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Related Manuals for Westerbeke 7.6 KW BTD 60Hz
Summary of Contents for Westerbeke 7.6 KW BTD 60Hz
- Page 1 INSTALLATION GUIDE WESTERBEKE 7.6 KW BTD - 60 Hertz 5.7 KW BTD - 50 Hertz MARINE DIESEL GENERATOR SET Publication #040457 Edition One April 1994 WESTERBEKE WESTERBEKE CORPORATION · MYLES STANDISH INDUSTRIAL PARK 150 JOHN HANCOCK ROAD, TAUNTON, 02780-7319 U.S.A.
- Page 3 • Extreme Care When Handling Engine Fuel (A constant danger of explosion or fire exists) Do not fill fuel tank(s) while the engine running. Do not smoke or an open flame near engine or the fuel tank. WESTERBEKE GENERATORS...
- Page 4 Keep protective shields and guards in their respective place at times. Do not check fluid levels or the drive belt's tension While the unit operating. Do not work on the equipment when mentally or physically incapacitated fatigue. WESTERBEKE GENERATORS...
- Page 5 Westerbeke, is not within Westerbeke's control and, accordingly, is provided to than Westerbeke customers only as a courtesy and service. WESTERBEKE CANNOT BE RESPONSmLE FOR TIIE CONTENT OF SUCH SOFTWARE, MAKES NO WARRANTIES OR REPRESENTATIONS...
- Page 6 FOREWORD Thank you for selecting a Westerbeke marine product for your use. We at Westerbeke are pleased to have you as a customer. Read this manual carefully and observe all safety precautions included throughout. Operating procedures, periodic preventive maintenance procedures,...
- Page 7 Directive(s) and Standard(s). 'c~~ Place Avon, Massachusetts, U.S.A (Signature) Date January 1. 1996 Carleton F. Bryant (Full Name) Chief Operating Officer (Title) 042021 WESTERBEKE CORPORATION, AVON INDUSTRIAL PARK, AVON. MA 02322 U.S.A .• TEL. {50B} 588-7700. FAX: (508) 559-9323. CABLE: WESTCORP...
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Page 9: Table Of Contents
REMOTE LUBE OIL FILTER KIT - PN#040078 ............. 73 TABLE OF STANDARD HARDWARE TIGHTENING TORQUES ........74 SPARE PARTS ........................76 SOUND GUARD INSTALLATION INSTRUCTIONS ....... 78 BID 7.6 KW POWER TAKE-OFF (PTO) ADAPTER ......79 WESTERBEKE GENERATORS... - Page 10 Air Intake Silencer Top Engine Oil Fill Fuel Run Solenoid Water Temperature Switch 20 Amp DC Circuit Breaker Lube Oil Dipstick Oil Fill Pre heat Solenoid Oil Pressure Sender A C Connections Outlet Oil Pressure Switch Fuel Lift Pum Lube Oil Filter 7.6 KW BTD RIGHT SIDE...
- Page 11 Unit I. D, Plate Water Temperature Sender Exhaust Elbow Water Temperature Switch Emergency Shut~off Switch DC Charging Alternator Unit Data Tag Belt Guard :::! Heat Exchang Starter with Solenoid DC Battery Ground Connection 7.6 KW BTD LEFT SIDE...
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Page 12: General
In addition, include a complete part description and part number for each part needed (see the separately furnished Parts List). Also, be sure to insist upon Westerbeke factory packaged parts because "will fit" or generic parts are frequently not made to the same specifications as original equipment. -
Page 13: General Specifications
Dimensions Length: 27.8 inches (706.1 mm) Width: 16 inches (406.4 mm) Height: 19.9 inches (505.46 mm) Weight 340 lbs (154.22 kgs) Fuel Consumption 0.53 U.S. gph (2 Iph) at full rated output (approximately) Inclination Not to exceed 25° WESTERBEKE GENERATORS... -
Page 14: 7.6 Kw Btd System Specifications
Oil Filter Full flow, paper element, spin-on type Sump Capacity (including filter) 3.7 U.S. qts (3.5 liters) 35 - 55 psi (2.5 3.8 kg/cm 2 ) Operating Oil Pressure (engine hot) Oil Grade API specification of CC or CD WESTERBEKE GENERATORS... - Page 15 175 - 200 cfm (4.95 - 5.66 cmm) Air Requirements (60 Hertz at 1800 RPM) NOTE: Increase air supply 15% for 50 hertz operation (1500 rpm) Engine Block 100 cfm or more to remove heat produced by the engine block during operation WESTERBEKE GENERATORS...
- Page 16 7.6 KW BTD SYSTEM SPECIFICATIONS (continued) TUNE-UP SPECIFICATIONS Injector Pressure ± 142 psi 1988 psi (140 kg/cm 2 10 kg/cm 2 ) ± ± Engine Timing 16° 1° BIDe (Spill Timing) Static EMISSION CONTROL SYSTEMS Smoke Puff Limiter WESTERBEKE GENERATORS...
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Page 17: Installation Checks
Also, check the contents of the shipment against the packing list and make sure that the proper notation is made if any discrepancies exist. These noted discrepancies are your protection against loss or damage. Claims concerning loss or damage must be made to the carrier, not to Westerbeke Corporation. WESTERBEKE GENERATORS... - Page 18 Special rigging work is best done by someone experienced and competent in handling heavy machinery. WESTERBEKE GENERATORS...
- Page 19 The generator set needs fresh cool air in whatever location in the vessel it is installed. Hot generator discharge air be removed from the generator area. The platform on which the generator and its !!lli§!. mounting rails are located must be strong enough to support the generator during all angles of vessel operation. WESTERBEKE GENERATORS...
- Page 20 This allows air to enter through this vent to prevent siphoning. Wlnl1l1 IUR ... tn LIlt WESTERBEKE GENERATORS...
- Page 21 The generator's exhaust system must be separate from any other engine' s exhaust system. Dry portions of the exhaust system between the engine's exhaust manifold and the water injected exhaust elbow must be insulated to hold in the heat. WESTERBEKE GENERATORS...
- Page 22 Engine damage resulting from tbis type of sea water entry is not a warrantable issue; tbe owner/operator should keep tbis in mind. WESTERBEKE GENERATORS...
- Page 23 Exhaust Elbow Installation The Westerbeke Corporation offers a 45° and 90° exhaust elbow as well as an exhaust riser you can install on your engine. Refer to the instructions below when installing the exhaust elbow purchased. NOTE: Fabricated exhaust elbows or risers attached to the exhaust manifold must not exceed 8 Ibs when unsupported.
- Page 24 Any fittings used to connect the hose to the oil gallery must be of steel or malleable iron composition. Brass must not be used for this application. WESTERBEKE GENERATORS...
- Page 25 A common ground for the negative (-) DC terminal connection is found at the bet! housing of the generator, next to the starter, in the form of a threaded grounding stud. The battery ground should be connected at this stud. Connect the battery's positive connection to the starter solenoid tagged for this connection. WESTERBEKE GENERATORS...
- Page 26 Batteries Make sure tbe positive battery connection is connected to the battery connection of tbe starting solenoid. The negative (-) battery connection should be connected to the ground stud tagged at the rear of the engine block. WESTERBEKE GENERATORS...
- Page 27 Ventilation should be accomplished with the aid of blowers especially when the vessel is not underway. Refer to the "SYSTEM SPECIFICATIONS" section of this manual for the airflow requirements of the generator set. WESTERBEKE GENERATORS...
- Page 28 NOTES WESTERBEKE GENERATORS...
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Page 29: Description Of Instrument Panel
GENERRTOR General The manually operated series of Westerbeke generators is equipped with toggle switches and optioual remote panels. The Standard Instrument Panel (shown above) includes two gauges which indicate water temperatnre in degrees Fahrenheit (WATER OF) and oil pressure in pounds per square inch (OIL PSI). - Page 30 P.N. 24943 Refer to the control circuit wiring diagram when installing the remote start/stop panel. NOTE: Reference the DC wire sizing chart on the fOllowing page for wire sizes connecting between the engine panel and remote. WESTERBEKE GENERATORS Revised Nov. 2000...
- Page 31 MIL area 'When a circuit, including t.he ground return. uses several different si%e conduct.ors. t.he voltage drop at the elect.rical device is the of t.he drops calculated for each SUIn si%e segment of the circuil. WESTERBEKE GENERATORS...
- Page 32 Description of Starting System Westerbeke diesel engines use electric starters assisted by glow plugs for both normal and cold weather starting. The fignre below shows a cross-sectional view of one cylinder. The glow plug is located in the combustion chamber so that its tip is in the injector nozzle's spray path. When the glow plug is energized by the PREHEAT button, the plug glows red at the tip and assists in igniting the fuel.
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Page 33: Preparation For Starting
This section of the manual provides the operator with preparation, initial starting, break-in, starting (cold or warm) and stopping procedures. Follow the procedures as presented, for the conditions indicated, and your Westerbeke generator set will give you reliable performance and long service life. Take the steps described below in starting your engine for the first time or after a prolonged shutdown or lay-up. -
Page 34: Starting Procedure
Engine damage resulting from this type of sea water entry is not a warrantable issue; the owner/operator should keep this in mind. WESTERBEKE GENERATORS... - Page 35 B+ path to the fuel run solenoid. This will be just a few seconds. B. After the generator is started and the starter switch is released, the generator's starter will not crank until someone again operates the PREHEAT switch first because this switch supplies voltage to the START switch. WESTERBEKE GENERATORS...
- Page 36 Allow the glow plugs to operate sufficiently to aid in starting during the preheat period whenever the temperature of the intake air is low and when the compression temperature does not rise enough. Refer to the preheat chart found in the "STARTING PROCEDURE" section of this manual. WESTERBEKE GENERATORS...
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Page 37: Stopping Procedure
A jumper has to be removed between the T -1 and T -2 connections at the panel connection terminal board. (Refer to the wiring diagram in the "ELECTRICAL SYSTEM" section of this manual for remote start/stop panel connections.) WESTERBEKE GENERATORS... - Page 38 NOTES WESTERBEKE GENERATORS...
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Page 39: Fuel System
Priming the Fuel System (Self-Bleeding) The Westerbeke self-bleeding fuel system is semiautomatic in operation. The self-bleeding feature of the fuel system allows for easy servicing of the fuel filters. Simply remove and replace the filter element (take care in catching any fuel that may drain out of the fuel filtering assembly as described in the "Replacing the Fuel Filter Element"... - Page 40 Select the parts for your engine from the Parts List and purchase spares from your local Westerbeke Dealer or Distributor. For example, filter kit #30200 includes replacement elements with gaskets (items #21 and 20). If a leak should develop at a fuel banjo or sealing...
- Page 41 To obtain long and satisfactory service from the injection pump, always use fuel which is free from impurities and maintain a good filtration and water separation system between the fuel tank and engine. Service this system regularly: the injection pump it saves will be your own. WESTERBEKE GENERATORS...
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Page 42: Dc Electrical System
DC ELECTRICAL SYSTEM Engine 12-Volt DC Control Circuit The Westerbeke 7.6 KW BID generator has a 12-volt DC electrical control circuit, as shown on wiring diagram #039284. Refer to this diagram when troubleshooting or servicing electrical components on the engine. -
Page 43: Bid Control Circuit Wiring Diagram #039284
IIF.Ug~:r I' " .., I· ,J=~ "-- ~~=L~i~ 1 _______ -------=-=---------------- O-C_ 1------------------: 0" . . TO 1'81-1 TO "1-10 1" ..'!""ie. tfP-wT'" '- _________________ ..J VCLT ..L ___________________________________ IIIKT8II WESTERBEKE GENERATORS... - Page 44 TYPICALLT OIlAW 200 10 WHEN CRANKIN!>. THE OURATION Of INQiVIDUAL CYCLES SHOULD NOT EXCEEO SECONOS_" SW'TeH WITH A CONTINUOUS IIATING or A",ps AT \2 vOC HILL ·~Af(E-THE NOl'lloiALLT SERVE THIS F"\.INCTION, BU1 A SWITCH MUST NEVER eE USED TO ST/l.RHR CIIICUIT. WESTERBEKE GENERATORS...
- Page 45 IS PIN REMOTE CONNECTOR TO Tal-I TO rBr-,o TS2-' 1"",,8,,·,,·1 • " T" iR'(\ '''-'j ,,.>(Olvl(\ HC!!..f!MITEB Of>T!ONAI.. "o""iIO(O a,,· • . . _ .. - JU.'" E"O"E ral-!. T$'·' • 5,1< _HTlREDl( '5'-) " "~'H 'B1-\ " . elKIW"T 151-! WESTERBEKE GENERATORS...
- Page 46 --zy FUSE K2-RUN RELAY IN~I02 STOP ISWITCH PREHEAT START KI-START RELAY rWIT~ rWIT~ -:;:,,- -:;:,,- l.':'J l.':'J OIL PRESS. SENDER WATER SENDER --c- T81-2 T81-3 T81-4 T82-2 TBI-5 T62-1 T82-3 T82-8 TB2-4 T82-5 T6 I - I 0 WESTERBEKE GENERATORS...
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Page 47: Cooling System
COOLING SYSTEM Description Westerbeke marine diesel generators are designed and equipped for fresh water cooling. Heat produced in the engine by combustion and friction is transferred to fresh water which circulates throughout the engine. This circulating fresh water cools the engine block and its internal moving parts. The heat is transferred e,,"lernally from the fresh water to raw water by means of a heat exchanger;... - Page 48 (-40) Filling the Fresh Water System A coolant recovery tank kit is supplied with each Westerbeke diesel engine. The purpose of this recovery tank is to allow for engine coolant expansion and contraction, during engine operation, without the loss of coolant and without introducing air into the cooling system.
- Page 49 7. Add coolant to the recovery tank, as required, to top off the fresh water coolant system and periodically check to see that the manifold is full of coolant by removing the pressure cap when the engine is cold. WESTERBEKE GENERATORS...
- Page 50 Always have a spare heat exchanger end gasket in case the present one becomes damaged when removing the end cover. Replace the gasket (refer to your engine model's heat exchanger end gasket part number), cover, and install a new zinc pencil. WESTERBEKE GENERATORS...
- Page 51 The water pump drive belt is properly adjusted if the belt can be deflected no less than 3/8 inch and no more than 112 inch (I0mm, 12mm) as the belt is depressed with the thumb at the midpoint between the two pulleys on the longest span of the belt. A spare drive belt should be carried on board. WESTERBEKE GENERATORS...
- Page 52 Cooling System Illustrated below is a typical Westerbeke engine cooling system. Both fresh water and raw water flow through their independent cooling circuits. Refer to your generator's Parts List for part numbers and part descriptions if you need to order cooling system parts for your engine.
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Page 53: Lubrication System
Raw water present in the oil can be the result of a fault in the exhaust system attached to the engine andlor siphoning through the raw water cooling circuit into the exhaust, filling it up to the engine. WESTERBEKE GENERATORS... - Page 54 Then check the quantity of oil with the lube oil dipstick. Fill to, but Oil Dipstick not over, the high mark on the dipstick, should the engine require additional oil. Upper [Hor •• l ---,;;.-- - ==== Lower li.it Crankcase WESTERBEKE GENERATORS...
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Page 55: Bt Generator
The addition of shim thickness will raise the no-load voltage and, conversely, the removal of shim thickness will lower the no-load Voltage. Varying shim thickness by .001 inch (0.025 mm) will change the no-load voltage by to 6 volts. WESTERBEKE GENERATORS... - Page 56 ©© These connections are used to change the output voltage of the generator under load. Should the voltage go below minimum. Reposition this connection to increase output voltage under load. VOLTAGE BAR WESTERBEKE GENERATORS...
- Page 57 3. Compound Transformer Auxiliary Windings B. EXCITER ROTOR E. BRIDGE RECTIFIER 1. Auxiliary Windings (a-b-c) 2. Diodes (6) 3. Rotating Field Windings 4. Pozi Resistor MAIN STATOR 1. Main Stator Windings 2. Main Stator Windings 3. Main Stator Auxiliary Windings WESTERBEKE GENERATORS...
- Page 58 The generator is a single-phase, reconnectable 120 volts AC two-wire or 1201240 volts AC three-wire, at 60 Hertz; or 110 volts AC two-wire, 1101220 volts AC three-wire, or 220 volts AC two-wire, at 50 Hertz. Refer to the "SYSTEM SPECIFICATIONS" section of this manual for ratings, located at the beginning of this manual. WESTERBEKE GENERATORS...
- Page 59 NOTE: The frame ground wire must be moved when changing from 110 volts, 50 Hertz to 220 volts, 50 Hertz, For making connections to the AC terminal block, use terminal ends for #10 studs which will accept #6 or #8 multi-strand wire, WESTERBEKE GENERATORS...
- Page 60 -- .., '---_C, 328.18 -+-'Nll~~";C' ,n .. ".:.' (.1.25 PS/POLCl Ship'$load (WHT) 32133 NO 240,vOft (211111 FlMPO ..POLC) ..___ "G~'~""""'-_ equipmeol -il'· (GRN) \ 52 S1 .. N Shore Power SWITch Connection Diagrams WESTERBEKE GENERATORS...
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Page 61: General Information And Care Of The Generator
See tbe rpmlHertzlfrequency chart on tbe next page. WESTERBEKE GENERATORS... - Page 62 3. The rear armature bearing is lubricated and sealed; therefore, no maintenance is required. If the bearing becomes rough or noisy, replace it. Generator Troubleshooting A complete and illustrated test on troubleshooting the BID series of generators is furnished in the Technical Manual which is available through your local dealer. WESTERBEKE GENERATORS...
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Page 63: Your Notes
YOUR NOTES WESTERBEKE GENERATORS... -
Page 64: Engine Troubleshooting
2. Defective fuel solenoid. 2. Check mechanical positioning of fuel solenoid for plunger bottoming. 3. Manually check movement of fuel solenoid plunger and throttle arm. 4. Check for voltage drop at solenoid during preheat. Check wire size from remote panels. WESTERBEKE GENERATORS... - Page 65 5. Emergency STOP switch or 5. Check operation of switch with STOP switch in panel defective, an ohmmeter. opening fuel run solenoid circuit 6. Switches andlor wiring. 6. Inspect all wiring for short circuits and loose connections. Inspect switches for proper operation WESTERBEKE GENERATORS...
- Page 66 3. Low resistance leak. 3. Check all wires for temperature rise to locate the fault. 4. Alternator. 4. Disconnect alternator at output, after a good battery charging. If leakage stops, remove alternator and bench test. Repair or replace. WESTERBEKE GENERATORS...
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Page 67: Maintenance And Adjustments
1. Change the engine's lubrication oil and oil filter. 2. Replace the fuel filter element in the engine-mounted secondary fuel filter. Change the fuel filter element and clean the filter/water sedimentor, if a separator has been installed, and if the model type pennits cleaning. WESTERBEKE GENERATORS... - Page 68 7. Check the raw water pump for internal wear. Examine the pump's cover, cam, and internal housing. Replace worn parts as needed. Check for leaks at seals or gaskets and repair them, as needed. Note: Items highlighted by an asterisk ( should be performed by a competent mechanic. WESTERBEKE GENERATORS...
- Page 69 # I Piston at TDC of its compression stroke. Confirm this by rotating the crankshaft approximately 20 before and after this point and the two valves for the # I cylinder should not move. Adjust the valve clearances for both the intake and exhaust valves for this cylinder WESTERBEKE GENERATORS...
- Page 70 2. Adjust the valve clearances at TDC for each cylinder when they are on their compression stroke. Remember the engine's firing order is 1 - 3 - 2. You may find that turning the engine's crankshaft is more easily accomplished when the engine's glow plugs are removed before the crankshaft is rotated. WESTERBEKE GENERATORS...
- Page 71 Changing the shim thickness by 0.004 inch (0.01 mm) changes the injection by approximately one degree. To advance the timing, decrease the shim thickness, as required. To retard the timing, increase the shim thickness, as required. Refer to your generator's Parts List for shim part numbers. WESTERBEKE GENERATORS...
- Page 72 The fuel shut-off solenoid #037100 is mounted in a threaded boss on the engine's block just aft of and below the engine's fuel injection pump. Proceed as follows when installing a replacement or new fuel shut -off solenoid. WESTERBEKE GENERATORS...
- Page 73 8mmbolt 6. Reassemble the coverlbracketry and test run the unit Ensure that the unit stops when the solenoid is de-energized. #037100 FUE" SHUT OFF SOLENOID #034569 LOCKNUT SOLENOiD ?LUNGER WESTERBEKE GENERATORS...
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Page 74: Lay-Up And Recommissioning
CD. Run the generator and check for proper oil pressure and make sure there are no leaks. CAUTION Do not leave the engine's old lubricating oil in the sump over the lay-up period. Lubricating oil and combustion deposits combine to produce harmful chemicals which can reduce the life of your engine's internal parts. WESTERBEKE GENERATORS... - Page 75 Should these connections appear corroded, they should be removed, cleaned, and reconnected. Make sure all AC leads are properly cleaned and reconnected. Make sure all AC leads are properly supported and not chafing as they exit the generator housing. WESTERBEKE GENERATORS...
- Page 76 Spares Lay-up time provides a good opportunity to inspect your Westerbeke engine to see if external items such as drive belts or coolant hoses need replacement. Check your basic spares kit and order items not on hand, or replace those items used during the lay-up, such as filters and zinc anodes.
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Page 77: Remote Lube Oil Filter Kit - Pn#040078
Contact your local dealer for information on purchasing this kit. ,!,pr! r TO Q-R IIIG illlllf1i..l1..i..8.Ii..A£.ll '1.1!ll.01i..:. GASKET CONTACTS BASE .tiQIf THe 1 oeAl! Oil TU! S WIlliG BEHoyED fOp lJi..S.IAI!AJ1QIi ElL!!. l..Ui..I!.II1! Til R GASKET CQHI6CJS BAse WESTERBEKE GENERATORS... -
Page 78: Table Of Standard Hardware Tightening Torques
28 - 33 3.7 -4.6 3/8 UNF 30 - 35 4.1-4.8 7/16 UNC 44 - 49 6.1 - 6.8 7116 UNF 50 - 55 6.9 - 7.6 112UNC 68 -73 9.4 - 10.1 112 UNF 73 - 80 1O.1-1l.l WESTERBEKE GENERATORS... - Page 79 2.5 -3.5 1.0 - 1.3 1.5 - 2.2 1.8-2.5 3.0 - 4.2 5.0 -7.0 3.0 -4.2 5.5 - 7.5 9.5 - 12.0 5.0 -7.0 8.0 - 11.0 16.0 - 19.0 NOTE: Convert kg-m to ft-lb by muluplymg by 7.233 WESTERBEKE GENERATORS...
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Page 80: Spare Parts
From the list provided directly above and from these inquiries, you can determine what spare parts may be needed. In addition, if you are planning a long ocean voyage, consult your Westerbeke dealer for a listing of the Westerbeke dealers located on your route. - Page 81 NOTES WESTERBEKE GENERATORS...
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Page 82: Sound Guard Installation Instructions
SOUND GUARD INSTALLATION INSTRUCTIONS For a copy of the Sound Guard installation instructions required for your generator set, please contact your local Westerbeke dealer. A four page installation brochure is available which covers all current Sound Guard model assembly/installations. WESTERBEKE GENERATORS... -
Page 83: Bid 7.6 Kw Power Take-Off (Pto) Adapter
(PUIroIP SOURCE) HVDJlECO PUIoIPS KALAMAZOO, HICH. (6:16) 349-1511 NOTE: Provisions should be made to prevent the PTO device from overloading the generator's engine. Install a pressure relief valve On the hydraulic pump to limit maximum pumping pressure. WESTERBEKE GENERA TORS...