Westerbeke 7.6 KW BTD 60Hz User manual

OPERATOR'S MANUAL
&
INSTALLATION GUIDE
WESTERBEKE
7.6 KW BTD -60 Hertz
5.7 KW BTD -50 Hertz
MARINE DIESEL
G ENE RATOR SET
Publication #040457
Edition One
April 1994
~ WESTERBEKE
WESTER BEKE CORPORATION · MYLES STANDISH INDUSTRIAL PARK
150 JOHN HANCOCKROAD, 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.
IWARNING 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. Know when
dangerous conditions can exist and take necessary precautions
to protect personnel and equipment.
Fuels, exhaust gases, batteries, electrical equipment, moving and hot
partS are potential hazards that could
result in serious personal injury or death. Follow recommended procedures carefully.
• Prevent Electric Shock
Shut offelectric power before accessing electrical equipment.
Use insulated mats whenever working on electrical equipment.
Make sure your clothing is dry, not damp (particularly shoes), and keep your skin surfaces dry when
handling electrical equipment.
Remove wristwatch andjewelry when working on electrical equipment.
Do not connect utility shore power
to vessel's AC circuits, except through a ship-ta-shore double
throw transfer switch. Damage
to vessel's AC generator may result if this is not done.
Be extremely careful when working on electrical components. High voltage can cause injury
or
death.
• Exhaust Gases Are Toxic
Ensure that exhaust system is adequate to
ex-pel gases discharged from the engine. Check exhaust
system regularly for leaks and make sure the exhaust manifolds are securely attached and no warping
exists.
Be sure the unit and its surroundings are well ventilated.
• Use Extreme Care When Handling Engine Fuel (A constant danger of explosion or fire exists)
Do not fill fuel tank(
s) while the engine is running.
Do not smoke or use an open flame near the engine or the fuel tank.
1
WESTERBEKE GENERATORS

• 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 NFPA are appropriate for all applications encountered in
this environment.
• Use Extreme Care When Servicing Batteries
Wear rubber gloves, a rubber apron, and eye protection when servicing batteries.
Lead acid batteries emit hydrogen, a highly-explosive gas, which can be ignited by electrical arcing or
by a lighted cigarette, cigar, or pipe. Do not smoke or allow an open flame near the battery being
serviced. Shut off all electrical equipment in the vicinity
to prevent electrical arcing during servicing.
• Avoid Moving Parts
Do not service the unit while it is running. If a situation arises in which it is absolutely necessary to
make operating adjustments, use extreme care
to avoid moving parts and hot exhaust system
components.
Do not wear loose clothing orjewelry when servicing equipment; avoid wearing loose jackets shirts
or sleeves, rings, necklaces, or bracelets that might be caught in moving parts.
Make sure all attaching hardware is properly tightened. Keep protective shields
and guards in their
respective place
at all times.
Do not check fluid levels
or the drive belt's tension While the unit is operating.
Do not work on the equipment when mentally
or physically incapacitated by fatigue.
WESTERBEKE GENERATORS 2

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. WESTERBEKE CANNOT BE RESPONSmLE
FOR TIIE CONTENT OF SUCH SOFTWARE, MAKES NO WARRANTIES OR REPRESENTATIONS
WITH RESPECT TIIERETO, INCLUDING ACCURACY, TIMELINESS OR COMPLETENESS
TIIEREOF, AND Wll.L IN NO EVENT BE LIABLE FOR ANY TYPE OF DAMAGES OR INJURY
INCURRED IN CONNECTION WITH, OR ARISING OUT OF, TIIE FURNISHING
OR USE OF SUCH
SOFTWARE.
For example, components and subassemblies incorporated in Westerbeke's products and supplied by others
(such as engine blocks, fuel systems and components, transmissions, electrical components, pumps and
other products) are generally supported
by their manufacturers with their own software, and Westerbeke
must depend on such software for the design
of Westerbeke's own product software. Such software may be
outdated and no longer accurate. Routine changes made
by Westerbeke's suppliers, of which Westerbeke
rarely bas notice in advance, are frequently not reflected in the supplier's software until after such changes
take place.
Westerbeke customers should also keep in mind the time span between printings
of Westerbeke product
software, and the unavoidable existence of earlier, non-current Westerbeke software editions in the field.
Additionally, most Westerbeke products include customer-requested special features that frequently do not
include complete documentation.
In summation, product software provided with Westerbeke products, whether from Westerbeke or other
suppliers, must not and cannot be relied upon exclusively as the definitive authority on the respective
product.
It not only ntakes good sense but is imperative that appropriate representatives of Westerbeke or
the supplier in question be consulted to determine the accuracy and currentness
of the product software
being consulted by the customer.
3
WESTERBEKE GENERATORS

FOREWORD
Thank you for selecting a Westerbeke marine product for your use. We at Westerbeke are pleased to have
you as a customer.
Read this manual carefully and observe all safety precautions included throughout. Operating procedures,
periodic preventive maintenance procedures, installation checks, system descriptions and minor
adjustment procedures are included herein
so you can operate your equipment safely and properly,
maintain the equipment at a high level
of efficiency, and ex-pecl dependable performance and long service
life in return.
Should your unit require special attention, contact your Westerbeke dealer for assistance. The Westerbeke
Service Organization is trained to provide the support necessary to ensure long-term dependable
performance.
WESTERBEKE GENERATORS 4

Engines & Generators
Declaration of Conformity
Application of Council Directive(s)
Standard(s) to Which Conformity
is declared
Manufacturers Name
Manufacturers Address
Type
of Equipment
Product Name
Model(s)
Product Options
Supplementary Information
EMC S9/336IEEC
92/31IEEC & 93/6SlEEC
CISP 12 (1990-01)
EN500S2-1 ( 1992)
IEC SOl - 2 (1991), +1- Skv AD
IEC SOl - 3 (19S4), 3 VIM
Westerbeke Corporation
41 Ledin Drive
Avon
Industrial Park
Avon, Ma. 02322, USA
Marine Diesel Generator
Westerbeke Marine
Diesel Generator
4.0/5.0BCD,5.717.6BTD
6.0/S.0BTD,7.5/10.0BTD
S.3/11.0BTD,9.4/12.5BTDA
12.0/15.0BTDB, 16.0/20.0BEDA
20.0/25.0BED, 25.0/32.0BEDA
All
1.)
The equipment listed is only for use in Marine Applications aboard boats.
2.)
The equipment listed must be located below decks on the vessel and
permanently installed in its location.
3.)
The equipment listed must bewired to the grounding system of the vessel.
I
the undersigned, hereby declare that the equipment specified above conforms to
the above Directive(s)
and Standard(s). f1 '1 t; .
Place Avon, Massachusetts, U.S.A C 'c~~ (L a., ~
(Signature)
Date January
1. 1996
042021
Carleton F. Bryant
(Full Name)
ChiefOperating Officer
(Title)
WESTERBEKE CORPORATION, AVON INDUSTRIAL PARK, AVON. MA 02322 U.S.A .• TEL. {50B} 588-7700. FAX: [phone]. CABLE: WESTCORP

TABLE OF CONTENTS
Section Page
GENERAL..................................... .......................8
GENERAL SPECIFICATIONS.... ............................9
7.6 KW BTD SYSTEM SPECIFICATIONS.................... ..... 10
INSTALLATION CHECKS................... .................................. 13
DESCRIPTION OF INSTRUMENT PANEL ....................................................................... 25
PREPARATION FOR STARTING ........................................................................................29
STARTING PROCEDURE ...................................................................................................30
STOPPING PROCEDURE........... ......
......... ............... ... ......................... ............ 33
FUEL SySTEM .....................................................................................................................35
DC ELECTRICAL
SySTEM .................................................................................................38
7.6
BID CONTROL CIRCUIT WIRING DIAGRAM #039284.............................................39
COOLING SYSTEM ......... ........ ... .......... ... ....... ...............................................................43
LUBRICATION SYSTEM................................ ..... 49
BT GENERATOR. ..........................................................
51
GENERAL INFORMATION AND CARE OF THE GENERATOR............ ......................57
YOUR NOTES.......................................................................................................................59
ENGINE TROUBLESHOOTING........................................................................................... 60
MAINTENANCE AND ADJUSTMENTS ............................................................................ 63
LAY-UP AND RECOMMISSIONING................................................................................70
REMOTE LUBE OIL FILTER KIT -PN#040078............................................................. 73
TABLE OF STANDARD HARDWARE TIGHTENING TORQUES.................................... 74
SPARE PARTS..................................................................................................................76
SOUND GUARD INSTALLATION INSTRUCTIONS ........ .......................78
BID 7.6 KW POWER TAKE-OFF (PTO) ADAPTER......... ............... 79
5 WESTERBEKE GENERATORS

~
~
a
Fuel Run Solenoid
gJ
z
~
20 Amp DC Circuit Breaker
i}l
Pre heat Solenoid
0\
AC Connections Outlet
Fuel Lift Pum
Air Intake Silencer
Lube Oil Filter
7.6 KW BTD
RIGHT SIDE
Top Engine Oil Fill
Water Temperature Switch
Lube Oil Dipstick
Oil Fill
Oil Pressure Sender
Oil Pressure Switch

--l
:::!
toO
'JJ
I
~
~
~
~
Water Temperature Sender
Water Temperature Switch
DC Charging Alternator
Belt Guard
Heat Exchang
Starter with Solenoid
7.6 KW BTD
LEFT SIDE
Unit I. D, Plate
45
0
Exhaust Elbow
Emergency Shut~off Switch
Unit Data Tag
DC Battery Ground Connection

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. Proper diagnosis of a problem is the
most important step to satisfactory repair; therefore, a troubleshooting table
is included.
Understanding
the Diesel Engine-Driven Generator
The diesel engine closely resembles the gasoline engine since the mechanism is essentially the same. The
cylinders are arranged above a closed crankcase; the crankshaft is
of the same general type as that of a
gasoline engine; and the diesel engine has the same type
of valves, camshaft, pistons, connecting rods,
and lubricating system.
Therefore, to a great extent, a diesel engine requires the same preventive maintenance as a gasoline
engine. The most important factors are proper ventilation and proper maintenance
of the fuel, lubricating
and cooling systems. Replacement
of fuel and lubricating filter elements at the time periods specified is a
must, and frequent checking for contamination (that is, water, sediment, or algae) in the fuel system is
also essential. Another important factor is the use
of the same brand of high detergent diesel lubricating
oil designed specifically for diesel engines. Be careful not to put gasoline in the diesel fuel tank(s).
Gasoline does not have the same lubricating qualities as diesel fuel; consequently, gasoline in the fuel
lines will damage components in the fuel injection pump and fuel injectors.
The diesel engine does differ from the gasoline engine, however, in its handling and firing of
fuel. The
carburetor and ignition systems are done away with and in their place are
two components -the fuel
injection pump and the fuel injectors.
Ordering Parts
Whenever replacement parts are needed, always provide the generator model number designation (i.e. 7.6
KW
BID ), engine serial number, and generator serial number as they appear on the data plates located
on the exhaust manifold and on the generator end. You must provide us with its information
so we may
properly identify your generator set. In addition, include a complete part description and part number for
each part needed (see the separately furnished Parts List). Also,
be sure to insist upon Westerbeke factory
packaged parts because "will fit" or generic parts are frequently not made to the same specifications as
original equipment.
Note that component locations in the manual are referenced from the front of the engine which is the
pulley/drive belt end. (The flywheel/generator end is the rear end.) Left and right sides are determined by
the engine; imagine straddling the engine and facing in the same direction as the front
of the engine: the
left side is at your left, the right side at your right.
Westerbeke generator sets are thoronghly checked and given a final run under various load conditions
before leaving the factory. Test running the generator ensures dependable operation, long service life, and
a satisfied owner.
Care at the factory during assembly and thorough testing have resulted in a Westerbeke diesel engine-
driven generator capable of many thousands
of hours of dependable service. However, what the
manufacturer cannot control is the manner or location the generator
is installed in the vessel or the
manner in which the unit
is operated and serviced in the field. That part is up to the buyer/owner-
operator.
WESTERBEKE GENERATORS 8

Engine Type
Combustion Chamber
Bore & Stroke
Piston Displacement
Firing Order
Direction of Rotation
7.6 BTD MARINE DIESEL GENERATOR SET
GENERAL SPECIFICATIONS
Diesel, four-cycle, three cylinder, fresh water-
cooled. Vertical, in-line, overheadvalve
mechanism. (12.5 hp at 1800 rpm, maximum).
Swirl type.
2.99 x 2.76 inches (75.9 x 70 mm)
58.09 cubic inches (0.952 liters)
1-3 -2
Clockwise, when viewed from the front
Maximum Torque (at 1800 rpm)
42 lb-ft (5.8 kg-m)
Compression Ratio
Compression Pressure
Valve Timing
Valve Seat Angle
Valve Clearance
(engine cold)
Engine Speed
Dimensions
Weight
Fuel Consumption
Inclination
23:1
398 psi (28 kg/cm2) at 280 rpm
Intake Opens 19°
BIDC
Intake Closes 51° ABDC
Exhaust Opens
51 °BBDC
Exhaust Closes 19° A
IDC
Intake 45°
Exhaust 45°
Intake 0.0098 inches (0.25 mm)
Exhaust 0.0098 inches (0.25 mm)
1800 rpm 60 hertz
1500 rpm 50 hertz
Length: 27.8 inches (706.1 mm)
Width:
16 inches (406.4 mm)
Height: 19.9 inches (505.46 mm)
340 lbs (154.22 kgs)
0.53 U.S. gph (2 Iph) at full rated output
(approximately)
Not to exceed 25°
9 WESTERBEKE GENERATORS

7.6 KW BTD SYSTEM SPECIFICATIONS
FUEL SYSTEM
General
Fuel
Injector Pump
Injectors
LiftPump
Air cleaner
Air Flow (engine combustion)
COOLING SYSTEM
General
Operating Temperature
Fresh Water Pump
Raw Water Pump
Raw Water Flow.
at 1800 rpm
(measured before discharging into exhaust
elbow)
System Capacity (fresh water)
LUBRICATION SYSTEMS
General
Oil Filter
Sump Capacity (including filter)
Operating Oil Pressure (engine hot)
Oil Grade
WESTERBEKE GENERATORS
Open flow -totally self-bleeding
No.2 Diesel (cetane #45 or better)
In-line plunger type (Bosch type)
Throttle type
12-volt DC; electric
Plastic Intake Silencer
30.2 cfm (0.85 cmm)
Fresh water-cooled block, thermostatically-
controlled with heat exchanger.
170 -1900 F (77 -880 C)
Centrifugal type, metal impeller, belt-driven
Positive displacement, rubber impeller,
mechanically-driven
6.5 -7.0 U.S. gpm (24.6 -26.5 Ipm)
4.0 qts (3.79 liters)
Pressure type by Trochoid pump, gear-driven,
with external pressure reliefvalve.
Full flow, paper element, spin-on type
3.7 U.S. qts (3.5 liters)
35 - 55 psi (2.5 3.8 kg/cm2)
API specification
of CC or CD
10

7.6 KW BTD SYSTEM SPECIFICATIONS (continued)
ELECTRICAL SYSTEM
Starting Battery
Battery Capacity
Starter
DC No-Load Current
DC Cranking Current
DC Alternator
ACGENERATOR
General -Single Phase
Voltage -Single Phase
Rating (Volts AC)
60 Hertz 1800 RPM
7.6KW
50 Hertz 1500 RPM
AC Circuit Breaker
Generator Electrical
End Cooling
Air Requirements (60 Hertz at 1800 RPM)
12-volt, ( - ) negative ground
350-400 Cold Cranking Amps
12-volt, 1.2 KW, Reduction type, solenoid
mounted.
90 Amp (max) at 11.5 volts
175 -200 Amps (engine cold)
12 Volt, DC -40 amps
Brushless, four-pole, revolving field, transformer
regulation. Prelubricated, single bearing design.
Reconnectable 120 volts or 1201240 volts, single
phase.
120 or 1201240 volts -60 Hertz; 220 volts -50
Hertz. Voltage regulation: ± 5 % no load to full
load. Frequency regulation:± 3 Hertz no load
to
full load.
120 volts
120/240 volts
220 volts
63.3 Amps
63.3/31.6 Amps
26 Amps
To
be rated at 120% of the generator's rated
amperage and voltage output
175 -200 cfm (4.95 -5.66 cmm)
NOTE: Increase air supply 15% for 50 hertz operation (1500 rpm)
Engine Block 100 cfm or more to remove heat produced by the
engine block during operation
11 WESTERBEKE GENERATORS

7.6 KW BTD SYSTEM SPECIFICATIONS (continued)
TUNE-UP SPECIFICATIONS
Injector Pressure
Engine Timing
(Spill Timing)
EMISSION CONTROL SYSTEMS
WESTERBEKE GENERATORS
1988 psi ± 142 psi
(140 kg/cm2 ± 10 kg/cm2)
16° ± 1° BIDe
Static
12
Smoke Puff Limiter

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 ofthis section
to advise
boatyards or installers on procedures already well-developed and well-understood. However, it is
important that the owner/operator realize there are details
of the installation which require periodic
checks to ensure the best operating conditions for the equipment and safe operating conditions
for the
personnel on board. Proper location and installation of the generator set in the vessel are of prime
importance.
Factors in the installation that must
be considered are ventilation, so as to cool the generator and to
provide air for engine combustion; exhaust system, to properly discharge raw cooling water, to quiet the
exhaust and to expel the exhaust gas; cooling water supply; the electrical connections, both AC and DC,
and a
fuel system that will provide an unrestricted fuel supply and properly filtered fuel to the fuel pump
on the engine.
II CAUTION II
For safety reasons, the generator's engine is not filled with lubricating oil for shipment.
Before leaving the factory, however, each generator set
is thoroughly tested with oil in
its engine. This testing, among other things, provides all internal parts with a coating of
oil. This oil acts as a preservative, providing reliable protection against corrosion for at
least one year
if the generator is properly stored.
Inspection of Equipment
The generator is shipped from the factory securely mounted and properly crated. Accessory equipment is
shipped in a separate small box, usually packed within the generator's crate.
Before accepting shipment of the generator set from the transportation company, the crate should be
opened and the contents inspected for concealed damage.
If either visible or concealed damage is noted,
you should require the delivery agent sign "Received in damaged condition" on the proper delivery
receipt. Also, check the contents of the shipment against the packing list and make sure that the proper
notation is
made if any discrepancies exist. These noted discrepancies are your protection against loss or
damage. Claims concerning loss or damage must be made to the carrier, not to Westerbeke Corporation.
13
WESTERBEKE GENERATORS

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.
Strain placed on the generator's lifting eyes by the lifting sling must not be in excess
of
10° from the vertical pain.
ENGINE
SLING LIFTING
ANGLE SHOULD BE
AS SMALL AS PDSSIBLE
LIFTING
EYE
The general rule in moving generators is to see that all equipment used is amply strong and firmly fixed
in place. Move the engine a little at a time
and see that it is firmly supported. Eliminate the possibility of
accidents by avoiding haste. Do not lift the generator by its crankshaft position. Certain situations exist
by which the engine must be lowered endwise through a small hatchway which cannot be made larger.
Under these conditions, if the opeuingofthe hatchway is extremely small, it is possible to reduce, to some
e,,"(ent, the outside dimensions of the generator by removing external components such as the cooling
system's accessory equipment should be removed
by a competent mechanic and special care should be
taken to avoid damage to any exposed parts. In addition, be careful not
to allow dirt from entering any
opeuing created
by the removal of equipment. Removed parts should be returned to their respective
position once the generator is in its installation area. Replace gaskets as needed for the parts that were
removed.
In case it becomes necessary to hoist the generator front-end upwards
or generator-end upwards, the
attachment
of lifting slings must be done carefully to avoid the possibility of damaging the parts on
which the weight
of the slings may bear. Special rigging work is best done by someone experienced and
competent in handling heavy machinery.
WESTERBEKE GENERATORS 14

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.
The mounting location must be dry, above low-lying vapor areas, and
in an area where bilge water and
water from above cannot splash or drip on the generator or drive engine. The drive engine and generator
must be accessible for minor servicing and repairs. Access for major repairs should be given
consideration as well. The generator set must be properly ventilated to provide fresh cooling air for the
generator end, for engine combustion needs, and to remove heat produced by the engine while operating.
The generator set needs fresh cool air in whatever location in the vessel it
is installed. Hot generator
discharge air !!lli§!. be removed from the generator area. The platform on which the generator and its
mounting rails are located must be strong enough to support the generator during all angles
of vessel
operation.
15 WESTERBEKE GENERATORS

Exhaust System
IWARNING 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.
• Dizziness • Vomiting
• Intense Headache • Muscular Twitching
• Weakness and Sleepiness • Throbbing in Temples
The generator must have its own separate exhaust installed
so that the entry ofraw water into the engine's
exhaust manifold and cylinders is prevented while the engine
is not running, or while the vessel is under
sailor power in which case the vessel may experience heeling, backing down from following seas, or any
other condition. Special attention must be taken to make certain the exhaust system is secure, tight and
free
of leaks.
The raw water supply through-hull sea cock fittings must be
of the flush-hull type. High-speed scoop
types or weedless scoop types must not be used, as they tend to encourage siphoning.
When a water lift type exhaust system is used, the
exhaust muflIer should be mounted
as close to the
engine
as practical. The exhaust discharge should
always drop downward into the exhaust muflIer.
Loops
in the exhaust hose between the water-injected
exhaust elbow and the water lift muflIer should be
avoided,
as these will trap and hold water.
For installations where the exhaust manifoldlwater-
injected exhaust elbow is within 8 inches or below
the vessel's water line, provisions must be made to
install a siphon-break or a vent in the raw water
supply hose to the water-injected exhaust elbow.
This stops the flow
of raw water that runs through
the raw water cooling system from filling the
exhaust and engine cylinders when the engine
is shut
down. This raw water supply hose must be looped
above the water line and the siphon-break or vent
must always be above the water line during all angles
of vessel operation
to prevent siphoning. The vent,
when used, must have its vent hose or tube routed
so
it can remain above the water line and empty of
water when the engine is shut down. This allows air
to enter through this vent to prevent siphoning.
WESTERBEKE GENERATORS 16
Wlnl1l1 IUR ... tn LIlt