Westerbeke 7.6 kw EDT Operator's Manual
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Westerbeke 7.6 kw EDT Operator's Manual

D·net diesel generators single phase
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OPERATORS MANUAL
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7 .6KW EDT 60 HZ
5.7KW EDT 50 HZ
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D·NET DIESEL GENERATORS
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PHASE .
NO. 52767
Rl'lfl!::fnN
3
JANUARY
2012
, WESTER~EKf;,CORPORATION
.150
JOHN HANCOCK ROAD
'MYLES STANDIsH INDUSTRIAL PARK' TAUNTON MA 02780
WEBSITE: WWW.WESTERBEKE.COM
NAiJl-l
Member National
M~rine
Manu/acwrers Association
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  • Page 1 D·NET DIESEL GENERATORS i ., PHASE . NO. 52767 Rl'lfl!::fnN JANUARY 2012 , WESTER~EKf;,CORPORATION .150 JOHN HANCOCK ROAD 'MYLES STANDIsH INDUSTRIAL PARK' TAUNTON MA 02780 WEBSITE: WWW.WESTERBEKE.COM M~rine NAiJl-l ..,..,..., Member National Manu/acwrers Association • • C" - _ _...
  • Page 2 Inspected and repaired. ~WIill!!ll!!A!Iii!!!'R~-Ni!!i!-I!I!IN ~G ! 'Generators Produce CARBON MON0XIDE. Regular Maintenance Required A WARNING DECAL is provided by WESTERBEKE and should be fixed to bulkhead near your engine Dr generator. WESTERBEKE also recommends installing CARBON MONOXIDE DETECTORS near the engine room.
  • 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 Acid may splash on the skin or situation arises in which it is absolutely necessary to into the eyes inadvertently when removing electrolyte make operating adjustments, use extreme care to avoid caps. touching moving parts and hot exhaust system components. WESTERBEKE Engines Generators &...
  • Page 5 USCG the NFPA. Sections of the ABYC standards of particular interest are: H-2 Ventilation P-I Exhaust Systems P-4 Inboard Engines E-9 DC Electrical Systems All installations must comply with Federal Code of Regulations (FCR). WESTERBEKE Engines & Generators...
  • Page 6 INSTALLATION When installing WESTERBEKE engines and generators it is important that strict attention be paid the following information: CODES AND REGULATIONS Strict federal regulations, ABYC gnidelines, and safety codes must be complied with when installing engines and generators in' a marine environment.

  • Page 7: Table Of Contents

    Measuring Resistance ........42 Voltage Connection Terminal ..... .42 Troubleshooting; ... : ........20 Lay-up and Recpmmissioning ......Generator Specifications ........Wiring Diagrams ...., ......Power Take-Off ..........Metric Conversion Data (Chart) ....... Suggested Spares ..........v-WESTERBEKE Engines & Generators...
  • Page 8 7.6 KW GENERATOR WIRING SCHEMATIC #044121 IREMOTE PANEL ~..al---EXHAUST INJECTION ELBOW DCLl,_-.;..~'" DRIVE COVER i?l""11~~~ ,t1t-:;(VfL-ISTAI~TSOLENOIO SEN1!OR.~" OIL PRESSURE ',ZINC ANOIOE-~~ ALTERNATOR LEFT FRONT SIDE EXCHANGER· COOLANT'PRESSURE CAP FILTER i:ONTROL_~£~ DIGITAL PANEL ~~~w~~r-,' n'OIL FILTER REAR !:k--OIL DRAIN HOSE CIRCUIT !'OWER TAKI:·OFF CONNECTION RIGHT SIDE...

  • Page 9: Introduction

    OF THE FURNISHING OR USE OF SUCH SOFTWARE. provided and a technical manual is available from your WESTERBEKE customers should also keep in mind the WESTERBEKE dealer. If you are planning to install tIns time span between printings of WESTERBEKE product equipment contact your WESTERBEKE dealer for software and the unavoidable existence of earlier WESTERBEKE'S installation manual.
  • Page 10 NOTE: A carbon nlOlwxide warning decal has been 'provided , , The engine and generator serial numbers and model numbers in the by WESTERBEKE AffIX this decal in a visible position , are located on a decal on the generator housing, Thke the engine room.

  • Page 11: Fuel,Engine Oil And Engine Coolant

    DIESEL FUEL, ENGINE OIL AND ENGINE COOLANT DIESEL FUEL ENGINE COOLANT WESTERBEKE recommends a mixture of 50% antifreeze USE A DIESEL FUEL WITH A CETANE RATING OF #45 OR HIGHER. and SO% distilled water. Distilled water is free from the (No.
  • Page 12 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 thrn-hull petcock is open.

  • Page 13: Digital Control Panel

    DIGITAL CONTROL PANEL DESCRIPTION LCD DISPLAY WESTERBEKE'jS, Digital Control Panel provides the Operating temperatures may cause the LCD display to vary operator with an LCD display that contunuously monitors in color. This is normal and a change in color will not affect all the operations of the generator in easy to understand the operation on the control panel.
  • Page 14 DIGITAL CONTROL PANEL/LCD SEQUENCE START SEQUENCE STOP SEQUENCE With the pre-start inspection completed, press the,START To stop the generator, press the STOP button. The display button and the automatic sequence will begin. The six will cycle thru the following text messages and shutdown. indicator lights will illuminate green and the panel will display the following text: Shutting'...

  • Page 15: Digital Control Box

    NMEfi.-200Q $)Istem or shill off the DC breaker the generator's control box for a WESTERLINK system. NlvlEA~2000 NOTE: Keep in mind that the Westerbeke generator maybe the power supply for the vessel'.s network. WESTERSEKE Engines & Generators...

  • Page 16: Remote Stop/Start Panel

    ,on the boat. The connecting harnesses come in three different lengths and two of these can be combined for a maximum run at,75' (22.l7M). NOTE: For additional information, contact your local WESTERBEKE dealer. 3·1/4" \O'.'IOIVIIIIII' CONNECTING EXTENSION 6"...

  • Page 17: Generator Break-In Procedure

    GENERATOR BREAK-IN PROCEDURE DESCRIPTION After 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 all times.

  • Page 18: Maintenance Schedule (Chari)

    MAINTENANCE SCHEDULE WARNING: When servioing"geilemiij,iingineoiimpiiiieiils;ihil jjCpow,r iiiu,t be turned ofiuSing either the . breaker or the ballery swi~~h. theengl~e WARNING: Never attempt to perform any service while running. Wearfheproper safety equipment such as goggles and gloves, and use the correct tools for each job. Disconnect the battery tenninals when servicing any the engine's DC electrical equipment.
  • Page 19 NMEA-2000 system or shut off the breaker the generator's control box/or a WESTERLlNK system. NOTE: Keep ill mind that the Westerbeke generator may be the DC power supply for the vessel's NMEA-2000 network, -...: WESTERBEKE Engines Generators...

  • Page 20: 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, requiting the utmost caution in handling.

  • Page 21: Cooling System

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

  • Page 22: Air Intake

    . . . " . " CAUTION: Never pedorm air intake maintenance with the generator running. ~WESTERBEKE Engines & Genera ors...

  • Page 23: Thermostat

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

  • 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 a self-priming, rotary pump with a non-ferrous housing and a Neoprene impeller. The impeller impeller pump. TIns pump draws water directly from the ocean, lake, or river from a thrn-hull opening through a hose has fle(dble blades which wipe against a curved cam plate to the water strainer.

  • Page 25: Engine Lubricating Oil

    46;;;=::::" , TIGHT LUBRICATION DIAGRAM ~~~,SSlIRE'-~WlI~., SWITCH OIL FII1'FR,-- OIL PRESSURE RELIEF VALVE FOR E)(TENSION 114" NPT USING AN BMM (11/16'; SOCKET OIL SCREEN TO DRAIN THE OIL OR PUMP THE WARMED OIL UP THRU THE HOSE. WESTERBEKE Generators -Engines &...
  • Page 26 RfMofEOILFlLTfflSCf .. '-... JNSTALLATION NOTE: Westerbeke is not responsible for engine failure due to incorrect installation of the Remote Oil FilJer. trrus popular accessory is used to relocate the engine's oil fil- ter from fue engine a more convenient location such as an room bulkhead.

  • Page 27: Starter Motor

    STARTER MOTOR DESCRIPTION The starter is a new type, small, light-weight is called a high-speed internal-reduction starter. The pinion shaft is separate from the mot()f shaft; the pinion . slidesonly on the pinion shaft. A reduction gear is installed between the motor shaft and a pinion shaft.
  • Page 28 Starter motors are either inertia type or pre-engaged. certified for marine use. Automotive starters do not meet In the pre-engaged model, the solenoid also moves an arm USCG standards. If in doubt, contact your WESTERBEKE that engages the starter motor to the flywheel of the engine. dealer.
  • Page 29 NOTE: Increase airsupply 15% for 50 Hetlz operation@ 1500 rpm Spin-on type Fuel Filter Engine Combustion 30.2 cfm (0.B5 cmm) Air cleaner Plastic intake silencer Generator Compartment 120'F (50'C) maximum 30.2 ctm (0.B5 cmm) AirFlow Temperature (engine combustion) Compartment Cooling 100 elm (2.8 cmm) WESTERBEKE' ..v' Engines & Generators...
  • Page 30 WIRING DIAGRAM #52414 (12 VOLn I: ,,:E : :a 000000 ,: CI =1:1: ...a. oI:iIo ...a. " < 110 UD 116 VIO i" Iii REO "00",...
  • Page 31 D·NET WIRING DIAGRAM #52793 (12 VOLT) ---- ' - - ~"----. ." • IHli'; i"~' ,~,- __ r." - '--- 111110 ..WESTERBEKE Engines Generators &...
  • Page 32 D-NET WIRING DIAGRAM #53477 (24 VOLT) ---- ---- --.-, - - - - - - ---- -,--- " , !.I!F\;;;;;;;;;;F'I\ ji~~~ .CJ- 'l~' [OJ'' r<:J-- 1 ~~§I .,,,,,,, '" ~WSStSj!fB'EkE . . . Engines Gener~tors &...

  • Page 33: Engine Adjustments

    ENGINE ADJUSTMENTS NOTE: WESTERBEKE recommends that the following engine adjust- ments be perfonned a competent engine mechanic. The information below is provived to assist the mechanic. DRIVE BELT ADJUSTMENT TORQUING THE CYLINDER HEAD BOLTS 'For your safety, WES1ERBEKE generator models come...

  • Page 34: Generator Frequency

    ENGINE ADJUSTMENTS GENERATOR FREQUENCY ADJUSTMENT (HERTZ) ELECTRONIC GOVERNOR· . The Electronic Governor regll!lrtes the engille-speed by Once the diesel generator set has been placed in operation; there may be adjustments required for engine speed (Hertz) sensing the engine's RPM with a magnetic pick-np at the during the engine's break-in period (first 50 hours) or after flywheel.

  • Page 35: Valve Clearauce Adjustment

    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 36: Spill Timing

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

  • Page 37: Oil Pressure

    ENGINE ADJUSTMENTS NOTE: WESTERBEKE recommends that the following engine adjust- ments be peiformed by a competent engine mechanic. The information ass~st _ below is provided to the meciuznk _ TESTING GLOW PLUGS OIL PRESSURE The engine's oil pressure,is constantly monitored by the control To inspect the plug, remove the electrical terminal connec- pane\.

  • Page 38: 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" erwironment one stroke per second to check if the fuel is injected cor- Disconnect the high pressure lines from the injectors and rectly in its axial direction.

  • Page 39: Engine Troubleshooting (Chart)

    Insufficient air for proper combustion (Check for restrictions In exhaust system; check ajr intake.). 3b. lmproperti timed injectors or valves or poor compression. 3e. Lack of air - check air intake and air filter. Check for proper ventilation . --"- ..v- WESTERBEKE Engines & Generators...
  • Page 40 #4 and #5. 6. Battery Voltage to ECU. 6. Check between pins P2-24 and P2-25. P2 ECU plug unplugged from ECU. Power turned ON. If voltage is present, ECU is faulty. WESTERBEKE Engines & Generators...
  • Page 41 OK and the problem in the battery charging circuit. WESTERBEKE Engines Generators &...
  • Page 42 5. Check the battery voltage. your battery is in gQod . condition the reading should be 12 13 volts. TESTING THE OUTPUT CIRCUIT ENGINE RUNNING #100RANGEB STARTER .ULtNUiIU #16 VlOLETR WESTERBEKE '..v' TO K·3 RELAY Engines & Generators...

  • Page 43: Alternator Testing

    If tests indicate a failed alternator, it will need to be disas- sembled and repaired. Any good alternator service shop can do the job. NOTE: WESTERBEKE'S Service Mwmal detailed instmetions for the disassembly and repair of their standard alternators. BATTERY CARE The minimum recommended capacity of the battery used in 3.

  • Page 44: Shore Powerconnections

    ' - _ / ..==-..---11'· '" ,. GROUND ,S2S111 SHORE POWER NOTE: Diagram shows connections for a two-wire, 120 volt system. For a, three-wire system, use the dotted lines for the other hot leg. WESTERBEKE Engines & Generators...

  • Page 45: Generator Information

    Repair n;tust be made quickly or major components will CARBON MONOXIDE DETECTOR rub and cause major damage to generator. WESTERBEKE recommends mounting a carbon monoxide detector in the living quarters. Carbon Monoxide, even in s~aU amounts is deadly.
  • Page 46 NOTE: This circuit breaker is avaiillble as a WESTERBEKE DC and supply it to the windings of the rotating field. This' add-on kit for earlier model generations; contact your creates an electromagnetic field which rotates through the WESTERBEKE dealer.

  • Page 47: Troubleshooting

    3. RESIDUAL VOLTAGE ExCITER CIRCUIT FAULTY . COMpONENT CHECKS:' 1~1+2 EXCITER STATOR WINDING(S) 8RIDGE RECTIFIER 3 TRANSFORMER AUX. WINDING 3 .MAIN STATOR AUX. WINDING NOTE: Reference the BT Troubleshooting guides on WESTERBEKE'S website under "TECHNICAL" for additional information. WWWWESTERBEKE.COM. Engines & Generalors...

  • Page 48: No Load Voltage Adjustment

    AC circuit has a separate neutral and groUad.circuit. This will prevent the unit jrom being a ground source in the vessel. b. Start the engine, monitor AC voltage. Adjust no-load AC voltage output as needed. WESTERBEKE ,..y: Eng/nilS & Generators'...

  • Page 49: Generator Voltage Adjustment

    GENERATOR VOLTAGE ADJUSTMENT NOTE: WESTERBEKE recommends that the following generator adjustments be peiformed by a quailified technician. BT GENERATOR· SINGLE PHASE (12 STUD) 120/240V 60Hz· ,12Q'L60Hz -'-~".'" OCID ®- 5E.'Jt7J ® N;:. ® THE GROUNO SHOWN ON THE '" TERMINAL BLOCK IS INSIDE THE' GENERATOR BOX ®...

  • Page 50: Residual Voltage Check

    NOTE: Current model bridge output are the posi-resistor inthe exciter rotor and four or rectifiers are configured more fail<il diodes mthe exciter rotor .. 1=.:'::;:' differently, but + and - are "'" WESTERBEKE still located at the corners. Engines & Generators...

  • Page 51: Bridge Rectifier

    POINT #3 deflection. If the rectifier fails any of the previous tests -4) it is defective and should be replaced. POINH4 NOTE: Different style/model meters produce opposite POINH5 results from the above tests. MOUNTING HOLE WESTERBEKE Engines Generators &...

  • Page 52: Exciter Rotor Field

    7.6KW BT GENERATOR SINGLE PHASE 'The diodes can be easily checked in place with the use of a EXCITER ROTOR/FIELD cornman automotive 12-volt high beam headlight bulb, some Auxiliary windings group a, b and 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 53: Measuring Resistance

    Lead #4 at the junction block. Lift both leads along with lead #7 at the terminal block. Compound Transformer Windings 0.019 - 0.021 Ohms LEADS COMPOUND HIGH 12 STUD TERMINAL BLOCK CIRCUIT BREAKER DT SINGLE PHASE (12 STUD) .120/60 VOLT CONFIGURATION , . WESTERBEKE Engines & Generators...
  • Page 54 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 or higher. A fuel conditioner such as Sta-Bil gasoline including engines and generators, for lay-up during the off-season or for long periods of inactivity.
  • Page 55 Lay-up time provides a good opportnnity 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 56: Power Take-Off

    The 7.6Kw E'ID produces llhp at a continuous 1800 rpm (8hp at 50Hz 1500 rpm). This horsepower can be utilized either for generator AC output or to operate the power take off. Contact your WESTERBEKE DlSTRIBUTORfor additional information. REMOVE COVER POWER TAKE OFF...
  • Page 57 & Engines Generators 116V -12/2011...

This manual is also suitable for:

5.7kw edt

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