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Westerbeke 10TWO, Technical Manual, Page: 100 / 158

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Summary of Contents for 10TWO

Page 1: ...HERTZ WMD 2 4 KW 50 HERTZ MARINE DIESEL GENERATORS PUBLICATION 33403 EDITION TWO JUNE 1993 j r v WESTERBEKE WESTERBEKE CORPORATION MYLES STANDISH INDUSTRIAL PARK j 150 JOHN HANCOCK ROAD TAUNTON MA 02...

Page 2: ...d by their manufacturers wi th their own software and Westerbeke must depend on such software for the design of Westerbeke s own product software Such software may be out dated and no longer accurate...

Page 3: ...CTION INDEX GENERAL Introduction Operation Installation Maintenance ENGINE OVERHAUL OTHER OVERHAUL Marine Engine Electrical System Cooling System External Transmissions GENERATOR SETS SERVICE BULLETIN...

Page 4: ...in the fuel system is also essential Another important factor is the use of the same brand of nhigh detergent diesel lubricating oil designed specifically for diesel engines The diesel engine does di...

Page 5: ...ny discrepancies This is your protection against loss or damage Claims for loss or damage must be made to the carrier not to J H Westerbeke Corporation RIGGING AND LIFTING The engine is fitted with li...

Page 6: ...e bed contributes much toward the satisfactory opera tion of the engine The engine bed must be of rigid construction and neither deflect nor twist when sub jected to the engine weight or the position...

Page 7: ...cular to the centerline or axis of the propeller shaft PROPELLER The type and size of propeller varies with the gear ratio and must be selected to fit the application based upon boat tests To utilize...

Page 8: ...ing to full position each 90 from the next one The engine alignment should be rechecked after the boat has been in service for one to three weeks and if necessary the alignment remade It will usually...

Page 9: ...s permissible to directiy connect a pipe nipple and a water jacketed exhaust elbow which two components weigh about 8 pounds 4 kg If there are more components to be rigidly connected to each other tha...

Page 10: ...o the engine exhaust manifold The engine should be run at maximum load during the measurement period Set up should be as shown below 1 For normally aspirated engines Pressure Test Mercury Test 1 1 2 M...

Page 11: ...lift pump provided will raise the fuel from the tank The amount of lift should be kept minimum 6 feet being maximum If a tank is already installed above the engine level it can be utilized in this po...

Page 12: ...e to the engine as possible to avoid voltage drop through long leads It is bad practice to use the starter batter ies for other services unless they require low amperage or are intermittent In cases w...

Page 13: ...station is in forward neutral and reverse the control lever on the transmission has moved into the respective position Some models do not require a stop cable because they have a fuel run solenoid Exa...

Page 14: ...f its higher lubr icant content 5 Ensure that the battery is fully charged and the electrolyte level is correct FUEL SYSTEM The fuel injection system of a compression ignition engine depends upon very...

Page 15: ...pump with the palm of your hand pump this primer with slow steady pumps until fuel free of air bubbles flows from this bleed screw Stop pumping and retighten the bleed screw NOTE An electric fuel pum...

Page 16: ...oid 3 Preheat for 15 to 20 seconds Panels with keyswitches Push in on the key to activate the pre heat and hold in panels with pushbuttons Panels with pushbuttons Push in on the preheat button to acti...

Page 17: ...ne mechanic check it WHEN ENGINE STARTS 1 Check for normal oil presure immediately upon engine starting Do not continue to run engine if oil pressure is not present within 15 seconds of starting the e...

Page 18: ...aches operating tem perature 170 190 F and returns this coolant to the engine through contraction as the engine cools WARNING The cooling system is pressurized when the engine is at operating temperat...

Page 19: ...uel clean Handle it with extreme care because water and dirt in fuel cause more trouble and service life of the injection system is reduced dramatically 7 Do not allow fuel to run low because fuel int...

Page 20: ...to make sure it is 190 or less Check engine coolant prior to each day s use Investigate any oil leaks immediately Check transmission lubricant prior to each day s use Race the engine in neutral when c...

Page 21: ...bolts vee belt tensions etc Pay par ticular attention to loose engine mounts and engine mount fittings These could cause mis alignment 8 Check conditions of zinc anode in engine heat exchanger DAILY C...

Page 22: ...entration of antifreeze depending on the area s winter climate Should more antifreeze be needed drain an approximate amount from the engine block and add a more concentrated mixture Operate the engine...

Page 23: ...eplace the impeller back into the pump until the Spring com missioning 6 with a clean cloth lightly soaked in oil place it in the opening of the intake manifold so as to block it closed DO NOT shove t...

Page 24: ...12 Batteries If batteries are to be left on board during the winter storage per iod insure that they are in a state of full charge and will remain that way to prevent them from freezing If not it woul...

Page 25: ...nd staffed mar ine engine service and rebuilding facilities The necessary procedures should be under taken only by such facilities Addi tional operating character istics are included in the Operation...

Page 26: ......

Page 27: ...WESTERBEKE 10 Two 12B Two PROPULSION Right Side Left Side 24...

Page 28: ...WESTERBEKE WMD 3KW GENERATOR Side Left Side 25...

Page 29: ...UT fUEL 1NLET 27 FfMI Lf FlAW WATER OUT i D HOSC VEL INLET 27NPT 20 00 28 50 DIMENSIONAL DRAWINGS Westerbeke 10Two 12B Two I 19 57 2 4 KW 3 KW GENERATOR 0 75 21 50 I I 4 G 1 Dimensions are subject to...

Page 30: ...number is stamped as shown below Engine number 1001 COOO The engine block serial number will also be found stamped in the block on a flange just below the number two injector The generator serial num...

Page 31: ...outlet fit II Tappet 20 Front bearing housing 3 Exhaust valve 12 Camshaft 21 Gear case 4 Intake valve 13 Oil pump 22 Oil drain plug 5 Oil filler cap 14 Piston 23 Oil pan 6 Rocker arm shaft 15 Connecti...

Page 32: ...2 Rocker cover 10 Piston 17 Ring gear 3 Push rod 11 Starter 18 Oil level gauge 4 Rocker arm 12 Rear plate 19 Oil filter 5 Exhaust valve 13 Water drain hose 20 Oil screen 6 Glow plug 14 Crankshaft 21...

Page 33: ...Capacity Starter Alternator Glow Plug 30 Vertical 4 cycle OH water cooled Swirl type chamber 2 65 mm 2 56 in x 68 mm 2 68 in 451 cc 27 52 ci 25 1 1 2 9 5 HP at 3000 RPM 10 Two Model 12 0 HP at 3600 R...

Page 34: ...o Propulsion Engine i I I I I TORQUE L B FT I I COINT I 1 _ I 0 50 F U E LeO N SUM P T ION _ ___ _ _ I I I l rl I 0 45 o I l i l j 0 40 LB PER HP HR 1400 2000 3000 3600 RPM WMD 3 KW Generator Model 60...

Page 35: ...cking 7 Worn piston rings and cylinder b Glow plug burned c Insufficient operating time for glow plug d Incorrect setting of throttle lever e Governor spring out of position REMEDY Use oil of lower vi...

Page 36: ...a Piston ring end gaps incorrectly positioned b Connecting rod tilted or distorted c Wear of piston ring d Wear of piston and cylinder 3 Oil down a Faulty stem seal b Wear of valve and valve guide RE...

Page 37: ...ind crank pin big end bearing b Wear of crank pin Grind crank pin c Connecting rod bent Straighten or replace 3 Piston piston pin and piston ring a Wear of cylinder Rebore cylinder to oversize and rep...

Page 38: ...2 cylinder at TDC on compression stroke adjust the clearance of the intake and exhaust valves of the No 2 cylinder 3 To posi tion the No 1 cylinder for TDC of compression align the timing mark on the...

Page 39: ...ENING TORQUE Note The cylinder head bolts when being torqued should be broken free one quarter to one halftum then torqued to the value given and in the proper order as shown Tightening Torque 25 3 28...

Page 40: ...h sides except where the cylin der bore periphery is to pre vent oil and water leakage therefore no gasket sealant is needed during assembling An engine model mark is stamped on the upper side of the...

Page 41: ...um die cast and the upper part is provided with an oil passage to supply oil to the rocker section via a supply tube from the front cam bearing The cover is also provided with a fill port for engine o...

Page 42: ...for visible water leakage or damage before cleaning 2 Prior to inspection and repair clean each part carefully and remove oil scale carbon and paint 3 Clean oil holes with compressed air and make sure...

Page 43: ...an the standard value ream the guide to achieve the desired clearance Valve Seat Check the valve seat for any damage and incorrect contact and if defective correct as illustrated After correcting lap...

Page 44: ...justing screw and if the surface in contact with the push rod is excessively worn replace Check the I D of the rocker arm bushing and the 0 0 of the rocker shaft rocker arm installation area and if th...

Page 45: ...bushing The cylinder head gasket is coated wi th sealant and there is no need of applying any additional sealant Tighten the cylinder head bolts in the illustrated order to the specified torque Insta...

Page 46: ...valve clearance With the piston Gf each cylinder at the top dead center of compression stroke insert a feeler gauge between the valve stem tip and the rocker arm face and adjust to the specified clear...

Page 47: ...ing Gear The flywheel is designed to provide a great inertial efficiency and to minimize torque variation The ring gear is shrink fitted to the flywheel and gear teeth are induction hardened to increa...

Page 48: ...pump and the cam lobes and journals are induction hardened The camshaft is supported in machined holes in the crankcase The front journal is provided wi th an oil hole to supply oil intermi t tently...

Page 49: ...Oil Pan The oil pan is made of sheet metal and is provided with an oil drain hose attached to the sump oil drain boss 46...

Page 50: ...del Fuel System Remove electric fuel pump and engine mounted fuel filter assembly Remove high pressure liner from injection pump to injectors Remove fuel return line from injectors and to injection pu...

Page 51: ...front bearing housing from the crankcase Draw out the crankshaft from the crankcase hole damage the main bearing Disassembly of Piston and Connecting Rod Be careful not Set the piston and connecting...

Page 52: ...e for signs of water leakage oil leakage and damage before cleaning it 2 Pr ior to inspection and repair clean each par t and remove the dust oil carbon deposits and water scale 3 Clean the oil galler...

Page 53: ...the piston The piston 0 0 should be measured at the lower part of the skirt across the thrust faces When an oversize piston is used finish the cylnder bore oversize as well First measure the outside d...

Page 54: ...cting rod aligner measure the bend and distortion of the rod and if excessive bend or distortion is found repair or replace After installing the connecting rod on the cr ankshaft measure the thrust cl...

Page 55: ...ng and connecting rod bearing Check the bearing surface for flaking melting seizure and incorrect contact and if defective replace With each main bearing and connecting rod bearing installed in the cr...

Page 56: ...r ence surface at the bearing installation side use the furnished tool adapter ring 1 Guide ring 2 Main bearing 3 Bearing installer 4 Bearing housing front or crankcase rear Removing the Main Bearing...

Page 57: ...lobe is worn in excess of the service limit replace the camshaft Check the slot for driving the oil pump for any wear and if the wear is excessive replace Tappet Check the bottom of the tappet the su...

Page 58: ...ckwashers o rings etc 7 Tighten the bolts and nuts on important parts of engine to spe cified torques using a reliable torque wrench 8 Use liquid sealants when required on nuts bolts and gaskets Refra...

Page 59: ...pin is pressed into a prescribed position by the guide After the installa tion is completed turn the push rod 90 degrees align the notch of the guide with that of the tool body and remove the piston...

Page 60: ...g rod assembly into the cylinder install the connecting rod cap and tighten to the specified torque Insert the bolts at the connecting rod side and tighten the nuts from the cap side When inserting th...

Page 61: ...e the front pulley nut i6 the proper specification Install the oil pump assembly Install the backplate Install the flywheel and tighten the bolts to the specified torque Install the oil screen and oil...

Page 62: ...e thermostat housing sea water pump bracket and drive belt Install the primary heat exchanger manifold and related hoses Attach the idle stop assembly generator fuel run solenoid Reinstall wir ing har...

Page 63: ...of the camshaft The oil from the oil pump is regulated by a check valve filtered by the cartridge type oil filter and supplied to each part of the engine through oil galleries in the engine block l O...

Page 64: ...lter The oil filter is an easy to handle cartr idge type filter with the filter body and element formed integral If the element has been contaminated or clogged and the oil pressure difference before...

Page 65: ...s before assembling 2 After assembling check that the pump shaft turns smoothly 3 Measure the clearance between the outer rotor and the pump body using a feeler gauge and if the clearance is excessive...

Page 66: ...o 23 PSI dur ing normal oper ation this swi tch oper ates an alarm buzzer When the alarm sounds check the oil pressure and water tem perature gauges on your instrument panel NOTE The alarm can also be...

Page 67: ...stead 3 Set the eng ine speed at 3000 RPM and measure the oil pressure If the oil pressure is less than the specifica tion check the lubricating system Oil pressure Greater tnan 3 5 kg cm2 50 lb in2 a...

Page 68: ...e a season as needed Changing the Fuel Filters The fuel filter element located in the electr ic fuel pump can be removed by undoing the base of the pump A 17 rom wrench 5 rom thick should be used to u...

Page 69: ...the transistor circuit is opened the plunger is pushed back upward by the spr ing force forcing the fuel out of the outlet port and at the same time the inlet valve opens and the fuel enters the lower...

Page 70: ...ecure them with the retainer so that they will not come out 2 Install the filter element and then the magnet and gasket in the base cover and tighten the cover with a 17 mm wrench to the ends of the s...

Page 71: ...nd plunger barrel is rotated by the control pinion installed on the outer the plunger barrel chang ing the The plunger periphery of The lower flange of the plunger fits in the slit of this plnlon and...

Page 72: ...ring Adjusting plate Plunger barrel Lever 3 Delivery Valve In addition to the function to deliver the fuel into the injector line after the fuel pressure has increased sufficiently high the delivery v...

Page 73: ...not recklessly try to disassemble the fuel injection pump Pump adjustment requires a test bench and acquired skill Avoid disassembly and adjustment of the pump when this equipment and knowledge are n...

Page 74: ...ck Examination 1 Delivery Valve Seat Check the contact surface of the deli very valve seat and if not showing good contact replace the delivery valve The delivery valve should show a slight resistance...

Page 75: ...elivery valve holder c Install the spring seat gasket and valve assembly to the valve holder and temporarily install this to the pump housing Be sure to install the O ring properly d Install the contr...

Page 76: ...he injection timing First remove the deli very valve holder and after pulling out the delivery valve and spr ing install the deli very valve holder only Tur n the crankshaft so as to bring 11 piston c...

Page 77: ...nt 2 Remove the fuel injection line from the injector 3 Loosen the injector nut and remove the assembly 4 Disassemble the holder assembly following manner nozzle in the a With the retaining nut held i...

Page 78: ...eedle will drag affecting injection performance 1 Install the nozzle assembly spacer and pressure pin to the retaining nut 2 Install the shim spring and flange in the body and install them to the abov...

Page 79: ...e tip of the nozzle and dripping occurs after injection the nozzle must be replaced because it is defective A very small amount of fuel may collect on the nozzle tip This is caused by chattering and t...

Page 80: ...he spring force is balanced with the centrifugal force of the governor weights thus maintaining the constant engine speed If the speed control lever 1 is pulled toward HIGH SPEED the governor spr ing...

Page 81: ...assembly 1 Remove the alternator 2 belt See nCooling Systemn Remove pulley pulley the crankshaft nut then the 3 Remove the fuel injec tion pump See nFuel Injection pumpn 4 Remove bolts case the gear t...

Page 82: ...the spring Governor Weight The governor weight is installed on the governor gear in mesh with the cam gear In order to improve the governor regulation the sliding shaft is provided with a stopper The...

Page 83: ...if defective replace b Check the operating part of the sliding shaft for damage and see if the operation is smooth If defective replace Reassembly For reassembling reverse the order of disassembly an...

Page 84: ...e with built in check valve Use For drawing out or press fitting piston pin For drawing out or press fitting main bearing with ring adapter for front bearing For testing com pression Mounts in place o...

Page 85: ...on of lubricating oil 4 Poor engine starting 5 Increased noise from engine parts Usually two or more of the above symptoms appear at the same time Symptoms 2 and 4 are caused by excessive fuel injecti...

Page 86: ...new the compression pressure is a little high because of the close fit between mating parts but after that the pressure decreases gradually as the parts get worn 2 When the compression pressure has d...

Page 87: ...ng the following precautions 1 Prepare all necessary parts for reassembling 2 Clean or wash the parts and apply oil as needed 3 Check all gaskets washers and oil seals and replace them with new ones 4...

Page 88: ...h e Valve seat sinkage 6 Valve Clearance engine cold 7 Valve a Stern O D b Clearance between stern and guide intake c Clearance between stern and guide exhaust d Seat face angle e Valve head thickness...

Page 89: ...o 3 b Bend and distortion c Big end thrust clearance 15 Connecting Rod Bearing a Type b Oil clearance c Undersize 16 Crankshaft a Type b Bend c End play d Journal O D e Pin 0 0 f Undersize finish dime...

Page 90: ...a Bend LUBRICATION SYSTEM STANDARD SERVICE VALUE LIMIT standard 0 25 0 035 0 050 standard 0 50 0 035 0 050 standard 0 75 0 035 0 050 Kelmet metal with back metal 0 029 0 090mm 0 15mm 0 25 0 50 0 7Smm...

Page 91: ...tion Pump a Model b Fuel injection rate Smoke set SS STANDARD VALUE Trochoid type 3 Skg cm2 SERVICE LIMIT 0 30mm 0 2Smm 0 2Smm 18 23 PSI to close 18 23 PSI to open 2 diesel fuel Filter paper type cart...

Page 92: ...ent Speed e Load output Terminal voltage Current Speed 3 Glow Plug a Type b Rated current c Resistance 89 STANDARD VALUE SERVICE LIMIT Centrifugal impeller type 20S F S to operate positive displacemen...

Page 93: ...olt nut 12mm bolt nut 14mm bolt nut Grade 5 cap crew 1 4 UNC 1 4 UNF 5 16 UNC 5 16 UNF 3 8 UNC 3 8 UNF 7 16 UNC 7 16 UNF 1 2 UNC 1 2 UNF 90 Kg m Ib ft 3 5 4 0 25 29 0 5 0 7 4 5 3 2 3 5 23 25 6 5 7 0 4...

Page 94: ...TS PAGE MARINE ENGINE ELECTRICAL SYSTEM Activation by Keyswitch 1980 onwards 92 Starter Motor 95 A1ternator 99 COOLING SYSTEM EXTERNAL TRANSMISSIONS 107 Type HBW Short Profile Sailing Gear 114 Type BW...

Page 95: ...TCH WIRI NG DIAGRAM So NOlE e w SENOEA _ N I T rUEL SOL w e wt J2 w 70 WIOO SCEt lTE S o P SENDER NOT USEO W Z j z 6 O WIOO IF CQUI t 12 ON 0 F RE HE AT SOL 92 SCHEMATIC DIAG AM IZVOC eAiT It eAT T A...

Page 96: ...shutting off the alarm The water temperature switch operates the opposite It closes when an overheat condition exists and the operating tem perature of the engine reaches 205 F and sounds the alarm T...

Page 97: ...charged batteries that are in a static state should read between 12 3 and 12 6 volts on the dial The term static means that the bat tery has not been charged or discharged for at least 2 hours If the...

Page 98: ...flatwasher located on the rear of the tachometer 3 Insert an insulated Phillips screwdriver into the calibration control slot and slowly turn counterclockwise to increase the RPM reading clockwise to...

Page 99: ...e starter swi tch is depressed The trouble may rest with the solenoid circuit breaker battery or engine itself Therefore check the circuit for starting without removing the starter and if no abnormali...

Page 100: ...rush of the coil and yoke In this case the shunt coil grounding wire will be disconnected Check for disconnection coil between brushes There must be continuity at both ends of Check condi tion of inst...

Page 101: ...ore than 10 seconds d Return Test With the battery connected be tween the solenoid terminal M and the body pullout the pinion by hand as far as the pinion stopper If the pinion returns immediately whe...

Page 102: ...rgely depends on the wir ing and bat tery Use proper size wire for the distance between the battery and the starter and tighten the terminals securely ALTERNATOR CAUTION DO NOT USE A HIGH VOLTAGE TEST...

Page 103: ...same as the battery voltage a defective alternator is suspected 5 With the ammeter terminals short circuited start the engine CAUTION MAKE SURE THAT WHEN THE ENGINE IS STARTED NO STARTING CURRENT IS...

Page 104: ...cable to battery The voltmeter should indicate the battery voltage 6 Start the engine 7 Turn on the 12 volt accessories equaling the amperage output of the alternator accelerate the engine to the spe...

Page 105: ...e might result to the rectifier molding Therefore the plates B and L should be gently bent at the center Alternative method for disassembling the stator winding brush holder regulator unit and the int...

Page 106: ...d to bend the connecting plates between the brush holder and the rectifier and possible damage the rectifier molding When reversing this procedure make sure that the stator winding leads are gently pu...

Page 107: ...Replace the rotor assembly Stator Assembly 1 Check for continuity between the leads of the stator coil If there is no continui ty the stator coil is defective Replace the stator assembly 2 Check for a...

Page 108: ...t Check for con tinuity between the heatsink and stator coil lead connection terminal If there is con tinui ty in both directions the diode is short circuited Replace the rec tifier assembly Diode Tri...

Page 109: ...e brush holder Reassembly Reverse the disassembly procedure but pay special attention to reassembly of the following 1 Install seals in front and rear of the front bearing as shown 2 To install the ro...

Page 110: ...The sea water flow is created by a posi ti ve displacement neoprene impeller pump gear pump in certain special cases Normally the pump draws sea water directly from the ocean via the seacock and sea...

Page 111: ...rse the new gasket in water for a moment before installing Install the gasket cover screws and washers Note No sealant is needed on the cover gasket for proper sealing In you intend to reuse the cover...

Page 112: ...gs outer surface position plastic spacer and O ring on shaft Press bearings and shaft assembly on outer race of bearings Take care to see that the shaft passes through the seal without damaging it Pre...

Page 113: ...reassembling rever se the order of disassembly belt adjustment can be made in the following manner a Adjustment of Alternator Belt The al ternator belt should deflect 10 to 12 rom deep when pressed a...

Page 114: ...of two types One is simply a choking device which opens and closes as the engine temperature rises and falls The second type has a by pass mechanism Usually this is a disc on the bottom of the thermos...

Page 115: ...flowing through the thermostat and electr ically transmits this reading to a water temperature gauge in the engine instrument panel 14 TRANSMISSION OIL COOLER Certain transmissions require oil coolin...

Page 116: ...TRANSMISSIONS 113...

Page 117: ...tance and optimum adhesion of paint The transmissions are immersion lubricated Maintenance is restricted to oil level checks see Maintenance 2 GEAR CAS ING The rotating parts of the HBW transmission a...

Page 118: ...vely driven mechanically operated multiple disc clutch system mounted on the output shaft The thrust force required for obtaining positive frictional engagement between the clutch discs is provided by...

Page 119: ...forces exerted by the clutch discs and the shifting operation is completed as described above Power flow in lever position _ A 8 5 SHAFT BEARINGS Both the input and the output shafts are carried in a...

Page 120: ...clearly legible 3 CONNECTION OF GEARBOX WITH ENGINE A torsio elastic damping plate between the engine and the transmission is to compensate for minor alignment errors and to protect the input shaft f...

Page 121: ...at there is at least 020 inch clearance between the shift arm and the shift cover before retightening the securing bolt The shift cable and pedestal control must allow the transmission shift arm to mo...

Page 122: ...sealed with Loc Tite orange Therefore do not loosen the 4 capscrews Removal or disturbing of this cover will void all warranty responsibilities by Westerbeke When installing the gearbox make certain...

Page 123: ...PM including sudden reversing at top speeds in the event of danger 4 OPERATION WITHOUT LOAD Rotation of the propeller without load freewheeling e g while the boat is sailing being towed or anchored in...

Page 124: ...RATION Al ways use the same fluid type when topping up 4 FLUID CHANGE Change the fluid for the first time after about 25 hours of operation then at intervals of at least once per year 5 CHECKING THE C...

Page 125: ...engine stopped The level must be between the upper and lower dipstick marks when the dipstick is completely screwed inserted into the housing 4 Change the oil initially after the first 30 hours therea...

Page 126: ...GENERATOR SETS CONTENTS PAGE Manual Starter Disconnect Toggle Switches 124 Generator 3KW 60 Hz and 2 4KW 50 Hz 130 123...

Page 127: ...ER DISCONNECT TOGGLE SWITCHES WIRING DIAGFIAM Sit lIIOI e wT NOC R e f utl L S IItIESo IS AL TEII NATOJI IZVOl T IoO AlT RNATOA I I I I I I I I SCHEMATIC DIAGRAM L___ 1 8A PM H AT SOL 124 I I I I I tv...

Page 128: ...switch is a single pole single throw normally closed swi tch This swi tch provides power to the fuel run solenoid instrument cluster and alternator excita tion after the oil pressure switch has close...

Page 129: ...e gener ator may be stopped from local or remote posi tions The green indicator light in the remote panel signals that the engine has started and to release the START swi tch only Hold the PREHEAT dep...

Page 130: ...power not on 20 amp circuit breaker tripped Connection to solenoid faulty Faulty switch Faulty solenoid Loose battery connection Low batteries Poor connections to fuel solenoid Defective fuel run sole...

Page 131: ...and air Check fuel solenoid linkage and repair for free move ment Stop engine by depres sing emergency stop switch on engine or manually moving throttle to shut off Test switch with ohmmeter Depress e...

Page 132: ...Check for loose connec tions Check output with voltmeter Insure 12 V present at regulator terminal Observe if gauges and panel lights are acti vated when engine is not running Test the oil pressure s...

Page 133: ...AC 33 5 AMP at 230 VAC 8 0 KW 115 or 115 230 VAC 34 0 AMP at 230 VAC 11 0KW 115 or 115 230 VAC 46 0 AMP at 230 VAC 12 5KW 115 or 115 230 VAC 52 0 AMP at 230 VAC Frequency 60 Hertz Standard 50 Hertz av...

Page 134: ...itation Rectifier 230v Internal Wiring Diagrams 6 12 5 KW 115v and 115 23Ov 115V 115V 4 2 Armature AC AC Field Excitation Rectifier 131 Armature Internal Wiring Diagram 3 and 4 4 KW 2 Wire 115 Volt AC...

Page 135: ...E Gener ator armature slip rings and brush rigs are numbered from inboard at the windings or flywheel end outward toward the rear support bearing 2A Residual Voltage Check Disconnect field leads from...

Page 136: ...50 to 70 volts AC is produced this should indicate that the generator is O K and that the bridge rectifier is defective 4 If no voltage is produced check the static capacitor s that it is not shorted...

Page 137: ...the 3 wire unit If so an internal short in the armature winding exists Replace the armature 6 5 7 7 8 0 11 0 and l2 5KW 1 ohm or less between slip rings 1 3 and 2 4 NOTE 3 and 4 wire units There shoul...

Page 138: ...insure the field coils have been posi tioned properly in the generator housing and will have the correct polarity the following test must be made before reassembly of the generator 1 2 Connect a 9 12...

Page 139: ...Load Hertz No Load Voltage No Load Voltage Test Bridge Rectifier Bridge rectifier may be 1 Set ohmmeter scale on DC zero meter Rxl the 2 Connect the lead from the meter to Point i4 with the lead from...

Page 140: ...into the compartment and directed toward the inlet at the generator end bell 6 Check condition of brushes for wear and contact with slip rings on armature Insure brushes are not sticking in holders Hi...

Page 141: ...YOUR NOTES 138...

Page 142: ...various components and service procedures which are important to the proper functioning of your eng ine and its suppor t systems You should familiar ize yourself wi th the subjects and make sure that...

Page 143: ...tigue of the fittings used to make such a connection If these fittings fail the engine loses its oil pressure and very quickly seizes Such pressure sensing devices must be bulkhead mounted and con nec...

Page 144: ...entering sea water stream should be as low as possible which is achieved by having inlet fittings as big in diameter as possible In addition to the above design considerations it is usually advan tag...

Page 145: ...range shown PIN BATTERY AMPERE HOURS VOLTAGE is 60 90 12 V D C 90 125 12 V D C 90 125 12 V D C 90 125 12 V D C 90 125 12 V D C 90 125 12 V D C 125 150 12 V D C 125 150 12 V D C 125 150 12 V D C 125 15...

Page 146: ...sso ciated alternator In full power systems number 4 wire is recom mended from the alternator to the spli tter and from the spli t ter to the batteries 3 Connect the alternator output terminal to the...

Page 147: ...and will remain at the same voltage state of charge REGULATOR Ntti sPLITTER POWER DISC SW I_ oB PN20 6S4 STARTING BATTERY S POWER DISCONNECT SWITCH 20 a O sERVI CE _ BAiTERY S SEE NOTE LTERNATOR DRVJ...

Page 148: ...the above gauge tests are positive the gauge is undoubted ly O K and the problem lies either with the conductor from the sender to the gauge or with the sender If either of the above gauge tests is n...

Page 149: ...us total distances by various wire sizes to and from source to load Total Length System of wire in Volts feet 12 12 12 12 12 24 24 24 24 24 32 32 32 32 32 PIN 1 to 5 5 to 10 10 to 20 20 to 30 30 to 40...

Page 150: ...ng at the heater for bleeding the air Nhile filling the system Avoid loops in hose runs which will trap air If any portion of the engine cooling water circuit to or from the heater rises above the eng...

Page 151: ...EMOVe flE1URN SE P S JppL EO rn e l lG l I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I...

Page 152: ...e socket metal circumference of The correct socket can be acquired through well known tool manufac turers such as Snap On New Britain Cromwell Proto and others The use of channel lock pliers vise grip...

Page 153: ...t holds it against the air intake silencer to properly install and adjust the connecting linkage to the throttle arm Figure A MANUAL CHECK Check the operation and bottoming of the fuel solenoid plunge...

Page 154: ...the run position 010 020 inches off the throttle stop screw as the plunger bottoms in the fuel solenoid NOTE The throttle arm stop screw is adj usted and wired sealed at the factory to allow the throt...

Page 155: ...model refer to the cooling system section of your parts manual Replace the zinc pencil as inspection dictates Refer to Illustration A Should material be flaking off the zinc it should be scraped clean...

Page 156: ...Periodic inspection of the solenoid s operation is also recommended at the initial 50 hour servicing and every 200 hours thereafter PIN NOTE The flexible rubber boot cover ing the solenoid must not b...

Page 157: ...por tant part in moving air through the generator for cooling In instal lations where surrounding air is limited outside air should be ducted to the area of the screened end bell inlet to provide this...

Page 158: ...without the fan slipping on the shaft If properly torqued and fan still slips replace the lockwashers Recirculation of generator cooling air through the generator must be avoided The generator compar...

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