Westerbeke 16.0KW-60Hz BED Service Manual Download | Manualshive

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Summary of Contents for 16.0KW-60Hz BED

Page 1: ...SERVICE MA UAL 71 B FOUR 71 DIESEL and 6 0KW 50Hz DIESEL TORS SINGLE AND THREE PHASE PUBUCATlON NO 43317 2ND EDITION I MARCH 2010...

Page 2: ...ess gas Carbon Monoxide is poisonous and can cause unconsciousness and death Symptoms ofCarbon Monoxide exposure can Include Dizziness Throbbing in Temples Nausea Muscular Twitching Headache Vomiting...

Page 3: ...ear the carburetor fuel line filter fuel pump or other potential sources of spilled fuel or fuel vapors Use a suitable container to catch all fuel when removing the fuel line carburetor or fuel filter...

Page 4: ...er Acid may splash on the skin or into the eyes inadvertently when removing electrolyte caps TOXIC EXHAUST GASES A WARNING carbon monoxide CO Is adeadlygas Ensure that the exhaust system is adequate t...

Page 5: ...ong with other cautions and notes to highlight critical information Read your manual carefully maintain your equipment and follow all safety procedures ENGINE INSTALLATIONS Preparations to install an...

Page 6: ...n break in the raw water supply hose to the exhaust elbow This hose must be looped a minimum of 18 above the vessel s waterline Failure to use a siphon break when the exhaust manifold injection port i...

Page 7: ...el Injection Pump 30 Electronic Governor 57 Fuel Lift Pump 31 Electronic Governor Troubleshooting 58 Fuel Injectors 32 Shore Power Transfer Switch 59 Glow Plugs 34 DC Wiring Diagram generator 60 Engin...

Page 8: ...name plate located on the generator end You must provide us with this information so we may properly identify your engine generator In addition include a complete part description and part number for...

Page 9: ...sion pressure tends to increase a little in a new engine until piston rings and valve seats have been broken in Thereafter it decreases gradually with the progress of wear ofthese parts When decrease...

Page 10: ...or replace starter 6 Check clutch for disengagement 1 Bleed air from fuel system 2 Clean or replace filter 3 Adjust injection pressure 4 Clean or replace nozzle 5 Repair or replace injection pump 6 A...

Page 11: ...on ring 3 Replace ring 4 Worn piston or cylinder 4 Replace piston and rebore cylinder OIL LEVEL FALLING 1 Defective stem seal 1 Replace stem seal 2 Worn valve and valve guide 4 Replace avalve and valv...

Page 12: ...TING ROD AND CONNECTING ROD BEARING 1 Worn connecting rod big end bearing 1 Replace bearing 2 Worn crankpin 2 Grind crankshaft 3 Bent connecting rod 3 Correct bend or replace PISTON PISTON PIN AND PIS...

Page 13: ...ay a Clean or replace nozzle h Poor chattering h Repair or replace nozzle c After injection drip c Repair or replace nozzle d Nozzle needle valve seized d Replace INTERMITTENT 1 Fuel filter clogged 1...

Page 14: ...the engine of any deposits of dirt and oil Be careful not to damage the disassembled parts Mount the engine on suitable engine stand for disassembly 1 Drain the engine oil and coolant from the engine...

Page 15: ...njo bolts Cap all the openings on the fuel return line injectors and injection pump a Remove the fuel injectors dust seals and sealing washers from the cylinder head b Remove the glow plugs 18 Remove...

Page 16: ...wn nuts will prevent the pump from falling from the engine EXTRACTOR HOLES NOTE Ifan extractor is not available replace the nut on the injection pump shaft loosely and with a nylon drift and hammer ge...

Page 17: ...remove the oil pump assembly 29 Remove the camshaft carefully Insure that all the pushrod tappets are seated into the engine block prior to attempting to remove the camshaft from the block 30 Remove t...

Page 18: ...drive the wrist pin from the piston and rod PISTON I IST N RING I I I I i I 1 lARGE END _ L PISTON ASSEMBLY d Protecting your eyes with safety glasses disengage and withdraw the snap rings Although m...

Page 19: ...a suitable drift into the injection nozzle hole then tap the drift with a hammer To install set the insert in position and insert the welch washer into the insert guide hole Secure the welch washer b...

Page 20: ...111m 0 020 0 059 in from the standard replace the valve and adjust the dimension L to the standard by adding some washers between the lower spring seat and the cylinder head f When dimension L become...

Page 21: ...Ib 14 5 kg 32 0 lb VALVE SPRING TESTER SJ TESTING THE SPRING FIniNG PRESSURE SPECIMEN VALVE SPRING VALVE GUIDE 1 Inspecting clearance between valve and guide Set a dial gauge with a magnet and check t...

Page 22: ...standard clearance REPLACING THE BUSHING REAMING THE BUSHING BORE TAPPET 1 Visual inspection Check the tappet for cracks and other damage and if damaged replace the tappet Check for abnormal wear of...

Page 23: ...usion and correct it if necessary Protrusion Limits 71 B 0 101 0 000 mm 0 0040 0 0000 in 71C 0 659 0 790 mm 0 026 0 031 in PROTRUDING LENGTH PISTON AND PISTON RING 1 Visual Inspection Check the slidin...

Page 24: ...0006 0 0016 in Limit 0 05 mm 0 002 in PISTON PIN BUSHING r 4 Small end bushing replacement Using a press press out the bushing Align the oil passages of the connecting rod and the small end bushing pr...

Page 25: ...Inspection Check the crankshaft for cracks or other damage Ifcracking is suspected thoroughly clean the crankshaft and perform a color test on the shaft or run a can dle flame over the crankshaft and...

Page 26: ...oversize Crankshaft end play is measured by setting a dial gauge on the rear end of the crankshaft and moving the crankshaft in the axial direction Crankshaft End Play 71Bn1C Standard 0 14 0 39 mm 0 0...

Page 27: ...GEAR SPINDLE 1 Visual inspection Check the damage on the bushing inner surface of the idler gear and the spindle sliding surface and if necessary replace the idler gear or spindle Check the oil passa...

Page 28: ...worn or frayed pick the old seal halves out of their grooves and thoroughly clean the half housings a With half housing held in a soft jawed vise and the seal recess uppermost settle one inch 25 mm o...

Page 29: ...ed The latter rocker shaft fasteners sho uld be bro ught do wn in very small increments wo rking fro m the center bo lts o ut Gaskets especially head gaskets might alSo be damaged during assembly they...

Page 30: ...ends are properly spaced around the circumference of the piston as shown on the previous page h Using a ring compressor fit the piston into the cylinder in the position as is shown c Install the caps...

Page 31: ...cover on the timing gear cover b 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 t...

Page 32: ...end of the engine 25 Tighten the cylinder head bolts Tighten the cylinder head bolts evenly in the sequence shown Tightening Torque 71 B 11 8 12 5 m kg 85 90ft lh 71 C 11 0 11 7 m kg 80 85ft lh 14 10...

Page 33: ...the front engine mounting bracket Tightening Torque 71 B 71 C 4 6 6 8 m kg 33 49ft lb 33 Install the intake manifold Tightening Torque 71B 71C 1 6 2 4 m kg 11 6 I7 4ft lb 34 Mount the fuel filter asse...

Page 34: ...ll the breaker panel and the preheat solenoid 48 Reinstall the engine electrical harness 49 Mount the complete exhaust manifold and the expansion tank to the cylinder head Torque Mounting Bolts 2 7 3...

Page 35: ...all the parts This should be done in three steps Torque to 10 12 lb ft c Reassemble the manifold end plates 71B and the connectors on the manifold Be sure to use new gaskets and coat the gasket surfa...

Page 36: ...rclockwise to reduce NOTE Should engine RPM be in question verify tachometer readings as shown at the instrument panel with a mechanical or strobe type tachometer at the engine crankshaft ADJUSTING ID...

Page 37: ...n pump Install the injection pump in the reverse order of removal noting the following points a Tighten the lock nut of injection pump drive gear to the specified torque Tightening Torque Injection Pu...

Page 38: ...the same time clean or replace the filter h Set the nozzle tester in a clean place where there is no dust or dirt c Mount the nozzle and nozzle holder on the nozzle tester d Use the fuel at the approx...

Page 39: ...use a metal tool to remove the carbon S After cleaning check to see if the needle valve comes down into the valve seat by its own weight when setting the nozzle body upright position and inserting nee...

Page 40: ...rod to the glow plug s wire connection and the other to the body of the glow plug as shown A good glow plug will have a 1 0 to 1 5 ohm resistance This method can be used with the plug in or out of the...

Page 41: ...STI 12 EX AUST 4 INTAKE 3 INTAKE 2 INTAKE 1 INTAKE 3 EX AUST 11 EXH USTI 3 2 1 1 WHEN NO 1 CYLINDER IS AT TOP DEAD CENTER 7 Tum the crankshaft once setting the piston of No 4 cylinder at TDC compressi...

Page 42: ...ow plugs use anti seize compound SETTING THE IDLE SPEED 1 Warm the engine to nonnal operating temperature 2 Stick a piece of suitable reflecting tape on the crankshaft pulley 3 Idle the engine 4 Use t...

Page 43: ...order of disassembly using the following procedure 1 Fill lithium grease lithium base NLGI No 2 into the following positions Ball bearings Approximately 1 3 space between both ball bearings Space bet...

Page 44: ...2 in INNER ROTOR o I f1TALLY MARKS 4 Clearance between outer rotor and pump body Check the clearance between the outer rotor and pump body with a feeler gauge Ifthe clearance exceeds the limit replace...

Page 45: ...rect socket which Is avaIlable from Snap On Proto NewBritain andothers Damage to the swItch will cause oil leaks and orswitch faIlure CURRENT ENGINES AND GENERATORS EARLY MODEL ENGINES OIL PRESSURE To...

Page 46: ...ill release the shaft bearing and seal assembly Removing the retaining rings will allow the bearings and seals to be disassembled for inspection NOTE It may be necessary to use a drift and arborpress...

Page 47: ...stroke called pinion gap 3 Ifthe pinion gap is not within the standard range 0 5 to 2 0 rom adjust it by increasing or decreasing the number of shims on the solenoid The gap is decreased as the numbe...

Page 48: ...bolts and remove the center bracket At the same time the washers for the pinion shaft end play adjustment will come off STARTER MOTOR ilNSPECT FOR IWEAR CHIPPING 4 Return test With a battery connecte...

Page 49: ...it if the service limit is exceeqed Also check the commutator outside surface for dirtiness and roughness If rough polish the commutator withfine crocus cloth Commutar O D Standard Brush and Brush Ho...

Page 50: ...nd play adjustment Set the end play thrust gap to between 0 5 to 2 mm by inserting an adjusting washer between the center bracket and the reduction gear a Fit the pinion shaft reduction gear washer an...

Page 51: ...ation access hole No results repair or replace meter b AC voltage not present check for proper alternator DC output voltage c Check for AC voltage at tach terminal on alternator to ground d Check elec...

Page 52: ...ce battery is not discharged along with the service battery If the alternator is charging the starting battery but not the service battery the problem is in the service battery charging circuitand not...

Page 53: ...e the wiring looking for breaks andpoor connections Alternator is Working 5 Check the voltage of the service battery This battery should have a voltage between 13 and 14 volts when the engine is runni...

Page 54: ...when cranking A switch with a continuous rating of175 amps at 12 VDC will normally serve this junction but a switch must never be used to make the starter circuit r I I PROPULSION ENGINE WIRING DIAGRA...

Page 55: ...II I I UFT UN _ 4_ _ __ P FUlL _I I V IE c J ALARM 0 SEIDEl FACIIOMETEI TO OPTIONAL ALTERNAIORS ADMIRAL PANEL CAPTAIN PANEL pRfSIOI I IE 72 AMP ALI 114 T 8 UN I yfRSAL PROPULS ION PRESIOIIIE 51 AMP A...

Page 56: ...n the vessel in which the generator is installed conIIlinsAC equipmentof120 volts Qnly it is recommended thatthe generator sAC terminal block be configured to pro vide one 120 voltAC hot leg for the v...

Page 57: ...ccording to amperage load the gener ator is furnishing To maintain a constant voltage output INTERNAL WIRING SCHEMATIC CIRCUIT BREAKER A circuit breaker is installed on all WESTERBEKE genera tors This...

Page 58: ...n terminal B and 10 CASE GND 170 270 V 3 PHASE VOLTAGE REGULATOR PARAU EL WYE STAR L L 208 VAC 30 50 Hz L N 120 VAC 10 60 Hz L L 190 VAC 30 50 Hz t N 110 VAC 10 60 Hz BlK AVR 180 160 V CASE GND SERIES...

Page 59: ...result of engine generator speed 1800 rpm 60 hertz 1500 rmp 50 hertz 2 To change generator frequency follow the steps below Configure the AC terminal block for the desired voltage frequency as shown...

Page 60: ...ntiometer Each of the two circuits are able to cause an adequate reduction in excitor voltage to safeguard the excitor windings and prevent their overheating The overload protection system has a delay...

Page 61: ...LOW THREE PHASE RED 1 1 I I I STATOR I RED r 6 WIRE RECONNECTABLE EXCITER RED RED RED W2 U1 V1 BLACK GREEN r I STATOR I i U2 _ B lACK t I r 1_2BLACK ___ UI I I I I I l _ o w I I I V2 G RETNENrfI1 r 1_...

Page 62: ...des on exciter rotor 1 Blown 6AMP buse fuse auxiliary circuit feed to AVR 2 Faulty voltage regulator 1 Open or shorted diodes in exciter rotor 1to 3diodes 2 Open or shorted exciter rotor winding 1 Fau...

Page 63: ...ing mode In such cases lessen the gain adjustment Calibration 1 With no power to the governor engine not running adjust the GAIN potentiometer to 9 00 o clock 2 Start the engine and adjust the speed b...

Page 64: ...essed and stays extended actuator leads from the terminal block Depress PREHEAT a Actuator fully extends a Short in lead to actuator b Actuator does not fully extend and b Replace controller connectio...

Page 65: ...us connection of shore power to generator output A CAUTION 8amage to the generator can result if utilityshore powerandgeneratoroutputare connected at the same time This type ofgenerator damage isnot c...

Page 66: ...NOTE 2 An on offswitch should be installed in this circuit to disconnect the starter from the battery in an emergency and when leaving the boat Twelve volt diesel engine starters typically draw 200 to...

Page 67: ...W FUEL SOl K I REMOTE START STOP PANEL A 55A SURGE 22A START ______________________ 3A RUN I RED ____ _____ TO TBt l L T 14GhEEN IA REEN STOP TB1 GND SWITCH I 22 I BLACK I I I ____ l LV i l _TOT82 1 I...

Page 68: ...aust Opens 51 BBDC Exhaust Closes 13 ATDC Intake 45 Exhaust 300 Intake 0 012 inches 0 3 mm Exhaust 0 012 inches 0 3 mm 1800 RPM 60 Hertz 1500 RPM 50 Hertz 1920 71 0 psi 135 5 0 kglcffi2 Static timed d...

Page 69: ...Hertz no load to full load 20 KW 60 Hertz 1800 rpm 120 Volts 166 Amps 1201240 Volts 166183 Amps 16 KW 50 Hertz 1500 rpm 230 Volts 72 7 Amps General 3 Phase Brushless six pole revolving field 20 0 KW...

Page 70: ...pm 3 0 kglcm2 431b in2 0 3 0 012 0 3 0 012 mm in 0 10 0 004 Positions 1 2 0 25 0 010 Positions 3 6 48 0 1 89 49 55 1 95 48 05 1 89 49 55 1 95 45 300 2 0 0 079 2 0 0 079 1 35 0 053 mm in 0 038 0 085 0...

Page 71: ...Liner Protrusion above Cylinder Block mm in 173 Q12 173 063 6 811 6 813 0 05 per 100 0 002 per 3 94 28 012 28 033 1 103 1 104 0 012 0 031 0 0005 0 0015 0 05 0 002 0 239 0 330 0 009 0 013 0 4 0 016 0...

Page 72: ...0 07 0 001 0 03 0 3 0 012 0 350 55 0 014 0 022 0 350 55 0 014 0 022 0 350 55 0 014 0 022 1 5 0 059 27 994 28 000 1 1021 1 1024 27 996 28 008 1 1022 1 1027 mm in 88 880 0 013 3 4989 0 005 0 054 0 080...

Page 73: ...910 51 940 2 044 2 045 51 660 51 690 2 034 2 035 51 410 51 440 2 024 2 025 51 160 51 190 2 014 2 015 0 008 0 0003 52 000 52 030 2 047 2 049 51 750 51 780 2 037 2 039 51 500 51 530 2 028 2 029 51 250...

Page 74: ...3 1 Injection Nozzle to Body 6 0 8 0 43 58 8 10 58 72 Injection pipe Flare Nut 2 5 3 0 18 22 2 5 3 0 18 22 Injection Pump Drive Gear Lock Nut 4 0 7 0 29 51 4 0 7 0 29 51 Injector Hold Down Nuts 1 6 2...

Page 75: ...Cold Cranking Amps CCA DC Charging Alternator Starter Starting Aid DC No Load Current DC Cranking Current 51 Amp rated belt driven 12 Volt reduction gear 3 WI Glow plugs sheathed type 2 of rated Amps...

Page 76: ...ut 2 101 3 159 1 14 0 22 0 Grade 6T Grade 5 Cap Screw 6mm bolt head nut 1 4 3 6 5 0 6 0 9 1 4 UNC 9 11 1 2 1 5 Smm bolt head nut 1 25 10 S 15 9 1 5 2 2 1 4 UNF 11 13 1 5 1 S 10mm bolt head nut 1 25 21...

Page 77: ...6168 2 1 82880 7 6 40080 2 2 18723 7 7 65529 3 2 74320 8 7 31520 3 3 28084 8 8 74891 4 3 65760 9 8 22960 4 4 37445 9 9 84252 5 4 57200 10 9 14400 5 5 46807 10 10 93614 MOVE DECIMAL POINT FOR HIGHER VA...

Page 78: ...haul 040 Engine Inspection 13 Rear Oil Seal 22 Engine Reassembly 23 Regulator Voltage 54 Engine Specifications 69 Regulator Voltage Adjustments 54 Exhaust Manifold 29 Rocker Arm Inspection 16 Frequenc...

Page 79: ...Case 11 Engine 4 Timing Cover 22 Valve Clearance 26 35 Timing Gear 11 Valve Guide 15 Tolerances and Limits Valve Seat 13 Camshaft 67 Valve Spring 15 Connecting Rod Connecting Rod Bearing 65 Voltage Re...

Page 80: ...IWM k 4 98 5C WESTERBEKE WESTERBEKE CORPORATION AVON INDUSTRIAL PARK AVON MA 02322 TEL 508 588 7700 FAX 508 559 9323...

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