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Serpentine
Pulley Kit - Slipping Belt Problem on your
Perkins 4.107 4.108 & Westerbeke 40 Solved |
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With more & more electronics being used on
boats, the demand for more 12v DC amperage is
increasing. If you are using a high output
alternator on a Perkins 4.107, 4.108 or
Westerbeke 40 with a standard belt 3/8 in, you
already know the problem. |
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The Solution: |
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Shown above: Perkins 4-108 with Bowman
manifold
and Balmar
with 2” mounting foot. |
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Trans Atlantic Diesels Inc. can supply an easy to fit
serpentine pulley kit (6 groove) for the Perkins 4.107, 4.108
& Westerbeke 40. With this kit you can achieve approx 150 amps
12 volts DC without the belt slipping (providing your
alternator has the capacity.)
Anyone who has tried to extract much more than 65 amps
out of the original pulley and belt configuration, will |
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know that black belt dust and squealing
from the slippage are all too familiar. Over tightening the
belt is not the answer as you will find out in the next
paragraph. |
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Important:
Tech Tip Warning!.
An over tightened belt, operated over a period
of time, can cause metal fatigue on the front
section of the crankshaft. This can result in
failure, breaking the crankshaft at the #1
journal. This generally occurs when owners have
over tightened their belt in an attempt to stop
or reduce slippage. The serpentine belt will not
slip using the same recommended tension as used
on the “V” belt. See figure 2 below. |
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Figure 1 – Kit Assembly |
Kit Includes:
(per fig1)
A. 1 x Crankshaft Serpentine
Pulley p/n T336-108C |
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B.
1 x New Fresh Water Pump with Serpentine Pulley
already fitted p/n T0054/336- 108W |
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C. 1 x Serpentine Pulley for
alternator. (17mm bore) Fits the Balmar 60, 70
and 90 series and most common Delco Alternators
and others. p/n T3781 |
D.
1 x 6 Groove Serpentine Belt p/n T060400 for
4-108
Only for
Westerbeke 40. 1 x 6 Groove Serpentine Belt p/n
T060415 |
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E.
1 x 1.3/8” x 3.1/2” Hose to extend fresh water
cross pipe to clear the wider belt (only needed
if Bowman Manifold is fitted.) as pictured
above. p/n T1.3750 |
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F.
1 x Front crankshaft oil seal in case the
original seal is damaged during pulley removal.
p/n 0730098 |
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G.
Only for Westerbeke 40 Bolt
and spacer kit. for Balmar with 2” mounting
foot: 1 x crankshaft bolt 32162316, 1 x
crankshaft washer 33124119 |
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When placing
your order: |
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We recommend ordering an additional spare belt.
Let us know which alternator you have to ensure
we supply you with the correct size pulley, as
these will vary between manufacturers. We cover
the most commonly used sizes per item “C” above. |
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Your kit will include a new water pump with the
serpentine pulley already installed. |
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For future reference, if you have a 4.107 or a
Westerbeke 40, the part # for a replacement
water pump using our serpentine pulley system
will now be U5MW0054 |
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This is a standard 4.108 pump which is fully
interchangeable but has a larger diameter shaft. |
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The part # for replacing a 4.108 pump is
unchanged. |
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For our records and future guidance, let us know
if you have a 4.107 a 4.108 or a Westerbeke 40.
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Installation
Procedure: |
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1.
Crankshaft Pulley. Remove positive battery
leads from starter motor and isolate positive
lead from battery. It will be necessary to stop
the engine from rotating when removing and re-torqueing
the crankshaft bolt. This can be done by
removing the starter motor and placing a pry bar
in the ring gear teeth on the flywheel. An
impact wrench can be used for removal but will
not ensure the correct torque when re fitting.
Remove the original crank shaft pulley retaining
bolt with a 1½” standard socket for the 4.107
& 4.108. For the Westerbeke 40 use a 1 1/8”.socket. With the bolt removed the pulley
should pull off quite easily by using two hands
and pulling evenly on both sides. Do not pry
against timing cover. This is a good opportunity
to inspect front seal for leaks and replace if
necessary, as the seal is now fully exposed. One
is included in the kit. Re fit the crank pulley
applying a smear of grease to the polished area
on which the seal rides. 4.107 & 4.108 tighten
the retaining bolt to 230 ft lbs if you have a
phosphate bolt (dull finish most popular) or 190
ft lbs if you have a cadmium coated bolt
(shinny). |
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Westerbeke
40 Only. Owners can purchase from us the
necessary replacement larger phosphate bolt
(32162316) and washer (33124119) to fit in place
of the original one. Tighten with 1 ½ in socket
to 230 ft lbs.
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Westerbeke 40 requires some additional bolts and spacers to
re-align alternator to be placed
as shown at left.
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Westerbeke 40 with Balmar 2” foot mount. |
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2.
Water Pump with Pulley. Drain anti freeze
coolant. Remove the old fresh water circulating
pump. Clean the gasket surfaces, and fit the new
water pump which will have the serpentine pulley
already installed. (new gasket supplied). 4.108
Owners with the Bowman manifold. (as configured
in the above picture) will be required to fit
the short supplied hose to bring the fresh water
cross over pipe forward slightly to avoid
contact with the new serpentine belt. This will
replace the existing hose. This does not apply
to others not using the Bowman manifold. |
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3.
Alternator Pulley. Replace the V pulley
on the alternator with the serpentine pulley. An
impact wrench works well for this. Some
alternators have a provision in the end of the
armature shaft for an allen wrench to hold
armature from turning while tightening with an
open wrench. Torque may vary according to your
alternator manufacturer. |
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4.
Serpentine Belt & Tension Fit the
new serpentine belt. Tension should be adjusted
using the original alternator adjusting arm so
that, with normal thumb pressure, the belt can
be depressed 3/8 of an inch at the center of the
longest span. (per fig 2) NOTE. The new belt
will require re tightening after a few hours of
operation. This check should be done while the
engine and belt is warm. Continue to check
tension until the new belt no longer stretches.
Following this procedure, periodic checks should
be made checking condition and tension. Carry a
spare! |
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5.
Replacing coolant. If you have not
changed your coolant within the
recommended period, this is a good time
to do so. We suggest a good quality
extended life ethylene glycol anti
freeze with corrosion protection and
rust inhibitor. Once coolant is filled
with a 50% 50% mix, approx. 6.6 qts.,
not including hot water heater, check
for leaks. Be sure to vent the air, and
monitor the fluid level and temperature
carefully before and after engine comes
up to working temperature. Caution: Do
not remove cap to check level until
engine has cooled down as the system
will be under pressure and could cause
burns. |
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Figure 2 – Belt Tension |
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Later
Replacement of a Worn out Pump with the Serpentine Pulley Already
Fitted. |
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All original pumps are supplied by the
manufacturer less pulleys. When fitting a
replacement pump avoid damaging pulley by
following instructions on the correct pulley
removal procedure as shown in your manual.
Be careful, the pulley is cast iron and will
easily break. They are expensive!
If you prefer,
play safe and
ship us your old pump and pulley, we will be
happy to change your pulley and supply a
replacement pump, (no charge for removal and
fitting the pulley) |
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Do you have a
Perkins 4.236? |
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If
you have a Perkins 4.236 and would be interested
in fitting a serpentine belt system please
indicate so in the form below. If we get enough
requests we will produce a serpentine system for
the 4.236 engine. We will keep your contact
information in the event we do proceed. |
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If you have any
questions or require technical assistance email us at
tadinc@earthlink.net
or call us at 804
642 9296. |
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To
request purchasing information for the Serpentine Pulley Kit, please fill out the form below and click on the
"Submit" button to send your request to Trans Atlantic Diesels. |
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This Page Last
Updated December 28, 2007 |
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