoid assembly.                         c. Worn commutator. Replace the armature assembly if
                                                                              the commutator OD is less than 35 mm (1.378 in.) or
4. The clutch drive assembly (2) for the following.                           if the undercut depth at any point is less than 0.2 mm
   Replace the clutch drive assembly if damaged:                              (0.008 in.). Do not undercut the insulation.
    a. Pinion gear turns roughly or turns in both directions.           10. Drive shaft (15) for the following. Replace the drive
    b. Pinion gear teeth broken or showing evidence of                      shaft if damaged:
       step wear.                                                          a. Scored' or damaged shaft where it turns in the
    c. Deep scoring or other damage to the shift lever collar.                bushing (6).
5. The brush holder assembly (3) for the following.                        b. Internal gear with teeth broken or showing evidence
   Replace the brush holder if damaged:                                       of step wear.
    a. Loose riveted joints.                                               c. Damaged spline. The clutch drive assembly must
    b. Cracked or broken insulation.                                          slide smoothly and easily over the full length of the
                                                                              spline.




                                                           Engines & Generators

                                                                   77
                                                  STARTER MOTOR
Component Electrical Testing                                                            BATIERY
(Figures 9 and 10)                                                                      TERMINAL
Perform the following electrical tests on the solenoid assem-
bly (1), armature assembly (13) and frame and field assem-
bly (19) to determine their serviceability.
1. Using a suitable ohmmeter, check the windings of the
   solenoid assembly (I) for continuity as follows:
   a. Check the resistance of the solenoid pull-in and
      hold-in windings in series by measuring the resist-
      ance between the motor terminal (see Figure 9) and
      the solenoid case. The resistance should be approxi-
      mately 0.95 ohms for 12-voIt starters and approxi-
      mately1.75 ohms for 24-voIt starters.
   h. An extremely high resistance reading indicates a
      break or fault in the winding continuity. A very low
      resistance reading indicates a short or ground in the
                                                                                                    MOTOR
      winding circuit. Either condition is cause for
                                                                                                   TERMINAL
      replacement of the solenoid assembly.
2. Check the armature (13) as follows for shorts, opens or                       FIGURE 9. SOLENOID TERMINALS
   grounds using suitable test equipment and instruments
   (test lamp must be 110 volts or less).
   a. Rotate the armature in a growler holding a steel strip
      such as a hacksaw blade against the armature. If a
      short circuit is present, the steel strip will vibrate in
      that area.
    h. Check the armature for grounds using a test lamp or
       ohmmeter. There shall be no continuity between the
       armature shaft and any point on the commutator.
    c. Check for opens by visually inspecting the points
       where the armature conductors join the commutator.
       A poor connection often will be indicated by signs of
       arcing or burning of the commutator.
    d. Replace armatures which are shorted, grounded or
       show evidence of opens.
3. Check frame and field assembly (19) for grounds or
   opens using a test lamp (110 volts max.) or ohmmeter,
   as follows:
    a. Check that there is continuity (no opens) between
       the field terminal that connects to the solenoid, and
       the connection points for the insulated brushes on
       the field coil straps.
    h. Check that there is no continuity (no grounds)
       between the frame and the field terminal that con-
       nects to the solenoid.
    c. Replace frame and field assemblies that have
       grounds or opens.                                                         FIGURE 10. FRAME AND FIELD ASSEMBLY




                                                          Engines & Generators

                                                                  78
                                                 STARTER MOTOR
Repair Procedures                                                  Remove or disconnect:
(Figures 3 and 11)                                                    a. The center support bearing (10) from the drive shaft
1. If necessary, replace the bearings (8 and 9, Figure 3) on             (15) using a locally fabricated tool as shown in
   the armature (13) as follows:                                         Figure 11.
   NOTE: Ball bearings which are removed from the                  Install or Connect:
   armature must be replaced with new bearings. The                   h. The center support bearing (10) from the drive shaft
   removal procedure causes internal damage to the                       (15) using a locally fabricated tool (Figure 11). With
   bearings.                                                             the drive shaft in a suitable support fixture, place the
Remove or disconnect:                                                    tool bolt ends through the access holes in the wide
                                                                         end of the drive shaft and squarely press the bearing
   a. C.E. and/or D.E. bearings (8 and/or 9) from the shaft
                                                                         off of the surface on the center shaft.
      of the armature (13) using a suitable bearing puller.
                                                                   3. If necessary, replace the bushing (6, Figure 3) in the
Install or Connect:
                                                                      drive housing (18) as follows:
   h. New C.E. and/or D.E. bearings (8 and/or 9) to the
                                                                      a. From inside the drive housing (18), drive out the
      armature assembly (13) using a tube that bears on
                                                                         plug (34) if present. Use a file to clean away rem-
      the bearing's inner race only. Press on the bearing
                                                                         nants of the old stake to allow installation of a new
      until the inner race bottoms out against the shoulder
                                                                         plug. Clean away any metal shavings.
      on the armature shaft.
                                                                      h. Using a suitable open tube, press out the bushing (6).
2. If necessary, replace the center support bearing (10,
   Figure 3) on the drive shaft (15) as follows:                      c. Using a suitable open tube, press the new bushing
                                                                         (6) into the drive housing (18) until the end of the
   NOTE: Ball bearings which are removed from the                        bushing is flush with the inside of the housing.
   drive shaft must be replaced with new bearings. The
   removal procedure causes internal damage to the                    d. Install a new plug (34), if used, to the drive housing.
   bearings.                                                             Stake housing material over the plug at three places,
                                                                         equally spaced.

                             TOP VIEW                          SIDE VIEW                             PRESS




        MATERIALS NEEDED-
                                                                                                                      ACCESS
         PIECE OF FLAT METAL STOCK ABOUT 5MM (OR 3/16 IN.)                      CENTER                                HOLE
                                                                                SUPPORT
          THICK, AND 55 MM (OR 2 114 IN.) SQUARE OR ROUND.
                                                                                BEARING
         THREE 6 MM OR 3/16 IN. BOLTS OF EQUAL LENGTH,
          LONG ENOUGH TO EXTEND AT LEAST 35 MM (1 3/8 IN.)                       CENTER
          BELOW THE FLAT STOCK WHEN INSTALLED THROUGH                             SHAFT----{
          IT. TO USE NUTS INSTEAD OF TAPPED HOLES, USE
          LONGER BOLTS TO COMPENSATE FOR NUT THICKNESS.

          1. LOCATE THREE HOLES EQUALLY AROUND A 32 MM
              (1.26 IN.) CIRCLE ON FLAT STOCK. DRILL AND TAP
              HOLES AS NEEDED TO MATCH BOLT THREADS.

          2. INSTALL BOLTS IN FLAT STOCK AND TIGHTEN. ENDS
             OF INSTALLED BOLTS SHOULD PASS THROUGH
             ACCESS HOLES IN END OF DRIVE SHAFT WITHOUT BINDING.

                                 FIGURE 11. TOOL FOR REMOVING CENTER SUPPORT BEARING



                                               t..."".,/WESTERBEKE
                                                      I Engines & Generators
                                                                79
                                                   STARTER MOTOR
ASSEMBLY                                                               1. Lubricate the D.E. housing bushing, shift lever, and
                                                                          drive shaft as described under LUBRICATION DURING
Lubrication During Assembly                                               ASSEMBLY.
1. The armature bearings (8 and 9, Figure 3) and drive shaft           Install or Connect:
   support bearing (10) are pennanently lubricated. Do not
   add lubricant to these bearings. Lubricate the following            2. The arms on the shift lever (11) with the shift collar on
   just before or during assembly (avoid excessive grease):               the drive shaft and clutch group (C).
   3.    D.E. housing bushing (6) (in drive housing).                  3. The assembled shift lever (11) and the drive shaft and
                                                                          clutch group (C) into the drive housing (18), aligning the
   b. The pivot hole and working surface on the ends of                   holes in the drive shaft support (17, Figure 7) with those
      the shift lever (11).                                               in the drive housing.
   c. The internal gear, shaft and spline on the drive shaft              3.   Make sure that the drive shaft support is fully seated
      (15).                                                                    in the drive housing and that the drive shaft bearing
Drive Shaft and Clutch Group                                                   (l0, Figure 7) remains fully seated in the drive shaft
(Figures 7 and 12)                                                             support.
1. If disassembled, position the drive shaft on the work sur-          4. Shift lever screw (21), washer (22) and nut (23).
   face with the internal gear end down and assemble the               Tighten:
   drive shaft and clutch group as follows:
                                                                           a. Nut to 4.5 Nm (40 lb-in.).
   Important:
                                                                       5. The plate (26), if used, and the drive housing plug (27)
   3.    If the center support bearing (10) is being replaced,            to the drive housing (18).
         install it on the drive shaft (15) as specified in REPAIR
         PROCEDURES, step 2, before proceeding with                    6. Washers (30 through 32) in the same number and posi-
         assembly.                                                        tions as noted at disassembly.
Install or Connect:                                                    7. The armature support bracket (16) to the drive housing
                                                                          (18), aligning the mark made prior to disassembly with
1. The drive shaft support (17) to the drive shaft (15), seat-            that on the drive housing.
   ing the bearing (10) in the support.
                                                                       8. Drive housing bolts (36 and 37).
2. The clutch drive assembly (2) to the drive shaft (15).
3. A new pinion stop (12) onto the drive shaft (15), the end                                            METAL BLOCK APPROX.
   with the recess for the stop rings (35) up.                                                              9 MM (3/16 IN.)
    3.   Install the stop rings (35) in the groove in the drive
         shaft (15).
    b. Pick up and support the assembly under the pinion
       stop (12). A metal block, with a V-shaped cutout
       that will slide over the shaft between the pinion gear
       and the stop, can be clamped in a vise to provide
       support (see Figure 12).
    c. Make sure the stop rings (35) (in the drive shaft                                     APPROX.
       groove) are fully seated in the pinion stop recess and                             38 MM (1 1/2 IN.)
       stake the upper edge of the pinion stop (12) over the
       stop ring (35) at four places, equally spaced. Do not
       allow staked metal to contact the drive shaft (15).
Assembly of Gear Reduction and Drive Group                                                                            14.2 MM
                                                                                                                      (0.56 IN.)
(Figure 6)
    Important:
    If the D.E. bushing (6) and plug (34) are being replaced,
    install them in the drive housing (18) as specified in
    REPAIR PROCEDURES, step 3, before proceeding with
    assembly.                                                                  FIGURE 12. PINION STOP SUPPORT BLOCK




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                                                STARTER MOTOR
Assembly of Frame, Field and Brush Holder Group                       NOTE: The brush leads may be damaged by excessive
(Figures 5,13 and 14)                                                 handling. Do not over-flex tlJe leads near the clip welds or
                                                                      the clips may break off.
                                      BRUSH HOLDER                    2. Brushes (4 and 5), if removed.
                                        ASSEMBLY                         a. See Figure 14 for the proper installed position of all
                                                                            brushes. Make sure the insulated brushes (5) go into
                                                                            the brush sockets of the brush holder assembly (3)
                                                                            that are mounted on the insulation.
                                                                         b. To install each brush, grasp the free end of the brush
                                                                            spring with needle nose pliers, twist clockwise to
                                                                            clear the brush socket and insert the brush partly into
                                                                            the brush socket.
                                                                         c. Gradually release the spring so that its end contacts
     SPRING POST                      BRUSH
                                      SOCKET
                                                                            the side (not end) of the brush (see Figure 13). This
                                                                            will hold the brushes retracted until after the brush
         FIGURE 13. BRUSH SPRING ON POST                                    holder is installed over the armature commutator.
                                                                      3. Grounded brush screws (39).
Install or Connect:                                                      a. Position the terminals of the grounded brush leads
                                                                            behind the terminal tabs on the brush holder (3) (see
1. Brush springs (7), if removed.
                                                                            Figure 13).
   a. Start each brush spring onto the post on the brush
                                                                          b. Insert the brush screws (39) through the terminal
      holder assembly (3) as shown in Figure 13, just
                                                                             tabs on the brush holder and thread them into the
      enough to hold the inside end of the spring from
                                                                             brush lead terminals.
      turning.
                                                                      Tighten:
   b. Grasp the free end of the spring with needle nose
      pliers and twist clockwise over the top of the brush                c. Grounded brush screws to 1.5 Nm (13 Ib-in.).
      socket.
   c. Push the spring fully onto the post and release the free
      end to engage the notch in the brush socket.

                                                       INSULATED BRUSH



                           INSULATION


                       BRUSH
                       SPRING



                  GROUNDED
                    BRUSH


                                                                                                     SPRING
                                                                                                      POST




                                    FIGURE 14. SPRINGS AND BRUSHES ON BRUSH HOLDER



                                                        Engines & Generators

                                                                 81
                                                 STARTER MOTOR
                                                                           Important:
4. The frame and field assembly (19) to the brush holder
                                                                           a. The O-ring can easily be damaged during installa-
   assembly.
                                                                              tion of the c.E. frame (14). To prevent such dam-
   a. Position the brush holder assembly (3) (with                            age, install the O-ring as described in the following
      installed brushes) over the terminal end of the frame                   steps.
      and field assembly (19).
                                                                           h. Install the O-ring on the frame, field and brush hold-
   h. Attach the terminals of the insulated brush leads to                    er group (A) so that it is against the shoulder on the
      the conductors in the frame and field assembly with                     field frame that will abut the C.E. frame when
      the insulated brush screws (29).                                        installed. This is the normal installed position for
Tighten:                                                                      the O-ring.
    c. The insulated brush screws to 1.5 Nm (13 Ib-in.).                   c. Carefully roll the O-ring out of its normal installed
                                                                              position up onto the major O.D. of the field frame.
Starter Assembly                                                              Allow the O-ring to remain in this position until the
(Figures 4 and 15)                                                            c.E. frame is partially installed.
Support the gear reduction and drive group (B) with the               6.   c.E. frame (14)
pinion gear end down and proceed as follows:
                                                                           a. Align the marks on the C.E. frame and frame and
Important:                                                                    field assembly (19, Figure 5) made prior to disas-
If the armature bearings (8 and 9) are being replaced, install                sembly.
them on the armature (13) as specified in REPAIR PROCE-                    h. Start the C.E. frame onto the frame and field assem-
DURES, step 1 before proceeding with assembly.                                bly, leaving a gap just slightly larger than the thick-
Install or Connect:                                                           ness of the O-ring (20).
1. Solenoid assembly (1).                                             7. Brush plate screw (42).
    a. Pivot the plunger of the solenoid assembly into                     a. Use a scribe or similar tool to align the tapped holes
       engagement with the shift lever in the gear reduction                  in the brush holder assembly (3, Figure 5) with the
       and drive group (B).                                                   screw holes in the C.E. frame (14).
    h. Position the solenoid assembly mounting flange and             Tighten:
       install the solenoid mounting screws (25).                          h. Brush plate screws to 2.8 Nm (25 lb-in.).
Tighten:                                                              8. Thru bolts (41).
    c. Solenoid screws to 2.8 Nm (25 lb-in.).                              a. Install the thru bolts and tighten them by hand but do
2. Frame seal (33).                                                           not close the gap between the C.E. frame and the
                                                                              frame and field assembly where the O-ring (20) goes.
3. The armature assembly (13) with bearings (8 and 9) into
   the gear reduction and drive group (B).                                 h. Roll the O-ring (20) back down into its installed
                                                                              position between the C.E. frame and the frame and
    a. Make sure the gear teeth are aligned, then seat the
                                                                              field assembly.
       bearing (8) on the armature shaft fully into the hous-
       ing recess.                                                         c. Align the timing ribs on the edge of the C.E. frame
                                                                              (14) with the timing spots on the frame and field
4. Frame, field and brush holder group (A).
                                                                              assembly (A) to assure proper brush alignment.
    a. Place the dowel pin (28) in the hole in the armature                   Refer to Figure 15. Marks are located in 2 places on
       support bracket of the gear reduction and drive                        the motor but will only match one way.
       group (B).
                                                                      Tighten:
    h. Position the frame, field and brush holder group over
                                                                           d. Thru bolts (41) to 8.5 Nm (75 Ib-in.).
       the armature assembly (13), align the hole for the
       dowel pin (28) and the marks made prior to disas-              9. The motor lead on the frame and field assembly (19,
       sembly, and seat in the gear reduction and drive                  Figure 5).
       group (B).                                                          a. Remove the nut from the terminal on the solenoid,
    c. Twist the brush springs (7, Figure 5) away from the                    install the motor lead terminal and reinstall the nut.
       brushes (4 and 5, Figure 5), slide the brushes in to           Tighten:
       contact the commutator on the armature (13),
                                                                           b. The nut on the terminal of the solenoid assembly to
       and release the brush springs to contact the ends of
                                                                              11 Nm (100 Ib-in.).
       the brushes.
5. O-ring (20).




                                                          Engines & Generators

                                                                 82
                                                   STARTER MOTOR
STARTER INSTALLATION                                                                                      C.E. FRAME
Testing After Repair Dr Overhaul
After repair or overhaul, the starter can be tested as speci-
fied in the Starter No-Load Test found in the TROU-
BLESHOOTING section.
After repair, overhaul, testing or replacement of the starter,
reinstall it using the following torques when making the elec-                                                  TIMING
trical connections to the starter.                                                                              MARKS


  A CAUTION: Make sure the negative battery cable
  is disconnected at the battery when making the elec-
  trical connections to the starter. Otherwise, injury
  may result. If a tool is shorted at the solenoid bat-
  tery terminal, the tool will heat enough to cause a
  skin burn.

Tighten:                                                                                                    FRAME AND
   a. Solenoid battery (B) terminal nut to 18 Nm (13 lb-ft.).                                               FIELD
                                                                                                            ASSEMBLY
   b. Solenoid switch (S) terminal nut to 1.8 Nm
      (16Ib-in.).                                                              FIGURE 15. ALIGNING TIMING MARKS
STARTER SPECIFICATIONS
All 12 Volt models have these No-Load Test Specifications:
                                                                AMPS                                      RPM
                VOLTS
                                                   Minimum               Maximum              Minimum             Maximum
                  10                                  125                  190                  3000               5600

All 24 Volt models have these No-Load Test Specifications:
                                                                AMPS                                      RPM
                VOLTS
                                                   Minimum               Maximum              Minimum             Maximum
                  20                                   75                     90                3600                   5400

Starter Solenoid current consumption:
                                                            PULL IN WINDING                          HOLD IN WINDING
           RATED VOLTAGE
                                                AMPS            VOLTS           OHMS        AMPS         VOLTS            OHMS
                  12                           52 - 59            10          0.17-0.19     12 -14         10          0.76 - 0.81
                  24                          100 -125            20          0.16 - 0.20   12 -14         20          1.15 -1.65




                                                            Engines & Generators

                                                                  83
                                                                                         WIRING DIAGRAM
                                                                                                            #44780
               ALTRNUOR        2np' 12A
                                                                                                                                                                                            ALleRNATOR   '2y   "'A
        II'.


                                                                                              o


                                                                                                                      , ._ _ _ _ _ _ _ _ _...:":...J    ;
                                                                                                                                                                                 , .. VIO

                                                               tl' 01.                                                                                                           III OIlG




                                                                                                                                                                  o


                                                                                                                                                            ....        IVIO
                                                               11011[1

                                                                                                                                                       II. II[OIVIO




aATTEo, SWI'CH                                 \11                                                                                                              AVI    O~SSUR[




    r~------l1--
    I          ~ "'"LlII'
        12-2' VOC                                                                            III Ill,.,

    L~                                                     0                                     '1. ttl
                                                                                            II. 1[1,'111'

                                                                                              .. 4 ""1

                                    -=-    STABlER MOTOR                                      . . . . LU

                                                                                             .14 1'111

                                                                                             114 VIO




I                                                I


                              1[0              ,.!!;!.
                                          a:
                                                ~        ".IEO           114 Rn
                                                                         ,uBllI:
                           au              . Is.
                                   ~SI"...-::lo.7"""""----"
                                      IlI"H'
                                                                                                                   III 1[1, ...,


                    '--_ _-"'WH"-I'~16l' J J
                                                                                                                                                                                  '''IU
                                                                                                                                      "1.t.1

                 '--_ _ _ _-'Y,,'O,~$.                   ". YlO                                                 OI. 0"                tit '[0



               L-_ _ _ _ _                 Y!.!I.!!.Oj$~ ~---.r          ~LD-"- ~
                                                              ......I"-t"__                                    ~,.jUf.t+:W--"."'I,:-',.",,:'___--'
                                                     Jf&u                          I---"-"--~-~~----'--'---
lOT[:
I. .[MOV[ JUMP'ER IMEI   (~'[CT'IG         ,. S[(OID R[MOT[ P'"IEl.
                                                                                                                                           "''1M'
2. GIQUID .,. T[lNIIAl   or    'I[HUT SOlUOID 01 24Y SYSUN OIl'.

                          ,.,                 182-1
                    m.    /WI                                                                                                                                         I'N!H!AT
                                                                                                                                                                      SWITCH
                                              Tl12-2
                                              lBI-5
                                              TBIl


                                              1BI-2                                                                                                                    START
                                                                                                                                                                       SWITCH
                                              T8'-IO

                                             TlI2'S
                                             T82-4

                                                                                                                                                                        STCP
                                                                                                                                                                       SWITCH
                                                                                         HOUR                  VOLT                tI,1I
                                                                                                              METER
    L-----""-"""''--~'BH                                                           I..   METER                                                              -           .. ~



                                                                                                     Engines & Generators

                                                                                                             84
                                          WIRING SCHEMATIC
                                                                  #44780


                                                                                           BATTERY 12-l"VOC




                       CIRCUIT
                       BREAKER                                                                STARTER

        ,-____~r~~~--------~~~~~~--~
              l _ ...J       I STARTER I
                      ~~:g~:rg:                                          ,SOLENOIOJ


                                                                                                            GtOWPLUGS


                                                                                          I PItEHEATi
                                                                                          ,SOLENOI ~


                                                                                                            AL HRNAlOR

                                  87
                      KISU.RT
                                  JO

                                                                      II:ZRUN
      ~,,,,,~,~I----------~--~----------~I'40 ~'7~                                   __________-.____~



                                                01 L PR[SS.    [lK.  TEWP.           WATER TEW'.
                                                  51' TeM        511 reH               $WI reM

         "
  r     'STO.
         ,s.neH                                                                                                           KZ-RUN RlAr
  I                                                                   IUODZ

                                                                                                                          "         '1



                                                                                                                          .
               PREHEAT                               START
               S.. , TeH                            $WI TeH                                                              III-START RElAY
              r-      ~                             r -,                                                                            .1
              l_ .J                                 L _ J
                                                                                                                       Oil 8YPASS SIITCH



                                                                                                                       AUI. 0.', SIITCH



                                                                                                                      Oil PRSS. SOlDER



181-1        TIIJ        TBI-.        1112-l        TBZ"      TlI-S        TIIl-.       TIll,'     TBZ'~    TIIl-5    WATER HM'    S[IID(I



                                                                                                                                        TIll-tO




  ~~

        STOP
        SWI TeH
                                                                                                                      OIL PRESS. GAUGE
                            PREHEAT                  START
                            SWI TeH                 5'" TeH
                                                                                       IND. LIGHT
                            r-    ~
                            l_ ...J
                                       -TfPI(Al REWOTE START/STOP 'ANfl CON[(TIOfilS-
                                                                                                                         VOL H4[ T[ R



             NOl[ .

             o REMOTE COfII[CTOR PINS
                                                                                                                          HQURM[l[R




                                                              Engines & Generators

                                                                           85
                                            REMOTE INSTRUMENT PANEL
                                                                    #44329                                STOP SWITCH



                                                                                                                                        2

                                                                                                                                        5
                                                                                                          o
 , __ _ _ ___ _ _ _ _ __ _ __
     ..   ..   ..   REMOTE
                     ..     ..  .. PANEL
                        .. CONTROL  .. .. (REAR VIEW)
                                            .. ..   ..         ..    ..   ..   ..
                                                                                    PREHEAT
                                                                                    SWI TCH
                                                                                      .. - :
                                                                                           1
                                                                                                       PREHEAT




                                                                                                          START SWI TCH




                                STOP
                               SWITCH
                                                                                               .t16 RED/VL


                                                                                                 116




                                                                                               116 RED/WHT




                                                                                                116 WHT



                                                                                                                          0)Q)Q)
                                         110 RED
                                                                          PREHEAT
                                                                                                                          @@@
 1
 :
                                 START
                                SWITCH
                                                                           SWITCH
                                                                                                                          @@
.1
 :
                           0                                                                   116 WHT/RED
                                                                                                                           MALE CABLE
                                                                                                                           CONNECTOR
                                                             114 RED                                                       REAR VIEW

                             114 RED
                                                                                               116 VEl/RED



 ~ .. - .. - .. - .. - .. - .. - .. - .. - .. - .. - .. - .. - .. - .. - .. - .. _ .. _I
                                 P.N. 44336




                                                                Engines & Generators

                                                                          86
                                                                                                 WIRING DIAGRAM
                                                                                                MARINE ENGINES #44781

                                 ALTERNATOR. 24V 42A                                                                                               ALTERNATOR   0       51A




                                     I


                 '" .,,' '00                                                                                                    OIL PRESSURE
                                     I
                                                                                                                                   ll1!ill
                                     I

                                 +~                                           !!.EJLI..I!.AJ.
                                                                               ~
                                  ~~                                           SWITCH
                                                                    (USED 6ifSOiirMODHS)

                                  Il.Mll.!U
                                 12-24 VDC
                                                  "


NOTE S:
I   THI$ '''ODUCT IS I"RoHeTEO BY" WAfrlUAt II[S(T CIRCUIT IIRtAl([R LOCATED IIEAR THE              S1
    STARTER.   exCESSIVE CURII(IH .'ll CAUSE THE BR[ ... It[R TO JRI' AND THE (NGIN[ .IlL
    SHUT DOWN        tHE IIUILD[!IfOWNEII lIun liE SURE THAT THE INSTIIUII[NT "ANEL. WilliNG. AND                          S2
    [116'''' AilE IItSTALLED TO PR(V[l1T CONTACT IIET.EEN ElECHtlCAl DEVICES ANO SEAWATER
2   AN ON-OFr SWITCH SHOULD liE     INSTAlLEO 8ETwEEN THE UTTERl AND STARTER TO
    DISCONNECT THE IIATTE'" 'N AN OHRGENCT AND WH(l1 tEAYING THE aOAT. A SW"CH
    .,TH A CONTINUOUS UTIli(; OF I1S AM'S  AT 12 VDC .'LL S[RYE THIS FUNCTION. THIS                                        PZ
    S.,TCH SHOULD NOT eE UseD TO MAI\[ OR 8REAII THE CIRCUIT.
                                                                                                    PI
1   THE PltrIll .'IIE AT 'LUG Z IS UNt/SED AND SHOULD II(   INSULATED. ("'I'TAIN PANEl ONLT

4
5
    THE G~AY .,ItE AT PLUG   1   IS UNUHD AND SHOULD Itt    INSULATED.   ADM.ltAl PANEl ONU
    CONNECT THE CIItCUIT I!II(AKER AND RESISTOR .,RE TO THE .,. f(ItMINAl FOR I l VOLr
                                                                                                                                                ADMIRAL
    SUTOIS ONLY. FOR l4 VOLT SlSTENS REMOVE THE CIRCUIT 8REUER AND CONNECT 01
    RESISTOR .,RE TO THE 114 LT 8tU .,RES AND THEN GAOUND THE '1' T(AWINAL.                                                                     PANEL



                                                                                                             - ---
                                                                                                             W"T!R TaP.
                                                                                                                                           -,
                                                                                                                 OAUOI!!
                                                                                                                     o




                                                                                                           110 RED




                                                                                                                                                                    Hr, 11il01
                                                                                                         Engines & Generators

                                                                                                               87
                                         WIRING SCHEMATIC
                                         MARINE ENGINES #44781

             + 
                ~______________-=BA~T~T~E~RY~I~2_2~.~Y~DC~________________~



                                 START
                                  SOl.          STARTER




                                                  Al TERNATOR




                                  lOA
     12Y (                   (   C.B.
     20A
     C.B



                                                                                         OPTIONAL ALTERNATORS
                 .,;
                 '"
                                                                                                                     I I . IT. 8lU      I

                                                                                                                          lot PI Hit

                 ....
                 ~
                 ....
                 ::>
                         0

                 z




                                                                                         PRESTOLITE 72 AMP         ALT



                KEY
                sw.


                                                           VOL TMETER


ADMIRAL
PANEL


                                                                               PRESTOLITE\LEECE-NEVILLE 90 AMP                    ALT


              PREHEAT
               SWI TCH

                                                                                                RED
                                                                                 ORN            ORN




                                                                                                       CASE GN

                                                                                               DISCONNECT JUMPER FOR
                                                                                               USE WITH TWO BATTERIES.



                                                                    LESTEK 135         160. 190 AMP    ALT.

                                                                                                                               Ih'.12UIII
                                                Engines & Generators

                                                          88
                                     ENGINE TROUBLESHOOTING

Hard Starting ...................................................................................................90
    Starter Inoperative ................................................................................ 90
    Starter Operates but engine does not turn over.. .................................. 91
    Engine turns over but does not start though fuel
    is being delivered to the injection pump .............................................. 92
    Engine turns over but does not start .................................................... 93
Unstable Low Idling ...................................................................................94
Insufficient Power .....................................................................................96
Excessive Fuel Consumption .....................................................................99
Excessive Oil Consumption ...................................................................... 10 1
Overheating .............................................................................................. l 02
White Exhaust Smoke .............................................................................. l 03
Dark Exhaust Smoke ................................................................................ l 04
Oil Pressure Does Not Rise ...... ................................................................ 105
Abnormal Engine Noise ............................................................................ l 06




NOTE: Use this section to quickly diagnose and repair engine failures.
        Each troubleshooting chart has three headings arrangedfrom lefi to right.
        #1 Check Point, #2 Trouble Cause, #3 Remedy




                                                          Engines & Generators

                                                                  89
                                     ENGINE TROUBLESHOOTING
                                                 HARD STARTING
                                          1)    STARTER INOPERATIVE

            Checkpoint                               Trouble Cause                                  Remedy



                                         NG                                       NG
      Transmission neutral switch                 Defective neutral switch                 Replace the neutral switch
           (if so equipped)
I                                    J
--.



                                         NG
                                                                                 ~
                                               Loose battery cable terminals             Clean and/or retighten the bat-
                Battery              I--
                                               Poor connections due to rusting           tery cable terminals




                                         NG                                       NG
                                                 Battery discharged or weak      '---    Recharge or replace the battery




                                         NG                                       NG
                                                Drive belt loose or broken       r--- Adjust or replace the drive belt



               OK


I                                     NG       Defective starter switch or        NG     Replace the starter switch or
            Starter switch           r---                                        r-
                                                                                         the starter relay
                                               starter relay

I
               OK


                                                                                  NG
                                     ~
                                               Defective magnetic switch or              Repair or replace the magnetic
            Starter motor
                                               starter relay
                                                                                 r---    switch



               OK


                                         NG
             Starter motor           I--           Defective starter motor       ~      Repair or replace the starter motor




                                                      Engines & Generators

                                                              90
                     ENGINE TROUBLESHOOTING
                              HARD STARTING
2)     STARTER MOTOR OPERATES BUT ENGINE DOES NOT TURN OVER

 Checkpoint                       Trouble Cause                                   Remedy



                     ~      Loose battery cable terminals
                                                              -
                                                                  NG   Clean and/or retighten the bat-
       Battery
                            Poor connections due to rusting            tery cable terminals




                      NG                                      ~
                              Battery discharged or weak               Recharge or replace the battery




                      NG                                          NG
                                                              r----
                               Drive belt loose or broken               Adjust or replace the drive belt




      OK


                      NG                                          NG
     Starter motor   r---       Defective pinion   gear       r----        Replace the pinion gear




                      NG      Defective magnetic switch
                                                                  NG   Repair or replace the magnetic
                                                              t--      switch




                      NG    Brush wear                            NG   Replace the brush and/or the
                            Weak brush spring
                                                              t--      brush spring



       OK


                      NG    Piston, crank bearing seizure,        NG   Repair or replace the related
        Engine       r---                                     t--
                            or other damage                            parts




                                  Engines & Generators

                                           91
                                    ENGINE TROUBLESHOOTING
                                               HARD STARTING
                        3)   ENGINE TURNS OVER BUT DOES NOT START
                      FUEL IS BEING DELIVERED TO THE INJECTION PUMP

          Checkpoint                               Trouble Cause                                      Remedy
 Continued from the previous page
             OK   I
                                             Injection nozzle injection starting
                                        NG                                          NG     Adjust or replace the injection
          Injection nozzle          -        pressure too low                      r----
                                                                                           nozzle
                                             Improper spray condition


             OK

                                             Defective fuel injection nozzle
                                        NG
          Injection pump            -        resulting in fuel drippage after
                                             fuel injection
                                                                                   - NG       Replace the delivery valve




                                        NG   Defective injection pump control      ~       Repair or replace the injection
                                             rack operation                                pump control rack




                                        NG   Injection pump plunger worn or        ~       Replace the injection pump
                                             stuck                                         plunger assembly



             OK


     Injection pump (VE pump)       ~        Injection pump drive shaft seizure ~          Replace the injection pump drive
                                             or other damage                               shaft

--



                                        NG   Injection pump governor spring        ~       Replace the injection pump
                                             seizure                                       governor spring




                                                   Engines & Generators

                                                           92
                             ENGINE TROUBLESHOOTING
                                          HARD STARTING
                      4)   ENGINE TURNS OVER BUT DOES NOT START

     Checkpoint                               Trouble Cause                                   Remedy


                                       Defective engine stop mechanism.            Replace the engine stop
                              ~                                           -
                                                                              NG
 Engine stop mechanism                                                             mechanism.




                                  NG    Defective fuel cut solenoid valve ~        Replace the fuel cut solenoid
                                        (VE pump)                                  valve



                      FUEL IS NOT BEING DELIVERED TO THE INJECTION PUMP


                                  NG
          Fuel                -               Fuel tank is empty          - NG             Fill the fuel tank




        OK

                                                                                   Repair or replace the fuel lines
       Fuel piping            -NG       Clogged or damaged fuel lines
                                        Loose fuel line connections
                                                                          - NG     Retighten the fuel line
                                                                                   connections


        OK


        Fuel filter           ~         Fuel filter overflow valve does
                                        not close
                                                                          ~        Repair or replace the fuel filter
                                                                                   overflow valve




                                  NG                                      ~        Replace the fuel filter element or
                                          Clogged fuel filter element
                                                                                   the fuel filter cartridge



        OK


       Fuel system            -
                                  NG         Air in the fuel system       ~ Bleed the air from the fuel system



             I
Continued on the next page




                                              Engines & Generators

                                                      93
                                 ENGINE TROUBLESHOOTING
                                 UNSTABLE LOW IDLING (PROPULSION)

          Checkpoint                           Trouble Cause                                       Remedy



        Low idling               - NG    Low idling improperly adjusted
                                                                               NG
                                                                             r---             Adjust the low idling




             OK




                                                                               NG
      Throttle control system    ~      Throttle control system
                                        improperly adjusted
                                                                             r---       Adjust the throttle control
                                                                                        system



             OK

I
                                  NG                                           NG
           Fuel system           r---   Fuel system leakage or blockage r---            Repair or replace the fuel system




                                  NG                                           NG
                                              Air in the fuel system         r--- Bleed the air from the fuel system




                                  NG                                           NG
                                        Water particles in the fuel system   t---               Change the fuel




             OK



             Fuel filter         ~         Clogged fuel filter element
                                                                               NG       Replace the fuel filter element or
                                                                             r-------
                                                                                        the fuel filter cartridge


                  I
    Continued on the next page




                                               Engines & Generators

                                                      94
                                   ENGINE TROUBLESHOOTING
                                       UNSTABLE LOW IDLING (PROPULSION)

             Checkpoint                              Trouble Cause                                   Remedy

    Continued from the previous page
                OK   I
             Injection pump            - NG   Defective governor lever operation -
                                                                                      NG   Repair or replace the governor
                                                                                           lever




                                        NG     Regulator valve improperly
                                                                                  -
                                                                                      NG   Adjust or replace the regulator
                                               adjusted (VE pump only)                     valve




                                        NG                                            NG
                                                    Broken plunger spring         -          Replace the plunger spring




                                        NG                                        ~
                                                        Worn plunger                        Replace the plunger assembly




                                        NG                                            NG
                                                                                                                             I
                                              Worn camshaft (In-line pump only)   -             Replace the camshaft




                                        NG
                                                                                  - NG
                                               Worn roller tappet (In-line pump
                                                                                              Replace the roller tappet
                                               only)




                                        NG                                            NG
                                                Worn cam disc (VE pump only)      -             Replace the cam disc




            Valve clearance            ~       Valve clearance improperly
                                                                                  -
                                                                                      NG
                                                                                             Adjust the valve clearance
                                               adjusted

l




                                                    Engines & Generators

                                                            95
                             ENGINE TROUBLESHOOTING
                                     INSUFFICIENT POWER

     Checkpoint                             Trouble Cause                                  Remedy



                                                                         NG
       Air cleaner           ~         Clogged air cleaner element      r----
                                                                                Clean or replace the air cleaner
                                                                                element



        OK

                             ~                                            NG
           Fuel                         Water particles in the fuel     r----           Replace the fuel




        OK

                              NG                                         NG
        Fuel filter          r----    Clogged inlet filter screen       r----        Clean filter screen



        OK

                                                                         NG
     Fuel feed pump          ~           Defective fuel feed pump       r----
                                                                                Repair or replace the fuel feed
                                                                                pump



        OK


     Injection nozzle        ~            Injection nozzle sticking     ~         Replace the injection nozzle




                                      Injection nozzle injection starting
                              NG                                           NG   Adjust or replace the injection
                                      pressure too low                    r--
                                                                                nozzle
                                      Improper spray condition


        OK


   Fuel injection pipes      ~        Fuel injection pipes damaged or    NG     Replace the fuel injection pipes
                                                                        r--
                                      obstructed


             I
Continued on the next page




                                            Engines & Generators

                                                    96
                               ENGINE TROUBLESHOOTING
                                        INSUFFICIENT POWER

        Checkpoint                             Trouble Cause                                    Remedy
Continued from the previous page
           OK   I

        Injection pump             ~         Defective delivery valve       ~           Replace the delivery valve




                                   NG
                                                 Defective timer            - MG       Repair or replace the timer




                                   NG                                           NG   Adjust or replace the control
                                         Improper control lever operation   -        lever




                                                                                     Adjust the injection timing
                                   NG
                                            Defective injection timing      ~        Repair or replace the injection
                                                                                     pump timer




                                   NG
                                            Weak governor spring            ~         Replace the governor spring




                                   NG             Worn plunger              ~        Replace the plunger assembly




                                   NG   Worn camshaft (in-line pump only)   ~             Replace the camshaft




  Continued on the next page




                                                  Engines & Generators

                                                         97
                                   ENGINE TROUBLESHOOTING
                                            INSUFFICIENT POWER

         Checkpoint                                Trouble Cause                                    Remedy
Continued from the previous page
            OK   I
                                       NG                                         NG
         Injection pump            !---            Worn roller tappet            t-----      Replace the roller tappet




            OK

                                            Exhaust gas leakage from the
         Turbocharger              ~        exhaust system                       ~        Repair or replace the related
                                                                                          parts
                                            Air leakage from the intake system




                                       NG                                         NG
                                            Defective turbocharger assembly r - Replace the turbocharger assembly




            OK
                                             Blown out cylinder head gasket
                                             Worn cylinder liner
     Compression pressure          ~         Piston ring sticking or broken      ~           Replace the related parts
                                             Improper seating between the
                                             valve and the valve seat

            OK


                                       NG    Valve clearance improperly           NG
        Valve clearance            r-                                            ~          Adjust the valve clearance
                                             adjusted



            OK


                                       NG                                         NG
          Valve spring             r----       Valve spring weak or broken       ~           Replace the valve spring




            OK


                                                                                  NG
         Exhaust system            ~              Exhaust pipe clogged           ~            Clean the exhaust pipe




            OK


                                       NG
  Full load adjusting screw seal   -         Open and improperly set
                                             adjusting screw seal                - NG     Adjust and reseal the adjusting
                                                                                          screw




                                                      Engines & Generators

                                                            98
                                 ENGINE TROUBLESHOOTING
                                 EXCESSIVE FUEL CONSUMPTION

          Checkpoint                          Trouble Cause                                      Remedy



                                                                               NG
                                 ~                                                    Repair or replace the fuel system
I
!
           Fuel system                            Fuel leakage               t--      related parts

i
             OK   I
I
                                                                               NG
            Air cleaner          ~       Clogged air cleaner element         t--
                                                                                      Clean or replace the air cleaner
                                                                                      element



             OK   I
I
         Low idling speed
                                  NG                                           NG
                                 t--   Poorly adjusted low idle speed        r-----      Adjust the low idle speed




             OK   I
I

                                       Injection nozzle injection starting
                                                                               NG
          Injection nozzle       ~     pressure too low                      r-----
                                                                                      Adjust or replace the injection
                                                                                      nozzle
                                       Improper spray condition


             OK   I

                                                                              NG
       Fuel injection timing     ~     Fuel injection timing improperly
                                       adjusted
                                                                             t--      Adjust the fuel injection timing




             OK   I
                                       Defective delivery valve result-
                                                                              NG
          Injection pump         ~     ing fuel drippage after fuel          t---       Replace the delivery valve
                                       injection


             OK   I
                                 ~     Air leakage from the turbocharger NG           Repair the turbocharger intake
          Turbocharger                                                  t--
                                       intake side                                    side


                  I
    Continued on the next page




                                             Engines & Generators

                                                     99
                                   ENGINE TROUBLESHOOTING
                               EXCESSIVE FUEL CONSUMPTION

         Checkpoint                               Trouble Cause                                Remedy
Continued from the previous page
            OK   I
                                       NG                                     NG
         Turbocharger              r---     Defective turbocharger assembly r - - - Replace the turbocharger assembly




            OK   I
                                                                              NG
        Valve clearance            ~        Valve clearance improperly
                                            adjusted
                                                                             r---       Adjust the valve clearance




            OK   I
                                            Blown out cylinder head gasket
                                            Worn cylinder liner
                                       NG                                     NG
     Compression pressure          -        Piston ring sticking or broken   I---       Replace the related parts
                                            Improper seating between the
                                            valve and the valve seat

            OK   I
                                       NG                                     NG
          Valve spring             -          Valve spring weak or broken    r---       Replace the valve spring




                                                  Engines & Generators

                                                       100
                                ENGINE TROUBLESHOOTING
                                EXCESSIVE OIL CONSUMPTION

            Checkpoint                       Trouble Cause                                Remedy



               Engine oil
                                 NG    Engine oil unsuitable            NG     Replace the engine oil
                                f---                                   ~


                                       Too much engine oil                     Correct the engine oil volume



               OK   I
                                 NG
          Oil seal and gasket   '---
                                       Oil leakage from the oil seal
                                       and/or the gasket
                                                                       - NG    Replace the oil seal and/or the
                                                                               gasket



               OK   I
                                 NG                                     NG
             Air breather       f---        Clogged air breather       r--          Clean the air breather

i
               OK   I
                                       Defective valve seals
    Inlet and exhaust valves     NG                                      NG    Replace the valve seals, the
    Valve seals
                                t--    Worn valve stems and valve      r----   valves, and the valve guides
                                       guides


               OK   I
I             Piston rings
                                 NG
                                t--
                                       Piston rings worn, broken or
                                       improperly installed
                                                                         NG
                                                                       r----
                                                                               Replace the piston rings or
                                                                               properly install

I
               OK   I
                                 NG    Cylinder lines scored or          NG
            Cylinder liners     f---
                                       worn
                                                                       r----     Replace the cylinder liners

I




                                              Engines & Generators

                                                    101
                             ENGINE TROUBLESHOOTING
                                           OVERHEATING

       Checkpoint                             Trouble Cause                                   Remedy



                                   NG         Insufficient antifreeze       NG         Replenish the antifreeze
        Cooling water         I--                                          r----
                                              Insufficient raw water                   Correct raw water flow



          OK   I
                                   NG      Drive belt loose or cracked      NG
         Drive belt            -           causing slippage                r---          Replace the drive belt




          OK   I
                                                                            NG
      Raw water pump           ~               Impeller or bearings        r---      Repair/replace raw water pump




          OK   I
                               ~                                            NG
        Water pump                          Defective water pump           r---- Repair or replace the water pump



          OK   I
Cylinder head and cylinder body   NG    Defective sealing cap resulting in  NG
                                f----                                      t---        Replace the sealing cap
sealing cap                             water leakage



          OK   I
                                   NG                                       NG
         Thermostat           I--            Defective thermostat          r--         Replace the thermostat




          OK   I
                               ~                                           - NG
                                        Cooling system clogged by                  Clean the foreign material from
       Cooling system
                                        foreign material                           the cooling system


               I
          OK   I
                                   NG
     Fuel injection timing     f----
                                        Fuel injection timing improperly
                                        adjusted
                                                                           - NG     Adjust the fuel injection timing




                                             Engines & Generators

                                                   102
                             ENGINE TROUBLESHOOTING
                                WHITE EXHAUST SMOKE

        Checkpoint                        Trouble Cause                               Remedy



                              NG                                      NG
             Fuel            r--       Water particles in the fuel   r--            Replace the fuel




           OK   I
                              NG
     Fuel injection timing   r--    Retarded fuel injection timing   ~      Adjust the fuel injection timing




           OK   I                   Blown out cylinder head gasket
                                    Worn cylinder liner
                              NG                                      NG
    Compression pressure     r--    Piston ring sticking or broken   r--       Replace the related parts
                                    Improper seating between the
                                    valve and the valve seat

           OK   I
         Turbocharger        ~          Defective turbocharger       ~         Replace the turbocharger




           OK   I
                                    Defective valve seals
Inlet and exhaust valves
Valve seals                  - NG   Worn valves stems and valve
                                                                      NG
                                                                     r--
                                                                            Replace the valve seals, the
                                                                            valves, and the valve guides
                                    guides


           OK   I
          Piston rings       ~      Piston rings worn, broken or      NG    Replace the piston rings or
                                                                     '--
                                    improperly installed                    properly install



           OK   I
                              NG
                                                                     - NG
                                    Cylinder lines scored or
        Cylinder liners      '-                                               Replace the cylinder liners
                                    worn




                                           Engines & Generators

                                                103
                        ENGINE TROUBLESHOOTING
                                 DARK EXHAUST SMOKE

  Checkpoint                            Trouble Cause                                       Remedy



                            NG
     Air cleaner        r---        Clogged air cleaner element         - NG     Clean or replace the air cleaner
                                                                                 element



     OK

                                  Injection nozzle injection starting
  Injection nozzle      - NG      pressure too low                      -
                                                                            NG   Adjust or replace the injection
                                                                                 nozzle
                                  Improper spray condition


     OK


                                                                            NG
Fuel injection timing   - NG      Fuel injection timing improperly
                                  adjusted
                                                                        r---:-   Adjust the fuel injection timing




      OK

                                  Defective delivery valve resulting
  Injection pump        -
                            NG    in fuel drippage after                '---
                                                                            NG     Replace the delivery valve
                                  fuel injection




                            NG                                              NG
                                    Excessive injection volume          r---:-     Adjust the injection volume




                                          Engines & Generators

                                                104
                                     ENGINE TROUBLESHOOTING
                                     OIL PRESSURE DOES NOT RISE

           Checkpoint                               Trouble Cause                                     Remedy



             Engine oil              r--
                                         NG   Improper viscosity engine oil
                                              Too much engine oil                 - NG     Replace the engine oil
                                                                                           Correct the engine oil volume



              OK


                                                 Defective oil pressure gauge                  Repair or replace the oil
     Oil pressure gauge or sendor
     Oil pressure indicator light    -
                                         NG
                                                 or sendor                        - NG         pressure gauge or sendor




              OK



               Oil filter            ~           Clogged oil filter element       ~        Replace the oil filter element or
                                                                                           the oil filter cartridge



              OK


                                         NG
    Relief valve and by-pass valve   -
                                              Relief valve sticking and/or weak
                                              by-pass valve spring
                                                                                  - NG     Replace the relief valve and/or
                                                                                           the by-pass valve spring



              OK


                                         NG                                           NG
              Oil pump               -           Clogged oil pump strainer        -          Clean the oil pump strainer




                                         NG                                           NG   Replace the oil pump related
                                                Worn oil pump related parts       -        parts



              OK



          Rocker arm shaft           ~           Worn rocker arm bushing
                                                                                      NG
                                                                                  r--      Replace the rocker arm bushing




              OK


                                                                                      NG   Replace the camshaft and the
              Camshaft               ~        Worn camshaft and camshaft
                                              bearing
                                                                                  r--
                                                                                           camshaft bearings

i

              OK

I
I
                                         NG                                           NG   Replace the crankshaft and/or
       Crankshaft and bearings       r--       Worn crankshaft and bearings       f---
                                                                                           the bearings




                                                     Engines & Generators

                                                          105
                                  ENGINE TROUBLESHOOTING
                                      ABNORMAL ENGINE NOISE
                                              1.   Engine Knocking

          Checkpoint                               Trouble Cause                                       Remedy
Check to see that the engine has been thoroughly warmed up   befo~e   beginning the troubleshooting procedure.




                Fuel              -
                                      NG
                                                    Fuel unsuitable              - NG               Replace the fuel


                                                                                        '--


             OK   I
                                                                                  NG
        Fuel injection timing     - NG      Fuel injection timing improperly
                                            adjusted
                                                                                 e---       Adjust the fuel injection timing




             OK   I
          Injection nozzle        - NG      Improper injection nozzle starting
                                            pressure and spray condition
                                                                                 ~          Adjust or replace the injection
                                                                                            nozzle



             OK   I
                                      NG
       Compression pressure       r--
                                            Blown out head gasket
                                            Broken piston ring                   - NG       Replace the head gasket or the
                                                                                            piston ring



                                           2. Exhaust Leakage Noise

                                                                                               Tighten the exhaust hose
                                      NG
           Exhaust System         r---        Loosely connected exhaust or
                                              broken exhaust hose                - NG          connections
                                                                                               Replace the exhaust hose


             OK   I
                                                                                            Replace the washers
  Injection nozzles and/or glow    ~        Loose injection nozzles and/or        NG
                                                                                 '--        Tighten the injection nozzles
  plugs                                     glow plugs
                                                                                            and/or the glow plugs
                                                                                        I                                      I
                I
    Continued on the next page




                                                   Engines & Generators

                                                        106
                                       ENGINE TROUBLESHOOTING
                                        ABNORMAL ENGINE NOISE
                                              2.        Exhaust Leakage Noise

            Checkpoint                                   Trouble Cause                                  Remedy
    Continued from the previous page

               OK   I

                                        NG     Loosely connected exhaust mani- NG            Tighten the exhaust manifold
           Exhaust manifold            r--                                    r---
                                               fold and/or glow plugs                        connections



               OK   I

                                        NG                                        NG
          Cylinder head gasket         r---    Damaged cylinder head gasket      r--         Replace the cylinder head gasket




                                                   3.     Continuous Noise


                                        NG                                        NG
               Drive belt              r---                Loosen drive belt     r---          Readjust the drive belt tension

1                                                                                        I
               OK   I
                                       ~~                                         NG
            Raw water pump                                Impeller or bearings   f----         Repair/replace raw water pump




               OK   I
                                                                                  NG
          Water pump bearing           ~       Worn or damaged water pump
                                               bearing
                                                                                 r---        Replace the water pump bearing




               OK j


             Alternator                ~~                 Defective alternator    NG         Repair or replace the alternator,
                                                                                 r---


               OK   I
                                                                                  NG
                                       ~
                                               Valve clearance improperly
            Valve clearance
                                               adjusted
                                                                                 r---          Adjust the valve clearance




                                                          Engines & Generators

                                                                 107
                                     ENGINE TROUBLESHOOTING
                                         ABNORMAL ENGINE NOISE
                                                4.     Slapping Noise

           Checkpoint                                Trouble Cause                                  Remedy


I                                        NG                                          NG
                                              Valve clearance improperly
           Valve clearance           r---
                                              adjusted
                                                                                 -          Adjust the valve clearance




              OK    I
                                         NG                                          NG
             Rocker arm              -               Damaged rocker arm          r---         Replace the rocker arm




              OK    I
                                         NG                                          NG
              Flywheel               -               Loose flywheel bolts        r---       Retighten the flywheel bolts




              OK    I
                                      NG
    Crankshaft and thrust bearings   r---     Worn or damaged crankshaft
                                              and/or thrust bearings
                                                                                 ~        Replace the crankshaft and/or
                                                                                          the thrust bearings



               OK   I
    Crankshaft and connecting rod     NG      Worn or damaged crankshaft         ~        Replace the crankshaft and/or
    bearings
                                     r---     and/or connecting rod bearings              the connecting rod bearings



              OK    I
                                         NG
                                                                                 ~
    Connecting rod bushing and                Worn or damaged connecting rod              Replace the connecting rod
    piston pin
                                     r---     bushing and piston pin                      bushing and/or the piston pin



               OK   I
                                              Worn or damaged piston and
       Piston and cylinder liner     - NG     cylinder liner                     ~        Replace the piston and the cylin-
                                                                                          der liner
                                              Foreign material in the cylinder




                                                       Engines & Generators

                                                            108
                                                    TORQUE DATA                                                  4.20.8
                                                          Kg-m (lb-It)                                         (30.45.8)




TIMING GEAR CASE

                                                                                       FUEL SYSTEM



                                                                          I         ~ 1.90.2
                                                                                     (13.71.5).

                            (18.83.6)


                                                                      o
                                                                         l ....    ("';:7'\~/~'I


                                                                                                                                             1.70.1
                                         16.01.0                                                                                          (12.30.7)
                                                                                                                                    ~
                                                                                                                ~                                  2.60.5
                                                                                                                            ~                    (18.8~.6)


                                                                                                                                    ~~".~@
       FLYWHEEL    
                                                                                                              ~.
                                                                                                               (Pr&
                                                                                                                                          !.,

                                                                                                                                            "
                                                                                                                                                     ~
                                                                                                                            '\l)
       HOUSING                                                                                                           0.60.2
                                                                                                                        (4.31.5)




                                                                                                                             2.10.5~
                                                                                                                            (15.23.6) ~

                                       2.60.5
                                     (18.53.6)




                                                                                                                                                  1.10.5




                                                                                                                                            r'"'
                          OIL COOLER
                                                     For steel        7.0            9.5  0.5 (         )
                                                     asbestos        (50.6)   -+   (68.6  3.6) New bolt
                                                     sandwich         7.0       11.5  0.5 (R            )
                                                     gasket          (50.6) -+ (83.1  3.6)   eused bolt

                                                     For lam;nated
                                                     steel sheet     7.0-+9.0 0.5        900' 3 o
                                                                   (50.6)-+(65.1 3.6) -+        o
                                                     gasket
                                                                      Apply MOS2 grease




         INTAKE/EXHAUST
         MANIFOLDS                                                                                           CYLINDER HEAD

                                                       Engines & Generators

                                                                 109
                                                         TORQUE DATA
                                                                    Kg-m (lb-fl)
                                                                                                                   PISTON




                                                                                        4--+60   +3   g:
                                                                                      (28.9)


                                  -          5.31.0
                                       -   (38.37.2)

                                      ;/                                                                                                 6 CYL.

                        '~                                                                                                              22.3:t2.2
                                                                                                                                      (161.2:t15.9)
    FUEL FILTER

                                               :4~~ ~Q~
                                           '''',",.."      ~


                                               ~~I      60:t5
                                                    (433.8:t36.2)




                                                                                                            FLYWHEEL



                                                                      2.6O.5
                                                                    (~8.83.6)




                                                                           2.6O.5
                    24.11      /                 ~......> - - - - -     (18.83.6)
                  (173.57.2) / 0 ~\




                  a~~iij~~~
                  I lol:.\\.~~
                  t~\~       r
                                           ~~2.1O.5
                                                   (15.23.6)
CYLINDER BODY (6 CYL. SHOWN)



                                                                                                                       TURBOCHARGER




                                                        ~       WESTERBEKE
                                                                Engines & Generators

                                                                        110
                                                              TORQUE DATA

                           8
                           ""-
                           ~~I
                                 _____
                                         i   I
                                                   2.6O.5
                                                 (lS.S3.6)
                                                                 Kg-m (Ib-It)
                                                                                                        
                                                                                                            ft   3.1O.5
                                                                                                         ~ W(22.43.6)

                                                                                                            re
                                                                                                                                       ~




                                             I




              THERMOSTAT
                                         I
              ASSEMBLY
                                                                                                         ROCKER ARM




             ~~///

  5.31~
(3S.37.2)
                                                                                                                    ~
                                                                                            /
                                                                                                 /~~,.'"
                                                                                                      ~~ ~                  (18.B3.6)



                                                                                                ~1.5 -~ ~~
                                                                                CAMSHAFT

                                                                                               (115.710.5)
                                                                                           Lubricate with engine oil       ~~     ~_

                                                                                                            5.51~
                                                                                                         (39.B7.2)




                                                                Engines & Generators

                                                                     111
                                                THE BE GENERATOR
                                             SINGLE AND THREE PHASE                               EMERGENCY
                                                                                                  STOP


                                                                                                  \
                                                                                                            GENERATOR BACK-END
DESCRIPTION
This generator is a four-pole, brushless, self-excited g~nerator
which requires only the driving force of the engine to produce
AC output. The copper and laminated iron in the exciter stator
are responsible for the self-exciting feature of this generator.
The magnetic field produced causes an AC voltage to be
induced into the related excitor rotor windings during rotation.
Diodes located in the exciter rotor rectify this voltage to DC
and supply it to the windings of the rotating field; This creates
an electromagnetic field which rotates through the windings
of the main stator, inducing an AC voltage which is supplied
to a load. An AC voltage is produced in the auxiliary
windings of the main stator and is, in tum, supplied to a
voltage regulator. The regulator produces a DC voltage to
                                                                            CIRCUIT
further excite the exciter stator windings, enabling the                    BREAKER
generator to produce a rated AC output. The voltage regulator               SWITCH
senses AC voltage output and adjusts DC excitation to the
exciter stator winding according to amperage load the
generator is furnishing To maintain a constant voltage output.
                                                                      MAINTENANCE

PARALLEL OPERATION                                                     A CAUTION: Prior to performing any maintenance,
Two or more of these generators may be run in parallel by               make certain that the generator is shut down, switches
simply adding a parallel device. The parallel device is added           are off and the unit is at room temperature.
to the electrical terminal box to ensure equal output of
generator voltage. Contact your WESTERBEKE dealer or
the WESTERBEKE factory for information on parallel                    Use compressed air to clean the generators extclior. Do not
operation.                                                            use liquids or water. Do not use compressed air on any
                                                                      interior components as this could result in short circuits.


                                                                                           ~            . AUTOMATIC
                                                                                                          VOLTAGE
                                                                                                         REGULATOR~


        PARALLELING DEVICE
        NOT SHOWN
                                                                                                                      ->1



                                                                                                                          TERMINAL


                                                                                                           LATOR




                               "" "-
                      AC TERMINAL

                                                           Engines & Gsnerators

                                                                112
                                 VOLTAGE REGULATOR ADJUSTMENTS
Description
The voltage regulator is an advanced design which ensures
optimum AC alternator performance. It is equipped with
complete protection circuitry to guard. against operating
conditions that could be detrimental to the AC alternator.
                                                                           c
                                                                            .
                                                                           ....    green    L...
                                                                           .....   yellow   L...

                                                                          -:.!--'H""ertz
                                                                           i!       Amp
                                                                            g       Slab
                                                                           ill       Volt
                                                                            as
                                                                           a
                                                                           "-



                                                                                     VOLTAGE REGULATOR DIAGRAM

                                                                     Amp-Hertz
                                                                     These two adjustments arc used in .:onjunction with the two
                                                                     protection circuits in the voltage regulator that are indicated
This potentiometer is used to adjust output voltage. At proper       by the illumination of a colored LED lights.
engine operating speed the output voltage should be held at
 1% from a no-load condition to a full rated generator output
                                                                     1. Delayed overload protection (yellow LED).
and from power factor 1.0 - 0.8 with engine drive speed              2. Low speed protection (red LED).
variations up to -6%.                                                Both systems have an intervention threshold which can be
Prior to starting the engine, tum the VOLT and STAB                  adjusted using the respective potentiometer. Each of the two
trimmers (using a mini phillips screwdriver) fully in a              circuits are able to cause an adequate reduction in excitor
counter clockwise (Minimum) direction until you feel them            voltage to safeguard the excitor windings and prevent their
hit their stops.                                                     overheating.
Tum the AMP and HER1Z trimmers completely clockwise                  The overload protection system has a delay which permits
(Maximum) in the same manner.                                        temporary overloading of the generator during times such as
With the alternator running at no-load, at normal speed, and         motor start-up or other similar load surge demands. The
with VOLT adjust at minimum, it is possible that output              regulator also has a third LED (green), that glows during
voltage will oscillate. Slowly rotate the VOLT adjust clock-         generator operation to indicate correct operation of the
wise. The voltage output of the alternator will increase and         regulator with the generator.
stabilize. Increase the voltage to the desired value. In this
situation, only the green LED will stay lit.

Stability
This potentiometer permits variation of the regulator'S
response to generator load changes so as to limit
overcompensation and obtain a minimum recovery time to
the normal voltage output.
In order to adjust the regulator stability the alternator must be
running at no-load and the output must be monitored.
Tum the STAB adjust slowly clockwise until the voltage
starts to fluctuate. At this point rotate the STAB adjust
counterclockwise until the voltage is stable within 1 or 2
tenths of a volt.




                                                              Engines & Generators

                                                                    113
                                             GENERATOR INFORMATION
USE OF ELECTRIC MOTORS                                                      Generator Frequency Adjustment
The power required to start an electric motor is considerably               Frequency is a direct result of engine/generator speed, as
more than is required to keep it running after it is started.               indicated by the following:
Some motors require much more current to start them than                    o    When the generator is run at 1800 RPM, the AC voltage
others. Split-phase (AC) motors require more current to start,                   output frequency is 60 Hertz.
under similar circumstances, than other types. They are com-
monly used on easy-starting loads, such as washing
                                                                            o    When the generator is run at 1500 RPM, the AC voltage
                                                                                 output frequency is 50 Hertz.
machines, or where loads are applied after the motor is
started, such as small power tools. Because they require 5 to               Therefore, to change the generator's frequency, the
7 times as much current to start as to run, their use should be             generator's drive engine's speed must be changed. Along with
avoided, whenever possible, if the electric motor is to be                  a reconfiguring of the AC output connections at the generator,
driven by a small generator. Capacitor and repulsion-                       a regulator board voltage output adjustment must also be
induction motors require from 2 to 4 times as much current                  made. See ELECTRONIC GOVERNOR in the manual.
to start as to run. The current required to start any motor
varies with the load connected to it. An electric motor con-
nected to an air compressor, for example, will require more                   A CAUTION: Prior to any cleaning or maintenance,
current than a motor to which no load is connected.                             make certain a/I switches are off and the generator is
In general, the current required to start liS-Volt motors connected             at room temperature.
to medium starting loads will be approximately as follows:
     MOTOR SIZE              AMPS FOR              AMPS FOR                 Generator Maintenance
                                                   STARTING
        (HP)                 RUNNING
                            (AMPERES)             (AMPERES)                 o    Maintaining reasonable cleanliness is important.
         1/6                    3.2              6.4 to 22.4-                    Connections of terminal boards and rectifiers may become
         1/4                    4.6              9.2 to 32.2-                    corroded, and insulation surfaces may start conducting if
         1/3                    5.2              10.4 to 72.S-                   salts, dust, engine exhaust, carbon, etc. are allowed to
         1/2                    7.2              14.4 to 29.2-                   build up. Clogged ventilation openings may cause
         3/4                   10.2              20.4 to 40.S-                   excessive heating and reduced life of windings.
          1                     13                  26 to 52                o    For unusually severe conditions, thin rust-inhibiting
                                                                                 petroleum-base coatings, should be sprayed or brushed
NOTE: In the above table the maximum Amps for Starting is                        over all surfaces to reduce rusting and corrosion. Typical
more for some small motors than for larger ones. The reason                      materials suggested are Daubert Chemical Co. "Non-
for this is that the hardest starting types (split-phase) are not                Rust AC-41O" and Ashland "Tectyle 506" or equivalent.
made in larger sizes.
                                                                            o    In addition to periodic cleaning, the generator should be
Because the heavy surge of current needed for starting                           inspected for (a) tightness of all connections, (b) evidence
motors is required fOf only an instant, the generator will not                   of overheated terminals and (c) loose or damaged wires.
be damaged if it can bring the motor up to speed in a few                   o    The drive discs on single bearing generators should be
seconds. If difficulty is experienced in starting motors, tum                    checked periodically jf possible for tightness of screws
off all other electrical loads and, if possible, reduce the load                 and for any evidence of incipient cracking failure. Discs
on the electric motor.                                                           should not be allowed to become rusty because rust may
                                                                                 accelerate cracking. The bolts which fasten the drive disc
Required Operating Speed                                                         to the generator shaft must be hardened steel SAE grade
Run the generator first with no load applied, then at half the                   8, identified by 6 radial marks, one at each of the 6
generator's capacity, and finally loaded to its full capacity as                 comers of the head.
indicted on the generator's data plate. The output voltage                  o    The rear armature bearing is lubricated and sealed; no
should be checked periodically to ensure proper operation of                     maintenance is required. However, if the bearing becomes
the generating plant and the appliances it supplies. If an AC                    noisy or rough-sounding, have it replaced.
voltmeter or ampere meter is not installed to monitor voltage
and load, check it with a portable meter and amp probe.                     o     Examine bearing at periodic intervals. No side movement
                                                                                  of shaft should be detected when force is applied. if side
NOTE: When the vessel in which the generator is installed                         motion is detectable, bearings are wearing or wear on
contains AC equipment of I20 volts only, it is recommended                        shaft of bearing socket outside bearing has occurred.
that the generator's AC tenninal block be configured to pro-                      Repair must be made quickly or major components will
vide one 120 volt AC hot leg for the vessel's distribution                        rub and cause major damage to generator.
panel. This will ensure good motor starting response from the               o     Compressed air can be used to clean the generator
generator.                                                                        exterior. Do not use compressed air on internal
                                                                                  components.




                                                                 Engines & Generators

                                                                    114
                             GENERATOR AC VOLTAGE CONNECTIONS
AC VOLTAGE CONNECTIONS
The frame ground wire (white/green) must be properly
positioned when changing the AC output configuration             L1                  o
                                                                                     2+3
                                                                                                                 L1
                                                                                                                             1+3
of the AC terminal block. For making connections to the AC
terminal block, use terminal ends for 114 inch studs that will
accept multi strand copper wire sized for the amperage rating
from the hot lead connection. The frame ground wire is white     L2
                                                                           5
                                                                                     o
                                                                                     6+7
                                                                                                                 L2
                                                                                                                           5+7
or white with a green strip. It connects between the neutral
stud and the generator frame.

Generator Frequency                                               L3                 0            N              L3
                                                                                              ~
                                                                           9        10+ II                                9+11
1. Frequency is a direct result of engine/generator speed:
   1800 rpm = 60 hertz; 1500 rpm = 50 hertz.                                                              "12
                                                                                                            8
2. To change generator frequency                                       SERIES Y                                          PARALLEL Y
                                                                       4BOV/60 Hz                                        20BV/60 Hz
   Configure the AC terminal block for the desired voltage                                                               190V/50 Hz
                                                                       3BOV/50 Hz
   frequency as shown. Ensure that the case ground wire is
   connected to the correct terminal block neutral ground
   stud.
NOTE: The white/green ground wire may be removed in those         L1                 0                           L1
                                                                         1 + 12      2+3
installations where the AC circuit has a separate neutral and
ground circuit. This will prevent the unit from being a ground
source in the vessel.
                                                                  L2                 0                           L2
IMPORTANT                                                                4+5         6+7
When changing from 50Hz to 60Hz the generator
power and nominal vottage will increase by 20%
but the current does not change from the 50Hz value.              L3                 0                           L3
Should voltage stay at 50Hz, then the output power
                                                                         8+9        10+ 1 1
may be increased by 5% due to improved ventilation.
This is accomlished by resetting the AVR potentiometer.
Changing froom 60Hz.to 50Hz, the voltage and power
values must decrease by 20% ot the 60Hz value.                         SERIES DELTA
                                                                       240V/60 Hz
                                                                                              2                          PARALLEL DELTA
                                                                                                                         120V/60 Hz
                                                                                                                                          2
                                                                       220V/50 Hz                                        1100V/50 Hz

                                                                               NOTE: IF WIRING FOR 50 Hz. THE 60 Hz JUMPER
                                                                               MUST BE REMOVED FROM THE REGULATOR.


                                                                                              SINGLE PHASE

                                                                                    L1                             l--+---L2
                                                                                              4   +   7         1 + 10



                                                                                               o
                                                                                              6,9
                                                                                                                o
                                                                                                            8+ 1 1




                                                                                                                         N

                                                                                                                         o
                                                                                              DOUBLE DELTA
                                                                                              120~240V/60 Hz
                                                                                              110-220V/50 Hz




                                                        Engines & Generators

                                                                 115
                                               INTERNAL WIRING DIAGRAM
                                            12 WIRE - 3 PHASE - RECONNECTABLE
,-------------,
I                                     I                                                                                        GROUND 111------.
I        A EXCITER STATOR             I                                                                                                      ..,r---.....
I                                     I                                                                        ~---~
1                                     I                                                                        ;    0 STATOR   ;

\                        : - -; - - : - - - -C- - - - - -:         ~~::==========~::s====~~ll.JY
I                        I1 EXCITER
     "'-Y=El--=lO"""W-+-' I
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                                               FUSE                           L ______ ~\  \              ~




                                                                                                              RED


            ..
            a:                                                                                                           RED
            tl
            ::IE
                                                                           2-3 FOR SENSING 100-140V                                12 WIRE 3 PHASE
            o
            ;::                                                            1-2 FOR SENSING 200-280V                                SHOWING PARALLEL Y
            z
            I!!
            o
            a..

                                                                                          THE (PO) PARALLEL DEVICE
                                                      YEllOW                              IS OPTIONAL UP TO 320 KVA.
                                                                                          THE LINK P ACTIVATES OR
                                                                                          DE-ACTIVATES THE PARALLELING
                                                                                          DEVICE IF IT IS PRESENT.




                                                                   Engines & Generators

                                                                       116
                            ELECTRONIC GOVERNOR ADJUSTMENTS
DESCRIPTION                                                                                TO ElECTlIONIC
                                                                                           CONTROLLER
The system is composed of three basic components:
                                                                                                           I.C.~"",jj"":: ~1n.            IIUl
1. Controller. Mounted in the instrument panel.                                        TOTERMIN N.
                                                                                                                                  ~




                                                                                                                                                     .1
                                                                                       IOARD It            'UltACJ:                       BlACK
2. Sensor. Installed on the bellhousing over the                                                                           ""2'-'"
                                                                                                                          'Y  . ......,
   flywheel ring gear.
                                                                                                  -                        '-"'3/T,
                                                                                                                                   -      IUCl/WH




                                                                                                                                                      r
3. Actuator. Mounted at the front of the engine and                                    TO SENSD             SHIELDEDll      ~                         TtGOVERNOR

   attached with linkage to the throttle arm of the                                               "         CAllLE
                                                                                                                           ..g,4~
                                                                                                                                   ~
                                                                                                                                          WHIR

   injection pump.                                                                                          VIOlET                        VIOlET
                                                                                                                           ~5"'"
                                                                                                                                   'oJ
                                                                                   {TO LINEAR ACT UATOfi
                                                                                                      -.!!,OlET                           , VIOLET
                                                                                                                            ,-,6~


                                                                                                                     TERMINAL BOARD #3
                                                          CONTROLLER
                                                                                                                     REFER TO WIRING DIAGRAMS
                                                          PN'30300B 12V
                                                          PNj39747 24V


                                                                          INSPECTION AND ADJUSTMENT
                                                                          The controller has two adjustment pods. You need a
                                                                          mini screw driver to adjust these. One is speed and the



    --
                                                                          gain. These are noted on the drawing of the controller.
                                                                          When you press the preheat switch, the actuator linkage
                                                                          attached to the throttle arm of the injection pump should
                                                                          move outward towards the injection pump and return
                                                                          back into the actuator in a quick motion.
                        SENSOR                                            Start the engine. The speed should be in the low idle
                        PN'039172
                                                                          range 600-700 rpm. If the engine speed is higher than
                                                                          this idle range, shut the engine down. Check the linkage
                                          LINEAR                          between the actuator and throttle arm. The throttle arm
                                          ACTUATOR
                                          PN#303007 12V
                                                                          stop should be about touching the open idle stop screw
                                          PN#3974624V                     boss. Adjust the linkage to position the throttle lever.
CONTROLLER ADJUSTMENT                                                     The controller has an adjustment screw for speed
1. Speed. This adjustment is used to raise or lower the                   adjustment. Turn this screw outward (counter clockwise)
   engine's speed to the desired hertz.                                   a few turns. Restart the engine.
2. Gain. This adjustment affects the reaction time of
   the actuator to the generator/engine load changes.                     NOTE: If there is any oscillating of the actuator linkage
                                                                          producing hunting, adjust the gain towards zero "0" until
   NOTE: A high gain adjustment can induce an oscillating                 this hunting is removed.
   of the actuator producing a hunting mode. In such
                                                                          Increase the engine speed slowly with the speed
   cases,lessen the gain adjustment.                                      adjusting screw turning it inward (clockwise). In some
                                                                          instances this screw may need to be turned 6-10 turns
Calibration                                                               before an increase in engine speed is noted. Bring the
                                                                          engine speed to 1800 rpm (60 Hz), 1500 rpm (50 Hz).
1. With no power to the governor, adjust the GAIN to                      Momentarily push the actuator linkage towards the
   9:00 o'clock.                                                          actuator and release. The actuator should quickly regain
2. Start the engine and adjust the speed by turning the                   proper speed. If there is any hunting adjust the gain
   speed pot clockwise to desired speed.                                  towards zero "0" until this hunting is removed.
                                                                          When the gain is adjusted you may need to readjust the
   NOTE: Controllers are factory adjusted to minimum rpm.                 speed at no load, shut the generator down.
   However. for safety, one should be capable of disabling
                                                                          Push the DC exciter circuit breaker in. Start the
   the engine if an overspeed should exist.                               generator.
3. At no-load, turn the GAIN potentiometer clockwise                      Check speed (Hertz) set at 60 Hz.
   until the engine begins to hunt. if the engine does                    Load the generator.
   not hunt, physically upset the governor linkage.
                                                                          If the governor is slow to react and maintain 60 Hertz
4. Turn the GAIN potentiometer counterclockwise                           adjust the gain clockwise. Again you may need to adjust
   until stable.                                                          the speed at no load.
   NOTE: The controller operates on I2VDC. The voltage                    You will find the governor will maintain 60  0.5 Hertz
   range is  20% (9.6VDC 12VDC 14.4VDC). {{voltage                       right up to the full rated amperage output for the
                                                                          generator.
   varies above or below these ranges, the controller will
   not operate and the engine will run in an idle mode until
   proper voltage is supplied to the controller.




                                                            Engines & Generators

                                                                   117
                         TROUBLESHOOTING THE ELECTRONIC GOVERNOR
              Problem                           Probable Cause                                          Verification/Remedy
System appears dead                   1. Low battery voltage at controller.            1. Check wiring for cause. Check battery state of charge.
(Engine runs at idle.)
                                      2. Stuck linkage.                                2. Lubricate, free up linkage between controller and throttle arm.
                                      3. No signal or weak signal from sensor.         3. Check for improperly installed or damaged sensor in flywheel
                                         (Measure AC voltage from sensor while            housing. Replace or adjust.
                                         engine is running at idle. Voltage should
                                         be 1.5 volts o,r greater.
                                      4. Check Actuator - depress PREHEAT and
                                         check for battery voltage between
                                         negative black lead at terminal block.
                                         a. Pu rple lead to black.                     4. Replace controller if battery voltage is not present at bOth
                                                                                           leads.
                                          b. Second pu rple to black.
                                      5. Pertorm the following check between
                                          terminals at the actuator and the negative
                                          DC lead at the controller terminal block.
                                          (Preheat depressed).
                                          a. Low voltage (1.20-2.0 VDC) at either          a. Broken actuatcr lead.
                                              actuator connection.
                                          b. Battery voltage at both actuator              b. Broken actuator lead.
                                             connections.
                                          c. Battery voltage at one actuator lead          c. Replace the actuator.
                                             but not the other.
Actuator fully extends when PREHEAT   1. Check controller. Lift one of the purple
is depressed and stays extended.      actuator leads from the terminal block.
                                      Depress PREHEAT.
                                          a. Actuator fully extends.                       a. Short in lead to actuator.
                                          b. Actuator does not fully extend and            b. Replace controller.
                                             connections.
                                      NOTE: Release PREHEAT and reconnect
                                      the purple lead.
Actuator hunts (oscillates) and       1. Linkage between actuator and throttle         1. Lubricate/free-up.
engine running.                          binding.
                                      2. Improper adjustment of GAIN on                2. Lessen GAIN adjustment (Recalibrate the Controller).
                                         controller.
                                      3. Inadequate DC power supply to
                                         controller, complete the following tests:
                                          Connect a DC voltmeter across the
                                          plus and negative leads at the
                                          controller terminal block.
                                          Lift both purple leads from the
                                          terminal block.
                                          Connect one purple lead to the
                                          C plus terminal and the other to ti,e
                                          DC negative.
                                          Momentarily depress PREHEAT.
                                          The actuator should fully extend.            3. If actuator does not fully extend, check the actuator leads.
                                                                                          If the voltage is less than specified, check for loose or poor
                                                                                          connections, low battery voltage, voltage drop in DC circuit
                                                                                          due to remote panel installation and small wire sizes making
                                                                                          connections.
                                                                                       DC voltage registering on the meter should be:
                                                                                          12 VDC System - 9.6 VDC or higher
                                                                                          24 VDC System - 19.2 VDC or higher
                                                                                       NOTE: Reconnect actuator leads properly after making this test.
                                      3a. Sensor positioned marginally too far         3a. Check the position of the sensor.
                                          away from flywheel teeth giving
                                          erratic signal voltage to controller.




                                                             Engines & Generators

                                                                     118
                                   BE TROUBLESHOOTING
                            NOTE: AC GENERATOR TROUBLESHOOTING MUST
                           BE PERFORMED WITH THE ENGINE OPERA TIN AT 60 HZ.


            FAULT                                                  PROBABLE CAUSE
NO AC VOLTAGE OUTPUT AT NO LOAO.        1. Short or open in the               4. Open in exciter
                                           main stator winding.                  stator winding.

                                        2. Shorted pozi-resistor              5. Open in rotating
                                           on exciter rotor.                     field winding.
                                        3. Four or more shorted or
                                           open diodes on exciter rotor.

RESIDUAL VOLTAGE PROOUCEO AT            1. Blown 6 AMP fuse                   3. Shorted or open main
NO LOAO 15 - 20 VOLTS AC.                  auxiliary circuit feed to AVR.        stator auxiliary winding.

                                         2. Faulty voltage regulator          4. AC circuit breaker tripped.

LOW AC VOLTAGE OUTPUT AT                 1. Reset voltage potentiometer.      3. Open or shorted exciter
NO LOAO 60 -100 VAC.                                                             rotor winding.
                                         2. Open or shorted diodes in.
                                            exciter rotor 1 to 3 diodes.      4. Faulty voltage regulator.

HIGH AC OUTPUT VOLTAGE                   1. Reset voltage potentiometer.
150 VAC OR HIGHER.
                                         2. Faulty voltage regulator.

UNSTABLE VOLTAGE OUTPUT.                 1. STB pod on regulator              2. Faulty voltage regulator.
(ENGINE SPEED STEADY)                       needs adjustment.

AC VOLTAGE DROP UNDER LOAD               1. Diode(s) on exciter rotor
60 -100 VOLTS AC.                           breaking down when load is
                                            applied (inductive) 1-3 diodes.




                                          Engines & Generators

                                                119
                                                                        GENERATOR MAINTENANCE

          A    CAUTION: Prior to performing any maintenance,
          make certain that the generatoe is shutdown, switches
          are off and the unit is at room temperature.


       CLEANING
       Use compressed air to clean the exterior of the                                                       3. Remove the seager rings with snap
       generator. Do not use liquids or water. Do not use                                                       ring pliers.
       compressed air on interior components as this could                                                   4. Remove the bearings with a proper
       cause short circuits.                                                                                    bearing puller.
                                                                                                             Rotation Diode Bridge
                             ~COVER                                                                          1. Disconnect the five wires of the
                                                                                                                rotating diode bridge.
        REAR      ~ QeJ--~__--FRONT PANElFRONT COVER                                                         2. Remove the blocking bolt and
        PANEL--                                                                                                 pulling gently, remove the
                                 .                          -   -SIDE PANELS
                                                                                                                diode bridge .
                                         .....a..IL I   '.
        TERMINAL BOARD~- --~~ AVR /COMPONENT

                                         ~~                                                                                    DIODE BRIDGE

               '"''              ~....-
"M_;:;'~\)~:~ __ "'B                                                                                   "'"
       ~-~r                          c                                 _   ~SPACERS
REAR                                                                       OO~
SEAL                HUB,._\\L-(lU                                                   - ----------DiSC
       DIODE ---"'1&.--0--   "   ~                                                                                                            DIODE
       BRIDGE     -"                           .~                               COUPLING HUB                                                  BRIDGE

               ARMATURE                                  "~ BEARING    ROTOR AND FAN


                                                                                                             REASSEMBLY
       DISASSEMBLY                                                                                           1. Heat the bearing with a special
                                                                                                                magnetic device and using insulated
       If it becomes necessary to disassemble
                                                                                                                gloves, assemble the bearings to
       the stator/rotor assembly, use the following
                                                                                                                the shaft.
       text as a guide.
       1. Insert a suitable puller (which can be
          easily made) and remove the exciter.                                                                2. Put the seager rings back into place.
                                                                                                                 Thoroughly clean the shaft and
       2. Extract the rotor using a hoist with
                                                                                                                 spread a thin layer of "Permabond"
          soft ropes of sufficient strength.
                                                                                                                 or similar product over the shaft seat.
          Carefully remove the rotor and place
          it on the prepared work area. It may
          be necessary to remove the front
          cover to extract the rotor due to the
          diameter of the fan.




                                                                   SNAP RING                                  3. Reassemble the exciter carefully,
                                                                   PLIERS                                        making sure the diode connecting
                                                                                                                 cables are turned toward the outside.
                                                                                                             4. Install the rotor and completely
 ROTOR/FAN ASSEMBLY                                                                                             reassemble the generator with all
                                                                                                                the covers back in place.


                                                                                                  WESTERBEKE
                                                                                                  Engines & GeneratDr~

                                                                                                        120
                                       45 BED GENERATOR SPECIFICATIONS
                              GENERAL                                                                             FUEL SYSTEM
Engine Type                Diesel, four cylinder, four-cycle, marine engine.
                           Vertical in-line overhead valve, water cooled              General                      Closed system with bleed points.
                           direct injection, 70 hp @1800 rpm and
                           60 hp @1500 rmp.                                           Fuel                         No.2 diesel oil (cetane rating of 45 or higher).

Aspiration                 Naturally aspirated.
                                                                                      Fuel Injection Pump          BOSCH Model A type (In-line).

Governor                   Integral with injection pump.
                                                                                      Fuel Injection Timing        WBTDC
                                                                                      Nozzle                       Multi-hole
Bore & Stroke              4.02 x 4.65 inches (102.0 x 118.0 mm).
                                                                                      Fuel Filter                  Full flow replaceable.
Piston Displacernent       262 cubic inches (4.3 liter).
                                                                                      (on engine)
Firing Order                1 - 3 - 4 - 2.
                                                                                      Air cleaner                  Replaceable paper element.
Cylinder Liner Type         Dry
                                                                                      Air Flow                     123 cfm.
Direction of Rotation      Clockwise, when viewed from the front.                     (engine combustion)
Engine Torque              210 ft-Ib @ 1500 rpm                                       Fuel Consumption             3.5 U.S. gph (13.2 Iph)
Corn pression Ratio         17:1
Dirnensions - inches (rnrn) Height:          33.6 inches   (855 mm)
                                                                                                               ELECTRICAL SYSTEM
w/out transmission          Width:           30.6 inches   (778 mm)                   Starting Battery             12 Volt, (-) negative ground.
                            Length:          62.5 inches   (1588 mm)
                                                                                      Battery Capacity             750 - 900 Cold Cranking Amps (CCA).
Weight (dry)                1585 Ibs (719 kgs).
                                                                                      DC Charging Alternator       51 Amp rated, belt-driven.

                     TUNE-UP SPECIFICATIONS                                           Starting Aid                 Glow plugs.

Compression Pressure        441 psi (31 kg/cm') at 200 rpm                            Starter                      12 Volt, 32.9 KW
(Limit of difference        Not to exceed 28.44 psi (20.0 kg/cm').                    DC Cranking Current          400 CCA.
Injector Pressure           2133 psi (150 kf/cm').
Valve Seat Angle            Intake 45"
                                                                                                               LUBRICATION SYSTEM
                            Exhaust 45.                                              General                      Gear type/pressure circulation.
Valve Clearance             Intake and exhaust.                                       Oil Filter                   Full flow, paper element, spin-on type.
(engine cold)               0.016 inches (0.40 mm).
                                                                                      Sump Capacity                14.5 U.S. qts (13.8 liters).
Engine Speed                50 Hz@ 1500 rpm                                           (not including filter)
                            60 Hz@ 1800 rpm
                                                                                      Operating Oil Pressure       25 - 85 psi.
                                                                                      (engine hot)
                        GENERATOR DATA
                                                                                      Oil Grade                    API Specification CG-4,
Generator Power @1800 (1500) rpm                                                                                   SAE 30, 10W-30, 15W-40.
45KW (35KW)
Design                      Brushless, four pole, revolving field,                                              EXHAUST SYSTEM
                            power take-off
                                                                                      Exhaust Elbow                45 elbow
Frequency                   All units adjustable to 50 or 60 Hertz ..
                                                                                      Exhaust Hose Size            4" 1.0. (101.6 mm) hose
Phase                       Three phase. Single phase units available.
Power Factor                0.8                                                                        ENGINE AIR REQUIREMENTS
Wire                        12 lead reconnectable                                     Combustion Air               1230 cfm
Voltage Regulation          standard  1% no load to full load.                       Note: The pressure differential between the outside of the engine compart-
Insulation                  Class "H", as defined by NEMA MGI-!.65                    ment versus the inside of the engine compartment should not exceed 2
                                                                                      inches of water (51 mrn) at full open throttle (measure with a manometer).
Cooling                     Direct drive centrifugal blower.
Temperature Rise            Within NEMA MGI-22.40 definition - full load
                                                                                                                COOLING SYSTEM
                            Meets "CE" requirements                                   General                      Fresh water-cooled block, thermostatically-
Interference Level
                                                                                                                   controlled with heat exchanger.
Voltage Output              60 Hertz                        50 Hertz
                            L-L      L-N                    L-L      L-N              Operating Temperature        170 -190 F (77 - 88 C).
Configuration
Series Star                 480      277                    400      230              Fresh Water Pump             Centrifugal type, metal impeller, belt-driven.
Parallel Star               208      120                    230      127
Series Delta                240      120                    230      115              Raw Water Pump               Positive displacement, rubber impeller,
Parallel Delta              130                             110                                                    eng ine-d riven.
Zig Zag                     400      230                    330      190              Coolant (Fresh Water)
Voltage regulator is adjustable  5%                                                  System Capacity              17 US qts (16.1 liters).

3 Phase amperage calculation: Amps=Watts/[Voltage x 1.732 x PF.]




                                                                           Engines & Generators

                                                                               121
                                                  55 BED GENERATOR SECTION
                              GENERAL                                                                           FUEL SYSTEM
Engine Type                 Diesel, four cylinder, four-cycle, turbocharged         General                      Closed system with bleed points.
                            marine engine. Vertical in-line overhead valve,
                            water cooled direct injection, 90 hp @1800 rpm          Fuel                         No.2 diesel oil (cetane rating of 45 or higher).
                            and 80 hp @1500 rpm.                                    Fuel Injection Pump          BOSCH Model A type (In-line).
Aspiration                  Turbo charged.                                          Fuel Injection TIming        12 BTDC
Govemor                     Integral with injection pump.                           Nozzle                       Multi-hole
Bore & Stroke               4.02 x 4.65 inches (102.0 x 118.0 mm).                  Fuel Filter (on engine)      Full flow replaceable.
Piston Displacement         202 cubic inches (4.3 liter).                           Air cleaner                  Replaceable paper element.
Firing Order                1 - 3 - 4 - 2.                                          AirFlow                      190 cfm.(6.2 cmm).
Direction of Rotation       Clockwise, when viewed from the front.                  (engine combustion)

Engine Torque (max.)        280 ft-Ib @1500 rpm.                                    Fuel Consumption             4.8 U.S. gph (18.2 Iph).

Compression Ratio           17:1.                                                                             ELECTRICAL SYSTEM
Dimensions - inches (mm) Height:             33.6 inches    (855 mm)                Starting Battery             12 Volt, (-) negative ground
w/out soung guard        Width:              30.6 inches    (778 mm)
                         Length:             62.5 inches    (1588 mm)               Battery Capacity             750 - 900 Cold Cranking Amps (CCA)
Weight (dry)                16471bs (746 kgs).                                      DC Charging Altemator        51 Amp rated, belt-driven
                                                                                    Starting Aid                 Glow plugs
                     TUNE-UP SPECIFICATIONS                                         Starter                      12 Volt, 2.9 KW
Compression Pressure        441 psi (31 kg/cm') at 200 rpm
                                                                                    DC No-load Current            2% of rated amps
(Limit of difference        Not to exceed 28.44 psi (20.0 kg/cm').
                                                                                    DC Cranking Current          450 amps (engine cold).
Injector Pressure           2630 psi (185 kf/cm').
Valve Seat Angle            Intake 45                                                                       LUBRICATION SYSTEM
                            Exhaust 45
                                                                                    General                      Gear type/pressure circulation
Valve Clearance             Intake and exhaust
(engine cold)               0.016 inches (0.40 mm).                                 Oil Filter                   Full flow, paper element, spin-on type.
Engine Speed                50 Hz@ 1800 rpm                                         Sump Capacity                14.5 U.S. qts (13.8 liters)
                            60 hz@ 1800 rpm                                         (not including filter)
                                                                                    Operating Oil Pressure       250 - 85 psi
                        GENERATOR DATA                                              (engine hot)
Generator Power @1800 (1500) rpm                                                    Oil Grade                    API Specification CG-4,
55KW(45KW)                                                                                                       SAE 30, 10W-30, 15W-40
Design                      Brushless, four pole, revolving field,                                             COOLING SYSTEM
                            power take-off
                                                                                    General                      Fresh water-cooled block, thermostatically-
Frequency                   All units adjustable to 50 or 60 Hertz ..                                            controlled with heat exchanger.
Phase                       Three phase. Single phase units available.              Operating Temperature        170 - 190 F (77 - 88 C)
Power Factor                0.8                                                     Fresh Water Pump             Centrifugal type, metal impeller, belt-driven.
Wire                        12 lead reconnectable                                   Raw Water Pump               Positive displacement, rubber impeller,
Voltage Regulation          Standard  1% no load to full load.                                                  engine-driven.
Insulation                  Class "H", as defined by NEMA MGI-!.65                  Coolant (Fresh Water)
                                                                                    System Capacity              17 US qts (16.1 liters)
Cooling                     Direct drive centrifugal blower.
Temperature Rise            Within NEMA MGI-22.40 defination - full load                                       EXHAUST SYSTEM
Interference Level          Meets "CE" requirements                                 Exhaust Elbow                45 elbow
VDltage Output              60 Hertz                        50 Hertz                Exhaust Hose Size            4" 1.0. (101.6 mm) hose
Configuration               L-L      L-N                    L-L      L-N
Series Star                 480      277                    400      230                               ENGINE AIR REQUIREMENTS
Parallel Star               208      120                    230      127
Series Delta                240      120                    230      115            Combustion Air               160 cfm
Parallel Delta              130                             110
Zig Zag                                                                             Note: The pressure differential between the outside of the engine compart-
                            400      230                    330      190
                                                                                    ment versus the inside of the engine compartment should not exceed 2
Voltage regulator is adjustable  5%                                                inches of water (51 mm) at full open throttle (measure with a manometer).
3 Phase amperage calculation: Amps=Watts/[Voltage x 1.732 x PJ.]




                                                                         Engines & Generators

                                                                              122
                                       65 BED GENERATOR SPECIFICATIONS
                              GENERAL                                                                               FUEL SYSTEM
Engine Type                 Diesel, six cylinder, four-cycle, Vertical in-line,         General                      Closed system with bleed points.
                            overhead valve, fresh water cooled direct
                            injection, marine engine. 100 hp @1800 rpm                  Fuel                         No.2 diesel oil (cetane rating of 45 or higher).
                            and 85 hp @1500 rpm.                                        Fuel Injection Pump          BOSCH Model A type (In-line).
Aspiration                  Naturally aspirated.                                        Fuel Injection Timing        WBTDC
Governor                    Integral with injection pump.                               Nozzle                       Multi-hole
Bore & Stroke               4.13 x 4.92 inches (105.0 x 125.0 mm)                       Fuel Filter (on engine)      Full flow replaceable.
Piston Displacement         396 cubic inches (6.5 liter)                                Air cleaner                  Replaceable paper element.
Firing Order                1-5-3-6-2-4                                                 Air Flow                     170 cfm.(6.2 cmm).
Cylinder Liner Type         Dry                                                         (engine combustion)

Direction of Rotation       Clockwise, when viewed from the front.                      Fuel Consumption             4.9 U.S. gph (18.5 Iph).

Engine Torque               313 ft-Ib @1500 rpm.                                                                  ELECTRICAL SYSTEM
Compression Ratio           17:1                                                        Starting Battery             12 Volt, (-) negative ground
Dimensions - inches (mm) Height:           34.2 inches       (868 mm)                   Battery Capacity             750 - 900 Cold Cranking Amps (CCA)
w/out transmission       Width:            30.6 inches       (778 mm)
                         Length:           74.9 inches       (1903 mm)                  DC Charging Alternator       51 Am prated, belt -d riven
Weight (dry)                19371bs (878 kgs).                                          Starting Aid                 Glow plugs
                                                                                        Starter                      12 Volt, 2.9 KW actuated shift.
                     TUNE-UP SPECIFICATIONS                                             DC No-load Current            2% of rated amps
Compression Pressure        441 psi (31 kg/em') at 200 rpm
                                                                                        DC Cranking Current          450 CCA
(Limit of difference        Not to exceed 28.44 psi (20.0 kg/cm').
Injector Pressure           2631 psi (185 kf/cm').                                                               LUBRICATION SYSTEM
Valve Seat Angle            Intake 45
                                                                                        General                      Gear type/pressure circulation
                            Exhaust 45
Valve Clearance                                                                         Oil Filter                   Full flow, paper element, spin-on type.
                            Intake and exhaust
(engine cold)               0.016 inches (0.40 mm)                                      Sump Capacity                14.5 U.S. qts (13.8 liters)
Engine Speed                                                                            (not including filter)
                            50 Hz@ 1500 rpm
                            60 Hz @1800 rpm                                             Operating Oil Pressure       28 - 85 psi
                                                                                        (engine hot)
                        GENERATOR DATA                                                  Oil Grade                    API Specification CG-4,
                                                                                                                     SAE 30, lOW-3D, 15W-40
Generator Power @1800 (1500) rpm
65KW(55KW)
Design                      Brushless, four pole, revolving field,
                                                                                                                   COOLING SYSTEM
                            power take-off                                              General                      Fresh water-cooled block, thermostatically-
Frequency                                                                                                            controlled with heat exchanger.
                            All units adjustable to 50 or 60 Hertz..
                                                                                        Operating Temperature        170 - 190 F (77 - 88 C)
Phase                       Three phase. Single phase units available.
                                                                                        Fresh Water Pump             Centrifugal type, metal impeller, belt-driven.
Power Factor                0.8
                                                                                        Raw Water Pump               Positive displacement, rubber impeller,
Wire                        12 lead reconnectable
                                                                                                                     engine-driven.
Voltage Regulation          Standard  1% no load to full load.
                                                                                        Coolant (Fresh Water)
Insulation                  Class "H", as defined by NEMA MGI-!.65                      System Capacity              25 US qts (23.7 liters)
Cooling                     Direct drive centrifugal blower.
                                                                                                                   EXHAUST SYSTEM
Temperature Rise            Within NEMA MGI-22.40 defination - full load
                                                                                        Exhaust Elbow                45 elbow
Interference Level          Meets "CE" requirements
                                                                                        Exhaust Hose Size            4" I.D. (101.6 mm) hose
Voltage Output              60 Hertz                        50 Hertz
Configuration               L-L      L-N                    L-L      L-N
Series Star                 480      277                    400      230                                   ENGINE AIR REQUIREMENTS
Parallel Star               208      120                    230      127                Combustion Air               170 cfm
Series Delta                240      120                    230      115
Parallel Delta              130                             110                         Note: The pressure differential between the outside of the engine compart-
Zig Zag                     400      230                    330      190                ment versus the inside of the engine compartment should not exceed 2
Voltage regulator is adjustable  5%                                                    inches of water (51 mm) at full open throttle (measure with a manometer)

3 Phase amperage calculation: Amps=Watts/[Voltage x 1.732 x P.F.]




                                                                           Engines & Generators

                                                                                  123
                                       95 BED GENERATOR SPECIFICATIONS
                              GENERAL                                                                          FUEL SYSTEM
Engine Type                Diesel, six cylinder, four-cycle, turbocharged          General                     Closed system with bleed points.
                           marine engine. Vertical in-line overhead valve,
                           fresh water cooled direct injection,145 hp              Fuel                        No.2 diesel oil (cetane rating of 45 or higher).
                           @.1800 and 125 hp @1500 rpm.                            Fuel Injection Pump         BOSCH Model A type (In-line).
Aspiration                 Turbocharged.                                           Fuel Injection Timing       12 BTDC
Governor                   Integral with injection pump.                           Noule                       Multi-hole
Bore & Stroke              4.13 x 4.92 inches (105.0 x 125.0 mm)                   Fuel Filter                 Full flow replaceable.
Piston Displacement        396 cubic inches (6.5 liter)                            (on engine)

Cylinder Liner Type        Dry                                                     Air cleaner                  Replaceable paper element.

Firing Order               1-5-3-6-2-4                                             AirFlow                     240 cfm (6.2 cmm)
                                                                                   (engine combustion)
Direction of Rotation      Clockwise, when viewed from the front.
                                                                                   Fuel Consumption            7.2 U.S. gph (27.3 Iph).
Engine Torque (max.)       423 ft-Ib @1800 rpm.
Compression Ratio          17:1                                                                             ELECTRICAL SYSTEM
Dimensions - inches (mm) Height:          34.2 inches      (867 mm)                Starting Battery             12 Volt,   H negative ground
w/out transmission       Width:           30.6 inches      (778 mm)                Battery Capacity             750 - 900 Cold Cranking Amps (CCA)
                         Length:          75.0 inches      (1903 mm)
                                                                                   DC Charging Alternator       51 Amp rated, belt-driven
Weight (dry)               2100 Ibs (952 kgs).
                                                                                   Starting Aid                 Glow plugs
                     TUNE-UP SPECIFICATIONS                                        Starter                      12 Volt, 2.9 KWactuated shift.
Compression Pressure       441 psi (31 kg/cm') at 200 rpm                          DC No-load Current            2% of rated amps
(Limit of difference       Not to exceed 28.44 psi (20.0 kg/cm')                   DC Cranking Current          450 CCA
Injector Pressure          2631 psi (185 kf/cm').
Valve Seat Angle            Intake 45                                                                       COOLING SYSTEM
                            Exhaust 45                                            General                      Fresh water-cooled block, thermostatically-
Valve Clearance            Intake and exhaust                                                                   controlled with heat exchanger.
(engine cold)              0.016 inches (0.40 mm)                                  Operating Temperature        170 - 190 F (77 - 88 C)
Engine Speed               50 Hz @1500 rpm                                         Fresh Water Pump             Centrifugal type, metal impeller, belt-driven.
                           60 Hz@ 1800 rpm
                                                                                   Raw Water Pump               Positive displacement, rubber impeller,
                                                                                                                engine-d riven.
                        GENERATOR DATA
                                                                                   Coolant (Fresh Water)
Generator Power @1800 (1500) rpm                                                   System Capacity              25 US qts (23,71 liters)
95KW (80KW)
Design                      Brushless, four pole, revolving field,                                           EXHAUST SYSTEM
                            power take-off                                         Exhaust Elbow                45 elbow
Frequency                   All units adjustable to 50 or 60 Hertz..               Exhaust Hose Size            4" I.D. (101.6 mm) hose
Phase                      Three phase. Single phase units available.
Power Factor                0.8
                                                                                                            LUBRICATION SYSTEM
                            12 lead reconnectable                                  General                      Gear type/pressure circulation
Wire
                                                                                   Oil Filter                   Full flow, paper element, spin-on type.
Voltage Regulation          Standard  1% no load to full load.
                            Class "H", as defined by NEMA MGI-!.65                 Sump Capacity                22.0 U.S. qts (20.8 liters)
Insulation
                                                                                   (not including filter)
Cooling                     Direct drive centrifugal blower.
                                                                                   Operating Oil Pressure       25 - 85 psi (3.5 - 4.2 kg/cm')
Temperature Rise            Within NEMA MGI-22.40 defination - full load           (engine hot)
Interference Level          Meets "CE" requirements                                Oil Grade                    API Specificationr CG-4,
                                                                                                                SAE 30, 10W-30, 15W-40
Voltage Output              60 Hertz                       50 Hertz
Configuration               L-L      L-N                   L-L      L-N
Series Star                 480      277                   400      230                               ENGINE AIR REQUIREMENTS
Parallel Star               208      120                   230      127            Combustion Air               190 cfm
Series Delta                240      120                   230      115
Parallel Delta              130                            110                     Engine Cooling               200 cfm
Zig Zag                     400      230                   330      190            Note: The pressure differential between the outside of the engine compart-
Voltage regulator is adjustable  5%                                               ment versus the inside of the engine compartment should not exceed 2
                                                                                   inches of water (51 mm) at full open throttle (measure with a manometer).
3 Phase amperage calculation: Amps=Watts/[Voltage x 1.732 x PJ.]



                                                                        Engines & Generators

                                                                             124
                                                             80N4 SPECIFICATIONS
                              GENERAL                                                                             FUEL SYSTEM
Engine Type                 Diesel, four cylinder, four-cycle, marine engine.         General                     Closed system with bleed points.
                            Vertical in-line overhead valve, water cooled
                            direct injection, 80 hp @ 2500 rpm.                       Fuel                        No.2 diesel oil (cetane rating 0145 or higher).

Aspiration                  Naturally aspirated.                                      Fuel Injection Pump          BOSCH Model A type (In-line).

Govemor                     Integral with injection pump.                             Fuel Injection Timing       WBmC

Bore & Stroke                                                                         Noule                       Multi-hole
                            4.02 x 4.65 inches (102.0 x 118.0 mm).
                                                                                      Fuel Filter                 Full flow replaceable.
Piston Displacement         262 cubic inches (4.3 liter).
                                                                                      (on engine)
Firing Order                1 - 3 - 4 - 2.
                                                                                      Air cleaner                 Replaceable paper element.
Direction of Rotation       Clockwise, when viewed from the front.
                                                                                      Air Flow                    150 clm.
Engine Torque               210 fHb    @     1500 rpm.                                (engine combustion)
Compression Ratio           17:1                                                      Fuel Consumption            4.7 U.S. gph (17.8Iph).
Dimensions - inches (mm) Height:              32.0 inches    (813 mm)
w/out transmission       Width:               25.2 inches    (645 mm)                                          ELECTRICAL SYSTEM
                         Length:              47.2 inches    (1168 mm)
                                                                                      Starting Battery            12 Volt,   H   negative ground.
Weight (dry)                971 Ibs (440.8 kgs).
                                                                                      Battery Capacity            750 - 900 Cold Cranking Amps (CCA).

                    TUNE-UP SPECIFICATIONS                                            DC Charging Altemator       51 Amp rated, belt-driven.
                                                                                      Starting Aid                Glow plugs.
Compression Pressure        441 psi (31 kg/cm') at 200 rpm
(Limit of difference        Not to exceed 28.44 psi (20.0 kg/cm').                    Starter                     12 Volt, 3 KW.
Injector Pressure           2133 psi (150 kf/cm').                                    DC No-load Cu rrent           2% 01 rated amps.
Valve Seat Angle            Intake 45"                                               DC Cranking Current         400 CCA.
                            Exhaust 45.
Valve Clearance             Intake and exhaust.                                                                LUBRICATION SYSTEM
(engine cold)               0.016 inches (0.40 mm).
                                                                                      General                     Gear type/pressure circulation.
Engine Speed                Idle: 600 - 900 rpm.
                            Cruise: 1800 - 2200 rpm.                                  Oil Filter                  Full flow, paper element, spin-on type.
                            Max: 2400 -2500 rpm.                                      Sump Capacity               14.5 U.S. qts (13.8 liters).
                                                                                      (not including filter)
                        COOLING SYSTEM                                                Operating Oil Pressure      25 - 85 psi.
General                     Fresh water-cooled block, therrnostatically-              (engine hot)
                            controlled with heat exchanger.                           Oil Grade                   API Specification CF or CG-4,
Operating Temperature       170 -190 F (77 - 88 C).     0
                                                                                                                  SAE 30, 10W-30, 15W-40.

Fresh Water Pump            Centrifugal type, metal impeller, belt-driven.
                                                                                                                 TRANSMISSION
Raw Water Pump              Positive displacement, rubber impeller,
                            engine-driven.                                            General                     (HURTH Standard Transmission) Case-hardened
                                                                                                                  helical gears, hydraulically operated multiple disc
Coolant (Fresh Water)                                                                                             clutch.
System Capacity             17 US qts (16.1 liters).
                                                                                      Gear Ratio (Standard)        2:00:1 (Hurth 45A) or (Hurth 63A)

                        EXHAUST SYSTEM                                                Propeller Shaft              Right handed-standard transmission.

Exhaust Elbow               45 0 elbow                                                Propeller Recommendations 22x16 P-2 blade or 22x14 P-3 blade
                                                                                      (using standard           propeller should allow the engine to reach its full
Exhaust Hose Size           4" I.D. (101.6 mm) hose                                   transmission)             rated rpm (2500 + 000 -100) at full open throttle
                                                                                                                while underway in forward gear.
                  ENGINE AIR REQUIREMENTS                                             Lubricating Fluid            Dextran III
Combustion Air               150 cfm                                                  Transmission Sump
                                                                                      Capacity Hurth 45            2.13 US qts (2.0 liters) approximate.
Note: The pressure differential between the outside of the engine compart-
ment versus the inside of the engine compartment should not exceed 2
inches 01 water (51 mm) at full open throttle (measure with a manometer).




                                                                         Engines & Generators

                                                                                125
                                                           11 OT4 SPECIFICATIONS
                             GENERAL                                                                            FUEL SYSTEM
Engine Type                 Diesel, four cylinder, four-cycle, turbocharged         General                      Closed system with bleed points.
                            marine engine. Vertical in-line overhead valve,
                            water cooled direct injection, 110 hp @ 2400            Fuel                         No.2 diesel oil (cetane rating of 45 or higher).
                            rpm.                                                    Fuel Injection Pump          BOSCH Model A type (In-line).
Aspiration                  Turbo charged.                                          Fuel Injection Timing        12 0 BTDC.
Governor                    Integral with injection pump.                           Nozzle                       Multi-hole.
Bore & Stroke               4.02 x 4.65 inches (102.0 x 118.0 mm).                  Fuel Filter                  Full flow replaceable.
Piston Displacement                                                                 (on engine)
                            202 cubic inches (4.3 liter).
Firing Order                                                                        Air cleaner                  Replaceable paper element.
                            1 - 3 - 4 - 2.
Direction of Rotation       Clockwise, when viewed from the front.                  AirFlow                      230 cfm.
                                                                                    (engine combustion)
Engine Torque (max.)        280 ft-Ib @ 1500 rpm.
                                                                                    Fuel Consumption             6.1 U.S. gph (23.1Iph).
Compression Ratio           17:1.
Dimensions - inches (mm) Height:             32.0 inches    (813 mm)                                         ELECTRICAL SYSTEM
w/out transmission       Width:              28.3 inches    (719mm)
                                                                                    Starting Battery             12 Volt, (-) negative ground
                         Length:             47.2 inches    (1168 mm)
                                                                                    Battery Capacity             750 - 900 Cold Cranking Amps (CCA)
Weight (dry)                987 Ibs (448.0 kgs).
                                                                                    DC Charging Altemator        51 Amp rated, belt-driven
                   TUNE-UP SPECIFICATIONS                                           Starting Aid                 Glow plugs
Compression Pressure        441 psi (31 kg/cm') at 200 rpm                          Starter                      12 Volt, 3 I

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The information on this web site has not been checked for accuracy. It is for entertainment purposes only and should be independently verified before using for any other reason. There are five sources. 1) Documents and manuals from a variety of sources. These have not been checked for accuracy and in many cases have not even been read by anyone associated with L-36.com. I have no idea of they are useful or accurate, I leave that to the reader. 2) Articles others have written and submitted. If you have questions on these, please contact the author. 3) Articles that represent my personal opinions. These are intended to promote thought and for entertainment. These are not intended to be fact, they are my opinions. 4) Small programs that generate result presented on a web page. Like any computer program, these may and in some cases do have errors. Almost all of these also make simplifying assumptions so they are not totally accurate even if there are no errors. Please verify all results. 5) Weather information is from numerious of sources and is presented automatically. It is not checked for accuracy either by anyone at L-36.com or by the source which is typically the US Government. See the NOAA web site for their disclaimer. Finally, tide and current data on this site is from 2007 and 2008 data bases, which may contain even older data. Changes in harbors due to building or dredging change tides and currents and for that reason many of the locations presented are no longer supported by newer data bases. For example, there is very little tidal current data in newer data bases so current data is likely wrong to some extent. This data is NOT FOR NAVIGATION. See the XTide disclaimer for details. In addition, tide and current are influenced by storms, river flow, and other factors beyond the ability of any predictive program.