User Manuals: Westerbeke RD80 Marine Diesel Engine

Manuals and User Guides for Westerbeke RD80 Marine Diesel Engine. We have 1 Westerbeke RD80 Marine Diesel Engine manual available for free PDF download: Service Manual

Westerbeke RD80 Service Manual

Westerbeke RD80 Service Manual (110 pages)

4-CYLINDER MARINE DIESEL ENGINES & GENERATORS

Brand: Westerbeke | Category: Portable Generator | Size: 8 MB

Table of Contents

Table of Contents
7
Introduction
9
Engine/Generator Specifications
11
Testing for Overhaul
12
- How to Judge Engine Overhaul Period
  12
  - Cause of Low Compression
    12
  - Measuring Compression Pressure
    12
- Overhaul Conditions
  12
  - Disassembly
    12
  - Reassembly
    13
Service Standards
14
Technical Data
17
- Tightening Torque
  17
- General Screws
  17
- Sealants
  17
Engine Troubleshooting
18
Engine Parts Identification
22
Cylinder Head
23
- Construction
  23
Cylinder Head Service
24
- Disassembly
  24
- Inspection
  24
  - Cylinder Head
    24
  - Valve Guide
    24
  - Valve Seat
    24
  - Valve
    25
  - Valve Spring
    25
  - Rocker Arm and Rocker Shaft
    25
- Reassembly
  25
Cylinder Block
27
- Construction
  27
Cylinder Block Service
29
- Disassembly
  29
- Inspection
  29
  - Cylinder Block
    29
  - Piston, Piston Pin and Piston Rings
    30
  - Connecting Rod
    31
  - Crankshaft
    31
  - Main Bearings and Connecting Rod Bearings
    31
  - Gearcase
    32
  - Timing Gears and Lube Oil Pump Gear
    32
  - Camshaft
    32
  - Fuel Injection Pump Camshaft
    32
  - Ball Bearings
    32
  - Tappets
    32
  - Push Rods
    32
- Reassembly
  32
Governor
37
- Description
  37
- Disassembly
  37
- Inspection
  37
  - Governor Lever
    37
  - Governor Spring
    37
  - Needle Bearing
    37
- Reassembly and Adjustment
  37
Engine Shutoff
38
- Engine with Manual Stop (Standard)
  38
- Optional Key Switch Shutoff (38B and 42B Only)
  38
  - Installing and Adjusting the Key Switch Shutoff Solenoid
    38
  - Key-Stop Solenoid System Operation Checking Procedure
    38
Engine Adjustments
39
Lubrication System Service
41
- Description
  41
- Disassembly
  41
  - Oil Filter and Oil Pump
    41
- Inspection
  41
  - Oil Pump
    41
- Reassembly
  42
- Testing the Oil Pressure
  42
- Oil Pressure Switch
  42
Fuel System
43
- Description
  43
Fuel System Service
45
- Disassembly
  45
  - Fuel Filter
    45
  - Fuel Lift Pump
    45
  - Fuel Injection Pump
    45
  - Injector
    46
- Inspection
  46
  - Fuel Filter
    46
  - Fuel Lift Pump
    46
  - Fuel Injection Pump
    46
  - Nozzle
    46
- Reassembly
  46
  - Injection Pump
    46
  - Installation and Adjustment of Fuel Injection Pump
    47
  - Injector
    48
  - Adjustment and Installation of Nozzle
    48
  - Holder Assembly
    48
Raw Water Cooling Circuit
50
- Description
  50
Raw Water Pump Service
51
- Pump Overhaul - Raw Water Pump PN 33636
  51
  - Disassembly
    51
  - Inspection
    51
  - Reassembly
    51
- Pump Overhaul- Raw Water Pump PN 24143
  52
  - Disassembly
    52
  - Inspection
    52
  - Reassembly
    52
Fresh Water Cooling Circuit
53
- Description
  53
Fresh Water Cooling Service
54
- Disassembly
  54
- Inspection
  54
  - Water Pump
    54
  - Thermostat
    54
- Reassembly
  54
  - Drive Belt Adjustment
    54
Admiral Control Panel
55
- Description
  55
Captain Control Panel
56
- Description
  56
Control Panel Troubleshooting
57
Control Panel - Early Models
59
- Activation by Key Switch
  59
Starter/Solenoid Service
60
- Description
  60
- Adjustment and Repair
  60
  - Pinion Gap Inspection
    60
  - No-Load Test
    60
  - Solenoid
    61
- Starter Disassembly
  61
- Starter Inspection
  62
  - Solenoid
    62
  - Inspecting the Armature
    62
  - Brush and Brush Holder Inspection
    62
  - Field Coil Inspection
    63
- Starter Adjustment and Reassembly
  63
DC Electrical System
64
- Description
  64
  - Engine 12-Volt Control Circuit
    64
- Charging System
  64
- Alternator Troubleshooting
  64
  - Checking for ~Roper Voltage
    64
- Battery Maintenance
  65
- Glow Plugs
  65
Alternator/Regulator Service
66
- Description
  66
- Alternator Troubleshooting
  66
  - Testing the Charging Voltage
    66
  - Output Test
    67
- Disassembly
  67
- Inspection
  68
  - Diode
    68
  - Checking for Short Circuit
    68
  - Checking for Open Circuit
    68
  - Checking Diode Trio
    68
  - Stator
    69
  - Field Coil (Rotor)
    69
  - Checking Brush and Brush Spring
    69
  - Checking the Slip Ring
    69
- Regulator
  69
- Reassembly
  70
Transmissions
71
DC Electrical System
72
Standard Hardware Torques
82
Metric Conversions
83
Generator Information
84
- Use of Electric Motors
  84
- Required Operating Speed
  84
- Generator Frequency Adjustment
  84
- Generator Maintenance
  84
- Generator Troubleshooting
  84
WMD Generator
85
- Description
  85
- Disassembly
  85
- Inspection
  85
- Reassembly
  85
WMD Generator Troubleshooting
86
- No Electrical Output
  86
- Flash Field Coils
  86
- Replacement of Field Coij(S)
  87
- Low Voltage Output
  87
- High Voltage Output
  88
- Solenoid with Throttle Linkage
  88
WMD Generator AC Internal Wiring Diagrams
89
WMD Generator DC Electrical System
90
- WMD Generator Wiring Diagram #24700
  90
- WMD Generator Wiring Schematic #24700
  91
BT Generator
92
- Description
  92
BT Generator Troubleshooting
93
- Residual Voltage Check
  95
- Bridge Rectifier
  95
  - Testing the Bridge Rectifier for Faults with an Ohmmeter
    96
- Internal Wiring Diagram
  96
- Component Resistance Values
  97
  - Models 11.0 & 12.5(A) BT
    97
- Component Resistance Checks
  97
  - Exciter Stator Windings
    97
- Exciter Rotor/Field
  98
- Main Stator Windings
  99
- Compound Transformer
  99
- Selector Switch
  99
- Bridge Rectifier Wiring
  99
- No-Load Voltage Adjustment
  100
- Voltage/Hertz Connection Bar
  100
BT Generator AC Voltage Connections
101
- Generator Frequency
  101
BT Generator 6 Terminal Block
102
- Wiring Connections
  102
BT Generator DC Electrical System
104

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