OPERATOR'S MANUAL & 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, MA 02780-7319 U.S.A.
SAFETY PRECAUTIONS The following symbols appear in this manual to call attention to and emphasize conditions potentially dangerous to the operator. I WARNING I The above symbol is used in the manual to warn of possible serious personal injury or loss of life. II CAUTION II The above symbol is used in the manual to caution personnel of possible damage to equipment. Read the manual carefully and thoroughly before attempting to operate the equipment.
• Do Not Alter or Modifv the Fuel SYstem Be sure all fuel supplies have a positive shut-<>ffvalve. Be cenain fuel line fittings are adequately tightened and free of leaks. Make sure a fire extinguisher is installed neart>y and is properly maintained. Be familiar with its proper use. Ex1.inguishers rated ABC by the NFP A are appropriate for all applications encountered in this environment.
IMPORTANT PRODUCT SOFTWARE DISCLAIMER Product software of all kinds, such as brochures, drawings, technical data, operator's and workshop manuals, parIS lists and pans price lists, and other information, instructions and specifications provided from sources other than Westerbeke, is not within Westerbeke's control and, accordingly, is provided to Westerbeke customers only as a courtesy and service.
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.
Engines & Generators Declaration of Conformity Application of Council Directive(s) EMC S9/336IEEC 92/31IEEC & 93/6SlEEC Standard(s) to Which Conformity is declared CISP 12 (1990-01) EN500S2-1 ( 1992) IEC SOl - 2 (1991), +1- Skv AD IEC SOl - 3 (19S4), 3 VIM Manufacturers Name Westerbeke Corporation Manufacturers Address 41 Ledin Drive Avon Industrial Park Avon, Ma. 02322, USA Type of Equipment Marine Diesel Generator Product Name Westerbeke Marine Diesel Generator Model(s) 4.0/5.0BCD,5.717.
TABLE OF CONTENTS Page Section GENERAL .................................... . . ...................... 8 ............................ 9 GENERAL SPECIFICATIONS ... . 7.6 KW BTD SYSTEM SPECIFICATIONS ................... . INSTALLATION CHECKS .................. . ..... 10 . ................................. 13 DESCRIPTION OF INSTRUMENT PANEL ....................................................................... 25 PREPARATION FOR STARTING ..............................................................
~ ~ a gJ z ~ Air Intake Silencer Top Engine Oil Fill Fuel Run Solenoid Water Temperature Switch 20 Amp DC Circuit Breaker i}l Lube Oil Dipstick Oil Fill Pre heat Solenoid 0\ Oil Pressure Sender A C Connections Outlet Oil Pressure Switch Fuel Lift Pum Lube Oil Filter 7.
Unit I. D, Plate Water Temperature Sender 0 45 Exhaust Elbow Water Temperature Switch Emergency Shut~off DC Charging Alternator Unit Data Tag --l Belt Guard :::! toO 'JJ I ~ ~ ~ Heat Exchang Starter with Solenoid DC Battery Ground Connection ~ 7.
GENERAL Introduction This manual contains the equipment operating procedures as well as additional information needed to help the operator keep the marine equipment in proper working order. Study and follow the instructions carefully. A planned maintenance program is included in this manual; adhering to the program will result in better equipment performance and longer equipment life.
7.6 BTD MARINE DIESEL GENERATOR SET GENERAL SPECIFICATIONS Engine Type Diesel, four-cycle, three cylinder, fresh watercooled. Vertical, in-line, overhead valve mechanism. (12.5 hp at 1800 rpm, maximum). Combustion Chamber Swirl type. Bore & Stroke 2.99 x 2.76 inches (75.9 x 70 mm) Piston Displacement 58.09 cubic inches (0.952 liters) Firing Order 1-3 - 2 Direction of Rotation Clockwise, when viewed from the front Maximum Torque (at 1800 rpm) 42 lb-ft (5.
7.6 KW BTD SYSTEM SPECIFICATIONS FUEL SYSTEM General Open flow - totally self-bleeding Fuel No.2 Diesel (cetane #45 or better) Injector Pump In-line plunger type (Bosch type) Injectors Throttle type LiftPump 12-volt DC; electric Air cleaner Plastic Intake Silencer Air Flow (engine combustion) 30.2 cfm (0.85 cmm) COOLING SYSTEM General Fresh water-cooled block, thermostaticallycontrolled with heat exchanger.
7.6 KW BTD SYSTEM SPECIFICATIONS (continued) ELECTRICAL SYSTEM Starting Battery 12-volt, ( - ) negative ground Battery Capacity 350-400 Cold Cranking Amps Starter 12-volt, 1.2 KW, Reduction type, solenoid mounted. DC No-Load Current 90 Amp (max) at 11.5 volts DC Cranking Current 175 - 200 Amps (engine cold) DC Alternator 12 Volt, DC - 40 amps ACGENERATOR General - Single Phase Brushless, four -pole, revolving field, transformer regulation. Prelubricated, single bearing design.
7.
INSTALLATION CHECKS General Because the crafts in which Westerbeke engines and generators are installed vary in design, installation procedures will vary according to your craft's specific design. It is not the intent of this section to advise boatyards or installers on procedures already well-developed and well-understood.
Rigging and Lifting The generator is fitted with lifting eyes. Rope or chain slings capable of supporting the generator's weight should be attached to the eyes and the generator lifted by means of tackle attached to these slings. Th lifting eyes have been designed to carry the full weight of the generator; therefore, auxiliary slings are not required or desired. II CAUTION II Slings must not be so short as to place significant stress on the generator's lifting eyes.
Generator Mounting - Location The complete generator unit is mounted on lightweight rails by means of four flexible isolator mounts that help prevent the transfer of vibration from the generator to the rails. Each generator mounting rail has several 112 inch bolt holes so bolts can be employed to properly secure the generator to its mounting platform.
Exhaust System I WARNING I Carbon monoxide gas is deadly! Carbon monoxide is a dangerous gas that can cause unconsciousness and is potentially lethal. Some of the symptoms or signs of carbon monoxide inhalation or poisoning are listed below.
Exhaust Back-Pressure The exhaust discharge hose must be of adequate size and minimal run to prevent excessive exhaust backpressure. Exhaust back-pressure should be checked before a generator is put into service. (Refer to illustration.) Excessive back-pressure will affect the engine's performance which affects generator AC power output. To measure for back-pressure, use a mercury manometer, a pressure gauge, or a water column. A boatyard or marine mechanic should have a manometer or a pressure gauge.
Dry stack-type exhaust systems (shown to the right) must be attached to the generator engine's exhaust manifold by means of a flexible connector pipe. This system must be properly supported, insulated, and routed so as not to allow water to enter the engine's cylinders by coming in through this piping. Provisions must be made for discharging the engine's raw cooling water overboard. ~I..."" .... ~ ... ~ CD""'::'" jI , ._-,. ~===14f.;;;1 \r 71'~.~. ...., ........ e:. XM5UL Txo.1 .z..- ': ~ ..
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. 45° ELBOW L Coat only one side of the exhaust gasket with High Tack adhesive sealant (manufactured by Permatex Company, Brooklyn, NY).
FUEL SYSTEM The generator must have its own fuel supply line; in other words, it must have its own pickup tubes and primary filter/water separator. DO NOT TEE OFF OF ANOTHER ENGINE'S FUEL SUPPLY. The fuel system should be installed in such a manner as to allow the engine-mounted fuel lift pump to maintain a positive iulet pressure to the injection pump under all operating conditions.
Raw Water Intake System Make sure the intake system (raw water cooling system) is in proper order. Check that the hull inlet, sea cock and strainer are unobstructed. Sea cocks and strainers should be at least one size greater than the inlet thread of the sea water pump. The strainer should be of the type that may be withdrawn for cleaning while the vessel is at sea and should be mounted below the water line to ensure self-priming.
II CAUTION II To avoid an overcharging condition, and a possible equipment failure, do not disconnect tbe DC battery source while tbe engine is running. Automatic Shutdown High Exhaust Temperature Shutdown Switch (normally closed) An exhaust temperature is located on the exhaust elbow. Should tbe switch's sensor indicate an excessive exhaust temperature, tbe switch will open and shut tbe generator off (an inadequate supply of raw water coolant causes high exhaust temperatures).
I WARNING I When servicing the battery or checking the electrolyte level, wear rubber gloves, a rubber apron, and eye protection. Battery acid may splash on the skin or into the eyes inadvertently when removing the electrolyte caps. Check the battery's electrolyte level and specific gravity to ensure maximum engine starting efficiency. Make sure the battery'S terminals are clean and tight.
NOTES WESTERBEKE GENERATORS 24
DESCRIPTION OF INSTRUMENT PANEL o o PREHERT 4 w START ~ WJ STOP ® GENERRTOR o o 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).
Remote Operation For starting and stopping the generator at a remote location, the same three switches are used. The PREHEAT and START switches are connected in parallel with the local panel's switches and serve the same functions as in the local panel. The STOP switch is connected in series with the local panel's STOP switch and serves the same function as in the local panel. The generator may be stopped from local or remote positions.
DC WIRE SIZING CHART Stranded Conductors for 12 Volt Circuits 10% Voltage Drop ,.,.... ,.,. B. National Electrical A. Society of Aut.omotive Engin.eers Type Wire Wire Sl~e Standing Circular ~II Area '0 '6X3D 1537 3. '"17 ••5. SS 43.7 •• 3 7. O. 9. '0. '5. 20. 3D. '0. 50. 0 '0 ,.x2:\ • 19:a1 "9x23 93<13 14810 25910 • .. ax21 34.7 2".7 21.7 <19.3 17.3 26D ... , 'D. 130 "0 ".7 B' 52 '3.3 37 32.7 28.7 70 eo 52.7 26 .S.7 '2 '7.3 2• ., 16. 132 26• 2'0 ......
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. The result is a rapid start with less wear on the starter.
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.
STARTING PROCEDURE 1. Depress and hold the preheat switch. Preheat according to the following chart. 2. While still depressing the PREHEAT switch, depress the START switch. As soon as the engine runs, release the START switch but continue to hold the PREHEAT switch depressed for an additional 2 - 3 seconds. This allows the engine to build up enough oil pressure to close the oil pressure shutdown switch and allow the engine to continue to run.
Engine Break-In Procedure Although your generator has experienced a minimum of one hour of test operations to make sure accurate assembly procedures were followed and that the generator operated properly, a break-in time is required. The service life of your engine is dependent upon how the engine is operated and serviced during its iuitial hours of use.
Starting Under Normal Conditions Follow the procedure below for normal starting of the generator. 1. Make sure there is sufficient fuel on board. Keep fuel tank(s) as full as possible. Check the fuel filters and water separators for the presence of contaminants and/or water. Drain and clean them as needed. 2. Check the coolant level in the plastic recovery tank. Add coolant solution as needed. NOTE: Excessive loss of coolant from the plastic recovery tank indicates a cooling system leak.
STOPPING PROCEDURE 1. Remove the AC electrical loaf from the generator and allow the generator to run for 3 to 5 minutes to stabilize its operating temperature. 2. Depress the STOP switch and hold it until the generator is completely stopped. 3. Now release the STOP switch. Remote Stopping Procedure To stop the generator, depress the STOP switch which opens the normally closed B+ path for voltage to the engine's run circuit. The bright green LED will go dim/faint when the generator slows and stops.
NOTES WESTERBEKE GENERATORS 34
FUEL SYSTEM Diesel Fuel Use No.2 diesel fuel with a cetane rating of 45 or higher. Never use kerosene or home heating oil since these fuels do not have the same lubricating properties as No.2 diesel fuel. In cold weather particularly, water vapor is produced by condensation when air is present in the fuel tank. Keep fuel tank(s) full and completely free of dirt and water. Fuel FilterlWater Separators A primary fuel filter of the water separating type must be installed between the fuel tank and the engine.
II CAUTION II Prolonged cranking intervals without the engine starting can result in filling the engine-mounted exhaust system with sea water coolant. This may happen because the sea water pump is pumping sea water through the sea water cooling system during cranking. This sea water can enter the engine's cylinders by way of the exhaust manifold once the exhaust system fills.
Fuel Injection Pump The illustration below shows the 7.6 KW BID's fuel system. The fuel injection pump, located to the right, is one of the most important components of the diesel engine and, therefore, calls for the utmost caution in handling. Furthermore, the fuel injection pump has been thoroughly bench-tested and should not be tampered with. Speed (hertz) and timing adjustment are the only adjustments the servicing dealer can perform on the injection pump.
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. II CAUTION n To avoid damage to the battery charging circuit, never shut off the engine battery switch while the engine is running.
7.6 BTD Control Circuit Wiring Diagram #039284 paoe 1 of2 '" ~I IE!lt!~IQB ", '" WrHEB ~ n, IEt:I~E!lHIlBE llHll.lB. \1 rq~ lllliJi -It: ~ ; '" ----rJ~ ... ~~ ~ EXHA ~~EBeI!JBE lllliJi pD ,~ y : 1 : , ,, 1 :"U ~ I· r J ~ ~ ,J=~ "-- ~ = , ri , , , , 1 , ~~=L~i~ .I i ,,1 1_______ O-C_ 1------------------: TO 1'81-1 0". TO "1-10 1".... ..1 ID -------=-=---------------l @ , ..,..- I o ! - l'- _________________ ..J '!""ie.
7.6MINIBTD Schematic Diagram #39284 page 2 00 o + 12 vIX GLOWP!.UGS r- -, 1 :( ; C.B. :20.1, ., :,'( 1c.s. - rI " : EMERGENCY L JSTOf> SW. I IDA , r 1 r : I lSToPSw. L l " (PREHEAT SW. L--+--+-_-( P _ EXHAUST TEMP. SWITC" WATER TEMP-SWITCH • OIL PIIESS. SWITCH STARTING AND STOPPING INSTRUCTIONS START, I. ALWATS PUS" Pll(oE:AT SWITCH riIlST. HOLD fOR I!> TO 2: WI1ILE COtlTltII,IlNG TO PUSH PRE~AT '0 " rU'EL SOL. SECOtlOS AS REQUIRfO. SWITCH, PUSH START SWITCH. 3.
7.6 BTD Control Circuit DC Wiring Diagram #044121 (Two Relays) ~I "'" ~EO QII TEgNATOR 51A PRESS 011 PRfSSltR:.-.n ~--U PIIMI> r---, "o\.o II cow filE! G"(lUM" TO BlQ(' I .. '1> ,tc/RED I I l YELiRCO : ." '" I~ [~,.. ,~,n'"l31~' ~ I 0 ~ ""> __________ •" ,,.>(Olvl(\ , , , • rtI, ~ , , 1 h'l _HTlREDl( 5,1< ~~I r J0 @)B @ ~ S'MTOi ~ .. I I ___ , TO rBr-,o 1"",,8,,·,,·1 T" iR'(\ "o""iIO(O UI START ~ __ ~ __ ~~~J~.
7.6 BTD DC Schematic Diagram #044121 (Two Relays) + • - • 12 VDC r' ~ I 20 AMP CIRCUIT L.; BATTERY WSWITCH STARTER STARTER SOLENOID BREAKER ,--l [r~"l L_..J 1 1 I l---, t I -L __ ...J I' ~i EMERGENCY I I STOP 1-1 SWI TCH PREHEAT SOLENOID GLOWPLUGS ,--l L.; i I I I L __ ...J AL TERNATOR 87 =.., B KI-START )\ 30 K2-RUN pm FUEL SOL. I HOlD~ 30 I 187 , r FUEL PUNP '~81-1 EXHAUST TEMP FUSE 8A WATER TEMP ~H ~H --zy -z9 -U- OIL PRESS. @- AUX. OIL PRESS.
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; similar in function to an automotive radiator.
ANTIFREEZE CONCENTRATION DATA Antifreeze Concentration Freezing Temperature % 23 13 30 35 45 50 60 -4 (-20) -22 (-30) -40 (-40) -58 (-50) 23 14 5 (-5) (-10) (-15) B. 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.
COOLANT RECOVERY TANK PRESSURE CAP COOLANT PASSAGE EXHAUST MANIFOLD Coolant Recovery Tank, Recommended Installation Fill the fresh water system as follows: I. Remove the pressure cap from the manifold. 2. Pour a clean, antifreeze mixture into the manifold and allow enough time for the coolant to fill the fresh water cooling system. 3. Start the engine and allow it to come up to its operating temperature. Monitor the coolant in the manifold and add antifreeze coolant as air is expelled.
Thermostat Generally, thermostats are of two types. One is simply a choking device which opens and closes as the engine's temperature rises and falls. The second type has a bypass mechanism. Usually, this is a disc on the bottom of the thermostat which moves downward to close off an internal bypass passage within the head. Since 1980, each type of thermostat has a hole punched through it. The hole is a bypass to prevent the exhaust manifold from overheating during the engine's warm-up.
Raw Water Pump The raw water pump is a self-bleeding, gear-driven, rotary pump with a non-ferrous housing and a neoprene impeller. The impeller has flexible vanes which wipe against a curved cam plate within the impeller housing, producing the pumping action. On no account should this pump be run dry. There should always be a spare impeller and impeller cover gasket aboard (an impeller kit). Impeller failures occur when lubricant (raw water) is not present.
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. -----PRESSURE CAP INJECTED ELBOW - - _ EXHAUST MANIFOLD WATER ~--~~;----TEMPERATURE SWITCH INCOMING RAW WATER HEAT "A"nAA'" ZINC FRESH WATER ~ FRESH WATER DRAIN RAW WATER . . .
LUBRICATION SYSTEM Engine Oil For engine lubrication, use lubricating oil designated for diesel service. These oils are classified according to the API specifications into service grades CA, CB, CC and CD. The use of CC or higher (CD) grades, made by well-known manufacturers is recommended. Engine Oil Viscosity (SAE Number) Use an oil having a viscosity best suited to the atmospheric temperature. Use of an all-season oil SAE IOW-30 with minimum viscosity change under different temperatures is suggested.
2. Replacement of the Oil Filter When removing the used oil filter, you may find it helpful and cleaner to punch a hole in the upper and lower portion of the old filter to drain the oil from it into a container before removing it. This helps to lessen spillage. A small style automotive filter wrench should be helpful in removing the old oil filter. Place some paper towels and a plastic bag around the filter when unscrewing it to catch any oil left in the filter.
BT GENERATOR This generator is a brushless self-excited generator, which requires only the driving force of the engine to produce AC output. The copper and laminated iron in the exciter stator are responsible for the selfexciting feature of this generator. The magnetic field produced causes an AC voltage to be induced into the related exciter rotor windings during rotation. Diodes located in the exciter rotor rectify this voltage to DC and supply it to the windings of the rotating field.
.... Securing " 7.6 BID - View of Generator Backend VOLTAGE BAR ©© ©© ©© ~ #2 #S VOLTAGE BAR WESTERBEKE GENERATORS The voltage bar has three leads coming in on one side from the transformer and a single lead on the other routed to the bridge rectifier. The single lead can be pOSitioned at either of the three connections. These connections are used to change the output voltage of the generator under load. Should the voltage go below minimum.
r-------, r---- -- --------, r , [~ I • 1>+ 4 I I 2 I 1 L _ _ _ _ _ _ _ _ _ _ _ _ _ J1 I I I I L ORANGE + [ 1 _______ J w z ~ .., ~ BLACK I I ~ G AC • ! 3 6 5 2 i T 3 ==7"'--== L.!lif!-tI •I AC 3 2 7 I N A L 1 YELLOW B L o • _J I WitT IGnEEN -KJGREEN M a II WHT/BlK E R 9 1o • 1 1 31 1 c ,. !I.e I : , Btl ~ i i , 1 1 1 - C :1 \1 I 1 • C K @ 5 J T U D BID 7.6 KW Generator's Internal Wiring Diagram A. EXCITER STATOR WINDINGS 1.
Generator Frequency Frequency is a direct result of engine/generator speed: 1800 RPM - 60 Hertz 1500 RPM - 50 Hertz To change the generator's frequency, refer to the "MAINTENANCE AND ADmSTMENTS" section of this manual. Load Connections The generator's data plate gives the voltage, current and frequency rating of the generator. An AC wiring decal is affixed to the inside of the louvered cover on the generator end. A diagram of the various AC voltage connections is provided on the decal.
120V 60Hz 0 ( ) 120/240V 60Hz T o FR....ME 'II~ ( ) TOFFi! .ME '11 II 0 0 0 0 0 0 Nc t::::::J Ll f ( 0 , { } "-10 t: (OJ 0 0 0 0 0 :J '-1 U U N Ll , 10/220V SOHz = 0 0 0 0 c 0 = [/il;~ ., o 0 0 0 = 0 000 0 0= o N TO a:::::::@) 220VSDHz "DVSOHz 0 Fa .... C 'ilFt<:r::~o~ IQO~':3= L, 'n u l..
Shore Power Connections If the installer connects shore power to the vessel's AC circuit, this must be done by means of the SHORE POWER/OFF/SHIPS GEN, center position-off transfer switch as shown below. Use of this switch prevents simultaneous connection of shore power to generator output. II CAUTION II Damage to the generator can result ifutility shore power and generator output are connected at the same time.
GENERAL INFORMATION AND CARE OF THE GENERATOR Use of Electric Motors The power required to start an electric motor is considerably more tban is required to keep it running after it is started. Some motors require much more current to start tban otbers. Split-phase (AC) motors require more current to start, under certain circumstances, tban other types. They are commonly used on easy-starting loads, such as washing machines, or where loads are applied after tbe motor is started, such as small power tools.
Load Applied 4-Pole Speed (rpm) Frequency (Hertz) Generator 120V (110) Plants Voltage 240V (220) Plants None 1830 (1530) 62 (52) 122 (ll2) 240 (224) Half 1800 (1500) 60 (50) 120 (110) 240 (220) Full 1755 (1455) 59 (49) 110 (100) 220 (200) The output voltage should be checked periodically to ensure proper operation of the generating plant and the appliances it supplies.
YOUR NOTES 59 WESTERBEKE GENERATORS
ENGINE TROUBLESHOOTING Introduction The tables which follow indicate troubleshooting procedures based upon certain problem indicators, the probable causes of the problems, and the recommendations to overcome these problems. Note that the engine's control system (electrical system) is protected by a 20-Ampere manual reset circuit breaker located on a bracket on the right side of the engine, just forward of the generator's end plate.
No ignition: cranks, but does not start; fuel solenoid energized. I. Faulty fueling system, I. Check for fuel to generator engine. 2. Check for air in fuel system. Bleed point on filter. 3. Fuel lift pump faulty. 4. Filters clogged. (Replace filters and allow system to self-bleed by depressing only the PREHEAT switch. Failure to stop. Engine stops. I. STOP switch failure. I. Stop engine by depressing emergency STOP switch on engine or manually moving the shut off lever on the injection pump side.
Battery not charging. 1. Alternator drive. 1. Check drive belt tension. Be sure alternator tnrns freely. Check for loose connections. Check output with voltmeter. Ensure 12 volts are present at the R terminal. Battery runs down. 1. Oil pressure switch. 1. Observe if gauges and panel lights are activated when engine is not running. Test the oil pressure switch. 2. High resistance leak to ground. 2. Check wiring. Insert sensitive (0-.25 Amp) meter in battery lines. (Do not start engine.
MAINTENANCE AND ADJUSTMENTS Introduction This section contains a scheduled preventive maintenance program and several adjustment procedures the owner/operator can perform without the benefit of sophisticated and e".-pensive tools and instruments. Preventive Maintenance Perform the preventive maintenance in accordance with the schedules listed in the following paragraphs.
*3. Retorque the cylinder head bolts. *4. Adjust valve clearances. 5. Adjust the water pump drive belt tension, if required. *6. Adjust the engine's no-load speed, if required (Hertz) and the regulator board's voltage output adjustment as needed. Please note that these adjustments are not a warrantable adjustment during or after the unit's break-in. 7. Check electrical connections to the fuel solenoid. Make sure the fuel solenoid operates properly when 10-12 volts are present at the solenoid during preheat.
Servicing After Every 800 Hours of Operation *1. Remove and check fuel injectors. Injector spray pressnre: 1988 psi ± 142 psi (140 kg/cm 2 ± 10 kg/cm2 ) Eliminate undesirable injection conditions including after dripping. A®~f"t4a;::;r.. . .4;';;;;;.----""1cf!\ *2. Check the engine's compression pressure. Remove each glow plug and check each cylinder's compression pressure. The engine's cranking speed is at 280 rpm. Standard 397.6 psi (28 kg/cm 2 ) GOOD Minimum 312.
B. Rotate the crankshaft 240° (degrees). This puts the #3 piston at the TDC position in it's cylinder. Adjust the valve clearances for the intake and exhaust valves of the #3 piston at the TDC position in it's cylinder. Adjust the valve clearances for the intake and exhaust valves of the #3 cylinder. C. Rotate the crankshaft another 240°. This puts the #2 piston at the TDC position in its cylinder. Adjust the valve clearances for the intake and exhaust valves of the #2 cylinder.
RDJUST VALVES TO 0.010 INCHES Adjust each valve's clearance by inserting a 0.010 inch (0.25 mm) feeler gauge between the rocker arm and the valve stem. (0.25 1(10 Injection Pump Timing Adjustment (Spill Timing) If your engine's fuel injection timing is not properly adjusted, the engine will not operate properly and may be difficult to start. Have the injection pump delivery rate checked by a well-established fuel injection shop.
Adjustments (Generator) Once the diesel generator set has been placed in operation, there may be adjustments required for engine speed (hertz) during the engine's break-in period (first 50 hours) or after this period. A no-load voltage adjustment may also be required in conjunction with the engine's speed adjustment. These are not warrantable adjustments as they relate to normal break-in and maintenance.
1. Visual access to the fuel injection pump's fuel rack is needed. To obtain this, remove the small square side coverlbracketry just below the fuel injection pump. This is shown as cover part #037045 and gasket #036981 in the parts list 2. Thread the locknut #034669 onto the solenoid and then apply a small amount of Teflon sealant to the threads on the solenoid. 3. Thread the solenoid into the boss on the engine and observe the solenoid plunger through the cover opening.
LAY-UP AND RECOMMISSIONING General Many owners rely on their boatyards to prepare their craft, including engines and generators, for lay-up during the off-season or for long periods of inactivity. Others prefer to accomplish lay-up preparation themselves. The procedures which follow will allow you to perform your own lay-up and recommissioning, or to use as a check list if others do the procedures.
Fuel System Top off your fuel tanks with No.2 diesel fuel. Fuel additives should be added at this time to control algae and condition the fuel. Care should be taken that the additives used are compatible with the primary filter/water separator used in the system. Change the element in your primary fuel filter/water separator, if the fuel system contains one, and clean the separator sediment howl. Change the fuel filter element on the engine and bleed the fuel system, as needed.
Starter Motor Lubrication and cleaning of the starter drive pinion is advisable, if access to the starter permits its easy removal. Make sure the battery connections are shut off before attempting to remove the starter. Take care in properly replacing any electrical connections removed from the starter. Cylinder Lubrication It is not necessary to remove the fuel injectors from the cylinder head to squirt light lubricating oil into the cylinders for the few months of normal lay-up.
3. Reinstall the batteries that were removed during the lay-up, and reconnect the battery cables, making sure the terminals are clean and that the connections are tight. Check to make sure that the batteries are fully-charged. 4. Check the condition of the zinc anode in the raw water circuit and clean or replace the anode as needed. Note that it is not necessary to flush the antifreeze/fresh water solution from the raw water coolant system. When the engine is put into operation.
TABLE OF STANDARD HARDWARE TIGHTENING TORQUES Unless stated otherwise for a specific assembly. use the following torque values when tightening standard hardware. kg-m Pitch lb-ft 6nun bolt head/nut 8nun bolt head/nut 10 mm bolt head/nut 10 nun bolt head/nut 12 mm bolt head/nut 12 nun bolt head/nut 12 nun bolt head/nut 13 mm bolt head/nut 14 mm bolt head/nut 14 mm bolt head/nut 16 mm bolt head/nut 16 nun bolt head/nut 1 1.25 1.25 1.5 1.25 (ISO) 1.5 1.75 1.5 1.5 2 1.5 2 2.9 - 5.1 0.4 - .07 7.2 - 11.61.
Socket Size Cylinder head bolt Rocker shaft hold down bolts M 10 (14mm) 54 - 61 7.5 - 8.5 M8(12mm) 14 - 22 2.0 - 3.0 M 8 (12 mm) II - 16 1.5 - 2.2 (See the "Torquing Cylinder Head Bolts" section of this manual.) Crankshaft pulley nut Connecting rod cap-nut M 16 (24mm) M8 (14 mm) 72.3 - 86.7 23 - 25 10-12 3.2 - 3.5 Oil pan drain plug (All models) M18 36.2 - 43.4 5.0 - 6.0 8.0 - 9.4 (or tighten firmly by hand) 1.1-1.
SPARE PARTS Since a possibility exists in which the engine may need to be serviced at sea or while in a port other than your home port, certain spare parts should be kept on board to help minimize delays in your voyage. Please refer to your engine's Parts List for part numbers when ordering spare parts. Listed below are those spare parts that should be carried on board at all times. 1. An impeller kit. 2. A fuel system hardware kit. 3. A secondary fuel filter element. 4. A water pump belt. 5. Hose clamps.
NOTES 77 WESTERBEKE GENERATORS
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.
BTD 7.6 KW POWER TAKE-OFF (PTO) ADAPTER The generator housing of the BID 7.6 KW is machined to accept the optional power take-off (PTO) adapter kit #34786. This kit allows the user to mount and to operate a hydraulic pump (or similar device) while the generator is operating. The operator is advised that the generator's drive engine produces a specific horsepower at 1800 rpm (continuous), 60 Hertz (8 HP at 1500, 50 Hertz).
