Westerbeke 6.5KW Technical Manual
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Westerbeke 6.5KW Technical Manual

Westerbeke 6.5KW Technical Manual

4 cylinder marine gasoline generator sets twg series
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See also: Operator's Manual
TECHNICAL MANUAL
WESTERBEKE
4 CYLINDER
MARINE GASOLINE
GENERATOR SETS
TWG SERIES
6.5KW, 8KW, 11KW
Publication # 34645
Edition Two
November 1987
jr-.v-
'WESTERBEKE
J
WESTERBEKECORPORATION
•
MYLES STANDISH INDUSTRIAL PARK
150 JOHN HANCOCK ROAD, TAUNTON, MA 02780-7319

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  • Page 1 TECHNICAL MANUAL WESTERBEKE 4 CYLINDER MARINE GASOLINE GENERATOR SETS TWG SERIES 6.5KW, 8KW, 11KW Publication # 34645 Edition Two November 1987 'WESTERBEKE jr-.v- WESTERBEKECORPORATION • MYLES STANDISH INDUSTRIAL PARK 150 JOHN HANCOCK ROAD, TAUNTON, MA 02780-7319...
  • Page 2 Gasoline with an ETHANOL content higher than 10% (E10) is not allowed and may void warranty. Engines & Generators...
  • Page 3 TECHNICAL MANUAL WESTERBEKE 4 CYLINDER MARINE GASOLINE GENERATOR SETS TWG SERIES 6.5KW, 8KW, 11KW Publication # 34645 Edition Two November 1987 ~r-.v- 'WESTERBEKE WESTERBEKECORPORATION MYLES STANDISH INDUSTRIAL PARK 150 JOHN HANCOCK ROAD, TAUNTON, MA 02780-7319...
  • Page 4 SAFETY PRECAUTIONS The following symbols appear in this manual to call attention • Use Extreme Care When Handling Engine Fuel to and emphasize conditions potentially dangerous to the (A constant danger of explosion or fire exists) operator. not fill fuel tank(s) while the engine is running. not smoke or use an open flame near the engine or the fuel tank.

  • Page 5: Table Of Contents

    TABLE OF CONTENTS INTRODUCTION ..............3 INSTALLATION ..............4 OPERATION ..............14 MAINTENANCE ..............18 ENGINE TECHNICAL DATA ..........21 TABLE OF TIGHTENING TORQUES ....... 28 TABLE OF STANDARD TIGHTEING TORQUES ..... 29 DISASSEMBLY FOR OVERHAUL........30 ENGINE INSPECTION AND REPAIR ......35 ENGINE ASSEMBLY ............
  • Page 6 Westerbeke, is not within Westerbeke's control and, accor- dingly, is provided to Westerbeke customers only as a cour- tesy and service. tiESTERBEKE CANNOT BE RESPONSIBLE FOR THE CONTENT SUCH SOFTWARE, MAKES WARRANTIES REPRESENTATIONS WITH RESPECT THERETO, INCLUDING THE ACCURACY,...

  • Page 7: Introduction

    Care at the factory during assembly and thorough testing have resulted in a Westerbeke gasoline engine driven generator capable of many thousands of hours of depend- able service.

  • Page 8: Installation

    This is your protection against loss or damage. Claims for loss or damage must be made to the carrier, not to J. H. Westerbeke Corporation. ---- Rigging and Lifting The generator is fitted with lifting eyes.
  • Page 9 It is wiser that special rigging work be done by experienced and competent people knowledgeable in the handling of heavy equipment. Extreme caution and care cannot be stressed enough. Generator Mounting - Location complete generator unit mounted lightweight rails through soft flexible isolator mounts that prevent the transfer of vibration from the generator to the rails.
  • Page 10 Air Reguirements (Minimum Values) Model Engine Generator 6.5 KW 40 cu.ft./min 200 cu.ft./min 8 KW 40 cu.ft./min 220 cu.ft./min 11 KW 53 cu.ft./min 250 cu.ft./min In confined compartments fresh cool air should be brought into the compartment by means of AC or DC blowers and necessary ducting. This air should be directed at the generator end bell opening.
  • Page 11 Exhaust System IWARNINGI CARBON MONOXIDE EXHAUST GAS IS DEADLY. Carbon monoxide is a dangerous gas that can cause unconsciousness and is potentially lethal. Some of the symptoms or signs of carb- on monoxide inhalation or poisoning are listed below. o Vomiting o Dizziness o Intense Headache o Muscular twitching...
  • Page 12 must always be above the water line at all angles vessel operation to prevent siphoning. The vent, when used, must have its vent hose or tube routed so as to be above the water line and to remain empty of water when the engine is shut down to allow air to enter through this vent and prevent siphoning.
  • Page 13 Fuel System The generator must have its own fuel supply line; in other words, it must have its own pickup tubes and primaryfilter/Water separator. DO NOT tee off another engine's fuel supply. Installations with the fuel tank(s) at or above the generator with the fuel supply lines to the engine's carburetor routed below the level of the fuel tank's top must have a means of shutting off the fuel to the generator's engine when the engine is not running.
  • Page 14 ___ ANTI-SIPHON OEVICE OR ELECTRICALLY OPERATED FUEL STOP VALVE LEVEl~ - - - - - - - ;:;;L-;::;- T;;; FUEL LINE BELOW FUEL TANK TOP LEVEL ANTI-SIPHON DEVICE OR ELECTRICALLY OPERATED FUEL STOP VALVE AT FUEL TANK WITHORAWAL FITTIN' ANTI-SIPHON DEVICE OR ELECTRICALLY OPERATED FUEL STOP VALVE FUEL TANK TOP LEVEL FUEl LINE ABOVE FUEL TANK...
  • Page 15 Cooling System The generator's engine is fresh water cooled by an engine-mounted heat exchanger. Sea water is used as the heat exchanger's cooling medium. Sea water is pumped through the heat exchanger by a belt-driven, positive displacement rubber impeller pump. Afterthe sea COOLANTIIECOVEJIYTAIIIC water cools the fresh water that circulates through the heat exchanger, the sea water is then injected into the exhaust...
  • Page 16 panel is available for controlling the generator from a remote location. Remote start panels include a green LED which lights when the engine runs at approximately 600 rpm. The purpose of the LED is to alert the operator to release the starter toggle switch in addition to continue indicating that the generator set is run- ning.
  • Page 17 IWARNINGI When installing the optional remote start panel or the optional remote instrument panel, it is the installer's responsibility to comply with U.S. Coast Guard Standards 33 CFR PART 183. Generator AC Load Connections CAUTION ALL 115 VOLT LOADS MUST BE DIVIDED UP AND CONNECTED IN SUCH A MANNER THAT CURRENT FLOWING IN ANY OF THE THREE LEGS (G1, G4, G2/G3) DOES NOT EXCEED THE LOWEST AMPERAGE RATING ON THE GENERATOR'S DATA PLATE.
  • Page 18 Shore Power Connections If the installer connects shore power into the vessel's AC circuit, this must be done by means of the SHORE POWER/OFF/SHIPS GEN, center position-off transfer switch as shown below. CAUTION Damage to the generator can result if utility shore power and generator output are connected at the same time.
  • Page 19 IMPORTANT RULES Important Important Important Always ventilate generator compartment before attempting start the generator. Keep this manual handy for reference whenever in doubt. Check engine coolant level before each day's use. Check engine lubricating oil level before each day's use. Avoid moving parts, keep belt guard in place.

  • Page 20: Operation

    OPERATION Preparing the Engine for Initial Start-Up The generator engine is shipped dry with the lubricating oil and coolant drained from the engine. Therefore be sure to follow these recommended procedures carefully before attempting to start the engine for the first time. Remove the oil fill cap from the engine rocker shaft cover and fill the engine oil sump with the proper amount of lubricating oil as specified in the Engine Specification section of this manual.
  • Page 21 While filling observe the open bleed petcock/plug at the back of the cylinder head and when coolant begins to flow out of this petcock/plug opening, close the petcock/replace the plug. Con- tinue filling the system at the filler neck and the manifold until the coolant level is approximately 1/2 inch from the filler neck base.
  • Page 22 Starting the Generator Engine (Ventilate the Generator Compartment for 5 minutes prior to attempting to start the engine). Depress the ON switch (black), and hold it. Depress the START switch (white). This will engage the starter and crank the engine over to start it. If the engine fails to start in 20 - 30 seconds, release the two switches.
  • Page 23 prevent this, pinch off the clear plastic hose running from the manifold to the plastic recovery tank. Restart the generator. Check the AC output. Load the generator. (Check data tag for rating). During generator break in (first 50 hours), avoid light loads. Vary the loads.

  • Page 24: Maintenance

    MAINTENANCE Daily Checks (before initial daily start-up) Check the level of oil in the lube oil sump with the dipstick. Keep level between upper lower marks dipstick. Check eng ine coolant level in the plastic coolant recovery tank. (Maintain the coolant level between ADD and MAX when cold.) Periodically remove belt guard and check belt tensions, 3/8 - 1/2 inch deflection between widest span.
  • Page 25 10. Inspect the exhaust system that it is secure and tight (no leaks). 11. Remove and clean air screen inlet on carburetor. 12. Clean and lube linkage between governor and throttle. Insure that it moves freely with no binding. 13. Adjust carburetor choke needed.
  • Page 26 NOTE: Electric fuel pump base gasket #34706 must be replaced. Clean carburetor inlet filter screen. Change engine lubrication oil and oil filter. 6A. Flush the raw water circuit with fresh water and then run an antifreeze mixture through the raw water circui t to protect it against freezing.

  • Page 27: Engine Technical Data

    ENGINE TECHNICAL DATA Type Gasoline, four cycle Number and arrangement Four cylinders in line, of cylinders vertical type Bore and stroke 6.5 and SKW 70.0 mm x 69.6 mm (2.76 in x 2.74 in) llKW 77.0 mm x SO.O mm (3.03 in x 3.15 in) Total piston displacement 1071 CC (65.4 cubic inches)
  • Page 28 Cylinder head Height 90.5 (3.563 in) Warp limit 0.15 (0.006 in) Grinding limit 0.20 (0.008 in) Valve seat Seat sinking (Dim "L") Standard 39.5 (1.555 in) Wear limit (0.059 in) Seat Angle 45· Intake Exhaust 41)· Seat Width Intake (0.055 in) Exhaust (0.055 in) Valve guide, valve and valve spring...
  • Page 29 Camshaft Camshaft run-out 0.30 (0.0012 in) Camshaft end-play Standard 0.02 - 0.18 mm (0.001 - 0.007 in) Wear limit 0.20 (0.008 in) Camshaft journal diameter Front and rear 41.949 - 41.965 (1.6515 - 1.6522 in) Center 41.919 - 41.935 (1.6504 - 1.651 in) Wear limit of journal 0.05 (0.0020 in)
  • Page 30 Connecting rod journal diameter Standard 39.940 - 39.956 mm (1.5724 - 1.5734 in) Wear limit 0.05 mm (0.002 in) Grinding limit 0.75 mm (0.030 in) Main bearing journal diameter Standard 49.938 - 49.956 mm (1.9661 - 1.9668 in) Wear limit 0.05 mm (0.002 in) Grinding limit 0.75 mm (0.030 in)
  • Page 31 Piston ring groove width 1.22 - 1.24 (0.048 - 0.050 Second 1.52 - 1.54 (0.0598 - 0.0606 Oil scraper 4.02 - 4.04 (0.1583 - 0.1591 Piston ring thickness 1.17 - 1.19 (0.0461 - 0.0469 Second 1.47 - 1.49 (0.0579 - 0.0587 Oil scraper none given Clearance between piston ring...
  • Page 32 Lubricating System Lubricating method Full Forced Oil Pump Type Trochoid pump Oil pressure at engine speed 1.75 - 2.50 kg/cm 2 1800 RPM (25 - 35 lb/in 2 ) .7 - 1.75 kg/cm 2 700 RPM (idle) (10 - 25 lb/in 2 ) Outer rotor and pump body clearance Standard 0.20 - 0.294 mm...
  • Page 33 Cooling System Fresh water circuit coolant capacity approximately 6.S & 8KW 4.7 liters (S quarts) llKW 6.6 liters (7 quarts) Fresh water pump Belt driven centrifugal type Metal impeller press fit to pump shaft 1200 - 1300 kg (264S - 2866 lb) Raw water pump positive displacement type, neoprene impeller belt .drive...

  • Page 34: Table Of Tightening Torques

    AC slip rings, single bearing design. 1800 RPM operation (1500 for 50 Hertz) Ratings (standard) 6.5KW 115/230 volts, 56/28 amps 60 Hertz, single phase 115/230 volts, 70/35 amps 60 Hertz, single phase llKW 115/230 volts, 94/47 amps...

  • Page 35: Table Of Standard Tighteing Torques

    TABLE OF STANDARD HARDWARE TIGHTENING TORQUES Unless stated otherwise for a specific assembly, use the following torque values when tightening standard hardware. Pitch Ib-ft kg-m Grade4T 6mm bolt head/nut 2.9 - 5.1 0.4 - 0.7 8mm bolt head/nut 1.25 7.2 - 11.6 1.0 - 1.6 10mm bolt head/nut 1.25...

  • Page 36: Disassembly For Overhaul

    DISASSEMBLY FOR OVERHAUL Removal Remove all AC and DC power connections from the unit. Shut off and disconnect fuel, raw water and exhaust connections. Unbolt unit and remove to the overhaul shop. Drain lubricating coolant from engine exchanger system. Generator Removal from Engine Disconnect engine wiring harness leads from engine connections, mark...
  • Page 37 NOTE: Rest the generator housing on its side, not on the inner end as damage to the field coil windings may result. Unbolt the armature and drive disc assembly from the flywheel, supporting the armature. Then, cocking the armature, draw its drive disc through the bellhousing clearing the generator outer housing securing bolt bosses.
  • Page 38 Disassembly of the Engine Block Remove the engine rocker cover and baffle assembly. Rotate the engine crankshaft so as to position the camshaft drive chain so that the master link is in a position that it can be disassembled. Remove the chain tensioner from the front timing gear cover.
  • Page 39 baring c th7n~ ap with Remove cap puller. main bearl main Remove crankshaft thrust 13. bearing inser washers.

  • Page 41: Engine Inspection And Repair

    ENGINE INSPECTION AND REPAIR NOTE: Before washing cylinder head block, check them for indications of water leaks, gas leaks, damage or cracks. Before checking, wash each part remove any adhered foreign matter (pieces of gasket, dust, oil, carbon, scale, etc.) Since the cylinder head, cylinder head cover, timing chain cover and other engine parts are made of aluminum, handle them carefully to ensure against damage.
  • Page 42 Measuring Method #1: Check the difference between the inner diameter of the guide and the diameter of the valve stem. Measuring Method #2: Check the valve deflection with a mounted dial indicator by moving the valve stem from side to side. NOTE: Separate the valve from the valve seat before measur ing.
  • Page 43 Checking Valve Check the contact surface of the valve face and valve seat for damage. Minor rough surface may be repaired with a valve grinder. If the valve stem is worn, damaged, bent or the end surface of the stem is dented, replace the valve. Check valve stem diameter...
  • Page 44 Check squareness valve spr ing. exceeds limit, replace with a new one. Squareness limit: Less than 3 mm (0.118 100 mm (3.937 in) Checking Valve seat Check the protruding length of the valve stem (dimension "L"). If it exceeds the specification, correct it as follows.
  • Page 45 Reface the valve with a valve grinder to the specified angle. Valve face angle: 45· Reface the valve seat with a valve seat cutter while checking the contact between the valve and valve seat. NOTE: Reface the valve seat taking care that the valve seat con- tacts the center position of the valve.
  • Page 46 Checking Cylinder Block Check cylinder block damage or cracks. If necessary, repair replace cylinder block. Check to see that the oil pas- sages coolant passages the cylinder block are open. clogged, remove with compressed air or a wire probe. Check cylinder block distortion.
  • Page 47 Checking Piston Check pistons carefully and replace, if severe burns or scratches on the external circumference of the piston are found. Measure the piston diameter 18 (0.7087 in) under the oil ring groove, at right angles with the piston pin location (but without the pin in place).
  • Page 48 Measure the side clearance be- tween the piston ring and ring groove • . NOTE: Measure clearance around total circumference of the ring groove. Side clearance limit: 0.15 (0.006 Side clearance limit: 0.15 (0.006 in) Checking Connecting Rod t:h"a/e Check the side of the connecting twist rod small end and large end for cracks or damage.
  • Page 49 Checking Connecting Rod Bearing Check the connecting rod bearing carefully and replace if it is worn, scored or flaked. Check the connecting rod bearing clear ance with a "plastigauge". If it exceeds the limit, correct crankpins with suitable grinder with suitable undersize bearings.
  • Page 50 Main Journal Crankpin Standard 49.938 - 49.956 39.940 - 39.956 (1.5724-1.5734 in) (1.9661-1.9668 in) Undersize 0.254 49.690 - 49.705 39.690 - 39.706 (1.9528-1.9534 in) . (1.5598-1.5604 in) Undersize 0.508 49.440 - 49.455 39.440 - 39.456 (1.9430-1.9436 in)' (1.5500-1.5506 in) Undersize 0.762 49.190 - 49.205 39.190 - 39.206 (1.9332-1.9338 in)
  • Page 51 Checking Main Bearing Check the main bearing carefully ------ replace worn, scored or flaked. Check the main bearing clearance with "p1astigauge". exceeds the limit, correct the main journals having crankshaft ground for undrsized main bearings. NOTE: Tighten the main bearing bolts specified torque.
  • Page 52 Measure extent uneven wear journals four locations (direction A and front back). Replace limit is exceeded. Uneven wear limit: 0.05 mm (0.020 in) Diameter of journal (standard): Front and rear: 41.949 - 41.965 mm (1.65l~ - 1.6522 in) Center: 41.919 - 41.935 mm (1.6504 - 1.651 in) Checking Flywheel and Ring Gear Check the flywheel for damage or wear on ring gear tooth surface and replace, if necessary.

  • Page 53: Engine Assembly

    ENGINE ASSEMBLY Take the following precautions: Make sure that all parts to be assembled are thoroughly cleaned. Be careful not to mix nuts and bolts. Metric and S.A.E. bolts are used on various engine assemblies. During assembly, recheck clearances and insure parts are being assembled in their proper order and facing in the correct direc- tion in relation to the engine block, e.g., pistons, piston rings,...
  • Page 54 l... '----11 1. Piston pin 6. Main bearing 11. Main bearing cap 2. Piston ring 7. Crankshaft 12. Side seal 3. Piston and connecting rod 8. Oil seal 13. Connecting rod bearing and cap 4. Connecting rod bearing 9. Thrust washers 5.
  • Page 55 C:;:h~'~~;;;;;------- da:m~----------- 20. End pl-=at-e----- 14. Oil pump :~:per 15. Timing :;:am and sprocket . Adjuster blade rocket . Chain 18. T" am and 21. Flywheel chain cover 22. Crankshaft pulley •...
  • Page 56 3 3 - - - - - - - - 4 26--------, 25--------... y--27 ® / / A ' - - - - 2 4 23. Valve Camshaft 30. Chain adjuster Cylinder head 27. Rocker 25. Bolt (cylinder head - timing Cylinder head bolt chain cover) 29.
  • Page 57 Assemble pistons con- necting rods according following procedure. Use piston setting tool. Assemble shown figure. Apply engipe external circumference piston pin. Set special tool and piston pin as shown in the figure. Press fit by pressing the top end of installer. piston pin is in the spe- cified position...
  • Page 58 Second Insert the piston into the cylinder block, ensuring that "F" mark stamped on the piston is facing toward the cra·nkshaft pulley end (engine front). suitable piston ring compressor. ·r"'-~· Insert main bearings block insur ing the bear ing oil ports properly aligned.
  • Page 59 Rear oil seal. Install the lower thrustwashers with the groove in the washer being directed outward. Insert lower main bearings. 10. Main bearing caps. NOTE: Match main bearing cap with the "Cap No.", and the arrow mark should point towards the front of the engine.
  • Page 60 15. Install oil pump with drive chain on both the crank- shaft and oil pump sprocket. 16. Timing chain and sprockets. Match the ring plate mark (shiny link) timing chain with the timing mar k of the crankshaft sprocket. Install crankshaft sprocket on the crankshaft, ensur ing not to change the...
  • Page 61 Tightening torque: 11.0 - 12.0 kg-m (80 - 87 lb-ft) 24. Valves. Assemble valves cylinder head with valve spring lifter and pivot. 25. Cylinder head. position the head gasket on the block. position the cylinder head. through Install capscrew head into timing chain cover.
  • Page 62 30. Install the camshaft drive sprocket washer and nut. Tightening torque: 7.0 - 8.0 kg-m (51 - 58 1b-ft) 31. Check camshaft play (clear ance between sprocket and thrust plate). If the end play exceeds specified limit, replace the thrust plate. Limit of camshaft end play: (0.008 0.20...
  • Page 63 Insert the distributor shaft by turning it, ensuring that the distributor shaft fits into the groove on the rear end of the camshaft. This groove is offset so the distributor can only be installed correctly to the camshaft. 34. Adjust engine timing according to specifications in the Engine Technical Data Section.
  • Page 64 38. Rocker cover. 39. Oil manifold tee, oil pressure sender and switch. 40. Fresh water pump. 41. Bellhousing. 42. Ignition coil and bracket. 43. Intake manifold. Tightening torque: 2.6 kg-m (14 - 19 lb-ft) 44. Carburetor and fuel pump. 45. Alternator and bracket. 46.
  • Page 65 59. Adjust nV n belt tension. belt deflection exer ting nv n 10 kg (22 lbs) force: For new belt: 9 - 11 (0.35 - 0.43 in) For used belt.: 10 - 12 (0.39 - 0.47 in)

  • Page 66: Lubrication System

    LUBRICATING SYSTEM Operation The lubricating system is a pressure feeding system using an oil pump. The engine oil forced out of the oil pump is passed through the oil filter. The oil passes through the oil filter and then to the various lubricating points in the engine and then returns to the lube oil sump.
  • Page 67 Checking Engine Oil Check for any eng ine oil leakage. Should leakage be detected, correct as needed. Tightening of fittings and bolts is considered normal maintenance and is the responsibility of the owner. Check eng ine oil level with the lube oil dipstick at least once daily prior to engine usage.
  • Page 68 Possible Cause Trouble Remedy Low Oil Pressure Oil leaks Refer to above. (unit shut-down) Low oil level or Add oil to proper incorrect grade level or change. Faulty oil pressure Test and replace. switch Clogged oil filter Remove and replace oil filter.
  • Page 69 Disassembling Oil Pump Disassemble in the following order. Cover Cotter pin Plunger assembly Outer rotor Sprocket Remove the sprocket by sup- porting sprocket pressing shaft out. Shaft and inner rotor assembly pump body Checking Oil Pump Examine the following parts and replace, if necessary. Pump body and cover, deformed or damaged.
  • Page 70 Check clearance between the outer rotor and pump body with a feeler gauge. If the clear ance exceeds the limit, replace rotor pump body. Clear ance limit: rnrn (0.014 in) 0.35 Check float rotors. Place straight edge across the pump body and measure the clearance between rotor and straight edge...
  • Page 71 Assembling the Oil Pump Assemble in the reverse order of disassembling. NOTE: Press the dr i ve gear onto the pump shaft until the end surface becomes flush with the end surface of the shaft. If the pressing pressure is less than the specified value, replace either the sprocket or shaft, or both.

  • Page 72: Cooling System

    COOLING SYSTEM Description Westerbeke mar ine generators are equipped wi th fresh water cooling. Transfer of heat from engine fresh water to sea water is accomplished by a heat exchanger, similar in function to an automotive radiator. Sea water flows through the tubes of the heat exchanger while fresh water flows around the tubes.
  • Page 73 Fresh Water Pump Removal Drain coolant from engine block. Remove pump drive belt loosening 12 volt alternator adjusting strap and pivot bolt. Remove coolant hose from pump to manifold. Remove belts mounting pump to engine block and remove pump. Checking Fresh Water Pump Check for water leaks.
  • Page 74 Sea Water Pump Removal Remove inlet and outlet hoses connected to nipples on pump. Note connections on pump for proper assembly. Loosen bolts mounting pump to support bracket and remove drive belt. Remove mounting nuts and bolts and lift pump from engine. Raw Water Pump Disassembly Disassemble in the following order.
  • Page 75 NOTE: Drive pulley not shown. Thermostat Removal The thermostat is mounted inside a housing on the back of the cylinder head next to the distributor. Drain the coolant. Remove the hose from thermostat housing to heat exchanger. Remove thermostat cover housing and bolts. Remove thermostat.
  • Page 76 POINT #1: Drain petcock located on the right inboard side of the engine heat exchanger. POINT #2: Remove the hose connected to the inlet of the fresh water circulating pump. Filling system with coolant: Replace inlet hose to fresh water circulating pump and close pet- cock on heat exchanger.
  • Page 77 Examine all parts for defects, corrosion and wear and replace as needed. Exhaust Manifold Installation If the manifold was removed as an assembly and left intact, it can be replaced on the cylinder head in the reverse order of removal. Do not reuse the gaskets~ install new ones and torque the bolts or...
  • Page 78 Cooling System Troubleshooting Trouble possible Cause Remedy Coolant leaks: It is recommended that when trying to locate a leak in the cooling system that the system be pressure tested using commercially available pressure tester such as the STANT iST255. Follow instructions with the tester. Locate and correct the leak.

  • Page 79: Governor

    GOVERNOR Governor Description governor belt-driven, mechanically operated maintains engine RPM under varying conditions of generator load. The engine speed determines the Hertz and voltage output of the generator. NOTE: Belt tension: 3/8 - 1/2 inch deflection at center of widest span with 22 lbs pressure applied to belt outer face.
  • Page 80 Hunting/Regulation If variation in engine speed between no load and full load is too great, adjust this eye bolt to draw the spring closer to the lever hub. The increase/decrease speed bolt may need to be adjusted as well. If the governor surges under load, adjust this eye bolt to move the spring away from the lever hub.

  • Page 81: Carburetor And Fuel System

    CARBURETOR AND FUEL SYSTEM Carburetor The carburetor a single barrel down draft type with a metal screened air intake filter (cleanable). The carburetor has two metering jets, one of which is adjustable (idle mixture). The other fast running jet is set at the factory and will accept no adjustment.
  • Page 82 Air Intake Screen Electric Fuel Pump engine mounted electric fuel pump supplies fuel the engine carburetor during engine operation. A cleanable filter screen is contained in its base. Remove the base by placing a wrench on the hex nut and twisting it loose from the bayonet -fittings.
  • Page 83 Troubleshooting the Fuel System Trouble possible Cause Remedy 1. Hard starting 1. Faulty check 1. Check choke adjustment and operation. 2. Fuel 2. Check fuel supply and correct type. Fuel pump 3. Check pump operation and clean filter screen. 4. Faulty idle jet 4.

  • Page 84: Dc Electrical System

    DC ELECTRICAL SYSTEM Safety Information This circuit designed and manufactured in compliance with united States Coast Guard Standards (33 CFR PART 183). No modifica- tions may be made installer or user. It is the installer's responsibility to assure that the installation of the generator set and any remote start panels or remote instrument panels are installed in compliance with the above Coast Guard Standards.

  • Page 85: Dc Wiring Diagram

    To STOP the generator, depress the STOP switch which opens the normally closed B+ path on the ON and START switches. The STOP switch must be held open until the generator comes to a stop. Remote start panels be connected to the generator set as indicated. A jumper has to removed between Tl and T2 at the panel connection terminal...
  • Page 86 6,8 and 11 KW GASOLINE GENERATORS WIRING HARNESS ELECTRIC FUEL LlFTPUMP EXHAUST TEMP SWITCH...
  • Page 87 Distributor The distr ibutor is a solid state type without breaker points and therefore requires no adjustment. It consists of a cap, rotor, signal generator, igniter and centrifugal advance system. The signal generator consists of a signal rotor, magnet and pickup coil.
  • Page 88 Distributor Disassembly Remove wires from distributor noting their position for replace- ment. Remove distr ibutor from engine. Remove cap. Remove rotor. Remove governor assembly. Remove pickup coil and igniter. Distributor Assembly Assemble in the reverse order of disassembly. Apply engine oil sparingly to the o-ring on the distributor shaft. Insert the distr ibutor shaft by turning it, ensur ing that the distributor shaft fits into the groove on the rear of the camshaft which is offset to provide proper timing.
  • Page 89 Spark Plugs Service spark plugs, clean gap or replace as needed. Plug Gap Spark plug gap: 0.8 + 0.05 O.8j:O.05 mm (0.031-+ 0.002 (O.031j:O.002 in) Spark plug torque: Damage and Deterioration kg-m 1.5 - 2.3 lb-ft) (10.8 - 16.6 Check plugs for damage and/or wear. Damage NOTE: Loc-tite "Anti-Seize"...
  • Page 90 Checking insulation resis- tance between the pr imary ter- minal coil case. (Megohmmeter 500 volt) Normal resistance: 10 megohms + coil should replaced should not meet resis- tance values given above. Checking Overspeed Module with gener ator running, manually move the throttle lever to full open.
  • Page 91 that the battery is being overcharged and will damage the battery if left unchecked. The voltage regulator is most likely at fault. When the battery is being charged (having electrical loads placed upon it and no charg ing current applied), it is normal for the needle to indicate between 11.4 and 12.6 volts.
  • Page 92 possible Cause Remedy Trouble 1. Low oil pressure or 2. Check oil, fresh water Engine stops overheated and sea water cooling. 2. Low oil pressure 2. Check for satisfactory operation with switch switch fails to close bypassed. 3. High water or 3.
  • Page 93 possible Cause Remedy Trouble 5. Alternator 5. Disconnect alternator at output, after a good battery charging. If leakage stops, re- place alternator pro- tective diode plate. That failing, replace alternator. 6. Overspeed circuit 6. Unit not run for drained battery months and fuse left in circuit drawing 0.025 amp.
  • Page 94 REMOTE PANEL INSTALLATION INSTALLER'S/OWNER'S RESPONSIBILITY Wiring between the generator set and either a remote start panel remote instrument panel must comply with u.S. Coast Guard Safety Regulations 33 CFR-183. The mimimum voltage required at the starter solenoid is 9 volts. Therefore, wire gauges from TBl-l to TB3-l and from TBl-2 to TB3-2 should be selected to give a maximum voltage drop of 1 volt or less.

  • Page 95: Ac Generator

    AC GENERATOR GENERATOR DESCRIPTION AND MODEL RATING Characteristics Design: Four pole revolving armature, inherently regulated, self limiting, rectifier excited, A.C. slip rings, single bearing designs. voltage Regulation: + 7 percent no load to full load. Frequency Regulation: 3 Hertz (5%) no load to full load. Insulation: Class F as defined by NEMA MGI-l.6S.
  • Page 96 GENERATOR TROUBLESHOOTING TWGMODELS 6.SKW, 8KW, 11 KW No Electrical Output Remove load from generator verify no output directly at generator output leads with voltmeter. Check for proper electrical connections. Refer to Internal Wiring diagrams. NOTE: Generator armature slip rings and b'rush rigs are numbered from inboard at the windings or flywheel end outward toward the rear support bearing.
  • Page 97 2-wire unit 5 Volts AC (Hot lead to neutral) 3 and 4 wire unit 2.5 volts AC (each hot lead to neutral approximate) Residual voltage checks O.K. You can assume the rotating armature and brush rig are O.K. The generator problem lies in the rec- tifier and/or field coils.
  • Page 98 Check for a short or open in the rotating armature or in the sta- tionary field coils. ROTATING ARMATURE (RESISTANCE VALUES) 1 ohm or less between slip rings (1 & 3) TWG 6.5KW, 8KW, 11KW and (2 & NOTE: 3- and 4-wire units: There should be no continuity found between slip rings (1 &...
  • Page 99 NOTE: There should be no continuity found between the field coils and the generator body. Replacement of Field Coil(s) Field coils are connected in series and the reisitance value given above this text total of the four field coils. determine the resistance value of one, divide by four. Each field coil has a mounting position on the generator housing and cannot be interchanged with another field coil.
  • Page 100 Low Voltage Output Verify voltage output at generator output leads with load applied to generator, check no load condition also. Check voltage at the load. Check rating for generator and verify load with amp probe at output leads. Check all connections to insure they are clean and secure.
  • Page 101 Check field coil resistance as per specification given in A-6. Insufficient cooling of the generator. Ambient air entering the generator should not exceed 104·F (40·C). Operating efficeincy of the generator decreases as the ambient air temperature entering the generator end bell increases above 104·F. Generators in confined areas may require the ducting of cool...
  • Page 102 TECHNICAL DATA 115 or 115/230 Volts AC 27.0 AMP at 230 Volts AC TWG6.5KW TWG8.0KW 115 or 115/230 Volts AC 34.0 AMP at 230 Volts AC TWG 11KW 115 or 115/230 Volts AC 46.0 AMP at 230 Volts AC Frequency 60 Hertz standard (50 Hertz available at reduced rating...
  • Page 103 Internal Wirin g Diagrams 6.5KW, 8KW 11 KW 115 Volt and 115/2'30 Volt Field Excitat· Recff. Siler Wiring ame as for 230v...

  • Page 104: Lay-Up And Recommissioning

    LAY-UP AND RECOMMISSIONING General Many owners rely on their boatyards to prepare their craft, including engines and generators, for lay-up during the off-season or for long periods of inactivity. Others prefer to accomplish lay-up preparation them- selves. The procedures which follow will allow you to perform your own lay-up and recommissioning, or to use as a check list if others do the procedures.
  • Page 105 Sea Water Circuit Close the thru-hull seacock. Remove the sea water intake hose from the seacock. Place the end of this hose into a 5-gallon bucket of clean fresh water. Before starting the engine, check the zinc anode found in the primary heat exchanger on the engine and clean or replace it as required.
  • Page 106 Recommissioning The recommissioning of your Westerbeke unit after a seasonal lay-up generally follows the same procedures as those presented in the "Preparation for Starting" section, page 14, regarding preparation for starting and normal starts. However, some of the lay-up procedures will need to be counteracted before starting the en- gine.

  • Page 107: Service Bulletins

    SERVICE BULLETINS The following Bulletins contain· supplementary and updated information about var ious components service procedures which important proper functioning of your engine and its support systems. You should familiarize yourself with the subjects make sure that consult appropriate Bulletin (s) whenever your engine requires service or overhaul.
  • Page 108 SERVICE BULLETIN DATE: BULLETIN NUMBER: 20 6/15/69 All Engines MODEL: SUBJEC~ Connecting Pressure Sensing Devices to Oil Galleries Oil pressure sensing devices, such as senders and switches, must never be connected directly to any oil gallery of an engine. The reason is simply that continued engine vibration causes fatigue of the fittings used to make such a connec- tion.
  • Page 109 SERVICE BULLETIN 5/6/74 DATE: BULLETIN NUMBER: 69 All Marine Generators and Marine Engines MODEL: Exhaust System Failures SUBJECT: When engine sea water is fed into an exhaust system so that the full stream strikes a surface, erosion may cause prema- ture failures.
  • Page 110 SERVICE BULLETIN 4/4/83 DATE: BULLETIN NUMBER: 87 All mar ine engines MODEL: Alternator Output Splitter SUBJECT: GENERAL DESCRIPTION: The spli tter is a solid state device which allows two batteries to be recharged and brought to the same ultimate voltage from a single alternator as large as 120 amp and, at the same time, isolates each battery so that discharg ing one will have no effect...
  • Page 111 On alternators which have an isolation diode between their output and regulator terminals, such as the Motorola units used with most WESTERBEKE engines, the regulator wire should be removed from the REG terminal and reconnected to the OUTPUT terminal as shown.
  • Page 112 SERVICE BULLETIN DATE: BULLETIN NUMBER: 92 4/28/76 MODEL: SUBJEC~ Troubleshooting water Temperature and Oil Pressure Gauges Given a presumably faulty gauge indication with the instrument panel energized, the first step is to check for 12 VDC between the ign. (B+) and neg.
  • Page 113 SERVICE BULLETIN 12/6/83 DATE: BULLETIN NUMBER: 133 MODEL: W10Two, W13, W2l, W27, W30, W33, W40, W50, W52, W58, W70, W80, W100, W120 (All Related Generators) SUBJECT: Zinc Pencil - tl1885 A zinc pencil PN 11885 is located in the sea water cooling circuit of all primary heat exchangers on the above models.
  • Page 114 SERVICE BULLETIN 4/3/84 DATE: BULLETIN NUMBER: 137 MODEL: 3KW, 4. 4KW, 7. 7KW, 8KW, llKW, 12. 5KW (Also Related 50 Hertz Units) SUBJECT: Cooling Fan Secur ing Nut Generator units must have proper air circulation while running to pro- vide for combustion air use by the engine and for cooling the...
  • Page 115 The cooling fan securing nut should be tight enough so that when force is applied to rotate the fan by pushing on the outer edge and blades with the palm of your hand (protect the hand with a cloth or a glove), you should be able to turn the generator and engine without the fan slipping on the shaft.
  • Page 116 SERVICE BULLETIN DATE: 5/25/84 BULLETIN NUMBER: 139 MODEL: All Propulsion and Generator Models SUBJEC~ Hydro-Hush Muffler Installations The illustrations shown with this text should be used as a guide when making an installation of a Hydro-Hush Muffler. When used in conjunction with a propulsion engine, the Hydro-Hush Muffler should be mounted close to the for-aft center line of the boat.
  • Page 117 The installation information given in this text is to be used as a guide only. WESTERBEKE cannot be responsible in any way for muffler installations. WESTERBEKE presumes installer to have a basic knowledge of marine installation requirements. Use as few right angle fittings as possible.
  • Page 118 ENGINE INSTALLATIONS min. Water Line 48" 2" I.D. max. ENCINE INSTALLATIONS WITH EXHAUST MANI- FOLD/WATER INJECTED ELBOW AT OR BELOW VESSEL WATER LINE ENCINE INSTALLATIONS WITH EXHAUST MANI- FOLD/WATER INJECTED ELBOW MINIMUM OF 6 INCHES ABOVE VESSEL WATER LINE.
  • Page 119 GENERATOR INSTALLATIONS ---lI.n. Syphon Break A..t;\.--..-- 12" ~~.'~ Raw Water Pump Raw Water Intake· Thru H.ull Fitting Generator Installations with exhaust manifold/water injected Generator Below Water Line elbow at or below vessel water line. Raw Water Pump Raw Water Intake· Thru Hull Fitting Generator Installations wi th Generator Above Water Line...
  • Page 120 3KW, 4.4KW, 7.7KW, 6KW, 6.5KW, 8KW, llKW, l2.5KW, l5KW, 20KW, 25KW, 32KW SUBJEC~ Installation - Coolant Recovery Tank Kit #44977 A coolant recovery tank kit is supplied with each Westerbeke generator (gasoline and diesel) and propulsion engine. The purpose of...
  • Page 121 Propulsion engines having domestic hot water heaters plumbed to the eng ine' s cooling system and the domestic water heater is higher than the engine manifold, require the use of our metal Remote Expansion i24l77~ Tank Kit then the plastic coolant recovery tank should not be used, and the hose attachment fitting on the engine manifold should be removed and plugged (1/8 N.P.T.
  • Page 122 SERVICE BULLETIN April 13, 1985 BULLETIN NUMBER: 153 DATE: All Current Production propulsion and Generator Models MODEL: Check valves and Fuel Pick-up Screens SUBJECT: Fuel starvation problems have occurred, resulting from the installer placing a check valve in the fuel supply line to the engine.
  • Page 123 Filling the Fresh Water Cooling System SUBJECT: A mixture of ethylene glycol based antifreeze and fresh water should be used in the fresh water cooling system of the 6.5KW, 8.0KW and 11.OKW gasoline generators. A 50/50 mixture of anti- freeze and fresh water is recommended in the fresh water cooling circuit.
  • Page 124 Add the antifreeze mixture at the filler neck (pressure cap) on the manifold until the mixture flows from the bleed petcock with no air, then close the petcock and continue to fill until the manifold is full. Start the engine, monitor the coolant level in the manifold and add coolant to keep it full.
  • Page 125 SERVICE BULLETIN January 6, 1987 BULLETIN NUMBER: DATE: All Gasoline Models MODEL: Fuel System Components SUBJECT: Installers are advised that with the increased availability and use of butane/alcohol blended gasolines, fuel system components MUST be t~ensure compatible with these types of blended gasolines. Failure compatibility will result in the component's failure and possible injury to the user.

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