OPERATOR'S MANUAL & INSTALLATION GUIDE WESTERBEKE CORPORATION DIESEL GENERA TORS SINGLE AND THREE PHASE MODEL BTD 8.0 KW, 10.0 KW, 11.0 KW BTD & A 12.5 KW 60 HERTZ MODEL BTD 6.0 KW, 7.5 KW, 8.3 KW BTD & A 9.
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 Svstem Be sure all fuel supplies have a positive shut-off valve. Be certain fuel line fittings are adequately tightened and free ofleaks. Make sure a fire extinguisher is installed nearby and is properly maintained. Be familiar with its proper use. Extinguishers rated ABC by the NFPA are appropriate for all applications encountered in this environment.
FOREWORD Thank you for selecting a Westerbeke marine product for your use. We at Westerbeke are pleased to have you as a customer.
IMPORTANT PRODUCT SOFTWARE DISCLAIMER Product software of all kinds, such as brochures, drawings, technical data, operator's and workshop manuals, parts lists and parts 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.
TABLE OF CONTENTS GENERAL 12 BID 8.0 KW MARINE DIESEL GENERATOR SET GENERAL SPECIFICATIONS 13 SYSTEM SPECIFICATIONS 14 BTD 10.0 KW MARINE DIESEL GENERATOR SET SPECIFICATIONS GENERAL 17 SYSTEM SPECIFICATIONS 18 BID 11.0 KW MARINE DIESEL GENERATOR SET GENERAL SPECIFICATIONS 21 SYSTEM SPECIFICATIONS 22 BTD 12.5 KW MARINE DIESEL GENERATOR SET GENERAL SPECIFICATIONS 25 SYSTEM SPECIFICATIONS 26 BIDA 12.
TABLE OF CONTENTS (CONTINUED) TABLE OF STANDARD HARDWARE TIGHTENING TORQUES 92 SOUND GUARD INSTALLATION INSTRUCTIONS 94 POWER TAKE-OFF (PTO) ADAPTER KlTS 95 WESTERBEKE GENERATORS 6
BTD 8.0 KW Generator Control Panel Intake Silencer Preheat Solenoid Charging Alternator 20 Amp DC Circuit Breaker Fuel Run Solenoid Switch Zinc Anode Block Drain ~ __ I'x<'h,,"ge, Fresh Water Drain Fuel Lift Pump Oil Pressure Sender 8.0 KW BTD Fresh Water Fill xhaust Manifold Exhaust Temperature DC Charging itch Alternator Fresh Water Circulating Pump Unit Data Tag Sea Water Ground Connection Starter with Solenoid 8.
BTD 10.0 KW Generator Preheat Solenoid Emergency Stop ide Oil Fill Intake Silencer DC Charging rnatar 20 Amp DC Circuit Srea AC Outlet Run __,4.nc Anode Heat Exchanger Fresh Water Block Drain -Exchanger Fresh Water Drain Lube Oil Filter Fuel Lift I Pressure Switch 10.0 KW BTD Emergency Shut rol Panel Fresh Water Coolant - - - - - ' " ' Exhaust Elbow Sea Water Pump DC Battery Ground Connection Heat Exchanger Starter with Solenoid 10.
BTD 11.0 KW Generator Water Air Bleed Top Engine Oil Control DC Charging Preheat Sollen<,id A C Con,nec,tior"'~ Fresh Water Slock Pressure Sender Lube Oil Dip,stick' Lube Oil Filter Fitter 11.0KW BTD Fresh Water Air Shut-off Switch Exhaust Temperature Switch Elbow Heat Exc;hang,,,/ DC Battery Ground Connection with Solenoid 11.
BTD 12.5 KW Generator 20 Amp DC Circuit Breaker Fuel Filter Lube Oil Fil DC Charging Control AC Fuel Lift i Pressure Switch Lube Oil Filter 12.
Preheat Solenoid Air Intake Silencer I Side Oil Fill DC Charging Alternator Control Panel 20 Amp DC Circuit Breaker Fuel Injection Pump Fuel Run Solenoid Lube Oil Filter ____ .... .... Lube Oil Drain Hose Oil Pressure Switch :l=! eo [JJ ;j ~ A C Connections Outlet Zinc Anode eo 1:i ~ Fresh Water Block Drain eo z ~ o 0; Fuel Filter Fuel Lift Pump Oil Pressure Sender 12.
~ Fresh Water Fill Cap t"i Lube Oil Fill Cap rn ;.l ~ ~ Emergency Exhaust Manifold Shut~off Switch ~ Z t"i ~ Exhaust Temperature Switch Belt Guard o ~ 0 45 Exhaust Elbow "" N Unit Data Tag Raw Water Pump DC Battery Ground Connection Heat Exchanger Starter with Solenoid 12.
GENERAL Introduction This manual contains the equipment operating procednres as well as additional information needed to help the operator keep the marine eqnipment in proper working order. Stndy 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.
BTD 8.0 KW MARINE DIESEL GENERA TOR SET GENERAL SPECIFICATIONS Engine Type Diesel, 4-cycle, 3-cylinder, fresh water-cooled Vertical, in-line overhead valve mechanism (14 hp at 1800 rpms maximum) Governor Mechanical, centrifugal weight type Combustion Chamber Swirl chamber type Bore & Stroke 2.87 x 3.07 inches (73 x 78 mm) Pistion Displacement 60 cubic inches (0.979 liters) Firing Order 1-3-2 Direction of Rotation Clockwise, when viewed from the front Maximum Torque (at 1800 rpm) 41.
SYSTEM SPECIFICATIONS FUEL SYSTEM: GENERAL Open flow, totally self-bleeding FUEL No.2 Diesel oil (cetane rating of 45 or higher) FUEL INJECTION PUMP Nippon Denso (Bosch M type) FUEL INJECTION TIMING 19° BIDC ±D.5 (static timing) NOZZLE INJECTORS Throttle type Pintle type FUEL PUMP FUEL FILTER(on engine) 12-Volt DC; Electro-Magnetic type Canister type, with replaceable element AIR CLEANER Metal-screen type AIRFLOW 32 cfm (.
SYSTEM SPECIFICATIONS CONTINUED ... ELECTRICAL SYSTEM STARTING BATfERY 12-Volt, ( - ) negative ground BATfERY CAPACITY 300-400 CCA DC CHARGING ALTERNATOR 12·volt DC, 50 Amp REGULATOR Internal regulator built into alternator STARTING AID Glow Plug, sheathed type 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) ACGENERATOR GENERAL Brushless, four-pole, revolving field.
SYSTEM SPECIFICATIONS CONTINUED ... ENGINE COMBUSTION AIR REQUIREMENTS (60 Hertz) AT 1800 rpm 32 cfm (.906 cmm) ENGINE COMPARTMENT COOLING AIR 100-200 cfm (2.83 - 5.
BTD 10.0 KW MARINE DIESEL GENERATOR SET GENERAL SPECIFICATIONS Engine Type Diesel, 4-cycle, 3-cylinder, fresh water-cooled Vertical, in-line overhead valve mechanism (16.5 hp at 1800 rpms maximum) Governor Mechanical, centrifugal weight type Combustion Chamber Swirl chamber type Bore & Stroke 3.07 x 3.07 inches (78 x 78 mm) Pistion Displacement 68 cubic inches (1.12 liters) Firing Order 1-3-2 Direction of Rotation Clockwise, when viewed from the front Maximum Torque (at 1800 rpm) 47.
SYSTEM SPECIFICATIONS FUEL SYSTEM: GENERAL Open flow, totally self-bleeding FUEL No.2 Diesel oil (cetane rating of 45 or higher) FUEL INJECTION PUMP Nippon Denso (Bosch M Type) FUEL INJECTION TIMING 19° BIDC ±O.5 (static timing) NOZZLE INJECTORS Throttle type Pintle type FUEL PUMP FUEL FILTER( on engine) 12-Volt DC; Electro-Magnetic type Canister type, with replaceable element AIR CLEANER Metal screen type-cleanable AIRFLOW 48 cfm (1.
SYSTEM SPECIFICATIONS CONTINUED ... ELECTRICAL SYSTEM STARTING BATfERY 12-Volt, ( - ) negative ground BATTERY CAPACITY 350-450 CCA DC CHARGING ALTERNATOR 12-volt DC, 50 Amp REGULATOR Internal regulator built into alternator STARTING AID Glow Plug, sheathed type STARTER 12-volt, 1.6 KW, reduction type, solenoid mounted DC NO-LOAD CURRENT 90 Amp (max.) at ll.5 Volts DC CRANKING CURRENT 175 - 200 Amps (engine cold) ACGENERATOR GENERAL Brushless, four-pole, revolving field.
SYSTEM SPECIFICATIONS CONTINUED ... General - 3 Phase 10.0 KW - 60 Hertz 7.5 KW - 50 Hertz Brushless six pole, revolving field. Sealed lubricated single bearing design. 12 Lead reconnectable for low voltage WYE, high voltage Delta. Solid State voltage regulator with protection circuitry.
BTD 11.0 KW MARINE DIESEL GENERATOR SET GENERAL SPECIFICATIONS Engine Type Diesel, 4-cycle, 4-cylinder, fresh water-cooled Vertical, in-line overhead valve mechanism (18.4 hp at 1800 rpms maximum) Governor Mechanical, centrifugal weight type Combustion Chamber Swirl chamber type Bore & Stroke 2.87 x 3.07 inches (73 x 78 mm) Pistion Displacement 80 cubic inches (1.
SYSTEM SPECIFICATIONS FUEL SYSTEM: GENERAL Open flow, totally self-bleeding FUEL No.2 Diesel oil (cetane rating of 45 or higher) FUEL INJECTION PUMP Nippon Denso (Bosch M type) FUEL INJECTION TIMING 19° BIDC ±O. 5 (static timing) NOZZLE INJECTORS Throttle type Pintle type FUEL PUMP FUEL Frr..TER( on engine) 12-Volt DC; Electro-Magnetic type Canister type, with replaceable element AIR CLEANER Metal screen type-cleanable AIRFLOW 42 cfm (1.
SYSTEM SPECIFICATIONS CONTINUED ... ELECTRICAL SYSTEM STARTING BATTERY 12-Volt, ( - ) negative ground BATTERY CAPACITY 300-400 CCA DC CHARGING ALTERNATOR l2-volt DC, 50 Amp REGULATOR Internal regulator built into alternator STARTING AID Glow Plug, sheathed type STARTER 12-volt, 1.6 KW, reduction type, solenoid mounted DC NO-LOAD CURRENT 90 Amp (max.) at 11.5 Volts DC CRANKING CURRENT 175 - 200 Amps (engine cold) ACGENERATOR GENERAL Brushless, four-pole, revolving field.
SYSTEM SPECIFICATIONS CONTINUED ... General - 3 Phase 11.0 KW - 60 Hertz 8.3 KW - 50 Hertz Brushless six pole, revolving field. Sealed lubricated single bearing design. 12 Lead reconnectable for low voltage WYE, high voltage Delta. Solid State voltage regulator with protection circuitry.
BTD 12.5 KW MARINE DIESEL GENERATOR SET GENERAL SPECIFICATIONS Engine Type Diesel, 4-cycle, 4-cylinder, fresh water-cooled Vertical, in-line overhead valve mechanism (23 hp at 1800 rpms maximum) Governor Mechanical, centrifugal weight type Combustion Chamber Swirl chamber type Bore & Stroke 3.07 x 3.07 inches (78 x 78 mm) Pistion Displacement 91 cubic inches (1.
SYSTEM SPECIFICATIONS FUEL SYSTEM: GENERAL Open flow, totally self-bleeding FUEL No.2 Diesel oil (cetane rating of 45 or higher) FUEL INJECTION PUMP Nippon Denso (Bosch M type) FUEL INJECTION TIMING 19° BIDC ±O. 5 (static timing) NOZZLE INJECTORS Throttle type Pintle type FUEL PUMP FUEL FILTER(on engine) 12-Volt DC; Electro-Magnetic type Canister type, with replaceable element AIR CLEANER Metal screen type-cleanable AIRFLOW 4S cfm (1.
SYSTEM SPECIFICATIONS CONTINUED ... ELECTRICAL SYSTEM STARTING BATTERY 12-Volt, ( -) negative ground BATTERY CAPACITY 300-400 CCA DC CHARGING ALTERNATOR 12-volt DC, 50 Amp REGULATOR Internal regulator built into alternator STARTING AID Glow Plug, sheathed type STARTER 12-volt, 1.6 KW, reduction type, solenoid mounted DC NO-LOAD CURRENT 90 Amp (max.) at 11.5 Volts DC CRANKING CURRENT 175 - 200 Amps (engine cold) AC GENERATOR GENERAL Brushless, four-pole, revolving field.
SYSTEM SPECIFICATIONS CONTINUED ... General - 3 Phase 12.5 KW - 60 Hertz 9.3 KW - 50 Hertz Brushless six pole. revolving field. Sealed lubricated single bearing design. 12 Lead reconnectable for low voltage WYE, high voltage Delta. Solid State voltage regulator with protection circuitry.
BTDA 12.5 KW MARINE DIESEL GENERATOR SET GENERAL SPECIFICATIONS Engine Type Diesel, 4-cycle, 4-cylinder, fresh water-cooled Vertical, in-line overhead valve mechanism (23 hp at 1800 rpms maximum) Governor Mechanical, centrifugal weight type Combustion Chamber Swirl chamber type Bore & Stroke 3.07 x 3.07 inches (78 x 78 mm) Pistion Displacement 91 cubic inches (1.
SYSTEM SPECIFICATIONS FUEL SYSTEM: GENERAL Open flow, totally self-bleeding FUEL No.2 Diesel oil (cetane rating of 45 or higher) FUEL INJECTION PUMP Nippon Denso (Bosch M type) FUEL INJECTION TIMING 19° BIDC ±O.5 (static timing) NOZZLE INJECTORS Throttle type Pintle type FUEL PUMP FUEL FILTER(on engine) 12-Volt DC; Electro-Magnetic type Canister type, with replaceable element AIR CLEANER Metal screen type-cleanable AIRFLOW 48 cfm (1.
SYSTEM SPECIFICATIONS CONTINUED ... ELECTRICAL SYSTEM STARTING BATTERY 12-Volt. ( -) negative ground BATTERY CAPACITY 300-400 CCA DC CHARGING ALTERNATOR 12-volt DC, 50 Amp REGULATOR Internal regulator built into alternator STARTING AID Glow Plug, sheathed type STARTER 12-volt, 1.6 KW, reduction type, solenoid mounted DC NO-LOAD CURRENT 90 Amp (max.) at 11.5 Volts DC CRANKING CURRENT 175 - 200 Amps (engine cold) ACGENERATOR GENERAL Brushless, four-pole, revolving field.
SYSTEM SPECIFICATIONS CONTINUED ... General - 3 Phase 12.5 A KW - 60 Hertz 9.3 A KW - 50 Hertz Brushless six pole. revolving field. Sealed lubricated single bearing design. 12 Lead reconnectable for low voltage WYE. high voltage Delta. Solid State voltage regulator with protection circuitry.
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.
Location The location should be such that it is dry, above low-lying vapor areas, and away from being splashed by bile water or water from above. It should be properly ventilated and accessible for minor servicing and repairs. Access for major repairs should be given consideration as well. The location must be properly ventilated to provide the fresh cooling air for the generator end and for engine combustion. Hot generator discharge air must be removed from the generator area.
J Sea Waler '''''' Sea Water Intal
Exhaust Back-Pressure Exhaust back -pressure should be checked prior to putting a generator into service. (Refer to illustration.) Excessive back-pressure will affect the engine's performance and the generator's power output. To measure the engine's back-pressure, either a mercury manometer or a water column must be acquired. A boatyard or marine mechanic should have a clear plastic tube and taping one end to a yardstick and fitting the other end with a 114 inch NPT (National Pipe Tap) fitting.
UCAUTION II Do not nse a scoop-type thru-hull fitting as a means of supplying sea water to the generator. Water pressure against this type fitting, while the vessel is under way, can push sea water past the sea water pump's impeller into the generator's exhaust system, filling it and the engine as well. Flush-type, clear, thru-hull fittings are recommended and should be located on the hull so as to be below the waterline during all angles of boat operation.
The best protection against carbon monoxide poisoning is a daily inspection of the complete exhaust system. Check for leaks around manifolds, gaskets, and welds. Make sure exhaust lines are not heating surrounding areas excessively. If excessive heat is present, correct the situation immediately. If you notice a change in the sound or appearance of the exhaust system, shut down the unit immediately and have the system inspected and repaired at once by a qualified mechanic.
Generator (Ae Output) Make sure that the AC output connections within the generator's districution box are tight and in accordance with the specific AC Load Connections diagram found later in this manual. (See the "BT GENERATOR" section of this manaul.) WARNING DO NOT smoke or allow an open flame near batteries. Lead acid batteries emit hydrogen, a highly-explosive gas. Batteries Make sure the positive (+) battery connection is connected to the battery connection of the starting solenoid.
OPERATION 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. Preparation for Starting Take the steps described below in starting your engine for the first time or after a prolonged shutdown or lay-up.
Starting Procedure o o PREHEAT 4 ~ . @ START ".- ). -' STOP 4k ~ ELAfIl'S£OTM Iplllmlll 0 II ...... "'0 CENERATOJ:i o o NOTE: When the generator is stopped after use, the water temperature and oil pressure gauges may stay at their running readings. When the generator is next used, depressing the PREHEAT switch will cause the water temperature and oil pressure gauge indicators to return to zero (deflect to the left of the gauge). The DC voltmeter will register system voltage.
Proper glow plug function is indicated by a voltmeter drop when the PREHEAT switch is depressed. This drop will be slight but discernible. If no voltage drop is noted, it may indicate defective glow plugs or a faulty preheat circuit (check for loose connections). While holding the PREHEAT switch depressed, depress the START switch. The starter motor will run, thereby cranking the engine.
Upon starting the generator set, check for proper operation and then encourage a fast warm-up. For the first 10 hours of the generator's operation, run the generator set between 20 and 60 percent of full load. After the first 10 hours of the generator's operation, the load may be increased to the rated full-load output. Periodically vary the load. Be aware of motor starting loads and the high current draw required for starting motors (see page 69 for an "Amps for Starting" chart).
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 FilterlW ater 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 fuel injection pump 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 benchtested and should not be tampered with. Running speed and timing adjustment are the only adjustments the servicing dealer can perform on the injection pump. Other types of adjustments or repairs must be performed by a qualified injection service shop.
ELECTRICAL SYSTEM Engine 12-Volt DC Control Circuit The engine that drives the generator end has a 12-Volt DC electrical control circuit, as shown on the wiring diagrams which are illustrated on the following pages. Refer to these diagrams when troubleshooting or servicing electrical components on the engine. II CAUTION II To avoid damage to the battery's charging circuit, never shut off the engine's battery switch while the engine is running.
DC CONTROL CIRCUIT WIRING DIAGRAM #36412 PAGEIOF2 A r ________--"""o-'c,,""---_____________~ //,-,7:~ID";"I-_-,.-_,,-0-"-"-0-- ' "J ML ',4RED!PUA 5TR'»E wt.TER , TEMF-_':' SENDER a a:o .~"'" " 0 "1---'-;£ WATER TEMP SWITCH 1 r:UEL SJLENOID TEMP. SWITCIi - .' CIRCUIT BREAKER EXHAUST .- o~ ; pj:lEHEAT .~ OIL PRESSURE SWITCH SOLENOID O,l RED £t- GgJ CIRCUIT 0 ., SREAKER ~ •~ OIL PRESSURE SENDER "e , ., ~ ~ GROUN~I~ TO -I • , e .-. .-.
DC CONTROL CIRCUIT WIRING SCHEMATIC #36412 PAGE20F2 ,C) I PREH~AT ;"b SOL I t--- :rca ,( 12CA -'f ! ~~: H"ERGE~CY ,r: ,-!", :;-:>~ 'Ow '~:5TOPSW ',PREH~AT SI-I • +----{ p EXHAUST TfMP 51.,' FU~l SOL ,~ ! O_~ GAUGE VOLTMETER 1 PUSH PREHi:AT 5WiTO< FIRST_HOLD FOR 15 TO 60 SECONDS AS REQ'u. START'I.t.LWf-..VS 2.WHILE :;,WI-'_EN C;::'HINUI:>jG Te! PUSH PR[HEAT SWITCH \ PUSH START SWITCH. GE,'l[H\TOR STAfHS,r{ELEIlSE START SWiTCH ONLY.
The charging system consists of an alternator with an internal voltage regulator, an engine-mounted circuit breaker, and a battery and connecting wires. Because of the use ofle's (integrated circuits), the electronic voltage regulator is very compact and is built into the rear bracket of the alternator. Charging Voltage Test If you suspect that the alternator is not producing enough voltage to charge the engine's battery, perform the following voltage test.
COOLING SYSTEM Description Westerbeke marine diesel engines are designed and equipped for fresh water cooling. Heat produced in the engine by combustion and friction is transferred to the fresh water which circulates throughout the engine. This circulating fresh water cools the engine block and its internal moving parts. The heat is transferred externally from the fresh water to sea water by means of a heat exchanger, similar in function to an automotive radiator.
ANTIFREEZE ADDITION DATA Antifreeze Concentration Freezing Temperature % 13 23 30 35 45 50 60 of 23 (-5) 14 (-10) 5 (-15) -4 (-20) -22 (-30) -40 (-40) -58 (-58) (0C) b. Filling the Fresh Water System A coolant recovery tank kit is supplied with each Westerbeke diesel generator. 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.
Fill the fresh water system as follows: I. Remove the pressure cap from the manifold. 2. Pour a clean, fresh water coolant mixture into the manifold and allow enough time for the coolant to fill the fresh water cooling system. 3. Replace the pressure cap on the manifold. 4. Remove the plastic cap from the coolant recovery tank and fill the tank with coolant halfway between the ADD mark and the MAX mark. Replace the cap. S.
Raw Water Pump The raw water pump is a self-priming, 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. '{' --- -,- - - f .
Exhaust Elbow Installation The Westerbeke Corporation offers a 45 0 and 90 0 exhaust elbow as well as an exhaust riser you can install on your propulsion engine. Refer to the instructions below when installing the exhaust elbow purchased for your generator. ELBOW FL.... NGE NOTE: Fabricated exhaust elbows or risers attached to the exhaust manifold shall not exceed 8 Ibs when unsupported. 1. Coat only one side of the exhaust gasket with "High Tack" adhesive sealant.
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 CCor higher (CD) grades made by well-known manufacturers is recommended. The oil selected should be used thereafter. Engine Oil Viscosity (SAE Number) Use oil having a viscosity best suited to the atmospheric temperature.
2. Replacement of the Oil Filter OIL fILTER. When removing the used oil filter, cover the filter with a plastic bag containing a few cloth rags or paper towels. This will allow both the filter element and spilled oil to be collected cleanly without spilling oil on the engine or in the bilge. (Oil or any other fluid on the engine reduces the engine's cooling ability. Please keep your generator's engine clean.) The replaceable cartridge-type oil filter requires no cleaning inside.
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.
GENERATOR AC DISTRIBUTION BOX BTD 10.0KW, 11.0KW, AND 12.SKW (A) Ye!lowM'hite 8tackNihile Optional AVA RedfWhite GreenNIhile Internal Wiring Schematic for 12 Stud BT Model with Voltage Regulator Circuit Removed AC r--------------, :1 8(JB :I ~. .__~A~ iI I : 4 3: i>t 2 I IL _ _ _ _ _ _ _ _ _ _ _ _ _ JI r---~======t===~====~~====~======:; ~ ~ ~1~1~~ + G AC B 3 --'- - __ J ORANGE 3 2 7 ~ ~ tt I 3 =7"P== L..!l-"H--I-I. I 0L-__~ BLACK -K}GREEN AC I IweT/S,".
i----------~ A ( + ~;:; ~ >- R~ ~~ " ~ ;:,= -;;: ;-------------------1 , B :, ,,, , • ,, • !I - ,, 2 I ~ . e" :, b , , , , 2 j , , ,, 3' , REO & Wt~!TE ;:: - ) '1 .- Fl T 6LACX :, :, • 3 , -------- YELLOW~ -*G * G , ,, -- 3 2 i ~..<= , , hL~ [13_J---~ •• 2 EL\D( GREEN 't'Ell GREEN E R M I N A L L o C • K WHITE+ - AC T B RED & WHlfE SLUE & ..... TE A.v.R. 18) 8tUE & """TE PLUG ...
A 1 r--------., I I C I ~---------------, • B I I • r--------, 2 I~ r=r-r.1' 1 OlJl , • 11 3' l i B 2 , _______________ J I , AC 6 : 5 ! I L : 0 1 7 E 3 ! Z "1 B H :!> A l _____ _ B l 0 C G RCD I F \ ® Y£LLOW • Bl.ut: A.V~I? • u S 1 U 0 G .. r=--,. fi , . . I\... -- J-~ IIL_el( t:hJ mDW -=
Optional Voltage Regulator An optional solid-state voltage regulator (board #34410) is available for use with the BT series generators. When installed, and the regulation switch is moved to the ELEC position, the regulator works together with the standard compound transformer regulator to regulate the generator's voltage output. In the ELEC mode, the regulator excitation to the group I exciter windings, and the transformer provides excitation to the group 2 exciter windings. Installation I.
NOTE: We recommend that the installer provide AC ampmeters (optional) so that the operator can observe the load being taken off each leg of the generator. A circuit breaker should be installed between the generator and the AC load. This circuit breaker should be rated for the generator's AC output and be able to react quickly to overloads, subject to motor starting considerations. 120V 60Hz 1201240V 50}+- 2 Os Os 60Hz 5 7lUl-i-...
120V 60Hz 0 ( ) , 20/240V 60Hz ( ) 0 I 0 0 0 0 0 0 'II~ TO FR .ME I ~ :J L, NI: ( ) ) ~ =< 0 f==l (OJ LO l.- 0 0 0 0 n TIN L, 110J;220V 50Hz = , To FRAME 110VSOHz = 0 o 0 220V 50Hz 0 = 0 0 0 0 = 0 RO Tn c ~ ..... t U N 0 (6) 'n U L, AC Voltage Connections (12 Stud Tenninal Block) (Used only with the BTD 8.0 KW Generator Set.) NOTE: The frame ground wire must be moved when changing from 110 Volts, 50 Hertz to 1220 Volts, 50 Hertz.
INTERNAL WIRING SCHEMA TIC 3 PHASE GENERATOR MODELS 10.0 BTD 11.0 BTD & 12.5 BTD r------l I C I I I I STATOR ,-----.c I EXCITF~ :I I i ____ .1 ___________ -, I I : : : : I : I i + a I 1 II I II IL ~ROTOR :I-C* I r---=-I i B I 1 _____ a b I 2 : I 4 3! I I ! I T__________ JI I I L_I- ________ --.l , 5 • , I I II I 3 L ---- F : i , I I j I. : : : : : : : : 2 : : :I I ., i I I I BiJ: FUSE 20 A. .J.
VOLTAGE REGULATOR #038468 Single & Three Phase 5 4 LED'S 3 Red Green Yellow HZ. 2 DOD 0 B + AMP. VOLT ]60HZ. The voltage regulator is of an advanced design which ensures optimum AC alternator performance. The regulator is equipped with complete protection circuitry to guard against operating conditions that could be detrimental to the AC alternator. Adjustments: I. Volts - This potentiometer is used to adjust AC output voltage. It has an additional range of ± 25-30 volts.
3. AmplHertz - These two adjustments are used in conjunction with the two protection circuits in the voltage regnlator that are indicated by illumination of a colored LED. I) Delayed overload protection (YELLOW RED) 2) Low speed protection (RED LED) Each of these two protection circuits reduces exciter voltage to safegnard the exciter windings and prevent overheating of the AC alternator. These two potentiometers are factory adjusted and sealed and should not be tampered with. 4.
3 PHASE AC TERMINAL BLOCK CONNECTIONS FOR WYE AND DELTA CONFIGURATION PARALLEL WYE (STAR) 12 10 11 12 L1 8 6 7 5 8 L2 4 2 3 SERIES DELTA SERIES WYE (STAR) 9 1 4 L3 I N L-L 208 VAC 39 60 HZ L-N 120VAC 1060HZ l-L 190 VAC 3~ 50 HZ l-N 110 VAC 19 50 HZ 1 10 11 a:::=J) 9 9 L1 L1 6 7 a:::=J) ~ 5 2 3 a:::=J) ~ 5 L2 Q) 1 L3 L3 ®- N L - L 460 VAC 31J 60 L - N 265 VAC 1" 60 L-L 380 VAC 39 SO L-N 220 VAC 19 SO HZ HZ HZ HZ L-L L2,L3-N L- L L2,L3-N 240VAC 120VAC 220VAC llQVAC '.
The illustration below shows the 3 phase AC generator backened with the louvered covers removed.
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. prevents simultaneous connection of shore power to generator output. Use of this switch II CAUTION II Damage to the generator can result if utility 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 than is required to keep it running after it is started. Some motors require much more current to start than others. Split-phase (AC) motors require more current to start, under similar circumstances, than other types. They are commonly used on easy-starting loads, such as washing machines, or where loads are applied after the 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 (112) 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.
ENGINE CONTROL PANEL General This manually-controlled series of Westerbeke marine diesel generators is equipped with toggle switches on the engine's control panel and, optionally, at remote panels. The following instructions and methods of correcting minor problems apply only to such toggle switch controls. Standard Instrument Panel 0 o ® st."" ~ All three switches are momentary contact type and serve the following functions: 1.
Engine Operation To start the engine, perform the following steps: 1. Preheat - Depress the PREHEAT switch. The voltmeter, panel lights, gauges and meters and fuel solenoid will be activated. The PREHEAT switch should be depressed in accordance with the chart in the It OPERA TrONI! section under "Starting Procedure" section. 2. Start - While still depressing the PREHEAT switch, depress the START switch. This will engage the start solenoid. Panel power and the fuel solenoid will be activated.
DC WIRE SIZING CHART Stranded Conductors for 12 Volt Circuits 10% Voltage Drop B. National ElectricaJ Code Type Wire A. Society oC Autonlotive Engineers Type Wire " Wire SI:r.., ,. 16x3O 1Silx29 Standing Clreular 1537 Mil Area " 19x27 " 19;(25 2336 3702 5833 Circuli Current In AMPS 10 lb23 , • • 19x21 16 " 49",21 49)(23 93'3 )-41110 25910 37360 2583 " " " " 4'07 Ei530 ,. 10 10380 • 37• .
ENGINE TROUBLESHOOTING Problem Probable Cause VerificationiRemedy PREHEAT switch is depressed: no panel indications, fuel solenoid, electric fuel pump and preheat solenoid not energized. Battery switch Check switch and/or battery connections. 20-Amp circuit breaker tripped. Reset breaker; if breaker trips again, check preheat solenoid circuit and run circuit for shorts to ground. START switch is depressed: no starter engagement Connection to solenoid faulty. Check connection.
Problem Probable Cause Verification/Remedy Failure to stop. Fuel solenoid return spring. Stop engine manually by moving the throttle lever to shut off. That failing, shut off fuel and air. Check fuel solenoid linkage and repair for free movement. STOP switch failure. Stop engine by depressing emergency STOP switch on engine or manually moving throttle to shut off. Test switch with ohmmeter. Fuel injection pump failure. Depress emergency STOP switch on engine.
Problem Probable Cause VerificationlRemedv Battery runs down (continued). High resistance leak to ground. Check wiring. Insert sensitive (0-.25 Amp) meter in battery lines. (Do not start engine.) Remove connections and replace after short is located. Low resistance leak. Check all wires for temperature rise to locate fault. Alternator. Disconnect alternator at output, after a good battery charging. If leakage stops, remove alternator and bench test. Repair or replace.
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 expensive tools and instruments. Preventive Maintenance (Engine) Perform the preventive maintenance in accordance with the schedules listed in the following paragraphs.
5. Adjust the alternator and water pump drive belt tension, if required. 6. Adjust the engine's no-load speed, if required (Hertz). Please note that this adjustment is not a warrantable adjustment during or after the unit's break in. 7. Lubricate the ball joint linkage between the run solenoid and the throttle arm. Servicing After Every 100 Hours of Operation I. Change the engine's lube oil and filter. 2. Adjust the alternator and water pump drive belt tension, if required. 3.
Servicing After Every 800 Hours of Operation *1. Remove and check fuel injectors. Injector spray pressure: 4GJl35l*-s JdI) ... ~.. II , POOR 1706 psi + 142 psi (120 kg/cm2 + 10 kg/cm2) Eliminate undesirable injection conditions including after dripping. *2. Check compression pressure. Remove each glow plug and check each cylinder's compression pressure. The engine's cranking speed is at 250 rpm. 8.0 KW, 10.0 KW, 11.0 KW, 12.
ADJUSTMENT OF VALVE CLEARANCE MODEL: BID 8.0KW & 10.0 KW II CAUTION II Adjust the valve clearance when the engine is cold. 0.010 inches (0.25 rnrn) Tighten the cylinder head bolts to the specified torque. 1. Pull off the air breather pipe from the rocker cover, and take off the rocker cover bolts. Adjust the valve clearances at IDC (Top Dead Center) for each cylinder when they are on their compression stroke (see below). 2. Align the timing marks on the gear case and on the crankshaft pulley as shown.
ADmSTMENT OF VALVE CLEARANCE MODEL: BID 11.0 KW & BID (A) 12.5 KW II CAUTION Nos, 1 and 4 piston T.O.C. mark I Injection timing {I.T.) mark n Adjust the valve clearance when the engine is cold. 0.010 inches (0.25 mm) Tighten the cylinder head bolts to the specified torque. Timing Mark 1. Pull off the air breather pipe from the rocker cover, and take off the rocker cover bolts. I 2. Adjust the valve clearances at IDC (Top Dead Center) for each cylinder when they are on their compression stroke.
Injection Timing Adjustment (BTD 8.0KW, IO.OKW, 11.OKW & 12.5KW) Incorrect fuel injection timing will result in hard engine starting and poor engine performance. Adjust the injection timing as follows: NOTE: The fuel lever (throttle) must be in the Run position while making the adjustment or no fuel will flow to the fuel injection pump. Refer to the cutaway view of the fuel injection pump and remove the high-pressure fuel line from the No. I fuel delivery valve holder. Remove the No.
If the specified (19° BID C) injection timing cannot be attained, adjust the timing by increasing or decreasing the thickness of the injection pump mounting shim. Changing the shim thickness by 0.004 inch (O.Olmm) changes the injection timing by approximately one degree. To advance the timing, decrease the shim !hichness, as required. To retard the timing, increase the shim thickness, as required. '. ". ' ..._';-,_ .. , .,. _____ TDC . \0 ;.···_·19' r·:,:·---" . ..
2. Adjust the engine's speed to obtain the frequency corresponding to the voltage selected by e,,'lending or shortening the Throttle Adjustment Linkage. Make sure the solenoid's plunger is completely bottomed in the solenoid. (See figure below.) II n CAUTION Failure of the solenoid to bottom in the solenoid will result in a failed solenoid. To avoid failure of the solenoid, ensure that the solenoid plunger bottoms in the solenoid. Check the solenoid's operation at the initial start-up.
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 bowl. Change the fuel filter elements on the engine and bleed the fuel system, as needed.
Spares Lay-up time provides a good opportunity to inspect the equipment to see if external items such as drive belts or coolant hoses need replacement. Check your basic spares kit and order items not on hand, or replace those items used during the lay-up, such as filters and zinc anodes. Batteries If batteries are to be left on board during the lay-up period, ensure that they are fully charged, and will remain that way, to prevent them from freezing.
TABLE OF STANDARD HARDWARE TIGHTENING TORQUES Unless stated otherwise for a specific assembly, use the following torque values when tightening standard hardware. Pitch Ib-ft 6mm bolt head/nut 8mm bolt head/nut 10 mm bolt head/nut 10 mm bolt head/nut 12 mm bolt head/nut 12 mm bolt head/nut 12 mm bolt head/nut 13 mm bolt head/nut 14 mm bolt head/nut 14 mm bolt head/nut 16 mm bolt head/nut 16 mm 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 - 11.61.0 - 1.6 13.
TABLE OF TIGHTENING TORQUES FT - LBS (KG - M) 8.0 & 10.0 BTD 12.5 BTD 11.0 BTD AND 12.5 BTDA Crankshaft Pulley Nut 108.5-144.7 (15-20) 144.6-180.8 (20-25) 108.5-144.7 (15-20) Main bearing cap bolt 36.2-39.8 (5.0-5.5) SAME SAME Connecting rod cap nut 23.1-25.3 (3.2-3.5) 39.7-43.3 (5.5-6.0) 23.1-25.3 (3.2-3.5) Flywheel bolt - with separate washers 83.2-90.4 (11.5-12.5) SAME SAME Flywheel attached 94.0-101.3 (13.0-14.0) SAME SAME Oil pan drain plug 36.2-43.4 (5.0-6.
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.
POWER TAKE-OFF (PTO) ADAPTER KITS The generator housing of the Generators is machined to accept an optional power take-off (PTO) adapter kit. 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 amount of horsepower at 1800 rpm. This horsepower can be ntilized either for generator AC amperage output or to operate the PTO device.
