Westerbeke 13.5 KW EDE страница 1 Скачать руководство пользователя | Manualshive

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Содержание 13.5 KW EDE

Страница 1: ...tz at 50 Hertz SINGLE AND THREE PHASE FIRST EDITION JULY 2008 WESTERBEKE WESTERBEKE CORPORATION MYLES STANDISH INDUSTRIAL PARK 150 JOHN HANCOCK ROAD TAUNTON MA 02780 7319 TEL 1 508 823 7677 FAX 1 508...

Страница 2: ...alattention Shutdown the unit and do not restart until it has been inspected andrepaired WARNING Generatoffi Pnx1UC6 CARBON MONOXIDE Regular Maintenanca Required AWARNING DECAL isprovidedby WESTERBEKE...

Страница 3: ...iring Diagrams 75 Generator Assembly 76 BE Troubleshooting 78 Metric Charts 79 Hardware Torques 81 SERIAL NUMBER LOCATION The engine s model number and serial number are located on a nameplate mounted...

Страница 4: ...e until piston rings and valve seats have been broken in Thereafter it decreases gradually with the progress of wear of these parts When decrease of compression reaches the repair limit the engine mus...

Страница 5: ...Injection too early 6 Adjust injection timing MAIN ENGINE TROUBLES 1 Low compression a Incorrect valve clearance a Adjust valve clearance b Inadequate contact of valve seat b Lap valve c Valve stern s...

Страница 6: ...ston ring 3 Replace ring 4 Worn piston or cylinder 4 Replace piston and rabore cylinder OIL LEVEL FALLING 1 Defective stem seal 1 Replace stem seal 2 Worn valve and valve guide 4 Replace avalve and va...

Страница 7: ...High oil pressure 1 Dirty oil or wrong SAE type oif in the engine 2 Relief valve is stuck Black exhaust smoke 1 Dirty flame arrester discharge from the 2 Lube oil is diluted engine 3 Valves are worn o...

Страница 8: ...the oil can be the result of a fault in the exhaust system attached to the engine and or a siphoning of raw water through the raw water cooling circuit into the exhaust filling the engine This problem...

Страница 9: ...portant Too thin a bead could cause leaks and too thick a bead could be squeezed out of location causing blocking or narrowing of the fluid feed lines To eliminate the possibility of leaks from ajoint...

Страница 10: ...al for HEAT EXCHANGER service ENGINE TUNING OPERATION After re assembly the engine must be tuned This will ensure that the engine operates at its maximum efficiency Fill the engine cooling system with...

Страница 11: ...Detach the injection pipes When Reassembling Blowout dust inside the pipes TIGHTENING TORQUE INJECTION PIPE RETAINING NUT__24 5 34 3 N m 2 5 3 5 Kgf m 18 1 25 3 ft Ibs NOZZL HOLDER ASSEMBLY AND GLOW...

Страница 12: ...cylinder head gasket with a new one 2 Tighten the cylinder head screws after applying sufficient oil 3 Tighten the cylinder head screws in a diagonal sequence starting from the center in the order of...

Страница 13: ...and the valve guide INJECTION PUMP 1 Remove the stop solenoid and the hi idling body 2 Remove the engine stop lever and stop solenoid guide 3 Remove the fuel injection pump assembly NOTE Before remov...

Страница 14: ...late 2 Put the specific tool from the injection pump side to catch the large governor spring Keep this spring slightly extended and place the speed control plate in its specified position 3 Using the...

Страница 15: ...L__ TOOL 3 Remove the drive pulley with gear puller 4 Remove the feather key When Reassembling Apply grease to the splines of the coupling TIGHTENING TORQUE FAN DRIVE PULLEY MOUNTING NUT 137 3 156 9 N...

Страница 16: ...ing 1 Insert the crankshaft collar after installing the gear case to the cylinder body CRANKSHAFT OIL SLINGER CRANKSHAFT COLLAR OIL PUMP DRIVE GEAR I IDLER GEAR 1 Remove the external snap ring 2 Detac...

Страница 17: ...d 4th cylinder pistons at the top dead center in compression then align all marks on each gear to assemble the timing gears set the idle gear last TIGHTENING TORQUE CAMSHAFT SET BOLT 23 5 27 5 N m 2 4...

Страница 18: ...on upward by lightly tapping it from the bottom of the crankcase with the handle of a hammer S Draw out the other piston in the same method as above When Reassembling 1 Before inserting the piston int...

Страница 19: ...onto the piston place the expander joint on the opposite side ofthe oil ring gap 3 Apply engine oil to the piston pin 4 When installing the piston pin immerse the piston in 80 C 176 F oil for 10 15 mi...

Страница 20: ...er mounting screws Remove the inside screws first and then the outside screws 2 Screw the two removed screws into the screw hole of the bearing case cover to remove it NOTE The length ofthe inside scr...

Страница 21: ...til the crank pin of the first cylinder comes to the center of the third cylinder 4 Repeat the above steps to draw the crankshaft completely out When Reassembling 1 Install the crankshaft sub assembly...

Страница 22: ...meters of the main bearing cases may vary so install them in the order of the markings A B for 3 cylinders and A B C for 4 cylinders from the gear case side 4 Match the alignment numbers and mark on t...

Страница 23: ...water pump assembly from the gear case cover 4 Remove the water pump flange 5 Press out the water pump shaft with the impeller on it 6 Remove the impeller from the water pump shaft 7 Remove the mecha...

Страница 24: ...on 2 Measure the valve stem O D with an outside micrometer 3 Measure the valve guide LD with a small hole gauge and calculate the clearance 4 If the clearance exceeds the allowable limit replace the v...

Страница 25: ...ry After correcting the valve seat be sure to check the valve recessing Correcting the Valve 1 Correct the valve with a valve refacer Correcting the Valve Seat 1 Slightly correct the seat surface with...

Страница 26: ...417 1 6614in ALLOWABLE LlMIT____ 41 2mm 1 6220in TILT ALLOWABLE LlMIT____1 0mm 0 039in VALVE SPRING SETTING LOAD 1 Place the valve spring on a tester and compress it to the same length it is actually...

Страница 27: ...ASH 1 Set a dial indicator lever type with its tip on the gear tooth 2 Move the gear to measure the backlash holding its mating gear 3 If the backlash exceeds the allowable limit cheek the oil clearan...

Страница 28: ...28 0 00871n ALLOWABLE LlMIT____ O 30mm 0 01181n BALANCER SHAFT SIDE CLEARANCE For Balancer Models Only 1 Set a dial indicator with the tip on the balancer shaft 2 Measure the side clearance by moving...

Страница 29: ...r gear bushing 1 0 with an inside micrometer and calculate the oil clearance 3 If the oil clearance exceeds the allowable limit replace the bushing 4 If it still exceeds the allowable limit replace th...

Страница 30: ...PISTON PIN BORE 1 0 1 Measure the piston pin bore I D in both the horizontal and vertical directions with a cylinder gauge 2 If the measurement exceeds the allowable limit replace the piston PISTON PI...

Страница 31: ...om the ring grooves 2 Measure the clearance between the ring and the groove with a feeler gauge or depth gauge 3 If the clearance exceeds the allowable limit replace the ring 4 If the clearance still...

Страница 32: ...1 0413In DIMENSION B_ 54 5 54 7mm 54 6 54 Smm 2 1456 2 1535in 2 1496 2 15741n DIMENSION C_2 B 3 2mm 2 B 3 2mm RADIUS 0 1102 0 12601n 0 1102 0 1260in The crankshaft journal must be fine finished to hig...

Страница 33: ...2201n UNDERSIZE DIMENSIONS OF CRANKPIN UNDERSIZE__ 0 2mm 0 4mm DIMENSION A RADIUS DIMENSION B RADIUS DIMENSION C DIA 0 008in 0 0161n 3 3 3 7mm 3 3 3 7mm 0 1299 0 14571n __0 1299 0 14571n 1 0 1 5mm 1 0...

Страница 34: ...kshaft journal must be fine finished to higher than 0 8 S V r V REPLACING THE CRANKSHAFT BEARING 1 Whell Removillg 1 Press out the used crankshaft bearing 1using a crankshaft bearing 1replacing tool W...

Страница 35: ...0 D25mm 2 36142 2 363180in REFER TO THE DATA IN THE UPPER RIGHT STOPPER UNDERSIZE DIMENSIONS OF CRANKSHAFT JOURNAL UNDERSIZE___D 2mm______0 4mm DIMENSION A RADIUS 0 008in 0 0161n 2 8 3 2mm 2 8 3 2mm 0...

Страница 36: ...3 43590in MAXIMUM WEAR ALLOWABLE LlMIT____ O 15mm 0 0059In FINISHING HORN TO 2 2 3 0 UM Rmax 00g l7 0 00118 in Rma _V r VV 2 Replace the piston and piston rings with oversize O 2Smm ones When the ove...

Страница 37: ...I I I I II I I L __ I I I I 1 I I I II p rI I II x x 2 I m I 0 u I h I I t____ l ______ J Engines Generators 34...

Страница 38: ...fiiN I I ZlrJ 1DI r I 7l I nltll t _____ 1 Til I I _ _ _ J I I I 1 _ Ii I L I I 1 000 10 1 0 1 I 001 000 I 1 11 r I I II I I n 1 _ 1 I I I I I J...

Страница 39: ...he alternator Drive belts that are too tight will pull the alternator out of alignment and or cause the alternator to wear out prematurely Excessive drive belt tension can also cause rapid wear of the...

Страница 40: ...move the hand lever at intervals ofone stroke per second while read ing tile injection starting pressure A CAUTION The sprayinjected from the norzle is Dfsuch velocity that it maypenetrate deeply int...

Страница 41: ...counterclockwise to see if the piston is at the compression top dead center or the overlap position Now referring to the table below readjust the valve clearance The piston is at the top dead center w...

Страница 42: ...tor faults When re installing the glow plugs use anti seize compound NOTE Do not guess the conditions ofother cylinders from a result oftesting one cylinder Be sure to measure the compression pressure...

Страница 43: ...MPU out of the opening one tum and then lock it in this position with the jam nut This will position the end of the MPU approximately 0 030 inches away from the flats of the ring gear teeth To ensure...

Страница 44: ...ve Oil Filter Sump Capacity includes oil filter Full flow paper element spin on type 6 3 U S qts 6 0 liters LUBRICATION SYSTEM Operating Oil Pressure 28 57 psi 2 0 4 0 kg cm2 engine hot Oil Grade API...

Страница 45: ...3Phase High Voltage WYE 400 Volts 50 Hertz DELTA 230 Volts 50 Hertz DELTA 230 Volts Amperage 3 phase Low Voltage WYE 51 Amps Amperage 3 phase Low Voltage WYE 66 Amps 60 Hertz High Voltage WYE 25 Amps...

Страница 46: ...other side of the circlip Install the next circlip in the recess at the shafts driven end against the shaft bearing 2 Warm the pump body on a hot plate to expand the body Then drop the shaftlbearing...

Страница 47: ...FOLD GROUND WIRES REFER TO THE WIRING DIAGRAM IN THIS MANUAL FOR WIRING CONNECTIONS TROUBLESHOOTING Prior to testing make certain the ships batteries are at full charge and that the starting system wi...

Страница 48: ...ther crewmembers of the danger NOTE Starter motors are either inertia type orpre engaged In the pre engaged model the solenoid also moves an arm that engages the starter motor to the flywheel ofthe en...

Страница 49: ...as been removed from terminal C 2 Connect another jumper from the battery post to the starter motor s housing momentarily If the motor fails to run the motor is the problem Magnetic Switch Test 1 Conn...

Страница 50: ...exceeded Also check the commutator outside surface for dirtiness and roughness Ifrough polish the commutator with fine crocus cloth 3 Cheek the commutator mica under cut and correct with a hacksaw bla...

Страница 51: ...clutch assembly 2 Check that the pinion gear turns freely and smoothly in the overrunning direction and does not slip in the cranking direction If the pinion slips or fails to rotate in both direction...

Страница 52: ...EARS APPLY GREASE ROLLER RETAINER ROLLERS I GEARS APPLYGREASE t l t DISASSEMBLING THE MAGNETIC SWITCH 1 Remove the drive end frame mounting screws 2 Disassemble carefully the over running clutch ball...

Страница 53: ...ntain a proper system voltage The regulator design utilizes all silicon semi conductors and thick film assembly techniques After the voltage has been adjusted to the proper regulating valve the entire...

Страница 54: ...the reading should be 12 to 13 volts MEASURING BATTERY VOLTAGE IGNITION ON ENGINE OFF TESTING THE OUTPUT CIRCUIT 1 Connect the positive probe to the output terminal Band connect the negative probe to...

Страница 55: ...battery charging circuit Troubleshoot the service battery charging circuit by checking the wiring and connections the solenoid isolator battery switch and the battery itself When the problem has been...

Страница 56: ...olding the IC regulator and remove the IC regulator 5 Remove the 4 screws holding the rectifier and the stator lead wires remove the rectifier 6 Unscrew the 2 nuts and 2 screws that hold the drive end...

Страница 57: ...appearance if it does not rotate smoothly replace the bearing 2 Measure the resistance across each lead of the stator coil with an ohmmeter If the measurement is not within factory specifications rep...

Страница 58: ...ty across each rectifier diode with an analog olunmeter Conduct the test in the Rxl setting The rectifier is nonnal if the diode conducts in one direction and not in the other NOTE Do not use a 500VMe...

Страница 59: ...STATOR DRIVE END ALTERNATOR SERVICE EXPLODED PARTS VIEW Ie REGULATOR Engines Generators 58...

Страница 60: ...52 rad 30 B 10 mm 0 39 in C Chamter 0 3 mm 0 01 in D 182 mm 7 16 in E 140 mm 5 51in F 35 mm dia 1 38 in dia G 60 mm dia 2 36 in dia H 37 mm 1 46 in I 21 9471021 960 mmdia 0 8641 to 0 8646 in dia J 24...

Страница 61: ...mm 1 06 in 0 35 mm dia 1 38 in dia I E 27 901027 95 mm di 1 098 to 1 100 in dio F 25 00 to 25 01 mm dia 0 984 to 0 9851n dia 2 For idle gear bushing A 175 mm 6 89 In B 40 mm 1 571n C 38 mm 1 49 in I...

Страница 62: ...arance When Cold 0 18 to 0 22 mm 0 0071 to 0 0087 in Valve Seat Width Intake 2 12 mm 0 0835 in Width Exhaust 2 12 mm 0 0835 in Valve Seat Angle Intake 1 047 rad 60 0 Angle Exhaust 0 785 rad I 45 0 Val...

Страница 63: ...0 55118 to 0 55189 in Push Rod Alignment 0 25 mm 0 0098 in Tappet to Tappet Gl lide Clearance 0 020 to 0 062 mm 0 07 mm 0 00079 to 0 00244 in 0 0028 in Tappet 0 0 23 959 to 23 980 mm 0 94327 to 0 9441...

Страница 64: ...ncer Shaft Side Clearance 0 07 to 0 22 mm 0 3mm Balancer Model Only 0 0028 to 0 0087 in 0 0118 in Balancer Shaft Journal 1 to Balancer Shaft Clearance 0 030 to 0 111 mm 0 2mm Bearing 1 Balancer Model...

Страница 65: ...ushing Clearance 0 014 to 0 038 mm 0 15 mm 0 00055 to 0 00150 in 0 0059 in IPiston Pin 0 0 25 002 to 25 011 mm 0 98433 to 0 98468 in _ __ Small End Bushing 25 025 to 25 040 mm 1 0 0 98523 to 0 98582 i...

Страница 66: ...ltage More than 13 5 V Stator Less than 1 0 0 Resistance Rotor 2 90 Resistance Slip Ring 14 4 mm 14 0 mm i 0 0 0 567 in 0 551 in IBrush 10 5 mm 8 4mm Length 0 413 in 0 331 in Glow Plug Resistance Appr...

Страница 67: ...to 3 43590 in 0 0059 in LUBRICATING SYSTEM Item Factory Specification Allowable Limit Engine Oil Pressure IAt Idle Speed 98 kPa or more 49 kPa 1 0 kgf cm2 or more 0 5 kgf cm2 14 psi or more 7 psi IEog...

Страница 68: ...lder assembly M20 x 1 5 49 0 to 68 6 5 0 to 7 0 36 2 to 50 6 Oil pressure switch R 1 8 14 7to 19 6 1 5 to 2 0 10 8 to 14 5 Injection pipe retaining nut M12x1 5 24 5 to 34 3 2 5 to 3 5 18 1 to 25 3 Ove...

Страница 69: ...nninal block be corifigured to provide one 120 voltAC hot legfor the vessel s distribution panel This will ensure good motor starting responsefrom the generator GENERATOR FREQUENCY ADJUSTMENT Frequenc...

Страница 70: ...ng separate TillS is the case of a generator equipped with auxiliary winding for regulator supply Supply is always connected to terminals 3 and 5 of the regulator o 4A 4 3A 31 2 EXCITER FIELD 1 In bot...

Страница 71: ...um counterclockwise and wait about twenty seconds During this period of time the voltage value decreases In this condition and while turning the potentiometer clockwise fix the generator voltage value...

Страница 72: ...and Cto A as shown on the drawing B c EXCITER ROTOR WINDINGS VIEW OF ROTOR FROM THE BEARING END 12 a CLOCKPosmON Disconnect these three wires from the diode bridge plates taking care not to drop any...

Страница 73: ...volts 10 12 2 4 10 5 7 NU L2 SO Hz L L 230 volts SO Hz L N 115 volts 60 Hz L L 271 volts 60 Hz L N 138 volts Refer to Note I L 0 o lote ttl Singlephase amperage load The phase CUl1Ymt must nQt exceed...

Страница 74: ...AC output voltage fault shut down eitherfrom low or high AC voltage or incorrectAC voltage displayed on the LCD display 3 There are three line connections When an L3 is not present on the AC terminal...

Страница 75: ...I PH 3 CHANGING BACKEHD BETWEEN I PHASE AND J PHASL ill 0 4 1 6 9 0 10 8t II 0 0 E OOUBl E DELTA 3 WlRE SPUT SINGLE PHASE 120 240V 60 H IIO 220V 50 HI seRIES DELTA 240V 50 Hz 220V 150 Hz PARALLEL OELT...

Страница 76: ...VOLTAGE REGULATOR 120 240V 60 HZ L1 L2 f 1 AC CiRCUIT ll f I BREAKER r I L1 L2 N L1 CONDENSER I I I I I I I I I I SUP ESSO 1 f 100 Ko I I AUXILIARY 6 AC TERMINAL BLOCK BLACK GREEN BLUE SINGLE PHASE IN...

Страница 77: ...ort 3 Place a large washer of at least 80rnm in diameter with a center hole of 15mm onto the threaded rod followed by a 12mm x 1 75 nut Center the rear bearing in the bearing boss of the support plate...

Страница 78: ...ark the connection points the generator leds connect to Make an illustration ifneeded whether the generator is to be reinstalled or a replacement is to be installed This is to ensure proper reconnecti...

Страница 79: ...D 15 20 VOLTS AC auxiliary circuit feed to AVR stator auxiliary winding 2 Faulty voltage regulator LOW AC VOLTAGE OUTPUT AT 1 Reset voltage potentiometer 4 Short in rotating field winding NO LOAD 60 1...

Страница 80: ...125 17 85937 7 32 0 21875 5 55625 23 32 0 71875 18 25625 15 64 0 234375 5 95312 47 64 0 734375 18 65312 1f4 0 250 6 35000 3 4 0 750 19 05000 17 64 0 265625 6 74687 49 64 0 765625 19 44687 9 32 0 28125...

Страница 81: ...x 454 Kilograms kg x2 205 Pounds PRESSURE Pounds Per Sq In psi x 6 895 Kilopascals kPa x 145 psi Inch es of Mercury Hg x 4912 psi x 2 036 Hg Inches of Mercury Hg x 3 377 Kllopascals kPa x 2961 Hg Inch...

Страница 82: ...1100 1154 1565 M30 46mm 402 545 568 770 1103 1495 1571 2130 1 B 590 800 660 895 910 1234 14 660 895 990 1342 M33 51 mm 546 740 774 1050 1500 2035 2139 2900 M36 55mm 700 950 992 1345 1925 2610 2744 37...

Страница 83: ...1 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 4 57200 10 9 14400 5 5 46807 10 10 93614 MOVE DECIMAL POINT FOR HIGH...

Страница 84: ...nor Springs Control Panel 11 Testing the Diodes 71 Idler Gear 13 Twelve Lead Winding Injection Pipes 8 Terminal Board Connections 72 Injection Pump 10 Hardware Torques 81 Main Bearing Case Assembly 19...

Страница 85: ...Bore J D 27 Piston Ring Clearance 28 Piston Ring Gap 28 Push Rod Alignment 24 Replacing Crankshaft Bearing 1 31 Replacing Crankshaft Sleeve 32 Replacing Small End Bushing 28 Replacing Valve Guide 21...

Страница 86: ......

Страница 87: ...Engines Generators 1128 DWIWM IO 08...

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