Problems with SET Zeise MPW5 generator

[bigwow]

BW was plugged into the mains for 18 months so the generator didn't get started. Came to start it and it was locked solid. I've got the head off, after quite a struggle, coming off the studs, and the piston is solid. I thought I'd split the generator from the engine, to make it easier to work on as it looks like I will need copious amounts of heat to remove the cylinder, I undid the 4 nuts and it would not split, there is a large pulley on the outside that has no visible means of removal, so stops the generator coming off the engine.
Anyone worked on these generators that can give me a few pointers.
No smart Alec comments please, I've been working on this all day and am really pissed off!!

 

[volvopaul]

Farryman engine ? Shocking thing , I've done loads like yours they don't sit idle for long before seizure. Whoever decided cooling an engine direct with sea water should have made cakes for a living.

Copious amounts of WD 40 down past the rings will help , then use a block of wood on the top of the piston to knock it down , you can then lift up the barrel until you see the little end pin , take the clips out and pin you can then lift off the barrel. You may also find that after that time the gen end is scrap as the end plate is alloy , the gasket fails , and bearing , sea water leaks into windings then it's all over. I had one of these sets a few years back, I inherited it from a job , the cost to make right was stupid so don't go buying unless you know the rest is still good.
The valves also corrode giving low compression so strip the head and reface the valves and head seats .

 

[Portofino]

I had a Farryman in a small compact Fischer Panda .
I soon realised I was looking at a chocolate tea pot .managed to extend life to sale of boat by ,devising a flush kit to wash through car antifreeze especially when sat in the winter ..Also attached extra zincs + copper bonding wire to the alloy gen case .
How ever life's a learning curve -next one /current boat has a small Mase .
USP here is air cooled .
No sea water comes in contact with the Yanmar ( trusty 1GM) engine or windings of the gen .
There's just a anoded - intercooler looks like a car radiator -size of a cornflake box - with a fan to blow the cooler air around .
Easy change out if ever needed .

 

[bigwow]

Thanks for the replies

Shows the pulley that appears to have no way of removing and is stopping the generator sliding back from the engine

Shows the WD40 in the cylinder and the carboned up studs are there supposed to be two locating tubes between cylinder and head? The valves look like they were done, before I got it, and not very well judging by the hylomar on the head joint and the leaking internal joints.
Having bought a fresh water cooling kit for this engine I need to persevere with the repair, within reason, and hope that the kit will keep any further problems at bay. I've been unable to locate a schematic of this engine any advise and leads would be gratefully received.

 

[volvopaul]

Splitting the gen end from the crank case won't help.
Take the whole engine off the sound shield base, there is a plate underside take off and undo big end bearing , the issue is between the 4 studs and barrel, try and take the studs out by warming the area of crank case around the studs.
The barrel will then come away with piston inside. Piston will be scrap so maybe use adrift underside of piston to push out barrel away from case.

 

[BruceK]

If it looks like it is going to defeat you or brute force may cause further damage take it to Brookefield Precision Engineering in Mochdre. Lovely old fella, ex Rolls Royce engineer, he does some superb work and has helped me out in a bind before.
https://www.facebook.com/bpengineering106

 

[BruceK]

There is a Yanmar 5kW genny going for £650 if interested.

 

[bigwow]

Well the barrel/liner is off!

Had to resort to the wizzer, surprisingly when cleaned up the piston seems OK.

 

[Greg2]

The We have one of these Zeisse gennys and had a problem with it running i.e. kept cutting out. Decided to have a go at resolving it and spent a reasonable sum on replacing the fuel supply side (injector, pump etc) only to have smoke stream from the gennie side when we finally got it going. Load of hassle getting it out of the boat and then putting it back.

Having spoken to a friend who completely refurbed one we have decided to cut our losses and scrap it. He spent an absolute fortune....sort of money getting close to buying a new one. Seems to chime with what Volvopaul says and I am guessing that water got into the genny side on ours.

Probably not helpful at this stage but it seems they can be a bit of a money pit.

If we go new the guys at NYA advise that Fishcer Panda are okay, not least because they have a closed coolant system. Just need to figure out if it is worth the expense.....definite case of man maths being required though......maybe an inverter and extra batteries is the sensible way to go!

 

[volvopaul]

K

Well the barrel/liner is off!

Had to resort to the wizzer, surprisingly when cleaned up the piston seems OK.

Hi looks better, you must remove the piston , use new rings in the new barrel, the barrel is tapered on the bore so the piston must go in from the top, don't try and slide the barrel over the piston.

 

[bigwow]

Thanks for that Greg, I think:encouragement:

 

[Greg2]

Thanks for that Greg, I think:encouragement:

I did think that my timing wasn't great!

 

[bigwow]

And to try and prevent further problems

 

[superheat6k]

When I needed parts for the Farymann on my Mastervolt I used these guys. Very good prices compared with marine suppliers.
http://www.dieselpower.co.uk

I have a parts manual for the Farymann with their part numbers rather than the genny makers - if you need it PM me.

 

[BruceK]

And to try and prevent further problems

Congrats on resurrecting the genny. I think the whole marina heard the mechie's swan song. By god it's noisy until it's in it's baffle box. No more excuses now. Moelfre next stop :encouragement: