Westerbeke 38B FOUR Manuel de l'opérateur

OPERATOR'S MANUAL & INSTALLATION GUIDE WESTERBEKE 7.6 KW BTD - 60 Hertz 5.7 KW BTD -50 Hertz MARINE DIESEL GENERATOR SET Publication #040457

~ ~ a Fuel Run Solenoid gJ z ~ 20 Amp DC Circuit Breaker i}l Pre heat Solenoid 0\ A C Connections Outlet Fuel Lift Pum Air Intake Silencer Lube Oil Fi

--l :::! toO 'JJ I ~ ~ ~ ~ Water Temperature Sender Water Temperature Switch DC Charging Alternator Belt Guard Heat Exchang Starter with Solenoid

GENERAL Introduction This manual contains the equipment operating procedures as well as additional information needed to help the operator kee

Engine Type Combustion Chamber Bore & Stroke Piston Displacement Firing Order Direction of Rotation 7.6 BTD MARINE DIESEL GENERATOR SET GENERAL S

7.6 KW BTD SYSTEM SPECIFICATIONS FUEL SYSTEM General Fuel Injector Pump Injectors LiftPump Air cleaner Air Flow (engine combustion) COOLING SYSTEM Gen

7.6 KW BTD SYSTEM SPECIFICATIONS (continued) ELECTRICAL SYSTEM Starting Battery Battery Capacity Starter DC No-Load Current DC Cranking Current DC Alt

7.6 KW BTD SYSTEM SPECIFICATIONS (continued) TUNE-UP SPECIFICATIONS Injector Pressure Engine Timing (Spill Timing) EMISSION CONTROL SYSTEMS WESTERBEKE

INSTALLATION CHECKS General Because the crafts in which Westerbeke engines and generators are installed vary in design, installation procedures wil

Rigging and Lifting The generator is fitted with lifting eyes. Rope or chain slings capable of supporting the generator's weight should be attac

Generator Mounting - Location The complete generator unit is mounted on lightweight rails by means of four flexible isolator mounts that help prevent

Exhaust System I WARNING I Carbon monoxide gas is deadly! Carbon monoxide is a dangerous gas that can cause unconsciousness and is potentially let

Exhaust Back-Pressure The exhaust discharge hose must be of adequate size and minimal run to prevent excessive exhaust back-pressure. Exhaust back

Dry stack-type exhaust systems (shown to the right) must be at-tached to the generator engine's exhaust manifold by means of a flexibl

Exhaust Elbow Installation The Westerbeke Corporation offers a 45° and 90° exhaust elbow as well as an exhaust riser you can install on your

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.

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

II CAUTION II To avoid an overcharging condition, and a possible equipment failure, do not disconnect tbe DC battery source while tbe engine is runnin

I WARNING I When servicing the battery or checking the electrolyte level, wear rubber gloves, a rubber apron, and eye protection. Battery

NOTES WESTERBEKE GENERATORS 24

General o DESCRIPTION OF INSTRUMENT PANEL PREHERT 4 w START ~ WJ STOP ® GENERRTOR o o o The manually operated series of Westerbeke generators is eq

SAFETY PRECAUTIONS The following symbols appear in this manual to call attention to and emphasize conditions potentially dangerous to the ope

Remote Operation For starting and stopping the generator at a remote location, the same three switches are used. The PREHEAT and START swit

DC WIRE SIZING CHART Stranded Conductors for 12 Volt Circuits 10% Voltage Drop A. Society of Aut.omotive Engin.eers Type Wire B. National Electrical C

Description of Starting System Westerbeke diesel engines use electric starters assisted by glow plugs for both normal and cold weather starting.

PREPARATION FOR STARTING This section of the manual provides the operator with preparation, initial starting, break-in, starting (cold or warm) and st

STARTING PROCEDURE 1. Depress and hold the preheat switch. Preheat according to the following chart. 2. While still depressing the PREHEAT switch, d

Engine Break-In Procedure Although your generator has experienced a minimum of one hour of test operations to make sure accurate assembly procedures w

Starting Under Normal Conditions Follow the procedure below for normal starting of the generator. 1. Make sure there is sufficient fuel on board. Kee

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 t

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 ha

• 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

II CAUTION II Prolonged cranking intervals without the engine starting can result in filling the engine-mounted exhaust system with sea water coolant.

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 th

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

7.6 BTD Control Circuit Wiring Diagram #039284 paoe 1 of2 '" ", '" ~I IE!lt!~IQB :i I A AI UMn8.~t,.p~ WrHEB IEt:I~E!lHIlBE

+ 12 vIX r--, 1 ; C.B. :( :20.1, . , r " I : EMERGENCY L JSTOf> SW. r 1 : lSToPSw. l " r , 7.6MINIBTD Schematic Diagram #39284 page

G"(lUM" TO BlQ(' IS PIN REMOTE CONNECTOR . • " T" iR'(\ ,,.>(Olvl(\ "o""iIO(O ~ , r tI, 5,1< • , ,

I' I L.; l---, ~i EMERGENCY I STOP 1-1 SWI TCH '~81-1 r' I L.; FUSE 8A t1 STOP ISWITCH 1-1 ---c-7.6 BTD DC Schematic Diagram #044121 (

COOLING SYSTEM Description Westerbeke marine diesel generators are designed and equipped for fresh water cooling. Heat produced in the engine by comb

ANTIFREEZE CONCENTRATION DATA Antifreeze Concentration Freezing Temperature % 13 23 (-5) 23 14 (-10) B. Filling the Fresh Water System 30 5 (-15) 35 -

COOLANT RECOVERY TANK PRESSURE CAP COOLANT PASSAGE EXHAUST MANIFOLD Coolant Recovery Tank, Recommended Installation Fill the fresh water system as fo

IMPORTANT PRODUCT SOFTWARE DISCLAIMER Product software of all kinds, such as brochures, drawings, technical data, operator's and works

Thermostat Generally, thermostats are of two types. One is simply a choking device which opens and closes as the engine's temperature rises a

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

Cooling System Illustrated below is a typical Westerbeke engine cooling system. Both fresh water and raw water flow through their independent cool

LUBRICATION SYSTEM Engine Oil For engine lubrication, use lubricating oil designated for diesel service. These oils are classified accord

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 p

BT GENERATOR This generator is a brushless self-excited generator, which requires only the driving force of the engine to produce AC output. The c

" Securing ... 7.6 BID - View of Generator Backend ©© ~ ©© #2 ©© #S VOLTAGE BAR WESTERBEKE GENERATORS VOLTAGE BAR The voltage bar has three

r , I 1 , [~ 1 1>+ 1 1 ~ i • 4 31 1 1 1 I I c I -I 2 I I ! 1 1 3 L _____________ J I r--------------, : , Btl r-------, 1 C I : \1 I [ L _______

Generator Frequency Frequency is a direct result of engine/generator speed: 1800 RPM - 60 Hertz 1500 RPM - 50 Hertz To change the generator's fre

120V 60Hz 120/240V 60Hz 0 ( ) T ( ) o FR ... ME 0 ( , { } .ME 'II~ "-TOFFi! '11 I I 0 t::::::J Ll N c f 10 (OJ t: :J 0 0 0 0 0 0

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 ca

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

GENERAL INFORMATION AND CARE OF THE GENERATOR Use of Electric Motors The power required to start an electric motor is considerably more tban is requir

Load Applied 4-Pole Speed Frequency Generator Voltage (rpm) (Hertz) 120V (110) 240V (220) Plants Plants None 1830 62 122 240 (1530) (52) (ll2) (

YOUR NOTES 59 WESTERBEKE GENERATORS

ENGINE TROUBLESHOOTING Introduction The tables which follow indicate troubleshooting procedures based upon certain problem indicators, the probabl

No ignition: cranks, but does I. Faulty fueling system, I. Check for fuel to generator not start; fuel solenoid engine. energized. 2. Check for air

Battery not charging. 1. Alternator drive. 1. Check drive belt tension. Be sure alternator tnrns freely. Check for loose connections. Check output

MAINTENANCE AND ADJUSTMENTS Introduction This section contains a scheduled preventive maintenance program and several adjustment procedures the owner

*3. Retorque the cylinder head bolts. *4. Adjust valve clearances. 5. Adjust the water pump drive belt tension, if required. *6. Adjust the engin

Servicing After Every 800 Hours of Operation *1. Remove and check fuel injectors. Injector spray pressnre: 1988 psi ± 142 psi (140 kg/cm2 ± 10 kg/cm2

Engines & Generators Declaration of Conformity Application of Council Directive(s) Standard(s) to Which Conformity is declared Manufacturers Name

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

Adjust each valve's clearance by inserting a 0.010 inch (0.25 mm) feeler gauge between the rocker arm and the valve stem. Injection Pump Tim

Adjustments (Generator) Once the diesel generator set has been placed in operation, there may be adjustments required for engine speed (hertz) during

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

LAY-UP AND RECOMMISSIONING General Many owners rely on their boatyards to prepare their craft, including engines and generators, for lay-up during

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. Ca

Starter Motor Lubrication and cleaning of the starter drive pinion is advisable, if access to the starter permits its easy removal. Make sure the

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

TABLE OF STANDARD HARDWARE TIGHTENING TORQUES Unless stated otherwise for a specific assembly. use the following torque values when tightening standa

Socket Size Cylinder head bolt M 10 (14mm) 54 - 61 7.5 - 8.5 M8(12mm) 14 - 22 2.0 -3.0 Rocker shaft hold down bolts M 8 (12 mm) II - 16 1.5 - 2.2 (S

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

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 loc

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) adapt

TABLE OF CONTENTS Section Page GENERAL ......... . . ...... 8 GENERAL SPECIFICATIONS ... . .....