Westerbeke 7.6KW BTD 60Hz Operator's Manual
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Westerbeke 7.6KW BTD 60Hz Operator's Manual

Westerbeke 7.6KW BTD 60Hz Operator's Manual

Marine diesel single phase generators
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OPERATORS MANUAL
7.6KW BTD 60HZ
5.7KW BTD 50HZ
ARINE DIESEL GENERAT
81
HA8E
PUBLICATION
040457
SECOND EDITION
FEBRUARY 2006
l""llY"
rWESTERBEKE
J
WESTERBEK£ CORPORATION
f
150 JOHN HANCOCK ROAD
•
MYLES STANDISH INDUSTRIAL PARK ~ TAUNTON MA 02780
WEBSITE: WWW.WESTERBEKECOM
...............
!VMMA
Member National Marine Manufacturers Association
4JI""~

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  • Page 1 .It ..& · ..0>.< ..<) IlI.D~' OPERATORS MANUAL 7.6KW BTD 60HZ 5.7KW BTD 50HZ ARINE DIESEL GENERAT HA8E PUBLICATION 040457 SECOND EDITION FEBRUARY 2006 rWESTERBEKE l""llY"...
  • Page 2 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 near engine or generator. bulkhead...
  • Page 3 SAFETY INSTRUCTIONS INTRODUCTION PREVENT BURNS - FIRE Read this safety manual carefully. Most accidents are caused by failure to follow fundamental rules and WARNING: Fire can cause injury or death! precautions. Know when dangerous conditions exist and take the necessary precautions to protect yourself, your •...
  • Page 4 SAFETY INSTRUCTIONS BATTERY EXPLOSION WARNING: Carbon monoxide (CO) is an invisible WARNING: Battery explosion can cause injury odorless gas. Inhalation produces flu-like symptoms, or death! nausea or death! • Do not smoke or allow an open flame near the battery •...
  • 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 Engine Adjustments (cont.) Parts Identification ..........Introduction ............Generator Frequency Adjustment....24 Fuel, Engine Oil and Engine Coolant ....Fuel Run Solenoid ........24 Preparations for Initial Start-Up ......Electronic Governor (optional) ....24A Generator Control Panels ........7 Valve Clearance Adjusttnent .......

  • Page 8: Parts Identification

    7.6KW BTD PARTS IDENTIFICATION TOP OIL FILL", INJECTORS THERMOSTAT ASSEMBLY CONNECTION FOR SIPHON BREAK DRIVE BELTS COVER _________ WATER INJECTED /-- -.-"'"---. EXHAUST ELBOW 1.0. PLATE ENGINE----- rlr;Tz~---::;;~-,__:;--+_-_L-.--_ EXHAUST TEMPERATURE DC ALTERNATOR-------- SHUTDOWN SWITCH EXHAUST MANIFOLD REAR ~POWER TAKE-OFF FLEXIBLE ISOLATED MOUNTS GENERATOR BACK-END...

  • Page 9: Introduction

    INTRODUCTION This WESTERBEKE Diesel Generator is a product of PRODUCT SOFTWARE WESTERBEKE's long years of experience and advanced Product software, (tech data, parts lists, manuals, technology. We take great pride in the superior durability and brochures and catalogs), provided from sources other than dependable performance of our engines and generators.
  • Page 10 SERIAL NUMBER LOCATION NOTE: A carbon l1wnoxide wanling decal has been provided by WESTERBEKE. Affzx this decal in a visible position in the and generator serial numbers and model numbers engine room. are located on a decal on the generator housing. Take the...

  • Page 11: Fuel, Engine Oil And Engine Coolant

    FUEL, ENGINE OIL AND ENGINE COOLANT ENGINE COOLANT FUEL WESTERBEKE recommends a mixture of 50% antifreeze and 50% distilled water. Distilled water is free from the CAUTION: Only use unleaded fuel with an octane chemicals that can con"ode internal engine surfaces.

  • Page 12: Preparations For Initial Start-Up

    PREPARATIONS FOR INITIAL START-UP PRESTART INSPECTION Before starting your generator set for the first time or after a CAUTION: When starting the generator, it is prolonged layoff, check the following items: recommended that all AC loads, especially large motors, • Make certain the cooling water thru-hull petcock is open.

  • Page 13: Generator Control Panels

    GENERATOR CONTROL PANELS DESCRIPTION REMOTE PANELS The control panel is equipped with an hour meter that There are two controls panels available for remote opera- registers elapsed time is used as a guide for scheduled tion of the generator that plug into the standard panel with maintenance.

  • Page 14: Starting/Stopping Procedure

    STARTING/STOPPING PROCEDURE REMOTE PANEL The remote panel uses the same three toggle switches with an LED light to indicate the generator is running. STARTING PREHEAT: Depress the PREHEAT switch for approximately 15 seconds (the LED light will illuminate). With the PREHEAT switch still depressed, depress that START switch.

  • Page 15: Starting/Stopping Procedure

    COMPLETE INSTRU ENT CONTROL PANEL STOPPING PROCEDURE INSTRUMENTS STARTING PREHEAT: The PREHEAT toggle switch serves two purposes: COOLANT TEMPERATURE GAUGE preheating the engine for easy starting and defeating of Engine coolant (water) temperature should normally indicate bypassing the engine oil pressure switch. The defeat function F (80 90°...

  • Page 16: Generator Break-In Procedure

    GENERATOR BREAK-IN PROCEDURE DESCRIPTION After the first 10 hours of the generators operation, the load can be increased to the full-load rated output, then Although your engine has experienced a minimum of one periodically vary the load. hour of test operations at the factory to make sure accurate assembly procedures were followed and that the Avoid overload at all times.

  • Page 17: Safety Shutdown Switches

    SAFETY SHUTDOWN SWITCHES SAFETY SHUTDOWN SWITCHES High Exhaust Temperature Switch The engine is protected by three automatic shutdown An exhaust temperature switch is located on the exhaust switches. Should a shutdown occur, do 110t attempt to restart elbow. Nonnally closed, tius switch will open and interrupt without finding and correcting the cause.

  • Page 18: Maintenance Schedule (Chart)

    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 19 At first 50 hours, then every 500 hours Hold·down bolts (see ENGINE ADJUSTMENTS). Adjust the Valve Clearances Adjust Valve Clearances (see ENGINE ADJUSTMENTS). *Heat Exchanger Remove, have professionally cleaned and pressure tested. *WESTERBEKE recommends this service be performed by an authorized mechanic. Engines & Generators...

  • Page 20: Fuel System

    This process is accomplished by instaIling and maintaining a proper fuel filter/water separator between the fuel tank and the generator/engine. Westerbeke recommends a 10 micron filter be used. FUEL INJECTION PUMP The fuel injection pump is the most impOitant component of the diesel engine, requiring the utmost caution in handling.

  • Page 21: Cooling System

    COOLING SYSTEM DESCRIPTION Wcstcrbeke marine diesel engines are designed and equipped fresh water coolant flows around the tubes; engine heat trans- for frcsh water cooling. Heat produced in the engine by com- fen"ed to the fresh water coolant is conducted through the tube walls to the raw watcr which is then pumped into the bustion and friction is transferred to fresh water coolant which circulates throughout the engine.

  • Page 22: Fresh Water Cooling Circuit

    COOLING SYSTEM FRESH WATER COOLING CIRCUIT CHANGING COOLANT The engine's coolant must be changed according to the NOTE: Refer the ENGINE COOLANT section the rec- MAINTENANCE SCHEDULE. If the coolant is allowed to omlllended antij1-eeze and vvater mixture to be used as the become contaminated, can lead to overheating problems.

  • Page 23: Thermostat

    COOLING SYSTEM THERMOSTAT RAW WATER INTAKE STRAINER A thennostat, located near the manifold at the front of the NOTE: Always install the strainer at or below the waterline engine, controls the coolant temperature as the coolant the strainer will always be self-priming. continuously flows through the closed cooling circuit.

  • Page 24: Heat Exchanger

    COOLING SYSTEM RAW WATER COOLING CIRCUIT RAW WATER PUMP The raw water flow is created by a positive displacement The raw water pump is a self-priming, rotary pump with a impeller pUl1lp. This pump draws water directly from the non-ferrous housing and a Neoprene impeller. The impeller ocean, lake, or river from a thru-hull opening through a hose has flexible blades which wipe against a curved cam plate to the water strainer.

  • Page 25: Engine Lubricating Oil

    ENGINE LUBRICATING OIL ENGINE OIL CHANGE When installing the new oil filter element, wipe the filter gasket's sealing surface on the bracket free of oil and 1. Draining the Oil Sump. Discharge the used oil through apply a thin coat of clean engine oil to the lUbber gasket the sump drain hose (attached to the front of the engine) on the new oil filter.

  • Page 26: Remote Oil Filter (Optional)

    REMOTE OIL FILTER (OPTIONAL) INSTALLATION NOTE: Westerbeke is not responsible for engine failure due to incorrect installation of the Remote Oil Filter. This popular accessory is used to relocate the engine's oil fil- ter [Tom the engine to a more convenient location such as an room bulkhead.

  • Page 27: Starter Motor

    STARTER MOTOR SOLENOID DESCRIPTION (+) POSITIVE The starting system includes the battery, starter motor, solenoid, TERMINAL and the start toggle switch. t~(l;I~ When the start switch on the instrument panel is depressed, / /, CllITent flows and energizes the starter's solenoid coil. The TERMINAL ?,?:~~)~\ energized coil becomes an electromagnet, which pulls the plunger...
  • Page 28 STARTER MOTOR SERVICE Westerbeke uses a standard marine starter motor which can be (+) POSITIVE serviced or rebuilt at any starter motor automotive service center. ,TERMINAL If replacing the starter motor, make certain the new motor is celtified for marine use. Automotive starters do not meet USCG standards.lfin doubt, contact your WESTERBEKE dealer.

  • Page 29: Engine Adjustments

    CYLINDER TORQUING THE HEAD BOLTS For your safety, WESTERBEKE generator models come After the initial break-in period (approximately 50 hours) and equipped with belt guards that cover over the belt(s) on the every 500 hours thereafter, the cylinder head bolts should be front of the engine.

  • Page 30: Engine Adjustments (Cont.)

    ENGINE ADJUSTMENTS GENERATOR FREQUENCY ADJUSTMENT (HERTZ) FUEL RUN SOLENOID Once the diesel generator set has been placed in operation, The fuel run solenoid is mounted in a threaded hole on the there may be adjustments required for engine speed (Hertz) engine's block just aft of and below the engine's fuel injec- during the engine's break-in period (first 50 hours) or after tion pump.

  • Page 31: Electronic Governor (Optional)

    TO 7/8" ORIGINAL MEASURE STANDARD NOTE: For additional infOlmation Electronic Governor Troubleshooting, to your WESTERBEKE Service Manual. refer Actuator The following instructions are for adjusting or replacing the actuator. 1. Shut-off the DC power to the generator. 2. DiscOImect the actuator wires from the Vviring harness.

  • Page 32: Valve Clearance Adjusttnent

    ENGINE ADJUSTMENTS VALVE CLEARANCE ADJUSTMENT Re-install the glow plugs (use anti-seize compound on the threads) and assemble the rocker cover and rocker cover NOTE: Retorque the cylinder head bolts before adjusting the bolts. See TIGHTENING TORQUE SCHEDULE in this engine's valves. See TORQUING THE CYLlNDER HEAD manual.

  • Page 33: Spill Timing

    ENGINE ADJUSTMENTS NOTE: WESTERBEKE recommends that the following engine adjust- ments be perfonned by a competent engine mechanic. The information below is provided to assist the mechanic. Injection Pump Timing Adjustment (Spill Timing) INJECTION PUMP mlIVERv'VALVE HOLDER If your engine's fuel injection timing is not properly adjusted, the engine will not operate properly, and may be difflcult to start.

  • Page 34: Testing Oil Pressure

    ENGINE ADJUSTMENTS GLOW PLUGS OIL PRESSURE To test the oil pressure, remove the oil pressure sender, then The glow plugs are wired through the preheat solenoid. PREHEAT install a mechanical oil pressure gauge in it's place. After When is pres?ed at the control panel this solenoid warming up the engine, set the engine speed at 1800 rpm and should "click"...

  • Page 35: Engine Troubleshooting (Chart)

    ENGINE TROUBLESHOOTING The following troubleshooting table describes certain problems Note: The engine electrical systenl is protected by a 20 amp relating to engine service, the probable causes of these prob- manual reset circuit breaker located on a bracket at the rear lems.
  • Page 36 ENGINE TROUBLESHOOTING Problem Probable Cause Verification/Remedy Generator engine overheats/shuts down. 1. Coolant not circulating. Thermostat - remove and test in hot water. Replace thermostat. 2. Loss of coolant check hoses, hose clamps, drain plug, etc. for leaks. 2c. Broken or loose belts tighten/replace.

  • Page 37: Alternator Testing

    ALTERNATOR TESTING DESCRIPTION Testing the Alternator 1. Start the Engine. The charging system consists of an alternator with a voltage After a few minutes of running measure the statting bat- regulator, an engine DC wiring harness, a mounted DC cir- tery voltage at the battery terminals using a multi-meter cuit breaker and a battery with connecting cables.
  • Page 38 ALTERNATOR TESTING e. Now check the voltage between the alternator output Alternator is Working CB+) terminal and ground. lfthe circujt is good, the Check the voltage of the service battery, TIlis baiLery voltage at the alternator should be the same as the bat- should have a voltage between 13 and J 4 volts when the tery, or an isoJator...

  • Page 39: Control Panel Troubleshooting (Chart)

    CONTROL PANEL TROUBLESHOOTING MANUAL STARTER DISCONNECT (TOGGLE SWITCHES) NOTE: The engine control system is protected by a 20 amp manual reset circuit breaker located on the engine as close as possible to the power source. Problem Probable Cause Verification/Remedy PREHEAT depressed, no panel indications Oil Pressure switch.

  • Page 40: Dc Circuit Battery

    DC CIRCUIT /BATTERY BATTERY CHARGING TESTING THE CIRCUIT The DC Circuit functions to start, operate and stop the If the battery is not charging, check the fuse. To test the generator's engine. The circuit is best understood by circuit, remove the fuse and test with a voltmeter between the reviewing the DC Wiring Diagram and Wiring Schematic.

  • Page 41: Wiring Diagram 44734

    7.6KW GENERATOR WIRING DIAGRAM 44734 fUSE 8A l'ONNICTI~G S[Cr)~D R,MOVe JUMPEll WHEN STOP PREf£AT SWITCH SWITCH _ _ #I.LR.EQiI!I:lL lSi' I 1(, 1 OPTIONAL HOlJ'lMETER Engines & Generators...

  • Page 42: Wiring Schematic 44734

    7.SKW GENERATOR WIRING SCHEMATIC 44734 f . - r" K2·RIIN IIW02 I YP I CAl R[MOTE NOT: l[MOI [ CON[CTOR Hour(~ll Engines & Generators...

  • Page 43: Wiring Diagram #039284

    7.6KW GENERATOR WIRING DIAGRAM #039284 ERI~ATOll 51 A 12 RED I 2 HE D I..U..E.L SOI.ENOID HLlR£D 11 14 PlJR/WHT R£D ~" PREHEAT SWITCH START SWITCH STOP SWITCH WESTERBEKE Engines & Generators...

  • Page 44: Wiring Schematic #039284

    7.6KW GENERATOR WIRING SCHEMATIC #039284 12 VDC I BATTERY STARTER SWITCH SOLENOID STARTER - - I ---+I~I ~~----------~--~ PREHEAT SOLENOID GLOWPLUGS - - I AL TERNATOR START CIRCUIT I 20 SWITCH 'CIRCUIT BREAKER BREAKER O.P. SENDER T62-2 TB 1-5 : PREHEAT SW I TC.H TBl- '"...

  • Page 45: Wiring Diagram #44121

    7.6 KW GENERATOR WIRING DIAGRAM #044121 AlTERNATOR BATTERY SWI TCH r~~------- STOP SWITCH 15 PIN REMOTE CONNECTOR I'---!a ,--_ _ _ _ _ _ -.-!.~I S,-R!!j,(CLO ' , -"W",-H 162 I . - + - - -_ _ ""TB2·2 ..J.J.L.JUll. _ _ ,--_ _ _ 2.JjI6LlJY('-',-'-"R'-'-£"-O 1- 5 OPTIONAL HOURMEIER...
  • Page 46 7.6 KW GENERATOR WIRING SCHEMATIC #044121 VDC------------. . ~------------12 r..., BATTERY SWITCH 20 AMP CIRCUIT BREAKER ________ ______________ r~~~ -,~ r-~~------~ L- _ _ AL TERNATOR KI-START ~UEL PUMP EXHAUST TEMP WATER TEMP OIL PRESS. SWITCH SWITCH SWITCH AUX. OIL PRESS. SWI Tel! K2-RUN OIL PRESS.
  • Page 47 WHITE TB1-5 ----- - to TB1-4 --- - to Start SWitch l~_~~ ________________________________________ - - - - - - - - - - - - - - - l ___________________ , i~~~¥lWTE REMOTE PANEL REAR VIEW WESTERBEKE Engines & Generators...

  • Page 48: Shore Power Connections

    7.6 KW BT SHORE POWER TRANSFER SWITCH CONNECTIONS If the installer connects shore power to the vessel's AC cir- 230 Volt/50 Hertz Two Wire Configuration cuit, this must be done by means of the SHORE POWERJ Notice the repositioning of the white ground lead on the ter- OFF/SHIPS GEN.
  • Page 49 SPECIFICATIONS 7.6KW BTD GENERATOR , ENGINE SPECIFICATIONS ELECTRICAL SYSTEM',' , ",';',"; ,', Starting Battery Engine Type 12-Volt, (-) negative ground Diesel, four-cycle, three-cylinder, fresh water-cooled, vertical in-line overhead valve Battery Capacity 600 900 Cold Cranking Amps (eCA) mechanism (11 Hp at 1800 rpm maximum) DC Charging Alternator 51 Amp rated, belt driven Aspiration...

  • Page 50: Generator Information

    GENERATOR INFORMATION USE OF ELECTRIC MOTORS Generator Frequency Adjustment The power required to start an electric motor is considerably Frequency is a direct result of engine/generator speed, as more than is required to keep it running after it is started. indicated by the following: Some motors require much more current to start them than •...

  • Page 51: Circuit Breaker

    DESCRIPTION Circuit Breaker This generator is a four-pole, bmshless, self-excited generator A circuit breaker is installed on all WESTERBEKE genera- which requires only the driving force of the engine to pro- tors. This circuit breaker wi]] automatically disconnect gener- duce AC output. The copper and laminated iron in the exciter ator power in case of an electrical overload.

  • Page 52: Troubleshooting

    7.6KW BT GENERATOR TROUBLESHOOTING The following troubleshooting chart is designed to give Only a few basic tools are necessary for diagnosis and repair. insight into problems which may be encountered with the BT These are hand tools: an amp probe and a quality volt-ohm- brushless generators operating on compound transformer reg- meter capable of reading less than one ohm due to the preci- ulation.
  • Page 53 BT GENERATOR TROUBLESHOOTING Only a few basic tools are necessary for diagnosis and repair. The following troubleshooting chart is designed to give These are hand tools: an amp probe and a quality volt-ohm- insight into problems which may be encountered with the BT brush1ess generators operating on compound transformer meter capable of reading less than one ohm due to precision required in reading component winding resistances.

  • Page 54: No Load Voltage Adjustment

    It connects Ib±Jj CIRCUIT CIRCUIT CIRCUIT CIRCUIT 1I" .._. _ _ between the neutral stud BREAKER BREAKER BREAKER • • BREAKER • --. BREAKER and the generator frame. WESTERBEKE Engines Generators &...

  • Page 55: Residual Voltage Check

    7.6KW BY GENERATOR SINGLE PHASE INTERNAL WIRING FOR 12 STUD BT GENERATOR r--- - ---' - - --- ---, h4 3: -t>I- L _ _ _ _ _ _ _ _ _ _ _ _ _ • ® • ORANGE BLACK -K1- GREEN...

  • Page 56: Bridge Rectifier

    7.6KW BT GENERATOR SINGLE PHASE BRIDGE RECTIFIER Testing The Bridge Rectifier For Faults With An Ohmmeter The bridge rectifier is supplied AC voltage fTom the auxiliary windings in the generator stator (C-3) and the compound Simpson 260) (Meter used: transfonner (D-3). The AC voltage measured across the AC 1.

  • Page 57: Exciter Rotor Field

    7.6KW BT GENERATOR SINGLE PHASE EXCITER ROTOR/FIELD The diodes can be easily checked in place with the use of a common automotive 12-volt high beam headUght bulb, some Auxiliary windings group a, band c. Locate the three ter- jumper leads and the generator's 12 volt starting battery. minal points on the exciter rotor for these auxiliary winding A short or an open in a diode can easily be found with the groups.

  • Page 58: Measuring Resistance

    7.6KW B1 GENERATOR SINGLE PHASE MEASURING RESISTANCE A three connection voltage connection terminal was added to this circuit located just below the AC terminal block at the lower left. Isolate the three numbered #1, #2, and #3 red and Main Stator Windings white-striped wires coming onto each of the three terminals.
  • Page 59 LAY-UP & RECOMMISSIONING GENERAL Fuel System [Gasoline] Many owners rely on their boatyards to prepare their craft, Top off your fuel tanks with unleaded gasoline of 89 octane including engines and generators, for lay-up during the or higher. A fuel conditioner such as Sta-Bil gasoline off-season or for long periods of inactivity.

  • Page 60: Lay-Up And Recommissioning

    Lay-up time provides a good opportunity to inspect your Lubrication and cleaning of the starter drive pinion is advisable, Westerbeke engine to see if external items such as drive belts if access to the starter permits its easy removal. Make sure the or coolant hoses need replacement.

  • Page 61: Engines & Generators

    Contact your WESTERBEKE COMMERCIAL GENERATOR SUPPLIER for additional infonnation. XRT POWER SYSTEM The XRT power system combined with a Westerbeke generator provides electrical and hydraulic power for fll'e/emergency apparatus The system generates electrical power for auxilIary lighting and provides continuous operation of up to three extrication tools at the same time.

  • Page 62: Metric Conversion Data (Chart)

    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...

  • Page 63: Suggested Spares

    IN A CANVAS FILTER CARTRIDGE CARRYING BAG INJECTOR SPARE PARTS KITS WESTERBEKE also offers two Spare Parts Kits, KIT B each packaged in a rugged hinged toolbox. ZINC ANODES Kit "A" includes the basic spares. Kit "B" is for more extensive off-shore cruising.
  • Page 64 & Engines Generators WM2;1J6DWI098...

This manual is also suitable for:

5.7 kw btd 50hz

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