Westerbeke 16.0 WTA - 50 Hz Technical Manual Download Page 76

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Summary of Contents for 16.0 WTA - 50 Hz

Page 1: ...ngine WESTERBEKE 20 0 YD 60 Hz 20 0 WTA 60 Hz 16 0 WTA 50 Hz Marine Diesel Generators Publication 24331 Edition Three November 1990 jr v WESTERBEKE J WESTERBEKECORPORATION MYLES STANDISH INDUSTRIAL PA...

Page 2: ...ngine WESTERBEKE 20 0 YD 60 Hz 20 0 WTA 60 Hz 16 0 WTA 50 Hz Marine Diesel Generators Publication 24331 Edition Three November 1990 jr v WESTERBEKE J WESTERBEKECORPORATION MYLES STANDISH INDUSTRIAL PA...

Page 3: ......

Page 4: ...GENERAL Introduction Operation Installation Maintenance ENGINE OVERHAUL OTHER OVERHAUL Marine Engine Electrical System Cooling System External Transmissions GENERATOR SETS HYDRAULIC CRANKING SYSTEM SE...

Page 5: ...d by their manufacturers with 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 R...

Page 6: ...is also essential Another important factor is the use of the same brand of high detergent diesel lubricating oil designed specifically for diesel engines The diesel engine does differ from the gasolin...

Page 7: ...YOUR NOTES 4...

Page 8: ...pancies 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 lifting rin...

Page 9: ...d engine 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 po...

Page 10: ...load ALIGNMENT OF ENGINE The engine must be properly and exactly aligned with the propeller shaft No matter what material is used to build a boat it will be found to be flexible to some extent and th...

Page 11: ...and the bolts removed whe never the boat is hauled out or moved from the land to the water and during storage in a cradle The flexibility of the boat often puts a very severe strain on the shaft or th...

Page 12: ...e manifold usually using simple metal hangers secured to the overhead All dry portions of the exhaust system should be wrapped in suitable insulation material to keep surface temperatures as low as po...

Page 13: ...fuel tanks should not be used It is not necessary to mount the tank above the engine level as the fuel lift pump provided will raise the fuel from the tank The amount of lift should be kept minimum 6...

Page 14: ...e ments Starter batteries should be located as close to the engine as possible to avoid voltage drop through long leads It is bad practice to use the starter batteries for other services unless they r...

Page 15: ...the pilot station is in forward neutral and reverse the control lever on the transmission is on the respective detent Check the throttle control lever and the stop run lever on the fuel injection pum...

Page 16: ...ch of the top Check this level after engine has run for a few minutes If trapped air is released the water level may have dropped If so refill tank to within one inch of top and replace filler cap 4 E...

Page 17: ...d wrench loosen one to two turns the nut securing the injector line to the injector Bleed point B Decompress the eng ine wi th the lever on the top of the cylinder head Crank the engine over with the...

Page 18: ...following normal starting procedures WESTERBEKE WS8 WTO 20 Figure 7 1 Open the bleed screw on the top inboard side of the engine mounted secondary fuel filter one to two turns using a 10mm box wrench...

Page 19: ...Figure 3 Figure 4 Figure 5 16 Figure 6 Figure 7 Typical Mechanical Fuel Lift pump...

Page 20: ...osition This activates the panel gauges lights and fuel solenoid or electric fuel pump if so equipped Continue to turn the keyswitch to the Start position and hold for no more than 20 seconds Some uni...

Page 21: ...l each day of operation 4 Recheck Transmission Fluid level This applies only subsequent to a fluid change or new installation In such a case stop the engine after running for several minutes at 800 RP...

Page 22: ...d with a fuel solenoid or electric fuel pump which shuts off the fuel supply when the keyswitch is turned to the OFF position 5 Close the seacock 6 Disconnect power to system with battery switch OPERA...

Page 23: ...se of residual heat from the heavy metal masses near the combustion chamber Prevention for this is to run engine at idle for a short period before stopping it High temperature reading after a stop doe...

Page 24: ...emperature frequently to make sure it is 190 or less Close all drain cocks and refill with water before starting out Investigate any oil leaks immediately Race the engine in neutral Run the engine unl...

Page 25: ...inspect water level 7 Check for loose fittings clamps connections nuts bolts vee belt tensions etc Pay par ticular attention to loose engine mounts engine mount fit tings These could cause mis alignm...

Page 26: ...ilter element 12 Replace air filter 13 Change the fluid in the transmission Refer to the Transmission Section of this manual for details END OF SEASON SERVICE 1 Drain fresh water cooling system by rem...

Page 27: ...storing the battery the battery terminals and cable connectors should be treated to prevent corrosion Recharge battery every 30 days 15 Check alignment 24...

Page 28: ...also suitable COMPANY BRAND American Oil Co American Supermil Motor Oil BP Canada Ltd BP Vanellus BP Vanellus Chevron Oil Co RPM DELO Multi service Oil Cities Service Oil Co CITGO Extra Range Contine...

Page 29: ...YOUR NOTES 26...

Page 30: ...re disassembly rework and reassembly instructions for the guidance of suitably equipped and staffed marine engine service and rebuilding facilities The necessary procedures should be under taken only...

Page 31: ...table engine stand for disassembly 2 Drain the engine oil coolant from the engine heat exchangers and and 3 Drain all lubricant from the transmission 4 Remove engine wiring harness in its entirety Lab...

Page 32: ...tirety 8 Remove the engine alternator and sea water pump 9 Remove the engine mounted fuel filter and fuel line to injection pump Note arrangement of sealing washers on banjo bolts at fuel filter and i...

Page 33: ...he fuel injection pump Note washer arrangement on fuel return line banjo bolts Cap all openings on fuel return line injectors and injection pump b Remove the fuel injectors dust seals and sealing wash...

Page 34: ...be mating marks on pump body flange and the timing gear case before removal a Remove the cover 1 and the lock nuts 2 b Loosen the two inj ection pump hold down nuts 3 Do not remove entirely The hold d...

Page 35: ...place the nut on the injection pump shaft loosely and with a nylon dr ift and hammer gently tap the injection pump shaft to dislodge it from the keyed drive gear f Once loosened remove the hold down n...

Page 36: ...that all the pushrod tap pets are seated into the engine block prior to attempting to remove the camshaft from the block 29 Remove the timing gear case from the front of the engine block Discard the o...

Page 37: ...alve from the cylinder head appropriate valve spring compressor to aid Arrange or label valves so as to replace them in guide from which they were removed 36 Disassemble assembly the rocker arm 34 ass...

Page 38: ...on ring remover rings remove the piston b Remove the wrist pin snap rings c Using a nylon drift drive the wr ist pin from the piston and rod Note If the piston pin is tightly fitted heat the piston he...

Page 39: ...ion limit 1 2 0 10 mrn 0 004 in 3 4 5 6 0 25 mrn 0 010 in 3 Insert inspection Check for cracks or damage on the insert and if detected replace it 4 Insert replacement a To remove the insert place a su...

Page 40: ...width of valve seat is 2 0 mm O OS in for both intake and exhaust sides b If the valve margin is less than the permissible limit replace the valve Valve margin limit 1 35 rom 0 053 in 2 Stem wear insp...

Page 41: ...t replace the spring Limit Inner spring 1 25mm 0 049 in Outer spring 1 37mm 0 054 in 3 Fitting pressure check Check the valve spring fitting pressure with a valve spring tester and if the pressure is...

Page 42: ...il the valve guide height reaches the indicated scale on the valve guide installer Note Be sure to press in the valve guide so that the inside chamber on the valve guide end faces to combustion chambe...

Page 43: ...ance between the bushing and shaft becomes equal to the standard clearance Tappet 1 Visual inspection 2 a Check the tappet for cracks and other damage and if damaged replace the tappet b Check portion...

Page 44: ...r or replace it Distortion limit 1 2 0 10 mm 0 004 in 3 4 0 25 mm 0 010 in Cylinder Liner 1 Wear inspection 1 remove oC 1ting dowels beloM q ing striig ft edge y 2 3 Z a Measure the liner bore at thre...

Page 45: ...wear scratches or any other damage Inspecting clearance between piston and cylinder liner a Check the clearance be tween the piston and the cylinder liner by measuring the cylinder bore and piston dia...

Page 46: ...nspection Using a connecting rod aligner check the bend and twist of the connecting rod and if exceeding the limit repair it with a press or replace it Bend limit 0 05 mm 0 002 in per 100 mm 3 9 in 3...

Page 47: ...side play wi th the dial gauge and if it exceeds the limit replace the connecting rod and crankshaft Side play limit 0 40 rom 0 016 in 6 Inspecting connecting rod bearing Check the connecting rod bea...

Page 48: ...if the diameter is less than the 1imit ref inish the crank pin and main journal to size for the next undersize bearing Crank pin standard diameter 57 112 57 125 mm 2 2485 2 2491 in Main journal stand...

Page 49: ...e end play exceeds the limit replace the thrustwasher with 0 178 mm 0 007 in over size Standard End play limit 0 14 0 39 mm 0 0055 0 0153 in 0 40 mm 0 0157 in 5 Inspecting main bearing Check the main...

Page 50: ...in the cylinder block and camshaft journal diameter If the oil clearance is more than the limit replace the camshaft or cylinder block Oil clearance limit 0 145 rom 0 0057 in 5 Inspecting camshaft run...

Page 51: ...rface of idler gear and the spindle sliding surface and if necessary replace the idler gear or spindle b Check the oil passage for clogging and if necessary clean the passage with compressed air or wi...

Page 52: ...heck the backlash between each gear and if it exceeds the limit replace the gears Note Before inspecting the backlash check the end play of the idler gear and clearance between the idler gear bushing...

Page 53: ...ng seal worn or frayed pick the old seal halves out of their grooves and thoroughly clean the half housings b Wi th half housing held in a soft jawed vise and the seal recess uppermost settle one inch...

Page 54: ...2 lbf ft Oil Pump 1 Checking Visually check the disassembled parts and replace faulty parts Check the sliding surface of pump cover with special care and replace the cover if the surface has steps or...

Page 55: ...ce between the rotor and straight edge wi th a feeler gauge If the clearance exceeds the limit replace the dr i ve gear dr i ve shaft inner rotor outer rotor and pump body Clearance limit 0 15 rnrn 0...

Page 56: ...ve the oil pressure sender then install a mechanical oil pressure gauge instead of the sender 2 After warming up the eng ine speed then read the gauge engine set to 2400 RPM oil pressure OIP I Z 3 kgl...

Page 57: ...e bolts and nuts on important parts of engine to spe cified torques using a reliable torque wrench G Use liquid sealants when required on nuts bolts and gaskets Refrain from using tape sealants 1 Inst...

Page 58: ...to the backsides of main bearing shells a Fit the main bearings on the cylinder block and the bearing caps respectively Check that the oilways align perfectly wi th those in the block b Fit the thrust...

Page 59: ...e position as is shown in Figure c Install the caps to the connecting rods ensuring that the identification numbers on the cap and connecting rod are matched Cap tightening torque 8 2 9 0 m kg 59 65 f...

Page 60: ...m kg 11 6 17 4 ft lb 10 Install each gear a While aligning the timing mark of each gear install the following gears on each position 1 Timing gear 2 Cam gear 3 Idler gear 4 Injection pump drive gear...

Page 61: ...Install the injection pump drive gear cover on the timing gear cover c Install the timing gear cover and tighten the timing gear cover attaching nuts and bolts after the crankshaft pulley has been ins...

Page 62: ...rque 1 60 2 30 m kg 12 17 ft lb 16 Attach the backing plate Tightening torque 3 3 4 8 m kg 23 9 34 7 ft lb 17 Install the flywheel a Install the flywheel onto the rear end of the crankshaft b Install...

Page 63: ...ecurely set in the tap pet concavity eam Qbe 21 position the valve cap on the top of valve stem 22 Install the rocker arm assembly onto the cylinder head Remember that the end of the rocker shaft havi...

Page 64: ...clearance cold Intake 30 mm 0 12 in Exhaust 30 mm 0 12 in AFTER THE ENGINE HAS BEEN REASSEMBLED WARM UP THE ENGINE AND READJUST THE VALVE CLEARANCES 25 Install the thermostat and thermostat housing 2...

Page 65: ...kg 1 8 2 9 ft lb 35 Connect the fuel line to the engine mounted fuel filter and the line to the injection pump Use new sealing washers 36 Connect the high pressure injector lines from the injection pu...

Page 66: ...ylinder head Torque mounting bolts 2 7 3 3m kg 20 24 ft Ib 47 Install new hose connections and clamps for cooling system 48 Reinstall the marine transmission and fill with proper lubricant 49 Fill the...

Page 67: ...mbly taking the following precautions a Fill lithium grease lithium base NLGI No 2 into the following positions Ball bearings Approx 1 3 space between both ball bearings Space between the ball bearing...

Page 68: ...the specified value Normal idle speed 600 700 RPM 2 To adjust engine idle speed loosen the lock nut 3 of the idle adjustment bolt and turn the bolt clockwise to increase idle speed and counter clockw...

Page 69: ...C f device Diesel Kiki 57828 3520 in the bolt hole of the injection pump distributor head Refer to step c Insure that the feeler needle of the measur ing device is in contact with the plunger inside o...

Page 70: ...ding the lines b Remove the fuel return line in its entirety from the top of the injectors Take care not to lose the two sealing washers and banjo bolt that attaches the fuel return line to each injec...

Page 71: ...the injection starting pressure of the nozzle is not within the limit loosen the cap nut on the nozzle holder insert flat screwdriver through the bolt hole of cap nut then turn the pressure adjusting...

Page 72: ...or other damage on mating sur faces and sliding surfaces of nozzle body and needle valve and if present replace the nozzle assembly 5 Assembling Assemble in the reverse order of disassembly noting the...

Page 73: ...ector pop b Air bleed by pumping the injector pop tester handle several times c Slowly lower the injector pop tester handle and check the value shown on the pressure gauge when injection is started In...

Page 74: ...ck the ato mizing condition Avoid the spray Make sure that the fuel is atomized uniformly and properly Make sure that the injection angle and direction are normal d If the atomizing condition is incor...

Page 75: ...YOUR NOTES 72...

Page 76: ...N PAGE MARINE ENGINE ELECTRICAL SYSTEM Q Activation by Keyswitch 1980onwards 74 COOLING SYSTEM EXTERNAL R TRANSMISSIONS S Type HBW Short Profile Sailing Gear 84 Type BW Transrnission 93 Warner Hydraul...

Page 77: ...Models which have a fuel solenoid may be turned off via the keyswitch Models with mechanical fuel lift pumps or no fuel solenoid are stopped by pulling a stop cable Some models have a combined throttl...

Page 78: ...e WIRI NG DIAGRAM SEE NOTE W SENDER oUEL 50 W ONLY SEtNOTE O P SENOER NOT USfD SECTION Q ACTIVATION BY KEYSWITCH SCHEMATIC DIAGRAM PRE HEAT SO 75...

Page 79: ...YOUR NOTES 76...

Page 80: ...IRCUIT The sea water flow is created by a positive displacement neoprene impeller pump gear pump in certain special cases Normally the pump draws sea water directly from the ocean via the sea cock and...

Page 81: ...ew impeller will result from overheating 6 ENGINE FRESH WATER It is preferable to fill your engine with a 50 antifreeze water mix ture This precludes the necessity of draining coolant in the winter Si...

Page 82: ...ne through the engine oil cooler and back to the oil pump The oil cooler may be cooled either by engine fresh water or by sea water 10 TRANSMISSION OIL COOLER Certain transmissions require oil cooling...

Page 83: ...ake sure of proper align ment of all the parts This should be done in three steps Torque to 10 12 lb ft 3 Reassemble the end plates connectors on the manifold Be sure to use new gaskets and coat the g...

Page 84: ...SINGLE PASS MANIFOLD Note Drawing is indicative only Specific models may vary in detail 81 o _ENGINGOIl c I IC CO SEA IVA rE p RES HWAar R...

Page 85: ...YOUR NOTES 82...

Page 86: ...SECTION S TRANSMISSIONS 83...

Page 87: ...ding a predetermined value and thus ensuring maximum protection of the engine The transmission units are characterized by low weight and small overall dimensions The gearbox castings are made of a hig...

Page 88: ...ven shaft propeller side of the transmission is fitted with a forged coupling flange except on the V drive model 4 MULTIPLE DISC CLUTCH INCLUDING OPERATION POWER TRAIN The engine torque is applied to...

Page 89: ...e friction torque are thus propor tional to the input torque applied Due to the cup springs 48 sup porting the clutch disc stack and a limitation of the range of axial travel of the external disc carr...

Page 90: ...sealing rings The running surface on the shafts is casehardened 7 LUBRICATION The transmissions are immersion lubricated The bearings are generously supplied with splash oil and oil mist INSTALLATION...

Page 91: ...inor alignment errors and to protect the input shaft from external forces and loads Radial play should be at least 0 5 nun 4 SUSPENSION OF ENGINE GEARBOX ASSEMBLY IN THE BOAT To protect the gearbox fr...

Page 92: ...ver and cover should be 0 5 mm The control cable or rod should be arranged at right angles to the actuating lever in the neutral position of the lever A larger amount of lever travel is in no way detr...

Page 93: ...ius etc 7 ENGINE GEARBOX COMPARTMENT Care should be taken that the engine gearbox compartment is properly ventilated OPERATION 1 INITIAL OPERATION Fill the gearbox with automatic transmission fluid Th...

Page 94: ...propeller without load e g while the boat is sailing being towed or anchored in a river as well as idling of the engine with the propeller stopped will have no detrimental effects on the gearbox Locki...

Page 95: ...s of operation then at intervals of at least onceaper year 5 CHECKING THE CABLE OR ROD LINKAGE The cable or rod linkage should be checked at shorter time intervals Check the zero position of the opera...

Page 96: ...th the 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...

Page 97: ...is present at the required parts whenever the front pump is turning and it should be noted that supply is posi tive in forward neutral and reverse conditions The unit has seals to prevent the escape...

Page 98: ...n back check only immediately after the engine has been shut off and again after the engine has been stopped for more than one hour overnight is excellent A noticeable increase in the oil level after...

Page 99: ...oler to prevent contamination of the new transmission Water hoses may collapse and reduce or completely shut off all flow to the cooler Collapsed hoses are usually caused by aging of the hoses or impr...

Page 100: ...CHANGING OIL boats Work boats the oil becomes smelling A seasonal oil change is recommended in pleasure require more frequent changes Change oil anytime contaminated changes color or becomes rancid 6...

Page 101: ...cient size to insure proper cooling 5 Check engine rotation and transmission pump setting and the pro peller rotation prior to assembling the transmission to engine 6 Check oil pressure and temperatur...

Page 102: ...tuds toward the engine so that the spline on the shaft at the front of the transmission enters the matching splined hole in the engine vibration dampener D Install and tighten four bolts with lockwash...

Page 103: ...l under pressure to the oil distribution tube and relief valve The relief valve maintains the oil pressure by remaining closed until the oil pressure reaches 60 PSI When the control lever is shifted t...

Page 104: ...depends upon the angle of installation as well as the reduction model The level must be maintained at the mark on the dipstick and should be checked periodically to ensure satisfactory operation When...

Page 105: ...crocus cloth to free valve or replace e Defective pistons and oil distributor seal rings Replace seal rings f Defective oil pump Check for wear and replace if necessary a Low oil supply Add oil refer...

Page 106: ...Case 1 Water in Lubricating Oil 2 Excessive Oil in Engine Crankcase or Flywheel Housing 3 Oil on Exterior of Marine Gear 4 Loss of Oil from Transmission 103 a Bearings and gears worn excessively in ge...

Page 107: ...YOUR NOTES 104...

Page 108: ...SECTION T GENERATOR SETS CONTENTS PAGE Controls Manual Starter Disconnect Toggle Switches 106 Generator 15 20KW from September 1981 112 Generator 15 20KW YD Series to September 1981 123 105...

Page 109: ...GRAM WIRI NG DIAGRAM I I I 1 I I r L l I 1 I scc NOTe a wT S NOCR e f UEL SOL tl sa NOTE e o P SENOER 01 L PRESSURE SWITCH PRE HEATER wllT r 1t Tr T C _ _f I t J I I I L___ _ I I I r I L ___ _ II I 0...

Page 110: ...ally closed switch This switch provides power to the fuel solenoid instrument cluster and alternator excitation after the oil pressure switch has closed upon starting Opening of this switch opens the...

Page 111: ...C Generator When starting the generator it is always a good plan to switch off all A C loads especially large motors until the engine has come up to speed and in cold climates starts to warm up These...

Page 112: ...K Fuel solenoid not functioning No ignition cranks does not start Fuel solenoid energized Probable Cause Battery switch or power not on 20 amp circuit breaker tripped Battery switch or power not on 20...

Page 113: ...stop switch Test switch for proper oper by continuity test Stop engine with fuel line shut off Check oil fresh water and sea water cooling Check for satisfactory operation with switch bypassed Same a...

Page 114: ...tive 0 25 amp meter in battery lines Do not start engine Remove connections and replace until short is located Check all wires for tem perature rise to locate fault Disconnect alternator at output aft...

Page 115: ...or output so as not to damage the voltage regulating circuits found within the control box See figure 4 for alternator connec tion diagram OPERATION NOTE 1 Do not exceed the maximum alternator shaft s...

Page 116: ...CONDUCTING TOOLS IS ESSENTIAL FOR SAFETY REASONS ONLY QUALIFIED ELECTRICIANS OR PERSONS THOROUGHLY FAMILIAR WITH ELECTRICAL EQUIPMENT SHOULD ATTEMPT THIS ADJUSTMENT PREVENTATIVE MAINTENANCE MECHANICA...

Page 117: ...a low electrical resistance when measured to shaft 1 Remove the hole cover item 10 on top anti drive end of the alternator 2 Crank engine until the rectifier comes into view and lock to prevent engin...

Page 118: ...ied and employed as a source of supply for the remaining five electro magnetic poles on the exci ter stator The voltage regulator controls the current flow to these poles thereby effecting voltage reg...

Page 119: ...ue CAUTION SOME COMPONENTS CARRY LIVE VOLTAGE AND THE USE OF INSULATED TOOLS IS RECOMMENDED Increase the size of the wiring leading to the load s as required Load wires should not run hot at continuou...

Page 120: ...ad wiring and voltage regulating connector Repair or replace if faulty and check further for cause Check speed is 1800 RPM Remove obstruction Do not permit ambient tem perature to exceed 40 C 104 F an...

Page 121: ...10 G12 I I I ONLY I I I I 1 I I 1____ 1 L __ 11 I I f 1 3 PHASE BRIDGE I I RECTIFIER L _____ l L __J ITEM 20 4 120V FROM T3 OR TAP USER TO ENSURE TH IS GROUND CONNECTION IS MADE THREE PHASE TYPICAL 6...

Page 122: ...T4 T4 0 T5 T5 T5 120 240 V SINGLE PHASE TI 1I t 3 0 trJ T2 t 3 0 tI T3 I _ L2 0 z Z trJ T4 t 3 H 0 z T5 0 H x oo T6 N T6 G RAME T6 c N 0 T7 IZ o T7 V fRAME SINGLE PHASE ALTERNATOR T8 T8 120 V 120 240...

Page 123: ...Figure 2 120...

Page 124: ...Ring 14 Cap Screw 0 312 18 UNC x 1 25 6 15 Lockwasher Split 0 313 6 16 Clamping Ring 17 Inlet Air Screen 4 18 Drip Shroud Inlet Air 19 Ball Bearing Anti drive End 20 Bridge Rectifier 21 Complete Rotor...

Page 125: ...YOUR NOTES 122...

Page 126: ...tor shaft it has a nut on the outside of the end bell A centrifugal blower on the front end of the rotor shaft circulates the generator cooling air which is drawn in th rough the end bell cover and di...

Page 127: ...wiring diagrams for typical control boxes on electric generating sets The electrical schematic and printed circuit board are shown in Figure 5 The voltage adjust rheostat Rn is optional on either VR22...

Page 128: ...3 09K 1 4W Resistor Film 28 0K 1 4W Resistor 8 2K Ohm 1 2W Res istor ISOK Ohm 1 2W Resistor 2700 0hm 1 2W Resistor Film 12 IK Ohm 1 4W Resistor Wire Wound 4K 5W Resistor I MEG Ohm 1 2W Resistor lOOK O...

Page 129: ...CONNECTION SCHEMATIC DIAGRAM 8 LI T3 TI iT4 T2 L2 L TlfX T8 L2 TI T7 T2 TI T5 T6 12 LO T3 9 L3 LITI L2 T4 T5 T7 niT TIO LO Tl2 TJr9 LI 9TI2 T6 TI L3 3 T4 Til rJ 0 T TIO T2 L2 6 LI T3 1 1 T5 T2 T4 1 0...

Page 130: ...eplate voltages Control components may have to be changed to match new current ratings when field reconnection for other voltage codes or voltages are made Under no circumstances shall the gene tor be...

Page 131: ...t if printed circuit board VR21 has been replaced or if damping potentIometer R27 has been unnecessarily adjusted it may be necessary to reset stability Set stability as follows 1 With generator set r...

Page 132: ...f residual is too low and the output voltage will not build uP flash the field as follows Proceed Table 1 with checkout according to steps in STEP NO I 2 3 4 5 1 Locate terminals 7 and 8 on voltage TA...

Page 133: ...hown in the il lustrations herein Use the following test procedures for testing generator components in conjunction with the troubleshooting tables F TESTING ROTATING RECTIFIERS Two different rectifie...

Page 134: ...ut voltage to the exciter field These SCR S are mounted in heat sinks on the voltage regulator and are tested as follows 1 Unsolder leads from CRl3 and CRl6 2 Using high scale on ohmmeter connect ohmm...

Page 135: ...ry leads H1 H2 T21 X 1 f I f l X 2 1 Resistance between H H2 should be 122 to 150 ohms 2 Resistance between X X2 should be 157 to 192 ohms 3 Resistance between H X H X2 H2_X and H2_X2 should be infini...

Page 136: ...Perform tests as follows 1 Remove rotor leads F and F2 from rotating rectifier assemblies 2 Connect ohmmeter leads between F and rotor shaft and between P and rotor shaft Meter should not register 3 I...

Page 137: ...SE MODELS TEST BETWEEN WIRE PAIRS TI T4 T7 TIO T3 T6 T9 T12 T2 TS T8 TII SINGLE PHASE MODELS TEST BETWEEN WIRE PAIRS TI T2 T3 T4 FIGURE 18 TESTING STATOR WINDINGS accurate instrument for this test suc...

Page 138: ...sary label the following wires 3 4 5 or 6 7 8 9 and 10 3 Remove four screws at corners 4 Remove used PC board 5 Install new PC board secure with four screws 6 Reconnect wires removed in step 2 at the...

Page 139: ...LING TO AVOID BENDING THROUGH STUD I INSERT PRY 8E HIND v R W E L THROUGH AI R UTLET OPENI JG TURN NUT OUT TO END OF GENERATOR TH ROUGH S T uIJ STRIKE WITH SOFT lAMMER VHI E 8RUSHLESS EXCITER PRYING F...

Page 140: ...nnections TROUBLESHOOTING PROCEDURES This troubleshooting information is divided into tables A B C and D as follows A No build up of AC output voltage B AC output voltage builds up but is unstable C A...

Page 141: ...tage Yes No Test 10 Are generator stator Builds Up But is Proc windings OK 11 N High or Low 11 Is commutating reactor CMR21 OK 12 I 12 Is reference transformer 1 Is set running at correct RPM See appr...

Page 142: ...be defective 8 Is brushless exciter stator winding OK 9 9 Is generator rotor field winding OK 10 10 Is brushless exciter rotor OK 11 11 Are generator stator windmgs OK 6 No Test Proc 7 3 G J P F K M...

Page 143: ...YOUR NOTES 140...

Page 144: ...about var ious components and service procedures which are important to the proper functioning of your engine and its support systems You should familiarize yourself with the subjects and make sure t...

Page 145: ...engine vibration causes fatigue 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 bu...

Page 146: ...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 tage...

Page 147: ...KW BATTERY RECOMMENDATIONS BATTERY AMPERE HOURS 60 90 90 125 90 125 90 125 90 125 125 150 125 150 125 150 125 150 150 170 170 200 200 minimum VOLTAGE 12 V D C 12 V D C 12 V D C 12 V D C 12 V D C 12 V...

Page 148: ...ciated alternator In full power systems number 4 wire is recommended from the alternator to the splitter and from the splitter to the batteries 3 Connect the alternator output terminal to the center s...

Page 149: ...oltage state of charge i t REGULl T I i J SEE _1 DRVIG JI 2070 I S LITTER I r lA PN20 654 I 20 f RNATOR v POWER DISC SW STARTI NG B TTEiRY S POWER DISCONNECT SWITCH a 5ERVI CE BATTERY S oJ Q 5TARTER J...

Page 150: ...h of the above gauge tests are positive the gauge is undoubtedly 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 i...

Page 151: ...engine If trapped air can rise to the heater then a petcock or other convenient method of bleeding that air is a necessity Study the attached sketches A convenient place to interrupt the engine cooli...

Page 152: ...NE iOTHERMOSTAT 1 HOUSI NG It a r If REMOVE WATER HEATER 6 SINGLE PASS MANIFOLD PRESSURE CAP MUST BE LOWER PRESSURE THAN ENGINE CAP FILL WATER HEATER AL ERNA TE INST IF HEATER COIL IS HrG iER THE N EN...

Page 153: ...screw Westerbeke P N 11357 Particular attention should be paid to this set screw at the time of commission ing of the engine and during regular servicing of the engine Ensure that it is tight If not...

Page 154: ...total distances by various wire sizes to and from source to load System Total Length of wire in I Volts feet 35 12 to 5 12 12 5 to 10 10 12 10 to 20 6 12 20 to 30 6 12 30 to 40 4 24 1 to 5 14 24 5 to...

Page 155: ...fitting at the heater for bleeding the air while 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 th...

Page 156: ...J EMO ff ET N eE O SUf P JEO n e1 lG 1 lE V 1 3 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 157: ......

Page 158: ...22208 and thus allow for the original factory adjusted shift pattern to be maintained IMPORTANT Removal or disturbing of the shift cover will void all warranty responsibi lity by Westerbeke Any HBW T...

Page 159: ...testing 1 The above chart is intended for reference use only as a 10 percent tolerance on these figures is common Comparison of ratios of actual readings to the above figures is often a more accurate...

Page 160: ...Lr J eXCITER STATOR GROUNO STUD User to insure this ground connection is made NOTES F3 F4 are tied together with butt connector in harness from generator to control panel A1 A2 are accessible only at...

Page 161: ...inc on your model refer to the cooling system section in your parts manual Replace the zinc pencil as inspection dictates refer to Illustration A Should material be flaking off the zinc it should be s...

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