Westerbeke 8.0KW - 60Hz EDT User manual

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/ OPERATORS MANUAL··
D-NET DIESEL GENERATORS .
. SINGLE AND THREE PHASE ..... i '.
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8.0KW - 60Hz EDT - 12.5KW - 60Hz EDT
6.0KW - 50Hz EDT' 9.4KW - 50Hz EDT'
. 10.0KW - 60Hz EDT 12.6KW - 60Hz EDT
7 .5KW- 50Hz EDT 10.4KW • 50Hz~EDT
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11.5KW- 60Hz EDT . 15.0KW -60Hz EDT
! . 9.2KW -. 12.0K"\L·~ 50Hz EDT
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NO.053060 .
REVISION FOUR
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"V§ WESTERBEKE
member WESTERBEKE CORPORATION. MYLES STANDISH INDUSTRIAL PARK
~JrJlr 150 JOHN HANCOCK ROAD. TAUNTON, MA 02780·7319 U.S.A.
;;J!I!. TEL: [phone]· FAX: [phone]· WEBSITE: www.WESTER8EKE.COM
.-
,

CALIFORNIA
PROPOSITION 65 WARNING
Diesel engineexhaust and some
of its constituents are known to
the State of Californiato cause
cancer, birth defects, and other
reproductive harm. .
A WARNING:
Exhaust gasses contain Carbon Monoxide, an odorless and
colorless gas. Carbon Monoxide Is poisonous and can,cause
unconsciousness and death. Symptoms of Carbon MonoxIde
exposure can Include:
- DIzziness
-Nausea
-Headache
- Throbbing in Temples
- Muscular Twitching
- Vomiting
- Weakness and Slfleplness -Inability to Think CoheTl/ntly
IF YOU OR ANYONE ELSE EXPERIENCE ANY OF THESE SYMPTOMS,
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.
This WARNING DECAL is provided by
WESTERBEKE and should be fixed to a
bulkhead near your engine or generator.
WESTERBEKEalso recommends installing
CARBON MONOXIDE DETECTORS in the
living/sleepIng quarten; of your vessel.
They aTl/inexpenslve and easily
obtainable at your local marine stOTl/.

SAFETY INSTRUCTIONS
INTRODUCTION
Read this safety manual carefully. Most accidents are
caused by failure to follow fundamental rules andprecau·
tions. Know when dangerous conditions existand take the
necessary precautions to protect yo,:,rse/f, your personne4
and your machinery.
The following safety instructions are in compliance with
the American Boat and Yacht Council (ABYC) standards.
PREVENT ELECTRIC SHOCK
A WARNING: Do not touch AC electrical connections
while engine is runnIng, or when connected to shore
power. Lethal voltage is present at these connections!
• Do not operate this machinery without electrical
enclosures and covers in place.
• Shut off electrical power before accessing electrical
equipment.
• Use insulated mats whenever working on electrical
equipment.
• Make sure your clothing and skin are dry, not damp
(particularly shoes) when handling electrical equipment.
• Remove wristwatch and all jewelry when working on
electrical equipment.
• Do not connect utility shore power to vessel's AC
circuits, except through a ship-to-shore double throw
transfer switch. Damage to vessel's AC generator may
result if this procedure is not followed.
• Electrical shock results from handling a charged capaci-
tor. Discharge capacitor by shorting terminals together.
PREVENT BURNS - HOT ENGINE
A WARNING: Do not touch hot engine parts or
exhanst system components. A running engine gets
very hot!
• Always check the engine coolant level at the coolant
recovery tank.
A WARNING: Steam can cause inj~~ or death!
• In case of an engine overheat, allow the engine to cool
before touching the engine or checking the coolant.
PREVENT BURNS - FIRE
A WARNING: Fire can cause injury or death!
• Prevent flash fires. Do not smoke or permit flames or
sparks to occur near the carburetor, fuel line, filter, fuel
pump, or other potential sources of spilled fuel or fuel
vapors. Use a suitable container to catch all fuel when
removing the fuel line, carburetor, or fuel filters.
• Do not operate with a Coast Guard Approved flame
arrester removed. Backfire can cause severe injury or
death.
• Do not operate with the air cleaner/silencer removed.
Backiire can cause severe injury or death.
• Do not smoke or permit flames or sparks to occur near
the fuel system. Keep the compartment and the
engine/generator clean and free of debris to minintize the
chances of fire. Wipe up all spilled fuel and engine oil.
• Be aware -diesel fuel will burn.
PREVENT BURNS - EXPLOSION
A WARNING: Explosions from fuel vapors can cause
injury or death!
• Follow re-fueling safety instructions. Keep the vessel's
hatches closed when fueling. Open and ventilate cabin
after fueling. Check below for fumes/vapor before run-
ning the blower. Run the blower for four ntinutes before
starting your engine.
• All fuel vapors are highly explosive. Use extreme care
when handling and storing fuels. Store fuel in a well-ven-
tilated area away from spark-producing equipment and
out of the reach of children.
• Do not fill the fuel tank(s) while the engine is running.
• Shut off the fuel service valve at the engine when serviciitg
the fuel system. Take care in catching any fuel that ntight
spill. DO NOT allow any smoking, open flames, or other
sources of fire near the fuel system or engine when servic-
ing. Ensure proper ventilation exists when servicing the
fuel system.
• Do not alter or modify the fuel system.
• Be sure all fuel supplies have a positive shutoff valve.
• Be certain fuel line fittings are adequately tightened and
free of leaks.
• Make sure a fire extinguisher is installed nearby and is
properly maintained. Be familiar with its proper use.
Extinguishers rated ABC by the NFPA are appropriate
for all applications encountered in this enviroinnent. .
-.v: WESTERBEKE
Engines & Generators
i

SAFETY INSTRUCTIONS
ACCIDENTAL STARTING
A WARNING: Accidental starting can cause injury
Dr death!
• Disconnect the battery cables before servicing the engine!
generator. Remove the negative lead first and reconnect
it
last.
• . Make certain all personnel are clear of the engine before
starting.
• Make certain all covers, guards, and hatches are re-
installed before starting the engine.
BATTERY EXPLOSION
A WARNING: Battery explosion can cause Injury
Dr death!
• Do not smoke or allow an open flame near the battery
being serviced. Lead acid batteries entit hydrogen, a
highly explosive gas, which can be ignited by electrical
arcing or by lit tobacco products. Shut off all electrical
equipment in the vicinity to prevent electrical arcing dur-
ing servicing.
• Never connect the negative (-) battery cable to the posi-
tive (+) connection terntinal of the starter solenoid. Do
not test the battery condition by shorting the terntinals
together. Sparks could ignite battery gases or fuel vapors.
Ventilate any compartment containing batteries to prevent
. accumulation of explosive gases. To avoid sparks, do not
disturb the battery charger connections while the battery
is being charged.
• Avoid contacting the terminals with tools, etc., to prevent
bums or sparks that could cause an explosion. Remove
wristwatch, rings, and any other jewelry before handling
the battery.
• Always tum the battery charger off before disconnecting
the battery connections. Remove the negative lead first
and reconnect it last when disconnecting the battery.
BATTERY ACID
A WARNING: SulfuriC acid In batteries can cause
severe injury Dr death!
• When servicing the battery or checking the electrolyte
level, wear rubber gloves, arubber apron, and eye protec-
tion. BatterIeS contain sulfuric acid which is destructive.
If it comes in contact with your skin, wash it off at once
with water. Acid may splash on the skin or into the eyes
inadvertently when removing electrolyte caps.
TOXIC EXHAUST GASES
A WARNING: Carbon monoxide (CO) Is a deadly gas!
• Ensure that the exhaust system is adequate to expel gases .
discharged from the engine. Check the exhaust system
regularly for leaks and make sure the exhaust manifolds
are securely attached and no warping exists. Pay close
attention to the manifold, water injection elbow, and
exhaust pipe nipple.
• Be sure the unit and its surroundings are well ventilated.
• In addition to routine inspection of the exhaust system,
install a carbon monoxide detector. Consult your boat
builder or dealer for installation of approved detectors.
• For additional information refer to ABYC T-22 (educa-
tional information on Carbon Monoxide).
A WARNING: Carbon monoxide (CO) is an invisible
odorless gas. Inhalation produces flu-like symptoms,
nausea or death!
• Do not use copper tubing in diesel exhaust systems. Diesel
fumes can rapidly destroy copper tubing in exhaust sys-
tems. Exhaust sulfur causes rapid deterioration ofcopper
tubing resulting in exhaust/water leakage.
• Do not install exhaust outlet where exhaust can be drawn
through portholes, vents, or air conditioners. Ifthe engine
exhaust discharge outlet is near the waterline, water could
enter the exhaust discharge outlet and close or restrict the
flow of exhaust. Avoid overloading the craft.
• Although diesel engine exhaust gases are not as toxic as
exhaust fumes from gasoline engines, carbon monoxide
gas is present in diesel exhaust fumes. Some of the symp-
tOllis or signs of carbon monoxide inhalation or poisoning
are:
Vontiting
Dizziness
Throbbing in temples
Muscular twitching
Intense headache
Weakuess and sleepiness
AVOID MOVING PARTS
A WARNING: Rotating parts can cause injury
Dr death!
• Do not service the engine while it is running. If a situa-
tion arises in which it is absolutely necessary to make.
operating adjustments, use extreme care to avoid touch-
ing moving parts and hot exhaust system components.
~ WESTERBEKE
Engines & Generators
ii

SAFETY INSTRUCTIONS
• Do not wear loose ~Iothing or jewelry when servicing
equipment; tie back long hair and avoid wearing loose
jackets, shirts, ,sleeves, rings, necklaces or bracelets that
could be caught in moving parts.
• Make sure all attaching hardware is properly tightened.
Keep protective shields and guards in their respective
places at all times.
• Do not check fluid levels or the drive belt's tension while
the engine is operating.
• Stay clear ofthe drive shaft and the transmission coupling
when the engine is running; hair and clothing can easily
be caught in these rotating parts.
HAZARDOUS NOISE
A WARNING: High noise levels can cause hearing
loss!
• Never operate an engine without its muffler installed.
• Do not run an engine with the air intake (silencer)
removed.
• Do not run engines for long periods with their enclosures
open.
A WARNING: Do not work on machinery when you are
mentally or physically Incapacitated by fatigue!
OPERATORS MANUAL
Many ofthe precedingsafety tips and warnings are repeated
in your Operators Manual along with other cautions and
notes to highlight critical information. Read your manual
carefully, maintain your equipment, and follow all safety
procedures.
ENGINE INSTALLATIONS
Preparations to instail an engine should begin with a thor-
ough examination of the American Boat and Yacht Council's
(ABYC) standards. These standards are a combination of
·sources including the USCG and the NFPA.
Sections of the ABYC standards ofparticular interest are:
H-2 Ventilation
P-l Exhaust systems
P-4 Inboard engines
E-9 DC Electrical systems
All installations must comply with the Federal Code of
Regulations (FCR).
ABYC, NFPA AND USCG PUBLICATIONS FOR
INSTALLING DIESEL ENGINES
Read the following ABYC, NFPA and USCG pUblications
for safety codes and standards. Follow their recommenda-
tions when installing your engine.
ABYC (American Boat and Yacht Council)
"Safety Standards for Small Craft"
Order from:
ABYC
15 East 26th Street
New York, NY 10010
NFPA (National Fire Protection Association)
"Fire Protection Standard for Motor Craft"
Order from:
National Fire Protection Association
11 Tracy Drive
Avon Industrial Park
Avon, MA 02322
USCG (United States Coast Guard)
"USCG 33CFR183"
Order from:
U.S. Government Printing Office
Washingt?n, D.C. 20404
Engines & Generators
iii

INSTALLATION
When installing WES1ERBEKE 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.
SIPHON-BREAK
For installations where the exhaust manifold/water injected exhaust elbow is close to
or will be below the vessel's waterline, provisions must be made to install a siphon-
break in the raw water supply hose to the exhaust elbow. This hose must be looped.a
ntinirnum of 20" above the vessel's waterline. Failure to use a siphon-break when
the exhaustmanifold injection port is at or below the load waterline will result in
raw water damage to the engine and possible flooding of the boat.
If you have any doubt about the position of the water-injected exhaust elbow relative
to the vessel's waterline under the vessel's various operating conditions} install a
siphon-break.
NOTE: A siphon-break requires periodic inspection and cleaning to ensure proper
operation. Failure to properly maintain a siphon-break can result in catastrophic
engine damage. Consult the siphon-break manufacturer for proper maintenance.
EXHAUST SYSTEM
The.exhaust hose must be certified for marine use. The system must be designed to
prevent water from entering the exhaust under any sea conditions and at any angle
of the vessels hull.
A detailed Marine Installation Manual covering gasoline and diesel
engines and generatolS is supplied with every unit sold. This manual
.is also available in pdf format on our website to download
Website: www.westerbeke.com
· "~IWESTERBEKE
.I Enoines & Generators
iv
AVAILABLE FROM
YOUR WESTERBEKE
OEALER

TABLE OF CONTENTS
Parts Identification .................................................... 2
Fuel Injection limingl .............................................. 28
Introduction ............................................................... .3 Preparation.............................................................28
Warranty Procedures ...............................................3
Serial Number Location ..........................................4 Inspection ............................................................
,,28
Adjustment .............................:..............................28
Fuel, Engine 011, and Engine Coolant.. ...................... 5
Glow Plugs ................................................................ 29
Digital Control Panel .................................................. 6
Starter Motor ............................................................ 30
LCD Sequence......................................................6A
Internal Components ...............................................7 Emergency Start....................................................31
Service.................................................................. .31
Remote Stop/Start Panel..........................................8
Alternator Testing .................................................. ... 32
Preparations for Initial Start-Up ................................ 9 Voltage Regulator....:.............................................32
Pre-Start Inspection .................................................9
Generator Voltage....................................................9 Checking the Service Battery................................34
Battery Care...........................................................34
Generator Break-In Procedure ................................. 10
Wiring Diagrams
Daily Operation ......................................................... 19
Safety Shutdown Switches ............................ : .......... 10
Higb Exhaust Temperature Switch........................ 11
DC Circuit Breaker....:........................................... 11
Oil Pressure Sensor................................................ 11
Coolant Temperature Sensor ............................:.... 11
Break-In Procedure/Daily Operation ..................... l1A
Maintenance Schedule ............................................ .12
Cooling System ......................................................... 14
Changing Coolant..................................................14
Thermostat.............................................................15
#54193 ...................................................................35
#54655 -24
V......................................................35A
#53477 -24
V......................................................35B
#54628 ................................................................35C
#54680 -24V......................................................35D
#52793 ...................................................................36
Generator Information ........................................... ... 37
BT Generator ........................................................... .. 38
Six and Twelve Stud lIIustrations ............................. 38
BT Generator/Single Phase (6 Stud) ...............".......39
Internal Wiring Diagram ............................ ............... 39
Raw Water Cooling Pump............................
,........ 15 Generator Voltage Adjustment.. ...... ........................ .40
Changing the Raw Water Impeller........................16 Six Stud Voltage Connections ...............................40
Heat Exchanger .....................................................16 Twelve Stud Voltage Adjustment .......................40A
Air Intake/Silencer .................................................... 17
No-Load Voltage Adjustment............................ :.',,41
Fuel System .......... .................................................... 18
Fuel LiftlWater Separator......................................18
Fuel Lift Pump ......................................................
18
Fuel Lift Pump Filter.............................................18
Full
Load Voltage Adjustment...............................41
AVR -Six Stud......................................................42
BT Generator Single Phase .. ,................................ 42
Shore Power Connections ........................................ 42
Fuel Filter ..............................................................18
BT Generator AVR (Three Phase) .............................43
Engine Lubricating Oil .................. ............................ 19
Internal Wiring Diagram .......................................... .44
Engine Oil Change................................................19
Regulator Sensing Three Phase .............................. .45
Oil Pressure ............................................................. .20
Internal Wiring Diagram (12 Stud)...........................46
Testing Oil Pressure...............................................
20
Remote Oil Filter ...................................................... 21
Engine Troubleshooting (Chart) ...............................22
BT Generator Troubleshooting Chart ...................... .47
Specifications (3 Cylinder Engine) .........................48
8.0/B.OKw - 10.0/7 .5Kw ............................ ................ 49
LCD Display Faults .................................................... 23
11.5/9.2Kw - 12.B/1 0.4Kw ........................................ 50
Engine Adjustments .................................................. 24
Drive BeltAdjustmen............................................ 24
Electronic Governor ..............................................24
Valve Clearance.....................................................
25
Specifications (4 Cylinder Engine) .........................51
12.5/9.4Kw - 15.0/12.0Kw ........................................ 52
,Lay-Up and RecommiSSioning .................................. 53
Testing Engine Compression.................................26
Power Take-Off ............................................. ............ 55
.Fuel Injecto~s ... "- .. "- ...,., .. "...................................... ,29
Raw Water Discharge Hose ........................ , ............. 56
Fuel Injectors ·· .................. : ................ , ............................. 27 Water Heater ................................................ ............ .57
Injector Testing:.....................................................28 Metric Conversion Data ................ : .......... ................. 58
Spray Pattern ..........................................................28 Suggested Spare Parts ............................................. 59
~ WESTERBEKE
EngInes & Generators
1

OIL
DC ALTEIINAT~IR--':'__ ,
DlL DRAIN
RAW WATER PUMP ___ .,
HEAT
CONTROL
PANEL
PREHEAT
20A DC CIRCUIT BRE/\KE~:---r~Q
AC
BREAKER OIL
PARTS IDENTIFICATION
EDT GENERATOR
LEFT SIDE
RIGHT SIDE
I.O.PLATE
~A:I-+--·EXH.AUST ELBOW
iM'~------I--I---""';SlrART SOLENOID
GENERATOR
BACKEND
-'OT'.OTtO MOTOR
MANIFOLD PRESSURE CAP
REAR
FILL
THERMOSTAT
ASSEMBLY
AIR INTAKE
SILENCER & FILTER
ENGINE BLOCK DRAIN PLUG
OIL DRAIN HOSE .
FRONT
REAR
MOUNT·
I
FUEL FILTER
~ WESTERBEKE
Engines & Generators
2

INTRODUCTION
This WESTERBEKE Diesel Generator is a product of
WESTERBEKE's long years of experience and advanced
technology. We take great pride in the superior durability and
dependable perfonnance of our engines and generators.
Thank you for selecting WESTERBEKE.
In order to get the full use and benefit from your generator it
is
important tbat you operate and maintain it correctly. This
manual is designed to help you do this. Please read this
manual carefully and observe all the safety precautions
throughout. Should your generator require servicing, contact
your
nearest WESTERBEKE dealer for assistance.
This is your operators manual. A parts catalog is also
provided and a technical manual is available from your
WESTERBEKE dealer. If you are planning to install this
equipment contact your WESTERBEKE dealer for
WESTERBEKE'S installation manual.
WARRANTY PROCEDURES
Your WESTERBEKE Warranty is included in a separate
folder. If, after 60 days of submitting the Warranty Registry
fonn you have not received a customer identification. card
registering
your warranty, please contact the factory In
writing with model infonnation, including the unit's serial
. number and commission date.
Customer Identification Card
,...".."WESTERBEKE
j Engines & Generators
Customer Identification
MR. GENERATOR OWNER
MAIN STREET
HOMETOWN, USA
Model
Expires Ser.#
PRODUCT SOFTWARE
product software, (tech data, parts lists, manuals,
brochures and catalogs), provided from sources other than
WESTERBEKE are not within WESTERBEKE's control.
WESTERBEKE CANNOT BE RESPONSIBLE FOR THE
CONTENT OF SUCH SOFTWARE, MAKES NO WAR-
RANTIES OR REPRESENTATIONS WITH RESPECT
THERETO, INCLUDING ACCURACY, TIMEliNESS OR
COMPLETENESS THEREOF AND WILL INNO EVENT
BE UABLE FOR ANY TYPE OF DAMAGE OR INJURY
INCURRED IN CONNECTION WITH OR ARISING OUT
OF THE FURNISHING OR USE OF SUCH SOFTWARE.
WESTERBEKE customers should also keep in mind the
time span between printings of WESTERBEKE product
software and the unavoidable existence ofearlier
WESTERBEKE manuals. In summation, product software
provided with WESTERBEKE products, whether from
WESTERBEKE or other suppliers, must not and cannot
be relied upon exclusively as the definitive authority on
the respective product. It not only makes good sense
but is imperative that appropriate representatives of
WESTERBEKE or the supplier in question be consulted
to determine the accuracy and currentness ofthe
product software being consulted by the customer.
NOTES, CAUTIONS AND WARNINGS
As this manual takes you through the operating procedures,
maintenance schedules, and troubleshooting of your marine
engine, critical infonnation will be highlighted by NOTES,
CAUTIONS, and WARNINGS. An explanation follows:
NOTE: An operating procedure essential to note.
A CAUTION: Procedures, which If no.' strictly
obseflled, can result in the damage or destruction of
your engine.
A WARNING: Procedures, which If not properly fol·
lowed, can result in personal Injury or loss of life.
Engines & Generators
3
•

INTRODUCTION
SERIAL NUMBER LOCATION
. The units's model number and serial number are located on a
nameplate that is mounred on the side of the engine's water
jacketed exhaust manifold. The engine's serial number can
also be found stamped into the engine block on the flat
surface of the blockjust above the manual shut-off lever.
Please take the time to enter this information on the
ill\!~tration of the nameplate below. This information will
proVide a quick reference when seeking technical /
information and/or ordering spares/repair parts. Jl:n
An identification ptate on the engine manifold also displays
the engine model and seLial number.
CARBON MONOXIDE DETECTOR
WESTERBEKE recommends mounting a carbon monoxide
detector in the vessels living quarters. Carbonmonoxide,
even illsmall amounts, is deadly.
The
presence of carbon monoxide indicated an exhaust leak
from the engine or generator or from the exhaust
elbow/exhaust hose, or the fumes from a nearby vessel are
entering your boat.
If carbon monoxide is present, ventilate the area with clean
air and correct the problem inunediately!
NOTE: A carbon monoxide warning decallws been provided
by WESTERBEKE. Affix this decal in a visible position in the
engine room.
UNDERSTANDING THE DIESEL ENGINE
The diesel engine closely resembles the gasoline engine,
since the mechanism is essentially the same. The cylinders
are arranged above a closed crankcase; the crankshaft is of
the same general type as that of a gasoline engine; and the
diesel engine has the same type of valves, camshaft, pistons,
connecting rods and lubricating system.
Therefore, to a greatextent, a diesel engine requires the
same preventive maintenance as a gasoline engine. The
most important factors are proper ventilation and proper
maintenance of the fuel, lubricating and cooling systems.
Replacement of fuel and lubricating filter elements at the
time periods specified is a must, and frequent checking for
contamination (that is, water, sediment, etc.) in the fuel
system is also essential. Another important factor is the use
of
the same brand ofhigh detergent diesel lubrication oil
designed specifically for diesel engines.
The diesel engine does differ from the gasoline engine,
however, in its method of handling and firing of fuel. The
carburetor and ignition systems are done away with and in
their place is asingle component- the fuel injection pump
which performs the function of both.
ORDERING PART$-
Whenever replacement/service parts are needed, always
provide the generator model number, engine serial number,
and generator serial number as they appear on the silver and
black name plate located on the generator end. You must
provide us with this information so we may properly identify
your generator set In addition, include a complete part
description and part number for each part needed (see the
separately furnished Parts List). Also insist upon
WESTERBEKE packaged parts because will fit or generic
parts are frequently not made to the same specifications as
original equipment.
SPARES AND ACCESSORIES
Certain spares will be needed to support and maintain your
WESTERBEKE generator. Your local WESTERBEKE
dealer will assist you in preparing an inventory ofspare parts.
See the SPARE PARTS page in this manual. For Engine and
Generator AccessoLies, see the ACCESSORIES brochure.
INSTALLAtiON. MANUAL
Publication #43400 provides detailed information for
installing generators.
EngInes & Generators
4