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OPERATORS MANUAL
D-NET DIESEL GENERATORS
8.0KW • 60Hz EDT
6.0KW • 50Hz EDT
12.5KW • 60Hz EDT
9.4KW • 50Hz EDT
10.0KW • 60Hz EDT
7.5KW • 50Hz EDT
12.6KW • 60Hz EDT
10.4KW • 50Hz EDT
11.5KW • 60Hz EDT
15.0KW • 60Hz EDT
12.0KW • 50Hz EDT
9.2KW • 50Hz
CATION NO.53060
THIRD EDITION
JUNE 2008
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WESTERBEKE CORPORATION' 150 JOHN HANCOCK ROAD
MYLES
STANDISH
INDUSTRIAL PARK' TAUNTON
MA
02780
WEBSITE: WWW.WESTERBEKECOM
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§§~
Member National Marine Manufacturers Association
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Table of Contents
Related Manuals for Westerbeke 8.0KW-60Hz ENDT
Summary of Contents for Westerbeke 8.0KW-60Hz ENDT
- Page 1 11.5KW • 60Hz EDT 15.0KW • 60Hz EDT 9.2KW • 50Hz 12.0KW • 50Hz EDT CATION NO.53060 THIRD EDITION JUNE 2008 WESTERBEKE CORPORATION' 150 JOHN HANCOCK ROAD STANDISH MYLES INDUSTRIAL PARK' TAUNTON 02780 WEBSITE: WWW.WESTERBEKECOM §§~ Member National Marine Manufacturers Association...
- Page 2 Shut down the unit and dD not restart until it has been Inspected and repaired. This WARNING DECAL is provided by WESTERBEKE and should be fixed to a bulkhead near your engine Dr generator. WESTERBEKE a/so recommends Installing CARBON MONOXIDE DETECTORS in the living/sleeping quarlers of your vessel.
- Page 3 SAFETY INSTRUCTIONS PREVENT BURNS - FIRE INTRODUCTION Read this safety manual carefully. Most accidents are WARNING: caused by failure to follow fundamental rules and precau- Fire can cause Injury death! tions. Know when dangerous conditions exist and take the personne~ necessary precautions to protect yourself, your •...
- Page 4 SAFETY INSTRUCTIONS TOXIC EXHAUST GASES ACCIDENTAL STARTING WARNING: Accidental starting can cause injury WARNING: Carbon monoxIde (CO) Is deadly gas! or 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 • Do not wear loose clothing or jewelry when servicing ABYC, NFPA AND USCG PUBLICATIONS FOR 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 A detailed 40 page Marine Installation Manual covering gaSOline and diesel, engines and generators, is available from your WESTERBEKE dealer. l"""'IWESTERBEKE Enaines & Generators...
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Page 7: Table Of Contents
TABLE OF CONTENTS Parts Identification ..........2 Fuel Injectors ............ Introduction ............3 Injector Testing ..........28 Warranty Procedures ........3 Spray Pattern ..........28 Fuel Injection Timing ........Serial Number Location ....... Diesel Fuel, Engine Oil and Coolant....5 Preparation ........... -
Page 8: Parts Identification
PARTS IDENTIFICATION EDT GENERATOR lEFT SIDE CONNECTION TO BREAK DC ALTER _ _ _ ~ I.D.PLATE RAW WATER llNC GENERATOR HEAT BACKEND FRONT STARTER MOTOR REAR DRIP PAN PREHEAT MANIFOLD PRESSURE FILL. RIGHT 81DE FILL CONTROL PANEL. THERMOSTAT ASSEMBLY FUSE 20A CIRCUIT atIt:l\l\t:rr INTAKE... -
Page 9: Introduction
OF THE FURNISHING OR USE OF SUCH SOFTWARE. provided and a technical manual is available from your WESTERBEKE customers should also keep in mind the WESTERBEKE dealer. If you are planning to install this time span between printings ofWESTERBEKE product equipment contact your WESTERBEKE dealer for software and the unavoidable existence of earlier WESTERBEKE'S installation manual. -
Page 10: Serial Number Location
NOTE: A carbon monoxide warning decal has been provided SERIAL NUMBER LOCATION by WESTERBEKE. Affix this decal in a visible position in the The engine's model number and serial number are located on engine room a nameplate mounted on the side of the engine's manifold. - Page 11 50 hours of break-in operation, and every 100 hours of operation thereafter. For recommended oil use SAE 15W-40 A coolant recovery tank kit is supplied with each generator. (oil viscosity). WESTERBEKE recommends the use of The purpose of this recovery tank is to allow for engine synthetic oil.
- Page 12 - - I - - - - t - 20 AMP DC BREAKER LIGHT DESCRIPTION Battery Voltage Oil Pressure WESTERBEKE'S Digital Control panel provides the 13.5 operator with an LCD display that continuously monitors all the operations of the generator in easy to understand text messages. SCROLL SCROLL...
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Page 13: Digital Control Panel
DIGITAL CONTROL PANEL Examples: STOP SEQUENCE Failure Light red. To stop the generator, press the STOP button. The display Coolant Temperature Light is orange. will cycle the following text messages and shutdown. thru High Engine Temp. Waiting for operator Shutting Press start to Down Reset ECU to ReStart... -
Page 14: Remote Stop/Start Panel
The connecting harnesses come in three different lengths and two of these can be combined for a maximum run at 75' (22.l7M). NOTE: For additional information, contact your local WESTERBEKE dealer. 3-1/4" (82.55MMl (57.15MM) / CONNECTING EXTENSION CABLES 6"... -
Page 15: Preparations For Initial Startup
Follow the procedures as presented be switched OFF until the engine has come up to speed for the conditions indicated and your WESTERBEKE and, in cold (jUmates, starts to warm up. This precaution generator set will give reliable perfonnance and long service life. -
Page 16: Generator Break·ln Procedure
When the engine is warm - almost Smokeless. WESTERLINK system. When the engine is overloaded - some Black Smoke. NOTE: Keep in mind that the Westerbeke generator maybe the DC power supply for the vessel's NMEA-2000 network. Engines & Generators... -
Page 17: Safety Shutdown Switches
SAFETY SHUTDOWN SWITCHES . " FROM ENGINE BLOCK SAFETY SHUTDOWN SWITCHES The "ENGINE" is protected by four automatic shutdown switches. Should shutdown occur, do not aJtempt to restart before correcting the cause as shown on the LCD Display screen. The following is a description of these automatic shutdown OIL MANIFOLD switches. -
Page 18: Break-In Procedure/Daily Operation
BREAK-IN PROCEDURE/DAILY OPERATION NOTE: After the first 20 hours of generator operation, check the BREAK-IN PROCEDURE maintenance schedule for the 20 hour service check. After the generator has been started, check for propcr operation NOTE: Some unstable running may occur in a cold engine. This and then encourage a fast warm-up. -
Page 19: Maintenance Schedule
MAINTENANCE SCHEDULE WARNING: Never attempt to perform any service while the engine is running. Wear the proper safety equipment such as goggles and gloves, and use the correct tools for each job. Disconnect the battery terminals when servicing any of the engine's DC electrical equipment. NOTE: Many of the following maintenance jobs are simple but others are more difficult and may require the expert knowledge of a service mechanic. - Page 20 NMEA-2000 system or shut off the DC breaker on the generator's control box for a WESTERUNK system. NOTE: Keep in mind that the Westerbeke generator maybe the DC power supply for the vessel's NMEA-2000 network. Engines & Generators...
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Page 21: Cooling System
When the engine is started cold, external coolant flow is pre- vented by the closed thermostat (although some coolant flow Westerbeke marine diesel engines are designed and equipped is bypassed around the thermostat to prevent the exhaust for fresh water cooling. Heat produced in the engine by com- manifold from overheating). -
Page 22: Thermostat
COOLING SYSTEM Refilling the Coolant Replacing the Thermostat After replacing the engine block drain plug, close the heat Remove the cap screws and disassemble the thermostat hous- exchanger's coolant petcock. Then pour clean, premixed ing as shown. When installing the new thermostat and gas- coolant into the manifold and when the coolant is visable in ket, apply a thin coat of sealant on both sides of the gasket NOTE:... -
Page 23: Changing The Raw Water Impeller
COOLING SYSTEM CHANGING THE RAW WATER PUMP IMPELLER NOTE: Also follow the above procedure after having run hard aground. Close the raw water intake valve. Remove the pump cover and gasket or O-ring with the aid of two screwdrivers or the engine temperature gauge ever shows a higher than of the pump. -
Page 24: Air Intake/Silencer
COOLING SYSTEM Zinc Anode If the zinc anodes need replacement, hold the hex boss into , which the zinc anode is threaded with a wrench while loos- A zinc anode, or pencil, is located in the raw water cooling ening the anode with another wrench. This prevents the hex circuit within the heat exchanger. -
Page 25: Fuel System
FUEL SYSTEM FUEL FILTERS DIESEL FUEL Use No.2 diesel fuel with a cetane rating of 45 or rugher. 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 26: Engine Lubricating Oil
ENGINE LUBRICATING OIL LUBRICATION DIAGRAM 2. Replacing the Oil Filter. When removing the used oil fil· ter, you may find it helpful and cleaner to punch a hole in the upper and lower portion of the old filter to drain the OIL PRESSURE oil from it into a container before removing it. -
Page 27: Oil Pressure
OIL PRESSURE FROM ENGINE BLOCK DESCRIPTION The lubricating system is a pressure feeding system using an oil pump. The engine oil is drawn from the oil sump by the oil pump, which drives the oil, under pressure, through the oil filter, oil cooler and various lubricating points in the engine. -
Page 28: Remote Oil Filter
Contact your WESTERBEKE dealer for more information. engine room bulkhead. NOTE: Westerbeke is not responsible for engine failure due to NOTE: Refer to ENGINE OIL CHANGE in this manual for incorrect installation of the Remote Oil Filter. -
Page 29: Engine Troubleshooting (Chart)
ENGINE TROUBLESHOOTING The tables which follow indicate troubleshooting procedures Note: the engine's DC electrical system is protected by a 20 amp based upon certain problem indicators, the probable causes of manual reset rocker type breaker mounted on the control box on the the problems, and the recommendations to overcome these generator. - Page 30 ENGINE TROUBLESHOOTING Probable Cause Problem Verification/Remedy Exhaust smoking problems 1. Blue smoke. 1. Incorrect grade of engine oil. 1a. Crankcase is overfilled with engine oil (oil is blowing out through the eXhaust}. 2. White smoke. 2. Engine is running cold. 2a.
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Page 31: Engine Adjustments
ENGINE ADJUSTMENTS DRIVE BELT ADJUSTMENT ELECTRONIC GOVERNOR drive Proper inspection, service and maintenance of the belts Governor regulates the engine speed by is important for the efficient operation of your engine (see sensing the engine's RPM with a magnetic pick-up at the Drive Belts under MAINTENANCE SCHEDULE). -
Page 32: Valve Clearance
ENGINE ADJUSTMENTS NOTE: WESTERBEKE recommends that the following engine adjust- ments be performed by a competent engine mechanic. The information below is provided to assist the mechanic. VALVE CLEARANCE ADJUSTMENT (b) With No.1 piston at top dead center on the compression stroke, the rocker arms will not be moved when the Make the following adjustments when the engine is cold. -
Page 33: Testing Engine Compression
ENGINE ADJUSTMENTS NOTE: WESTERBEKE recommends that the following engine adjust- ments be peiformed by a competent engine mechanic. The information below is provided to assist the mechanic. FUEL INJECTORS TESTING ENGINE COMPRESSION In case of severe vibrations and detonation noise, have the... -
Page 34: Fuel Injectors
FUEL INJECTORS REMOVING THE INJECTORS Inspecting Spray Pattern 1, Operate the hand lever of the nozzle tester at intervals of NOTE: Injector must be serviced in a "clean room" environment. one stroke per second to check if the fuel is injected cor- 1. -
Page 35: Fuel Injection Timing
FUEL INJECTION TIMING PREPARATION ADJUSTMENT Close the fuel shut-off valve. a. If the fuel injection timing is incorrect, change the thickness of shims under the fuel injection pump. An b.Disconnect the No.1 fuel injection pipe from the increase or decrease of the shims by O.lmm (0.004 in) cylinder head and injection pump. -
Page 36: 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 7 to 15 The glow plugs are wired through the preheat solenoid. seconds. If the plugs don't heat up quickly. check for a short When PREHEAT is pressed at the control panel this solenoid circuit When reinstalling the glow plugs. -
Page 37: Starter Motor
STARTER MOTOR DESCRIPTION The starter is a new type, small, light-weight and is called a SOLENOID high-speed internal-reduction starter. The pinion shaft is separate from the motor shaft; the pinion slides only on the pinion shaft. A reduction gear is installed between the motor shaft and a pinion shaft. -
Page 38: Emergency Start
SERVICE If the starter falls to spin, the motor is probably faulty. WESTERBEKE uses a standard starter motor which can be arching occurred, there is no juice reaching the serviced or rebuilt any starter motor automotive service solenoid. -
Page 39: Alternator Testing
A working alternator runs bot. A failed The following infonnation applies to the standard alternators alternator can become very bot. Do not touch the that are supplied with WESTERBEKE'S Engines and Generators. alternator until if bas cooled. ELECTRICAL CHARGING CIRCUIT LOW BATTERY/FAULTY CIRCUIT... - Page 40 ALTERNATORS TESTING/TROUBLESHOOTING MEASURING BATTERY VOLTAGE TESTING THE ALTERNATOR ENGINE OFF) CAUTION: Before starting the engine make certain that everyone is clear of moving parts! Keep away from sheaves and belts during test procedures. ~tart the Engine. 2. After the engine has run for a few minutes, measure the starting battery voltage at the battery tenninals using a multinleter set on DC volts.
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Page 41: Checking The Service Battery
If tests indicate a failed alternator, it will need to be disas- sembled and repaired. good alternator service shop do thejob. NOTE: WESTERBEKE'S Service Manual has detailed instmctions for the disassembly and repair of their standard alternators. BATTERY CARE The minimum recommended capacity of the battery used in 3. - Page 42 WIRING DIAGRAM #52793 r----------- -, ~'" ;;;w CAUTION: When servicing or replacing DC components, turn off the 20 amp DC circuit breaker. Engines & Generators...
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Page 43: Wiring Diagram (24 Volt)
WIRING DIAGRAM #53477 (24 VOLT) ! [=~ r - - lI11 1(11$11". QI. fllf!ll !?=li IIlItl1 CAUTION: When servicing or replacing DC components, off the 20 amp DC circuit breaker. Engines & Generators... -
Page 44: Generator Information
Carbon Monoxide Detector the generating plant and the appliances it supplies. an AC WESTERBEKE recommends mounting a carbon voltmeter or ampmeter is not installed to monitor voltage and monoxide detector in the vessels living quarters. Carbon load. check it with a portable meter and amprobe. -
Page 45: Bt Generator
NOTE: This circuit breaku is available as a WESTERBEKE tion. Diodes located in the exciter rotor rectify this voltage to add-on for earlier model generations;... - Page 46 BT GENERATOR SINGLE PHASE [SIX STUD] r----------l ;-----------1 TERMI~L 50 Hz ~-------------------, 1~!)_1 1.:!:.!_aS(J! q=b* 4 11.1 . , . _ C ... _ I " ~-----------------j L ____ 3 ____ 11~1~1~le/l®1 YELLOW & ill; _ _ _ "" i--.1iC GREEN ._I_~l"I"""...
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Page 47: Generator Voltage Adjustment
GENERATOR VOLTAGE ADJUSTMENT NOTE: WESTERBEKE recommends that the following generator tests and adjustments be peiformed a quailified technician. Generator Frequency d. After the no-load hertz adjustment is made, the no-load voltage may need to be readjusted. In most cases, if the 1. -
Page 48: No Load Voltage Adjustment
GENERATOR VOLTAGE ADJUSTMENT g~nerator NOTE: WESTERBEKE recommends that the following tests and adjustments be performed by a quailified technician. FULL-LOAD VOLTAGE ADJUSTMENT NO-LOAD VOLTAGE ADJUSTMENT Voltage adjustment is made with the generator regulation The voltage hertz connection bar that is used when changing from 60Hz to 50Hz can also be used to increase or decrease being governed by the compound transformer. -
Page 49: Shore Power Connections
« SWITCH ..--f<D NOTE: Ship to shore switches are available at your :® ..WESTERBEKE dealer..SHIP'S LOAD <-ir CAUTION: Heavy motor leads should be shut off before sWitching shore power to generator power or (NEUTRAL)! 'Y-'... - Page 50 BT GENERATOR VOLTAGE REGULATOR ADJUSTMENTS [THREE PHASE] Description Amp-Hertz The voltage regulator is an advanced design which ensures These two adjustments are used in conjunction with the two optimum AC generator performance. It is equipped with protection circuits in the voltage regulator that are indicated by the illumination of colored LED lights.
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Page 51: Bt Generator Three Phase
BT GENERATOR INTERNAL WIRING 3 PHASE TWELVE WIRE RECONNECT ABLE ------.., EXCITER STATOR DSTATOR - - - - - - r - - - - - I - - -., 12- I 10- ROTOR FIELD EXCITER DIODES ---- _ _ ..l - - - t - - I.. - Page 52 REGULATOR SENSING 3 PHASE WYE·DELTA CONFIGURATIONS NOTE: WESTERBEKE recommends that the followi!1g generator tests and adjustments be peiformed by a qualified technician. Description SERIES WYE (STAR) The regulator is equipped with seven numbered tencinals (0 to 6) and their related brass jumpers. The illustrations shown cpnnection points and jumpers for the 3 phase config- uration of the generator.
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Page 53: Internal Wiring Diagram
BT GENERATOR· SINGLE PHASE (12 STUD) r-------.., r--------, r - - - - - - - - - - :~i4 ,.----11---- 1 ..• • -t>J- 2 ..• ===?'~ L _____________ • 3 • • WHT/BLK L213l2l-+- f-------... - Page 54 3 Transformer Aux. Winding 3 Main Stator Aux. Winding Selector Switch Circuit Connections (from the Transfonner Aux. winding to the connections on the Bridge Rectifier) NOTE: Reference the BTTroubleshooting guides on WESTERBEKE'S website under "TEeHAN/CAL" for additional information. www.WESTERBEKE.COM. Engines & Generators...
- Page 55 SPECIFICATIONS • ENGINE 8.0/6.0 KW EDT, 1 0.on.5 KW EDT, 11.5/9.2 KW EDT. 12.6/10.4KW EDT GENERAL FUEL SYSTEM Engine Type Diesel, four-cycle, three-cylinder, fresh water- General Open flow, self priming. cooled, vertical in-line overhead valve No.2 diesel oil (cetane rating of 45 or higher). Fuel mechanism.
- Page 56 o.on SPECIFICATIONS • GENERATOR 1 .SKW EDT AC GENERATOR (3 Phase) AC GENERATOR (Single Phase) Brushless, six-pole, revolving field. Sealed Three Phase Single Phase Brushless, four-pole, revolving field. lubricated, single-bearing design. 12 Lead 10.0 KW - Pre-lubricated, single-bearing design. 7.SKW-50Hz reconnectable for low voltage W'fE, high...
- Page 57 SPECIFICATIONS • GENERATOR 11.5/9.2KW EDT AC GENERATOR (Single Phase) AC GENERATOR (3 Phase) Single Phase Brushless, four pole, revolving field. General - 3 Phase Brushless, six-pole, revolving fiekl. Sealed 11.5 Kw • 60 Hertz lubricated, single-bearing design. 12 Lead Pre-lubricated, single bearing design. Reconnectable, single phase transformer 9.2 Kw •...
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Page 58: Specifications (3 Cylinder Engine)
SPECIFICATIONS • ENGINE 12.5/9.4KW EDT & 15.0/12.0KW EDT GENERAL ELECTRICAL SYSTEM Engine Type Diesel, four-cycle, four-cylinder, fresh water- Starting Battery 12 Volt, negative ground cooled, vertical in-line overhead valve Battery Capacity 800 - 1000 Cold Cranking Amps (CCA) mechanism. DC Charging Altemator SO Amp rated, belt-driven Displacement 107.3 cubic inches (1.7S8 liter) - Page 59 SPECIFICATIONS • GENERATOR 12.5/9.4KW EDT AC GENERATOR (3 Phase) AC GENERATOR (Single Phase) Brushless, Six-pole, revolving field. Sealed Single Phase Brushless, four-pole, revolving field. Three Phase 12.5 KW • 60 HERR lubricated, single-bearing design. 12 Lead Pre-lubricated, single-bearing design. 9.4 KW • 50 HERR reconnectable for low voltage WYE, high Reconnectable, single-phase transformer voltage Delta.
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Page 60: Lay·up And Recommissioning
LAY-UP & RECOMMISSIONING GENERAL Fuel System [Gasoline] Top off your fuel tanks with unleaded gasoline of 89 octane Many owners rely on their boatyards to prepare their craft, including engines and generators, for lay-up during the or higher. A fuel conditioner such as gasoline STABIL off-season or for long periods of inactivity. - Page 61 Lay-up time provides a good opportunity to inspect your Lubrication and cleaning of the starter drive pinion is WESTERBEKE engine to see if external items such as drive advisable, if access to the starter pennits its easy removal. belts or coolant hoses need replacement. Check your basic...
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Page 62: Power Take·off
This horsepower can be utilized either for generator AC KIT #034786 for 12 stud BT units. output or to operate the power takeoff. KIT #037134 for 6 stud BT units. Contact your WESTERBEKE DEALER for additional infonnation. REMOVE COVER STUDS AND HARDWARE... -
Page 63: Raw Water Discharge Hose
./ WATER INJECTED /' EXHAUST ELBOW EXHAUST WHEN A SYPHON BREAK IS NOT REQUIRED WESTERBEKE recommends that the hose (installer supplied) discharging raw water from the heat exchanger to the water injected exhaust elbow be looped above and down to the inlet fiffing on the elbow. -
Page 64: Metric Conversion Data
STANDARD AND METRIC CONVERSION DATA LENGTH-DISTANCE Inches (in) x 25.4 Millimeters (mm) x .0394 Inches Feet (ft) x .305 Meters (m) x 3.281 Feet Miles x 1.609 Kilometers (km) x .0621 :: Miles VOLUME Cubic Centim~ters x Cubic Inches (in!) x 16.387 :: .061 Imperial Pints (IMP pt) x... -
Page 65: Suggested Spare Parts
SUGGESTED SPARE PARTS WESTERBEKE MARINE DIESEL GENERATORS CONTACT YOUR WESTERBEKE [)EALER FOR SUGGESTIONS AND ADDITIONAL INFORMATION WATER PUMP IMPELLER KIT HARDWARE KIT DRIVE BELTS WESTERBEKE RECOMMENDS CARRYING ENOUGH SPARE ENGINE OIL (YOUR BRAND) FOR AN OIL CHANGE (50TS.) AND A GALLON OF PREMIXED COOLANT. - Page 66 rWESTERBEKE Engines & Generators 112aWM DWII07 REVrSED JUNE 2008...