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Westerbeke 7.6 EGTD - User Manual

Westerbeke 7.6 EGTD
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OPERATORS
MANUAL
. .
7.6
E
GTD
60HZ
5.
7 E
GTD
50HZ
MARINE
DIESEL
GENERATORS
·
SIN
E
HASE
REVISIONO
JULY
2016
l..,_.
rWESTERBEKE
j
WESTERBEKE
CORPORATION
150
JOHN
HANCOCK
ROAD
I MYLES
STANDISH
INDUSTRIAL
PARK
TAUNTON
MA
02780
WEBSITE:
WWW.
WESTERBEKE.COM
..,_..,Air
NMMA
Member
NIJJional
Marine
Manufacturus
Association
..,...
..
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Summary

Safety Instructions

Electrical and Battery Safety

Guidelines for preventing electrical shock, battery explosions, and acid hazards.

Fire, Explosion, and Exhaust Hazards

Precautions against fire, explosions from fuel vapors, and toxic exhaust gases.

Operational and Noise Hazards

Warnings about accidental starting, moving parts, and high noise levels.

Installation Procedures

Codes and Regulations

Compliance requirements for installing engines and generators in marine environments.

Siphon-Break and Exhaust System

Installation of siphon-breaks and requirements for marine exhaust systems.

Generator Break-In Procedure

Procedure Overview

Explanation of the break-in period requirements for new engines.

Daily Operation and Stopping

Daily checklist for starting, operating, and safely stopping the generator.

Safety Shutdown Switches

Shutdown Switch Descriptions

Details on high temp, low oil pressure, and overspeed shutdown switches.

Check Engine LED and Circuit Breaker

Function of the Check Engine LED and engine circuit breaker protection.

Engine and Generator Identification

Serial Number Location

Information on locating serial and model numbers for technical support.

Diesel Engine Basics

Understanding diesel engine operation and preventive maintenance.

Ordering Parts and Spares

Procedures for ordering parts and recommended spare items.

Fluid and Coolant Management

Fuel System Care

Diesel fuel specifications and advice for maintaining fuel supply cleanliness.

Engine Oil Recommendations

Engine oil type, change intervals, and guidelines for synthetic oil use.

Engine Coolant and Recovery Tank

Coolant mixture, antifreeze properties, and the function of the recovery tank.

Initial Start-Up Preparations

Prestart Inspection Checklist

Essential checks before starting the generator for the first time or after a layoff.

Starting Precautions and Coolant Purging

Recommendations for initial start-up and purging air from the cooling system.

Generator Control and Operation

Control Panel Overview

Description of engine-mounted and remote control panels and their functions.

Starting and Stopping Procedures

Step-by-step guides for starting and stopping using different control panels.

Maintenance Schedule

Daily Checks

Essential checks to perform each day before starting the generator.

Initial 50 Hours Maintenance

Maintenance tasks required during the first 50 hours of operation.

Periodic Maintenance Intervals

Tasks for 50, 100, 250, 500, and 1000 operating hours or yearly.

Fuel System Details

Fuel Specifications and Filtration

Diesel fuel type, filters, and water separator requirements.

Fuel Pump and Filter Maintenance

Information on fuel lift pump, injection pump, and engine fuel filter.

Cooling System Management

System Overview and Circuits

Explanation of fresh water and raw water cooling circuits.

Coolant Maintenance

Procedure for changing, refilling, and maintaining engine coolant.

Raw Water System Components

Details on raw water strainer, pump, heat exchanger, and zinc anode.

Engine Lubricating Oil and Starter

Engine Oil Change Procedure

Steps for draining oil, replacing the filter, and refilling the sump.

Remote Oil Filter Installation

Instructions for installing the optional remote oil filter kit.

Starter Motor Operation and Troubleshooting

Components of the starting system and steps for diagnosing issues.

Engine Adjustments and Tuning

Drive Belt and Cylinder Head Torque

Adjusting drive belt tension and re-torquing cylinder head bolts.

Fuel Injectors and Valve Clearance

Service for fuel injectors and adjustment of valve clearance.

Injection Timing and Glow Plugs

Setting injection pump timing and testing glow plugs.

Oil Pressure Testing

Procedure for testing engine oil pressure and related switches.

Engine Troubleshooting

Electronic Controller and Shutdowns

ECU function, causes of engine shutdowns, and Check Engine light.

Gauge and Common Issue Diagnosis

Troubleshooting gauges and common engine problems like no start or low power.

Alternator and DC System

Alternator Testing and Inspection

Procedures for testing alternator output and visual inspection.

DC Circuit and Battery Maintenance

Overview of the DC circuit, testing, and battery maintenance.

Wiring Diagrams and Schematics

Wiring Diagram and Schematic

Visual representation of the generator's electrical connections.

Panel Wiring Diagrams

Wiring details for instrument and remote control panels.

Generator Specifications

Engine, Electrical, and Cooling Specs

Key specifications for engine, electrical system, and cooling.

AC Generator and Cooling Specs

Generator ratings, voltage, frequency, and cooling requirements.

Generator Information and BT Series

Generator Operation and Maintenance

Using electric motors, frequency adjustment, and generator maintenance.

BT Generator Description and Wiring

Overview of BT generator, circuit breaker, and internal wiring.

BT Generator Troubleshooting and Testing

Procedures for troubleshooting, testing components, and adjusting voltage.

Domestic Hot Water Heater Connections

Installation Overview

Steps for installing the heater by-pass fixture and connecting hoses.

Cooling System Integration

Connecting the water heater to the engine's cooling system.

Lay-Up and Recommissioning

Lay-Up Procedures

Steps for preparing the engine and systems for storage.

Recommissioning Procedures

Steps to prepare the engine for operation after storage.

Power Take Off Systems

Power Take Off Adapter

Description and installation of the PTO adapter kit for accessories.

Conversion Data

Length, Volume, and Mass Conversions

Conversion factors for length, volume, and mass measurements.

Pressure, Torque, and Velocity Conversions

Conversion factors for pressure, torque, and velocity.

Power, Fuel, and Temperature Conversions

Conversion factors for power, fuel consumption, and temperature.

Suggested Spare Parts

Recommended Spare Parts

List of essential spare parts to keep on hand for maintenance.

Available Spare Parts Kits

Description of available spare parts kits for purchase.

Summary

Safety Instructions

Electrical and Battery Safety

Guidelines for preventing electrical shock, battery explosions, and acid hazards.

Fire, Explosion, and Exhaust Hazards

Precautions against fire, explosions from fuel vapors, and toxic exhaust gases.

Operational and Noise Hazards

Warnings about accidental starting, moving parts, and high noise levels.

Installation Procedures

Codes and Regulations

Compliance requirements for installing engines and generators in marine environments.

Siphon-Break and Exhaust System

Installation of siphon-breaks and requirements for marine exhaust systems.

Generator Break-In Procedure

Procedure Overview

Explanation of the break-in period requirements for new engines.

Daily Operation and Stopping

Daily checklist for starting, operating, and safely stopping the generator.

Safety Shutdown Switches

Shutdown Switch Descriptions

Details on high temp, low oil pressure, and overspeed shutdown switches.

Check Engine LED and Circuit Breaker

Function of the Check Engine LED and engine circuit breaker protection.

Engine and Generator Identification

Serial Number Location

Information on locating serial and model numbers for technical support.

Diesel Engine Basics

Understanding diesel engine operation and preventive maintenance.

Ordering Parts and Spares

Procedures for ordering parts and recommended spare items.

Fluid and Coolant Management

Fuel System Care

Diesel fuel specifications and advice for maintaining fuel supply cleanliness.

Engine Oil Recommendations

Engine oil type, change intervals, and guidelines for synthetic oil use.

Engine Coolant and Recovery Tank

Coolant mixture, antifreeze properties, and the function of the recovery tank.

Initial Start-Up Preparations

Prestart Inspection Checklist

Essential checks before starting the generator for the first time or after a layoff.

Starting Precautions and Coolant Purging

Recommendations for initial start-up and purging air from the cooling system.

Generator Control and Operation

Control Panel Overview

Description of engine-mounted and remote control panels and their functions.

Starting and Stopping Procedures

Step-by-step guides for starting and stopping using different control panels.

Maintenance Schedule

Daily Checks

Essential checks to perform each day before starting the generator.

Initial 50 Hours Maintenance

Maintenance tasks required during the first 50 hours of operation.

Periodic Maintenance Intervals

Tasks for 50, 100, 250, 500, and 1000 operating hours or yearly.

Fuel System Details

Fuel Specifications and Filtration

Diesel fuel type, filters, and water separator requirements.

Fuel Pump and Filter Maintenance

Information on fuel lift pump, injection pump, and engine fuel filter.

Cooling System Management

System Overview and Circuits

Explanation of fresh water and raw water cooling circuits.

Coolant Maintenance

Procedure for changing, refilling, and maintaining engine coolant.

Raw Water System Components

Details on raw water strainer, pump, heat exchanger, and zinc anode.

Engine Lubricating Oil and Starter

Engine Oil Change Procedure

Steps for draining oil, replacing the filter, and refilling the sump.

Remote Oil Filter Installation

Instructions for installing the optional remote oil filter kit.

Starter Motor Operation and Troubleshooting

Components of the starting system and steps for diagnosing issues.

Engine Adjustments and Tuning

Drive Belt and Cylinder Head Torque

Adjusting drive belt tension and re-torquing cylinder head bolts.

Fuel Injectors and Valve Clearance

Service for fuel injectors and adjustment of valve clearance.

Injection Timing and Glow Plugs

Setting injection pump timing and testing glow plugs.

Oil Pressure Testing

Procedure for testing engine oil pressure and related switches.

Engine Troubleshooting

Electronic Controller and Shutdowns

ECU function, causes of engine shutdowns, and Check Engine light.

Gauge and Common Issue Diagnosis

Troubleshooting gauges and common engine problems like no start or low power.

Alternator and DC System

Alternator Testing and Inspection

Procedures for testing alternator output and visual inspection.

DC Circuit and Battery Maintenance

Overview of the DC circuit, testing, and battery maintenance.

Wiring Diagrams and Schematics

Wiring Diagram and Schematic

Visual representation of the generator's electrical connections.

Panel Wiring Diagrams

Wiring details for instrument and remote control panels.

Generator Specifications

Engine, Electrical, and Cooling Specs

Key specifications for engine, electrical system, and cooling.

AC Generator and Cooling Specs

Generator ratings, voltage, frequency, and cooling requirements.

Generator Information and BT Series

Generator Operation and Maintenance

Using electric motors, frequency adjustment, and generator maintenance.

BT Generator Description and Wiring

Overview of BT generator, circuit breaker, and internal wiring.

BT Generator Troubleshooting and Testing

Procedures for troubleshooting, testing components, and adjusting voltage.

Domestic Hot Water Heater Connections

Installation Overview

Steps for installing the heater by-pass fixture and connecting hoses.

Cooling System Integration

Connecting the water heater to the engine's cooling system.

Lay-Up and Recommissioning

Lay-Up Procedures

Steps for preparing the engine and systems for storage.

Recommissioning Procedures

Steps to prepare the engine for operation after storage.

Power Take Off Systems

Power Take Off Adapter

Description and installation of the PTO adapter kit for accessories.

Conversion Data

Length, Volume, and Mass Conversions

Conversion factors for length, volume, and mass measurements.

Pressure, Torque, and Velocity Conversions

Conversion factors for pressure, torque, and velocity.

Power, Fuel, and Temperature Conversions

Conversion factors for power, fuel consumption, and temperature.

Suggested Spare Parts

Recommended Spare Parts

List of essential spare parts to keep on hand for maintenance.

Available Spare Parts Kits

Description of available spare parts kits for purchase.

Westerbeke 7.6 EGTD Specifications

General IconGeneral
Model7.6 EGTD
Power Output7.6 kW
Fuel TypeDiesel
AC Voltage120/240V
AC Frequency60 Hz
PhaseSingle Phase
Starting SystemElectric

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