Westerbeke 4KW-7.7KW-11KW-12 5KW User manual

OPERATOR'S
MANUAL
for
WESTERBEKE DIESEL
GENERATOR SETS
4 KW· 7.7KW· 11 KW· 12.5 KW
Publication Number 32461
Printed in U.S.A.

FOREWORD
Thank you for having selected a Westerbeke Diesel Generator for
your use.
This manual describes the procedures for proper handling and main-
tenance of the Generator Set Models of 4, 7.7, 11 and 12.5 KW rating.
TO maintain your engine always in its best operating condition and
to enable it to perform best, it is important to handle it properly
and carry out complete maintenance according to this manual.
If you have any questions about your equipment or in the event of
a failure, please contact your nearest distributor or dealer.
We look forward to your continued patronage.
4 KW WITH MOUNTED INSTRUMENT PANEL
1

TABLE OF CONTENTS
PAGE
GENERAL SPECIFICATION'S ••••••.•••••••• 3
CAUTIONS IN HANDLING ENGINE ..•....... 4
1. BREAKING IN..................... 5
2. PREPARATIONS. • . . . . • . . . . • . . • . . . •. 6
3. STARTING PROCEDURES ••••..••.•..• 7
4. STOPPING PROCEDURES •.•••..•.•••. IO
5. CAUTIONS ON STARTING
AND OPERATION •••.•••.••..•..••.• 10
6. REQUIREMENTS FOR PROPER
OPERATION
6-1 Lubrication system •...•..•• 12
6-2 Fuel System •.••.•.•..•...•. 13
6-3 Cooling System •..••.•.••••. 15
6-4 Wiring diagram •.•• see page 18
7. GENERATOR EXPLODED VIEW •.••.•••• 19
8. GENERATOR MAINTENANCE •••.••..••. 22
9. ENGINE MAINTENANCE .••.••..••.••• 22
10. TROUBLESHOJTING ••..•...•.....••• 25
11. SERVICE DATA .................... 27
12. TABLE OF TIGHTENING TORQUES ..••• 28
SEE WIRING DIAGRAMS FOLLOWING PAGE 29
2

GENERAL SPECIFICATIONS
ITEM CHARACTERISTIC
Type
Combustion chamber
No. of cylinders
~ Bore & stroke (inches)
~ Cu. In. displacement
Compression ratio
Firing order
Dry weight, std. elbs)
Fuel
~ Injection pump
~ Nozzle
~ Injection pressure
Governor
Lubrication system
....J
a Oil filter
~ Engine oil capacity
~
Cooling system
§
Coolant capacity
Star ter V-HP
~ Alternator V-A
;::
~ Glow plug
Battery capacity
~ Rating
~ Deductions
4 K"
7.7KW llKW
12.5KW
Vert.,4 cycle, water cooled diesel engine
Swirl chamber type
2 3 4 4
2.76x3.07 2.87x3.07 2.87x3.07 3.07x3.07
37
23
1-2
29B
60
23
1-3-2
374
.2 diesel fuel only
Bosch type
Throttling type
All model-s: 1707 Ibs.
BO
23
1-3-4-2
434
Centrifu9al weight type
Pressure lubrication
Filter paper type
91
23
1-3-4-2
498
2.5 qts 4.0 qts 4.0 qts 4.2 qts
For accuracy, depend on dipstick markings
Forced circulation, water cooling by
heat exchanger
6 qts 5 qts 8 qts 8 qts
Always fill to top of filler neck
12-2 12-2 12-2
12-2
12-50 12-50 12-50 12-50
Sheathed type -
all
models
60
AH
75
AH 90 AH 90 AH
4
KW 7.7KW
11K"
12.SKW
3%
for each
1000
feet
above sea level
1% for each 10·
above 8S-F
10% for continuous duty
3

•
•
•
•
•
•
•
•
CAUTIONS IN HANDLING ENGINE
Always use proper engine oil and watch oil pressure during opera-
tion.
Use clean fuel, free from impurities and water content.
Prevent entry of air and water into the fuel system.
In case the starter motor pinion fails to engage wi th the ring
gear at the time of starting, turn on the starter switch again
after the starter motor has come to a complete stop.
Prevent the temperature of cooling water from falling too low.
Pay attention to the color of exhaust gas.
Clean or replace the fuel filter and oil filter periodically.
Replenish or replace oil as specified.
SAFETY PRECAUTIONS
•
•
•
•
•
•
Install unit in a properly ventilated space.
Do not touch moving parts during operation.
Do not touch hot parts such as exhaust pipe, and do not place com-
bustible materials there.
Inspect and adjust parts of the engine only after it is stopped.
CheCk and refill engine oil, cooling water and fuel after the
engine is brought to a stop.
Check water level in the coolant recovery tank.
pressure cap on manifold if engine is hot.
Do not remove
* Always use tools of proper sizes and full caution dur ing ser-
vicing_
* Be sure that current carrying wires are protected from abrasion
and that all connections are tight.
4

BREAKING IN
Service life of your generator is dependent upon how the engine is
operated and serviced during the initial 10 hours of operation!
Your new engine needs at least
10 hours of conditioning opera-
tion for breaking each moving
part in and maximizing perfor-
mance and life of engine.
Perform this conditioning care-
fully, bearing the following
points in mind:
1.
Since generator sets
current, your control
control of load.
operate at 1800
of the breaking
RPM to obtain 60 cycle
in process is limi ted to
2. Do not ever attempt to BREAK IN your generator set by running at
NO LOAD.
3. Immediately on starting the set, add approximately 25% load to
cause a fast warm up.
4. For the first 10 hours of operation, run between 20 and 60 percent
load.
5. After 10 hours, you may load as needed, except that:
o. You must avoid overload at all times. Overload is signalled by
smoky exhaust and/or a reduction in speed and voltage.
Explanation:
"Breaking in" a new engine is basically a seating of the piston rings
to the cylinder walls. This is not accomplished by long periods of
running idle, nor by early running under full load.
Idle running may
smo'ky operation.
lar results.
glaze the cylinder walls causing oil consumption and
ExceSS1ve loads may score cylinder walls with simi-
As indicated above, use a short warm up period under moderate load for
the first ten hours of operation. For the next forty hours, use
approximately 70% load. This kind of careful operation will result in
best results from your engine.
5

PREPARATIONS
Take steps as shown below in starting your engine for the first time
or after a prolonged shut-down.
1. Fill your engine with oil up to
or near the upper limi t on the
dipstick. Use a good grade of
oil wi th API specification of
::c or better. For quantity of
oil, you may refer to the
General Specifications page.
However, it is best always to
be guided by dipstick measure-
ment as angle of installation
has some effect.
2. Your engine is supplied with a
coolant recovery system to
which the following instruc-
tions apply:
a) Fill engine completely to
the neck of the manifold cap.
b) Then fill the recovery
tank to the bot tom level 1 i ne.
Need for adding coolant is
indicated when a cold engine
has coolant level below the
bottom level line.
c) In winter add antifreeze
as described on page 16. Anti-
freeze may be used year round
if changed annually.
3. Fill the fuel tank wi th Diesel
fuel. The interior of the fuel
tank must be maintained clean.
Be careful not to allow intro-
duction of dirt when filling
fuel.
4. Eng ine oil, coolant
transmission levels should
checked at least once a
prior to engine use.
and
be
day
6

STARTING PROCEDURES
Instrument panel, description and use of:
Note 1: When generator is stopped after use, the water temperature
and oil pressure gauges may stay at their running readings.
Note 2: When generator is next to be used, depress preheat switch.
The temperature and pressure gauges will "ZERO" and the volt-
meter will register battery voltage. The electric fuel pump,
mounted on the engine, will also begin to operate, purging
any air accumulated in the system.
Note 3: The generator is now prepared for starting.
for specific instructions.
7
See next page

STARTING PROCEDURES
1. If making an initial start
after lay-up, fuel filter ser-
vicing or rep.airs, depress the
preheat switch for 15 to 25 se-
conds _ This' will energize the
fuel pump allowing it to purge
the system of any accumulated
air_ This will preheat the
glow plugs at the same time_
(See table below for preheating
time_ )
PREHEAT
STOP
~
Quick-heat type (Yl14T)
Atmospheric temperature
preheating time
+s"c
{+41-F}
or
higher
Approx_ 10 sec.
+5 'c
(+41-F)
to
-5 ·c (+23"F) Approx. 20 sec.
_ SoC
(+23"F)
or lower
Approx 30 sec _
Limit of continuous use
1 minute
2. Proper glow plug function is indicated by voltmeter drop when key
is depressed. This drop will be slight but discernible. If no
voltage drop is noted, it may indicate defective glow plugs or a
faulty preheat circuit (check for loose connection).
8

3. Starting
While still holding preheat
switch depressed, depress the
start switch. The starter
motor will run thereby cranking
the engine. As soon as the
engine runs, release the start
switch which will return to its
normally open position.... Con-
tinue holding the preheat
switch depressed for 2 or 3
seconds. This defeats the low
oil pressure shutdown until the
engine oil pressure rises to
normal running pressure.. Now
release the preheat switch ..
PREHEAT START
.sTOP
~
Should the engine not start when start switch is depressed for 10 to
l2 seconds, wait 30 seconds and repeat "3- with adequate preheat time.
~ever run the starter motor for more than 30 seconds at a time.
5. Operation
With the engine running, check that oil pressure and battery
charge voltage are registering and that raw water is discharging
with the exhaust.. During engine operation, do not depress start
switch as this will damage starter motor ..
6. Warm-up operation
Operate at reduced load until water temperature rises to the 140
to 150 degree range.
9

STOPPING PROCEDURE
PREHEAT START
L Stop
To stop the generator, depress
the stop switch until engine
stops completely and then-
release.
STOP
~
CAUTIONS ON STARTING AND OPERATION
1. Normal starting
Follow the procedures below for routine starting of your engine.
1) Check the engine oil level and refill if necessary.
2) Insure that you have sufficient fuel. Keep tank as full as
possible.
3) Check cooling water level, and refill if necessary.
Note: Check for leaks of water or oil, particularly when
signs of such leak are found on the bottom of the engine or
in the drip tray.
4) Start the engine in accordance with the procedures given on
the preceding pages.
5) Allow the engine to warm up to 140'-150' F before placing the
engine under heavy load.
2. Starting under cold conditions
The following three adverse condi tions concur as the atmospher ic
temperature drops exceedingly, and the engine must, under such
conditions, be started by taking steps described below:
LUBRICATING OIL TURNS VISCOUS Make certain that oil used
is adequate for the prevailing atmospheric temperature.
Check the oil also for deterioration.
VOLTAGE ACROSS BATTERY TERMINALS DROPS
battery is fully charged.
Check that the
THE TEMPERATURE OF
TEMPERATURE DOES NOT
operate sufficiently
3. Cautions during operation
INTAKE AIR IS
RISE ENOUGH
to aid starting.
LOW AND COMPRESSION
Allow the glow plug to
See table on page 8.
Confirm that the oil pressure is normal during normal operation.
Confirm that exhaust gas is as follows:
10

*
*
*
Wh i le eng i ne is ·cold ••••••.••..••.••••.•• Wh i te smoke
When the engine grows warm ............•.. Almost smokeless
When the engine is overloaded ........•..• Some black smoke
Check for abnormal noise such as knocking, friction or leakinl
sounds, and vibration and blow-back sounds.
Check for leaks of fuel and engine oil.
A knocking sound is heard
acceleration and at idle.
in other cases.
while the engine is cold, during quicl
Confirm that no knocking sound is hear(
7.7 K!;
11

REQUIREMENTS FOR PROPER OPERATION
LUBRICATION SYSTEM
1. Engine oil
For engine lubrication, use diesel engine oil. Diesel engine oils
are classified ac-cording to the API Specifications into grades CA,
ca, cc and CD. Anyone of them is usable, but use of CC or higher
grades prepared by well-known makers is recommended.
2. Engine oil viscosity
Use oil having viscosity best suited to the atmospheric tem-
perature. Use of an all-season oil SAEIDW-30 with minimum visco-
sity change under different temperatures is suggested.
Atmospheric temperature Viscosity
20'C (6S'F) or higher
SAE 30 or lOW-3D
S"C (41"F) - 20"C (6a"F) SAE 20 or IOW-30
s·c (41'F) or lower SAE 10W-30
3. Oil pressure
The oil pressure during operation of the engine is indicated by
the oil pressure gauge.
During normal operation •.•......... Oil pressure will range between
50 and 70 PSI.
At the time of- cranking ••....•...•• Pressure will rise proportion-
ately with speed.
4. Engine oil change
To renew engine oil, discharge old oil through the sump drain hose
attached at front of engine while engine is still warm.
Drain old oil completely, replace the hose, plug the end securely
and add fresh oil through the oil inlet port on the valve cover.
After refilling oil, idle the engine for several minutes and stop.
Then check the quanti ty of oil by the oil level gauge. Fill to
but not over the high mark on the dipstick.
12

5. Replacement of oil filter
Being a replaceable cartridge
type, the oil filter requires
no cleaning inside.
In install ing the oil filter.
apply engine oil thinly on to
the O-ring, and then tight-en it
by hand firmly.
When removing the used filter,
cover over with a plastic bag.
This will allow both filter
element and spilled oil to be
collected cleanly without
spilling oil in the bilge.
Note A: After market filters are not recommended
material standard or diameters of important
be entirely different from genuine parts.
since the
items might
Note B: Immediately after filter change and oil fill, run engine
to enSure that oil pressure is normal and that there are
no oil leaks.
FUEL SYSTEM
1. Diesel fuel
USE #2 DIESEL FUEL. NEVER OSE KEROSENE OR HEAVY OIL.
In cold weather, particularly, much water vapor is produced when
much air is present in the fuel tank. The tank, therefore, should
be kept full as much as possible.
The fuel tank, furthermore, needs to be kept completely free of
dirt and water.
2. To this end, it is most
desirable that a primary fuel
filter of the water entrapment
type be installed between the
fuel tank and' engine. Such a
filter is available under part
'24985. (See your local
dealer. )
Water entrapment filter '24985
is shown opposite. Inspect
frequently for presence of
water in the clear bowl. Drain
it off by loosening the air
vent and opening the drain.
13

3. Notes on fuel system
See below a typical exploded view of a fuel system. The one shown
is for the 4 KW. Those for the 7.5, 11 and 12. 5KW are similar
except for the number of cylinders.
rhe Westerbeke self-bleeding fuel system is automatic in opera-
tion. Therefore, it is unlikely that the operator will be forced
to service the system at sea.
For that unlikely possibility, however, it is recommended that the
following parts be carried onboard.
Banjo washers 11, 30, 31, 33, 34, 45
Injector seat washers 42
Lift pump filter and gaskets 6, 7, B
Fuel filter element and gaskets 13, 14 ,15
14

If a leak should develop at a banjo or washer that cannot be
remedied by a simple tightening of the screw, renew the washers.
The engine can be started by taking the steps described on pages 8
and 9. In caseS where the engine cannot be started easily, loosen
two injection nuts on the nozzle side, turn the starter motor and
then tighten the nuts firmly.
4. Cleaning fuel filter and replacing filter element
After the first 50 hours of operation, loosen the retainer ring
116 and discard filter element #15. Clean bowl #17 and re-instail
new filter, using new gasket #13 and #14.
This same treatment is required of the filter element #6 in the
fuel lift pump. Similarly, replace new filter element #6 using
new gasket #7 and i8.
After the first 50 hour change, the change period may be increased
to 200 hours or once per season.
5. Fuel injection pump
The fuel injection pump is one of the most important components of
the diesel engine and thus it calls for the utmost caution in
handling. Furthermore, the fuel injection pump has been
.thoroughly shop-adjusted and should never be readjusted care-
lessly.
Such adjustment, whenever necessary, should be performed at an
authorized service station as a precision pump tester and skills
are required.
To obtain long and satisfactory use of your injection pump:
Always use fuel which is free from impurities.
Clean and renew the fuel filter periodically.
Inspect water entrapment filter regularly.
COOLING SYSTEM
1. Cooling water
As cooling water, use soft water with least impurity content such
as tap water (potable water) or rainwater".
2. Antifreeze
In cold distr iets, eare should be taken to prevent cooling water
from freezing. Cooling water when frozen expands to "break the
heat exchanger and the cylinder block, and it is essential that
antifreeze be added to cooling water in a quantity being propor-
15

*Antifreeze of poor quality will cause corrosion of the
cooling system, and thus always use antifreeze containing
rust inhibitor and prepared by a reliable maker, and never
use it mixed with antifreeze of a different brand.
ANTIFREEZE ADDITION DATA
Antifreeze
Concentration
% 13 23
30 35
45 50 60
Freezing
"C
-5 -10 -15 -20 -30 -40 -50
te!!!}?:erature
! "Fl
(23) (14)
(5) !-4) !-22)
!-40) !-58)
Note: It is advisable that
selected on the basis of
s·c (lO'F) lower than
perature.
3. Alternator belt tension
The alternator belt is properly
tense if it deflects 10 to
12 nun (0.39 to 0.47 in) as it
is depressed with a finger be-
tween the pulley and pulley of
the long distance side.
Excessive tension can cause
quick wear of the belt and
bearings of the water pump and
the alternator. Excessive
slackness or presence of oil on
the belt, on the other hand,
can lead to engine overheating
and insufficient charging due
to a slipping belt.
CAUTION:
antifreeze concentration be
a temperature which is about
the actual atmospheric tem-
Never attempt to adjust tension of the fan belt while the
engine is in operation.
16

"
4. Fresh water cooling system (See Note 5 on page 6.)
The system consists of a sea water pump which pumps raw sea "water
through a heat exchanger to remove heat from the coolant. The raw
wa~er is discharged overboard through the exhaust line.
The engine coolant (fresh water with or without antifreeze) is
circulated by the fresh water pump in continuous cireui t. pumped
through the cylinder block, cylinder head, heat exchanger and back
to the fresh water pump.
The total system is very reliable and requires only a daily check
of the water level in the system plus routine check of hose clamps
and fittings.
It is likely that zinc electrodes will waste away from contact
with sea water. It is also possible for the raw water pump
impeller to fail due to lack of sea ..... ater or deterioration. An
early "sign-of impeller" failure is less ..... ater and more stearn at the
":, exhaust through hull fitting.
It is recommended. therefore, that zinc electrodes, an impeller
kit, a pump belt and a thermostat ..... ith gasket be kept onboard at
all times. These parts should be ordered from your nearest
stocking dealer and used as inspection dictates.
17

WIRING DIAGRAM FOR ENGINE SYSTEM
Your engine is of 12V system and its electric circuit is as shown in
the diagram in pocket of back cover.
For installing electrical parts, connect them correctly by referring
to the diagram and at the same time check for damaged wire sheathing
and confirm that grounding is provided properly. Care must always be
taken while working on the electrical system.
Never shut the engine battery switch off while the engine is running.
Damage to the battery charging alternator will result should this be
done.
GENE RATOR COMPONENT OF GENERATOR SET
All generators for the inherently regulated series (4, 7.5, 11, 12.5)
are identical in design and alike except for length of the various
sizes.
Wear iog and replaceable parts are similar throughout.
bearing~ (8), rectifier (42), capacitor (45) all bear a
commonality. (See page opposite.)
Brushes (39),
high degree of
It is necessary only to give correct model and serial number to obtain
correct parts from your local Dealer or Distributor.
Occasionally when a generator set is started, there will be no voltage
build-up. When this occurs, the fields must be flashed to restore
residual magnetism. The fields may be flashed with a 6 or 12 volt
battery as follows: stop the engine; remove the generator end cover.
You will notice the
positive (+) lead from the
field coil is connected to
the + terminal of the rec-
tifier (Part 42, opposite
page), the negative lead
from the field coil is
connected. to the opposite
negative unmarked terminal
of the rect i fier. Using
alligator clips, connect
field coil positive to
battery positive and field
coil negative to bat~ery
negative for approximately
10 seconds. The set will
then build voltage and
output. (Be careful not
to connect on the AC
terminals as this will
destroy the rectifier.)
115V
Armature
F1eld W1ncI1lIr
18
AC
AC
Field
Excitatior.
Rectifier
,

19