Westerbeke 8.0KW-60Hz Service Manual

Single and three phase marine diesel generators

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Page 1 SERVICE MANUAL 44A FOUR and 3SC THREE MARINE DIESEL ENGINES 8.0KW-60Hz 6.0KW-SOHz BTDA 10.0KW-60Hz 7.SKW-SOHz BTDA 12.5KW-60Hz 9.4KW-SOHz BTDB 1S.0KW-60Hz 12.0KW-SOHz BTDC Single and Three Phase MARINE DIESEL GENERATORS PUBLICATION NO.45100 FIRST EDITION March 2001 WESTERBEKE WESTERBEKE CORPORATION MYlES STANDISH INDUSTRIAL PARK ' ~508-&3-76n...
Page 3 SAFETY INSTRUCTIONS PREVENT BURNS FIRE INTRODUCTION Read this safety manual carefully. Most accidents WARNING: caused by failure to follow fundJJ.mental rules and precau- Fire can cause injury or death! tions. Know when dangerous conditions exist take necessary precautions to protect yourself, your personnel, •...
Page 4 SAFETY INSTRUCTIONS TOXIC EXHAUST GASES ACCIDENTAL STARTING WARNING: Accidental starting can cause injury WARNING: Carbon monoxide (CO) is deadly gas! or death! • Ensure that exhaust system is adequate expel gases • Disconnect the banery cables before servicing the engine/ discharged from the engine.
Page 5 SAFETY INSTRUCTIONS c10lhing ABYC, NFPA AND USCG PUBLICATIONS FOR • not wear loose or jewelry whe servicing equipment: tie back long hair and avoid weari ng loose INSTALLING DIESEL ENGINES jackets, shins. sleeves, rings, necklaces bracelets that Read the following ABYC, NFPA and USCG publicalions could be...
Page 6 INSTALLATION When installing WESTERBEKE engines and generators important that strict attention be paid the following information: CODES AND REGULATIONS be complied with Strict federal regulations. ABYC guidelines. and safety codes must when installing engines generators marine environment. SIPHON· BREAK installations...
Page 7 Single and Three Phase MARINE DIESEL GENERATORS PUBLICATION NO.45100 FIRST EDITION March 2001 WESTERBEKE WESTERBEKE CORPORATION· MYLES STANDISH INDUSTRIAL PARK 150 JOHN HANCOCK ROAD, TAUNTON, MA 02780-7319. TEL 1-508-823-7677 FAX 1·508 884·9688· WEBSITE: WVtW.WESTERBEKE.COM ..,""~,.". NMMA Member National Marine Manu/acturers Association...
Page 8 Shut down the unit and do not restart until It has been Inspected and repaired. This WARNING DECAL is provided by WESTERBEKE and should be fixed to bulkhead near your engine or generator. ~S1FRBEKEalso recommends installing CARBON MONOXIOE DE1FCTORS in the living/sleeping quarters of your vessel.
Page 9: Table Of Contents
TABLE OF CONTENTS Parts Identification/Engines ......... Service Data-Standards And Iimits ....52 Parts Identification/Generators ......3 Special Tools - Engine ........54 Introduction ............. 4 Wiring Diagram - Engines ......... Engine Troubleshooting ........5 Wiring Schematic - Engines ......57 Testing For Overhaul ...........
Page 10: Parts Identification/Engines
PARTS IDENTIFICATION 44A/35C THREE PRESSURE CAP WATER INJECTED EXHAUST THERMOSTAT 20A CIRCUIT WATER HEATER REAR FRONT ZINC ANODE OIL FILL OPTIONAL V-ORIVE TRANSMISSION ILLUSTRATED COOLER RIGHT SIDE AIR INTAKE/AIR FILTER FRONT _F'REfIEAT SOLENOIO LIFT PUMP DC ALTERNATOR ~ffB~~i;~(;?-""""'~---FUEL FILTER RAW WATER REAR UNIT 1.0_ START...
Page 11: Parts Identification/Generators
PARTS IDENTIFICATION/GENERATORS GENERATOR EMERGENCY STOP SWITCH LEFT SIDE CONNECTION TO BREAK _o"nu" AITI'RN,ATOIL ,-,qt---+---EXHA.UST ELBOW """'r----++---S"rART SOLENOID ~:STAF!TER MOTOR HEAT REAR OIL PAN MANIFOLD PRESSURE CAP "UULA~I FILL PREHEAT OIL FILL RIGHT SIDE ASSEMBLY AIR INTAKE SILENCER & FILTER PUMP OIL FILL BACK·END ENGINE BLOCK DRAIN PLUG...
Page 12: Introduction
Ser. #UOOOO,EI02 OF THE FURNISHING OR USE OF SUCH SOFTWARE. 2/5/200 Expires WESTERBEKE customers should keep in mind the time span between printings of WESTERBEKE product software and the unavoidable existence of earlier WESTERBEKE The WESTERBEKE serial number is an alphanumeric product software.
Page 13: Engine Troubleshooting
ENGINE TROUBLESHOOTING The following troubleshooting chart describes certain NOTE: The engine's electrical system is protected by a 20- problems relating to engine service, the probable causes of ampere manual reset circuit breaker. The preheat solenoid is these problems, and the recommendations to overcome mounted on the same bracket.
Page 14 1. Excessive engine oil. 1. Correct oil level. 2. Excessive rise of oil into combustion chamber. a. Poor piston contact. a. Check. b. Seized piston ring. b. Replace or clean. c. Excessive piston-to-cylinder clearance. c. Replace or correct. (contmued) WESTERBEKE Engines & Generators...
Page 15 ENGINE TROUBLESHOOTING PROBLEM PROBABLE CAUSE VERIFICATION/REMEOY SMOKY EXHAUST (coni.) WHITISH OR PURPLISH (cont.) d. Worn valve stern and valve guide. d. Replace. e. Low engine oil viscosity. e. Replace. Excessive oil pressure. Correct. 3. Injection timing is too late. 3. Adjust. 4.
Page 16 ENGINE TROUBLESHOOTING PROBABLE CAUSE PROBLEM VERIFICATION/REMEDY ENGINE KNOCKS WITHOUT MUCH SMOKE KNOCKING 1. Main engine troubles. a. Overheated cylinder. a. See OVERHEATING; LOW OUTPUT b. Carbon deposits in cylinder. b. Clean. 2. Too early injection timing. 2. Correct. 3. Correct. 3.
Page 17: 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 detennined by various conditions such as lowered engine of these parts.
Page 18: Engine Disassembly
ENGINE DISASSEMBLY GENERATOR ENGINE DISASSEMBLY Disconnect the AC wiring and unplug the engine's DC Take the following precautions: wiring harness at the generator control paneL Remove the • Clean the exterior of the engine of any deposits of battery cables from the engine and tape over the tenninals. dirt and oil.
Page 19 ENGINE DISASSEMBLY 15. Remove goven-lOr assembly. 23. Remove tbe cylinder head assembly. Lift the cylinder head straight up with a hoist. a. Remove the tie rod cover. h. Remove the spring from the tic rod with pliers to NOTE: the gasket seized and the cylinder head connor disconnect the tie rod from the fuel injection pump.
Page 20 ENGINE DISASSEMBLY 27. Remove the rear plate. The rear plate is doweled in VALVE SPRING position. Pull 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 21 ENGINE DISASSEMBLY TIMING GEARS ORDER OF DISASSEMBLY NUMBERS INDICATE THE SUGGESTED ORDER OF INJECTION DISASSEMBLY PUMP CAMSHAFT IDLER GEAR REMOVE 10 THRU 12 AS AN ASSEMBLY I/I~ FUEL INJECTION PUMP CAMSHAFT GEAR OIL PUMP GEAR FRONT PLATE CAMSHAFT 7T1MING GEAR CASE CRANKSHAFT PULLEY Engines &...
Page 22 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 23 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 hammer. WESTERBEKE Engines Generators &...
Page 24: Inspection
INSPECTION CYLINDER HEAD AND VALVE MECHANISM 1. Cylinder head. Using a heavy accurate straight edge and a feeler gauge, check the bottom face for warpage in three positions, lengthwise, two crosswise and two widthwise as CHECK shown in the illustration. If warpage exceeds the limit, /THREADS reface the bottom face with a surface grinder.
Page 25 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 (47mm) LIMIT 1.81 (46mm) MEASURING DIRECTIONS SPRING SQUARE NESS STANDARD 1.5' MAXIMUM SPRING TEST FDRCE .
Page 26 STANDARD 0.051 ·0.071 in (1.3 '1.8mm) replace the cylinder head assembly. LIMIT 0.098 in (2.5mm) VALVE SINKAGE STANDARD 0.020 ± 0.0098in (0.5 ± 0.25mm) LIMIT 0.059 in (1.5mm) WESTERBEKE Engines Generators &...
Page 27 INSPECTION f-L.~~.nu.",u REFACING THE VALVE~EATS orO;) _ , - ? '00 ~ '-"0 r-;?f/O/ i;;) _ _ _ _ COMBUSTION JET c. After refacing the valve seat, put Japping compound 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 28 ENGINE INSPECTION TIMING GEARS AND FLYWHEEL· INSPECTION POINTS GASKET REPLACE INJECTION PUMP CAMSHAFT BEARING CHECK FOR NOISE (SPINNING) ANOWEAR GEARS CHIP~S CHECK TEETH FOR WEAR, BURRS, OR GASKET REPLACE CAMSHAFT CHECK FOR BEND OR DAMAGE TO THE LOBES r<-------TIMING GEAR CASE INSPECT FOR CRACKS/DISTORTION GASKET OIL SEAL...
Page 29 INSPECTION 10. Camshaft (3) Measure the lobe height and base circle as shown in the illustration. Subtract the base circle from the a. Measure the diameter of the journal and the bore in the lobe height to find the lobe lift. If the lobe lift bushing for the shaft find the clearance as shown in exceeds the limit, replace the camshaft.
Page 30 INSPECTION 13. Idler gear. 15. Pistons, piston rings and piston pins. a. Measure the bore in the idler gear for the shaft and the a. Measure the diameter of the piston at its skirt in a diameter of the shaft to find the clearance. If the direction transverse to the piston pin with a micrometer clearance exceeds the limit.
Page 31 ENGINE INSPECTION CYLINDER BLOCK, CRANKSHAFT, PISTONS AND OIL PAN· INSPECTION POINTS CYLINDERS PISTON RINGS INSPECT FOR CRACKS, -='=- OvUNCO, CHECK END CLEARANCE ;o--~:" OR RIDGES AT TOP OF ~-., AND INSPECT FOR WEAR 8 3 ' RING TRAVEL, AND DAMAGE CYLINDER BLOCK CHECK FOR WARPAGE ON TOP FACE,...
Page 32 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 clearance between the "k. .. (1) Measure "C'. and If "C'.
Page 33 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 crankpin fillets to a radius of 0.098 in to the big end of the connecting rod and tighten the (2.5mm).
Page 34 INSPECTION (3) If the clearance exceeds the limit, install a new 17. Cylinder Block bearing and check the clearance again. 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 35: Assembly
ASSEMBLY CYLINDER BLOCK, CRANKSHAFT, PISTONS AND OIL PAN PISTON COAT THE ENTIRE SURFACE WITH ENGINE OIL CAMSHAFT APPLY ENGINE OIL TO JOURNALS AND LOBES '" BEARINGS " LUBRICATE THE INSIDE SURFACES WITH ENGINE OIL f;\~ ~"" BEARINGS ® LUBRICATE THE INSIDE SURFACES WITH ENGINE OIL CONNECTING ROO CAP NUTS...
Page 36 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 Loctite 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 37 ASSEMBLY 8. Connecting rod cap installation. a. Push the piston into position until the big end of the ""~-- ~ ~NO.1 connecting rod is put into position over the crankpin. ---r Then turn the crankshaft 180 while pushing on the top COMPRESSION of the piston.
Page 38 ASSEMBLY TIMING GEARS AND FLYWHEEL NEW GASKET THRUST PLATE BOLT TORQUE 1 Kg-m ± 10.8 1 Nm ± OIL SEAL LUBRICATE WITH ENGINE OIL '\CAMSHAFT APPLY ENGINE OIL TO JOURNALS AND LOBES NEW GASKET GASKET BACK PLATE BOLT . IIJ;IIJI" 1 Kg-m ±...
Page 39 Make sure the camshaft rotates freely. Check the end NOTE: Install the starter to the rear plate before installing the play for the camshaft. plate to the cylinder block for convenience of rear plate instal/ation. WESTERBEKE Engines & Generators...
Page 40 ASSEMBLY 23. Flywheel installation. 24. Cylinder head bottom face cleaning. Scrape the gasket from the bottom face of the cylinder head. a. Install a safety bar (M12x 1.25) in the rear end of the crankshaft. NOTE: After scraping the gasket, rub off gasket remnants from the face with an oilstone smeared with engine oil and b.
Page 41 ASSEMBLY 29. Installation of the cylinder head. Place the cylinder 37. Fuel injection nozzle installation. head in position on the cylinder block, making sure the a. Put the gasket on the nozzle. guide bolts are all in alignment with their respective bolt h.
Page 42 Put the belt in position on the pulley. Move the alternator away from the engine to make an adjustment to the belt. c. Tighten the bolts. d. Make sure the tension of the belt is correct, about 1I2"deftection at the center with pressure. WESTERBEKE Engines Generators &...
Page 43: Exhaust Manifold/Heat Exchanger
They will coolant recovery tank tubing. also service transmission and engine oil coolers. 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.
Page 44: Fuel Injection Pump
Keep the disassembled injection pump parts in clean diesel fuel. CAUTION: Anytime the injection pump is disassembled, new O-ring must be instal/ed. Make sure the threads of the delivery valve holder do not cause damage to the O-rings . WESTERBEKE ..v" Engines & Generators...
Page 45 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 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 46: Governor
GOVERNOR DISASSEMBLY SEQUENCE AND INSPECTION SPRING PIN -<------2 TIE ROD "1-<<--_ _ 0 SPEED CONTROL LEVER CHECK SHAFT FOR DEFECTS TORQUE SPRING AND WEAR Assembly. SPEED CONTROL a. Install the levers in position. LEVER --------.., b. Put the O-ring on the governor shaft. c.
Page 47: Fuel Injection Timing
FUEL INJECTION TIMING Preparation Adjustment a. Close the fuel shut-off valve. a. If 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. An cylinder head and injection pump. increase or decrease of the shims by 0.1 mm (0.004 in) will vary the timing 1°.
Page 48: Fuel Injectors
The copper washers should not be reused. Replace Y2~7? with new washers. 2. Tighten the nozzle on the cylinder head to the specified torque. i!!~': tI!\'I\\' NOZZLETORQUE 4Ib-" (5.5 0.5 kgf·m) ± ± GOOD NOZZLE RECONDITION / REPLACE -----'----' WESTERBEKE ..v' Engines & Generators...
Page 49: Glow Plug Testing
GLOW PLUG TESTING GLOW PLUGS c. Re-install the plugs in the engine and test them again. The plugs should get very hot (at the terminal end) within The glow plugs are wired through the preheat solenoid. 7 to 15 seconds. If the plugs don't heal up quickly, check When PREHEAT is pressed at the control panel this solenoid for a short circuit.
Page 50: Starter Motor
STARTER MOTOR No-Load Test DESCRIPTION The starter can be roughly divided into the following sections: 1. Connect the ammeter, voltmeter, and battery to the starter as illustrated. • A motor section which generates a drive power. • An overrunning clutch section which transmits an arma- 2.
Page 51 STARTER MOTOR 4: Retum test: With a battery connected to the solenoid ter- minal M (-) and to the starter body, manually pull out the pinion fully. The pinion must return to its original position qs;;:~~ CONNECTOR OFF ATTRACTION TEST ~-:-.._~:-- when released from holding by hand.
Page 52 STARTER MOTOR STARTER INSPECTION Solenoid Inspect the solenoid for continuity between tenninals Sand M and ·between tenninals S and body. No continuity should be found between Sand M. Continuity should be found between S and the body and M and the body. Brush and Brush Holder Insllec1lion 1.
Page 53 STARTER MOTOR COMMUTATOR MICA UNDERCUT STARTER ADJUSTMENT AND REASSEMBLY Measure the undercut of mica insulation between the adja- cent segments. undercut exceeds the limit, recondition the CAUTION: Before installing, thoroughly clean the mica or replace the armature. starter flange and mounting surfaces, remove all oil, old STANDARD 0.020 (0.5...
Page 54: Raw Water Pump
WATER PUMP Disassembly 2. Install the shaft into the bearings. Support the bearings at their center races. Push the shaft into the bearings, push- will The pump, as removed from the engine, have hose ing at the impeller drive slot end using the base of the attachment nipples threaded into its inlet and outlet ports.
Page 55: Engine Adjustments
ENGINE ADJUSTMENTS VALVE CLEARANCE ADJUSTMENT Make the following adjustments when the engine is cold. a. Remove the cylinder head cover. b. Slightly loosen the cylinder head bolts and retighten them to the specified torque in the number sequence shown below. TIGHTENING TORQUE 4lb·ft (88 5 Nm)
Page 56: Testing Engine Compression
ENGINE ADJUSTMENTS TESTING ENGINE COMPRESSION AIR INTAKE FILTER/SILENCER Make certain 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 may 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 the oil pressure gauge on the instrument panel. During nonna} operation, the oil pressure will range between 40 and 60 psi (2.8 and 4.2 kg/cm'). OIL PREi,SUFIE. NOTE: A newly started, cold engine can have an oil pressure SEND OR reading up to 60 psi (4.2 kg!cm"), A wanned engine can have...
Page 59: Adjusting Idle Speed
ENGINE ADJUSTMENTS ADJUSTING THE IDLE SPEED Drive Belt Adjustment a. Loosen the locknut on the idle adjustment bolt on the Proper inspection, service and maintenance of the drive belts fuel injection pump. is important for the efficient operation of your engine. b.
Page 60: Service Data-Standards And Iimits
SERVICE DATA - STANDARDS AND LIMITS Repair Limit Component Standard Component Standard Repair Limit mm (inches) mm (inches) mm (inches) mm (inches) ENGINE COMPONENTS ENGINE COMPONENTS Compression pressure """, ..427 psi at 290 rpm ....384 psi Lobe height of fuel injection (30.0 kg/cm') (27.0 kg/em') pump camshaft .......
Page 61 SERVICE DATA - STANDARDS AND LIMITS Component Specified Value / Standard Repair Limit inches(mm) inches(mm) Sealant Mating Part Component - - - - - - - - - - - - - - - - ENGINE COMPONENTS THREAD PARTS Crankshaft loctite Stop solenOid...
Page 62: Special Tools - Engine
CAMSHAFT BUSHING INSTALLER [033583J FOR REMOVING AND INSTAlliNG THE FRONT CAMSHAFT BUSHING 033583 THE ABDVE TODLS ARE AVAILABLE FROM YOUR WESTERBEKE OR MITSUBISHI DEALER. NOTE: IN ADDiTION TO THESE TOOLS THE FOLLOWING ADDiTIONAL TOOLS WDULD BE NEEDED: BEARING PULLER. VALVE SEAT CUTTER TOOL, PROPER DIAL GAUGES.
Page 63 44A FOUR AND 35C THREE TORQUE SPECIFICATIONS MAJOR BOLTS AND NUTS TORQUE Clamp Width Bolt or Nut Diameter Pitch across flats length kg -m ft - Ib Alternator Bracket 3.8-5.3 27-38 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...
Page 64: Wiring Diagram - Engines
135e 44A FOUR THREE MARINE ENGINE WIRING SCHEMATIC #39144 ~'l"DC H .. ATU N6TES: SOL. I. TIIII ,ItOIIUCT II 'lOnCTn II II,,"Ulll I[sn CIRCUiT IIIUItER Lo<: .. 1£O "EAM TN[ .nAlTU. [XCEUIV( CUllEn WILL ,.tUlE THE 8R(AKE~ TO Tkl, AND HIE nlillE W'1.l '------------- 1KJft.
Page 65: Wiring Schematic - Engines
135e 44A FOUR THREE MARINE ENGINE WIRING DIAGRAM #39144 -" j,..1.£'LLU,\o!.~ Nm: An on-off switch should be installed in this circuit to disconnect the starter from the battery in "~ an emergency and when " leaving the boat. Twelve volt engine starters typically draw 200 to 300 PANEL amps when cranking.
Page 66: Specifications - 44A Four
SPECIFICATIONS 44A FOUR ENGINE FUEL SYSTEM SPECIFICATIONS Engine Type Diesel, four-cycle, four-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 .. Fuel Injection Pump In-line plunger type (BOSCH). Displacement 107.3 cubic inches (1.758 liter) Fuel Injection Timing...
Page 67: Specifications - 35C Three
SPECIFICATIONS 35C THREE ENGINE SPECIFICATIONS FUEL SYSTEM Engine Type Diesel, fourvcycle, 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 .. Fuel Injection Pump In-line plunger type (BOSCH). Displacement 80A cubic inches (1.318 liter) Fuel Injection Timing...
Page 68: Dc Electrical System (Alternator)
DC and AC converters, and shut down the engine TESTING THE before performing DC testing. No AC tests should be ~ea;;;§i~Fei~ ALTERNATOR VOLTAGE made without proper knowledge of AC circuits. (IGNITION ON • ENGINE OFF) ~::::::::::::~ST~A~RT:"ING "'"'" WESTERBEKE BATTERY Engines Generators & GROUND...
Page 69 DC ELECTRICAL SYSTEM Checking the Service Battery 7. Now check the voltage between the alternator output tenni- nal (B+) and ground. If the circuit is good, the voltage Check the voltage of the service battery. This battery should at the alternator will be the sarne 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 51 A MANOO ALTERNATOR DISASSEMBLY AND TESTING WARNING: A failed alternator can become very hot. 00 not touch until the alternator has cooled down. PULLEY REAR HOUSING WARNING Before starting the engine, make certain that everyone is clear of moving parts! Keep away from sheaves and belts during test procedures.
Page 71: Mando Alternator Service
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. WESTERBEKE Engines Generators &...
Page 72 MANOO ALTERNATOR SERVICE 10. Place an oversized V-belt around the pulley and fasten REMOVE ALTERNATOR the pulley in a vise. Disconnect the negative (-) battery ground cable. 11. Use a 7/8 in. box wrench to loosen and remove the 2. Disconnect the wiring leads. pulley nut.
Page 73 MANOO 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.
Page 74 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.
Page 75 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 FINGERS the rotor leads clear the steel blocks.
Page 76 16. Install the Phillips screw for the brush/regulator assembly cover. TORQUE: 25 - 351b-1t (2.8 - 5.1 17. Install the capacitor. 18. Install the terminal nuts. 19, Install the jumper. 20. Install the last terminal nut. WESTERBEKE Engines & Generators...
Page 77: Generator Wiring Diagram
GENERATOR WIRING DIAGRAM #44735 .,,""" i!..Ll.0 ~t~U.'!.L;_~~ Sls04tllA;URf ,,,,,. WATER 0"<>' ,» ", "0 "~ "-\ r<P • .oW '" 'WG5 ." ,.0 " ," ~I T~~Ii~:QR ~~~_,4~Q~ ." " " *40= !t< Qq~",", ~QI E~QIQ '1.1/:1 IIDm "'~'" ll.MlJ.ll ,;f-8 ll.1.1..Qj TfMPE~~TUBf...
Page 78: Generator Wiring Schematic
GENERATOR WIRING SCHEMATIC #44735 8A'T(~~ '2-(4VDC BAIT[Rr C I Reu I : SWITCH 6R(~~[R ART( R r - f---'L---{ L_-.! SURlER ISOL £ GLOWf'lIJGS r - - EMERGENCT STOP PREHEAT SWITCH ISOLE~OI~ AL TERNA TOR " lB~.3 I - START :>-- ~"'-----------<>---+-----------"'.1'·f.!"."------------~~r_----~-------;"O:_EL 161'1...
Page 79: Remote Panel Schematic
REMOTE INSTRUMENT PANEL #44329 STOP SWITCH PREKEAT SWITCH START SWITCH STOP SW ITCH < " .:1"16 REDfVL ~122 R::D 16 elK '-ty ttl6 RED/WHT f(lJ(z)V r0~C2 16 WH, CD CD C:..:; ®®@ c::o C I 0 RED PREHEAT SWITCH START SWITCH #16 WHTIREO MALE CABLE...
Page 80: Specifications - Generator
Operating Oil Pressure 50 - 60 psi (3.5 - 4.2 kg/cm') System Capacity 5.0 US qts (4.7 liters) (engine hot) (Fresh Water) Oil Grade API Specification CF or CG-4, SAE 30, 10W-30, 15W-40 REVISED MAY 2002 WESTERBEKE Engines Generators &...
Page 81 SPECIFICATIONS 10.0KW BTDA AC GENERATOR (Single Phase) AC GENERATOR (3 Phase) Sing Ie Phase Brushless, four-pole, revolving field. Brushless, six-pole, revolving field. Sealed Three Phase Pre-lubricated, single-bearing design. 10.0 Kw - 60 Hertz lubricated, single-bearing design. 12 Lead Reconnectable, single-phase transformer 7.5 Kw - 50 Hertz reconnectable for low voltage WYE, high voltage Delta.
Page 82 SPECIFICATIONS 15KW BTDCI12.5KW BTDB GENERAL FUEL SYSTEM Engine Type Diesel, four~cycJe, four-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. Fuel Injection Pump In-line plunger type (BOSCH). Displacement 107.3 cubic inches (1.758 liter) Nozzle...
Page 83 SPECIFICATIONS 15KW BTOC AC GENERATOR (Single Phase) AC GENERATOR (3 Phase) Brushless, six-pOle, revolving field. Sealed Single Phase Brushless, four-pole, revolving field. Three Phase 15.0 Kw - 60 Hertz lubricated, single-bearing design. 12 Lead Pre·lubricated, single-bearing design. Reconnectable, single-phase transformer 12.0 Kw - 50 Hertz reconnectable for low voltage WYE, hiQh regulation (optional solid-state voltage...
Page 84: Bt Generator Single/Three Phase
BT GENERATOR SINGLE/THREE PHASE Ths generator is a four-pole, brushless, self-excited generator A circuit breaker is installed on all WESTERBEKE genera- tors. This circuit breaker will automatically disconnect gener- which requires only the driving force of the engine to pro- duce AC output.
Page 85: Stud Internal Wiring Schematic
COMPOUND TRANSFORMER WINDlNGL.019-.021Q 8T GENERATOR SINGLE PHASE 12 STUD COMPOUND TRANSFORMER AUXILIARY WINDINGS 4.0-4.5Q COMPO UNO G BRIDGE RECTIFIER TRANSFORMER AC TERMINAL BOARO BRIDGE BREAKER RECTIFIER 'em,e"OT '''''lem1" TERMINAL 1 & 4 CONNECTION WESTERBEKE 1-2+3 -.Y" [VOLTAGE HERTZ Engines & Generators CONNECTION]...
Page 86: Internal Wiring Schematic 6 Stud
BT GENERATOR/SINGLE PHASE 10KW·15KW GENERATORS r----------l r-------------------l Hz TERMINAL '00: II : * :!f%f- ~-----------------~ 60c'yc. A.V.R. eye. REOf WHITE (TO HEFn7NOLTS BAR) PLUG "EO SUD: ~SLACK/WHrrE' ""''" , ".-- BLtJEIWHrTe ..+ .. (TO PIN #6TERM.. (TO SELECTOR SWlTCH) GREEN BLUE IWHITE YEu.cm IWHITE...
Page 87: Bt Generator Voltage Regulator
3. Increase the engine speed to its nonnal speed (frequency). The red "LED" light will go out and the AC voltage out- Stab Volt put will return to nonnal. With the above adjustments made, the regulator should func- tion normally. VOLTAGE REGULATOR DIAGRAM WESTERBEKE -.,.yo Engines Generators &...
Page 88: Bt Generator Troubleshooting
& ~~RE~D====~+~ k~~~~ '" '" *~'" GREEN ,-- GReeN L-... F) ..--', => GREEN => GREEN YELLOW / YELLOW BLACK ~~/======~B~LA~C~K======~~~~====~~========~~ BLACK BLUE BLACK 60eye. A.v.R. BLUE L.~Y~EL~L~OW~---------------~ ~--------------~~--~ 50 eye. 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 problem/fault may lie.
Page 90 BT GENERATOR TROUBLESHOOTING/SINGLE PHASE CURRENT RECTIFIERS E. A.C. Tenninal Board F. Selector Switch ARE CONFIGURED SLIGHTLY DIFFERENTLY BUT TEST H. Optional AVR POINTS ARE THE SAME. G. Bridge Rectifier ~---2 The model code number is found stamped in the generator housing on a flat surface above the rear generator carrier bearing.
Page 91 PLUG TERMINAL TWO "Ktt'Nl"J--\-{.::::5§~~ BLA.CI<--t"N BLUE BLUE VOLTAGE/HERn CONNECTION BAR -i--.:'O:'i'l"'~ YElLOW ",JI,,",JJ---GRIOEN BLACK AVR PLUG RI'Cn~IER) (TO BRIDGE ':..;)!J-- BLACK (TO HERTZ BAR) SELECTOR SWITCH (TO SELECTOR SWITCH) WESTERBEKE BLACK Engines & Generators (TO SELECTOR SWITCH) REVISED MAY 2002...
Page 92 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 REVISED MAY 2002...
Page 93 BT GENERATOR TROUBLESHOOTING/SINGLE PHASE No-Load Voltage Adjustment 115V 50Hz 120V 60Hz 120/240V 60Hz 230V 50Hz ® ® Voltage adjustment is made with the generator regulation if" being governed by the compound transfonner. ® 7 ----II' 1. The selector switch must be in the COMP position. 2.
Page 94 JUMPER /5 REQUIRED BETWEEN LOAD CONNECTIONS, NOTE: For ouput leads from the AC tenninal block use terminal ends for 114" 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 1-------' DSTATOR -=--_~'---~.11 I-- - - - - - - - - - -., 12- .-----+-1 .-r------.9 ~----+_...
Page 96 BT GENERATOR TROUBLESHOOTING/3 PHASE NOTE: AC generator troubleshooting must be peifonned with the engine operatil7. at PROBABLE CAUSE FAULT 4. Open in exciter NO AC VOLTAGE OUTPUT AT NO LOAD. 1. Short or open in the main stator winding. stator winding. 2.
Page 97: Special Tools - Generator
ROUND TIP 12" 15.5 mm Drill ,..,-----(304.8 m m ) - - - - - - - -..,. 1-1/4" (31.75 mm) Deep 1.5 Pilch Tap 1" (25.4 mm) Deep PROPER USE OF HOUSING PULLER Material: Aluminum WESTERBEKE Engines Generators &...
Page 98: 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 particlarly effective on use clean engine oil! cy!inder~head copper gaskets as resists fuel, oil and water. WESTERBEKE Engines Generators &...
Page 99 STANDARD AND METRIC CONVERSION DATA LENGTH-DISTANCE x 25.4 x .0394 Inches (in) = Millimeters (mm) = Inches Feet (ft) x .305 = Meters (m) x 3.281 = Feet x 1.609 .0621 Miles = Kilometers (km) x = Miles VOLUME Cubic Inches (in') x 16.387 = Cubic Centimeters x .061...
Page 100: Metric Conversions
Pints Liters Liters Pints Liters Pints Pints 2.11 0.47 2.84 12.68 4.23 14.79 0.95 3.31 3.79 6.34 16.91 1.42 4.26 8.45 19.02 1.89 4.73 10.57 21.13 2.37 TEMPERATURE 105 140 175 212 80 100 °C WESTERBEKE -..v' Engines Generators &...
Page 101 Water Pump-Raw ......46 Wiring Schematics and Diagrams Exciter Rotor Field ....84 Main Stator Windings ....83 Engine ......56-57 Voltage Hertz Adjusting ....85 Generator ......69 Voltage Regulator ..... 79 Remote Instrument Panel ....71 WESTERBEKE Engines & Generators...
Page 104 WESTERBEKE Engines & Generators 1042-WM-DW-112001...

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Westerbeke 8.0KW-60Hz Service Manual

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