Related Manuals for Westerbeke 4KW-7.7KW-11KW-12 5KW
Summary of Contents for Westerbeke 4KW-7.7KW-11KW-12 5KW
- Page 1 OPERATOR'S MANUAL WESTERBEKE DIESEL GENERATOR SETS 4 KW· 7.7KW· 11 KW· 12.5 KW Publication Number 32461 Printed in U.S.A.
- Page 2 FOREWORD Thank you for having selected a Westerbeke Diesel Generator 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.
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Page 3: Table Of Contents
TABLE OF CONTENTS PAGE GENERAL SPECIFICATION'S ••••••.•••••••• 3 CAUTIONS IN HANDLING ENGINE ..•..4 BREAKING IN..... 5 PREPARATIONS. • ..• ..• . . • . . . •. 6 STARTING PROCEDURES ••••..••.•..• STOPPING PROCEDURES •.•••..•.•••. -
Page 4: General Specifications
GENERAL SPECIFICATIONS ITEM CHARACTERISTIC 7.7KW llKW 12.5KW 4 K" cycle, water Type Vert.,4 cooled diesel engine Combustion chamber Swirl chamber type No. of cylinders Bore stroke (inches) 2.76x3.07 2.87x3.07 2.87x3.07 3.07x3.07 & Cu. In. displacement Compression ratio Firing order 1-3-2 1-3-4-2 1-3-4-2 Dry weight, std. -
Page 5: Cautions In Handling Engine
CAUTIONS IN HANDLING ENGINE • engine Always use proper 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... -
Page 6: Breaking In
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 breaking each moving part in and maximizing perfor- mance life engine. -
Page 7: Preparations
PREPARATIONS Take steps as shown below in starting your engine for the first time or after a prolonged shut-down. Fill your engine with oil up to or near the upper limi t on the dipstick. Use a good grade of wi th API specification of ::c or better. -
Page 8: Starting Procedures
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"... - Page 9 STARTING PROCEDURES making initial start after lay-up, fuel filter ser- PREHEAT 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 accumulated air_ This will preheat...
- Page 10 Starting While still holding preheat switch depressed, depress PREHEAT START start switch. starter motor will run thereby cranking engine. soon engine runs, release the start switch which will return to its normally open position..Con- .sTOP tinue holding preheat switch depressed seconds.
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Page 11: Stopping Procedures
STOPPING PROCEDURE PREHEAT START Stop To stop the generator, depress stop switch until engine STOP stops completely then- release. CAUTIONS ON STARTING AND OPERATION Normal starting Follow the procedures below for routine starting of your engine. Check the engine oil level and refill if necessary. Insure that you have sufficient fuel. - Page 12 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 abnormal noise such as...
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Page 13: Requirements For Proper Operation
REQUIREMENTS FOR PROPER OPERATION LUBRICATION SYSTEM 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. -
Page 14: Fuel System
Replacement of oil filter Being replaceable cartridge type, the oil filter requires no cleaning inside. 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. - Page 15 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.
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Page 16: Cooling System
leak should develop at banjo or washer that cannot remedied by a simple tightening of the screw, renew the washers. The engine can be started by taking the steps described on pages 8 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. - Page 17 *Antifreeze poor quality will cause corrosion cooling system, thus always 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 Freezing "C te!!!}?:erature ! "Fl (23) (14) !-4)
- Page 18 " 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)
- Page 19 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. 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.
- Page 21 GENERAL INFORMATION AND CARE OF GENERATORS Use of Electric Motors ~equired The power to start electric motor is considerably more than required keeping it running after 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...
- Page 22 applied, then half gener a tor capac i ty wi th no load finally when loaded full capacity rated nameplate. Generator Vol tage Load Speed llSv. 230v. plants 4 Eole Freguencl:: Plants AEElied None 1830 Half 1800 Full 1755 The output voltage should be checked periodically to insude proper operation of the generating plant and appliances.
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Page 23: Engine Maintenance
RECOMMENDED ENGINE MAINTENANCE Check and service your engine at specified intervals to maintain it in 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. Daily inspection before use Checkup of engine oil level and refilling No refill is required i f the level is near the upper limit... - Page 24 Cleaning of fuel filter Adjustment of engine idle Servicing at every 200 hours of operation Replacement of engine mounted fuel filter elements Repla~ement of fuel.filter (cartridge type) Servicing at every 400 hours of operation Cleaning of fuel tank '*B. Adjustment of valve clearanc·e '*c.
- Page 25 Checkup of compression pressure eac~ Remove glow plug and check cylinders, one by one, using a compresslom pressure gauge. If the preSsure differs more than 2.5 kg/cm 2 (35.6 psi) between cylinders or if the kg/cm 2 cylinder pressure less than (369.8 psi)
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Page 26: Troubleshojting
TROUBLESHOOTING ENGINE DOES NOT START PROBLEM REMEDY Starting switch is defective Correct connections and contacts Deficient drive torque of The battery is exhausted, trouble the starter motor with the starter motor, or dirty or loose wiring Improper viscosity of engine Check the viscosity and renew oil if necessary Use glowplug starting aid... - Page 27 ENGINE OVERHEATING PROBLEM REMEDY water shortage Ref ill Cooling leaks Repair Water or renew loose or Clean smeared with Belt Raw water pump defective Repair or renew BATTERY UNDERCHARGED PROBLEM REMEDY improper Rectify Belt tension Rectify Faulty wiring circuit not functioning Replace Alternator (observe...
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Page 28: Service Data
SERVICE DATA Valve clearance (engine cold) in.) 0.25 (0.010 (both intake and exhaust) Compression pressure kg/cm 2 at 320 RPM kg/cm 2 at 280 RPM 7.7 - 11 - 12.5KW Engine oil capacity (including oil f 4 KW (0.74 liters gal) (0.93 gal) -
Page 29: Table Of Tightening Torques
TABLE OF TIGHTENING TORQUES 1b/ft. Cylinder head bolt (MIO) 7.7, 11, 12.5 KW 50.7-57.9 (M12) 7.7 KW 11-12 79.6-86.8 86.8-94.0 12-13 (M14) 12.5 KW 15-16 108.5-115.7 Crank pulley nut 4 KW 15-20 108.5-144.6 7.7, 11, 12.5 KW 20-25 108.5-180.8 Main bearing cap bolt 7.7, 11, 12.5 KW 5.0-5."5 36.2-43.4 Connecling rod cap nut 4, 7.7, 11 KW... -
Page 30: See Wiring Diagrams Following
"WESTERBEKE GENUINE PARTS" are available from authorized distributors and dealers. Please order your spare parts from your nearest distribu- tor or dealer. - Page 31 ---;01"1 240V I~IRII'li INTERNAL DINiflPl'S l20V ~--<' FOR 7.lIM 12DV AND 120mDV llSV illSV FIELD txClT A"fI ()II RECTIFIER AWA1URE AA"A1URE FIELD txCITATI()II RECTIFIER W IR ItI3 SftI'E FOR l2Of2LICW...
- Page 32 IN1E~L WIRI~ DJI\GRPtE ill5V FOR 11 12.5 ll5V FIElD EXCITAnil'l RECTIFIER AIl' I ' \ TURE FIllD EXCITATION RECTIFIER WIRING SAI'£ AS FOR 2?IJV FIElD WINDING...
- Page 33 115'1 ll5V 115V INlERMl WIRltii 120 V(U IIIIERIIIl W IRI tIi ql(W • Hill: l2OI2Lj() VOLT BfMltIi END FlEW EXCITATIOO FIELD EXCITATlll' 1 BfMlfl3 ElID RECTIFIER RECTIFIER ».:,----, '"7=--1 AWATURE FlEW WINllHI3 FIELD HIMlHE...
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