Westerbeke 8.0KW BCDT60Hz Owner's Manual
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Westerbeke 8.0KW BCDT60Hz Owner's Manual

Westerbeke 8.0KW BCDT60Hz Owner's Manual

Marine diesel generators, single phase
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OWNERS MANUAL
8.0 KW BCDT 60Hz
7.0 KW BCDT 50Hz
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'MARINE DIESEL GENERATORS
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PUBL ATION NO.46294
FIRST EDITION
... JULY2001
WESTERBEKE
WESTERBEKE CORPORATION· MYLES STANDISH INDUSTRIAL PARK
150 JOHN HANCOCK ROAD· TAUNTON MA 02780-7319. TEL. 1-508-823-7677
. FAX
1-508-884-9688· WEBSITE: www.WESTERBEKE.COM
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.AL"f1!A
Member Natiomd Marine ManufacturersAssociation

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  • Page 1 7.0 KW BCDT 50Hz 'MARINE DIESEL GENERATORS PUBL ATION NO.46294 FIRST EDITION ... JULY2001 WESTERBEKE WESTERBEKE CORPORATION· MYLES STANDISH INDUSTRIAL PARK 150 JOHN HANCOCK ROAD· TAUNTON MA 02780-7319. TEL. 1-508-823-7677 . FAX 1-508-884-9688· WEBSITE: www.WESTERBEKE.COM mm ..AL"f1!A Member Natiomd Marine ManufacturersAssociation...
  • Page 2 GET OUT INTO THE FRESH AIR IMMEDIATELY. If symptoms persist, seek medical attention. Shut down the unit and do not restart until it has been inspected and repaired. A WARNING DECAL is provided by WESTERBEKE and should be fixed to a bulkhead near your engine or generator.
  • Page 3 SAFETY INSTRUCTIONS INTRODUCTION PREVENT BURNS - FIRE Read this safety manual carefully. Most accidents are caused by failure to follow fundamental rules and precau- WARNING: Fire can cause injury death! tions. Know when dangerous conditions exist and take the necessary precautions to protect yourself, your personne~ •...
  • Page 4 SAFETY INSTRUCTIONS ACCIDENTAL STARTING TOXIC EXHAUST GASES WARNING: Accidental starling can cause injury WARNING: Carbon monoxide (CO) is deadly gas! death! • Ensure that the exhaust system is adequate to expel gases • Disconnect the battery cables before servicing the engine! discharged from the engine.
  • Page 5 SAFETY INSTRUCTIONS ABYC, NFPA AND USCG PUBLICATIONS FOR • Do not wear loose clothing or jewelry when servicing equipment; tie back long hair and avoid wearing loose INSTALLING DIESEL ENGINES jackets, shirts, sleeves, rings, necklaces or bracelets that Read the following ABYC, NFPA and USCG publications could be caught in moving parts.
  • Page 6 INSTALLATION When installing WESTERBEKE engines and generators it is important that strict attention be paid to the following information: CODES AND REGULATIONS Strict federal regulations, ABYC guidelines, and safety codes must be complied with when installing engines and generators in a marine environment.

  • Page 7: Table Of Contents

    TABLE OF CONTENTS Parts Identification ..................Introduction ....................Warranty Procedures ................3 Serial Number Location ..............3 Installation ....................Exhaust System ................... 7 Raw Water Cooling ................8 Control Panel ......: ............... 10 Fuel, Engine Oil and Engine Coolant ........... Preparations for Initial Start·Up ............

  • Page 8: Parts Identification

    PARTS IDENTIFICATION .CONTROL BOX AIR INTAKE FILTER THERMOSTAT HOUSING INTERNAL COOLANT PUMP DRIVE BELT MOUNTS~ VIBRATION OIL FILL THERMOSTAT /HOUSING COOLANT FILL SOLENOID~ PREHEAT ZINC---' EXHAUST ~AIR INTAKE FILTER MAN\FOlD~""" .:;ft-'''\'I''---r''--:l7'''H'~I----'-FUEL LIFT PUMP CONTROL BOX· SIDE OIL FILL t']'l/~%TI:_RAW WATER PUMP •...

  • Page 9: Introduction

    THE FURNISHING OR USE OF SUCH SOFTWARE. For additional installation information. see WESTERBEKE INSTALLATION MANUAL FOR MARINE ENGINES & WESTERBEKE customers should also keep in mind the time GENERATORS, Publication #43268. span between printings of WESTERBEKE product software and the unavoidable existence of earlier WESTERBEKE order to get the full use and benefit from your generator, manuals.
  • Page 10 RECOMMISSIONING section in this manual. In addition, include a complete part description and part number for each part needed (see the Parts List). Insist upon WESTERBEKE packaged parts because will fit or generic parts are frequently not made to the same specifications as original equipment.

  • Page 11: Installation

    INSTALLATION The following installation instructions cover the Westerbeke 8 Kw SPECIAL FUEL RETURN ..i 1/4" HOSE-MALE BARB Diesel Generator. Additional general information may be found in " SUPPLIED Westerbeke's INSTALLATION MANUALfor MARINE ENGINES and GENERATORS, Publication #43268. The following factors should be considered when planning the installation of your Westerbeke 8 K w generator: Size and weight of the generator.
  • Page 12 INSTALLATION LOCATION AND MOUNTING VENTILATION Allow for the sufficient intake of cool air for proper engine A solid, level mounting platform is very important for the proper operation of your generator. Select a location that will allow combustion and the discharge of the heated air while the generator adequate space on all sides for ventilation and servicing.

  • Page 13: Exhaust System

    A carbon monoxide warning decal has been provided by Westerbeke. Display this decal near your engine or generator, on your cabin bulkhead, or in some other prominent location. Westerbeke Corporation presumes that the installer of this marine...

  • Page 14: Raw Water Cooling

    Use a separate hose for this loop, and rim it outside of STARTING BATTERY CONNECTIONS the sourtdshield. The Westerbeke 18.0 KW Generator is negative grounded. The SIPHON BREAK generator should be connected to its own 12V starting battery (125A minimum).
  • Page 15 INSTALLATION CONTROL PANEL Mount this plug-in control panel in any desired remote location. The panel is furnished with 32.8 ft. (10 m) of cable; additional cable is available if more cable length is required. When installing, pass the cable though bulkheads by disconnecting the cable at the control panel.

  • Page 16: Control Panel

    CONTROL PANEL DESCRIPTION The oil pressure/coolant temperature warning light (red) lights up when either the oil pressure is too low or the engine is overheated. This plug-in remote control panel provides the operator with all The engine will shut down if it overheats or there is an oil the necessary information and controls to use the generator.

  • Page 17: Fuel, Engine Oil And Engine Coolant

    FUEL, ENGINE OIL AND ENGINE COOLANT DIESEL FUEL ENGINE COOLANT Westerbeke recommends a mixture of 50% antifreeze and Use fuel that meets the requirements or specifications of Class 2-D (ASTM), and has a cetane rating of #45 or better. 50% distilled water. Distilled water is free from the chemicals that can corrode internal engine surfaces.

  • Page 18: Preparations For Initial Start-Up

    PREPARATIONS FOR INITIAL START-UP PRESTART INSPECTION Before starting your generator for the first time or after a pro- longed layoff, check the following items: • Check the engine oil level: add oil to maintain the level at the full mark on the dipstick. •...

  • Page 19: Starting/Stopping Procedure

    STARTING/STOPPING PROCEDURE ELECTRIC START OPERATING THE GENERATOR After the generator has started, run it with a medium load for warmup. Ifpossible, apply the load in stages. CAUTION: All AC loads must be switched off before starting. This precaution will prevent damage caused by unanticipated operation of AC machinery and CAUTION: Never operate the engine for long...

  • Page 20: Break·ln Procedure (Daily Operation)

    BREAK-IN PROCEDURE/DAILY OPERATION NOTE: BREAK-IN PROCEDURE Some unstable running may occur in a cold engine. This condition should abate as normal operating temperature After the generator has been started, check for proper opera- is reached and loads are applied. tion and then encourage a fast wann-up. Run the generator between 20% to 60% of full load for the fIrst 10 hours.

  • Page 21: Safety Shutdown Switches

    SAFETY SHUTDOWN SWITCHES SAFETY SHUTDOWN SWITCHES Low Oil Pressure Switch The generator is protected by three automatic shutdown A low oil pressure shutdown switch is located off the switches. Should shutdown occur, do not attempt to restart engine's oil gallery. Normally open in a static state, this without finding and correcting the cause.

  • Page 22: Maintenance Schedule

    Clean off excessive corrosion. Starler motor' Check the solenoid and motor for corrosion. • Remove and lubricate. Clean and lubricate the starter motor pinion drive. (continued) 'Westerbeke recommends that this service be performed by an authorized mechanic. Engines & Generators...
  • Page 23 Check the no-load speed. speed Cleaning the Keep the generator's surface clean. Surface • generator dirt and oil will inhibit the generator's ability to remain cool. 'Westerbeke recommends that this service be performed by an authorized mechanic. Engines & Generators...

  • Page 24: Cooling System

    COOLING SYSTEM DESCRIPTION Drain the engine coolant by loosening the drain plug on the Westerbeke marine diesel engines are designed and equipped engine block and opening the manifold pressure cap. Flush for fresh water cooling. Heat produced in the engine by , the system with fresh water, then start the refill process.

  • Page 25: Thermostat

    COOLING SYSTEM NOTE: Periodically check the condition of the manifold COOLANT TEMPERATURE SWITCH pressure cap. Ensure that the upper and lower rubber seals The coolant temperature switch is located near the thermostat are in good condition and check that the vacuum valve opens housing (see illustration).

  • Page 26: Raw Water Pump

    COOLING SYSTEM RAW WATER PUMP RAW WATER INTAKE STRAINER NOTE: Always install the strainer at or below the waterline so the The raw water pump is a self-piiming, rotary pump with a non-ferrous housing and a neoprene impeller. The impeller has strainer will always be self-priming.

  • Page 27: Heat Exchanger

    COOLING SYSTEM Heat Exchanger Service Zinc Anode A zinc anode, or pencil, is located in the raw water cooling After approximately 1000 hours of operation, remove, clean and pressure test the engine's heat exchanger. (A local auto- circuit within the heat exchanger. The purpose of having zinc anodes is to sacrifice them to electrolysis action taking motive radiator shop should be able to clean and test the heat place in the raw water cooling circuit, thereby reducing the...

  • Page 28: Engine Lubricating Oil

    ENGINE LUBRICATING OIL ENGINE OIL CHANGE APPLY CLEAN ENGINE OIL WHEN INSTALLING 1. Draining the oil sump. Discharge the used oil through the sump drain hose (attached to the front of the engine) while the engine is warm. Drain the used oil completely, replace the hose in its bracket and replace the end cap SPIN ON OIL securely.

  • Page 29: Fuel System

    FUEL SYSTEM DIESEL FUEL FUEL FILTERS Use No.2 diesel fuel with a cetane rating of 45 or higher. Do The fuel injection pump and the fuel injectors are precisely not use kerosene or home heating fuel. manufactured and they must receive clean diesel fuel, free from water and dirt.

  • Page 30: Glow Plugs

    GLOW PLUGS DESCRIPTION Re-install the plugs in the engine and test them again. The plugs should get very hot (at the terminal end) within 20 to The glow plugs are wired through the preheat solenoid. 25 seconds. If the plugs don't heat up quickly, check for a When the START button is pressed at the control panel this short circuit.

  • Page 31: Starter Motor

    STARTER MOTOR DESCRIPTION The starting system includes the battery, starter motor, solenoid, and starter button. When the starter button on the instrument panel is depressed, current flows and energizes the starter's solenoid coil. The energized coil becomes an electromilgnet, which pulls the plunger into the coil, and closes a set of contacts which allow high current IGNITION', to reach the starter motor.
  • Page 32 STARTER MOTOR SERVICE Westerbeke uses a standard marine starter motor which can be serviced or rebuilt at any starter motor automotive service center. \(+) POSITIVE ~.-\\ TERMINAL If replacing the starter motor, make certain the new motor is certified for marine use. Automotive starters do not meet USCG standards.

  • Page 33: Control Box

    'COOLlN,~G ,BATTERY CHARGER (INTEGRAL CONTROLLER) iBRIDGE • RECTIFIER CAPACITOR , CURRENT TRANSFORMER" 230V 50Hz 120V 60Hz 120/240V 60Hz NOTE: Ll (lnd L2 lW,.t pll ..!~~~f~tm":rellt chen~ NOTE: W/= froto (;0 tl> $tOe opel1ltDl"smanulI1 GENERATOR CONNECTION /W'/WESTERBEKE {EngineS & Generators...

  • Page 34: Dc Control Circuit

    12 VOLT DC CONTROL CIRCUIT TEST WITH THE ENGINE RUNNING DESCRIPTION The engine has a 12 volt DC electrical control circuit that is shown on the wiring diagrams that follow. Refer to these diagrams when troubleshooting or when servicing the DC BLACK (-) electrical system on the engine.

  • Page 35: Wiring Diagram (#41990)

    116 BlK "' ~~~~~~I~m~ BlK~ !W!!..!!...j---+--/~~rr­ I -- 114 JAN '" BRIDGE ZJ!A...I!!ll. ECTlfIER - '" '14 RED -+_~~~~~ U_-+ ___ 1'4 RED/WHT II. RED " '" CAPACITOR BATTERY CHARGER 114 BLACK GENERATOR CONNECTOR GENERATOR , "fIV',WESTERBEKE Engines & Generators...

This manual is also suitable for:

7.0kw bcdt50hz8.0 kw bcdt 60hz7.0 kw bcdt 50hz

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