Page 1: ...SERVICE MANUAL 90AFOUR MARINE DIESEL ENGINE and 32 0 KW 60 Hz BEDA 25 0 KW 50 Hz BEDA MARINE DIESEL GENERATORS SINGLE AND THREE PHASE PUBLICATION NO 43750 Revision 2 I February 2018 rw WESTERBEKE...
Page 2: ...Throbbing in Temples Muscular TWitching Vomiting Weakness and Sleepiness Inability to Think Coherently IF YOU OR ANYONE ELSE EXPERIENCEANY OF THESE S ltfPTOMS GET OUTINTO THE FRESHAIR IMMEDIATELY Usy...
Page 3: ...ingle and Three Phase 106 Generator AC Voltage Connections 107 Voltage Regulator Adjustments 109 Internal Wiring Schematics 11O BE Troubleshooting 112 Electronic Governor 113 Troubleshooting the Elect...
Page 4: ...shooting of your marine engine critical information will be highlighted by NOTES CAUTIONS and WARNINGS An explanation follows NOTE An operating procedure essential to note A CAUTl ON Procedures which...
Page 5: ...low to provide a quick reference when using this service manual SPECIFICATION MODEL RPM___________ KW ____________ KVA VOLTS _________ AMPS ENG HP ENG SER NO GEN SER NO PF PHASE WIRES_________ RATING_...
Page 6: ...Timing Nozzle Fuel filter on engine Air Intake Silencer Air Flow engine combustion Fuel consumption i FUEL SYSTEM Closed SYStem with ble points 2 D Cetane of 45 orhigher SAEJ313 Diesel grade accordin...
Page 7: ...ANT TEMPERATURE SWITCH COOLANT TEMPERATURE SENDER FUEL PRIMER OIL PRESSURE SENDER IDENTIFICATION PLATE REAR FRONT RIGHT SIDE LEFT SIDE STARTER WITH SOLENOID ENGINE OIL FILTER REAR FRONT Engines Genera...
Page 8: ...rhaul it is important to measure the engine com pression pressure regularly At the same time the engine speed at which the measurement ofcompression pressure is made should be checked because the comp...
Page 9: ...on pump faulty e Inspect pump Repair or replace pump as needed 2 Fuel injectors faulty inadequate spray 2 Remove and test nozzles Repair nozzles as needed 3 Low injection pressure 3 Adjust injection p...
Page 10: ...4 Leak in fuel line or fuel filter 4 Repair fuel line or replace fuel filter 5 Air in injector fuel line injection pump fuel filter or fuel filter water separator 5 Bleed air 6 Seized or leaky deliver...
Page 11: ...e compartment air supply KNOCKING ENGINE KNOCKS WITHOUT MUCH SMOKE 1 Main engine troubles 1 Check a and b a Overheated cylinder c a See ENGINE OVERHEATS SHUTS DOWN LOW OUTPUT b Carbon deposits in cyli...
Page 12: ...Replace timing gear 4 Broken valve spring 4 Replace valve spring 5 Excessive clearance between rocker arm and bushing 5 Replace bushing 6 Excessive clearance between idler gear bushing and 6 Replace b...
Page 13: ...VERIFICATION REMEDY __ 1 Warm up engine 2 Correct oil level 3 Check a through f a Check b Clean or replace c Correct or replace d Replace valve stem and guide e Replace engine oil f Inspect the lubric...
Page 14: ...tion starting pressure 2 Adjust starting pressure 3 Seized nozzle 3 Replace nozzle 4 Worn nozzle 4 Replace nozzle 5 Nozzle leaking 5 Tighten nozzle or replace sealing gasket 6 Injector not operating p...
Page 15: ...oil cooler 3 Clean 4 Diesel fuel is diluting the oil 4 Injection pump repair ENGINE OVERHEATS 1 V belt slackening or slippery with oil 1 Adjust replace or clean belt SHUTS DOWN 2 Low oil level or poor...
Page 16: ...NOTE For transmission service and maintenance refer to your transmission owner s manual To rebuild a transmis sion contact your WESTERBEKE dealer or a qualified marine transmission service facility If...
Page 17: ...THE FLYWHEEL WITH ARING GEAR BREAK TOOL REMOVING THE FLYWHEEL 10 Remove the engine back plate 11 Remove the exhaust manifolel 12 Remove the alternator and alternator adjusting strap 13 Remove the raw...
Page 18: ...skets 27 Remove the fuel injectors 0 rings and gaskets from the cylinder head ROCKER COVER COVER ROCKER COVER 28 Loosen the cylinder head bolts gradually in the numbered sequence shown in the illustra...
Page 19: ...to the timing mechanism a Coolant pump b Crankshaft pulley c Timing gear cover and gasket d Fuel injection pump NOTE See Fuel Injection Pump Removal under FUEL SYSTEMfor detailed instructions on remo...
Page 20: ...oil cooler and gasket c Oil filter housing gasket d Sump stiffeners e Lube oil sump and gasket f Lube oil pump assembly WBRICATION SYSTEM DISASSEMBLY g Lower block h Block to lower block left and righ...
Page 21: ...j Snap rings k Piston Pins Use the following method to remove a piston pin 1 Remove the snap rings 2 Heat the piston and connecting rod assembly to 122 158 F 50 70 C 3 Remove the piston pin l Connecti...
Page 22: ...0303 0 0374 in 0 770 0 950 mm 4 Measure the manifold contact surface distortion in siX directions as shown in the illustration If the distortion exceeds the limit grind the surface or replace the cyli...
Page 23: ...valve stem Valve contact position in relation to the valve seat must be at the center of the circumference and the contact width must be the standard value Check that the protruding length of the valv...
Page 24: ...placed b Installation Fit the clip onto the valve guide Use the valve guide replacer Mazda 49 0107 451A to tap the valve guide in from the side opposite the combustion chamber until the valve guide he...
Page 25: ...ing on the cylinder block Standard camshaft bearing diameter No 1 2 047 2 048 in 52 000 52 030 mm No 2 2 037 2 038 in 51 750 51 780 mm No 3 2 028 2 029 in 51 500 51 530 mm No 4 2 018 2 019 in 51 250 5...
Page 26: ...deflection of each push rod using a dial gauge as shown Rotate the push rod slowly and measure the maximum deflection If the measured value exceeds the specified limit replace the push rod Deflection...
Page 27: ...ann when installed oil must be able to flow through these openings c When the press fitting is complete correct the dia meter ofthe bushing with a pin hole grinder or a spi ral expansion reamer so tha...
Page 28: ...oove and the piston ring with a feeler gauge If the clearance exceeds the specified limit replace the pis ton or the whole set of piston rings Clearance limit Top ring 0 0098 in 0 25 mm Second ring 0...
Page 29: ...00051 in 0 013 mm B type 0 00154 in 0 039 mm Connecting Rods 1 Check the side surfaces ofthe big end and the small end ofeach connecting rod for cracking or any other damage Replace if necessary 2 Che...
Page 30: ...place if necessary b Check to see ifthe oil holes are clogged Clean if necessary 2 Check the crankshaft for deflection a Support both ends ofthe crankshaft on V blocks b Set a dial gauge on the middle...
Page 31: ...stall a metal seal saver on the crank shaft to restore it This will make the surface ofthe crank shaft smooth again REMOVAL REAR OIL SEAL CRANKSHAFT Cylinder Block 1 Cylinder block inspection and repa...
Page 32: ...the idler gear and the idler gear hub a Measure the inner diameter ofthe idler gear Standard idler gear diameter 1 732 1 734 in 44 009 44 034 mm MEASURING mLERGEAR INNER DIAMETER b Measure the outer...
Page 33: ...ICANTS in this manual Tighten the bolts and nuts on the important parts ofthe engine to the specified torques using a reliable torque wrench Tighten fasteners in the specified torque sequences and in...
Page 34: ...ngs INSTAWNG MAIN BEARINGS 2 Check the oil clearance of the crankshaft and main bear ings with a plastigauge a Remove any foreign material from the main journal or bearing b Position the plastigauge o...
Page 35: ...he main journal ACAUTION Install the thrust washers so that the inner surface of the ail groove faces the cylin derblock 5 With the main bearing caps set move the crankshaft backward and forward to im...
Page 36: ...ton c Insert a snap ring into one of the piston pin holes 34 d Position the piston and connecting rod assembly so that the matching number on the big end of the con necting rod faces the same side as...
Page 37: ...rted so that the front marks F face front b Applyengine oil liberally to the cylinder liner walls piston circumference and rings c Check to be sure that each oiljet aligns to the oil path in the pisto...
Page 38: ...onnecting rod bearing cap afteraligning the cap and can nectiilg radmating marks Back Plate Install the back plate Back plate tightening torque 28 38 ft lb 3 8 5 3 m kg flywheel and Flywheel Washer 1...
Page 39: ...s of the gasket between the cylinder block and the timing gear case TRIMMIHG THE BLOCK TO TIMING GEAR CASE GASKET S Apply a silicon based sealant to the areas where the gasket was trimmed off APPLYING...
Page 40: ...and the oil sump then set the sump stiffeners and install the sump Oil sump tightening tOrque 14 19 ft lb 1 9 2 6 m kg A CAUTION Be sure the oilsump attaching bolts do not twist the gasket INSTAUJRG O...
Page 41: ...ON GEAR 5 INSTAWIG FUEL INJECTION PUMP 6 b Tighten the fuel injection pump bolts to the specified torques see illustration Tightening torques A 14 19 ft lb 1 9 2 6 m kg B 27 38 ft lb 3 8 5 3 m kg Timi...
Page 42: ...t Alternator bracket tightening torque 27 38 ft lb 3 8 5 3 m kg ALTERNATOR BRACKET INSTAWNG ALTERNATOR BRACKET Cylinder Head Install the cylinder head and gasket onto the cylinder block NOTE Remove an...
Page 43: ...Rocker shaft support 4 Rocker 5 Wave washer 6 Snap ring WAVE WASHER SNAP RING INSTALLING ROCKER ARM ASSEMBLY Cylinder Head Bolts 1 Measure the length of each cylinder head bolt from below the head If...
Page 44: ...sure the notch on the injector bracket is engaged in the hole in the cylinderhead Fuel injector tightening torque 34 40 ft lb 4 7 5 5 m kg INSTAWNG FUEL INJECTORS Fuel Return Lines Install the fuel i...
Page 45: ...fuel lift pump Fuel line tightening torque Joining bolt 21 7 25 3 ft lb 3 0 3 5 m kg Bracket bolt 5 8 8 0 ft lb 0 8 to 1 1 m kg INSTALLING FUEL SUPPLY LINE TO FUEL LIFT PUMP 5 Install the fuel injecti...
Page 46: ...leg underside and spacer into the alternator bracket 2 Swing the alternator into position on the adjusting strap and fasten Lightly tighten 3 Install the drive belt and adjust the belt tension 4 Tight...
Page 47: ...EM for inspection and servicing information Install the hose connector elbow and the hose from the coolant pump Starter Motor Install the starter motor Oil Pressure Switch and Oil Pressure Sender Inst...
Page 48: ...od quality antifreeze and distilled water Fill the engine oil sump to the mark on the dipstick with lube oil A P I spec CF or CG 4 The engine should be test run under load prior to rein stalling At th...
Page 49: ...mbly and left intact it can be replaced on the cylinder head in the reverse order ofremoval Do not reuse the gaskets install new ones a Loosely attach the manifold elbows to the cylinder head using ne...
Page 50: ...MAINTENANCE SCHEDULE Drive belts must be properly tensioned Loose drive belts will not provide proper alternator charging and will eventually damage the alternator Drive belts that are too tight will...
Page 51: ...p the rings are faulty Abnormally high readings on all cylinders indicate heavy carbon accumulation a condition that might be accompanied by high pressures and noise NOTE In case ofsevere vibrations a...
Page 52: ...ent bolt until the idling speed is within the standard range The idle speed will increase when the adjusting bolt is turned clockwise and decrease when turned counterclockwise 3 Tighten the locknut 4...
Page 53: ...cm2 at 1800 rpm 50 55 lb in2 3 5 3 9 kglcm2 at 3600 rpm Low Oil Pressure TESTING THE 01L PRESSURE The specified safe minimum oil pressure is 4 3 1 4 psi 0 3 0 I kglcm2 Agradual loss ofoil pressure usu...
Page 54: ...rubbing them with compound on a sur face plate 0 b Check the relief valve for wear or damage c Check for a weak orbroken relief valve spring Measure the spring s free length Standard relief valve spri...
Page 55: ...IONS Lubrication system type Oil pump Type Relief valve opening pressure Oil filter Type Oil filter relief valve opening pressure Oil cooler Type Oil filter body ReHef valve opening pressure Oil sump...
Page 56: ...discharge pressure TO TRANSMISSION Oil COOLER PROPULSION ENGINES ONLY The raw water pump is a self priming rotary pump with a non ferrous housing and a neoprene impeller The impeller has flexible van...
Page 57: ...fill the system with coolant 9 Pressure test the system and check for leaks HEAT EXCHANGER COVER THERMOSTAT Visually check the thermostat for damage Then put it in water and raise the water temperatur...
Page 58: ...rts for the following conditions and replace ifnecessary 1 Cracking of the water pump body 2 Wear in the areas that the impeller contacts the seal 3 Breakage ofthe seal spring 4 Check that the shaft b...
Page 59: ...mpressed air 6 Press the impeller onto the shaft bearing AcAut10N a When pressing make sure the lower edge of the shaft rests on ablock b Press the water pump impeller until its edge is flush with the...
Page 60: ...pliers or a pair of screwdrivers 4 Remove the cam screw and cam 5 Remove the bearing housing releasing the shaft bearing and seal assembly This will allow the bearing and seal assembly to be inspecte...
Page 61: ...a RETURN LINE FURSYSTEM CHANGING THE FUEL FILTER 1 Shut off the fuel supply 2 Open the bleed screw on the top of the filter Place a con tainer under the fuel filter and open the drain on the bot tom o...
Page 62: ...ng plug on the fuel filter 4 Repeatedly depress and release the primer until only fuel no air bubbles flows out of the air bleeding plug hole 5 Retighten the air bleeding plug 6 Depress the primer and...
Page 63: ...then lift it out The injector seats in the cylinder head on a copper seal ing washer This washer should be removed with the injector and replaced with a new washer when the injec tor is reinstalled S...
Page 64: ...nes 3 Keep the reading on the pressure gauge ofthe nozzle tester just below the injection starting pressure while pumping the handle of the nozzle tester as quickly as possible so that a pulsating whi...
Page 65: ...torque 34 0 40 0 ft lb 4 7 5 5 kg m fY TORQUING THE FUEL INJECTOR HOLDER BRACKET FUEL INJECTION PUMP NOTE The fuel injection pump is a very important compo nent ofthe diesel engine requiring the utmos...
Page 66: ...sion Model Remove the shut off solenoid assembly and moun g bracket Disconnect the throttle cable and remove the cable attachment bracket Remove the dipstick assembly and the injection pump lower rear...
Page 67: ...ock pin on the timing gear case and its hole on the injection pump flange are aligned then install the injection pump 1ighten the installation bolts to the specified torque If the alignment is not cor...
Page 68: ...all ground connections Clean and tighten the con nections as required Replace damaged wiring or compo nents Continuity Check Disconnect the field lead on the starterfrom the solenoid M terminal and i...
Page 69: ...as the drive pinion moves into the crankingposition andspins BATTERY CARBON PILE NOTE During the no load test close the switch and operate the starterfor cycles of30 seconds maximum Between cycles all...
Page 70: ...to operate b Remedies listed under Failure to operate with verylow orno current with veryloworno current High speed with high current a Shorted fields a Inspect and test field and frame assembly Refer...
Page 71: ...G 10 CENTER SUPPORT 28 DOWEL PIN BEARING 29 INSULATED BRUSH SCREW 11 SHIFT LEVER 30 WASHER FIBER 12 PINION STOP 31 WASHER THIN ONE OR 13 ARMATURE TWO MAY BE USED 14 C E FRAME 32 WASHER THICK 15 DRIVE...
Page 72: ...ed locally 14 41 1 SOLENOID ASSEMBLY S Frame field and brush holder group A dowel pin 28 and frame seal 33 a The armature assembly 13 may come offwith the frame field and brush holder group A or may b...
Page 73: ...eduction and Drive Group Figure 6 Remove OT disconnect 1 Housing bolts 36 and 37 2 Armature support bracket 16 G Important I 30 a The washers 30 through 32 may stick to the anna ture support bracket o...
Page 74: ...t groove for bum that may have been formed through repeated cranking cycles Such burrs may make removal ofthe pinion stop and clutch drive assembly 2 difficult Ifburrs are found use a suitable file to...
Page 75: ...llowing Replace the brush holder if damaged a Loose riveted joints b Cracked or broken insulation 6 Brushes 4 and 5 for excessive wear a The minimum allowable brush length is 12 mm 0 472 in Replace ex...
Page 76: ...volts or less a Rotate the armature in a growler holding a steel strip such as a hacksaw blade against the armature If a short circuit is present the steel strip will vibrate in thatarea b Check the a...
Page 77: ...fixture place the tool bolt ends through the access holes in the wide end of the drive shaft and squarely press the bearing off of the surface on the center shaft 3 If necessary replace the bushing 6...
Page 78: ...35 in the drive shaft groove are fully seated in the pinion stop recess and stake the upper edge of the pinion stop 12 over the stop ring 35 atfour places equally spaced Do not allow staked metal to...
Page 79: ...osition of all brushes Make sure the insulated brushes 5 go into the brush sockets ofthe brush holder assembly 3 that are mounted on the insulation b To install each brush grasp the free end of the br...
Page 80: ...h springs to contact the ends of the brushes 5 0 ring 20 Important a The 0 ring caneasily be damaged during installa tion ofthe C E frame 14 To prevent such dam age install the 0 ring as described in...
Page 81: ...noidbat tery terminal the tool will heatenough to causea skin burn lighten a Solenoid battery B tenninal nut to 18 Nm 13 lb ft b Solenoid switch S tenninal nut to 1 8 Nm 16 lb in STARTERSPECIFICATIONS...
Page 82: ...off the water temperature gauge will continue to register the last temperature reading indicated by the gauge before electrical power was tum off The oil pressure gauge will fall to zero when the key...
Page 83: ...E S OIL PRESSURE FALLS BELOW 5 10psi 0 4 0 7 kg cm2 IN THIS EVENT THE ALARM WILL EMIT A PULSATINGSIGNAL THE ALARM WILL ALSO SOUNO IFTHECOOLANT TEMPERATURE IN THE FRESHWATER COOLING CIRCUIT RISES TO 21...
Page 84: ...meter through calibra tion access hole No results repair or replace meter 2 AC voltage not present check for proper alternator DC output voltage 3 Check for AC voltage at tach terminal on alternator t...
Page 85: ...batteries 0 Monitor your voltmeter for proper charging during engine operation 0 Check the electrolyte level and specific gravity with a hydrometer 0 Use only distilled water to bring electrolytes to...
Page 86: ...ore starting the engine make certain that everyone is clear ofmovingparts Keep awayfrom sheavesandbelts during testprocedures A WARNING When testing with amultimeter DCandAC circuits are often mixed t...
Page 87: ...s Jump the 12 V to the Exe terminalfrom a known 12V source and operate the alternator Ifthe voltage output is 13 14 volts the alternator is o k Trace the causefor 12 volts notpresentat the Exe termina...
Page 88: ...alternator 4 Attach a new heavy gauge output cable s from the alternator s output terminal s Using the cable sizes indicated LENGTH REQUIRED UP TO 6 4 WIRE UP TO 12 2 WIRE UP TO 20 0 WIRE ALWAYS USE...
Page 89: ...ts 4 12 volts Alt Output 12 6 volts 12 volts 14 2 volts Alternator Testing The regulator is functioning properly and the batteijes are in good condition 1 Test the voltage at the alternator plug with...
Page 90: ...NCTION THIS SWITCH SHOULD NOT BEUSEDTO MAKE OR BREAK THE CIRCUIT r 1 nt p C 8U12 R 1 I I I I I I I I I I I I I I _ _ loll I I I I I l 110 RD 1_ _ ___ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ ADMIRAL PANEL NOTE U...
Page 91: ...tery in an emergency and when leaving the boat A switch with a continuous rating of 300 amps at 12VDC will serve this function This switch should not be used to make or break the cir cuit IM I I I ll...
Page 92: ...transmission fluid Shift into gear forward and reverse shifting should be smooth and positive Direct changes from forward to reverse are permissible since the multiple disc clutch permits changing at...
Page 93: ...T handle in place of a screw on theirfilter assemblies After running the engine shut down and recheck the fluid level A WARNING Neverpull out the dipstick while the engine is running Hot fluid willspl...
Page 94: ...equal actuating lever travel from Neutral position Nto Reverse position Aand Forwardposition B If this mechanism is in any way tampered with the transmis sion warranty will be void SHAFT COUPLINGS WE...
Page 95: ...make certain that shifting is not impeded by restricted movability ofthe Bowden cable or rod linkage by unsuitably positionedguide sheaves too small a bending radius etc In order to mount a supportfor...
Page 96: ...maximum permissible ATF temperature should not exceed 230 F 110 C This temperature can only be reached for a short time A CAUTION Ifthe transmission fluid temperature is too high stop the engine imme...
Page 97: ...ssion The shifting mechanism and transmission actuating lever should be free ofdirt and well lubricated to ensure proper operation Shifting Into Gear Place the gear shift in Neutral before starting th...
Page 98: ...oil to drain into a container 0 Reconnect the oil cooler return line 0 Use a suction pump to remove the transmission oil through the filler cap dipstick hole 0 Clean off the transmission and properly...
Page 99: ...pray with lubricant 0 Inspect the gear shift cable linkage and attaclnnents Look for corrosion ofthe end fittings cracks or cuts in the conduit and bending ofthe actuator rods Lubricate all moving par...
Page 100: ...e cooler causing cross leaks to occur These internal cooler leaks will cause one of the fol lowing two problems 1 Transmission fluid will leak into the flow of raw water and be discharged overboard th...
Page 101: ...ou suspect a majorproblem in your transmission immediately contact your WESTERBEKE dealer or an authorized marine transmissionfacility 97 Verification Remedy 1 Mount aflexible coupling with another st...
Page 102: ...M24 36mm 203 275 288 390 553 750 789 1070 M27 41 mm 295 400 417 565 811 1100 1154 1565 M30 46mm 402 545 568 770 1103 1495 1571 2130 1 8 590 800 660 895 910 1234 14 660 895 990 1342 M33 51 mm 546 740 7...
Page 103: ...289 35 0 40 0 Oil pan bolts 14 19 1 9 2 6 Cylinder head bolts 00 NOTTORQUE Oil pan drain plug 36 2 43 4 5 0 6 0 Cylinder head cover 1 4 2 5 0 2 0 35 Oil pump pipe 5 8 8 0 0 8 1 1 Damper 16 24 2 2 3 4...
Page 104: ...50 35 psi 1 5 0 kg cm Intake 45 Exhaust30 Intake 0 012 inches 0 3 mm Exhaust 0 014 inches 0 35 mm 1800 RPM 60 Hertz 1500 RPM 50 Hertz 100 General Fuel Fuel Injection Pump Fuel Injection liming Nozzle...
Page 105: ...25 KW 50 Hertz 1500 rpm 230 Volts 108 7 Amps AC GENERATOR 3 Phase General 3 Phase 20 0 KW 60 Hertz 16 0 KW 50 Hertz Voltage 3 Phase 60 Hertz VoHage 3 Phase 50 Hertt Amperage 3Phase 60Hertz 8 powerfac...
Page 106: ...IPSTICK FRONT ZINC ANODE EMERGENCY STOP SWITCH 70 EXHAUST ELBOW LED LIGHTS HEAT EXCHANGER REAR ACTUATOR LEFT SIDE COOLANT FILL CA_e RIGHTSIDE 102 EXHAUST TEMPERATURE SWITCH LUBE OIL FILL CAP BLOCK DRA...
Page 107: ...he vessel s distribution panel This will ensure good motor starting responsefrom the generator Generator Frequency Adjustment Frequency is a direct result ofengine generator speed as indicated by the...
Page 108: ...The STOP switch should be depressed until the generator stops rotating 1 2 3 CONTROL PANEL 3 START The START toggle switch is a double pole single throw switch The switch serves two purposes starting...
Page 109: ...xc Terminal BATTERY RUNS DOWN 1 Oil pressure switch 1 Observe ifthe gauges and panel lights are activated when the engine is not running Test the oil pressure switch 2 High resistance leakto ground 2...
Page 110: ...windings ofthe main stator and is in turn supplied to a voltage regulator The regulator produces a DC voltage to further excite the exciter stator windings enabling the gen erator to produce a ratedA...
Page 111: ...OTE IF WIRING FOR 50 HZ THE 60 HZ JUMPER MUST BE REMOVED FROM L1 L2 L3 THE REGULATOR 0 1 2 3 0 5 6 7 N 9 o A4 8 12 10 11 y SERIES Y 480V 60 Hz 380V 50 Hz PARAU El WYE STAR L L 208 VAC 3 ff 60 Hz L N 1...
Page 112: ...ame L1 120 240V 60Hz 0 L2 CIRCUIT BREAKER 0 L1 N 120V60Hz 0 0 CIRCUIT BREAKER 1 L1 Generator Frequency 1 Frequency is a direct result of engine generator speed 1800 rpm 60 hertz 1500 nnp 50 hertz 2 To...
Page 113: ...iometer Each ofthe 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 wh...
Page 114: ...UJ 3 REGULATOR red green yeUow Hertz Amp I Slab I Vall r I I I I I I I I I I 5 J J EXCITER STATOR J RED BLUE YELLOW THREE PHASE 6WIRE RECONNECTABLE REGULATOR 81 UE lwlWES l ERBEKIE fEngines Generator...
Page 115: ...GULATOR BUIE YB LOW WINDINGS FUSE ROTE This fuse 6 3 AMP maybe located on the regulator BE GENERATOR WINDING RESISTANCE VALUES IN OHMS SINGLE PHASE 20 25 BE 32 BE EXCITER STATOR 18 06 18 20 EXCITER RO...
Page 116: ...rcuit feed to AVR stator auxiliary winding 2 Faulty voltage regulator Low AC voltage output at no load 1 Open or shorted diodes in 3 Faulty voltage regulator 60 100VAC exciter rotor 1to 3diodes 2 Open...
Page 117: ...ibration 1 With no power to the governor adjust the GAIN to 9 00 o clock 2 Start the engine and adjust the speed by turning the speed pot clockwise to desired speed NOTE Controllers arefactory adjuste...
Page 118: ...xtends a Short in lead to actuator b Actuatordoes notfully extend and b Replace controner connections NOTE Release PREHEAT andreconnect the purplelead Actuator hunts oscillates and 1 Linkage between a...
Page 119: ...utputare connected at the same time This type ofgenerator damage is not covered under the warranty it is the installer s responsi bility to make sure all ACconnections are correct 120 VOLT 60 HZ THREE...
Page 120: ...TAH llZRED 6 20A cI RCU IT eJlilllR 11 C 8RN 112 RED EMERGENCY J STOP SWITCH __j REMOVE THIS _ I Ltt c o 1 r t o i JUMPER WHEN i CONNECTING A J llZ RED 0 EXHAUST TEMPERATURE YL IQI AL TFRNATOR 51 A x...
Page 121: ...NERATOR WIRING SCHEMATIC 040425 SINGLE RELAY PREHEAT SOLENOID r L __ _ START SWITCH L _I STARTER SOLENOID r 1 L D STARTER AIR INTAKE HEATER PREHEAT SWITCH I K 30 87 ISWITCH I FUEL SOLENOID HOURMETER O...
Page 122: ...114 PURIWHT 1 12 voe L o l imr OIL PRESS lliJl E B GROUND TO BLOC II 0 4 1 12 l R EOt __ _ l ll4 PUR tU R D r 1 1 l _J__J 114 TAN 2 AtO CJ 112 RCO 20A CIRCUIT EMERGENCY STOP SWITCH tU BRR _j I 14 PUA...
Page 123: ...P SWITCH 81 Kl START 30 L _ _ 12 RUll I PREHEAT I ISOl ENOI AlR INTAKE HEATER ALTERNATOR R FUEL SOL _____ i _ ____ 3 fO 8 1________________ _ _ _ i OIL PRESS EXH TEMP WATER TEMP SW SW SW TBl I 1114002...
Page 124: ...Ull CTING ASECOllD REMOTE PMIEl 32 KW BEDA GENERATOR WIRING DIAGRAM 44737 TWO RELAYS PLUG IN REMOTE START STOP PANEL IU I IWllT llf TAii tt RED z GIOIMO 1 TERllllAl or Pll HEAT SOLENOID 1111 z SYSTEM...
Page 125: ...SOL K2 RUN r e 1 1 t 4 s1 t _ 1 SA r STOP I SWITCH _ TBH r I I 181 3 STOP SWITCH TBI PREHEAT SWITCH r l_ J 182 2 EXH TEMP WATER TEMP SWITCH SWITCH IU002 START SWITCH r 1 L_J TB1 TB2 I START SWITCH r 1...
Page 126: ...SSURE w IDl 114 RED H RtD r l J li l lJl I 1111 BATTERY SWITCH I v r 11 PUR WffT 1 2 voe L LI _ lli Tilo MQlQR 1 J f_ t12 T LIREO GROUND T BLOCK t _ _ _ 11 l O _ IU TU Q Ill 8RM 112 RED EMERGENCY STOP...
Page 127: ...1 L __ J 87 STARTER SOLENOID r 1 KI START 30 START SWITCH Kl STARTER AIR INTAKE HEATER ALTERNATOR OUTPUT r 86 85 oo 1 L _ J D I I STOP _ SWITCH r I PREHEAT I fSWITCH r 1 sToP I I SWITCH HOURMETER OIL...
Page 128: ...EL _ tl2 2 l IL 0 Ill W 0111 l l T12 1 lli IWl G l112 32 KW BEDA GENERATOR WIRING DIAGRAM 44806 TWO RELAYS PLUG IN REMOTE START STOP PANEL AT A lil fflATURE I HOUR Ya T 110 OIG II I II IED HIRT flllll...
Page 129: ...8T 1 1 WATER TEMP EXH TEMP SWITCH OIL PRESS 8A SWITCH SWITCH r ISTOP I SWITCH IUOOZ o J PREHEAT START SWITCH SWITCH r i 1 r 1 4 __ 1 t _ J L_J T81 2 181 3 lBH r1 I I STOP SWITCH PREHEAT SWITCH r i J 1...
Page 130: ...move the generator end from the engine Attach this Generator End Lifting Eye to the four screw holes located under the control panel To use this Lifting Eye remove the generator s control panel and sc...
Page 131: ...l 1 __ R 130TYP 10 25 MM DRILL 404 11 25 DEEP AND TAP M12XUS 1 00 DEEP M12THREADED ROD 1 sJll LG OVERALL X1 7SPITCH This tool allows a mechanic to safely remove and install the generator drive disks b...
Page 132: ...Overhaul 6 Parts Identification 5 Reassembly 31 Specifications 4 Troubleshooting 7 Exhaust Manifold 45 46 47 Fuel System Bleeding 60 Feed Line 43 Fuel System continued Feed Pump Strainer 60 Filter 42...
Page 133: ...BEDAGenerator Wiring Schematic 040425 Tachometer 49 80 Tappets 23 32 Testing for Overhaul 6 Thermostat 16 44 54 55 Timing Gear Case 17 37 Timing Gear Cover 17 39 Timing Gears 17 30 38 Torques 90A Four...
Page 134: ...361 6 6 56168 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...
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