Technical 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 Gasoline with an ETHANOL content higher than 10% (E10) is not allowed and may void warranty. Engines & Generators 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 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. 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. The above symbol is used in the manual to warn of possible serious personal injury or loss of life. • Do Not Alter or Modify the Fuel System CAUTION Be sure all fuel supplies have a positive shutoff valve. Be certain fuel line fittings are adequately tightened and The above symbol is used in the manual to caution personnel free of leaks. of possible damage to equipment. Make sure a fire extinguisher is installed nearby and is Read the manual carefully and thoroughly before attempting properly maintained. Be familiar with its proper use. Ex to operate the equipment. Know when dangerous conditions tinguishers rated ABC by the NFPA are appropriate for all can exist and take necessary precautions to protect personnel applications encountered in this environment. and equipment. Fuels, exhaust gases, batteries, electrical equipment, and moving and hot parts are potential hazards that could result in • Use Extreme Care When Servicing Batteries serious personal injury or death. Follow recommended proce dures carefully. Wear rubber gloves, a rubber apron, and eye protection when servicing batteries. Always operate bilge blowers for at least five minutes before starting a gasoline-fueled engine; ensure no gasoline fumes are Lead acid batteries emit hydrogen, a highly-explosive gas, present before starting. which can be ignited by electrical arCing or by a lighted cigarette, cigar, or pipe. Do not smoke or allow an open flame near the battery being serviced. Shut off all electri • Prevent Electric Shock cal equipment in the vicinity to prevent electrical arcing during serviCing. Shut off electric power before accessing electrical equip ment. Use insulated mats whenever working on electrical equip • Ayoid Moving parts ment. Do not service the unit while the unit is running; if a situa Make sure your clothing is dry, not damp (particularly tion arises in which it is absolutely necessary to make shoes), and keep your skin surfaces dry when handling operating adjustments, use extreme care to avoid moving electrical equipment. parts and hot exhaust system components. Remove wristwatch and jewelry when working on electri Do not wear loose clothing or jewelry when servicing cal equipment. equipment; avoid wearing loose jackets, shirts or sleeves, rings, necklaces, or bracelets that might be caught in Do not connect utility shore power to vessel's AC circuits, moving parts. except through a ship-to-shore double-throw transfer switch. Damage to vessel's AC generator may result if this Make sure all attaching hardware is properly tightened. is not done. Keep protective shields and guards in their respective place at all times. Be extremely careful when werking on electrical com ponents. High voltage can cause injury or death. Do not check fluid levels or drivebelt tension while the unit is operating. Do not work on the equipment when mentally or physical • Exhaust Gases Are Toxic ly incapacitated by fatigue. Ensure that the exhaust system is adequate to expel gases discharged from the engine. Check exhaust system regularly for leaks and make sure the exhaust manifolds are securely attached and no warping exists. Be sure the unit and its surroundings are well-ventilated. 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 ........................................................ 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 IMPORTANT PRODUCT SOFTWARE NOTICE Product software of all kinds, such as brochures, drawings, technical data, operator's and workshop manuals, parts lists and parts price lists, and other information, instructions and specifications provided from sources other than 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 OF SUCH SOFTWARE, MAKES NO WARRANTIES OR REPRESENTATIONS WITH RESPECT THERETO, INCLUDING THE ACCURACY, TIMELINESS OR COMPLETENESS THEREOF, AND WILL IN NO EVENT BE LIABLE FOR ANY TYPE OF DAMAGES OR INJURY INCURRED IN CONNECTION WITH, OR ARISING OUT OF, THE FURNISHING OR USE OF SUCH SOFTWARE. For example, components and sub-assemblies incorporated in Westerbeke's products and supplied by others (such as engine blocks, fuel systems and components, transmissions, electri cal components, pumps and other products) are generally sup ported 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 customers should also keep in mind the time span between pr intings of Westerbe~e product software, and the unavoidable existence of earlier, non-current Westerbeke software editions in the field. Addi tionally, most Westerbeke products include customer-requested special features that frequently do not include complete documen tation. In sum, product software provided with Westerbeke products, whether from Westerbeke or other suppliers, must not and can not be relied upon exclusively as the definitive authority on the respective product. It not only makes good sense but is imperative that appropriate representatives of Westerbeke or the supplier in question be consulted to determine the accuracy and currency of the product software being consulted by the customer. 2 INTRODUCTION This manual is a basic guide to the installation, start-up, opera tion, maintenance, overhaul and troubleshooting of your Westerbeke gasoline engine driven generator. The information contained within is important to the unit's dependability and service life. A. Read it. B. Keep it in a safe, dry place. C. Keep it handy for reference at all times. Understanding the Gasoline Driven Generator The gasoline engine driving the AC generator is -in many ways simi lar to the gasoline engine in your automobile. The cylinders are ver tical in line, overhead camshaft chain dr i ven. Solid state type distributor, horizontally mounted, camshaft driven. Pressure type lubrication system with fresh water cooled engine block. Thermostat controlled. It follows therefore to a great extent that the gasoline engine used 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 driven generator capable of many thousands of hours of depend able service. What we as the manufacturer cannot control is the treatment the unit receives in the field. That part is up to you. Ordering Parts Whenever replacement parts are needed, always include the complete part description and part number (see separately furnished Parts List). Be sure to include the engine's serial number along with that of the generator and its model number. Also, be sure to insist upon Westerbeke factory packaged parts, because "will fit" parts are fre quently not made to the same specifications

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