Westerbeke 22.0KW EDE-60Hz Service Manual
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Westerbeke 22.0KW EDE-60Hz Service Manual

Westerbeke 22.0KW EDE-60Hz Service Manual

D-net diesel generators, single and three phase
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D
SERVICE MANUAL
D-NET DIESEL GENERATORS
22.0KW EDE
17.0KW EDE
--
-
-
17.0KW EDE
13.5KW EDE
at 60 Hertz
at 50 Hertz :
SINGLE AND THREE "PHASE
FIRST EDITION
JULY 2008
~
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: WWWWESTERBEKE.COM
NAII'A
Member National Marine Manufacturers Association
... WO.

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  • Page 1 60 Hertz at 50 Hertz : SINGLE AND THREE "PHASE FIRST EDITION JULY 2008 WESTERBEKE WESTERBEKE CORPORATION· MYLES STANDISH INDUSTRIAL PARK 150 JOHN HANCOCK ROAD' TAUNTON 02780-7319' TEL. 1-508-823-7677 ---- FAX 1-508-884-9688' WEBSITE: WWWWESTERBEKE.COM NAII'A Member National Marine Manufacturers Association...
  • Page 2 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 Installing CARBON MONOXIDE DETECTORS in the living/s/eeping quarters of your vessel.

  • Page 3: Table Of Contents

    TABLE OF CONTENTS SERIAL NUMBER LOCATION Testing for Overhaul ............Engine Troubleshooting ........... The engine's model number and serial number are located on Disassembly Procedures ..........a nameplate mounted on the side of the engine's manifold. The engine's serial number can also be found stamped into Assembly Procedures ............

  • Page 4: Testing For Overhaul

    TESTING FOR OVERHAUL Precautions for Disassembly and Reassembly HOW TO DETERMINE ENGINE OVERHAUL PERIOD When servicing an engine,keep in mind the fonowing Cause of Low Compression precautions. Generally, the time at which an engine should be overhauled Disassembly is determined by various conditions such as lowered engine 1.

  • Page 5: Engine Troubleshooting

    ENGINE TROUBLESHOOTING The following troubleshooting chart describes certain problems relating to engine service, the probable causes of these problems, and the recommendations to overcome these problems.This chart may be of assistance in determining the need for an engine overhaul. PROBLEM PROBABLE CAUSE VERIFICATION/REMEDY HARD STARTING...
  • Page 6 ENGINE TROUBLESHOOTING VERIFICATION/REMEDY PROBLEM PROBABLE CAUSE LOW OUTPUT OVERHEATING {tont.} Add coolant. 1. Low coolant level. 2. Loose V-belt 2. Adjust or replace V-belt. 3. Incorrect injection timing. 3. Adjust injection timing. 4. Low engine oil level. 6. Add engine oil. EXCESSIVE OIL OIL LEAKAGE CONSUMPTION...
  • Page 7 ENGINE TROUBLESHOOTING PROBLEM PROBABLE CAUSE PROBLEM PROBABLE CAUSE Low oil pressure. 1. Low oil level. Blue exhaust smoke Lube oil is diluted. discharge from the Wrong SAE type oil in the engine. 2. High lube oil level. engine. 3. Faulty or wrong type oil filter. 3.

  • Page 8: Disassembly Procedures

    DISASSEMBLY PROCEDURES GENERATOR Always observe the used oil as it is removed. A yellow/gray emulsion indicates the presence of water in the oiL Although PISTON this condition is rare, it does require prompt attention to The piston's skirt is coated with molybdenum disulfied, prevent serious damage.

  • Page 9: Assembly Procedures

    ASSEMBLY PROCEDURES GENERAL INFORMATION Surface Preparation Thoroughly remove all substances deposited on the gasket application surfaces using a gasket scraper or wire brush. Check to ensure that the surfaces which the silicone gasket is to be applied is flat. Make sure that there are no oils, APPLY GREASE greases and foreign substances deposited on the application surfaces.

  • Page 10: Assembly Instructions

    ASSEMBLY INSTRUCTIONS Be aware of these common problems that can occur during ENGINE TUNING OPERATION assembly. After re-assembly, the engine must be tuned. This will ensure Insufficient Lubrication. Heavily oil sliding and that the engine operates at its maximum efficiency. Fill the reciprocating parts, lightly oil head bolts and other fasteners, engine cooling system with an antifreeze mixture and the...

  • Page 11: Disassembly/Assembly

    DISASSEMBLY/ASSEMBLY CYLINDER HEAD COVER 1. Remove the top of each glow plug and remove the glow plug strap. 2. Remove the breather hose. 3. Remove the head cover bolts. 4. Remove the cylinder head cover. HEAD COVER SCREWS BREATHER. HOSE INJECTION PIPES Loosen the scerws on the pipe clamps.
  • Page 12 2.4 - 2.8 Kgf-m 17.4 - 20.3 ft-Ibs E!li ~m 00e~d 4 Cylinder A TO N OR R: TO TIGHTEN ER HEAD GROOVE MAKER CERTAIN THE PUSH RODS ARE PROPERLY ENGAGED WESTERBEKE \ IN THE GROOVES WHEN REASSEMBLINGV' Engines & Generators...
  • Page 13 DISASSEMBLY /ASSEMBLY INJECTION PUMP 1. Remove the stop solenoid and the hi-idling body. 2. Remove the engine stop lever and stop solenoid guide. 3. Remove the fuel injection pump assembly. NOTE: Before removing the injection pump assembly, be sure to remove the stop solenoid, hi-idling body, engine stop lever and stop solenoid guide.
  • Page 14 DISASSEMBLY ASSEMBLY INJECTION INJECTION PUMP (CO NT.) PUMP STOP SOlENOID-4::::::='~~~ GOVERNOR SPRINGS AND SPEED CONTROL PLATE NOTE: Use a l.2mm diameter hard wire with its end hooked, SPECIAL TOOL overall length of200mm (7.87 in). The tip of a wire is bent t WIRE HOOK like a hook to grasp the governor springs.
  • Page 15 DISASSEMBLY/ASSEMBLY GOVERNOR SPRINGS AND SPEED CONTROL PLATE (CO NT.) SPECIAL TOOL SPECIAL _ _ PEED CONTROL STEP 10 STEPS LEVER TOOL SPRING STEP LARGE SPRING DRIVE PULLEY 1. Lock the flywheeL Remove drive pulley mounting nut. 3. Remove the drive pulley with gear puller. Remove the feather key When Reassembling Apply grease...
  • Page 16 DISASSEMBLY ASSEMBLY CAM GEAR IDLE GEAR GEAR CASE 1. Remove the hour meter gear case (if equipped). 2. Remove the gear case. 3. Remove the O-rings. When Reassembling Apply liquid gasket (Three bond 1215 or equivalent) INJECTION PUMP GEAR CRANK GEAR both sides of the hour meter gear case gasket.
  • Page 17 DISASSEMBLY ASSEMBLY CAMSHAFT SET BOLT FORK LEVER HOLDER FUEL CAMSHAFT AND FORK LEVER ASSEMBLY CAMSHAFT 1. Remove the fuel feed pump. 1. Remove the camshaft set bolts and draw out the camshaft. 2. Detach the fuel camshaft retainer. When Reassembling 3.
  • Page 18 DISASSEMBLY ASSEMBLY PISTONS CRANK GEAR Completely clean the carbon out of the cylinders. 1. Draw out the crank. gt<ar with a puller. 2. Remove the connecting rod cap. 2. Remove the feather key. 3. Tum the flywheel to bring the piston to top dead center. 4.
  • Page 19 DISASSEMBLY ASSEMBLY PISTON RING AND CONNECTING ROD 1. Remove the piston rings using a piston ring tooL 2. Remove the piston pin and separate the connecting rod from the piston. 0.79 rad (45 ") 0.79 rad (45 0) When Reassembling -L--f--l'c---r--.L.T----I-t-l-PISTON PIN HOLE 1.
  • Page 20 DISASSEMBLY ASSEMBLY BEARING CASE COVER PISTON RING AND CONNECTING ROD (CONT.) 1. Remove the bearing case cover mounting screws. Remove the inside screws first and then the outside screws. 2. Screw the two removed screws into the screw hole of the EXPANDER JOINT bearing case cover to remove it.
  • Page 21 DISASSEMBLY ASSEMBLY CRANKSHAFT NOTE: Before disassembling and during reassembly, check the side clearance of the crankshaft. 4 Cylinder CRANKSHAFT BEARING 1 1. Remove the main bearing case screw. 2. Pull out the crankshaft assembly, take care not to damage the crankshaft bearing. 3 Cylinder 1.
  • Page 22 DISASSEMBLY ASSEMBLY MAIN BEARING CASE ASSEMBLY 1. Remove the two main bearing case screws and remove the main bearing case assembly being cautious with the thrust bearing and crankshaft bearing. 2. Remove the main bearing case. When Reassembling main 1. Clean the oil passage in the bearing case.
  • Page 23 DISASSEMBLY ASSEMBLY THERMOSTAT ASSEMBLY 1. Remove the thermostat cover mounting screws and remove the thermostat cover. 2. Remove the thermostat assembly. LOOSEN THIS HOSE CLAMP TWIST THE THERMOSTAT ASSEMBLY THERMOSTAT ASSEMBLY When Reassembling 1215 1. Apply a liquid gasket (Three bond or equivalent) only at the thermostat cover side of the thermostat cover gasket.

  • Page 24: Servicing

    SERVICING VALVE RECESSING 1. Clean the cylinder head surface, valve face and valve seat. 2. Insert the valve into the valve guide. 3. Measure the valve recessing with a depth gauge. 4. If the measurement exceeds the allowable limit, replace the·valve.
  • Page 25 SERVICING VALVE SEATING (CONT.) VALVE GUIDE 1.0. (INTAKE AND EXHAUST) FACTORY SPECIFICATIONS __ 8.015 - 8.030mm Before correcting the valve and seat, check the valve stem 0,31555 - O.31614in and the I.D. of the valve guide section, repair them Do not hit the valve guide with a hammer during necessary.
  • Page 26 SERVICING VALVE LAPPING 1. Apply compound evenly the valve lapping surface. 2. Insert the valve into the valve guide. Lap the valve onto its seat with a valve flapper or screwdriver. 3. After lapping the valve, wash the compound away and apply oil, then repeat valve lapping with oil.
  • Page 27 SERVICING PUSH ROD ALIGNMENT TIMING GEAR BACKLASH 1. Set a dial indicator (lever type) with its tip on the gear 1. Place the push rod on V blocks on a surface plate. tooth. 2. Measure the push rod alignment. 2. Move the gear to measure the backlash, holding its 3.
  • Page 28 SERVICING BALANCER SHAFT SIDE CLEARANCE (For Balancer IDLER GEAR SIDE CLEARANCE Models Only) 1. Set a dial indicator with its tip on the idle gear. 1. Set a dial indicator with the tip on the balancer shaft. 2. Measure the side clearance by moving the idle gear to the 2.
  • Page 29 SERVICING OIL CLEARANCE BETWEEN THE IDLER GEAR SHAFT AND THE (CO NT.) IDLER GEAR BUSHING FACTORY SPECIFICATlONS __ 0.025 • 0.066mm OIL CLEARANCE OF BALANCER SHAFT JOURNAL 1 0.00098 • 0.00260in FACTORY SPECIFICATION8..-..0.030 - 0.111mm 0.00118·o.00437in ALLOWABLE LlMIT _ _ 0.10mm ALLOWABLE lIMIT _ _ ' 0.2mm 0.0039in 0.00791n...
  • Page 30 SERVICING PISTON PIN BORE 1.0. CAM HEIGHT 1. Measure the piston pin bore I.D. in both the horizontal 1. Measure the height of the cam at its highest point with an and vertical directions with a cylinder gauge. outside micrometer. 2.
  • Page 31 SERVICING MEASURING PISTON 0.0. CONNECTING ROD SMAll END /" FEELER GAUGE WHEN REMOVING CLEARANCE BETWEEN PISTON RING AND GROOVE 1. Remove the carbon from the ring grooves. WHEN INSTALLING 2. Measure the clearance between the ring and the groove with a feeler gauge or depth gauge. REPLACING THE CONNECTING ROD SMALL END the clearance exceeds the allowable limit, replace the BUSHING...
  • Page 32 SERVICING SIDE CLEARANCE OF THE CRANKSHAFT CRANKSHAFT JOURNAL 1. Move the crankshaft to the flywheel side. 2. Set a dial indicator on the crankshaft. 3. Measure the end play by pulling the crankshaft toward the crank gear. 4. If the measurement exceeds the allowable limit, replace the thrust bearing 1 and 2.
  • Page 33 SERVICING OIL CLEARANCE BETWEEN THE CRANKPIN AND THE CRANKPIN BEARING 1. Clean the crankpin and crankpin bearing. 2. Put a strip of plastigage on the center of the crankpin in each direction as shown. 3. Install the connecting rod cap and tighten the connecting rod screws to the specified torque and remove the cap again.
  • Page 34 SERVICING REPLACING THE CRANKSHAFT BEARING 1 Whell Removillg 1. Press out the used crankshaft bearing using a crankshaft bearing replacing tool. Whell Jrutalling 1. Clean a new crankshaft bearing and crankshaft journal bore, apply engine oil to them. 2. Using a crankshaft bearing 1 replacing tool, press in a new bearing so that its seam directs toward the exhaust manifold side.
  • Page 35 SERVICING UNDERSIZE DIMENSIONS OF CRANKSHAFT JOURNAL UNDERSIZE ___ D.2mm _ _ _ _ _ _ 0.4mm 0.008in 0.0161n DIMENSION A 2.8 - 3.2mm 2.8 • 3.2mm (RADIUS 0.1102 - 0.1260in 0.1102 - 0.1260in DIMENSIONB 1.0 -1.5mm 1.0 -1.5mm (RADIUS) - -0~0591in 0.0394 0.0394 - 0.05911n...
  • Page 36 SERVICING CYLINDER WEAR ROTOR LOBE CLEARANCE 1. Measure the clearance between the lobes of the inner Measure the LD. of the cylinder at the six positions with rotor and outer rotor with a feeler gauge. a cylinder gauge to find the maximum and minimum LD. 2.
  • Page 37 II!, ~;;:::p:rI! I §~ ____ l ______ L __ & Engines Generators...
  • Page 38 r ------ "7l nltll '"~ °'1 ° ! 001.)000 _ _ _ _ _ .1. (~~I;: I~ I ,r-'-- ...--". .. _ .. _ , , _ .. I 1--_- =n;;:~'1 Ii:::: "'""''''''''''' ZlrJ.1DI\ #fiiN;I!I...

  • Page 39: Engine Adjustments

    ENGINE ADJUSTMENTS Drive belt adjustment. Proper inspection, service and maintenance of the drive belts is important for the efficient operation of your engine. Drive belts must be properly tensioned. Loose drive belts GLOW PLUG will not provide proper alternator charging and will ·CONNECTION STRAP eventually damage the alternator.
  • Page 40 ENGINE ADJUSTMENTS REMOVING THE INJECTORS Inspecting Spray Pattern NOTE: Injector must be in a clean room" erMmnment. selViced Operate the hand lever of the nozzle tester at intervals of one stroke per second to check if the fuel is injected cor- 1.

  • Page 41: Valve Clearance

    ENGINE ADJUSTMENTS CHECKING VALVE CLEARANCE Valve clearance must be checked and adjusted when engine is cold. 1. Remove the head cover. 2. Align the ITC mark line on the flywheel and projection PROJECTION FLYWHEEL on the housing so that the No.1 piston comes to the compression or overlap top dead center.

  • Page 42: Testing Engine Compression

    INE ADJUSTMENTS TESTING OIL PRESSURE To test oil pressure, remove the hex head plug from the oil gallery and install a mechanical oil pressure gauge in its place. After warming up the engine, set the engine speed at 1800 rpm and read the oil pressure gauge. Oil PRESSURE BETWEEN 30 AND 40 PSI AT 1800/1500 RPM NOTE: A newly started, cold engine may have an oil pressure reading up to...

  • Page 43: Testing Magnetic Pick-Up Coil

    ENGINE ADJUSTMENTS TESTING THE MAGNETIC PICK UP COIL MAGNETIC PICK-UP [MPU] INSTALLATION The MPU is installed in the threaded opening on the side Test the speed sensor connector for voltage and resistance of the flywheel bellhousing. This positions the MPU over values.

  • Page 44: Specifications

    SPECIFICATIONS 17.0/13.5 EDE . LUBRICATION SYSTEM ENGINE SPECIFICATIONS Engine Type Diesel, four-cycle, three-cylinder, fresh Operating Oil Pressure 28 - 57 psi (2.0 - 4.0 kg/cm water-cooled, vertical in-line overhead valve (engine hot) mechanism. Oil Grade API Specification CF, CG-4, CF-4 or CH-4 Aspiration Naturally aspirated SAE 10W-30, 15W-40...
  • Page 45 GENERATOR SPECIFICATION 3 PHASE 17.0/13.5 EDE 22.0/17.0 EDE AC GENERATOR (3 Phase) AC GENERATOR (3 Phase) Three Phase Brushless, six- pole, revoMng field. Sealed Three Phase Brushless, six- pole, revolving field. Sealed 17.0 Kw - 60 Hertz lubricated, single-bearing design. 12 Lead 22.0 Kw - 60 Hertz lubricated, single-bearing design.

  • Page 46: Raw Water Pump

    RAW WATER PUMP (PN #042175) EXPLODED PARTS VIEW TYPICAL HOSE ARRANGEMENT MOUNTING GASKET HOUSING Reassembly 1. Install the shaft into the first bearing. Support the bearings at their center race when doing this. Install the circlip. Position the first bearing so it mates against the circlip. Install the shaft into TYPICAL ASSEMBLY the second bearing.

  • Page 47: Starter Motor

    STARTER MOTOR TROUBLESHOOTING Prior to testing, make certain the ships batteries are at full charge and that the starting system wiring connections (terminals) are clean and tight. Pay particular attention to the ground wire connections on the engine block. To check the wiring, cranking the starter for a few seconds, never more than 10 seconds at a time, then run your hand along the wires and telTllinals looking for warm spots...
  • Page 48 If the starter spins, the solenoid is faulty. SERVICE If the starter fails to spin, the motor is probably faulty. WESTERBEKE uses a standard starter motor which can be cur~nt no arching occurred, there is no reaching the serviced or rebuilt at any starter motor automotive service solenoid.
  • Page 49 STARTER MOTOR FROM BAITERY (+) POST BENCH TESTING THE STARTER MOTOR When bench testing the starter motor, make certain it is securely held in place. Motor Test Using a fully charged battery, run a jumper from the bat- teries (+) post to the connecting lead that has been removed from terminal C ..
  • Page 50 STARTER MOTOR NOTE: To orden;pare [farts. contact your WESTERBEKE dealer. STARTER INSPECTION Solenoid 3. Cheek the commutator mica under cut and correct with a Inspect the solenoid for continuity between terminals S and hacksaw blade if the under cut has beeome to shallow.
  • Page 51 STARTER MOTOR OVERRUNNING CLUTCH 1. Inspect the pinion gear for wear or damage. If there is any defect, replace the overrunning clutch assembly. 2. Check the pinion gear turns freely and smoothly that in the overrunning direction and does not slip in the cranking direction.
  • Page 52 STARTER MOTOR DISASSEMBLING THE MOTOR DISASSEMBLING THE MAGNETIC SWITCH 1. Unscrew the nut and disconnect the connecting lead from 1. Remove the drive end frame mounting screws. the magnetic switch. 2. Disassemble carefully the over-running clutch, ball, 2. Remove the two long bolts and separate the end frame, spring, gears, rollers, and retainer.
  • Page 53 WARNING: working alternator runs hot. A failed The following information applies to the standard alternators alternator can become very hot. Do not touch the that are supplied with WESTERBEKE'S Engines and Generators. alternator until if bas cooled. ELECTRICAL CHARGING CIRCUIT...
  • Page 54 ALTERNATORS TESTING/TROUBLESHOOTING MEASURING BATTERY VOLTAGE TESTING THE ALTERNATOR (IGNITION ON ENGINE OFF) CAUTION: Before starting the engine make certain that everyone is clear of moving parts! Keep away from sheaves and belts during test procedures. 1. Start the Engine. 2. After the engine has run for a few minutes, measure the starting battery voltage at the battery terminals using a multimeter set on DC vol a.
  • Page 55 Any good alternator service shop can do the job. NOTE: WESTERBEKE'S Service Manuall1as detailed instructions for the disassembly and repair of their standard alternators. BAnERYCARE The minimum recommended capacity of the battery used in 3.
  • Page 56 ALTERNATOR SERVICE DISASSEMBLY 1. Secure the hex end of the pulley shaft with a mtchet wrench, then loosen the nut and remove the nut and pulley. 5. Remove the 4 screws holding the rectifier and the stator lead wires, remove the rectifier. Unscrew the 3 rear end cover screws and the B terminal nut and remove the rear end cover.
  • Page 57 ALTERNATOR SERVICE DISASSEMBLY Unscrew the 4 screws holding the retainer plate and ALTERNATOR TESTING remove the retainer plate. Check the bearing for smooth rotation and worn appearance. if it does not rotate smoothly, replace the bearing. 2. Measure the resistance across each lead of the stator coil with an ohmmeter.

  • Page 58: Alternator Testing

    ALTERNATOR TESTING 10. Test the continuity across each rectifier diode with an analog olunmeter. Conduct the test in the (Rxl) setting. The rectifier is nonnal if the diode conducts in one direction and not in the other. NOTE: Do not use a 500V Megger for tests as it will destroy the rectifier! Do not use an auto digital multimeter as it is difficult to check continuity.
  • Page 59 ALTERNATOR SERVICE EXPLODED PARTS VIEW STATOR DRIVE END Ie REGULATOR; Engines & Generators...

  • Page 60: Special Tools

    20 mm (0.79 in.) are available from your 20 mm dia. (0.79 in. dia.) WESTERBEKE dealer. 68 mm dia. (2.68 in. diO.) 59.8 to 59.9 mm dia. (2.354 to 2.358 in. dia.) 64.8 to 64.9 mm dia. (2.551 to 2.555 in. dia.)
  • Page 61 SPECIAL TOOLS r--tL- N° "c Diesel Engine Compression Tesler 07909-31251 (G) Code No : 07909-30208 (Assembly) 07909-30934 (A to F) 07909-31271 (I) 07909-31211 (E and F) 07909-31281 (J) 07909-31231 Application: Use to measure diesel engine compression and diagnostics ntled for major overhaul. (7) AdaptorF (I) Gauge (2) 'l..JOint...

  • Page 62: Service/Standards And Limits

    SERVICE DATA STANDARDS AND LIMITS ENGINE BODY Item Factory Specification Allowable Limit Cylinder Head Surface 0.05 mm 1500 mm Flatness 0.0020 in. / 19.69 in. Compression Pressure 3.53 to 4.02 MPa 2.55 MPa/ (When Cranking with Starting Motor) 290 min· (rpm) 290 min·...
  • Page 63 SERVICE DATA .. STANDARDS AND LIMITS Limit Factory Specification Allowable Item Valve Timing (Exhaust Valve) 1.05 rad (60 0) (Open) before B.D.C. (Close) 0.21 rad (12°) after T.D.C. Valve Spring 41.7 to 42.2 mm 41.2 mm Free Length 1.6220 in. 1.6417 to 1.6614 in.
  • Page 64 SERVICE DATA STANDARDS AND LIMITS Factory Specification Allowable Limit Item 0.12 to 0,48 mm 0.9mm Idle Gear Side Clearance 0.0354 in. 0.0047 to 0.0189 in. Idle Gear Shaft to Idle Gear Bushing Clearance 0.025 to 0.066 mm 0.1 mm 0.00098 to 0.00260 in. 0.0039 in.
  • Page 65 SERVICE DATA STANDARDS AND LIMITS Item Factory Specification Allowable Limit Top Ring 1.25 mm (Ring Gap) 0.25 to 0.40 mm 0.0098 to 0.0157 in. 0.0492 in. Second Ring to Ring Groove Clearance 0.093 to 0.128 mm 0.2mm 0.0037 to 0.0050 in. 0.0079 in.
  • Page 66 SERVICE DATA STANDARDS AND LIMITS ELECTRICAL SYSTEM Allowable Limit Factory Specification Item (0.0.) Starter Commutator 29.0 mm 30.0 mm 1.142in. 1.181 in. 4 Cylinder (0.0.) Commutator 34.0 mm 35.0 mm 1.339 in. 1.378 in. 3 Cylinder 0.20 mm Mica 0.45 to 0.75 mm 0.0177 to 0.0295 in.
  • Page 67 SERVICE DATA STANDARDS AND LIMITS Item Factory Specification Allowable 0.025 to 0.087 mm O.2mm Crankpin to Crankpin Bearing Oil Clearance 0.007~ 0.00098 to 0.00343 in. Crankpin 46.959 to 46.975 mm (O.D.) 1.84878 to 1.84941 in. Crankpin Bearing 47.000 to 47.046 mm (I.D.) 1.85039 to 1.85220 in.

  • Page 68: Torque Specifications

    TORQUE SPECIFICATIONS _NOTE • For "*" marked screws, bolts and nuts on the table, apply engine oil to their threads and seats before tightening. • The letter "M" in Size x Pitch means that the screw, bolt or nut dimension stands for metric. The size is the nominal outside diameter in mm of the threads.

  • Page 69: Generator Information

    GENERATOR INFORMATION USE OF ELECTRIC MOTORS GENERATOR FREQUENCY ADJUSTMENT The power required to start an electric motor is considerably more Frequency is a direct result of engine/generator speed, as indicated than is required to keep it running after it is started. Some motors by the follmving: require much more current to start tHem than others.

  • Page 70: Electronic Regulation

    ELECTRONIC REGULATION SR7·2G AVR ~F~~~~S~~fj~~~Wr ADJUSTABLE THRESHOLD 5 AMP FUSE OVERLOAD PROTECTION t::.::l INTERVENTION CI.) "' A I m~ I"C\ ADJUSTABLPTHRESHOLO G);~ OF UNDERSPEED iHrlZ . ----rCONNECT FOR 60Hz Stab· ®§:..,.,l"'Tl!""rrn~nr-T'I'..,..PROTECT/ON INTERVENTION ®!5 6----<REMOVE fOR 50Hz volt 3 1 - - . .
  • Page 71 ELECTRONIC REGULATION SR7-2G AVR lER~IHAl BLOCK ,onN(CIiOlIS SNOWN ARE CONFIGiRW FOR lO-WY,r 11nlln~ TERMINAL BUlCK Hertz: With this potentiometer, which is nonnally TO AG SENSE pre-calibrated then sealed by the manufacturer, it is possible CONNECTIONS to adjust the low frequency protection intervention. To recalibrate this protection, you must take the generator to a' normal zero load condition, tum the potentiometer clockwise until the limit position is reached, then decrease...

  • Page 72: Exciter Rotor Troubleshooting

    EXCITER ROTOR TROUBLESHOOTING LOW VOLTAGE· EXCITER ROTOR TESTING THE EXCITER ROTOR WINDINGS AND ROTATING FIELD These windings are tested in pairs: A to 0,0 to C, and C to A shown on drawing. Position the exciter rotor/rotating field so transient suppressor is visible at the O'Clock position.

  • Page 73: Terminal Board Connections

    TWELVE LEAD WINDING/TERMINAL BOARD CONNECTIONS AND (NOMINAL) VOLTAGES (SERIES WYE) (PARALLEL WVE) SERIES PARAllEL SERIES DELTA STAR STAR 10-11 10.12 10':11 1-12 5·7 Hz L-L 230 volts Hz L-L volts Hz L-L volts SO Hz L-N volta SO Hz L-N 230 volta L-N ) volts SO Hz...
  • Page 74 CHANGING HERTZ AND VOLTAGE CAUTION: precaution against an unintentional start, shut OFF the 20 Amp DC breaker on the control panel. CONNECT FOR 60Hz Refer to the previous page that illustrates the various AC REMOVE FOR 50Hz voltage output configurations for both the 60 Hertz and 50 Hertz applications.

  • Page 75: Internal Schematic

    AC OUTPUT CONFIGURATIONS VOLTAGE SENSING BOARD CONNECTIONS [ill [IT] lTIl 9 lOt" -SERIES WYE" -PARAl.I.EL WYE- -seRIES DELTA- "PARALLEL OELTA- 480V'SO Hz 208V/60 Hz 240V/50 120V/GO 380V 150 Hz (90VfSO Hz 220V 150 Hz IIOV/50 Hz [ill "10 NOTE: ECU REOUIRED TO BE R£-PROGRAMED WHEN CHANGING ANY THE fOLLOWING SETTINGS "OOUBl.E DEL TA-...
  • Page 76 GENERATOR WIRING SCHEMATICS 1 - - EXCITER STATOR : CONDENSER ---~- EXCITER I · ROTOR IYELlll?l I~ . . .-~ BLUE DIODES THREE PAIRS SUP~ESSO~ AUXILIARY _-.1 AC TERMINAL BLOCK . ~Amp· 100 Ko f---'----' Hertz· ~ StalJ- .BLACK voll-- GREEN SINGLE PHASE :: ..
  • Page 77 MECC ALTE GENERATOR ASSEMBLY OF THE GENERATOR TO THE ENGINE 4. Rotate the generator by hand two full revolutions to 1. Position the rotor assembly onto the flywheel aligning the ensure the generator rotates freely. Reinstall the rear holes in the drive discs with the holes in the flywheel. vent cover.
  • Page 78 MECC ALTE GENERATOR MAINTENANCE/PARTS BREAKDOWN INSPECTION/CLEANING Periodically the rotor carrier bearing. Replace this Remove all oil. grease and dust build up from the inspect dirt, external surface of the generator. Build-up reduces heat bearing at 10,000 hours ofnonnal operation or sooner if wear is evident.

  • Page 79: Be Troubleshooting

    TROUBLESHOOTING NOTE: AC GENERATOR TROUBLESHOOTING MUST BE PERFORMED WITH IRE ENGINE OPERATIN AT 60 HZ. FAULT PROBABLE CAUSE NO AC VOLTAGE OUTPUT AT NO LOAD. 1. Short or open in the 4. Open in exciter main stator winding. stator winding. 2.
  • Page 80 DECIMAL TO METRIC EQUIVALENT CHART Fractions of Fractions of Metric (mm) Decimal (in.) Metric (mm) Decimal (in.) an inch an inch 1/64 0.015625 0.39688 33/64 13.09687 0.515625 1/32 0.03125 0.79375 17/32 0.53125 13.49375 0.046875 1.19062 35/64 0.546875 13.89062 3164 1/16 0.0625 1.58750 9/16...
  • Page 81 STANDARD AND METRIC CONVERSION 'DATA LENGTH-DISTANCE Inches (in) x 25.4 Millimeters (mm) x .0394::: Inches Feet (ft) .305 ::: Meters (m) x 3.281 ::: Feet Miles 1.609 :: Kilometers (km) .0621 Miles DISTANCE EQUIVALENTS 1 Degree of Latitude:::: 60 Nm :::: 111.120 km 1 Minute of Latitude:: 1 Nm 1.852 km VOLUME...
  • Page 82 Heavily oil all sliding and reciprocating components when assembling. Always Specialized gasket sealers such as HYLOMAR work well in applications requir- use clean engine oil! ing non-hardening properties. HYLOMAR is particlarly effective on copper cylinder-head gaskets as it resists fuel, oil and water. '",..,/WESTERBEKE ~ngines & Generators...
  • Page 83 METRIC CONVERSIONS INCHES TO MILLIMETERS MILLIMETERS TO INCHES Inches Inches Inches I Inches 25.40 381.00 0.0394 0.5906 50.80 508.00 0.0787 0.7874 0.1181 0.9843 76.20 635.00 101.60 0.1575 1.1811 762.00 127.00 0.1969 1.3780 889.00 254.00 1016.00 0.3937 1.5748 (~.3 10 MILLIMETERS 1 CENTIMETER, 100 CENTIMETERS 1 METER", 39.37 INCHES FEET)

  • Page 84: Fuel Injectors

    INDEX Alternators ......52 Removing Injectors ...... 37 Spray Pattern ......37 Disassembly ......55 Testing Engine Compression ....39 Exploded View ......58 Testing Oil Pressure ..... 39 Troubleshooting ......52 Valve Clearance ......38 Assembly Instructions ....... 7 Engine Troubleshooting .....

  • Page 85: Wiring Diagrams

    INDEX Starter Motor ......CrankpinlCrankpin Bearing Oil Clearance ..30 Crankshaft Alignment ....29 Bench Testing ......48 Crankshaft Bearing lIReplacing .... 31 Exploded View ......51 Service ....... 47 Crankshaft Sleeve Wear ....32 Cylinder Wear ......33 Troubleshooting .......
  • Page 87 Engines & Generators #1128-DWIWM-IO/08...

This manual is also suitable for:

17.0kw ede-50hz13.5kw ede-50hz

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