Westerbeke 7.6kw-60Hz EDT Service Manual
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Westerbeke 7.6kw-60Hz EDT Service Manual

Westerbeke 7.6kw-60Hz EDT Service Manual

D-net diesel, single phase generators
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SERVICE MANUAL
- - - - - .
.
.
D·"NET DIESEL GENERATORS
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- - - - -
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. --,---< - - -
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; I
7.6KW • 60Hz 15.7KW • 50Hz EDT
, . 5.5KW • 60Hz 15.0KW • 50Hz
ED' C ..
REVISIONi~
. . MARCH2010
V6
WESTERBEKE
I
-"AT......
WESTERBEKE CORPORATION. MYLES STANDISH INDUSTRIAL PARK
I
~:1!"'ft'
" .
150 JOHN HANCOCK ROAD. TAUNTON MA 02780-7319· TEL. 1-508·823·7677
,
___
_ ___ ..
. FAX 1-508·884·9688· WEBSITE: Www.WESTERBEKE.COM

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  • Page 1 , . 5.5KW • 60Hz 15.0KW • 50Hz REVISIONi~ . . MARCH2010 WESTERBEKE -"AT..WESTERBEKE CORPORATION. MYLES STANDISH INDUSTRIAL PARK " . ~:1!"'ft' 150 JOHN HANCOCK ROAD. TAUNTON MA 02780-7319· TEL. 1-508·823·7677 _ ___ .. . FAX 1-508·884·9688· WEBSITE: Www.WESTERBEKE.COM...
  • Page 2 Shut down the unit and do not restart until It has been inspected and repaired. A WARNING DECAL Is provided by WESTERBEKE and should be fixed to bulkhead near your engine or generator. WESTERBEKE also recommends installing...
  • Page 3 Use a suitable container to catch all fuel when removing the fuel line, carburetor, or fuel filters. f-v.rl WESTERBEKE Engines & ,Generators ;"-...
  • Page 4 Consult your boat builder or dealer for installation of approved detectors. WARNING: Do not work on machinery when you are mentally physically incapacitated by fatigue! 1"'MT1 WESTERBEKE Engines Generators &...
  • Page 5 SAFETY INSTRUCTIONS OPERATORS MANUAL ABVC, NFPA AND USCG PUBLICATIONS FOR INSTALLING DIESEL ENGINES Many of the preceding safety tips and wamings are repeated in your Operators Manual along with other cautions and Read the following ABYC, NFPA and USCG publications notes to highlight critical infonnation.
  • Page 6 AVAILABLE FROM NOTE: A siphon-break requires periodic inspection and cleaning to ensure proper YOUR WESTERBEKE operation. Failure to properly maintain a siphon-break can result in catastrophic DEALER engine damage. Consult the siphon-break manufacturer for proper maintenance. EXHAUST SYSTEM The exhaust hose must be certified for marine use.

  • Page 7: Table Of Contents

    TABLE OF CONTENTS Digital Control Box ...........41 Introduction ..............7.6/5.7KW Wiring Diagram ........Engine Troubleshooting ..........Specifications· 7.6/5. 7KW ........43 Testing for Overhaul ........... 7 Specifications· 5.5/5.0KW ........44 . Engine Disassembly ............ Generator Information ..........45 Cylinder Head ............10 7.6/5.7 EDT Generator Single Phase .......

  • Page 8: Introduction

    Mode17.6KW Ser. # OF THE FURNISHING OR USE OF SUCH SOFTWARE. Expires WESTERBEKE customers should also keep in rrrlnd the time spao between printings of WES1ERBEKE product SERIAL NUMBER LOCATION software aod the unavoidable existence of earlier WES1ERBEKE manuals. Product software provided with...

  • Page 9: Engine Troubleshooting

    1. Check and retighten connector. 1. Air trapped in fuel system. 2. Clogged filter. 2. Clean or replace filter. 3. Contaminated fuel tank. 3. Clean tank. INSUFFICIENT INTAKE AIR 1. Air intake obstructed. 1. Cleanlntake. (continued) 1""ffIVi WESTERBEKE Generators Engines &...
  • Page 10 ENGINE TROUBLESHOOTING PROBLEM PROBABLE CAUSE VERIFICATION/REMEOY lOW OUTPUT POWER OVERHEATING 1. low coolant level. 1. Add coolant 2. Adjust or replace V-belt 2. loose V-belt 3. Incorrect Injection timing. 3. Adjust injection timing. 4. Low engine oil level. 6. Add engine oil. EXCESSIVE OIL OIL LEAKAGE CONSUMPTION...
  • Page 11 ENGINE TROUBLESHOOTING PROBLEM PROBABLE CAUSE VERIFICATION/REMEDY SMOKY EXHAUST (cont.) WHITISH OR PURPLISH (cont •• ) d. Worn valve stem and valve guide. d. Replace. e. Low engine oil viscosity. e. Replace. Excessive oil pressure. Correct. 3. Injection timing is too late. 3.
  • Page 12 LOW OIL PRESSURE 1. Worn Bearings. 1. Engine overhaul replace bearings. 2. Relief valve malfunction. 2. Overhaul all pump. 3. Clogged all cooler. 3. Repair. 4. Diesel dilution of the 011. 4. Injection pump repair. (continued) 1"JMf WESTERBEKE Engines Generators &...
  • Page 13 ENGINE TROUBLESHOOTING PROBLEM PROBABLE CAUSE VERIFICATION/REMEOY LCD DISPLAY FAULTS 1. Check battery. 1. Battery on. 2. 20 amp breaker off. 2. Turn breaker off. 3. Loose display connection. 3. Check all cable connections. 4. 1 amp fuse blown (faulty). 4. Check/replace. Determine cause. LOW OIL PRESSURE 1.

  • Page 14: Testing For Overhaul

    The engine requires overhaul when oil consumption is high, blowby evident, and compression valves are at minimum or below. Engine compression should be 398 psi, 28 kg/Cnf at rpm. rVV"1 WESTERBEKE Engines Generators &...

  • Page 15: Engine Disassembly

    See SPECIAL TOOLS - GENERATOR. MOTOR LABEL THE WIRES BACK Lock the ring gear with ring gear brake before disassembly. 1"VV'1 WESTERBEKE Engines & Generators The engine should be securely mounted on a sUltabte engine stand.
  • Page 16 ENGINE DISASSEMBLY SEQUENCE FOR LOOSENING CYLINDER HEAD BOLTS 1. Remove engine heat exchanger. If possible, leave one end of each hose connection attached to the part being removed. For maintenance, see HEAT EXCHANGER. 2. Remove the starter motor. For starter motor repair, see STARTER MOTOR 3.

  • Page 17: Cylinder Head

    (0.295 In) shown going through that order two or three times. Tighten each bolt a little at a time until all are tightened to the specified torque. FRONT • PRESS-FITTING THE VALVE GUIDE BOLT TIGHTENING SEQUENCE WESTERBEKE Engines & Generators...

  • Page 18: Valve And Valve Spring Inspection

    VALVE AND VALVE SPRING INSPECTION Valve Spring Fitting Pressure Check. Check valve VALVE REMOVAL spring fitting pressure with a valve spring tester and, if the 1. Dismount the cylinder head· assembly. pressure is less than the limit, replace the spring. 2.

  • Page 19: Valve Instaliationnalve Clearance

    VALVE INSTALLATION I VALVE CLEARANCE Installation Install the valve and valve springs. Refer to the illustrations and callouts shown below. FRONT • NOTE: Be careful not to damage the spring and stem seal by excessively compressing the spring when installing the valve spring.

  • Page 20: Gear Case/Governor

    OIL PUMP RELIEF PLUNGER ASSEMBLY Torque 5.8 -7 .Oft-Ib Torque 28.9 - 36.21t-lb (4.0 -1;jjm-kg) (O.B -1.0m-' WESTERBEKE TAPER PLUG Engines Generators & Torque 10.8 -15.9ft-lb (1.5 - 2.2m-kg)

  • Page 21: Timing Gear

    TIMING GEAR CAMSHAFT Installation REMOVING THE TIMING GEARS 1. Remove the snap ring and disassemble the idler gear. Press-fit the crankshaft gear onto the crankshaft. 2. Remove the valve camshaft and the injection pnmp Press-fit the valve camshaft gear and the ignition pump camshaft on which the gears are press-fitted, remove the camshaft gear onto their respective shafts.
  • Page 22 CAMSHAfT PISTONS AND CONNECTING RODS Remove the rings from each pistOl! with the piston ring pliers: Inspecting The Camshaft Using the piston setting tool, pull out the piston pin from each Make a thorough inspection of the injection pump and the piston.

  • Page 23: Piston And Connecting Rod

    PISTON AND CONNECTING ROD § INSTALLATION INSPECTION Inspect the parts as indicated in the illustration. 1. Reassemble the piston and connecting rod, using the Piston Pin Setting Tool, by pressing the piston pin in to Damage, wear the set position. and ring gap.

  • Page 24: Crankshaft

    PISTON AND CONNECTING ROD Place a heavy hammer as shown. Coat the bearing surface of the connecting rod caps with Gently press down with the foree of your engine oil. Fit each cap to the connecting rod using the match hand.
  • Page 25 CRANKSHAFT ®[JJ INSPECTING THE CRANKSHAFT To check the crankpins and main journals for tapering and out-of,round wear, the diameter of each crankpin or main journal should be measured at two places along the crankpin or main journal, in two directions "An uB"...

  • Page 26: Cylinder Block

    CYLINDER BLOCK .Af''«.", __ ~ COVER -:---~:::"'-2:":4l OIL FILTER SHAFT --l--=---..o..BEARING BEARING-----:::--W CYLINDER BLOCK INSPECTION Check the cylinder block for cracks and damage. If neces- sary, repair or replace it entirely. Check to see that oil or 2.1r.-·;;o;i~' cooling water passages are not clogged and, if clogged, remove with compressed air or a wire.

  • Page 27: Governor System

    GOVERNOR SYSTEM INSPECTING THE GOVERNOR COMPONENTS Check levers tDr smDDIh mDvemenl. Check springs INSTALLING THE SPEED CONTROL LEVER tDr tallgue. TORQUE SPRING SET ASSEMBLY When the torque spring set has been disassembled and inspected and defective parts replaced, reassemble and adjust the torque spring set using the following procedure: Approx SPRING CASE...
  • Page 28 GOVERNOR ELECTRONIC GOVERNOR ACTUATOR Leaving the dial gauge set, its condition unvaried, depress the spring stopper and slide over the torque spring set support The electronic governor aclllator regulates engine speed by dial spring case. Read the dellection of the gauge which allowing more or less fuel to be delivered to the injectors to corresponds to the projection of the spring stopper from the...

  • Page 29: Engine Assembly

    ENGINE ASSEMBLY Install the fuel injection nozzles. Install the fuel overflow Install the Thermostat and Thermostat Housing pipe. Use new sealing washers throughout in the same order . 1. Inspect the thermostat housing and the housing gasket. as were the old washers. Apply some sealant to the gasket when reassembling.
  • Page 30 Check all AC and DC wiring connections alternator and engine pulleys. not, insert or remove to WESTERBEKE's wiring schematics and diagrams. spacers as needed, to align the alternator. See ALTERNATOR for service and testing. Generator. Mount the generator back end assembly with it's control panel.

  • Page 31: Exhaust Manifold

    They will also service transmission and engine oil coolers. 6. Repaint the assembled heat exchanger with Westerbeke 'Clean al,d replace the mannold. heat resistant spray enamel. Q.~_-:--Repl"ce "'nc anodB.

  • Page 32: Fuel Injection Pump

    7. Fit the lower seat to the plunger. Insert the plunger into the barrel side. S. Depress the tappet roller assembly and install the stopper pin. 9. TIghten the delivery holder. Delivery holder tightening Torque: 25.3 - 28.2 ft-Ib (3.5 - 3.9 kg-m). I""fItT1 WESTERBEKE Engines & Generators...
  • Page 33 FUEL INJECTION PUMP I INJECTION TIMING INJECTION PUMP NOTE: The fuel shut-off lever must be in the RUN position while making the adjustment or no fuel will flow from the fuel injection pump. UNION 1. Remove the high pressure fuel line from between fue No. 1 injector and fue No.

  • Page 34: Fuel Injectors

    ADJU"'··==""",=""",==== ing the injection starting pressure. SHIM START TO INJECTION PRESSURE 1988 142psl (140 ±10kg/cm') ± NOZZLE TESTER (""'fAT1 WESTERBEKE Generators EngInes &...
  • Page 35 FUEL INJECTORS REMOVING THE INJECTORS Inspecting Spray Pattern NOTE: Injector tnllSt 1. Operate the hand lever of nozzle tester at intervals of e Serviced in a "clean room environment. • connect the one stroke per second to check if !he fuel is injected cor- gh ~essure loosen the lin lines from the injectors and...
  • Page 36 FUEL INJECTORS DISASSEMBLING AND INSPECTING INSTALLING 1. Clamp the nozzle holder in a vise, then remove the Install the nozzle and nozzle holder assembly in the reverse capnut. order of removal. When installing the nOZ2,le and nozzle holder assembly, use a new copper washer 2.

  • Page 37: Glow Plugs

    GLOW PLUGS Re-install the plugs in'the engine and test them again. The DESCRIPTION plugs should get very hot the terminal end) within 20 to The glow plugs are wired through the preheat solenoid. 25 seconds. If the plugs don't heat up quickly, check for a When PREHEAT is pressed at the control panel-this solenoid short circuit.

  • Page 38: Coolant Circulating Pump

    COOLANT CIRCULATING PUMP DISASSEMBLY 1. Remove the pump pulley boss by using a support and press. BALL BEARlN'GS, 2. Remove the bearing shaft from the impeller and bearing housing by using a support block and press. SHAFT 3. Remove the snap ring with snap ring pliers and press out the water pump shaft from the bearings.

  • Page 39: Raw Water Pump

    RAW WATER PUMP (PN. 48080) 2. Install the oil seal in the pump housing. Disassembly 3. Support the pump.Lubricate the shaft and slide it thru the N~TE: Refer to the following page for parts list and exploded oil seal and press the bearings with shaft into the housing Vlew.
  • Page 40 RAW WATER PUMP (PN.48080) PARTS LIST KEY NO. PART NUMBER AND PART NAME QUANITY RAW WATER PUMP 48080 49172 SHAFT IMPELLER COVER 49170 IMPELLER KIT (O-RING GLYCERIN) 48500 & 34458 WEAR PLATE 49171 302575 DOWEL 48253 SPRING SEAL WASHER IMPELLER COVER SCREW 34463 48359 IMPELLER COVER O-RING...

  • Page 41: Starter Motor

    STARTER MOTOR DESCRIPTION No·Load Test 1. Connect the ammeter, voltmeter, and battery to the starter The starter can be roughly divided into the f<>llowing sections: as illustrated. • A motor section which generates a drive powee • An overrunning clutch section which transmits an arma- 2.
  • Page 42 STARTER MOTOR Return test: With a battery connected to the solenoid ter- minal M (-) and to the starter body, manually pull out the pinion fully. The pinion must return to its original position ~~~ CONNECTOR OFF ATTRACTION TEST when released from holding by hand. 3.
  • Page 43 STARTER MOTOR STARTER INSPECTION Solenoid Inspect solenoid for continuity between terminals S and between terminals S and body. No continuity should be found between S anll M. Continuity should be found between S and the body and M and body. Brush and Brush Holder Inspection L Check the brushes.
  • Page 44 STARTER MOTOR 2. Greasing. Whenever the starter has been overhauled, Field CoillnspeGtion apply grease to the following parts: 1. Check for insulation between one end (brnsh) a. Armature shaft gear and reduction gear. coil and yoke. b. All bearings. 2. Check for continuity between both ends (brnshes) of the coil c.

  • Page 45: Pressure

    OIL PRESSURE OIL PRESSURE SENSOR DESCRIPTION When performing an overhaul, it is recommended that the oil The lubricating system is a pressure fed system using a gear pressure sensor be replaced. When installing the new sensor, style oil pump, driven off the front crankshaft and located in use some liquid Tefton sealant on the threads (only) of the the front gear case.

  • Page 46: Engine Adjustments

    Each cylinder is adjusted following the engine's firing cylinder is still low, apply a small amount of oil into the order (1-3-2 for WESTERBEKE three cylinder engines). cylinder to seal the rings and repeat the test. If compression Valve adjustment beginning with cylinder #1. Rotate the comes up - the rings are faulty.

  • Page 47: Alternator Testingjtroubleshootlng

    A working alternator runs hot. A failed The following information applies to the stal)dard alternators alternator can become very hot. Do not touch the that are supplied with WESTERBEKE'S Engines and Generators. alternator until if has cooled. ELECTRICAL CHARGING CIRCUIT...
  • Page 48 ALTERNATORS TESTINGJTROUBLESHOOTING MEASURING BATTERY VOLTAGE TESTING THE ALTERNATOR (IGNITION ON ENGINE OFF) CAUTION: Before starling the engine make cellain that everyone is clear of moving parts! Keep away from sheaves and belts during test procedures. Start the Engine. 2. After the engine has run for a few minutes, measure the starting battery voltage at the battery terminals using a rnultimeter set on DC volts.
  • Page 49 If tests indicate a failed alternator, it will need to be disas- sembled and repaired. Any good alternator service shop can do tbejob. NOTE: WESTERBEKE'S Service Manual has detailed instructions for the disassembly and repair of their standard alternators. BATTERY CARE...

  • Page 50: Digital Control Box

    NMEA-2000 system or shut off the DC breaker on the generator:S control box for a W.ESTERUNK system. NOTE: DURING OPERATION THE COLOR HOTE: Keep in mind that the Westerbeke generator maybe OF THE LCD DISPUY MAY VARY. power supply for the vess,el's NMEA-2000 network. tlte...
  • Page 51 7.6KW/5.5KW GENERATOR WIRING DIAGRAM #52414 r----------------, ~18/1HM lOIlM ill ~l9JIHlIII H~9m~ ;: ;; ~ngm ~'IIIII (~89111 ~J,9~OGII Qlf( (l)d U ¥ lUI!t " 1 OIAIiJ mill L-il' • f' -~ ~"'"'''' • f " " I :' '-" ;: E ~'!~ •...
  • Page 52 SPECIFICATIONS· 7.615. 7KW EDT GENERATOR ENGINE SPECIFICATIONS ELECTRICAL SYSTEM 12-Volt, (-) negative ground Engine Type Diesel, four-cycle, three-cylinder, fresh Starting Battery water-cooled, vertical in-line overhead valve SOO -1 000 Cold Cranking Amps (GGA) Battery Capacity mechanism (11 Hp at 1800 rpm maximum). DC Charging Alternator 50 Amp rated, bell driven Aspiration...
  • Page 53 SPECIFICATIONS· 5.5J5.0KW EDC GENERATOR ENGINE SPECIFICATIONS ElECTRICAL SYSTEM Engine Type Starting Battery 12-Von, (-) negative ground Diesel, lour-CYCle, three-cylinder, Iresh water-cooled, vertical in-line overhead valve Battery Capaclly 800 -1000 Cold Cranking Amps (CCA) mechanism (9.2 Hp 1800 rpm maximum). Starter 12-Volt, reduction Aspiration Naturally aspirated...

  • Page 54: Generator Information

    AC equipment of 120 volts only, it is recommended that the generator's AC terminal block be configured to pro- vide one 120 volt AC hot leg for the vessel's distribution panel. This will ensure good motor starting response from the generator. WESTERBEKE & EngInes Generators...

  • Page 55: Edt Generator Single Phase

    7.6/5.7KW EDT GENERATOR SINGLE PHASE Circuit Breaker . DESCRIPTION A circuit breaker is installed on all WESTERBEKE genera- This generator is a four-pole, brushless, self-excited generator tors. This circuit breaker will automatically disconnect gener- which requires only the driving force of the engine to pro- duce AC output.

  • Page 56: Troubleshooting

    7.6/5.7KW EDT 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 mlo/ be encountered with the BT These are hand tools: an amp probe and a quality volt-ohm- meter capable of reading less than one ohm due to the preci- brushless generators operating on compound transformer reg- ulation.

  • Page 57: No-Load Voltage Adjustment

    It connects LOAD LOAD bl>\vieen the neutral stud LOAD CONNECT I ON 'ONI-II:C110N CONNECTION aTld Ihe genemor fIBme. LOAD ' " CONNECTION 1"'t'IVI WESTERBEKE WHEN WIRING 120V/&Olil. A JUMPER IS R(OUIRED BETW[EN LOAD CONN£CT IONS Engjnes & Generators...

  • Page 58: Residual Voltage Check

    NOTE: Current model bridge output are the posi-resistor in the exciter rotor and four or rectifiers are configured more failed diodes in the exciter rotor. differently, but + and - are 1""fAT! WESTERBEKE still located at the comers. Engines Be Generators...

  • Page 59: Bridge Rectifier

    7.6/5.7KW EDT GENERATOR SINGLE PHASE Testing The Bridge Rectifier BRIDGE RECTIfIER for faults With An Ohmmeter The bridge rectifier is supplied AC voltage from the auxiliary windings in the generator stator and the compound (y3) (Meter used: Simpson 260) transfonner (D-3). The AC voltage measured across the AC 1 .

  • Page 60: Exciter/Rotor Field

    7.6J5.7KW EDT GENERATOR SINGLE PHASE The diodes can be easily checked in place with the use of a EXCITER ROTOR/FIELO common automotive l2·volt high beam headlight 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 61: Measuring Resistance

    Lift both leads along with lead #7 at the terminal block. Compound Transformer Windings 0.019·0.021 Ohms COMPOUND HIGH 12 STUD TERMINAL BLOCK BRIDGE CIRCUIT BREAKER SINGLE PHASE STUDI VOLT CONFIGURATION 120/60 TERMINAL WESTERBEKE Engines Generators &:...

  • Page 62: Shore Power Transfer Switch

    7.6/5.7KW EDT SHORE POWER TRANSFER SWITCH CONNECTIONS 230 Volt/50 Hertz Two Wire Configuration the installer connects shore power the vessel's AC cir- cuit, this must be done by means of the SHORB POWER! Notice the repositioning of the white ground lead on the ter- OFF/SHIPS GEN.
  • Page 63 WESTERBEKE generators. This circuit breaker will AC output. The stator houses two sets of windings; the main automatically disconnect generator power in case of an stator wirulings and the exciter windings.

  • Page 64: Troubleshooting

    1. Electrical connections are faultyAoose Check/clearAlghten electrical connections Noisy Operation 1. Faulty support bearing 1. Inspect rear rotor carrier bearing 2. Generator rotor connection to engine 2. Inspect security of rotor to flywheel Is loose 1"'fIVi WESTERBEKE Engines Generafors &...

  • Page 65: Dual Exciter No-Load Voltage Adjustment

    5.5/5.0KW EDe GENERATOR SINGLE PHASE NOTE: When changing Hertz produced by the generator, an DUAL EXCITER NO-LOAD VOLTAGE ADJUSTMENT engine speed adjustment at the throttle arm linkage must be These generators have dual Hertz and no-load voltage made. The output connections on the terminal blocks adjustment connectors at each capacitor.

  • Page 66: Single Exciter No-Load Voltage Adjustment

    THE GROUND SHOWN TERMINAL BLOCK IS INSIDE THE GENERATOR BOX GENERATOR BACK END SHOWN 120Vl60Hz -- -- 3iIC :::j!C.--. ACTERMINAL BOARD LOAD CONNECTlON SINGLE EXCITER CIRCUIT WHEN WIRING 120V/60Hz. A JUMPER IS REQUiRED BETWEEN LOAD CONNECTIONS ,"""'", WESTERBEKE Engines Generators &...

  • Page 67: Edc Generator Single Phase

    5.515.0KW EDC GENERATOR SINGLE PHASE Testing the Battery Charging Circuit INTEGRAL CONTROLLER (I. 1. Bridge Rectifier The Integral Controller (lC.) is an encapsulated, solid-state unit that supplies a DC charging voltage to the generator's Normal AC voltage running to the rectifier (while the starting battery while the generator is opening.

  • Page 68: Testing The Exciter Windings

    5.5/5.0KW EDe GENERATOR SINGLE PHASE Unplug any other connections from the capacitor(s) noting TESTING THE EXCITER WINDINGS their position on the capacitor. Place one lead of the RESIDUAL VOLTAGE: Dual Exciter 7 • 9 Volls AC from each winding ohmmeter on plug connection and the other lead on plug AC voltage is induced in these windings by the rotating connection #50 Hertz.

  • Page 69: Shore Power Transfer Switch

    5.5/5.0KW EDC GENERATOR SINGLE PHASE 7. During 12 volt excitation, output voltage ranges are as 6. 12 volt DC excitation (low or AC output voltage) the generator may be excited using 12 volts DC taken from follows: the engine's starting battery. This voltage is applied Dual Exciter 12 -14 VAC acrosS the #50 leads of the exciter circuit wind-...

  • Page 70: Testing Component Resistance Values

    5.5/5.0KW EDe GENERATOR SINGLE PHASE Testing Component Resistance Values Rotating Field/Auxiliary Windings and Diodes Two sets of windings are found in the rotor assembly. voltage is produced in two groups of windings as the rotor turns at rated rpm. The AC voltage passes through each of the two diodes mounted on the isolated fixture just before the rotor carrier bearing.

  • Page 71: Special Tools

    Lifting Eye, remove the generator's control panel and A local machine shop should be able to fabricate these tools at a modest price, but first check with your local WESTERBEKE screw the Lifting Eye to the generator end.
  • Page 72 SERVICE DATA STANDARDS AND LIMITS 7.6/5.7 EDT AND 5.5/5.0 EDC GENERATORS Specllled Value {Slandard Repair limit Component Component Specilied Value {Standard Repair limit Inches(mm) Inches(mm) Inches(mm) inches(mm) COMPRESSION {TIMING CYLINDER BLOCK Cylinder Compression ... 398.16 psi at 280 rpm ..••..••..• 355.5 psi Camshaft Hole Diameter kgfcm~ Pressure...
  • Page 73 FrontJoumal ........B.II Be.ring Journ~to Cylinder ..............0.006 (0.15) Block Hole Cle.rance Lobe Height ........1.078 (27.37) ...... 0.039 (1.0) Major Diameter of Cam ....1.078 (27.37) ...... 0.039(-1.0) .(Intake and Exhaust) Oil Clearance ................0.006 (0.15) WESTERBEKE Engines Generators &:...

  • Page 74: Specifications· 7.6/5. 7Kw

    TORQUE SPECIFICATIONS· 7.6/5.7KW AND 5.5/5.0KW GENERATORS COMPONENT FT·LB (M·KG) FT·LB (M·KG) COMPONENT Alternator Bracket .., ..... 27 - 38 (3.8 - 5.3) Injection Pump Hollow Screw M10 (14) ........7.2 -10.8 (1.0 -1.5) Back Plate ........24 - 35 (3.3 - 4.8) Injectors ..........

  • Page 75: Standard Hardware Torques

    STANDARD HARDWARE TORQUES NOTE: Unless stated othelWise for a specific assembly, use the following torque values when tightening standard hardware. Pitch Ib-n kg-m Grade 71, 8T and B_B Grade 4 Pilch Ib·n lqJ-m 6mm bolt headlnut 5.B-&7 0.B-1.2 6mm bolt headlnut 2.9-5.1 0.4-0.7 14.5-21.7...

  • Page 76: Metric Conversions

    Pints Liters Pints Liters Liters Pints Liters Pints 0.47 2.84 2.11 12.68 0.95 3.31 4.23 14.79 1.42 3.79 6.34 16.91 1.89 4.26 8.45 19.02 2.37 4.73 10.57 21.13 TEMPERATURE 105 140 175 212 80 100 °C WESTERBEKE Engines & Generators...

  • Page 77: Index

    INDEX Injection Pump ........... _ ..25 AC Voltage Connections ........57, 58 Alternator Testing ........... .38 Injection Pump Camshaft Removal ......14 Block- Cylinder ............19 Injection Timing ............26 Bridge Rectifier ..........' " ..50 Injectors - Fuel ............27 Camshaft ..............
  • Page 78 Valve Timing ............63 Valve Seat Repair ............ 10 Torque Spring Set............20 Valve Spring .............. 11 Tools-Generator Disassembly ........62 Wiring Diagrams: Torques: 7.6/5.7 and 5.515.0 Wiring Diagram ....42 Standard Hardware ..........66 Westerbeke Components ........65...
  • Page 79 -.v- WESTERBEKE - Engines Generators &...

This manual is also suitable for:

5.5kw-60hz edt5.0kw-60hz edt5.7kw-60hz edt5.5kw-60hz edc5.0kw-60hz edc

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