Westerbeke 7.6KW ETD 60HZ Operator's Manual
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Westerbeke 7.6KW ETD 60HZ Operator's Manual

Marine diesel generators
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OPERATORS MANUAL
7.6KW ETO 60HZ
5.7KW ETO 50HZ
MARINE 01
EL GENERATORS
SECOND EDITION
DECEMBER 2007
~
WESTERBEKE
WESTERBEKE CORPORATION -150 JOHN HANCOCK ROAD
MYLES STANDISH INDUSTRIAL PARK - TAUNTON
MA
02780
WEBSITE: WWW.WESTERBEKE.COM
----
!\IMM4 Member National Marine Manufacturers Association
~~.,.,

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  • Page 1 OPERATORS MANUAL 7.6KW ETO 60HZ 5.7KW ETO 50HZ MARINE 01 EL GENERATORS SECOND EDITION DECEMBER 2007 WESTERBEKE WESTERBEKE CORPORATION -150 JOHN HANCOCK ROAD MYLES STANDISH INDUSTRIAL PARK - TAUNTON 02780 ---- WEBSITE: WWW.WESTERBEKE.COM !\IMM4 Member National Marine Manufacturers Association ~~.,.,...
  • Page 2 WARNING Generators Produce CARBON MONOXIDE. Regular Maintenance Required lFJy~::!~:,:! A WARNING DECAL is provided by WESTERBEKE and should be fixed to a bulkhead near your engine or generator. WESTERBEKE also recommends installing CARBON MONOXIDE DETECTORS near the engine room. They are inexpensive and easily obtainable at your local hardware store.
  • Page 3 SAFETY INSTRUCTIONS PREVENT BURNS - FIRE INTRODUCTION Read this safety manual carefully. Most accidents are WARNING: caused by failure to follow fundamental rules and 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 ACCIDENTAL STARTING TOXIC EXHAUST GASES WARNING: Accidental starting can cause injury WARNING: Carbon monoxide (CO) is deadly gas! or death! • Ensure that the exhaust system is adequate to expel gases • Disconnect the battery cables before servicing the engine/ discharged from the engine.
  • Page 5 SAFETY INSTRUCTIONS • Do not wear loose clothing or jewelry when servicing ABYC, NFPA AND USCG PUBLICATIONS FOR 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 ........24 Fuel, Engine Oil and Engine Coolant....Electronic Governor ........24 Preparations for Initial Start-Up ......6 Valve Clearance Adjustment ....... 25 Digital Control Panel ........... Engine Compression ........

  • Page 8: Parts Identification

    7.6KW GENERATOR PARTS IDENTIFiCATION "nlllll:""rlnll SIPHON BREAK INJECTION THERMOSTAT ASSEMBLY DRIVE BELT COVER PRESSURE SENSOH--.? ..~--STARTER ZINC MOTOR LEFT FRONT SIDE HEAT EXCHANGER COOLANT PRESSURE CAP -..""... RAW WATER PUMP REAR RIGHT SIDE MOUNTS Engines & Generators...

  • Page 9: Introduction

    OF THE FURNISHING OR USE OF SUCH SOFTWARE. provided and a techmcal manual is available from your WESTERBEKE customers should also keep in mind the WESTERBEKE dealer. If you are planning to install this time span between printings ofWESTERBEKE product equipment contact your WESTERBEKE dealer for software and the unavoidable existence of earlier WESTERBEKE'S installation manual.
  • Page 10 SPARES AND ACCESSORIES Certain spares will be needed to support and maintain your WESTERBEKE engine. Your local WESTERBEKE dealer will assist you in preparing an inventory of spare parts. See the SPARE PARTS page in this manual. For engine An identification plate on the engine manifold also displays accessories, see WESTERBEKE'S ACCESSORIES brochure.

  • Page 11: Fuel, Engine Oil And Engine Coolant

    DIESEL FUEL ENGINE COOLANT fuel that meets the requirements or specification of Class WESTERBEKE recommends a mixture of 50% antifreeze 2-D (ASTM), and has a cetane rating of #45 or better. and 50% distilled water. Distilled water is free from the chemicals that can corrode internal engine surfaces.

  • Page 12: Preparations For Initial Start-Up

    PREPARATIONS FOR INITIAL START-UP PRESTARTINSPECTION 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 al/ AC loads, especially large motors, • Make certain the cooling water thru-hull petcock is open. be switched OFF until the engine has come up to speed •...

  • Page 13: Digital Control Panel

    BREAKER (ECU) . START BUTTON LIGHT DESCRIPTION Battery Voltage Oil Pressure WESTERBEKE'S Digital Control panel provides the 13.5 operator with an LCD display that continuously monitors VI?C all the operations of the generator in easy to understand text messages. SCROLL...
  • Page 14 DC power to the generator with a NMEA-2000 system or shut off the DC breaker on the generator's control boxJor a WESTERUNK system. NOTE: Keep in mind that the Westerbeke generator may -be power supply for the vessel's NMEA-2000 network.

  • Page 15: Generator Break-In Procedure

    GENERATOR BREAK-IN PROCEDURE DESCRIPTION Mter the first 10 hours of the generator's operation, the load can be increased to the full-load rated output, then periodi- Although your engine has experienced a minimum of one cally vary the load. hour of test operations at the factory to make sure accurate Avoid overload at times.

  • Page 16: Maintenance Schedule (Chart)

    MAINTENANCE SCHEDULE WARNING: Never attempt to pedorm 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. /)isconnect 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...
  • Page 17 Remove, have professionally cleaned and pressure tested. NOTE: When servicing! changing DC components. The DC power must be turned off using "WESTERBEKE recommends this service be performed by an authorized mechanic. either the DC breaker or the battery switch. CAUTION (WESTERLINK NMEA-2000): The electronic components in the Digital Diesels draw a very small amount of amperage (milU-amps) from the generator's starting battery when the unit is in a static state.

  • Page 18: Fuel System

    This process is accomplished by installing 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 important component of the diesel engine, requiring the utmost caution in handling.

  • Page 19: Cooling System

    DESCRIPTION fresh water coolant flows around the tubes; engine heat trans- Westerbeke marine diesel engines are designed and equipped ferred to the fresh water coolant is conducted through the for fresh water cooling. Heat produced in the engine by com-...

  • Page 20: Fresh Water Cooling Circuit

    COOLING SYSTEM FRESH WATER COOLING CIRCUIT CHANGING COOLANT The engine's coolant must be changed according to the NOTE: Refer to the ENGINE COOLANT section for the rec- MAINTENANCE SCHEDULE. lfthe coolant is allowed to ommended antifreeze and water mixture to be used as the become contaminated, it can lead to overheating problems.

  • Page 21: Thermostat

    COOLING SYSTEM THERMOSTAT RAW WATER INTAKE STRAINER A thennostat, located near the manifold the front of the NOTE: Always install the strainer or below waterline so engine, controls the coolant temperature as the coolant strainer will always be self-priming. continuously flows through the closed cooling circuit When clean raw water intake strainer is a vital component of the the engine is first started, the closed thennostat prevents engine's cooling system.

  • Page 22: Raw Water Cooling System

    COOLING SYSTEM RAW WATER COOLING CIRCUIT RAW WATER PUMP The raw water pump is a self-priming, rotary pump with a The raw water flow is created by a positive displacement impeller pump. TIus 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 23: Engine Lubricating Oil

    ENGINE LUBRICATING OIL When installing the new oil filter element, wipe the filter ENGINE OIL CHANGE 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 rubber gasket the sump drain hose (attached to the front of the engine) on the new oil filter.

  • Page 24: Remote Oil Filter (Optional)

    REMOTE OIL FILTER (OPTIONAL) REMOTE OIL FILTER KIT PN#040078 NOTE: INSTALLATION Westerbeke is not responsible for engine failure due to incorrect installation the Remote Oil Filter. This popular accessory is used to relocate the engine's oil fil- ter from the engine to a more convenient location such as an c-ngine room bulkhead.

  • Page 25: Starter Motor

    STARTER MOTOR DESCRIPTION The starter is a new type, small, light-weight and is called a high-speed internal-reduction starter. The pinion shaft is separate from the motor shaft; the pinion slides only on the pinion shaft. A reduction gear is installed between the motor shaft and a pinion shaft.
  • Page 26 If the starter to spin, the motor is probably faulty. fails WESTERBEKE uses a standard starter motor which can be If no arching occurred, there is no juice reaching the serviced or rebuilt at any starter motor automotive service solenoid.

  • Page 27: Generator Specifications

    SPECIFICATIONS • 7.6KW ETD GENERATOR ENGINE SPECIFICATIONS ELECTRICAL SYSTEM Engine Type Diesel, four-cycle, three-cylinder, fresh Starting Battery 12-Volt, (-) negative ground water-cooled, vertical in-line overhead valve Battery Capacity 800-1000 Cold Cranking Amps (CCA) mechanism (11 Hp at 1800 rpm maximum) DC Charging Alternator 51 Amp rated, belt driven Aspiration...

  • Page 28: Wiring Diagram #52441

    e;;! &217 A RElEAS( TO SYSTEM f21~·N ~~~~fr.t'..~~p r~~~~ ~~[ ~~R ~~:P~aS~~rkWIlWiG 62:69 DI~GAAM AOO(O OPTOIN_L REMOTE SIS CaNtlE TIOM 7.6KW ETD WIRING DIAGRAM #52414 Ei297 2'0'0\ Pi-PIN Z' WAS COHH(CT£O TO KI-PIN 86 16·A[DI TO 111-16. REMOVE -RED) BEUHN 112-30 AND IIl·al (It'YiHTIIf£DI TO IIl- 0 I II-REO) ItEfwHN II)·]Q...

  • Page 29: Engine Adjustments

    ENGINE ADJUSTMENTS NOTE: WESTERBEKE recommends that the following engine adjust- ments be performed by a competent engine mechanic. The infonnation below is provived to assist the mechanic. DRIVE BELT ADJUSTMENT TORQUING THE CYLINDER HEAD BOLTS For your safety, WESTERBEKE generator models come...

  • Page 30: Engine Adjustments (Cont.)

    ON THE CONTROL PANEL ECU SWITCHES BOARD MUST 8E SWITCHED: ON FOR 50 HZ AND OFF FOR 60 HZ. SCREW/NTO 3/16" TO 7/8" ORIGINAL MEASURE STANDAilD NOTE: For additional infomw.tion and Electronic Governor Troubleshooting, refer to your WESTERBEKE Service Manual. Engines Generators &...

  • Page 31: Valve Clearance Adjustment

    Each cylinder 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 32: Spill Timing

    ENGINE ADJUSTMENTS NOTE: WESTERBEKE recommends that the following engine adjust- ments be peiformed by a competent engine mechanic. information below is provided to assist the mechanic. Injection Pump Timing Adjustment (Spill Timing) INJECnON PUMP If your engine's fuel injection timing is not properly adjusted,...

  • Page 33: Oil Pressure

    ENGINE ADJUSTMENTS NOTE: WESTERBEKE recommends following engine adjust- that the ments be peiformed by a competent engine mechanic. information below is provided to assist the mechanic. TESTING GLOW PLUGS OIL PRESSURE The engine's oil pressnre,is constantly monitored by the control...

  • Page 34: Fuel Injectors

    FUEL INJECTORS REMOVING THE INJECTORS Inspecting Spray Pattern 1. Operate the hand lever of the nozzle tester at intervals of NOTE: Injector must be serviced in a "clean room" environment. one stroke per second to check if the fuel is injected cor- 1.

  • Page 35: Engine Troubleshooting (Chart)

    ENGINE TROUBLESHOOTING The following troubleshooting table describes certain NOTE: The engine's electrical system is protected by a problems relating to engine service, the probable causes of rocker type manual reset circuit breaker mounted on the the problems, and the recommendations overcome these generator's control box next to the LCD Display Panel.
  • Page 36 ENGINE TROUBLESHOOTING VeriflcationJRemedy Problem Probable Cause Exhaust smoking problems Blue smoke. Incorrect grade of engine oil. 1a. Crankcase is overfilled with engine oil (oil is blowing out through the exhaust). 2. White smoke. 2. Engine is running cold. 2a. Faulty injector or incorrect injector timing. 3.

  • Page 37: Alternator Testing

    A working alternator runs hot. A failed The following information applies to the standard 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 38 ALTERNATORS TESTING/TROUBLESHOOTING MEASURING BATTERY VOLTAGE TESTING THE ALTERNATOR ENGINE OFF) CAUTION: Before starting tbe engine make certain tbat everyone is clear moving parts! Keep away from sheaves and belts during test procedures. 1. Start the Engine. 2. After the engine has run for a few minutes, measure the starting battery voltage at the battery terminals using a multimeter set on DC volts.

  • Page 39: Battery Care

    RUNNING) tests indicate a failed alternator, it will need to be disas- sembled and repaired. Any good alternator service shop can do the job. NOT~ WESTERBEKE'S Service Manual has detailed instructions/or disassembly and repair a/their standard alternators. BATTERY CARE The minimum recommended capacity of the battery used in the reading between .75 and 1.1 volts, the...

  • Page 40: Shore Power Connections

    7.6 KW BT SHORE POWER TRANSFER SWITCH CONNECTIONS the installer connects shore power to the vessel's AC cir- 230 Volt/5D Hertz Two Wire Configuration cuit, this must be done means of the SHORE POWER! Notice the repositioning of the white ground lead on the ter- OFF/SHIPS GEN.

  • Page 41: Generator Information

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

  • Page 42: Kw Generator Single Phase

    7.6KW BT 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- ator power in case of an electrical overload.

  • Page 43: 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 44: No Load Voltage Adjustment

    7.6KW BT GENERATOR SINGLE PHASE NO-LOAD VOLTAGE ADJUSTMENT After the no-load hertz adjustment is made, the no-load voltage may need to be readjusted. In most cases, if the Voltage adjustment is made with the generator regulation generator was producing the correct no-load voltage at being governed the compound transformer.

  • Page 45: Residual Voltage Check

    7.6KW BT GENERATOR SINGLE PHASE INTERNAL WIRING FOR 12 :lii.iii BT GENERATOR r-------, r-------, r--------------, .--+-1 • . . . 1>1- :::::::;7'~ L _____________ • WHT/ BLK .!l~tt-+ I-------J WHT IGREEN • • « AC BLACK ORANGE -Kl- GREEN YELLOW RESIDUAL VOLTAGE CHECK Apply 12 volt DC excitation to the exciter stator wind- ings as explained in paragraph 2.

  • Page 46: 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 from the auxiliary windings in the generator stator (c:::-3) and the compound Simpson 260) (Meter used: transformer (D-3). The AC voltage measured across the AC 1.

  • Page 47: Exciter Rotor Field

    7.fiKW BT GENERATOR SINGLE PHASE The diodes can be easily checked in place with the use of a EXCITER ROTORIFIELD common automotive 12-volt high beam headlight bulb, some Anxlliary windings group 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 48: Measuring Resistance

    7.6KW BT GENERATOR SINGLE PHASE MEASURING RESISTANCE A three connection voltage connection terminal was added to this circuit located just below the AC terminal block lower left. Isolate the three numbered red and #1, #2, Main Stator Windings white-striped wires coming onto each of the three terminals. 1.

  • Page 49: Lay-Up And Recommissioning

    LAY-UP AND RECOMMISSIONING GENERAL CAUTION: Do not leave the engine's old lubricat- th~ir Many owners rely on their boatyards to prepare craft, including engines and generators, for lay-up during the off- Ing oil in the sump over the lay-up period. Lubricating season or for long periods of inactivity.
  • Page 50 Lay-up time provides a good opportunity to inspect your Lubrication and cleaning of the starter drive pinion is WESTERBEKE engine to see if external items such as drive advisable, if access to the starter pennits its easy removaL belts or coolant hoses need replacement Check your basic...

  • Page 51: Power Take-Off

    The 7.6Kw ETD produces Ilhp at a continuous 1800 rpm (Shp at 50Hz 1500 rpm). This horsepower can be utilized either for generator output or to operate the power take off. Contact your WESTERBEKE DISTRIBUTOR/or additional information. REMOVE COVER POWER TAKE OFF KIT #34786 (SAE-B)

  • Page 52: Metric Conversion Data (Chart)

    STANDARD AND METRIC CONVERSION DATA LENGTH-DISTANCE Inches (in) x 25.4 Millimeters (mm) x .0394 Inches Feet (tt) x .305 :: Meters (m) x 3.281 Feet Miles x 1.609 :: Kilometers (km) x .0621 :: Miles DISTANCE EQUIVALENTS 1 Degree ofLatitude :: 60 Nm 111.120 km 1 Minute of Latitude:: 1 Nm = 1.852 km VOLUME...

  • Page 53: Suggested Spares

    SUGGESTED SPARE PARTS CONTACT YOUR WESTERBEKE DEALER FOR SUGGESTIONS AND ADDITIONAL INFORMATION WESTERBEKE RECOMMENDS CARRYING ENOUGH ENGINE OIL (YOUR BRAND) FOR AN OIL CHANGE AND A GALLON OF PREMIXED COOLANT. THERMOSTAT SPARE DRIVE BELTS FUEL SYSTEM HARDWARE KIT MOLDED IN-LINE...
  • Page 54 Engines & Generators WMDW11096/05...

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