Transcription of SERVICE MANUAL - Westerbeke
1 SERVICE MANUAL 7 .6KW 60Hz/5. 7KW 50Hz BTD and 60 50Hz BCD 60 50Hz BCDA 60 50Hz BCDB Single Phase DIESEL GENERATORS PUBU CA nON NO. t3N7J THIRD DmONlSEPTL~ER I". SERVICE MANUAL 7 .6KW-60Hz/5. 7KW-50Hz BTD and BCD BCDA BCDB Single Phase MARINE DIESEL GENERATORS PUBLICA nON NO. 038673 THlRD EDmONlS PT ."lBER 19911 TABLE OF CONTENTS latradaetiall .. _ .. _ .. _ .. __ . __ l Engina TratiblesbDllting .. _ .. _ .. 3 Testing III O erlIaal . ____ .. ___ .. _. ____ . __ .. _ .. _ .. 7 Engine Disassembly. ____ .. _ .. _ .. 8 Cyliader . _____ .. 1 0 YJJw: aad Villn Spring IIISJICctiDn _ .. _ .. 1 I V~1ft IlISbllatianIValwe Clearance .. _ .. 12 liar Cast/GlIWemor __ _____.
2 __ _ .. 1 J .ing &ear .. ____ .. ____ .. __ .. _____ ._ .. 14 \aft .. 14 Piston ad Connecting Rod .. _ .. _ .. 15 ClaIksban .. 17 Cytillder BI,ck ._ .. 19 Gole,IO' Sysl:etn .. _ .. 20 ~ne .tsseabI' .. 22 EDailstllanitold .. 24 .. _ ..24 flel .. ;eetiOl:l PuIIIp .. ___ .. _ ..25 PtIIIpJ1njmon Tillling .. _ .. 26 .. _ .. _ .. _ .. 27 Gin< PIIgS .. _ ..29 Cirulatillg Pomp .. _ .. _ .. _ .. __ .30 IIa-Wmr PIIIIIp .. _ ..3I starter lIotor ..32 Dil P'ressii~ SwitclllOil PilISSII~ .. __ ._ .. _ .. 36 EIgioe .. djustllftlts .. _ .. _ .. 37 .ttterut .. _ ..39 DC Wiring Diagram (~ine) .. 41 un DC Wiring SchelUtie lengine) .. 42 1 DC Wirillg ).
3 43 DC Wiring Schematic lenginej .. oI.: Generator Inlili"lUtioa .. 4 5 BT &enemar Single Phase .. ~ .. ~ Troubleshooting ._ .. _ .. _ ..47 MO .. D<id Volt1ge Adjvstmenl .. _ _ . _ ..48 Residoal Volt1ge Check ..t9 Bridge ~ili~ .. 50 EItiter/Rotor Field .. 51 Measuring Resistance ._ .. _ .. _ .. 52 Shore Power TrJIIsfer Switch .. __ .. _ ..53 Specificatioos .. _ .. >' BC Generatar Single Pbase _ .. __ ..55 Trooblesbooting .. 56 DIal EIciter lIo .. ad Voltage Adjilslillent ..51 Shore hwer Transfer Switc .. 57 Single EIcit~ lIo lud Yoltage Adju$Mleilt ..58 talegral Contl1lll~ .. _ .. _ .. _ .. 59 Testing tile Satlery Charging Circuit .. _ .. 59 Sallast Rnistor.
4 _ .. ___ .. __ .~ .. 60 Testillg tile Exciter Windings .. _ .. _ .. 60 Field-Testing CapacitOlS_ .. __ .. __ .. 60 Testillg Component Resistance YaliltS .. 62 SpecificatiollS __ .. _ .. _ .. _ .. _ .. 63 Spft:ial Tools .. 64 Semee Gata/Tolerances & .. 65 Torque Specificatioll$ .. __ .. _ .. _ .. _ .. 67 Slandanllbnlware Torques .. _ .. _ .. _ .. 68 Metric ClNI'ItTSions .. 69 lodeI. ,_ .. _ .. _' .. _ .. _ .. _ .. _ .. 10 INTlIODUCTION PllOOUCT SORWW Product som.~ (ta;h d=. p>ru .. ~ !:n> <"""" ODd c:> ) 1'""'-fmm """= OIher "'"" l'I.'ES1 BUIEKE "'" noI ,..,lhin .. 'ESlEUIEKE-S ccnuaI_ WErr RlIEXE aNNOT BE RESPONSIBU FOR THE CO,,"7 ENTOF SUCH SOfTWARE. MII KES NO II~RRM71ES OR REPRESENTATIONS wrm RESPECT TH RIT(), INCWOINGACCURACY.
5 TIMEliNESS OR COMPu:T NESS mERmF AND WIll INNO C',ENT BE FOR 17Pt: OF OR INJURY INCURRED IN CONNECTION wrm OR ARISING OUT OF 111 FUNNfSHING OR USE OF SUCH SOfTWARE.. 'ES1 UtSEKE CUWlm<rS >hoold 1II'" kc:qJ '" IIIInd tho ""'" !op:UI between prm!Jftl> of Westerbeke produa "'~wan: and tho .. VOIdabIe <u:""" of earlier y, 'ESTERBEKE MANUAL ., I'!'odu<t ..,ftv,= prG>'1 Ikd ""til "',ESIERBEKE products.. -b<1ha-from Westerbeke Of Dtb:r suppliers. mUS!. DOl. lDd ta/IIIOI be rcliod upon .~ as tho! Iknrulivc autbonty "" !he respeclI"< pro:Juct. II "'" only lIlWI &ood .sc"", bullS dIlpcnlI> < ilia! ~te ~ of WES't'ERBEKE Of !he >llPP!ier III qUC$bOll be coosulltd '" d<temune.
6 Ac:ancr and aIImIlD<", of tho produa "., bcllll con<ull ! by .. ~ 1tIllES, CAUTIONS AND WARNIMCS .. IIW.. cUes you dwoullh tho disasocmbIy. lrupc<!Ian and ossnnbIy ~ of your .",..~. allal WorrnaIJOn wtIl be: "'gIili,hIcd by NOTES. CAUTIONS, and WARNINGS. An upl3lWlOft f<>llows: 1 IITE:/tII DfN"""" pTOC~"",."~,., .. A CAII11 OflI: ~ wItkI! It lIIIt stridIJ , .. _ ~It irI tie ~ ., *WrH: ,..-r !IIi . Jt'!Ci"'IIf. A WARNING; ~*'t!$, rftticb It _ '*"'*,,, frIl .. I'M IfISIIIt 1IJ ~ 1tIfIIt'f.,. " life. OROEIUNG PARTS ~ lqllaa:mcnl potts .. needa1. a/woys tho I"1 IOnICIf _I """,bu. en""" ocna/ number. _ "'..,..,..a'\aI ntanbcr as !:hey appear ()<I !he .. t .. Mel black _-pille Ioca<ed Of!
7 Tho! ~ elO1. Yeu ..-p!'O"III< IIS";II! dns Information so .. may prOperly denufy )'(U a]"ncI~. ID .-Idiuon. inchade C(1D1pi<oe pon tIeoa1pc>orI K1d poll ..,bef for each pan. :Icd (see tho ~ly fumishcd!>om !At). Also lnm1 upon Westerbeke p; ~ parU beoust W'lU fit or cmmc portS .. ~y not made '" tho <am< Sp ;ificmolls .. on,~ oqwpm<:ru. 2 CUSTOMER IDENTIACATION CARD i __ IWESTERBEKE lho WESlERBEKE "",.>I number ~ an alphanumenc I10 WIIba <hal. can .. ISI 1t1 &~l\InJ tht d>Ic of manufOCWt'l: of you< W SiERBEKE ~"nclJe""""" lho Iir>I ~ ,..,;,.. !he dccadt! (A~]'NA. BaI970s. ~ [)..]9'IOo),!he oecO<>d dwxtcr r<pr=1S1bo >-= 1ft tho d< !he fourth and fifth Dl,II"!lbef ~nI1 !
8 He IIl<>IIIh of 5aUAL HUMBER LDCATION lho enJll>C and number<; and modo] ''""''bet< .. ~ "" deal on !he JeroeralO< """' .., lho enl"'" smoI number an """ be found ~ 'Ill<> tho .",.. block jU$I ~ d)e 1t1p:uon pump. lho senemor ..w IIII mbcr .. swnpcd tnl(l!he Jen=ll<l< housIn, Oft tho :. "" !he leh nd< of !he An idrnuiicauon pUle "" !he enX"" ma/ufald :oIso d,spL:ly;: tho """"" mo<\I:J and senaI numm. The ,..:tiono COI'IWn detailed .. f~ relaun& 10m. poper opo:t:&Uon dunaen<lic::s of tho "' '" cornpooelllS and ~ oflhc eng""'_ 1n<1uded "'" tUpeCtion and re&$.Kmbly IftSU\lC1 Jons for tho ZUodanc:c: of tqlDfIp I and sWJed ~ enl'''' ..,..".,. and rebuilclinl focihhes.
9 The .. ory p' .. dwc< <houId be III'Idauhn ""ly by """h focditoe:s Add,1 IOnOl detailed InfOfJn3UO<l ond .,.""fis:"""". "'" pnmdaI III od>or so.;lJOnS Df Lt." ,.]. covenn! tht ,.,..,..,.. a11<rDa1<1f. = 1I>0I01". ""I"'" lIdJU>LmenL>. coolin, pump>. =-ENGINE TROUBLESHOOTING pr<JlIIcm> , 10 eacme 0CI'VIDt. lilt I' U~of .aT : T1t< nil_'S ~lu",caI IJ fI'OUCl<d Iro 11 ~ Ib<>t .. ubi .. " .. _ .. , Ai 1"," III "'dCOi"" -,.", ~ "'_ wnw bfmh< no. pnlottJ: IIDintD,J IS IIIe5< II II .. n. -. ~ be 01-"""" .. ~ _otd""tN_~ .. """ I .. """ "".-lOW tIWIIJIIG S/'E D I Er9nt .>05aIWf""" , ReI*' ..,ms_DI L~tDIJ', '--1 .",.. DnII}'. ,--4. ,CU" .. , .. QurlIIfIfII'UIs Ill __ S.
10 DeIoo;M <Inf. S. __ CO "'*' _ I. IleItaM II\IJI ___ &. < '**" 10< d<5o!r "' .. ,. DffK1l'lE IlETlOII rna 1. ,., ~ .. lUll PIIM9I 1. :al1ud ~ L CIav;Ic 1uII __ L __ 3. \.oW .. P<mIn. 3. A<tuv:.., IftSSln 4. ~ $IlIlI'I. 4. Dun ~ S.~_~I .. ~Iult 5. ~ or .. 1UI'CI I.. Il10 .. &.. ~ IIIIrriI --"""'" I . \.oW"''' .. l .. ---~ I . AQJnI_ damna! ..-_tal ..,-c. ___ L 1 IIdItt .. __ .. , .. ~ .. ~-~ I . eo .. _1uII:I1IW\ItI;II ~ IIIIoIIglSIIeI I . IIfe/IU 0lSI& I. I'aIDa II1lI _ I. ~ JIISIDII "'" JIISIDII me I. ~,,-qlnCl~ .. ~ .. __ L~gIow~ :a. fIDItt gIOor ~_ 1. ;z 1 NcI_ .. , .. 'flOlM IIOS*O\ .. SI!II .. SIiIIIn; ~ 5. ~ <lUI cr I'OSIlIlII """' .. ~""'" "'" """"""" Stt HAIID SfNfmKi IUEtTIOII smEM OIIT Of ~ 1.
