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
carelessly.
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
GENERAL
INFORMATION
AND
CARE
OF
GENERATORS
1.
Use
of
Electric
Motors
The
power
~equired
to
start
an
electric
motor
is
considerably
more
than
1S
required
for
keeping
it
running
after
it
is
once
started.
Some
motors
require
much
more
current
to
start
them
than
others.
split
phase
(A.C.)
motors
require
more
current
to
start
them,
under
similar
circumstances,
than
other
types.
They
are
commonly
used
on
easy
starting
loads,
such
as
washing
machines
or
where
loads
are
applied
after
the
motor
is
started
such
as
small
power
tools.
Since
they
require
5
to
7
times
as
much
current
to
start
as
to
run,
their
use
should
be
avoided
whenever
possible
if
the
electric
motor
is
to
be
driven
by
a
small
generator.
Capacitor
and
repulsion-induction
motors
require
from 2 to
4
times
as
much
current
to
start
them
as
to
run
them.
The
current
required
to
start
any
motor
varies
with
the
load
connected
to
it.
An
electr
ic
motor
connected
to
an
air
compressor,
for
example,
will
requir_e
more
than
a
motor
to
which
no
load
is
connected.
In
general,
the
current
required
to
start
115
volt
motors
con-
nected
to
medium
starting
loads
will
be
approximately
as
follows:
MOTOR
AMPS
FOR
AMPS
FOR
SIZE
RUNNING
STARTING
1/6
3.2
6.4
to
22.4*
1/4
4.6
9.2
to
32.2*
1/3
5.2
10.4
to
72.8*
1/2
7.2
14.4
to
29.2
3/4
10.2
20.4
to
40.8
1
13
26
to
52
*Note
that
in
the
above
table
the
maximum Namps
for
starting"
is
more
for
some
small
motors
than
for
larger
ones.
This
is
because
the
hardest
starting
types
(split-phase),
are
not
made
in
larger
sizes.
Because
the
heavy
surge
of
current
required
for
starting
motors
is
required
for
only
an
instant,
the
generator
will
not
be
damaged
if
it
can
bring
the
motor
up
to
speed
in
a
few
seconds
of
time.
If
difficulty
is
experienced
in
starting
motors,
turn
off
all
other
electrical
loads
and,
if
possible,
reduce
the
load
on
the
electric
motor.
2.
Required
Operating
Speed
Although
individual
units
and
models
may
vary
slightly,
the
normal
voltage
and
frequency
of
typieal
60
cycle
engine-driven·
generators
described
in
this
book
are
approximately
as
follows
when
run
first
20
wi
th
no
load
finally
when
nameplate.
Load
applied,
then
at
half
loaded
to
its
full
the
gener a tor
capac i ty
capacity
as
rated
on
Generator
Vol
tage
Speed
llSv.
230v.
AEElied
4
Eole
Freguencl::
plants
Plants
None
1830
61
129
258
Half
1800
60
120
240
Full
1755
58~
115
230
and
the
The
output
voltage
should
be
checked
periodically
to
insude
proper
operation
of
the
generating
plant
and
appliances.
If
the
genera-
tor
is
not
equipped
with
a
voltmeter,
it
can
be
checked
with
a
portable
meter.
3.
Maintenance
See
the
engine
instruction
book
for
engine
maintenance.
BRUSHES
-
Check
the
brushes
for
wear
after
about
1000
hours
of
operation
and
every
few
hundred
hours
of
operation
thereafter.
They
should
be
replaced
when
worn
down
to
one
half
inch.
Whenever
replacing
brushes
or
removing
them
to
do
other
service
work,
remove
one
brush
at
a
time
and
put
the
screws
back
into
the
brush
holder
to
hold
the
wire
terminals
on
place
so
there
will
be
no
difficulty
replacing
the
wires
correctly.
COMMUTATOR
- A
commutator
and
is
brownish
in
color.
may
be
cleaned
wi
th
very
cloth.
)
in
good
condi
tion
has
a
glossy
finish
If
it
gets
greasy,
rough
or
dirty,
it
fine
sandpaper.
(Do
not
use
emery
BEARINGS -
All
ball
bearings
used
in
these
generators
are
packed
with
grease
before
assembly
-
no
further
greasing
is
required.
If
they
become
rough
or
worn
they
should
be
replaced.
21
RECOMMENDED
ENGINE
MAINTENANCE
Check
and
service
your
engine
at
specified
intervals
to
maintain
it
in
its
best
conditions
and
permit
it
to
perform
as
it
should.
As
for
those
asterisked
items,
it
is
suggested
that
you
have
them
performed
by
an
authorized
distributor
or
dealer.
1.
Daily
inspection
before
use
A.
Checkup
of
engine
oil
level
and
refilling
No
refill
is
required
if
the
level
is
near
the
upper
limit
line
of
the
gauge.
B.
Checkup
of
cooling
water
and
refilling
Refill
up
to
the
filler
cap
neck.
C.
Check
your
fuel
supply
D.
Checkup
of
gauges
and
meters
After
starting
your
'engine,
check
oil
pressure,
water
tem-
perature
and
voltage
reading.
E.
Checkup
for
loose
parts
(fan
belt
or
bolt,
etc.),
damage
and
leaks
F.
Checkup
for
abnormality
with
exhaust
gas,
noise
and
vibration
2.
Servicing
following
initial
50
hours
of
operation
A.
Renewal
of
engine
oil
B.
Replacement
of
oil
filter
C.
Renewal
of
cooling
water
o.
Adjustment
of
valve
clearance
(See
SERVICE
DATA)
*E.
Tightening
of
bolts
and
nuts
*F.
Adjustment
of
engine
idle
3.
Servicing
at
every
100
hours
of
operation
A.
Renewal
of
engine
oil
B.
Replacement
of
oil
filter
22
C.
Cleaning
of
fuel
filter
D.
Adjustment
of
engine
idle
4.
Servicing
at
every
200
hours
of
operation
A.
Replacement
of
engine
mounted
fuel
filter
elements
E.
Repla~ement
of
fuel.filter
(cartridge
type)
5.
Servicing
at
every
400
hours
of
operation
A.
Cleaning
of
fuel
tank
'*B.
Adjustment
of
valve
clearanc·e
'*c.
Checkup
of
starter
motor,
alternator
and
regul'ltor
Check
the
brush
and
surface
of
commutator
for
the
degree
of
wear.
Replace
the
brush
if
it
is
worn
beyond
the
limi
ts
of
wear.
*D.
Checkup
of
glow
plugs
Check
the
glow
plugs
for
blow-out.
E.
Removal
of
cooling
water
and
flushing
is
suggested.
6.
Servicing
at
every
800
hours
of
operation
'*A.
Checkup
of
nozzles
Set
the
injection
starting
+142
pressure
to
1707
-0
psi
and
eliminate
undesirable
injection
conditions
in-
cluding
n
after
dr
ipping".
,fdIJ,'
I
POOR
Sfil
23
*B.
Checkup
of
compression
pressure
Remove
eac~
glow
plug
and
check
cylinders,
one
by
one,
using
a
compresslom
pressure
gauge.
If
the
preSsure
differs
by
more
than
2.5
kg/cm2 (35.6
psi)
between
cylinders
or
if
the
cylinder
pressure
is
less
than
26
kg/cm
2
(369.8
psi)
at
320
RPM
for
the
4
KW
and
at
280
RPM
for
the
7.5
KW,
11
KW
and
12.5
KW
correct
it.
*C.
Fuel
injection
adjustment
In
case
of
severe
vibration
during
idling,
have
it
repaired
at
an
authorized
distributor
or
dealer
which
is
equipped
with
a pump
tester.
*0.
Checkup
of
alternator
and
regulator
Regulate
the
voltage
and
current
by
use
of a circuit
tester.
*E.
Checkup
of
starter
motor
pinion
and
flywheel
ring
gear
Rectify
the
chamfered
area
that
has
been
severely
damaged
by
use
of
an
oil
stone
or
some
pencil
grinder,
and
r-eplace
the
part
if
it
is
damaged
allover.
*F.
Tightening
of
bolts
and
nuts
7.7
KW
ENCLOSED
I N
SOUND
GUARD
24
TROUBLESHOOTING
1.
ENGINE
DOES
NOT
START
a.
b.
c.
d.
e.
f.
g.
h.
PROBLEM
Starting
switch
is
defective
Deficient
drive
torque
of
the
starter
motor
Improper
viscosity
of
engine
oil
Engine
too
cold
Seizure
of
moving
parts
Air
present
in
fuel
system
No
fuel
in
fuel
tank
Fuel
filter
clogged
REMEDY
Correct
connections
and
contacts
The
battery
is
exhausted,
trouble
with
the
starter
motor,
or
dirty
or
loose
wiring
Check
the
viscosity
and
renew
oil
if
necessary
Use
glowplug
starting
aid
Rectify
Purge
thoroughly
with
electric
fuel
pump
Ref
ill
Clean
or
renew
2.
ENGINE STALLS
WHILE
IN
OPERATION
PROBLEM
a.
Fuel
tank
is
empty
b.
Fuel
filter
clogged
c.
Air
present
in
fuel
system
3.
IMPROPER
OIL
PRESSURE
PROBLEM
REMEDY
Refill
Clean
or
renew
Retighten
fuel
line
connections
to
allow
electric
fuel
pump
to
run
long
enough
to
purge
air
thorou9hly
REMEDY
a.
Oil
shortage
Refill
b.
Oil
leak
through
connections
Repair
c.
Oil
pressure
switch
Replace
defective
25
4.
ENGINE
OVERHEATING
PROBLEM
REMEDY
a.
Cooling
water
shortage
Ref
ill
b.
Water
leaks
Repair
c.
Belt
loose
or
smeared
with
Clean
or
renew
oil
d.
Raw
water
pump
defective
Repair
or
renew
5.
BATTERY
IS
UNDERCHARGED
PROBLEM
REMEDY
a.
Belt
tension
improper
Rectify
b.
Faulty
wiring
circuit
Rectify
c.
Alternator
not
functioning
Replace
(observe
vol
tmeter)
d.
Battery
faulty
Replace
e.
Faulty
voltage
regulator
Repair
or
renew
12,5
KH
26
SERVICE
DATA
1.
Valve
clearance
(engine
cold)
(both
intake
and
exhaust)
2.
Compression
pressure
4KW
7.7
-
11 -12.5KW
3.
Engine
oil
capacity
(including
oil
f
11
ter
4.
Firing
order
4
KW
7.7KW
11KW
12.SKW
4
KW
7.7KW
11 - 12.SKW
0.25
mm
(0.010
in.)
32
kg/cm
2
at
320
RPM
32
kg/cm
2
at
280
RPM
2.8
liters
(0.74
u S
gal)
3.5
liters
(0.93
u S
gal)
4.5
liters
(1.19
U S
gal)
5.0
liters
(1.
32
U
S
gal)
1-2
1-3-2
1-3-4-2
5.
Injection
timing
-
BTDC
of
compression
stroke
when
started
at
smoke
set
position.
Marine
Engine
Generator
6.
Injection
starting
pressure
7.
Cooling
water
capacity
(in
engine
body
alone)
4
KW
7.7KW
llKW
l2.SKW
27
23·
+
19·
+
1707
2.1
1
3.0
1
3.5
1
3.7
1
1.
5'
1.
5·
+142
o
psi
ters
(0.56
u S
gal)
ters
(0.79
U S
gal)
ters
(0.92
U
S
gal)
ters
(0.98
U S
gal)
TABLE
OF
TIGHTENING
TORQUES
Cylinder
head
bolt
(MIO)
7.7,
11,
12.5
KW
7-8
(M12)
7.7
KW
11-12
4,
11
KW
12-13
(M14)
12.5
KW
15-16
Crank
pulley
nut 4 KW
15-20
7.7,
11,
12.5
KW
20-25
Main
bearing
cap
bolt
7.7,
11,
12.5
KW
5.0-5."5
Connecling
rod
cap
nut
4,
7.7,
11
KW
3.2-3.5
Connecting
rod
cap
bolt
12.5
KW
11.5-12.5
Flywheel
bolt
11.5-12.5
Oil
pan
drain
plug
5-6
Oil
filter
1.1-1.3
Delivery
valve
holder
(injection
pump)
4-5
Holder
mounting
bolt,
nozzle
1.5-2.0
Holder
body
and
retaining
nut,
nozzle
6-8
Glow
plug
General
screw
tightening
torque
M6
M8
M10
M12
M14
28
1.5-2.0
0.7
1.7
3.5
6.4
9.5
1b/ft.
50.7-57.9
79.6-86.8
86.8-94.0
108.5-115.7
108.5-144.6
108.5-180.8
36.2-43.4
23.1-25.3
83.2-90.4
83.2-90.4
36.2-43.4
8.0-9.4
28.9-36.2
10.8-14.5
43.4-57.9
10.8-14.5
5.1
12.3
25.3
46.3
68.7
WESTERBEKE
GENUINE
PAR~S
"WESTERBEKE
GENUINE PARTS"
are
super
ior
and
reliable
because
they
have
been
produced
under
an
excellent
quality
control
system
and
have
passed
the
standard
after
strict
inspection.
After
market
parts
are
not
recommended
from
the
viewpoint
of
their
material
standard
and
manu-
facturing
method
which
may
be
entirely
different
from
those
of
genuine
parts.
"WESTERBEKE
GENUINE PARTS"
are
available
from
our
authorized
distributors
and
dealers.
Please
order
your
spare
parts
from
your
nearest
distribu-
tor
or
dealer.
This
operators
manual
is
your
guide
for
day
to
day
operation
and
maintenance
of
your
engine.
For
those
who
desire
more
complete
repair
and
parts
data
the
following
may
be
ordered
from
your
nearest
Westerbeke
Distributor
or
Dealer.
Technical
Manual
•••.••.••••
Publication
130041
Part
List
••..•••.•...•.••..
Publication
132139
29
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