Westerbeke 8.0KW-60Hz - User Manual

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OPERATORS MANUAL
MARINE DIESEL GENERATORS
8.0KW • 60Hz ......... 6.0KW • 50Hz BTDA
10.0KW • 60Hz ......... 7.5KW • 50Hz BTDA
11.5KW • 60Hz ........ ,9.2KW • 50Hz BTD
12.5KW • 60Hz ......... 9.4KW • 50Hz BTDB
12.6KW • 60Hz ...... 10.4KW • 50Hz BTD
15.0KW - 60Hz ..... 12.0KW • 50Hz BTDC
Single an hase
PUBLICATION NO.44800
THIRD EDITION
JUNE 2008
WESTERBEKE CORPORATION' 150 JOHN HANCOCK ROAD
MYLES STANDISH INDf.lSTRIAL PARK' TAUNTON MA 02780
WEBSITE: WWW.WESTERBEKE.COM
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.J,YJJ!.ttfIJ Member NaJil>nal Marine Manu/aCIJITwAssociafiqn

Summary

California Proposition 65 Warning

Carbon Monoxide Hazard

Safety Instructions

Prevent Electric Shock

Instructions to avoid electrical hazards, emphasizing safety precautions.

Prevent Burns - Hot Engine

Warnings about touching hot engine parts and exhaust system components.

Prevent Burns - Fire

Precautions to prevent fires from fuel vapors and sparks.

Prevent Burns - Explosion

Safety instructions regarding fuel vapor explosion risks during refueling.

More Safety Instructions

Accidental Starting Precautions

Warnings and precautions to prevent accidental engine starting.

Battery Explosion Hazards

Safety measures to prevent battery explosions from hydrogen gas ignition.

Battery Acid Safety

Precautions for handling sulfuric acid found in batteries.

Toxic Exhaust Gases

Information about carbon monoxide hazards from exhaust gases.

Moving Parts Hazards

Warnings and precautions regarding moving parts of the engine.

Additional Safety and Installation Guidance

Hazardous Noise Warnings

Warnings about potential hearing loss from high noise levels.

Engine Installation Standards

Guidance on ABYC standards for engine installations.

Diesel Engine Installation Publications

Listing of relevant publications for diesel engine installation codes.

Installation Requirements

Codes and Regulations Compliance

Importance of complying with federal regulations and ABYC guidelines.

Siphon-Break System Installation

Requirements for installing a siphon-break in exhaust systems.

Exhaust System Requirements

Requirements for marine-certified exhaust hoses and systems.

Parts Identification

Left Side Components

Diagram and labels for the left side of the generator.

Right Side Components

Diagram and labels for the right side of the generator.

Introduction to the Manual

Product Software Disclaimer

Disclaimer regarding product software and its accuracy.

Understanding Manual Notations

Explanation of how notes, cautions, and warnings are highlighted in the manual.

Manual Information and Resources

Serial Number Location

Location of engine and generator serial numbers for reference.

Understanding Diesel Engines

Basic comparison of diesel engines to gasoline engines.

Ordering Replacement Parts

Information required for ordering replacement parts.

Spares and Accessories

Guidance on acquiring necessary spare parts and accessories.

Fluid Management

Diesel Fuel Specifications and Care

Diesel fuel requirements and care for the fuel supply.

Engine Oil Recommendations

Recommendations for engine oil viscosity and API classification.

Engine Oil Pressure Monitoring

Normal operating oil pressure range and readings.

Engine Coolant Requirements

Recommendations for antifreeze mixture and coolant system care.

Generator Control Panels

Control Panel Switches Explained

Explanation of the functions of the control panel switches.

Instrument Gauges Explained

Description of the generator's instrument panel gauges.

Remote Panel Operation

Information on using the remote start/stop panel.

Initial Start-Up Preparations

Pre-Start Inspection Checklist

Checklist for pre-start inspection before initial generator operation.

Generator Voltage and Frequency Settings

Specifications for generator voltage and frequency settings.

Starting and Stopping Procedures

Starting System Overview

Explanation of the diesel generator starting system with glow plugs.

Preheat Procedure

Procedure for preheating the engine before starting.

Engine Start Procedure

Procedure for starting the engine using the start switch.

Remote Starting Procedure

Instructions for starting the generator from a remote panel.

Advanced Starting and Stopping

Starting in Cold Conditions

Tips for starting the generator in cold weather.

Stopping Procedure

Step-by-step procedure for stopping the generator.

Remote Stopping Procedure

Instructions for stopping the generator from a remote panel.

Safety Shutdown Switches Explained

Description of automatic shutdown switches protecting the engine.

Generator Break-In Procedure

Break-In Procedure Description

Importance and purpose of the engine break-in period.

Break-In Checks and Monitoring

Checks to perform during the generator's break-in period.

Generator Adjustments During Break-In

Information on required adjustments during and after break-in.

Daily Operation Guide

Daily Operation Checklist

Daily checklist before starting the generator.

Starting the Generator

Procedure for starting the generator and applying loads.

Stopping the Generator

Procedure for stopping the generator and removing loads.

Maintenance Schedule

Cooling System

Cooling System Description

Explanation of how the Westerbeke cooling system works.

Fresh Water Cooling Circuit

Details on the fresh water coolant circulation within the engine.

Coolant Recovery Tank

Function and placement of the coolant recovery tank.

Changing Engine Coolant

Procedure for draining and refilling the engine coolant.

Cooling System Maintenance

Refilling Coolant Procedure

Steps for refilling the coolant after draining.

Replacing the Thermostat

Procedure for replacing the engine thermostat.

Thermostat Functionality

Function and location of the thermostat in the cooling circuit.

Raw Water Cooling Circuit

Explanation of the raw water cooling circuit operation.

Raw Water Pump Maintenance

Information on the raw water pump and impeller maintenance.

Cooling System Components

Changing Raw Water Pump Impeller

Step-by-step guide to changing the raw water pump impeller.

Raw Water Intake Strainer Maintenance

Maintenance and cleaning of the raw water intake strainer.

Heat Exchanger Details

Description of the heat exchanger's function and components.

Cooling System Service and Air Intake

Zinc Anode Service

Purpose and maintenance of the zinc anode.

Heat Exchanger Service

Service requirements for the heat exchanger.

Air Intake; Silencer System

Importance of air intake for engine operation.

Air Intake Filter;Silencer Maintenance

Maintenance and replacement of the air intake filter.

Fuel System

Diesel Fuel Requirements

Diesel fuel requirements and quality standards for diesel engines.

Fuel Water Separator Function

Importance and function of the fuel water separator.

Fuel Injection Pump Servicing

Information on the fuel injection pump and servicing cautions.

Fuel Lift Pump Checks

Checks for the fuel lift pump and its operation.

Fuel System Maintenance

Fuel Filter System

Importance of fuel filters for clean diesel fuel delivery.

Fuel Lift Pump Filter Replacement

Replacement schedule for the fuel lift pump filter.

Engine Fuel Filter Maintenance

Maintenance of the engine's main fuel filter.

Engine Lubricating Oil

Lubrication System Diagram

Diagram showing the engine lubrication system components.

Engine Oil Change Procedure

Procedure for draining and refilling engine oil.

Engine Oil Pressure Monitoring

Normal operating oil pressure and typical readings.

Engine Oil Filter and Sump

Replacing the Oil Filter

Procedure for replacing the engine oil filter.

Filling the Oil Sump

Steps for adding new engine oil after a change.

Oil Pressure System

Oil Pressure System Description

Explanation of the engine's lubricating system and oil pressure.

Testing Engine Oil Pressure

Procedure for testing engine oil pressure.

Low Oil Pressure Diagnosis

Minimum safe oil pressure and potential causes of low pressure.

Oil Pressure Relief Valve

Location and function of the oil pressure relief valve.

Remote Oil Filter Installation

DC Electrical System

Alternator System Components

Description of the charging system components.

Alternator Troubleshooting

Troubleshooting steps for alternator and charging circuit issues.

Testing the Alternator

Procedures for testing the alternator's functionality.

DC Electrical System Checks

Alternator Testing Procedures

Further steps for testing the alternator output and voltage.

Service Battery Voltage Check

Procedure for checking the service battery voltage.

12 Volt DC Control Circuit

Information on the engine's 12-volt DC control circuit.

Battery Capacity and Care

Minimum recommended battery capacity and care.

Battery Maintenance

Battery Maintenance Schedule

Recommendations for battery maintenance and care.

Glow Plugs

Glow Plug Description

Explanation of how glow plugs function in the starting system.

Glow Plug Inspection

Procedure for inspecting and cleaning glow plugs.

Glow Plug Testing

Methods for testing glow plug resistance and current draw.

Generator Wiring Diagram

Generator Wiring Schematic

Generator Wiring Diagrams (Continued)

Generator Wiring Schematics (Continued)

Remote Instrument Panel

Engine Troubleshooting Guide

Engine Troubleshooting (Continued)

Engine Troubleshooting (Further)

Control Panel Troubleshooting

Manual Starter Disconnect Troubleshooting

Troubleshooting for manual starter disconnect switch issues.

Gauge Troubleshooting

Diagnosing issues with water temperature and oil pressure gauges.

Engine Adjustments

Drive Belt Adjustment Procedure

Procedure for adjusting and maintaining drive belt tension.

Engine Speed and Shutdown

Information on engine speed control and shutdown solenoid.

Electronic Governor System

Explanation of the electronic governor system.

Actuator Adjustment or Replacement

Instructions for adjusting or replacing the electronic governor actuator.

Engine Adjustment Details

Valve Clearance Adjustment

Procedure for adjusting valve clearances on the engine.

Engine Performance Adjustments

Testing Engine Compression

Procedure for testing engine cylinder compression.

Fuel Injector Service

Information on checking, removing, and installing fuel injectors.

Low Compression Diagnosis

Diagnosing low compression issues in cylinders.

Generator Information

Electric Motor Starting Current

Information on starting current requirements for electric motors.

Generator Frequency Adjustment

How to adjust generator frequency via engine speed.

Generator Maintenance Practices

General maintenance practices for the generator.

Carbon Monoxide Detector Recommendation

Recommendation for mounting a carbon monoxide detector.

BT Generator Overview

BT Generator Description

Description of the BT generator's self-excited operation.

BT Generator Internal Wiring

Internal Wiring Schematic (Six Stud)

Wiring schematic for the 6-stud BT generator with AVR.

Generator Voltage Adjustment

Generator Frequency Settings

Relationship between engine speed and generator frequency.

Six Stud AC Voltage Connections

Wiring configurations for 6-stud AC voltage connections.

Twelve Stud AC Voltage Connections

Wiring configurations for 12-stud AC voltage connections.

Generator Voltage Adjustment Procedures

No-Load Voltage Adjustment

Procedure for adjusting no-load voltage output.

Full-Load Voltage Adjustment

Procedure for adjusting full-load voltage output.

BT Generator Troubleshooting

Low Voltage Troubleshooting

Component checks for low AC voltage output.

No AC Voltage Output Troubleshooting

Component checks for no AC voltage output.

Exciter Circuit Faulty Troubleshooting

Component checks for faulty residual voltage exciter circuit.

Lay-Up and Recommissioning

Lay-Up Procedures Overview

Introduction to lay-up and recommissioning procedures.

Propeller Shaft Coupling Lay-Up

Lay-up procedures for propeller shaft coupling.

Fresh Water Cooling Lay-Up

Lay-up procedures for the fresh water cooling system.

Lubrication System Lay-Up

Lay-up procedures for the engine lubrication system.

Lay-Up Procedures for Systems

Fuel System Lay-Up Procedures

Lay-up procedures for diesel fuel systems.

Raw Water Cooling Lay-Up

Lay-up procedures for the raw water cooling circuit.

Cylinder Lubrication Lay-Up (Gasoline)

Cylinder lubrication for gasoline engines during lay-up.

Component Lay-Up Procedures

Starter Motor Lay-Up

Lay-up and cleaning procedures for the starter motor.

Cylinder Lubrication Lay-Up (Diesel)

Cylinder lubrication for diesel engines during lay-up.

Intake Manifold Lay-Up (Diesel)

Lay-up procedures for diesel intake manifold and exhaust.

Battery Storage During Lay-Up

Battery care and storage during lay-up.

Lay-Up and Recommissioning Steps

Transmission Lay-Up

Lay-up procedures for the transmission.

Spare Parts Inspection for Lay-Up

Recommendations for inspecting and ordering spare parts.

Recommissioning Procedures

Procedures for recommissioning the engine after lay-up.

Generator Specifications (8.0 kW - 12.6 kW)

General Specifications

General specifications for the generators.

Fuel System Specifications

Fuel system specifications and components.

Electrical System Specifications

Electrical system specifications and components.

Cooling System Specifications

Cooling system specifications and components.

Generator Specifications (Continued)

Tune-Up Specifications

Tune-up specifications for engine adjustments.

Lubrication System Specifications

Lubrication system specifications.

Generator Specifications (12.5 kW - 15.0 kW)

General Specifications

General specifications for the 12.5kW and 15.0kW models.

Fuel System Specifications

Fuel system specifications for these models.

Electrical System Specifications

Electrical system specifications.

Cooling System Specifications

Cooling system specifications.

Generator Specifications (12.5 kW - 15.0 kW) Continued

Tune-Up Specifications

Tune-up specifications for these models.

Lubrication System Specifications

Lubrication system specifications.

Engine Torque Specifications

Major Bolts and Nuts Torque

Torque specifications for major engine bolts and nuts.

Standard Hardware and Sealants

Bolt Head Markings Identification

Identification markings on bolt heads.

Standard Torque Specifications

Torque specifications for standard bolts and nuts.

Metric Torque Specifications

Torque specifications for metric bolts and nuts.

Sealants and Lubricants Guide

Recommended sealants and lubricants for assembly.

Standard and Metric Conversion Data (Length, Volume, Mass, Pressure)

Length and Distance Conversions

Conversion data for length and distance measurements.

Volume Conversions

Conversion data for various volume measurements.

Mass and Weight Conversions

Conversion data for mass and weight measurements.

Pressure Conversions

Conversion data for pressure measurements.

Standard and Metric Conversion Data (Torque, Velocity, Power, Fuel)

Torque Conversions

Conversion data for torque measurements.

Velocity Conversions

Conversion data for velocity measurements.

Power Conversions

Conversion data for power measurements.

Fuel Consumption Conversions

Conversion data for fuel consumption.

Standard and Metric Conversion Data (Temperature, Liquid Weights)

Temperature Conversions

Conversion data for temperature measurements.

Liquid Weights

Conversion data for liquid weights.

Raw Water Discharge Hose

Power Take Off Systems

Power Take Off Adapter

Description and function of the power take off adapter.

Power Take Off Kits

Part numbers for power take off kits.

Suggested Spare Parts

Spare Parts Kits

Description of available spare parts kits.

Westerbeke 8.0KW-60Hz Specifications

General

Brand	Westerbeke
Model	8.0KW-60Hz
Category	Inverter
Language	English