II' c., o Ii L D ~.' q OWNERS MANUAL 8.0 KW BCDT 60Hz 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 .... < .
CALIFORNIA PROPOSITION 65 WARNING Exhaust gas from diesel and gasoline engines (and some of its constituents) are known to the State of California to cause cancer, birth defects, and other reproductive harm. AWARNING: Exhaust gasses contain Carbon Monoxide, an odorless and colorless gas. Carbon Monoxide is poisonous and can cause unconsciousness and death.
SAFETY INSTRUCTIONS INTRODUCTION PREVENT BURNS - FIRE Read this safety manual carefully. Most accidents are caused by failure to follow fundamental rules and precautions. Know when dangerous conditions exist and take the necessary precautions to protect yourself, your personne~ and your machinery. The following safety instructions are in compliance with the American Boat and Yacht Council (ABYC) standards.
SAFETY INSTRUCTIONS ACCIDENTAL STARTING TOXIC EXHAUST GASES A WARNING: Accidental starling can cause injury A WARNING: Carbon monoxide (CO) is a deadly gas! or death! • 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 manifold! water-injected elbow is securely attached. • Be sure the unit and its surroundings are well ventilated. Run blowers when running the generator set or engine.
SAFETY INSTRUCTIONS • • 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.
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.
TABLE OF CONTENTS Parts Identification .....................................................................................2 Introduction ..................................................................................................3 Warranty Procedures .......................................................................... .3 Serial Number Location ...................................................................... 3 Installation ..................................................................
PARTS IDENTIFICATION .CONTROL BOX AIR INTAKE FILTER ~ THERMOSTAT HOUSING INTERNAL COOLANT PUMP DRIVE BELT VIBRATION MOUNTS~ OIL FILL I COOLANT FILL THERMOSTAT /HOUSING PREHEAT SOLENOID~ ZINC---' EXHAUST ~AIR INTAKE FILTER MAN\FOlD~""" .:;ft-'''\'I''---r''--:l7'''H'~I----'-FUEL CONTROL BOX· LIFT PUMP SIDE OIL FILL t']'l/~%TI:_RAW WATER PUMP • OIL FILTER EXHAUS.
INTRODUCTION This WESTERBEKE marine generator is a product of WESTERBEKE'S many years of experience and advanced technology. We take great pride in the superior durability and dependable performance of our engines and generators. Thank you for selecting WESTERBEKE. This owner's manual contains infonnation and instructions for the installation, operation, maintenance and service of your generator. For additional installation information.
INTRODUCTION . Generator Serial Number SPARES AND ACCESSORIES Certain spare parts will be needed to support and maintain your Westerbeke generator when cruising (see SUGGESTED SPARE PARTS). Often even a simple item such as a proper fuel filter can be difficult to obtain along the way. The generator model number and specifications are located on a decal on the generator housing. SPECIFICATION ~ MODEL _______ _ RPM __________ _ KW ___________ _ .
INSTALLATION I The following installation instructions cover the Westerbeke 8 Kw Diesel Generator. Additional general information may be found in Westerbeke's INSTALLATION MANUALfor MARINE ENGINES and GENERATORS, Publication #43268. The following factors should be considered when planning the installation of your Westerbeke 8 Kw generator: SPECIAL FUEL RETURN ..i 1/4" HOSE-MALE BARB " SUPPLIED 1. Size and weight of the generator. i SPECIAL FUEl. SUPPLY. 2. Location and mounting surface.
INSTALLATION LOCATION AND MOUNTING VENTILATION A solid, level mounting platform is very important for the proper operation of your generator. Select a location that will allow adequate space on all sides for ventilation and servicing. Locate the generator away from living quarters, and away from bilge splash and vapors. The mounting platform may be of wood, metal or fiberglass. It must be horizontal and should be as small as possible to minimize vibrations.
INSTALLATION EXHAUST SYSTEM For more information about exhaust system design, see Westerbeke's INSTALLATION MANUALfor MARINE ENGINES and GENERATORS, Publication # 43268. It is important to install a proper exhaust system to avoid engine flooding. The system must be designed to prevent water from entering the exhaust line under any sea conditions and at any angle of the vessel's hull. Exhaust system failures are not covered by Westerbeke's warranty.
INSTALLATION RAW WATER COOLING SYSTEM Raw Water Intake Siphon-Break A flush-type through-hull fitting is recommended for the raw water intake. It should be located on the boat's hull where it will be below the waterline during all angles of the boat's operation. See Westerbeke's INSTALLATION MANUAL for MARINE ENGINES and GENERATORS for complete installation guidelines.
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. Refer to the following illustration for control panel dimensions. 5-5/8" (142.9 mm) \ 1-15/16" (49.2 mm) 213116" (11.4 mm) 1 I" 'I . J L M. "~0""-t..T.... DDD~- 3-11 1 o I. .
CONTROL PANEL The oil pressure/coolant temperature warning light (red) lights up when either the oil pressure is too low or the engine is overheated. The engine will shut down if it overheats or there is an oil pressure failure. DESCRIPTION This plug-in remote control panel provides the operator with all the necessary information and controls to use the generator. The panel has START and STOP buttons, an LED proportional load indicator, and coolant and oil pressure warning lights.
FUEL, ENGINE OIL AND ENGINE COOLANT DIESEL FUEL ENGINE COOLANT Use fuel that meets the requirements or specifications of Class 2-D (ASTM), and has a cetane rating of #45 or better. Westerbeke recommends a mixture of 50% antifreeze and 50% distilled water. Distilled water is free from the chemicals that can corrode internal engine surfaces.
PREPARATIONS FOR INITIAL START-UP PRESTART INSPECTION Before starting your generator for the first time or after a prolonged layoff, check the following items: • Check the engine oil level: add oil to maintain the level at the full mark on the dipstick. • Check the fuel supply and examine the fuel filter/separator bowls for contaminants. MANIFOLD PRESSURE CAP • Check the DC electrical system. Inspect wire connections and battery cable connections.
STARTING/STOPPING PROCEDURE OPERATING THE GENERATOR ELECTRIC START After the generator has started, run it with a medium load for warmup. Ifpossible, apply the load in stages. A CAUTION: All AC loads must be switched off before starting. This precaution will prevent damage caused by unanticipated operation of AC machinery and will prevent a cold engine from stalling.
BREAK-IN PROCEDURE/DAILY OPERATION NOTE: Some unstable running may occur in a cold engine. BREAK-IN PROCEDURE After the generator has been started, check for proper operation and then encourage a fast wann-up. Run the generator between 20% to 60% of full load for the fIrst 10 hours. This condition should abate as normal operating temperature is reached and loads are applied. A CAUTION: 00 not operate the generator for long periods of time without a load being placed on the generator.
SAFETY SHUTDOWN SWITCHES SAFETY SHUTDOWN SWITCHES Low Oil Pressure Switch The generator is protected by three automatic shutdown switches. Should shutdown occur, do not attempt to restart without finding and correcting the cause. Refer to the ENGINE TROUBLESHOOTING section of this manual. A low oil pressure shutdown switch is located off the engine's oil gallery. Normally open in a static state, this switch's sensor monitors the engine's oil pressure.
MAINTENANCE SCHEDULE In order to use this Maintenance Schedule, it will be necessary to log your engine hours. Use your engine hourmeter or record your engine hours by running time. A WARNING: Never attempt to perform any service while the generator 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.
MAINTENANCE SCHEDULE FREQUENCY COMPONENT Valve clearances' AFTER FIRST 50 HRS DAILY OR EVERY 8 HOURS WEEKLY EVERY 100 HOURS • • • • Cylinder compression Cylinder head bolts • • Visual inspection Hardware fastenings and electrical connections Generator connections EVERY 2100 HOURS MAINTENANCE Adjust the valve clearances; (see ENGINE ADJUSTMENTS}. Check the compression pressure (see ENGINE ADJUSTMENTS}. Retorque the bolts (see TIGHTENING THE CYLINDER HEAD under ENGINE ADJUSTMENTS.
COOLING SYSTEM DESCRIPTION Drain the engine coolant by loosening the drain plug on the engine block and opening the manifold pressure cap. Flush , the system with fresh water, then start the refill process. Westerbeke marine diesel engines are designed and equipped for fresh water cooling. Heat produced in the engine by combustion and friction is transferred to fresh water coolant which circulates throughout the engine.
COOLING SYSTEM NOTE: Periodically check the condition of the manifold pressure cap. Ensure that the upper and lower rubber seals are in good condition and check that the vacuum valve opens and closes tightly. Carry a spare <:ap. COOLANT TEMPERATURE SWITCH The coolant temperature switch is located near the thermostat housing (see illustration).
COOLING SYSTEM RAW WATER PUMP RAW WATER INTAKE STRAINER The raw water pump is a self-piiming, rotary pump with a non-ferrous housing and a neoprene impeller. The impeller has flexible vanes which wipe against a curved cam plate within the impeller housing, producing the pumping action. On no account should this pump be run dry as water acts as a lubricant for the impeller. There should always be a spare impeller and impeller cover gasket (an impeller kit) onboard.
COOLING SYSTEM Zinc Anode Heat Exchanger Service A zinc anode, or pencil, is located in the raw water cooling circuit within the heat exchanger. The purpose of having zinc anodes is to sacrifice them to electrolysis action taking place in the raw water cooling circuit, thereby reducing the effects of electrolysis on other components of the system. The condition of the zinc anode should be checked monthly and the anode cleaned or replaced as required. Spare anodes should be carried on board .
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 I SPIN ON OIL securely. PN#36918 NOTE: Thread size for the lube oil drain hose capped end is II4NFT. Always observe the used oil as it is removed.
FUEL SYSTEM DIESEL FUEL FUEL FILTERS Use No.2 diesel fuel with a cetane rating of 45 or higher. Do not use kerosene or home heating fuel. The fuel injection pump and the fuel injectors are precisely manufactured and they must receive clean diesel fuel, free from water and dirt. To ensure this flow of clean fuel, the fuel must pass through at least two fuel filters, a fuel filter/water separator and the engine's spin-on fuel filter.
GLOW PLUGS DESCRIPTION The glow plugs are wired through the preheat solenoid. When the START button is pressed at the control panel this solenoid should "click" on and the glow plugs should begin to get hot. Re-install the plugs in the engine and test them again. The plugs should get very hot (at the terminal end) within 20 to 25 seconds. If the plugs don't heat up quickly, check for a short circuit. When reinstalling the glow plugs, use anti-seize compound on the threads.
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 to reach the starter motor. At the same time, the plunger also serves to push that starter pinion to mesh with the teeth on the flywheel.
STARTER MOTOR SERVICE Westerbeke uses a standard marine starter motor which can be serviced or rebuilt at any starter motor automotive service center. If replacing the starter motor, make certain the new motor is certified for marine use. Automotive starters do not meet USCG standards. If in dO)lbt, contact your WESTERBEKE dealer. \(+) POSITIVE ~.-\\ TERMINAL ~"------1: (M) TERMINAL TO REMOVE FOR SERVICE IGNITION TERMINAL TO CONTROL PANEL 1. Disconnect the negative battery cable. . 2.
8 KW BCOT CONTROL BOX TERMINAL BOARD K1 RELAY REDIWHITE TO TB·3 ~ K3 RELAY /,RESET BUTTON FUSE ,PROTECTS THE BATTERY 'CHARGER AGAINST EXCESSIVE CURRENT ~20A K2 RELAY 'COOLlN,~G i m~ AIR ,BATTERY CHARGER (INTEGRAL CONTROLLER) iBRIDGE • RECTIFIER CAPACITOR , CURRENT TRANSFORMER" 230V 50Hz 120V 60Hz 120/240V 60Hz NOTE: Ll (lnd L2 lW,.t pll ....
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 electrical system on the engine. BLACK (-) A CAUTION: To avoid damage to the battery charging circuit, never shut off the engine battery switch while the engine is running.
8 KW BCDT WIRING DIAGRAM \ #41990 .12 VEL/RED WHi BlK o ..J FUEL SOlENel D ~1J-f'fl l'1I';'l ~ ~ BATTERY SWITCH 1_ ~;: - - - - - - - - _1:_:..:_:_:.:_.:_:..:_;t~~===~·!l12l...!!!REc!lO_-, i ; : -~;~oc ~ .. \~ ~-~ L-+~~~~_-...l > ~ 114 REO/VIO STARTER MOTOR """lOW I~ ~;;u ~'plo-~i-!---*--..!lJL.!!l.b.b!!!!""-+---, 1---t=l:::::j=t;~..tJ'I IC3 181 ~ /....!l---!•.::I.~VI~O:..... • ® .... -~ 4---=:::~ CURRENT ~~~~~~I~m~ i1Q I -- BRIDGE ECTlfIER - ZJ!A...I!!ll. 1S*=__-..!JIIW!6..
8 KW BCOT WIRING SCHEMATIC #41990 BATTERY 12 voc C I RCUI T BREAKER r -____~~r~-~d~~--~ I ___ J __~------o_--_r~ BlA K3-PREHEAT 30 T81-3 K2-RUN RELAY r -________*-__________________~~--------------~86~ 85 KI-START 86 K3~PREHEAT RELAY 85 r -______~8~6~ ~,.:..:: - ~ GENERATOR OIL PRESS. L~.:':!'..I~CO."ECTOR SWITCH eN/C. CIRCUIT BRUMEI ..• RED ,. , BROWN GREY GREEN BLACK OILIT[NP GROUND S 2. fUEL START ,. YEllOW BATTERY. GLOW G WHITE 3• LOAD 0 0 ) 0 9 2. 2 -.f.
ENGINE ADJUSTMENTS NOTE: WESTERBEKE recommends that the following engine adjustments be performed by a competent engine mechanic. The i"riformation below is provided to assist the mechanic. GENERATOR FREQUENCY ADJUSTMENT (HERTZ) FUEL RUN SOLENOID Once the diesel generator set has been placed in operation, there may be adjustments required for engine speed (Hertz) during the engine's break-in period (first 50 hours) or after this period.
ENGINE ADJUSTMENTS NOTE: WESTERBEKE recommends that the following engine adjustments be peiformed by a competent engine mechanic. The information below is provided to assist the mechanic. DRIVE BELT ADJUSTMENT TORQUING THE CYLINDER HEAD BOLTS Excessive drive belt tension can cause rapid wear of the belt . and reduce the service life of the fresh water pump's bearing. A slack belt or the presence of oil on the belt can cause belt slipping, resulting in high operating temperatures.
ENGINE ADJUSTMENTS NOTE: WESTERBEKE recommends that the following engine adjustments be performed by a competent engine mechanic. The information below is provided to assist the mechanic. Injection Pump Timing Adjustment (Spill Timing) If your engine's fuel injection timing is not properly adjusted, the engine will not operate properly, and may be difficlllt to start. Have the injection pump delivery rate checked by a well-established fuel injection shop.
ENGINE ADJUSTMENTS NOTE: WESTERBEKE recommends that the following engine adjustments be peiformed by a competent engine mechanic. The information below is provided to assist the mechanic. VALVE CLEARANCE ADJUSTMENT NOTE: Retorque the cylinder head bolts before adjusting the engine's valves. See TORQUING TIlE CYLINDER HEAD BOLTS. Re-install the glow plugs (use anti-seize compound on the threads) and assemble the rocker cover and rocker cover belts. See the TIGHTENING TORQUE SCHEDULE in this manual.
ENGINE TROUBLESHOOTING Note: The engine s electrical system is protected by a 20 amp The following troubleshooting table describes certain problems relating to engine service, the probable causes of these problems. and the recommendations to overcome these problems. Problem Start switch depressed, no start, no panel indications. manual reset circuit breaker located on a bracket at the rear of the engine. Probable Cause Verification/Remedy 1. Battery Switch not on. 1.
ENGINE TROUBLESHOOTING Problem Generator engine overheats/shuts down. Generator engine shuts down, Low oil pressure. Exhaust smoking problems Probable Cause VerificationJRemedy 1. Raw water not circulating. 2. Coolant not circulating. 1. Raw water pump failure. Check impeller - replace. 2. Obstruction ?t raw water intake or raw water filter. 2a. Thermostat - remove and test in hot water. Replace thermostat. 2b. Loss of coolant - check hoses, hose clamps, drain plug, etc. for leaks. 2c.
SHORE POWER TRANSFER SWITCH If the installer connects shore power to the vessel's AC circuit, this must be done by means of the Shore Power Transfer Switch .. Set the transfer switch shown in the diagrams to the OFF position. This switch prevents simultaneous connection of shore power to generator output. 230 VOl.T/50 HERTZ TWO WIRE CONFIGURATION N G l1 A CAUTION: Damage to the generator can result if utility shore power and generator output are connected at the same time.
GENERATOR INFORMATION USE OF ELECTRIC MOTORS GENERATOR FREQUENCY ADJUSTMENT The power required to start an electric motor is considerably more than is required to keep it running after it is started. Some motors require much more current to start them than others. Split-phase (Ae) motors require more current to start, under similar circumstances, than other types.
GENERATOR TROUBLESHOOTING Problem Alternator excitation failure Remedy Probable Cause 1. Low engine speed. 2. Faulty capacitor. 3. Faulty windings. 1. Check rpm and set at a nominal value of 3700 rpm without a load for 60 Hertz (3100 rpm for 50 Hertz). 2. Check and replace. 3. Check the windings' resistance as follows: Stator 0.65 ohms Rotor 3.90 ohms Excitation 2.60 ohms High no-load voltage (over 135V) 1. Engine speed too high. 2. Capacitor rating is too high. 1. Check and adjust rpm. 2.
LAY-UP AND RECOMMISSIONING GENERAL RAW WATER COOLING CIRCUIT Many owners rely on their boatyards to prepare their craft, including engines and generators, for lay-up during the off season or for long periods of inactivity. Others prefer to accomplish lay-up preparation themselves. Close the through-hull fitting. Remove the raw water intake hose from the fitting. Place the end of this hose into a bucket of clean fresh water. Clean the raw water strainer.
LAY-UP AND RECOMMISSIONING STARTER MOTOR RECOMMISSIONING Lubrication and cleaning of the starter drive pinion is advisable. Make sure the battery connections are shut offbefore attempting to remove the starter. Take care in properly replacing any electrical connections removed from the starter.
8.0 KW BCDT/7.0 KW BCDT GENERATOR SPECIFICATIONS ENGINE SPECIFICATIONS COOLING SYSTEM Engine Type Diesel, four-cycle, two cylinder, raw water cooled, vertical, in-line overhead valve mechanism Cooling System Fresh water-cooled block, thermostatically controlled Governor Mechanical,centrifugal weight type Operating Temperature 170 - 190°F (77 - 88°C) Combustion System Direct Injection Raw Water Pump Positive displacement, rubber impeller, gear-driven, self-priming Bore and Stroke 2.98-x 2.
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 DISTANCE EQUIVALENTS 1 Degree of Latitude = 60 Nm = 111.120 km 1 Minute of Latitude = 1 Nm = 1.852 km VOLUME Cubic Inches (in3) x 16.387 = Cubic Centimeters x .061 =in3 Imperial Pints (IMP pt) x .568 = Liters (L) x 1.76 = IMP pt Imperial Quarts (IMP qt) x 1.137 = Liters (L) x.
METRIC CONVERSIONS INCHES TO MILLIMETERS Inches mm 1 2 3 4 5 10 25.40 50.80 76.20 101.60 127.00 254.00 mm Inches 15 20 25 30 35 40 MILLIMETERS TO INCHES 381.00 508.00 635.00 762.00 889.00 1016.00 mm Inches mm Inches 1 2 3 4 5 10 0.0394 0.0787 0.1181 0.1575 0.1969 0.3937 15 20 25 30 35 40 0.5906 0.7874 0.9843 1.1811 1.3780 1.5748 10 MILLIMETERS = 1 CENTIMETER, 100 CENTIMETERS = 1 METER = 39.37 INCHES (3.3 FEET) INCHES TO METERS Inches Meters 1 2 3 4 5 ,6 0.0254 0.0508 0.0762 0.1016 0.
STANDARD HARDWARE BOLT HEAD MARKINGS Metric bolt class numbers identify bolts by their strength with 10.9 the strongest. Bolt strength classes are embossed on the head of each bolt. Customary (inch) bolts are identifed'by markings two to grade eight (strongest), The marks correspond to two marks less than the actual grade, Le.; a grade seven bolt will display five embossed marks. Use the torque values listed below when specific torque values are not available.
TORQUE SPECIFICATIONS lb-ft (Kg-m) Cylinder Head Bolt, main (wet), M10 (14) 54.36 - 61.46 (7.5-8.5) Cylinder Head Bolt, sub (wet), M6 (12) 14.46 - 21.69 (2.0 - 3.0) Connecting Rod Cap Nut, M8 (14) 23.14 - 25.31 (3.2 - 3.5) Flywheel Bolt, M10 (17) 61.45 - 68.69 (8.5 - 9.5) Crankshaft Pulley Nut, M16 (17) 72.31 - 86.77 (10.0 -12.0) Main Bearing Cap Bolt, M10 (17) 36.15 - 39.77 (5.0 - 5.5) Rocker Shaft Hold-down Bolt, M8 (12) 10.85 -15.91 (1.5-2.2) Rocker Cover Nut, M6 (10) 3.62 - 5.
-,,-" SUGGESTED SPARE PARTS ,r WESJERBEKE MARINE DIESEL GENERATORS CONTACT YOUR WESTERBEKE DEALER fOR ADDITIONAL SUGGESTIONS AND INFORMATION , ' • ~ . . COl .. / f - ~ ~ , .. 0., ~ . ' HARDWARE KIT :IiAWWATER !PUMP IMPELLER lAND GASKET FO'EL/WATER . FILTER Il;jlRTRIDGES WESTERBEKE RECOMMENDS CARRYING ENOUGH SPARE ENGINE OIL (YOUR BRAND) FOR AN OIL CHANGE AND ALSO A GALLON OF PREMIXED COOLANT FOR THE COOLING SYSTEM. WESTERBEKE also offers engine spares in ,t.
Engines & Generators 1054-WMJDW-7/2001
