Westerbeke 11KW, Technical Manual

Page 1: ...E 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 ...

Page 2: ...Gasoline with an ETHANOL content higher than 10 E10 is not allowed and may void warranty Engines Generators ...

Page 3: ...KE 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: ...ks and make sure the exhaust manifolds are securely attached and no warping exists Be sure the unit and its surroundings are well ventilated Use Extreme Care When Handling Engine Fuel A constant danger of explosion or fire exists Do not fill fuel tank s while the engine is running Do not smoke or use an open flame near the engine or the fuel tank Do Not Alter or Modify the Fuel System Be sure all ...

Page 5: ...ORQUES 28 TABLE OF STANDARD TIGHTEING TORQUES 29 DISASSEMBLY FOR OVERHAUL 30 ENGINE INSPECTION AND REPAIR 35 ENGINE ASSEMBLY 47 LUBRICATION SYSTEM 60 COOLING SySTEM 66 GOVERNOR 73 CARBURETOR AND FUEL SYSTEM 75 DC ELECTRICAL SYSTEM 78 DC WIRING DIAGRAM 79 AC GENERATOR 89 LAY UP AND RECOMMISSIONING 98 SERVICE BULLETINS 101 1 ...

Page 6: ...d by their manufacturers with their own software and Westerbeke must depend on such software for the design of Westerbeke s own product software Such software may be out dated and no longer accurate Routine changes made by Westerbeke s suppliers of which Westerbeke rarely has notice in advance are frequently not reflected in the supplier s software until after such changes take place Westerbeke cu...

Page 7: ...ed to drive our generator requires the same preventative maintenance that any intelligent operator would give the gasoline engine in his automobile The most important factors to unit longe vity are proper ventilation maintenance of the fuel system ignition system cooling system and generator end Care at the factory during assembly and thorough testing have resulted in a Westerbeke gasoline engine ...

Page 8: ...or 1 there fore auxiliary slings are not required or desired CAUTION Slings must not be so short as to place the generator lifting eyes in significant sheer stress Strain on the generator lifting eyes must not be in excess of 10 from the vertical The general rule in moving generators is to see that all equipment used is amply strong and firmly fixed in place Move the engine a litle at a time and s...

Page 9: ...h that it is dry and above low lying vapor areas and away from being splashed by bilge water or water from above It should be properly ventilated and accessible for minor ser vicing and repairs Access for major repairs should be given con sideration as well The location should be properly ventilated The platform on which the generator is mounted should be strong enough to support the generator and...

Page 10: ...s that the generator will have to start and run The amperage draw of a motor when starting can be as much as 3 5 times its normal running amperage Determine the average AC load of the vessel and size the generator to handle this load with reserve Model Volts Amps 6 5 614 60 Hertz 115 230 56 28 4 9 514 50 Hertz 115 230 43 21 8 0 614 60 hertz 115 230 70 35 6 0 514 50 Hertz 115 230 52 26 11 0 614 60 ...

Page 11: ...gh speed scoop type fit tings should not be used as they tend to encourage siphoning When a water lift type exhaust system is used the exhaust muf fler should be mounted as close to the engine as practical The exhaust discharge should al ways drop downward into the exhaust muffler Loops in the exhaust hose between the water injected exhaust elbow and the water lift muffler should be avoided as the...

Page 12: ...re as measured bya gauge instrument should not exceed the fol lowing speCifications 3 inches of mercury 0 104 kg cm2 39 inches of water in a water column 099 kg cm2 at 40 C 22 ounces psi 11 2 psi Exhaust Elbow Exhaust Excessive back pressure can be caused by a small diameter exhaust hose a small muffler sharp bends in the exhaust hose fittings water pockets and a high volume of water in the exhaus...

Page 13: ...om the generator s start stop panel orfrom the vessel s deck Installations where the gen erator is located above the fuel tank s whereby the routing of the fuel supply line to the generator s car buretor remains above the top level of the fuel tank do not require this anti siphon shut off valve A manually operated service shut off valve should be located between the fuel pickup at the tank and the...

Page 14: ...solenoid shut off valve is not recommended as these maytax the fuel lift pump s abilityto drawfuel through a check valve Check valves can trap dibris under their seat which inhibits the valve s ability to close In addition if a check valve s cracking pressure is too high it may cause vapor lock It is recommended that an approved filter separator be used in the fuel supply between the fuel tank and...

Page 15: ...the cause of injury Electrical System Characteristics The generator is started by a conventional separate cranking motor which includes a self contained posi tive engaging starter solenoid Battery recharging capacity is provided by an alternator with approximately 50 Amps output capacity A circuit breaker located within 7 inches of the battery connection to the starter solenoid protectsall subsequ...

Page 16: ...e the START switch when the green LED lights but continue depressing the ON switch After releasing the START switch con tinue holding the ON switch until oil pressure is sufficient to close the oil pressure safety switch providing the normal B path to the ignition system Note that it is now impossible to energize the starter while the generator is running until someone again operates the ON switch...

Page 17: ... output This is a single phase 4 lead wi th vol tage com binations of 115 volt two wire or 115 230 volt three wire All 115 volt devices must be connected to one of the two 115 volt sources and all 230 volt devices must be connected to the 230 volt source For all 115 volt loads half of the generator s rated capacity may be taken from leads Gl and G2 G3 and half from G4 and G2 G3 230 Volt loads are ...

Page 18: ...TWO WIRE 128 VDLT SYSTEM FOR THREE WIRE i z GeneralOr N GI t L _ _ _ _ _ _ SY_S TEM USE DOITED LINES FOR THE OTHER HOT LEGS I I L ____ J r Q I __ I I I I I I I I I I I I I L_L2 Ship S LOAD SHIP TO SHORE SWITCH 3 POLEI PN 328B8 48 AMPS POLE PN 32B89 8B RMPS POLE PH 32818 125 AMPS POLE PN 32133 288 AMPS POLE NOTE DIAGRAM SHOWS CONNECTIONS FOR A TWO WIRE 120 VOLT SYSTEM FROM THE GENERATOR WITH THREE ...

Page 19: ...pment beware of electrical shock Do not wear jewelry Disconnect electrical power before working on electrical equipment Use properly insulated tools and equipment 7 Beware of exhaust gas leaks Carbon monoxide exhaust gas can be deadly Carbon monoxide is a colorless and odorless gas a product of combustion from a gasoline engine To protect yourself from this gas inspect the exhaust system regularly...

Page 20: ...gine Specification section of this manual Use a good brand of oil having an A P I Spec of SE or SE CC 2 Fill the fresh water cooling system with a mixture of anti freeze and fresh water Follow the antifreeze manufacturer s instruction and add rust inhibitors if needed Do not use an overcon centration of antifreeze To properly fill the engine s fresh water cooling system remove the manifold fill ca...

Page 21: ...l metal box are routed through grommetted holes to protect the AC leads against chaffing 4 Connect DC starting battery leads securely to the tagged connec tion points on the engine Always connect the ground lead last The starting battery swi tch should be in the OFF position and the three fuses in the control panel removed from their respective holders when making these connections Reinstall the f...

Page 22: ...e is warmed up shut engine down by depressing the STOP swi tch red Keep switch depressed until eng ine stops completely Check eng ine sump oil level and fresh water coolant level initial start Add oil and coolant as needed This is to replenish oil that is now filling internal oil galleries and the filter Coolant is needed to replace air that has been expelled from the fresh water cooling system To...

Page 23: ...eating and damage can occur from excessive cranking CAUTION Prolonged cranking intervals without the engine starting can result in filling the exhaust system attached to the engine with sea water coolant This may happen because sea water pump is pumping sea water through the sea water cooling system during crank ing This sea water can enter the engine s cylinders by way of the exhaust manifold onc...

Page 24: ...rating The oil must have an API spec of SE or SE CC Retorque the cylinder head hold down bolts engine warm Adjust the valve clearances engine warm Clean and regap spark plugs Check zinc anode in heat exchanger Clean and replace as needed If zinc is flaking scrape clean Check zinc end of exchanger for zinc pieces and clean from exchanger Check belt tensions 3 8 1 2 inch deflection at widest span Cl...

Page 25: ...lean and or replace primary fuel filters 7 Check condi tion and strength of antifreeze mixture in the fresh water cooling circuit Strengthen the mixture as needed Drain the coolant and replenish should the coolant become discolored 8 Clean the carburetor air inlet screen every 300 hours of engine operation or more frequently as needed 9 Check ignition circuit every 300 400 hrs A Clean rotor and ca...

Page 26: ... gapped prior to recom missioning Close off the carburetor air intake with an oily rag 7 Remove the impeller from the sea water pump and inspect its con dition Do not reinstall it in the pump until the engine is recommisioned 8 Check alternator and raw water pump drive belts 9 Insure fuel tanks are full and when filling gasoline stablizers and conditioners as well as carburetor conditioners should...

Page 27: ...Limit of difference between cylinders Valve clearances engine warm Valve side Intake Exhaust Cam side Intake Exhaust 21 Gasoline four cycle Four cylinders in line vertical type 70 0 mm x 69 6 mm 2 76 in x 2 74 in 77 0 mm x SO O mm 3 03 in x 3 15 in 1071 CC 65 4 cubic inches 1490 CC 90 9 cubic inches 9 2 1 9 0 1 Single overhead cam OHC chain driven 15 BTDC 44 ABDC 53 BBDC 6 ATDC 15 BTDC sS ABDC sS ...

Page 28: ...ntake and exhaust Standard Wear limit Valve spring constant Rocker arm and rocker arm shaft Bore in rocker arm Clearance in rocker arm Standard Wear limit 22 90 5 mm 3 563 in 0 15 mm 0 006 in 0 20 mm 0 008 in 39 5 mm 1 555 in 1 5 mm 0 059 in 45 41 1 4 mm 0 055 in 1 4 mm 0 055 in 0 018 0 053 mm 0 007 0 0021 in 0 20 mm 0 0079 in 8 063 8 083 mm 0 3174 0 3182 in 8 080 8 045 mm 0 3161 0 3167 in 7 980 m...

Page 29: ...ce Oil clearance Standard Wear limit Available undersize connecting rod bearing Crankshaft and main bearings Crankshaft run out 23 0 30 mm 0 0012 in 0 02 0 18 mm 0 001 0 007 in 0 20 mm 0 008 in 41 949 41 965 mm 1 6515 1 6522 in 41 919 41 935 mm 1 6504 1 651 in 0 05 mm 0 0020 in 0 035 0 076 mm 0 0014 0 0030 in 0 065 0 106 mm 0 0026 0 0042 in 0 15 mm 0 0059 in 44 119 mm 1 7401 43 919 mm 1 7291 44 11...

Page 30: ...n below oil ring groove 6 5 8KW llKW Piston and cylinder clearance 6 5 8 KW Standard 11 KW Standard Wear limits 24 39 940 39 956 mm 1 5724 1 5734 in 0 05 mm 0 002 in 0 75 mm 0 030 in 49 938 49 956 mm 1 9661 1 9668 in 0 05 mm 0 002 in 0 75 mm 0 030 in 0 023 0 042 mm 0 0009 0 0017 in 0 25 mm 0 010 in O sO mm 0 020 in 0 75 mm 0 030 in 0 10 0 15 mm 0 0039 0 0059 in 0 30 mm 0 0118 in 0 25 mm 0 010 in 0...

Page 31: ...in boss Flywheel run out 25 1 22 1 24 mm 0 048 0 050 in 1 52 1 54 mm 0 0598 0 0606 in 4 02 4 04 mm 0 1583 0 1591 in 1 17 1 19 mm 0 0461 0 0469 in 1 47 1 49 mm 0 0579 0 0587 in none given 0 03 0 07 mm 0 0012 0 0028 in 0 03 0 07 mm 0 0012 0 0028 in none given 0 15 mm 0 0059 in 0 2 0 4 mm 0 008 0 016 in 0 2 0 04 mm 0 008 0 016 in 0 3 0 9 mm 0 012 0 035 in 1 0 mm 0 039 in 0 25 mm 0 010 in 0 50 mm 0 02...

Page 32: ...e Oil pressure switch normally open Oil capacity sump and filter Lubricant Full Forced Trochoid pump 1 75 2 50 kg cm2 25 35 lb in2 7 1 75 kg cm2 10 25 lb in2 0 20 0 294 mm 0 0078 0 0116 in 0 35 mm 0 0134 in 0 03 0 12 mm 0 0012 0 0047 in 0 25 mm 0 0098 in 0 04 0 10 mm 0 0016 0 0039 in 0 15 mm 0 0059 in 0 02 0 056 mm 0 0008 0 0022 in 0 10 mm 0 0029 in 45 5 mm 1 791 in 700 1300 kg 1543 2865 lb Full f...

Page 33: ...driven centrifugal type 1200 1300 kg 264S 2866 lb positive displacement type neoprene impeller belt drive type 2S 3 ltr min 6 7 gal min 26 S 1tr min 7 gal min Opens 9S C 20S F Single barrel downdraft Metal screen Mechanical 12 volt activated Belt driven governor mechani cally linked to throttle arm Engine speed 1800 RPM SO RPM 12 volt pulsating type with self contained filter screen cleanable 0 8 ...

Page 34: ... 220 cu ft min 7 80 cu m min 250 cu ft min TABLE OF TIGHTENING TORQUES kg m lb ft Cylinder head 7 8 8 2 56 59 Manifold Intake 1 9 2 6 14 19 Exhaust 1 9 2 3 14 17 Main bearing caps 6 6 7 1 48 51 Connecting rod bearing caps 3 0 3 5 22 25 Camshaft sprocket nut 7 0 8 0 51 58 Crankshaft pulley nut 11 0 12 0 80 87 Flywheel 8 3 9 0 60 65 Backplate 7 0 10 0 51 72 Spark plugs 1 5 2 3 11 17 Timing chain cov...

Page 35: ...head nut 1 25 21 7 32 5 3 0 4 5 10mm bolt head nut 1 5 19 5 30 4 2 7 4 2 12mm bolt head nut 1 25 ISO 36 2 57 9 5 0 8 0 12mm bolt head nut 1 5 36 2 50 6 5 0 7 0 12mm bolt head nut 1 75 34 7 49 2 4 8 6 8 _ Grade 7T 8Tand 8 8 6mm bolt head nut 1 5 8 8 7 0 8 1 2 8mm bolt head nut 1 25 14 5 21 7 2 0 3 0 10mm bolt head nut 1 25 28 9 39 8 4 0 5 5 10mm bolt head nut 1 5 26 8 37 6 3 7 5 2 12mm bolt head nu...

Page 36: ...ator fan 4 Remove each br ush from its holder individually and resecure the electrical connections to the respective brush holder as each brush is removed This is to help insure keeping the con nections on the correct holder Examine each brush and if worn to 1 2 inch in length replace 5 Remove the exhaust screen from the bellhousing and remove the 4 bolts and lockwashers holding the outer generato...

Page 37: ...ocal radiator repair shop or replace as needed 11 Remove circuit Examine replace the starter motor and breaker assembly starter and repair or as needed 12 Remove sea water pump drive belt and mounting bracket 13 Remove governor and mounting bracket 14 Remove 12 volt alternator and mounting bracket 15 Remove carburetor fuel pump and intake manifold 16 Remove ignition coil and mounting bracket 17 Re...

Page 38: ... drive gear 5 Remove the cylinder head with valves 6 Remove the valves wi th the aid of a suitable valve spring com pressor tool Make sure the removed valves are kept in sequence for each cylinder 7 Remove the engine oil sump 8 Remove pulley cover the and front crankshaft front timing gear 9 Remove the lube oil assembly and drive chain pump 10 Remove each connecting rod bear ing cap and remove the...

Page 39: ...12 ap with baring c aln e Remove th7n cap puller main bearl main crankshaft thrust the ts and Remove 13 bearing inser washers 33 ...

Page 40: ...34 ...

Page 41: ... solutions that will be harmful to the alumi num Checking Cylinder Head 1 Replace the cylinder head if it has any damage such as water leaks gas leaks or cracks 2 Measure the extent of warping flatness on the lower surface along the areas shown in the figure If the warping is more than specifications grind the surface or replace 5traight etlgs Height of cylinder head 90 5 mm 3 5630in Warp limit 0 ...

Page 42: ...at a position near the valve guide Replacing the Valve Guide 1 Remove the valve seal from the valve guide 2 Knock the guide out toward the opposite side of the combus n chamber with a valve guide installer 3 Place a clip on the new valve guide and drive it in from the opposite side of the combustion chamber with the valve guide installer NOTE The shape of the intake valve guides differs from that ...

Page 43: ...tem diameter limit Intake valve 7 980 mm 0 3142 in Exhaust valve 7 975 mm 0 3140 in Check the thickness head margin and the Replace if less than cified limit Minimum valve head thickness 1 Omm 0 00394 in of valve diameter the spe Limit of reduction in diameter Intake 7 980 mm 0 3142 in Exhaust 7 975 mm 0 3140 in Checking Valve Spring 1 Check the valve spring for corrosion or damage and replace if ...

Page 44: ...sion L to the standard by adding some washers between the lower spring seat and cylinder head tOO Oll9 When the dimension L becomes more than 1 5 mm larger than the standard replace both the valve and cylinder head 2 Check for contact between the valve and valve seat as follows a Apply a thin coat of Prussian Blue or Redlead on the valve seat contact face b Insert the valve into the valve guide an...

Page 45: ...th a good valve lapping compound 4 Measure the dimension nLn 5 Adjust the dimension nL n to the standard by adding some washers between the lower spring seat and cylinder head Checking Rocker Arm and Shaft 1 Check each component part of the rocker arm assembly for damage or cracks If necessary replace with a new one 2 Check to see that the oil passages of the rocker arm and shaft are open If any c...

Page 46: ...lace the cylinder block Measure the wear on the cylinder bores at the six positions shown in the figure with an inside micrometer The wear is the difference between the maximum X_X IS the thrt direotion and minimum diameters If the wear limit rebore the cylinder is more than the specified Standard bore diameter 11 KW 77 0 77 019 mm 3 03l5 3 0323 in 6 5 8 KW 70 0 70 019 mm 2 7559 2 7567 in Maximum ...

Page 47: ... diameter 6 5 8 KW 69 944 69 964 mm 2 7537 2 7545 in 11 KW 76 954 76 974 mm 3 0297 3 0305 in 3 Check the clearance between the piston and cylinder wall Clearance limit 0 15 mm 0 0059 in 18 mm 0 7087 111 Checking Piston Rings 1 Check the piston rings for cracks burning or wear and replace if necessary 2 Measure the piston ring end gap Replace if it exceeds the limit NOTE Push a ring into the cylind...

Page 48: ...damage If necessary replace the connecting rod 2 Check the connecting rod for bends or twists with a suitable alignment fixture If realign ment is necessary correct by using a press and applying a gradual pressure to the rod or replace the connecting rod Permissible deflection 0 04 mm per 100 mm 0 002 in per 4 in 3 Check the connecting rod side play with a dial indicator or a feeler gauge as shown...

Page 49: ...9 0 0019 in Limit 0 10 mm 0 0039 in Checking Crankshaft 1 Check the crankshaft for cracks or other damage If necessary replace the crankshaft 2 Check to see that the oil pas sages of the crankshaft are open If any clogs are found remove them with compressed air or a suitable wire 3 Check the cr ankshaft for wear If it exceeds the limit correct the crankshaft with a suitable grinder and use with su...

Page 50: ...e following points a When grinding the crank shaft finish the place of uR as shown in the figure b The crankshaft processing diameters are as shown in the table above 4 Check the crankshaft alignment If it exceeds the limit replace with a new one Maximum allowable run out 0 05 mm 0 0020 in 5 Check the crankshaft end play wi th a dial indicator as shown in the figure If it exceeds the limit replace...

Page 51: ...ue Cap tightening torque 6 6 7 1 kg m 48 51 1b ft Bearing clearance Standard 0 023 0 042 mm 0 0009 0 0017 in Limit 0 08 mm 0 0031 in Checking Camshaft 1 Check the camshaft for cracks wear or damage and replace if necessary 2 Measure the run out If it exceeds the 1imit rep ace the camshaft Limit of runout 0 03 mm 0 0012 in 3 Measure the cam lobe height and replace if the wear exceeds the limit Cam ...

Page 52: ...th surface and replace if necessary 2 Replace the ring gear by the following procedure a Heat the ring with a torch b Remove the ring gear by striking its circumference c Heat the new ring gear to 250 300 C 480 570 F on a hot plate or in an oven Before slipping it onto the flywheel make sure that the chamfered side of the ring gear is directed toward the engine NOTE Excessive heat may destroy orig...

Page 53: ... e g pistons piston rings bearings and bearing caps D Apply lubr icating oil to moving parts dur ing assembly Insure that moving parts when assembled on the engine rotate or slide and are not subject to binding or excessive tension E I f there are mating mar ks scr ibed dur ing disassembly reference them correctly for assembly F Use new gaskets lockwashers o rings etc G Tighten the bolts and nuts ...

Page 54: ...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 Thrust washers 10 Main bearing 48 ...

Page 55: ...17 16 30 14 Oil pump C h 15 Timing ch am and sprocket 16 am and sp 17 Adjuster blade rocket Chain da m 18 T per 19 O lmg chain cover 1 pan 20 End pl at e 21 Flywheel 22 Crankshaft pulley 49 ...

Page 56: ...33 4 26 25 23 Valve 24 Cylinder head 25 Bolt cylinder head timing chain cover 26 Camshaft 27 Rocker arm 28 Cylinder head bolt 29 Locknut camshaft sprocket 50 y 27 f I M f J A 24 30 Chain adjuster ...

Page 57: ... pressing the top end of installer The piston pin is in the spe cified position when the lower end of gu ide touches the bottom of block The pressing load is 500 1500 kg 1100 3300 lbs I f the load is other than 500 1500 kg replace the piston pin or connecting rod 2 Assemble piston rings using a suitable piston ring expander a Install both rings second and top rings with R mark on the top surface b...

Page 58: ...ine front Use a suitable piston ring compressor 4 Insert main bearings on the block insur ing the bear ing oil ports are properly aligned r 5 Install the upper thrustwashers with the groove in the washer being directed outward crankshaft thrust side 6 Crankshaft Be careful that the thrustwashers do not drop as the crankshaft settles in place 52 ...

Page 59: ... bolts NOTE Make sure the crankshaft rotates smoothly after installing Cap bolt tightening torque 6 6 7 1 kg m 48 51 lb ft 12 Insert the side seal ensuring that the hole in seal is pointed either toward the inside or out side of cylinder block 13 Connecting rod caps NOTE Apply engine oil onto the surface of the connecting rod bearing prior to installing Insure that the rod caps are properly matche...

Page 60: ...of the timing chain and camshaft sprocket is not changed 17 Timing chain adjuster blade 18 Timing chain damper 19 Timing chain front cover 20 21 22 NOTE Cut off any excess portions of the cover gasket at both ends Tightening torque 1 9 3 1 kg m 14 22 Ib ft Oil pan Backplate Tightening torque 7 10 kg m 51 72 Ib ft Flywheel NOTE Install the flywheel by placing it on the crankshaft and rotating it to...

Page 61: ...correct b position the camshaft on the cylinder head 27 Rocker shaft assembly install the valve rocker arms on the rocker arm shaft Insure that there is 1 mm 039 in of offset between the center of the rocker arm adjusting screw and that of the exhaust valve stem 28 Cylinder head bolts NOTE Tighten the cylinder head bolts in the order shown in the figure Tightening torque 7 8 8 2 kg m 56 59 lb ft w...

Page 62: ...it with the pin and hook b Install the chain adjuster NOTE After the adjuster is installed the pin is released by the action of the timing chain which is actuated when the engine is cranked once or twice and the sleeve projects automa tically thus applying tension to the camshaft drive chain 33 Distributor a Turn the crankshaft until the piston in No 1 cylinder reaches top dead center of the compr...

Page 63: ...t 1 and 3 and intake 1 and 2 with the piston at the top dead center of the compression stroke of No 1 cylinder b Rotate the crankshaft 360 and adjust the remaining valves Valve side Cam side 36 Thermostat Intake valve 0 25 mm 0 010 in 0 18 mm 0 007 in NOTE Be sure to position the thermostat with the bleed hole at 12 o clock Insure ther mostat body is inboard of the block Install the thermostat hou...

Page 64: ... and related hoses 50 Exhaust manifold assembly and related hoses Tightening torque 1 9 2 3 kg m 14 17 lb ft 51 Armature and drive disc assembly Tightening torque Drive disc to armature 6 9 7 6 kg m 50 55 lb ft Drive disc to flywheel 2 5 2 8 kg m 18 20 lb ft 52 Generator housing NOTE Be sure bear ing seats properly and that the bear ing lock pin is in place 53 Exhaust screen 54 Generator brushes 5...

Page 65: ...59 Adjust nVn belt tension nvn belt deflection exer ting 10 kg 22 lbs force For new belt 9 11 mm 0 35 0 43 in For used belt 10 12 mm 0 39 0 47 in 59 ...

Page 66: ...hrough 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 When the oil pressure exceeds the specified pressure the oil pushes open the relief valve in the oil pump and returns to the oil pan thereby keeping the oil pressure within its specified range J j 60 ...

Page 67: ...of adequate oil is the responsibility of the owner operator Gauges and alarms are provided to warn against loss of proper engine oil pressure Monitoring of engine operating gauges is the responsibility of the owner operator Engine oil capacity All including filter 3 7 Oil Sump 3 0 Troubleshooting the Oil System Trouble Oil leak possible Cause 1 Loose oil drain hose liters 3 9 u S quarts 3 3 Imp qu...

Page 68: ...nstead 2 Electrically jump the oil pres sure switch connections 3 Start the engine operate at 1800 RPM and allow engine to warm up 4 Measure the oil pressure If less than the specification check the lubricating system Gauge 1 2 3 4 5 6 7 Oil pressure 1 75 2 5 kg cm2 7 kg cm2 25 35 PSI 5 lb in2 Remedy Refer to above Add oil to proper level or change Test and replace Remove and replace oil filter Re...

Page 69: ... pressing the shaft out 6 Shaft and inner rotor assembly 7 pump body Checking Oil Pump 4 1 3 1 Examine the following parts and replace if necessary a Pump body and cover deformed or damaged b Plunger worn or damaged 2 2 Check the clearance between the lobes of the rotors with a feeler gauge If the clearance exceeds the limit replace both rotors Clearance limit 0 25 mm 0 010 in 63 ...

Page 70: ...i th a feeler gauge I f the clear ance exceeds the limit replace the drive gear drive shaft inner rotor outer rotor and pump body Clearance limit 0 15 rnrn 0 0059 in 5 Then place a straight edge across the pump cover and measure the clearance between the straight edge and cover If the cover exceeds the limit correct the pump cover by grinding or replace it 6 Clearance limit 0 15 rnrn 0 0059 in Che...

Page 71: ...d surface of the shaft If the pressing pressure is less than the specified value replace either the sprocket or shaft or both Pressing pressure 700 1300 kg 1540 2860 lbs NOTE Make sure that when assembled the tally marks on both outer rotor and inner rotor face toward the outside cover side OUTER ROTOR INNER ROTOR 4 I TALLY MARKS Reinstall the pump in the engine 65 ...

Page 72: ...engine warms up the thermostat begins to open up allowing full flow of engine fresh water through the external cooling system Sea Water Circuit The sea water flow is created by a posi ti ve displacement neoprene impeller pump Normally the pump draws sea water directly from the ocean via the sea cock and sea water strainer Sea water then flows directly from the discharge of the sea water pump to th...

Page 73: ...ler by pulling straight outwards parallel to the pump shaft This is best done with a pair of pliers applied to the impeller hub 3 Coat the replacement impeller and the chamber into which it mounts with grease 4 Carefully align the impeller keyway or other locking mechanism wi th the shaft Take care that all the impeller blades bend in the same direction and trailing 5 Inspect the front cover for w...

Page 74: ...4 1 Impeller cover with graphite bushing screws lockwashers and gasket Ref 20 24 2 Impeller and key Ref 18 19 3 Drive pulley and key Ref 16 4 Bearing housing screws and lockwashers NOTE Shaft 17 withdrawn through the front of the pump with the bearing housing bearing and seal assembly Ref 5 10 5 Cam and screw Ref 14 15 6 Small retaining ring and seal Ref 5 9 7 Large retaining ring Ref 6 8 Bearing ...

Page 75: ...llation 1 Install in reverse order using a new housing gasket coated on both sides with gasket cement NOTE Insure that the small vent hole in the thermostat is at the 12 o clock position when the thermostat is installed 2 Replenish the coolant and start the engine and check that there are no leaks Engine Coolant It is recommended that an antifreeze mixture be used in the engine fresh water cooling...

Page 76: ...until level is between MIN and MAX Monitor coolant level from recovery tank Add coolant as needed Should an extreme loss of coolant be found investigate cause before further engine operation Exhaust Manifold Removal Removal of the exhaust manifold from the eng ine should be done as a complete assembly in the following manner 1 Drain the engine and cooling system of all coolant 2 Remove the exhaust...

Page 77: ...ant b Gradually tighten each fitting to make sure of proper align ment of all the parts This should be done in three steps Torque to 10 12 lb ft c Reassemble the end plates connectors on the manifold Be sure to use new gaskets and coat the gasket surfaces with a suitable gasket cement such as High Tack Torque the nuts to 8 10 lb ft d Reinstall the exhaust connections and plug into the manifold usi...

Page 78: ...aw Water System 2 Loose or broken water pump drive belt 3 Faulty thermostat 4 Faulty overheat switch 5 Scale and sediment in cooling system 6 Faulty circulating pump 2 Adjust or replace 3 Remove and replace 4 Remove and replace 5 Flush engine cooling system and heat ex changeri replenish coolant 6 Remove and replace 1 Loose or broken raw 1 Adjust or replace water pump drive belt 2 Faulty raw water...

Page 79: ...ng the unit up to operating tem perature before attempting an adjustment NOTE If the governor is severely out of adjustment manually adjust the linkage at no load to obtain a safe output voltage before proceeding with the adjustment There are three adjusting points on the governor illustration Bumper Screw Hunting Regulation Adjustment Refer to the 1 Increase Decrease Speed This adjusting bolt is ...

Page 80: ...er screw into the governor far enough so that it increases the no load speed Governor Maintenance 1 Periodically lubricate linkage arm attaching points at governor arm and throttle lever Use a graphite lubricant or equivalent NOTE Free movement of this linkage arm is important for proper governor throttle operation 2 Governor oil capacity 3 ounces tlO 30 motor oil NOTE Do not overfill governor 3 C...

Page 81: ...at room temperature Adjust the choke by loosening the three cover securing screws and rotating the cover clockwise to LEAN the choke and counterclockwise to ENRICH the choke The choke is initially set at the factory for an average of 70 F room temperature The choke may need readjustment at engine commissioning for the ambient temperature of the area the engine is operating in The choke index mark ...

Page 82: ...the bayonet fittings Clean the screen as needed A new base gasket 134706 must be installed each time the pump base is removed and reinstalled WARNING Shut off fuel service valve at engine when servicing fuel system Take care to catch fuel when opening filter elements 00 NOT allow any smoking open flames sparks or other sources of fire near the fuel system when servicing Insure proper ven tilation ...

Page 83: ...ck pump operation and clean filter screen 4 Adjust idle jet 1 Clean or replace the needle valve 2 Float in carburetor 2 Repair or replace leaking float 3 Float chamber gasket damaged or securing screws are loose 3 Poor perform nce 1 Main jet clogged at generator speed 2 Carburetor inlet filter clogged 3 Fuel pump filter clogged 4 Air intake filter screen dirty 77 3 Replace gasket and or tighten sc...

Page 84: ...t a remote location release the start switch when the green LED shines Continue depressing the ON switch It is only necessary to con tinue holding the ON switch after releasing the start switch until oil pressure is sufficient to close the oil pressure safety switch pro viding the normal B path to the ignition system Note that it is now impossible to energize the starter while the generator is run...

Page 85: ...TRUMENT OR CONTROL PaNEl S COMPlY WITH U S COAST 8 0 HerR Ie ACCESSO l B y U HI 2 NJLUQ NOT NECESSARILY 50 COMPLY AND ARE INTENDED TO BE INSTAllED ABOVE DECK AND ISOLATEQ FROM SOLINE SOURC S IN ACCORDANCE WITH 33 CFR 1I3 410 b IT IS THE RESPONSIBILITY Of THE IOd MANU TUIH R TO INSuAt THAT THE INSTALlATION OF THESE EN RATOR _ANO OPTlOrU lLY I THEIR REMOTE INSTRUMENT OR CONTROL PANlL COMPLY WITH I T...

Page 86: ...en o ELECTRIC FUEL LlFTPUMP 6 8 and 11 KW GASOLINE GENERATORS WIRING HARNESS EXHAUST TEMP SWITCH ...

Page 87: ...ean and free of corrosion Replace if defective 2 Remove the high tension cord from one of the spark plugs and hold its tip 5 10 mm 0 20 0 40 in away from a grounded surface Crank the engine An intense bluish white spark should be visible under normal conditions If no spark is visible it is possible that the igniter and or pickup coil are defective Replace both the igniter and pickup coil after che...

Page 88: ...igniter Distributor Assembly 1 Assemble in the reverse order of disassembly 2 Apply engine oil sparingly to the o ring on the distributor shaft 3 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 4 Adjust engine timing according to the specifications in the Engine Technical Data...

Page 89: ...s for clean and secure terminal ends Resistance value of high tension lead wire is 410 ohms per inch of wire NOTE When removing leads from __ spar k plugs be sur e to pull at the plug cap not at the high tension lead Ignition Coil Resistance Check Plug Gap O 8j O 05 mm O 031j O 002 in 1 Resistance value of primary coils is 0 8 0 2 ohms RXI scale Damage and Deterioration Damage Ohmmeter Checking Pr...

Page 90: ...y reconnected and functioning BEFORE operating generator The voltmeter in the remote instrument panel can be a useful instru ment in determining the status of your electrical system and warn you when an abnormality occurs The voltmeter will indicate differently depending when the readings are taken Fully charged batteries that are in a static state should read between 12 3 and 12 6 volts on the di...

Page 91: ...reheat solenoid cir cuit and run circuit for shorts to ground No ignition cranks 1 Overspeed module 1 Reset circuit by de pressing stop switch does not start tripped Starts stops when ON switch released 2 Fuse blown 3 Lack of fuel 2 Check fuses replace if necessary 3 Check for fuel to generator set Check fuel lift pump 4 Choke faulty 4 Check to see that it is not jammed Should be closed if engine ...

Page 92: ...ctions and short circuits Not charging battery 1 Alternator drive or battery runs down 1 Check drivebelt and its tension Be sure alternator turns free ly Check for loose connections 2 Oil pressure switch 2 Observe if gauges and light are on when engine is not running Test the normally open oil pressure switch by disconnecting one lead If lights go out replace oil pressure switch 3 High resistance ...

Page 93: ...it drained battery 87 Remedy 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 Unit not run for months and fuse left in circuit drawing 0 025 amp ...

Page 94: ...ide 9 volts at the starter solenoid when bat tery terminal voltage is down to 10 volts indicative of a deeply discharged battery Where 16 wire is shown in the table of Minimum Wire Gauges below we recommend using 14 wire for greater strength and or lower voltage drops MINIMUM WIRE GAUGES AWG Wire Length from Generator to Remote Panel Terminals 0 16 16 20 20 25 25 32 32 40 40 50 50 65 TB1 1 to TB3 ...

Page 95: ...0 definition when operating at full load Cooling Centrifugal blower direct connected Radio Interference Level Capacitors minimize interference within the limits of most marine applications Armature Balanced laminated steel double dipped and baked Ratings 115 230 VAC or 115 VAC single phase 4 wire 1 0 power factor 1800 RPM at 60 Hertz 1500 RPM at 50 Hertz Model Amp Hertz KW TWG6 5 56 28 60 6 5 TWG8...

Page 96: ...tor armature slip rings and b rush rigs are numbered from inboard at the windings or flywheel end outward toward the rear support bearing 2A Residual voltage Check Disconnect field leads from bridge rectifier Note position of leads on rec tifier to and to Operate the generator and check AC out put no load on generator Measure voltage between neutral lead and hot lead s 90 5VoitsAC Hot Neutral 2 Wi...

Page 97: ...f 50 to 70 volts AC is produced this should indicate that the generator is O K and that the bridge rectifier is defective 4 If no voltage is produced check the static capacitor s that it is not shorted to ground If found faulty remove connection from output terminal at brush rig and repeat step 3 5 Flash Field Coils Units may lose their residual magnetism from extended stor age rough handling duri...

Page 98: ...s between slip rings 1 3 and 2 4 NOTE 3 and 4 wire units There should be no continuity found between slip rings 1 2 2 3 and 3 4 If continuity is found an internal short exists between these windings and the armature should be replaced NOTE All units There should be no continuity found between any of the slip rings and the armature s central steel shaft If con tinuity is found the windings are shor...

Page 99: ... insure the field coils have been posi tioned proper ly in the generator housing and will have the correct polarity the following test must be made before reassembly of the generator 1 Connect a 9 12 volt DC battery to the leads off the coils that would normally be connected to the and connectors of the bridge rectifier These leads are unmarked and the polari ty in their connection to the DC batte...

Page 100: ...rtz No Load Voltage No Load Voltage 3 Test Bridge Rectifier 61 61 5 51 51 5 131 135 Volts Generator Cold 126 130 Volts Generator Hot Bridge rectifier may be faulty and should be checked as follows 1 Set ohmmeter scale on Rxl DC zero the meter 2 Connect the lead from the meter to point 4 with the lead from the meter momentarily contact points iI i 2 i 3 and i5 No deflec tion of the needle should oc...

Page 101: ... into the compartment and directed toward the inlet at the generator end bell 6 Check condition of brushes for wear and contact with slip rings on armature Insure brushes are not sticking in holders High Voltage Output 1 Verify voltage at generator output leads No load voltage 126 130 volts Generator Hot 61 61 6 Hertz 51 51 5 Hertz 2 Check internal wiring of generator leads attached to brush rig a...

Page 102: ...NICAL DATA 115 or 115 230 Volts AC 27 0 AMP at 230 Volts AC 115 or 115 230 Volts AC 34 0 AMP at 230 Volts AC 115 or 115 230 Volts AC 46 0 AMP at 230 Volts AC 60 Hertz standard 50 Hertz available at reduced rating 1800 60 Hertz 1500 50 Hertz 115 VAC 132 VAC 108 VAC 115 VAC output voltage 96 230 VAC 264 VAC 216 VAC ...

Page 103: ...Internal Wirin TWG g Diagrams 6 5KW 8KW 11KW 115 Volt and 115 2 30 Volt 97 Field Excitat Recff Ion Siler Wiring ame as for 230v ...

Page 104: ...antifreeze con centration throughout the cooling system Now recheck the antifreeze solution s strength Lubrication System With the engine warm drain all the lubricating oil from the oil sump Remove and replace the oil filter Place some paper towels and a plastic bag around the filter to catch the oil during its removal When installing the new oil filter be sure to apply a small amount of oil on th...

Page 105: ... to remove this cloth before recommissioning Make a note to remove the cloth prior to start up The through hull exhaust part can be blocked in the same manner Starter Motor Lubrication and cleaning of the starter drive pinion is advisable if access to the starter permits its easy removal Ensure that the battery connections are shut off before attempting to remove the starter Take care in properly ...

Page 106: ...up or a replacement if required Install the sea water pump cover with a new cover gasket IWARNINGI Wear rubber gloves a rubber apron and eye protection when servicing batteries Lead acid batteries emit hydrogen a highly explosive gas which can be ignited by electrical arcing or a lighted cigarette cigar or pipe Do not smoke or allow an open flame near the battery being serviced Shut off all electr...

Page 107: ...ut var ious components and service procedures which are important to the proper functioning of your engine and its support systems You should familiarize yourself with the subjects and make sure that you consult the appropriate Bulletin s whenever your engine requires service or overhaul 101 ...

Page 108: ...on is simply that continued engine vibration causes fatigue of the fittings used to make such a connec tion If these fittings fail the engine loses its oil pressure and very quickly seizes Such pressure sensing devices must be bulkhead mounted and connected to the oil gallery using an appropr iate grade of lubricating oil hose Any fittings used to connect the hose to the gallery must be of steel o...

Page 109: ...s not strike a surface directly Also the velocity of the entering sea water stream should be as low as possible which is achieved by having inlet fittings as big in diameter as possible In addition to the above design considerations it is usually advantageous to divide the sea water flow at the point of entry to the exhaust system so that only a portion of it enters the exhaust system The remainde...

Page 110: ...output of the asso ciated alternator In full power systems number 4 wire is recom mended from the alternator to the spli tter and from the splitter to the batteries 3 Connect the alternator output terminal to the center splitter ter minal 4 Connect one splitter side terminal to one battery s 5 Connect the other splitter side terminal to the other battery s 6 When the splitter is installed both bat...

Page 111: ...R WHITE BLACK SEE IOTE POWER DISCONNECT SPLITTER SW ITCH t l K STARTER P 1 00 0 B STARTING BATTERY PN 20654 POWER DISCONNECT SWITCH 2 u B SERVICE BATTERY ALTERNATOR SHIP S SERVICE LOADS NOTE 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...

Page 112: ...ale the normal reading for this situation If both of the above gauge tests are positive the gauge is undoub tedly OK and the problem lies either with the conductor from the sender to the gauge or with the sender If either of the above gauge tests is negative the gauge is probably defective and should be replaced Assuming the gauge is OK proceed as follows Check the conductor from the sender to the...

Page 113: ...exchanger For the location of the zinc on your model refer to the cooling system section in your parts manual Replace the zinc pencil as inspection dictates Refer to Illustration A Should material be flaking off the zinc it should be scraped clean or be replaced by a good solid zinc pencil If it appears that a lot of material has been flaking off the zinc then it is advised that the end cap of the...

Page 114: ...W for The fan on the back end of the above model generators plays an impor tant part in moving air through the generator for cooling In installations where surrounding air is limited outside air should be dueted to the area of the screened end bell inlet to provide this needed air for cooling and combustion as well The security of the generator fan holddown nut should be checked at installation co...

Page 115: ...thout the fan slipping on the shaft If properly torqued and the fan still slips replace the lockwashers Recirculation of generator cooling air through the generator must be avoided The generator compartment ventilation must be sufficient to prevent generator air recirculation Insure that the screened end bell inlet and the screened discharge slots at the flywheel are not obstructed preventing good...

Page 116: ... above the water line a minimum of six inches 6 with the vent or syphon break installed at the top of this loop The vented loop when used can be a mechanical syphon break as sho wn in the illust ation or a simple tee arrangement with a small hose or tube 3 16 1 4 inch I D routed to the transom exhaust discharge or to a separate thru hull fitting located above the water line This hose or tube must ...

Page 117: ...al for back pressure specifications The exhaust hose diameters shown are minimums Exhaust hose diameter for the discharge hose will have to be incresed if the length of run from the Hydro Hush Muffler to the thru hull discharge is excessive 25 30 feet depending on the number of bends CAUTION THE SEA WATER PUMP WILL CONTINUE TO FILL THE EXHAUST SYSTEM WITH SEA WATER DURING CRANKING THE ENGINE EXHAU...

Page 118: ...ter Line 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 48 2 I D max 112 ...

Page 119: ...elbow at or below vessel water line Raw Water Intake Thru H ull Fitting Generator Below Water Line Raw Water Intake Thru Hull Fitting Generator Installations wi th Generator Above Water Line exhaust manifold water injected elbow minimum of 6 inches above vessel water line 113 12 Raw Water Pump Raw Water Pump ...

Page 120: ...sible for monitoring and filling FILLING THE ENGINE S COOLING SYSTEM A The engine cooling system must be filled completely full and be free of all air Pay particular attention to propulsion engines having domest ic hot water heaters plumbed to the engine s fresh water cooling circuit ensuring that that portion of the system is free of air and engine coolant circulation is taking place through the ...

Page 121: ... hose attachment fitting on the engine manifold should be removed and plugged 1 8 N P T Plug The remote expansion tank serves the engine cooling system basically in the same manner as the plastic coolant recovery tank On a cold engine the tank should be kept filled between 1 4 and 1 2 full FUNCTION OF MANIFOLD PRESSURE CAP From Coolant Tank COOLANT RETRACTION to Coolant Tank COOLANT EXPANSION Cool...

Page 122: ... engine 2 Fuel tank pick up tubes have been found to randomly have fine gauze screens installed in them by the tank manufacturer These gauze screens can clog from debris in the fuel and stop fuel flow from the tank resulting in loss of engine power and or engine stoppage If a fuel starvation problem is encountered check fuel supply to the engine from the fuel tank and examine the pick up tube for ...

Page 123: ...erators A 50 50 mixture of anti freeze and fresh water is recommended in the fresh water cooling circuit Follow the mixture directions as given by the antifreeze manufacturer 2 Insure that the coolant recovery tank supplied with each generator is installed as shown in Service Bulletin 147 Coolant Recovery Tank Ii 1 3 Remove the pressure cap from the manifold and open the air bleed petcock located ...

Page 124: ...r that has accumulated in that area to be expelled Clean coolant should flow from the opened petcock Add more coolant to the manifold to keep it full 6 When the thermostat opens and flow is noted at the manifold filler neck top off the manifold and install the pressure cap Add antifreeze mixture to the coolant recovery tank to bring its level up to between the ADD and MAX 7 Engine fresh water cool...

Page 125: ...m Components Installers are advised that with the increased availability and use of butane alcohol blended gasolines fuel system components MUST be compatible with these types of blended gasolines Failure t ensure compatibility will result in the component s failure and possible injury to the user 119 ...