Westerbeke 11.5KW-60Hz Service Manual
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Westerbeke 11.5KW-60Hz Service Manual

Marine diesel engines
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SERVICE MANUAL
44A-44B-44C"FOUR '
35C-35D-35E-THREE
MARINE DIESEL ENGINES
8.0KW • 60Hz " 6. OKW • 50Hz BTOA
10.0KW • 60Hz' , 7.5KW • 50Hz BTOA
11.SKW • 60Hz
9.2KW· 50Hz BTO,:(elec)
12.SKW • 60Hz' 9.4KW· 50HzBTOB
12.6KW •
"6llHz
10.4KW· 50Hz BTO'(elec)
'15.0J(W.
60Hz 12.0KW • 50Hz BTOC
--.~
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- - - "--
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-.-
...
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, ' Single and Three Phase
MARINE DIESEL GENERATORS
, ' . ' o f".
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, PUBLICATION NO.45100
REVISION 2
APRIL 2010

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  • Page 1 -(lRIJ " 'fer ~LD"'" SERVICE MANUAL 44A-44B-44C"FOUR ' 35C-35D-35E-THREE MARINE DIESEL ENGINES 8.0KW • 60Hz " 6. OKW • 50Hz BTOA 10.0KW • 60Hz' , 7.5KW • 50Hz BTOA 11.SKW • 60Hz 9.2KW· 50Hz BTO,:(elec) 12.SKW • 60Hz' 9.4KW· 50HzBTOB 12.6KW •...
  • Page 2 Shut down the. unit and do not restart until It has blfen Inspected and repaired. This WARNING DECAL provided by WESTERBEKE and should be flxed to bulkhead near your engIne genemtor. . WE$TERsEKEa!so recommends installing CARBON MONOXIDE DETECTORS In the IlvInll/Sleeplng quartem tif your vessel.
  • Page 3 • Make sure a fire extinguisher is installed nearby and is before touching the engine or checking the coolant. properly maintained. Be familiar with its proper use. Extinguishers rated ABC by the NFPA are appropriate for all applications encountered in this environment. WESTERBEKE Engines & Generators...
  • Page 4 Acid may splash on the skin or into the eyes inadvertently when removing electrolyte caps. -...v: WESTERBEKE Engines & Generators...
  • Page 5 SAFETY INSTRUCTIONS ABVC, NFPA AND USCG PUBLICATIONS FOR • Do not wear loose clothing or jewelry when servicing equipment; tie back long hair and avoid wearing loose INSTALLING DIESEL ENGINES jackets, shirts, sleeves, rings, necklaces or bracelets that Read the following ABYC, NFPA and USCG publications could be caught in moving parts.
  • Page 6 INSTALLATION When installing WESTERBEKE engines arid generators it is important that strict attention be paid to the following information: CODES AND REGULATIONS Strict federal regulations, ABYC guidelines, and safety codes must be complied with when installing engines and generators in a marine environment.

  • Page 7: Table Of Contents

    TABLE OF CONTENTS Parts Identification/Engines ..........2 Wiring Schematic - Engines ..........Parts Identification/Generators .......... Specifications - 44-Four Models ........Specifications - 35-Three Models ........Introduction ................ .4 Engine Troubleshooting ............DC Electrical System (Alternator) ........62 Mando Alternator Service ..........Testing for Overhaul...
  • Page 8 WATER INJECTED EXHAUST THERMOSTAT 20ACIRCUIT REAR FRONT . OIL FILL DRAIN HOSE COOLER RIGHT SIDE I INTAKE/AIR FILTER FRONT l@L ___ PRE'HEAT SOLENOIO DC ALTERNATOR 'll.~~~a&"~r---FUEl FILTER RAW WATER REAR UNIHD, HEAT EXCliANGiER LEFT SIDE ... WESTERBEKE Engines Generators &...

  • Page 9: Parts Identification/Generators

    PARTS IDENTIFICATION/GENERATORS GENERATOR EMERGENCY STOP SWITCH LEFT SIDE CONNECTION TO ~'"'"UN BREAK '0t<>ct-t---E'XHAUSTELBOW _ _ --'I-IL_-!iTART SOLENOID RAW WATER ru .. r--:-_ _ HEAT REAR FRONT ' ! ' O (iLANTJ PRESSURE CAP .FILL FILL PREHEAT RIGHT SIDE THERMOSTAT ASSEMBLY AIR INTAKE SILENCER &...

  • Page 10: Introduction

    Ser. #UOOOO-ESll OF THE FURNISHING OR USE OF SUCH SOF1WARE. Expires: 8/5/2013 WESTERBEKE customers should keep in mind the time span between printings ofWESTERBEKE product software and the unavoidable existence of earlier WESTERBEKE The WESTERBEKE engine serial number was an product software.

  • Page 11: Engine Troubleshooting

    1. Air trapped in fuel system. 1. Check and retighten connector. 2. Clogged filter. 2. Clean or replaee filter. 3. Contaminated fuel tank. 3. Clean tank. INSUFFICIENT INTAKE AIR 1. Clogged air cleaner. 1. Clean or replace air cleaner. (continued) """ WESTERBEKE Engines Generators &...
  • Page 12 1. Correct oil level. 2. Excessive rise of oil into combustion chamber. a. Check. a. Poor piston contact. b. Replace or clean. b. Seized piston ring. c. Excessive plston-to-cylinder clearance. c. Replace or correct. (continued) ... WESTERBEKE Engines & Generators...
  • Page 13 ENGINE TROUBLESHOOTING VERIFICATIONJREMEDY PROBLEM PROBABLE CAUSE SMOKY EXHAUST (cont.) WHITISH OR PURPLISH (cont.) d. Worn valve stem and valve guide. d. Replace. e. Low engine 011 viscosity. e. Replace. I. Correct. I. Excessive 011 pressure. 3. Injection timing is too late. 3.
  • Page 14 7. Replace. LOW OIL PRESSURE 1. Worn Bearings. 1. Engine overhaul replace bearings. 2. Relief valve malfunction. 2. Dverhaul oil pump. 3. Clogged 011 cooler. 3. Repair. 4. Diesel dilution of the oil. 4. Injection pump repair. WESTERBEKE Engines .& Generators...

  • Page 15: Testing For Overhaul

    TESTING FOR OVERHAUL HOW TO DETERMINE ENGINE OVERHAUL PERIOD OVERHAUL CONDITIONS Cause of Low Compression Compression pressure tends to increase a little in a new engine until piston rings and valve seats have been broken in. Generally, the time at which an engine should be overhauled Thereafter, it decreases gradually with the progress of wear is determined by various conditions such as lowered engine of these parts.

  • Page 16: Engine Disassembly

    Put plugs or caps on the openings of the injection pump and nozzle connectors. GOlf tees work well as plugs. transmission manual. To rebuild a transmission contact your WESTERBEKE dealer or an authorized transmission service 14.Remove the fuel injection nozzle .. Loosen the fuel center.
  • Page 17 ENGINE DISASSEMBLY 15. Remove governor assembly. 23. Remove the cylinder head assembly. Lift the cylinder head straight up with a hoist. a. Remove the tie rod cover. NOTE: b. Remove the spring from the tie rod with pliers to the gasket is seized and the cylinder head cannot be separatedJrom the cylinder block, tap around the thick disconnect the tie rod from the fuel injection pump.
  • Page 18 ENGINE DISASSEMBLY 27. Remove the rear plate.The rear plate is doweled in VALVE SPRING position. pun the plate as straight as possible when REMOVAL removing it. 28. Remove the oil seal case. Remove the bolts that hold the oil seal case in position. Remove the case from the cylinder block with a screwdriver.
  • Page 19 ENGINE DISASSEMBLY TIMING GEARS ORDER OF DISASSEMBLY NUMBERS INDICATE THE SUGGESTED ORDER OF INJECTION DISASSEMBLY PUMP CAMSHAFT . IDLER GEAR 12 . 10 THRU 13BEARING • 12 FUEL INJECTION PUMP CAMSHA.FT GEAR OIL PUMP 6'FRONT PLATE CAMSHAFT . PLATE GEAR CASE CRANKSHAFT PULLEY Engines &...
  • Page 20 ENGINE DISASSEMBLY 31. Remove the timing gear case. Remove the bolts that 37. Remove the oil pump. Remove the bolts that hold the oil hold the timing gear case in position and remove the case. pump to the cylinder block and remove the pump. 38.
  • Page 21 Lay the cylinder block with its bottom (oil pan) side up. b. Remove the bolts that hold the main bearing caps in position. Remove the caps. c. Remove the front and rear bearing caps with a sliding hanrmer. WESTERBEKE Engines & Generators...

  • Page 22: Inspection

    INSPECTION CYLINDER HEAD AND VALVE MECHANISM Using a heavy accurate straight edge and 1. Cylinder head. a feeler gauge, check the bottom face for warpage in three positions, lengthwise, two crosswise and two widthwise as CHECK shown in the illustration. warpage exceeds the limit, THREADS reface the bottom face with a surface grinder.
  • Page 23 INSPECTION 3. Valve springs. Check the squareness and free length. If the squareness and/or free length exceeds the limit, replace the spring. VALVE SPRING FREE LENGTH STANDARD 1.85 in (47mm) MEASURING LIMIT 1.81 in (46mm) DIRECTIONS SPRING SQUARENESS STANDARD 1.5' MAXIMUM SPRING TEST FORCE·...
  • Page 24 INSPECTION 0.39± 0.020 In (10±0.5 mm) -' y ' - ----_ VALVE GUIDE-..,.., ..-", _ _ _ '~r- .,(L CYLINDER HEAD/ GOOD CONTACT MUST BE UNIFORM AROUND THE COMPLETE CIRCUMFERENCE HEIGHT TO THE TOP OF THE VALVE NORMAL SIZE 0.391n (10mm) VALVE AND VALVE SEAT CONTACT c.
  • Page 25 INSPECTION l . . L_-"UUI"~ REFACING THE VALVE SEATS '--_ _ _ COMBUSTION JET c. After refacing the valve seat, put lapping c,ompound on 9. Combustion jet replacement. Replace the combustion the valve face and lap the valve in the valve seat. jets only when they are cracked or defective.
  • Page 26 ENGINE INSPECTION TIMING GEARS AND fLYWHEEL· INSPECTION POINTS TAPPET INSPECT FOR WEAR GASKET BEARING (SP"~N1N'G) CHECK FOR NOISE AND WEAR GEARS CHECK TEETH WEAR, BURRS, OR CHIPS GASKET CHECK FOR BEND OR DAMAGE TO THE LOBES ~~----_"TlNIII' '"GEAR CASE """..INSPECT FOR CRACKS/DISTORTION GASKET FLYWHEEL...
  • Page 27 NOTCH IN CLEARANCE BETWEEN THE TAPPET AND THE CYLINDER BLOCK BUSHING STANDARD 0.0059 in (0.15mm) 0.041.-(1 mmrJL OIL HoLES -IL~<l---IENDS ~-\~:k3 BUSHING INSTALLING THE . CAMSHAFT GOOD BUSHING CAM CONTACT FACE OF THE TAPPET WESTERBEKE Engines & Genera.tors...
  • Page 28 Heat a new ring up to a temperatnre of 302"F (l50°C) with a piston heater and iilstall it to the COMPRESSION RING flywheel with its uncharnfered side foremost REMOVING THE RING GEAR MEASURING THE CLEARANCE BETWEEN THE PISTON RING AND GROOVE ... WESTERBEKE Engines & Generators...
  • Page 29 ENGINE INSPECTION CYLINDER BLOCK, CRANKSHAFT, PISTONS AND OIL PAN· INSPECTION POINTS CYLINDERS INSPECT FOR CRACKS, OR RIDGES ATTOP OF RING TRAVEL. CYLINDER BLOCK CHECK FOR WARPAGE ON TOP FACE. INSPECT FOR PLUGGED OIL . HOLES. CHECK FOR OAMAGE PISTON----c:-=:::+ TO PLUGS OR DOWELS. INSPECT FOR WEAR, SCORING, CRACKS, OVERHEATING AND...
  • Page 30 INSPECTION d. Put the piston ring in a gauge or in the bore in a new f. Check the connecting rod for bend or twist as follows: cylinder block and measure the elearance between the "k'. If "C" exceed 0.0020 in (1) Measure "C"...
  • Page 31 INSPECTION 16. Crankshaft CAUTION: a. Clearance between crankpin and connecting rod Grind all the crankpins of one bearing. crankshaft to the same undersize. (1) Install the bearing (uPPer and lower halves) and cap Finish the crank pin fillets to radius of 0.09B in big end of connecting rod and tighten the (2.5mm).
  • Page 32 INSPECTION (3) If the clearance exceeds the limit, install a new 17. Cylinder Block bearing and check the clearance again. a. Measure the bore at the top, middle and bottom points (4) If the clearance still exceeds the limit, grind the on axes A and B with a cylinder bore gauge.

  • Page 33: Assembly

    ASSEMBLY CYLINDER BLOCK, CRANKSHAFT, PISTONS AND OIL PAN PISTON COAT THE ENTIRE SURFACE WITH ENGINE OIL PISTONPIN~ FORCE FIT APPLY ENGINE OIL TO JOURNALS AND LOBES <""' 1 BEARINGS LUBRICATE THE INSIDE SURFACES WITH ENGINE OIL BEARINGS l\'9 LUBRICATE THE INSIDE CONNECTING ROO SURFACES WITH ENGINE OIL CAP NUTS...
  • Page 34 ASSEMBLY 1. Main bearing installation. 4. Side seal installation. a. Install the upper halves of the main bearings in the a. Coat the side seals with Lectite Ultra Blue. cylinder block and the lower halves in the main b. Insert the side seals between the cylinder block and the bearing caps so their tabs fit into the notches in the front and rear caps and push them in by hand as far as cylinder block and the main bearing caps ..
  • Page 35 ASSEMBLY 8. Connecting rod cap installation. MARK TO Push the piston into position until the big end of the connecting rod is put into position over the crankpin. Then the crankshaft 180· while pushing on the top turn NO.1 COMPRESSION of the piston.
  • Page 36 ASSEMBLY TIMING GEARS AND FLYWHEEL TAPPETS LUBRICATE ENGINE OIL THRUST PLATE TO: . TORQUE 0.1 Kg-m 1.1:< 10.8:< OIL SEAL ENGINE OIL JOURNALS AND LOBES GASKET BACK PLATE BOLT TORQUE TO: TORQUE TO: 17.5 Kg-m 6.5:< 1 Kg-m ± 172:< 25Nm 10Nm ±...
  • Page 37 ASSEMBLY 11. Front plate installation. a. S'crape the gasket from the cylinder block and front plate. h. Coat the gasket contact surface of the cylinder block with adhesive and put a new gasket in position, making sure the holes in the gasket are all in alignment with the holes in the cylinder block.
  • Page 38 ASSEMBLY 23. Flywheel installation. . Cylinder head bottom face clearling. Scrape the gasket from the bottom face of the cylinder head. 12x 1.25) in the rear end of the a. Install a safety bar crankshaft. NOTE: After scraping the gasket, rub off gasket remnants from the face with an oilstone smeared with engine oil and b.
  • Page 39 ASSEMBLY 37. Fuel injection nozzle installation. 29. Installation of the cylinder head. Place the cylinder head in position on the cylinder block, making sure the Put the gasket on the nozzle. guide bolts are all in alignment with their respective bolt b.
  • Page 40 ASSEMBLY 52. Fnel run solenoid installation applicable]. a. Remove the tie rod c o v e r . ) b. Coat the threads of the stop solenoid with thread sealant Bond 1212). Coat the length of the threads to be (Three turned in the governor case.
  • Page 41 7. Flush out the coolant recovery tank and it's connecting 6. Repaint the assembled heat exchanger with Westerbeke tube. resistant spray enamel. ASSEMBLY 1. If the manifold was removed as an assembly and left...

  • Page 42: Fuel Injection Pump

    Keep tlui disassembled injeciion pump parts in clean' diesel fuel. CAUTION: Anytime the injection pump is disassembled, new O-ring must be installed. Make sure the threads of the delivery valve holder do not cause damage to the D·rings • ..WESTERBEKE Engines Generators &...
  • Page 43 FUEL INJECTION PUMP 3. Install each control sleeve with the center tooth in 6. Inspection after assembly. alignment with the line mark of the control rack. Put a. After the injection pump has been assembled, check to the plungers in position in the barrels. see if the control rack moves freely without any .

  • Page 44: Governor

    GOVERNOR DISASSEMBLY SEQUENCE AND INSPECTION -+----2 TIE ROO SPRING CHECK SLIDING SLEEVE CONTACT _ _ ----f FACE FOR WEAR k----,3 SPEED CONTROL LEVER 6SHAFT/ CHECKSHAFr FOR DEFECTS AND WEAR 1. Assembly. SPEED CONTROL a. Install the levers in position. LEVER ---->.l. Put the O-ring on the governor shaft.

  • Page 45: Fuel Injection Timing

    FUEL INJECTION TIMING Preparation Adjustment a. Close the fuel shut-off valve. the fuel injection timing is incorrect, change the b. Disconnect the No.1 fuel injection pipe from the thickness of shims under the fuel injection pump. cylinder head and injection pump. increase or decrease of the shims by O.lmm (0.004 in) will vary the timing by 1°.
  • Page 46 The copper washers should not be reused. Replace with new washers. 2. TIghten the nozzle on the cylinder head to the specified torque. NOZZLE TORQUE 4lb-ft (5.5 0.5 kgf-m) ± ± RECONDITION / REPLACE ' . ' ..-v- WESTERBEKE Engines & Generators...

  • Page 47: Glow Plug Testing

    GLOW PLUG TESTING GLOW PLUGS TERMINAL To inspect the plug, remove the electrical terminal connections, .END· then unscrew or unclamp each plug from the cylinder head. Thoroughly clean each plug's tip and threads with a soft brush and cleaning solution to remove all carbon and oil deposits.

  • Page 48: Starter Motor

    STARTER MOTOR DESCRIPTION No-Load Test 1. Connect the ammeter, voltmeter, and battery to the starter The starter can be roughly divided into the following sections: as illustrated. • A motor section which generates a drive power. • An overrunning clutch section which transmits an anna- 2.
  • Page 49 ADJUSTING SHIMS BRUSHES --"'Iif'l . STARTER MOTOR ---.f\i~..., "'I'u. __ SNAP LEVER SPRING NOTE: inspect. clean and (if necessary) replace the brush, commutator, solenoid, armature, etc. See the following pages. PINIDN WESTERBEKE Engines Generators &...
  • Page 50 STARTER MOTOR STARTER INSPECTION Solenoid Inspect the solenoid for continuity between terminals S and M and.between terminals S and body. No continuity should be found between S and M. Continuity should be found between S and the body and M and the body. Brush and Brush Holder InSIJecltion 1.
  • Page 51 Bearing shaft washers and snap rings. d. Bearing sleeves. Pinion. Sliding portion oflever. CAUTION: Never smear the starter fitting surlace, termInals, brushes, commutator with grease. 3. After reassembly. check by conducting a no-load . test again. WESTERBEKE Engines Generators &...

  • Page 52: Raw Water Pumps

    RAW WATER PUMP (PN.33636) Disassembly 2. Install the shaft into the bearings. Support the bearings at The pump, as removed from the engine, will have hose their center races. Push the shaft into the bearings, push- attachment nipples threaded into its inlet and outlet ports. ing at the impeller drive slot end using the base of the They may be left in place removed if they interfere with...

  • Page 53: Parts List

    1. Support 'the bearings inner race. Press the shaft into the bearings so that the drive end of the shaft extends beyond the second bearings inner race by 19/32" (15mm) 1132" (.5mm) NOTE: The seals'flat suifaces that have printing and numbers face toward each other. WESTERBEKE "IIV' Engines & Generators...
  • Page 54 PUMP(PN. RAW WATER 48080) PARTS LIST PART NUMBER AND PART NAME QUANITY KEY NO. . 46060 RAW WATER PUMP 49172 SHAFT 49170 IMPELLER COVER 46500 IMPELLER KIT (O·RING & GLYCERIN) 34456 49171 . WEAR PLATE 302575 DOWEL . 4B253 SPRING SEAL WASHER IMPELLER COVER SCREW 34463 48359...

  • Page 55: Engine Adjustments

    ENGINE ADJUSTMENTS VALVE CLEARANCE ADJUSTMENT Make the following adjustments when the engine is cold. a. Remove the cylinder head cover. Slightly loosen the cylinder head bolts and retighten them to the specified torque in the number sequence shown below. TIGHTENING TORQUE ±...

  • Page 56: Testing Engine Compression

    ENGINE ADJUSTMENTS TESTING ENGINE COMPRESSION AIR INTAKE FILTER/SILENCER Make certafu the oil level (dipstick) is at the correct level and the air intake filter is clean. The battery and starter motor must also be in good condition. INTAKE a. Warm the engine to normal operating temperature. &...

  • Page 57: Generator Frequency Adjustment

    ENGINE ADJUSTMENTS GENERATOR FREQUENCY ADJUSTMENT (HERTZ) FUEL RUN SOLENOID Once the diesel generator set has been placed in operation, The fuel run solenoid is mounted in a threaded hole on the there niay be adjustments required for engine speed (Hertz) engine's block just aft of and below the engine's fuel injec- during the engine's break-in period (first 50 hours) or after tion pump.

  • Page 58: Oil Pressure

    ENGINE ADJUSTMENTS OIL PRESSURE The engine's oil pressure, during operation, is indicated by the oil pressore gauge on the instrument panel. Doring nonnal operation, the oil pressore will range between 40 and 60 psi (2.8 and 4.2 kg/cm'). ~~~SSUIRE, NOTE: A newly started, cold engine can have an oil pressure SENOOR reading up to 60 psi (4.2 kg/cm').

  • Page 59: Drive Belt Adjustment

    ENGINE ADJUSTMENTS Drive Belt Adjustment ADJUSTING THE IDLE SPEED Proper inspection, service and maintenance of the drive belts a. Loosen the locknut on the idle adjustment bolt on the is important for the efficient operation of your engine. fuel injection pump. Drive belts must be properly tensioned.

  • Page 60: Service Data-Standards And Limits

    . 0.15/100 (0.0059/3.94 max.) (0.0031 - 0.0075) (0.0118) Fuel injection pump camshaft ... 0.07 - 0.20 ......0.30 gear and all pump gear (0.0028 - 0.0079) (0.0118) Lobe height 01 camshaft ....35.72 (1.4063 ....34.72 (1.3669) WESTERBEKE Engines & Generators...
  • Page 61 SERVICE DATA· STANDARDS AND LIMITS Component Specified Value Standard Repair Limit inches(mm) inches(mm) Component Sealant Mating Pari ENGINE COMPONENTS THREAD PARTS Crankshaft Stop solenoid ......Loctite #587 Ultra Blue ..•. Governor case Diameter of journal ....51.985 - 52.000 (2.04665 - 2.04724) Water drain jOint ....

  • Page 62: Special Tools - Engines

    CAMSHAFT BUSHING INSTALLER [033583] FOR REMOVING AND INSTALLING THE FRONT CAMSHAFT BUSHING 033583 THE ABOVE TOOLS ARE AVAILABLE FROM YOUR WESTERBEKE OR MITSUBISHI DEALER. NOTE: IN ADDITION TO THESE TOOLS THE FOLLOWING ADDITIONAL TOOLS WOULO BE NEEDEO: BEARING PULLER. VALVE SEAT CUTTER TOOL. PROPER DIAL GAUGES.

  • Page 63: Torque Specifications

    TORQUE SPECIFICATIONS MAJOR BOLTS AND NUTS TORQUE Clamp Width Bolt or Nut Diameter Pitch across flats length kg-m ft - 27-38 Altemator Bracket 3.8-5.3 36.6 Back Plate 3.3-4.8 24-35 32.5 Connecting Rod Cap 3.55±0.25 27±72 34.8±2.5 Coolant Pump 1.6±2.4 12-17 17.2 Coolant Pump Pulley .
  • Page 64 PROPULSION MODELS WIRING SCHEMATIC #39144 START ,unn NOTES: ~Ol. -"'+---.,.; t-----t; .. .--------4 c,.CUIT I. TM/I f'IlODUCT " PlDTI£CTED A IIIdIIIAL lun IJU.IIO LOCATED IIUI THE ITU.n.. UCUIIVf cunEIiT WILL CAliSE THt IIIEAIIElt Tltl' ,1,110 TilE EIII'"£ W'LL lIM:i 1~'AfrE.Du/m5MUHII~lJU:lriU~ ~~ld:~.~~M~~~ 1~~;Ei~D h~~11 "AllC: r--";',.,.,.~':----':',,:-:,,-::,,:---:,,-::,,:-:,,-:,,:-,:-:,,-:,,:-,:-=-+...
  • Page 65 PROPULSION MODELS WIRING DIAGRAM #39144 ----:--_. i - - -- -~~~=-=C~ NotE ,f:] +1u:I:l 1l1~~ h!IW NO!!: An on-off switch should be InslBlled in this cirr:ult to disconnect the starter from the balllJlJlln an emergency and when leaving the boat. Twelve volt engine starters ADMIRAL typically draw 200 to 300...
  • Page 66 44A, 44B, 44C FOUR ENGINE SPECIFICATIONS SPECIFICATIONS FUEL SYSTEM Engine Type Diesel, four-cycle, four-cylinder, tresh waler- General Open flow, self pnming. cooled, vertical in-line overhead valve Fuel No.2 diesel oil (cetane rating of 45 or higher). mechanism. Fuel Injection Pump In-line plunger type (BOSCH).
  • Page 67 Oil Grade API Specificalion CF or CG-4, SAE 30, lOW-3~, 15W-40 51 Amp raled, bel~driven DC Charging Altemalor Starting Aid Glow plugs, sheathed type 12 VolI, reduction gear Starter Cold Cranking 150 -175 DC Amps Amp Draw WESTERBEKE Engines & Generators...

  • Page 68: Dc Electrical System (Alternator)

    DC ELECTRICAL SYSTEM ALTERNATOR 1. Start the engine. 2. After the engine has run for a few minutes, measure the The charging system consists of a DC belt driven alternator starting battery voltage at the battery terminals using a with a voltage regulator, an engine DC wiring barness, a multimeter set on DC volts.
  • Page 69 DC ELECTRICAL SYSTEM Checking the Service BaHery 7. Now check the voltage between the alternator ontput tenni- and ground. the circuit is good, the voltage (B+) Check the voltage of the service battery. This battery should at the alternator will be the same as the battery, or if an have a voltage between 13 and 14 volts when the engine is isolator is in the circuit the alternator voltage will be zero.
  • Page 70 WESTERBEKE 51A MANDO ALTERNATOR DISASSEMBLY AND TESTING WARNING: A failed alternator can become very hot. Do not touch. until the alternator has cooled down. WARNING Before starting the engine, make certain that everyone is clear moving parts! Keep away from sheaves and belts during test procedures.

  • Page 71: Mando Alternator Service

    MANDO ALTERNATOR SERVICE e. Remove the regulator cover. TESTING THE EXCITER LEAD f. Temporarily re-install Jumper (A) and all associated nuts. Leave Jumper (B) installed. g. Remove the plastic plug from the side of the regulator. h. Connect a jumper betweeu the top brush lead and the ground.
  • Page 72 MANDO ALTERNATOR SERVICE REMOVE ALTERNATOR Place an oversized V-belt around the pulley and fasten the pulley in a vise. Disconnect the negative battery ground cable. Use a 7/8 in. box wrench to loosen and remove the Disconnect the wiring leads. pulley nut.
  • Page 73 MANDO ALTERNATOR SERVICE 2. Inspect and test the diode-trio assembly: Using a commercial diode tester, a l2-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. FRONT BEARING DIODE TERMINAL BEARING...
  • Page 74 7. Test the stator windings as follows: a. Using an ohmmeter or test lamp, check for continuity between all three leads (I, 2, and 3). A low ohm reading or lit test lamp should be observed. INTERNAL CIRCUIT WIRING WESTERBEKE Engines & Generators...
  • Page 75 Install the four bolts and tighten them. rpRGUE; 35 - 651b-ft (4.0 - 7.3 Nm) NOTE: the front housing is' new, the through-bolt will not be tapped. FRONT BEARING ASSEMBLING THE BEARINGS WESTERBEKE Engines & Generators...
  • Page 76 MANDO ALTERNATOR SERVICE INSTALL ALTERNATOR 7. Install the spacer and the fan. Then push the pulley, lockwasher and nut onto the shaft. Tum the· nnt a few Install the alternator, screws and washers. turns. . 2. Connect the wiring leads. 8.
  • Page 77 GENERATOR WIRING DIAGRAM #44735 !! . .llE..!!.tJOR 51)1.- I ?VOC ST ARlrR MOTOR NOTE: An on-off switch should be inslBlled in this ..FC~, ~I circuit disconnect the starter from the baUery In -+~ ~ an emergency and when r -__ -W ..
  • Page 78 GENERATOR WIRING SCHEMATIC #44735 FUEL SOL. PUMP ."TER TEMP. EXH. TEMP. 01 L PRESS. SWITCH SWITCII sWITCIl STOP KZ-RUN REL.o.T ISIITCK lM4Gn2 " PREHEAT START r-., SIITCII KHTART RUA' SWITCH " AUX, O.P. SIITCH OIL PAESS. SENDER ..UR TEIIP. UNDER T81-2 1a2-2 182-1...
  • Page 79 REMOTE INSTRUMENT PANEL #44329 STOP SW I Te" PREHEAT SWITCH REMOTE CONTROL PANEL (REAR VIEW) _.-- .. - " - " - , ' - " - .. - " - , ' - " - " - " - " - " - " START SWITCH {>...
  • Page 80 SPECIFICATIONS -11.5BTO, 12.6BTO, 10.0BTOA, 8.0BTOA GENERAL FUEL SYSTEM Engine Type Diesel, four-cycle, three-cylinder, fresh water- General Open flow, self priming. cooled, vertical in-line overhead valve Fuel No.2 diesel oil (cetane rating of 45 or higher). mechanism. In-line plunger type (BOSCH). Fuel Injection Pump Displacement 80.4 cubic inches (1.318 liter)
  • Page 81 SPECIFICATIONS 8.0KW BTDA AG GENERATOR (Single Phase) Single Phase Brushless, four·pole, revolving field. Pre·lubricated, single·bearing design. Reconnectable, single·phase tlllnsformer regulation (optional solid'slate vollage regulation). Vollage 120 or 120/240 Volts· 60 Hertz 230 Volts· 50 Hertz. Voltage regulation: ±5% no load to full load. Frequency regulation: .5 Hertz (.60%) no load to full load.
  • Page 82 API Specilication CF or CG·4, Oil Grade SAE30, 1 OW-3~, 15W-40 DC Charging Alternator 50 Amp rated, belt-driven Starting Aid Glow plugs, sheathed type 12 Volt, reduction gear Starter Cold Cranking 175 - 200 amps (approx,) Amp Draw WESTERBEKE -..yo Engines & Generators...
  • Page 83 Ambient Temperature Ambient Temperature Recommendations Recommendations NOTE: Forced ventilation should be provided NOTE: Forced ventilation should be provided to maintain generator compartment to maintain gene",tor compartment tempe"'tures below 104"F (40"C). tempe",tuflls below 104"F (40"C). WESTERBEKE " y Engines Generators &...
  • Page 84 Engine Combustion 56 cfm (1.6 cmm) Air Requirements (60 Hertz), at 1800 rpm Generetor Compartment 122'F (50'C) maximum Ambient Tempereture HOTE: Forced ventilation should be provided Recommendations to maintain generator compartment temperatures below 122'F (50'C). WESTERBEKE -.,.y: Engines & Generators...

  • Page 85: Bt Generator Single/Fhree Phase

    BT GENERATOR SINGLE/THREE PHASE This generator is a four-pole, brushless, self-excited generator A circuit breaker is installed on all WESTERBEKE genera- which requires· only the driving force of the engine to pro- tors. This circuit breaker will automatically disconnect gener- duce AC output The copper and laminated iron in the exciter ator power in case of an electrical overload.
  • Page 86 MAIN STATOR AUXILIARY WINDlNGS_1.5-1.8Q COMPOUND TRANSFORMERWINDlNGL.019-.021Q 8T GENERATOR SINGLE PHASE 12 STUD COMPOUND TRANSFORMER AUXILIARY WINDlNGS _ _ _ _ _ COMPOUND . G BRIDGE RECTIFIER BRIDGE RECTIFIER BREAKER 'JUNICTIOINTERtMINAI 1 & TRANSFORMER CONNECTION WESTERBEKE 1-2-03 "MI': [VOLTAGE HERTZ Englnes·& Generators CONNECTION]...
  • Page 87 BT GENERATOR/SINGLE PHASE 10KW·15KW GENERATORS r----------1 r----------, 50 Hz TERMINAl\r-_ _ .., r------------,-------, 6 . 2 60 Hz tERMINAL J ... \6 :: • II : - - 7 ~-----------------~ <. ml" l~+~L , _________ " II!l>T01(~ YELlOW & RED ~7c- ~ GREEN F)-- -',...
  • Page 88 GREEN GREEN AC 9 L..- L-- - ',GREEN GREEN YELLOW ( YELLOW BLACK BLACK " " BLACK BLUE BLACK 60cyc. L-~~ --"':!~ A.v.R.I-'-_ _ _ _ _ _ _ _ BLUE 50 eye. YELLOW PLUG ,,,,,,,WESTERBEKE . ,Engines Generators &...
  • Page 89 BT GENERATOR TROUBLESHOOTING Testing Residual Voltage 3. The absence of any voltage from the generator indicates a fault with the main stator windings C-l and C-2 and/or 1. The amount of no-load voltage produced by the the compound transformer windings D-l and D-2. generator can be an indicator of where in the generator Apply 12 volt DC excitation to the exciter stator windings the problernlfault may lie.

  • Page 90: Component Resistance Values

    BT GENERATOR TROUBLESHOOTING/SINGLE PHASE E •. · A.C. Terminal Board F. Selector Switch H,OptionaI G. Bridge Rectifier The model code number is found stamped in the generator housing on a flat surface above the rear generator carrier bearing. NOTE: These two model BT generators are used on models rated lower than the capabilities ojthe generator.
  • Page 91 NOTE: No continuity should be found between either of these lifted leads or to the generator case/ground. lWO GREI'NI:)'-H~~ BLACIH;;\9:J1~ BLUE VOLTAGE/HERTZ CONNECTION BAR 1#~iel BLACK AVR PLUG REC'n~IEij]1 (rD BRIOGIE (10 HERtz BAR] (TO SELECTOR SWITCH) '"'" WESTERBEKE Engines &. Generlltors (TO SELECTOR SWITCH)

  • Page 92: Bt Generator Troubleshooting (Chart)

    AC output voltage will drop to zero. A short or an open in a diode can easily be found with the above without having to unsolder and isolate each diode to check it with an ohmmeter. WESTERBEKE Engines Generators &...
  • Page 93 BT GENERATOR TROUBLESHOOTING/SINGLE PHASE No-Load Voltage Adjustment 120V 60Hz 120/240V 60Hz 115V5P"z 230V 50Hz Voltage adjus1ment is made with the generator regulation being governed by the compound transformer. 1. The selector switch must be in the COMP position. 2. To confirm no-load voltage, start the generator and apply a momentary (moderate) load to excite the transformer.

  • Page 94: Bt Generator Troubleshooting

    A JUMPER IS REDUIREO BETWEEN LOAD CONNECTIONS. NOTE: For ouput leads from the terminal block use terminal ends for }/4"studs that . accept multi-strand copper wire sized for the average rating from the hot lead connection WESTERBEKE Engines & Generators...
  • Page 95 BT GENERATOR INTERNAL WIRING 3 PHASE TWELVE WIRE RECONNECTABLE r - - - - - - - - - - - - - , EXCITER STATOR r------ ===t: DSTATOR ~~:: =:=:::=i:====:'~ --- - -i - - - - - -- - --, ...-J1----.'7 8 ...
  • Page 96 GENERATOR AC VOLTAGE CONNECTIONS BE THREE PHASE " ..VOLTAGE REGULATORS AC TERMINAL CONNECTIONS THREE PHASE CONNECTIONS THREE PHASE 12 WIRE . The regulator is equipped with seven numbered tenninals (0 to 6) and their related brass jumpers. The illustrations shown connection points and jumpers for the 3 phase con- figuration of the generator.

  • Page 97: Bt Generator Troubleshooting (Single Phase)

    ~'~! =:::==j:~===::~ r -----: - -- -----: :====t =::::~:~=== EXCITER I 8· ROTOR FIELD r-----;-, DiODES .-----~----------~ - - _ _ _ _ _ _ _ VOLTAGE REGULATOR => IIreen >- wellolll Ttfertz 51mb 110" WESTERBEKE -..¥ Gener~tors Engines &...
  • Page 98 R~GULAToR BT GENERATOR VOLTAGE ADJUSTMENTS (3 PHASE) Description Amp-Hertz The voltage regulator is an advanced design which ensures These two adjustments are used in conjunction with the two optimum AC generator performance. It is equipped with protection circuits in the voltage regulator that are indicated complete protection circuitry to guard against operating by the illwnination of colored LED lights.
  • Page 99 BRH !!IRED/lilT T62-' R[Dlr~T .lIG ttL PR!'JiEA.T • PRESSURE Iii WIlT 152-2 WATER SWiTCH TEMP 1111-5 T81·3 {;:-/ START SWITCH T61-10 182-4 STOP L==~,,~,,~U~""'" SWITCH VOLT _-€ HOUR I I R D 182.8 METER METER WESTERBEKE EngineS & Generators...
  • Page 100 IND. LIGHT c-;.;;-' I-;V-' ..L __ ->j-- p-------j -TYPICAL RE~OTE START/STOP PANEL CONECTIONS- i'---1 Lo-J NOTE: VOL n.\ETER 01. REMOTE COHEerOR PINS 2. JUMPER SETTING: JI CPE'N-50HZ -?J-- >---\<i+ I CLOSE -60HZ J20PEN-S-ISKI! J2 CLOSE-20-95KW WESTERBEKE Engines & Generators...

  • Page 101: Electronic Governor (Optional)

    This voluige spread is the result of the dislarlce the MPU is positioned from the flat of the flywheel ring gear tooth. " The closer to the tooth, the higher the AC signal. The further away, the lower the AC signal. WESTERBEKE -..y" Engines & Gimeralors...

  • Page 102: Electronic Governor (Adjustments)

    12VDC. The voltage rang';s ± 20% (9.6VDC 12VDC 14.4VDC}.lfvaltage varies above or below these ranges, the controller will not operate and the engine will run in an idle mode until ADJUSTMENT proper voltage supplied to the controller. -..v- WESTERBEKE Engines & Generators...

  • Page 103: Linear Actuator Troubleshooting

    MPU positioned marginally too far away from flywheel e. Check the position of the MPU. teeth giving erratic AC Input to controller. Check resistance value 950 -1000 ohm If problems continue to persist, contact your WESTERBEKE dealer for addllional assistance ..,. WESTERBEKE Engines" Generatore...

  • Page 104: Special Tools - Generator

    SPECIAL TOOLS· GENERATOR Lifting Eye Tool FIELD FABRICATED TOOLS This tool allows a mechanic to safely remove the generator These drawings provide a means by which simple tools can end from ·the engine by attaching this Generator End Lifting made to assist in the removal of the generator end from Eye to the four screw holes located under the control panel.

  • Page 105: Standard Hardware

    Specialized gasket sealers such as HYLOMAR work well in applications requir- Heavily oil all sliding and reciprocating components when assembling. Always ing non-hardening properties. HYLOMAR is particlarty effective on usa clean englna 0111 copper cylinder-head gaskets as resists fuel, oil and water. WESTERBEKE Engines & Generators...
  • Page 106 Miles Per Gallons US (MPG) x .425 " Kilometers Per Liter (Km/L) Kilometers Per Liter (Km/L) x 2.352 = US MPG TEMPERATURE Degree Fahrenheit (OF) = (OC X 1.8) + 32 Degree Celsius (OC) = (OF - 32) x .56 WESTERBEKE Engines Generators &...
  • Page 107 METRIC CONVERSIONS INCHES TO MILLIMETERS MILLIMETERS TO INCHES Inches Inches Inches Inches 381.00 0.5906 25.40 0.0394 50.80 508.00 0.0787 0.7874 635.00 0.9843 76.20 0.1181 101.60 762.00 0.1575 1.1811 127.00 1.3780 889.00 0.1969 254.00 1.5748 1016.00 0.3937 10 MILLIMETERS 1 CENTIMETER, 100 CENTIMETERS 1 METER 39.37 INCHES (3.3 FEET) INCHES TO METERS...

  • Page 108: Index

    Generator ....... 71 Main Stator Windings ....82 Generator with Electronic Governor ..89-90 Voltage Hertz Adjusting ....84 Remote Instrument Panel ....72 Voltage Regulator ....... 88 Glow Plug Testing ...... .41 WESTERBEKE Engines & Generators...
  • Page 109 WESTERBEKE Engines & Generators 1150-7/2010...

This manual is also suitable for:

10.0kw-60hz15.0kw-60hz6.0kw-50hzbtda9.2kw-50hz btd9.4kw-50hzbtdb8.0kw-60hz ... Show all

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