Westerbeke 15.0BTD60-HERTZ, 12.0BTD50-HERTz Operator's Manual

OPERATOR'S MANUAL

&

INSTALLATION GUIDE

WESTERBEKE

15.0

12.0

BTD

MARINE

GENERA

SINGLE

60 -HERTZ

50 -HERTZ

DIESEL

TOR

&

THREE

Publication #36856

Edition

Two

SETS

PHASE

j'-..Y"

. WESTERBEKE CORPORATION 0 MYLES. STANDISH INDUSTRIAL PARK .

May 1995

rWESTERBEKE

j 150 JOHN HANCOCK ROAD, TAUNTON,

•

TEL: (508)823-76770 FAX: (508)884-9688 0 WEBSITE: WWW.WESTERBEKE.COM

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.

IIWARNINGI

The

above symbol is used in the manual to warn

serious personal injury or loss

of

life.

of

possible

CAUTION

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 exits and take necessary precautions to protect and equipment.

Fuels, exhaust gases, batteries, electrical equipment, and moving and hot parts are

personal injury or death. Follow recommended proce-

serious dures carefully.

PJways

operate bilge blowers for at least five minutes before starting a gasoline-fueled engine; ensure no gasoline fumes are present before starting.

• Prevent Electric

Shut off electric power before accessing electrical equipment.

potential hazards that could result in

Shock

personnel

• Use Extreme Care When Handling Engine Fuel (A constant

Do

not fill fuel tank(s) while the engine is running.

Do

not smoke or use

fuel tank.

•

Do

Not

Be

sure all fuel supplies have a positive shutoff valve.

Be

certain fuel line fittings are adequately tightened and

free

of

Make sure a fire extinguisher is installed nearby and is properly maintained.

tinguishers rated ABC

applications

danger

Alter

or

leaks.

encountered in this environment.

of

explosion

an

open flame near the engine or the

Modify the Fuel System

Be

familiar with its proper use. Ex-

by

the NFPA are appropriate for all

or

fire exists)

• Use Extreme Care When Servicing Batteries

Wear rubber gloves, a rubber apron, and eye protection when servicing batteries.

Lead acid batteries emit hydrogen, a

which can be ignited

cigarette, cigar, or pipe.

flame near the battery being serviced. Shut off all electri-

cal equipment in the vicinity to prevent electrical arcing during servicing.

by

electrical arcing or

Do

highly-explosive gas,

by

not smoke or allow

a lighted

an

open

Use

insulated mats whenever working on electrical equip-

ment. Make sure your clothing is dry, not damp (particularly

shoes), and keep your skin surfaces electrical

Remove wristwatch and jewelry when working on electrical

Do

except through a ship-to-shore double-throw transfer switch. Damage to vessel's is not done.

Be

ponents. High voltage can cause injury or death.

equipment.

equipment. not connect utility shore power to vessel's

AC

extremely careful when working on electrical com-

dry

when handling

AC

generator may result

• Exhaust Gases Are Toxic

Ensure that the exhaust system is adequate to expel 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.

circuits,

if

this

• Avoid Moving Parts

Do

not service the unit while the unit is running; tion arises in which operating adjustments, use extreme care to avoid moving parts and hot exhaust system components.

Do

not wear loose clothing or jewelry when servicing

equipment; avoid wearing loose jackets, shirts or sleeves,

rings, necklaces, or bracelets that might be caught in moving parts.

Make sure Keep protective shields and guards in their respective place at all times.

Do

is operating.

Do

ly

incapacitated

all attaching hardware is properly tightened.

not check fluid levels or drivebelt tension while the unit

not work on the equi pment when mentally or physical-

it

is absolutely necessary to make

by

fatigue.

if

a situa-

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 related information), instructions and specifications provided from sources other than Westerbeke, is not within Westerbeke's control and, accordingly, is provided beke customers only as a courtesy and service. WESTERBEKE TENT

OF

SUCH SOFTWARE, MAKES NO WARRANTIES OR REPRESENTATIONS WITH RESPECT

CANNOT BE RESPONSIBLE FOR THE CON-

to

Wester-

THERETO, INCLUDING THE ACCURACY, TIMELINESS OR COMPLETENESS THEREOF, AND WILL IN NO EVENT BE LIABLE FOR ANY TYPE OF DAMAGES ARISING OUT OF, THE FURNISHING

OR

USE OF SUCH SOFTWARE.

OR

INJURY INCURRED IN CONNECTION WITH,

OR

For example, components and subassemblies incorporated into Westerbeke's products and supplied

by others (such as engine blocks, fuel systems and components, transmissions, electrical components, pumps and other products) are

must depend on such software however,

may

be outdated and

generally supported

for

the design

no

longer accurate. Routine changes made

by

their manufacturers with their own software, and Westerbeke

of

Westerbeke's own product software. Such software,

by

Westerbeke's suppliers, of which Westerbeke rarely has 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 software, and the unavoidable existence

of

earlier, non-current Westerbeke software editions in the field. Ad-

ditionally, most Westerbeke products include customer-requested special features that frequently

of

Westerbeke product

do

not in-

clude complete documentation.

In summation, product software provided with Westerbeke products, whether from Westerbeke pliers, must It

not plier in question be consulted sulted

not

only

makes

by

the customer.

and cannot be relied upon exclusively as the definitive authority on the respective product.

good

sense, but is imperative that appropriate representatives

to

determine the accuracy and currency

of

Westerbeke

the product software being con-

or

other sup-

or

the sup-

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 Should

your

unit require special attention, contact your Westerbeke dealer

Service Organization is trained

level of efficiency, and expect dependable performance and long service life in return.

for

assistance. The Westerbeke

to

provide the support necessary

to

ensure long-term dependable perfor-

mance.

If,

within 60 days

tomer Identification Card (see below) registering

of

submitting the Warranty Registration Form

your

warranty, please contact the factory in writing with

for

your unit, you have not received a Cus-

Model information, including the unit's serial number and commission date.

from:

WESTERBEKE AVON

INDUSTRIAL

AVON,

MA

CORPORA

PARK

02322

liON

Mail

To:

CUSTOMER

Adam

Smith

85

Maple

Alden, Model

Expires

IN

BTD

7/7/88

Street

12234

15.0KW

WESTERBEKE

AUON

J"_USTRUIIL

TBLIX:

IDENTIFICATION

92-4444"

P.RK, FAX:

Ser

.•

iIIIIUON.

'1&017)

"'l1li

e2322 • 'I'ZL

SS'-9323

..

C

••

1234(706

(617)

LJ:: WBSTeORP

588-77

••

TABLE OF CONTENTS

Section .........................................................................

GENERAL BTD SYSTEM INSTALLATION OPERATION FUEL ELECTRICAL

DC

CONTROL COOLING LUBRICATION BT

GENERATOR

........................................................................... 2

15.0KW

GENERAL

SPECIFICATIONS

...................... 3

SPECiFiCATIONS ............................................... 4

CHECKS

................................................... 7

.....................................................................

SYSTEM

.................................................................

SYSTEM

CIRCUIT

SySTEM

SYSTEM

.....................................................

WIRING

DIAGRAM

...........

..........................................................

..................................................

..............................................................

22 & 23

Page

14 18 21

25 31 33

GENERAL OF

THE ENGINE ENGINE

INFORMATION

GENERATOR

CONTROL

AND

.....................................................

PANEL.

............................................

TROUBLESHOOTING

CARE

.......................................

MAINTENANCE & ADJUSTMENTS LAY-UP & RECOMMISSIONING TABLE

TIGHTENING SOUND

INSTRUCTIONS

TORQUE

INDEX

OF

STANDARD

TORQUES

GUARD

HARDWARE

.................................................

INSTALLATION

...............................................................

SPECIFICATIONS

...............................................................................

.....................................

............................................

.................................

39 41 43 48 56

59

60 61 62

BTD 15.0 KW Generator

Control

Heat

Exchanger

Panel

Water

Exhaust

~

-----:.;:~

Injected

Elbow

Lube

Oil

Fill

Cap

Fresh

Lube

Water

Lube

Oil

Fill

I.D.

Plate

DC

Charging

Alternator

Oil

Drain

Cap

Filter

Hose

Zinc

Anode

Oil

Pressure

Sender

15KW

1

Lube

BTD

Oil

Dipstick

Oil

Pressure

Switch

Introduction

GENERAL

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 equipment performance and longer equipment to

satisfactory repair; consequently, a troubleshooting table is included.

Understanding

the

Diesel

Engine

life. Proper diagnosis

to

the program will result in better

of

a problem is the most important step

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 gasoline engine; and the diesel engine has the same type

of

valves, camshaft, pistons, connecting rods and

of

the

same general type as that of a

lubricating system.

Therefore, The most important factors are proper ventilation and proper maintenance

ing systems. Replacement

frequent checking

important factor is the use

to

a great extent, a diesel engine requires

of

fuel and lubricating filter elements at the time periods specified is a must, and

for

contamination (that

of

the same brand

is,

water, sediment, etc.) in the fuel system is also essential. Another

the

same preventive maintenance as a gasoline engine.

of

the

fuel, lubricating and cool-

of

high detergent diesel lubricating oil designed specifically for

diesel engines.

The diesel engine does differ from the gasoline engine, however, in its method

of

handling and firing of fuel.

The carburetor and ignition systems are done away with and in their place is a single component - the fuel

pump

injection

- which performs the function of both.

Ordering

When contacting

Parts

your

Westerbeke dealer, parts distributor,

or

the factory about

your

Westerbeke unit, always provide the generator's model number, the engine's serial number and the generator's serial number as they appear on the scarlet and gold nameplate located on the generator end. You must provide us with

this information

Note that component locations in the manual are referenced from the front ley/drive belt end. (The flywheel/generator mined

by

the left side is at

so

we

may properly identify

your

unit.

of

the engine which is the pul-

or

transmission end is the rear end.) Left and right sides are deter-

the engine; imagine straddling the engine and facing in the same direction as the front

your

left, the right side at

your

right.

of

the engine:

Westerbeke engines and generator sets are thoroughly checked and given a final run under various load

conditions before leaving the factory. This is done

to

ensure dependable operation, long service, and a satis-

fied owner.

Care at the factory during assembly, and thorough testing, have resulted in a Westerbeke diesel enginedriven generator capable of many thousands cannot

control the treatment the unit receives in

of

hours

of

dependable service. However, the manufacturer

the

field. That part is up

to

the owner/operator.

2

BTC 15.0 KW MARINE DIESEL GENERATOR SET

GENERAL SPECIFICATIONS

Engine Type

Governor

Combustion Chamber

Bore

& Stroke

Piston Displacement

Order

Firing

Direction

of

Rotation

Maximum Torque

Compression Ratio

Compression Pressure

Valve Timing

Diesel, 4-cycle, 4-cylinder, fresh water-cooled Vertical, in-line overhead valve mechanism

(30

hp at 1800 rpms maximum)

Mechanical, centrifugal weight type

Swirl chamber type

3.307 x

128 cubic inches

3.701

inches (84 x 94 mm)

(2.1

liters)

1-3-4-2

Clockwise, when viewed from the front

Ib-ft

(11

79.6

21

:1

355.5 psi (25 kg/cm

kg-m) at 1900 rpm

2

)

at 150 - 200 rpm

Intake Opens 30° BTDC Intake Closes 50° ABDC

Valve Seat Angle

Valve Clearance

(engine cold)

Engine Speed

Dimensions

Weight

Fuel Consumption

Inclination

Exhaust Exhaust Closes

Opens 74° BBDC

30°

Intake 30° Exhaust 30°

Intake 0.0098 Exhaust

inches (0.25 mm)

0.0098 inches (0.25 mm)

1800 rpm 60 Hertz 1500 rpm 50 Hertz

Height:

25.06 inches (637 mm)

Width: 18.13 inches

Length:

38.00 inches (945 mm)

683 Ibs (309.8 kgs)

1.8 gph

(6.81

Iph) at full rated

output (approximate)

Continuous

Temporary

15°

20°

(not

ATDC

(461

mm)

to

exceed 20 min.)

3

FUEL SYSTEM

General

Fuel

SYSTEM SPECIFICATIONS

flow, totally self-bleeding

Open

No.2

Diesel oil (cetane rating

of

45

or

higher)

Fuel Injection

Pump

Fuel Injection Timing

Nozzle

Injectors

Lift Pump

Fuel Filter (on engine)

Cleaner

Air

Air Flow (engine combustion)

COOLING SYSTEM

General

Operating Temperature

CAY DPA Injection

0

23

BTDC ± 0.50 (static timing)

pump

Throttle type

Bosch type

12-Volt; lift capacity 6

ft

(1.8

Spin-on replaceable cartridge

Metal screen type - cleanable

67 cfm (1.89 cmm)

Fresh water-cooled

block thermostatically-controlled with heat exchanger

-1900 F (77 - 88

170

0

C)

m)

Fresh Water Pump

Sea Water Pump

Sea Water Flow, at 1800 rpm

(measured before discharging into exhaust

System

elbow)

Capacity

LUBRICATION SYSTEM

General

Oil Filter

Capacity (includes filter)

Sump

Centrifugal type, metal impeller, belt-driven

Positive displacement, rubber impeller, gear-driven

5.6 gallons per minute (21.2 Ipm)

10

qts (9.5 liters) approximate

Pressure type gear-driven with

flow, paper element, spin-on type #35828

Full

7 qts (6.6

by

Trochoid pump

external pressure relief valve

liters)

4

Operating

Oil

Pressure (engine hot)

35 - 45 psi (2.8 - 3.5 kg/cm

2

)

Oil

Grade

ELECTRICAL

Starting Battery

Battery

DC Charging

Regulator

Starting Aid

Starter

DC

DC Cranking Current

AC

General

Capacity(C. C.A.)

No-Load Current

GENERATOR

SYSTEM

Alternator

API specification

12-Volt,(-) negative ground

300 - 400 cold cranking Amps

12-Volt DC,

Internal regulator built into alternator

Glow plug, sheathed type

12-Volt, 1.6KW, reduction type solenoid mounted

90 Amp. (max.) at 11.5 Volts

250 Amps (engine cold)

225 -

Brushiess, four-pole, revolving field. Pre-lubricated, singlebearing design. Reconnectable, single-phase transformer regulation (optional solid-state voltage regulation).

CF

50 Amp

OR CG-4

Rating 60 Hertz (1800 rpm)

15KW

50 Hertz (1500 rpm) 12KW

Single Phase

120

or

Voltage 220 Volts - 50 Hertz Voltage regulation: Frequency rotation:

120 Volts

120/240 Volts

220 Volts

120/240 Volts - 60 Hertz

± 5% no load

to

full load

± 3 Hertz (5%) no load

125 Amps

125/62.5 Amps

60 Amps

to

full

load

5

General

Rating - Three

Phase 15KW - 60 Hertz 12KW - 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.

Voltage - 3

Phase (60 Hertz)

Low

voltage WYE 208 volts High voltage WYE 480 volts DELTA

Voltage - 3 Phase (50 Hertz)

High voltage WYE DELTA 220 volts

Amperage - 3 Phase (60 Hertz)

Low

voltage WYE 99 Amps High voltage WYE 43 Amps DELTA

Amperage - 3 Phase (50 Hertz)

High voltage WYE 43 Amps DELTA

Generator Cooling Air Requirements, (60 Hertz), at 1800 RPM

225 -

250

din

(6.37 - 7.08 cmm)

NOTE: Increase air supply 15% for 50 Hertz operation (1500 rpm)

Engine Combustion Air

67

dm

Requirements,

(60 Hertz), at 1800 RPM

(1.89 cmm)

TUNE-UP SPECIFICATIONS

Injector Pressure 1707 psi (120 kglcm

240 volts

380 volts

86 Amps

75 Amps

2

+ 10kglcm

2

- 0 kglcm

2

)

Engine Timing

GENERATOR

COMPARTMENT

Ambient Temperature

19° BTDC ± .5°

104° F(40°C) Maximum

NOTE: Forced ventilation should be provided as needed to maintain generator compartment ambient temperature 1040 F.

6

General

INSTALLATION CHECKS

Because the crafts in which Westerbeke engines and generators are installed vary cedures will vary according

or

boatyards

installers on procedures already well-developed and well-understood. However, it is important

that the owner/operator realize there are details the best operating conditions

Proper location and installation of the generator set

Factors air and

in

the installation that must be considered are ventilation, so as

for

engine combustion; exhaust system,

to

expel the exhaust gas; cooling water supply; fuel supply; and electrical connections.

to

your craft's specific design.

of

the installation which require periodic checks

for

the equipment and safe operating conditions

in

the vessel are

to

properly discharge raw cooling water,

It

is not the intent

of

for

prime importance.

to

cool the generator and

in

design, installation pro-

of

this section

to

advise

to

ensure

the personnel on board.

to

provide

to

quiet the exhaust

Factors

in

the location that must be considered are proper support and access for servicing and repairs.

There are four 1/2-inch bolt holes

mounting platform.

in

each generator mounting rail

7

to

properly secure the generator

to

its

Location

The location should be such that it is dry, above low-lying vapor areas, and away from being splashed

bilge water repairs. Access

tilated

charge air rails are located should be strong enough

Exhaust

The exhaust system provides an outlet line The system also discharges sea water which has passed through the engine's sea water circuit

with hot exhaust gases. This mixing helps haust system and the sea water supply water into the exhaust through the sea water cooling circuit and haust through the circuit's thru-hull discharge port. charge starting and possibly cause damage

or

water from above. It should be properly ventilated and accessible

for

major repairs should be given consideration as well. The location must be properly ven-

to

provide the fresh cooling air

must be removed from

for

the generator end and

the

generator area. The platform on which the generator and its mounting

to

support the generator unit during all angles of vessel operation.

for

engine combustion.

for

minor servicing and

Hot

generator dis-

System

to

vent engine exhaust gases out

to

cool the exhaust gases and exhaust elbows and pipe. The ex-

to

the exhaust must be configured

to

prevent the entry

If not prevented, sea water entering through the dis-

port

can fill the exhaust system's muffler and enter the engine's cylinders. This will prevent proper

to

internal engine components.

of

and away from the vessel.

to

prevent the siphoning of sea

of

sea water into the ex-

by

mixing it

by

The sea water supply hose

Generator

to

the exhaust system's water injection elbow should be routed Oooped) at least

Above

Water Line

12 inches above the vessel's water line. An anti-siphon break should be installed at the the generator set is installed at high enough above the vessel's water line no

matter what the angle

The sea water supply thru-hull seacock fittings should not be used, as they tend

of

or

below the water line (see page 9). The

so

as

to

remain above the water line when

heel

or

roll may be.

must be

to

encourage siphoning.

of

the flush-hull type. High-speed

top

of

the

8

SeaWater

top

of

this

loop

should be placed

vessel is underway,

scoop

type fittings

Fump

when

Generator

BeloN Water Line

The exhaust discharge from the water lift muffler should be routed well above the water line then downward to

the thru-hull discharge. This routing will prevent sea water from entering if the thru-hull discharge fitting

or

becomes submerged when the vessel heels tions. Refer

to

the figures

for

recommended exhaust system installations.

rolls while underway,

or

is subjected

to

following sea condi-

Exhaust Back-pressure

Exhaust back-pressure should be checked prior putting a generator into service. (Refer

to

the illustra-

to

tion.) 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 A

boatyard

manometer. A water column can be made

a clear plastic

or

a water column must be acquired.

or

marine

tube

mechanic

should

and taping one end

to

have a .

by

taking

a yardstick and fitting the other end with a 1/4 inch NPT (National

Pipe Tap) fitting. Fill the tube half-full with water. If

your

generator set does

exhaust manifold, one must be drilled and tapped

not

have a tapped hole in its

for

a 1/4-inch NPT fitting.

at

Measure baCk-pressure

the exhaust elbow when

the generator is under a full load. Back-pressure, as

measured

by

a manometer

or

water column, should

not be over the following specifications:

~

~.

~/4

NPT

-Insulation

..

.

Exhaust

Elbow

48

3S

38

2S

28

Exhaust

\

9

2 inches 27 inches

of

15.6 ounces

1.0

PSI

mercury

water in a water column

PSI

NOTE: Other pressure gauges may be available

to

test

for

exhaust back-pressure.

Oil Drain

An oil sump drain hose is installed on the engine with the discharge end secured the engine. Oil may be drained from this hose

by

removing the

cap

and the discharge end

the support bracket and lowering the hose into a container. The hose cap fitting is 1/4 inch-NPT (National

Pipe Tap) and can be extended,

Cooling

System

The generator's engine is fresh water cooled

or

have a pump added,

by

an engine-mounted heat exchanger. Sea water is used as

for

easier removal

the heat exchange's cooling medium. Sea water is pumped into the exchanger then injected into the exhaust discharge, carrying with it the heat removed from the engine's fresh water cooling system.

Sea water should be supplied

to

the sea water pump through a flush-type hull fitting using a wire-reinforced

hose between the thru-hull fitting and the sea water pump. This sea water should be directed through a

visual-type sea water strainer and then delivered

to

strainer and

the sea water pump should be wire-reinforced

to

the pump. Hoses routed from the thru-hull fitting

to

prevent the hose from collapsing during the

generator's operation (suction from the pump may collapse a non-reinforced hose).

or

should be mounted at

below the water line

to

make sure the sea water line remains primed.

by

a bracket at the front of

of

the old oil, if desired.

by

a sea water pump and is

Sea water strainers

the hose from

to

the

CAUTION

Do

not

use 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

The use

be below the waterline during all angles

of

common-type street elbows is not recommended

of

boat operation.

for

plumbing the sea water cir-

cuit. These generally have very restrictive inside diameters. Machined fittings are preferred.

Automatic

Shutdown

High Exhaust Temperature Shutdown Switch (normally closed)

An exhaust temperature switch is located on the exhaust elbow. This switch will open and shut the fuel solenoid OFF (which turns OFF the engine) should the switch's sensor indicate an excessive exhaust temperature (an inadequate supply opens at 260 -2700 F (127

-1320 C). This switch resets at approximately 2250 F (10]0 C).

of

sea water coolant causes high exhaust temperatures). This switch

10

High Water Temperature Shutdown Switch (normally closed)

A high water temperature switch is located on the thermostat housing. This switch will open and shut the fuel solenoids

reach approximately 2050 F (96

OFF (which turns OFF the engine) should the fresh water coolant's operating temperature

0

C). This switch resets at 195

0

F (10-r C).

Low Oil Pressure Shutdown Switch (normally open)

A low oil pressure shutdown switch is located off the engine's oil gallery. This switch's sensor monitors the engine's oil pressure.

Should the engine's oil pressure fall

to

10

-15

psi, the switch will open shutting OFF

the fuel solenoid (which turns OFF the engine).

Although diesel engine exhaust gases are not as toxic as exhaust fumes from gasoline engines, carbon monoxide is present gas that can cause unconsciousness and is of carbon monoxide inhalation

in

diesel exhaust fumes. Carbon monoxide is a dangerous

potentially lethal. Some of the symptoms

or

poisoning are listed below.

or

signs

o Dizziness o Vomiting o I ntense headache o Muscular twitching o Weakness and sleepiness o Throbbing in temples

If you experience any of the above symptoms, get out into fresh air immediately.

The best protection against carbon monoxide poisoning is a daily inspection

of

the complete exhaust sys-

tem. Check for leaks around manifolds, gaskets, and welds. Make sure exhaust lines are not heating sur-

rounding areas excessively.

change

the sound

or

in

system inspected and repaired at once

Make sure there are

no weight could cause deflection tions of the exhaust system

If excessive heat is present, correct the situation immediately. If you notice a

appearance of the exhaust system, shut down the unit immediately and have the

by

a qualified mechanic.

unnecessary objects suspended from any portion of the exhaust lines. Excessive

or

distortion of the lines, resulting in damage

to

ensure there is no deterioration of the insulation.

or

leaks. Inspect insulated por-

Intake System

Make sure the intake system (sea water cooling system) is

in

proper order. Check that the hull inlet, seacock

and strainer are unobstructed. Seacocks 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 the vessel is at sea and should be mounted below the water line

lines

to

ensure there are no collapsed sections, which would restrict water flow. Make sure there are no air

to

ensure self-priming. Inspect the sea water

for

cleaning while

leaks at any of the connections.

11

Fuel System

must

The generator

have its own fuel supply; filter/water separator. DO NOT tee off another engine's fuel supply. The fuel system should be installed such a manner as jection

pump

to

allow the engine-mounted fuel lift pump

under all operating conditions. The minimum size of the fuel supply line and fuel return line

in

other words, it must have its own pickup tube and primary

to

maintain a positive inlet pressure

to

the in-

in

is 1/4 inch, inside diameter, and there should be a primary fuel filter installed between the fuel tank and the fuel lift pump. A secondary fuel filter has been installed on the engine between the fuel lift pump and the injection pump; this filter has a replaceable filter element. Make sure that the fuel supply and return lines are securely anchored

to

prevent chafing and that all fittings are sufficiently tightened

to

prevent leaking. Also

make sure your fuel system has a positive shut-off valve; know its location and how it operates.

Note: Ensure that the fuel pickup tubes in the fuel tank supplying the generator are clear of

any gauze

screen type strainers. These can easily clog and cause fuel starvation

to

the

or

generator's engine.

DO NOT use mechanical type check valves

in

lieu of a manual shut off valve.

Be sure there is a fire extinguisher installed near the unit and that it is properly maintained. Be familiar with its use. An extinguisher with the NFPA rating of ABC is appropriate for all applications

in

this environment.

Electrical System

The electrical system should be checked

or

clamps

from vibration. Check

plastic ties and that all wiring harnesses are spaced at intervals close enough

to

ensure that all engine harness connections are tight and that they are made

to

ensure that all wiring harnesses are properly tied down with

to

prevent chafing

to

the

appropriate terminals.

Generator

Make sure that the AC output connections within the generator's distribution with the specific AC Load Connections diagram found later tion

of

(AC

Output)

this manual, page 33.)

box

are tight and in accordance

in

this manual. (See the "BT GENERATOR" sec-

IIWARNINGII

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

The negative

(-)

battery connection should be connected

12

to

the battery connection

to

the system ground (engine block).

of

the starting solenoid.

When servicing the battery

or

checking electrolyte level, wear rubber gloves, a rubber apron, and eye protection. Battery acid may splash on the skin removing electrolyte caps.

or

into the eyes inadvertently when

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.

Ventilation

The ventilation requirements

engine cylinders; cooling air is required for the generator end; and ventilating air is required

of

the generator sets include the following: combustion air is required

to

for

the

clear the bil-

ges below the generator, as well as the compartment in which the generator is located, of potentially toxic

and flammable diesel fumes. Refer

requirements

of

the generator set, page

to

the "SYSTEM SPECIFICATIONS" section of this manual

5.

for

the airflow

13

OPERATION

This section warm), and stopping procedures. Follow the procedures as presented, your

Westerbeke generator set will give you reliable performance and long service life.

of

the manual provides the operator with preparation, initial starting, break-in, starting (cold

for

the conditions indicated, and

Preparation for Starting

Take the steps described below in starting lay-up.

your

Fill on the dipstick reading). an needed in

Each unit is supplied with a coolant recovery kit (part #24977) as standard equipment, ing applies:

engine with oil

SAE number suitable

your

generator's engine, refer

a.

Remove the pressure cap from the engine's exhaust manifold and slowly fill the engine's cooling system with a mixture TEM"

section

b.

Make sure the plastic recovery tank is properly mounted near the unit (with the bracket provided) in a location where it can be monitored and filled easily (see page 26). The recovery tank should be mounted at manifold level

up

to

or

near the upper limit on the dipstick (the installation angle

Select a readily available lubricating oil with an API specification

for

the temperature in

of

water and antifreeze suitable

of

this manual, page 26.) Replace the pressure cap on the manifold.

or

above.

your

engine

to

the "SYSTEM SPECIFICATION" section

for

the first time

your

operating area (see page 31). For the quantity

for

your

temperature zone. (See the "COOLING SYS-

or

after a prolonged shutdown

may

have an effect

of

CC

of

this manual, page

to

which the follow-

or

CD

or

and

of

or

oil

4.

c.

Coolant should be added its operating temperature has been reached, ensure that and the engine's recovery tank half

Fill the fuel tank with a engine's fuel system is

the return fuel flow. When the returning fuel is free

ready

to

start.

NOTE: When the PREHEAT switch is depressed, the gized; use the PREHEAT switch intermittently

Activating the PREHEAT switch energizes the fuel run solenoid, drawing the throttle arm into the preset run position. Ensure that the arm moves rapidly and smoothly.

Ensure that the TION CHECKS"

cooling system. With the manifold filled and the pressure cap installed, fill the plastic

full. Monitor this recovery tank daily and add coolant as needed.

totally self-bleeding. Depress the PREHEAT switch

Installation Checks have been made in accordance with those specified in the "INSTALLA-

section

to

the plastic recovery tank after the engine has been filled and started. After

good

grade

of

this manual (refer

all air is expelled

No. 2 diesel fuel and prime the fuel system

of

air, the engine's fuel system is bled and the engine is

glow

plugs in the cylinder head are ener-

to

prevent overheating the

to

page

7)

and that there is

out

for

15

to

glow

no

AC load on the generator.

of

up

30 seconds and monitor

plugs.

the engine's manifold

to

the engine. The

14

Starting

Procedure

0

PREHEAT

.~'.

e

START

. "."'-

@

...'.

'-."

STOP

'~

...

"'.'

~

GENERATOR

ELAPSED

TIME

I

mllUDI!I

Hours

0

II

o

0

Standard Instrument Panel,

Switches and Gauges

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 The DC voltmeter will register system Voltage. The electric on-engine fuel pump, glow plugs, and fuel run solenoid are also energized.

Depress and hold the PREHEAT switch. Preheat according

Atmospheric Temperature

F

(+5 (+5 (_50

0 0

C)

C) C)

or to

or

higher

+23

lower

+410 F +410 F

0

+23

Limit of continuous use

to

return

to

zero (deflect

to

the following chart:

Preheating Time

0

F

(_50

C)

Approx. 10 sec. Approx. Approx.

to

the left

20

sec.

30

sec.

1 minute

of

o

the gauge).

15

Proper glow plug function is indicated by a voltmeter drop when the PREHEAT switch is depressed. This drop will be slight but discernible. tive glow plugs

If no voltage drop is noted, it may indicate defec-

or

a faulty preheat circuit (check for loose con-

nections).

While holding the PREHEAT switch depressed, depress the START engine. As soon as the engine runs, release the but continue holding the PREHEAT switch depressed for 2 seconds. Release the

reaches approximately

sure shutdown until the engine's oil pressure rises

running pressure.

switch. The starter motor will

Now

PREHEAT

20

psi. This bypasses the Low Oil Pres-

release the

switch when the oil pressure

PREHEAT

run,

thereby cranking the

START

to

switch.

switch,

or

its normal

3

Should the engine not start when the

depressed for

10

to

12 seconds, release both switches and wait 30 seconds; repeat the procedure above.

START

switch is (Proper Glow Plug Indication)

Never run the starter motor for more than 30 seconds at a time.

CAUTION

Prolonged cranking intervals

to

system attached sea water cranking. the

exhaust system fills. Prevent thru-hull gine water

pump

This

shutoff,

cranking needed

entry

is

the

is

pumping

sea water can enter

drain

to

not

a warrantable issue;

without

engine

sea water

the

exhaust muffler, and correct

the

engine starting

with

sea water coolant.

through

the

engine'S cylinders via

this

from

happening

the

sea water

can

This

by

the

closing

obtain a start. Engine damage resulting

the

owner/operator

should

result

may

cooling

the

exhaust

cause

in

filling

the

exhaust

happen because

system

during

manifold

the

sea water

for

the

from

keep

excessive en-

this

type

in

mind.

supply

of

the

once

sea

Once the engine starts, check instruments for proper oil pressure and battery charging Voltage. Never at-

tempt

to

engage the starter while the engine is running. Apply a light load

engine's operating temperature

to

come up

to

140 -150° F

(60

- 66"

C)

to

the generator and allow the

before applying any heavy loads.

NOTE: Some unstable running may occur in a cold engine, but this condition should smooth out as the operating temperature is reached

and when a load is applied

to

the

(170

- 190°

F)

generator.

Stopping Procedure

Remove the

AC electrical load from the generator and allow the generator lize its operating temperatures. Depress the stopped.

release the

STOP

Now

Break-In Precautions

Because the generator set operates at control of the generator's engine break-in is governed

Do

not

attempt

to

break-in your generator set

switch.

STOP

1800 rpm

by

to

run for 3

to

5 minutes

switch and hold it until the generator is completely

to

produce 60 Hertz,

by

the current drawn from the generator.

or

at 1500 rpm

to

produce

running it without a load.

16

to

50

stabi-

Hertz,

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.

Avoid overload at all times. An overload is signalled

by

a smoky exhaust, with reduced output voltage and

frequency. Monitor the current being drawn from the generator and keep it within the generator's rating.

Be aware of "Amps

for

Starting" chart).

starting loads and the high current draw required

for

starting motors (see page 39 for an

motor

Starting Under Normal Conditions

Follow the procedure below

Check the engine's

lubricating oil level prior

at the high mark on the dipstick.

Check the

coolant level in the plastic recovery tank.

NOTE: Excessive leak. Check the entire cooling system; pressurize the system excessive

coolant loss, the system must be refilled as outlined under the "Preparation for Start-

ing" section of this manual, page 14.

for

routine starting of the generator:

to

each day's use. Add oil as needed and maintain the oil level

loss

of

coolant from the plastic recovery tank indicates a cooling system

to

locate the leak. In cases of

Visually examine the unit;

Checkto

ensure that there is sufficient fuel in the tank and examine the filter/separator bowls

look

for

any

abnormalities and correct them as needed.

for

contaminants.

Clean and drain the bowls as needed.

Start the generator operating temperature

following the procedure given under "Starting Procedure," page 15, and allow the engine's

to

reach 140 - 1500 F (60 - 66

0

C)

before placing the generator under a heavy load.

Starting Under Cold Conditions

Under extremely cold temperatures, the following conditions can occur. Follow the instructions listed below when operating

LUBRICATING OIL TURNS VISCOUS - Make certain that the lubricating oil used conforms with the ratings for the prevailing atmospheric temperature. Refer page 31,

for

VOLTAGE ACROSS

mize

voltage

THE TEMPERATURE OF THE INTAKE

RISE

ENOUGH ever the temperature of the intake air is Refer

to

the preheat chart found in the "Starting Procedure" section

your

generator set in cold weather.

to

the "LUBRICATION SYSTEM" section

an atmospheric/oil viscosity specification table.

BATTERY TERMINALS DROPS - Make certain that the battery is fully charged

drop

across the battery terminals.

AIR

IS LOW AND THE COMPRESSION TEMPERATURE DOES NOT

-Allowthe

glow

plugs

to

operate sufficiently

low

and when the compression temperature does not rise enough.

of

this manual,

to

aid in starting during the preheat period when-

of

this manual, page

15.

mini-

17

FUEL

SYSTEM

Diesel Fuel

Use

No.2

diesel fuel with a cetane rating

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.

of

45.

Never

use kerosene

or

home heating oil.

Fuel Filters

A primary fuel filter entrapment type must be installed between the fuel tank and the engine. available from beke representative builder. This filter, adapted

with fittings for either hose tubing. Mount it in an accessible

water accumulation frequently.

Such a filter, shown here, is

boatbuilder's use, comes complete

place, inspect it often and drain off

If a water trap type filter is not installed between the fuel tank and the engine-mounted fuel system, any water in the fuel system will tend

lay in the bottom pump. Internal metal parts of the lift pump will rust. Particles will pass on

to

filters and eventually

tion pump and injectors with damag-

ing results and the possibility expensive repairs. Remember, water

to

damage is not covered under the Westerbeke warranty.

the engine's fuel system

of

your

local Wester-

or

of

the electric lift

the

water

your boat-

for

the

or

metal

to

the injec-

to

of

Although most boatbuilders supply a water trap/filter, some trap/filter as an optional extra at moderate cost. The filter is supplied with fittings for either hose tubing fuel lines.

by

Generator models covered

One is in the base

tem.

of

charge side

The self-bleeding feature the filter elements. (Take care switch and allow the electric fuel pump tem. (No fittings should

to

fails

start, stop and wait a few moments, and then repeat the bleed procedure as indicated above.

the electric fuel pump.

of

this manual have

the electric fuel pump and the other in the filter assembly located just after the dis-

of

the fuel system allows for easy servicing

to

catch any fuel when removing these filter elements.) Energize the PREHEAT

be opened.) Then proceed

to

two

replaceable fuel filters in the engine-mounted fuel sys-

operate for 20 - 30 seconds

to

do

not. Westerbeke offers a sedimenter/water

of

the filters. Simply remove and replace

to

prime and bleed air from the sys-

start the engine as you normally would. If the engine

18

or

metal'

Notes on Fuel System

The illustration that follows is an exploded view

ators. The figure also illustrates the self-bleeding and priming system used

The Westerbeke self-bleeding fuel system is semiautomatic in operation. While it is unlikely that the operator will be forced

washers, injector seat washers, electric at

all times. Select the parts beke Dealer gine fuel system components should be purchased.

If a leak should develop at a fuel banjo

tightening

to

service the system at sea, the possibility does exist. Therefore, it is recommended that banjo

lift pump filter and gasket, fuel filter and gasket be carried on board

for

your engine from the Parts List and purchase spares from

or

Distributor. For example, a fuel system hardware kit that contains sealing washers

or

of

the fitting, replace the washers with one

of

a typical fuel system for 4-cylinder diesel-engine gener-

by

Westerbeke.

your

sealing washer location and cannot be corrected

of

those in the kit.

local Wester-

for

on-en-

by

a simple

Replacing Filter Elements

After the first 50 hours of operation, replace the filter element located in the base Remove the fuel pump's base using an open end wrench. Take care in catching the filter element and fuel within the pump. in the center of the base, and then

This same service is required ter and replace it with a new cartridge. Take care in catching any fuel that may be spilt while removing the cartridge.

Install a new element and sealing washer for the base. Ensure that the magnet is located

reinstall the locking base onto the securing pins at the base of the pump.

of

the secondary fuel filter. This filter is a spin-on type. Simply unscrew the fil-

of

the electric fuel pump.

MANUAL

PRIMER

FUEL

IN-COMING

FILTER

ELEMENT

LI

FT

PUMP

SPIN-ON

After the first 50-hour change, the change period may be increased

quality fuel filter/water separators ator's engine, and which are serviced regularly, will increase the service life of the on-engine filters.

installed along the fuel supply line between the fuel tank and the gener-

to

200 hours

FUEL

FILTER

or

once per season. Good

19

Fuel Injection Pump

The fuel injection the utmost caution in

pump

is one of the most important components of the diesel engine and therefore calls for

handling. Furthermore, the fuel injection

should not be tampered with.

Running speed (Hertz) and timing adjustment are the the injection pump.

Other types of adjustments

or

repairs must be performed

shop.

ELECTRIC LIFT PUMP

pump

has been thoroughly bench-tested and

only adjustments the servicing dealer can perform on

by

a qualified injection service

INCOMING

FUEL

INJECTOR

PUMP

Typical Fuel System

To

obtain long and satisfactory service from the injection pump, always use fuel which is free from impurities

and maintain a

vice this system regularly; the injection pump it saves may be

good

filtration and water separation system between the fuel tank and generator engine. Ser-

your

own.

20

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 follow on pages 22 and 23. Refer

to

these diagrams when troubleshooting

or

servicing

electrical components on the engine.

CAUTION

To avoid damaging the battery's charging circuit, never shut off the engine's battery switch while the engine is running.

However, shut off the engine's battery switch

to

avoid electrical shorts when working on the

engine's electrical circuit.

Battery Specification

The minimum recommended capacity of the battery used in the engine's 12-Volt DC control circuit is

125 Ampere-Hours (minimum) for the generator set covered

by

this manual.

90

CAUTION

When quick-charging the battery with an external charger, be sure

to

disconnect the battery

cables from the battery. Leaving the charging circuit connected while quick-charging will

damage the alternator's diodes.

-

Alternator

CAUTION

When testing the alternator circuit (charging circuit),

do

not use a high-voltage tester such as

a megger; damaged diodes could result.

When operating the generator,

do

not disconnect the positive battery terminal from the B ter-

minal on the alternator, nor disconnect the negative battery terminal from the ground.

cleaning the engine/generator with a steam cleaner, be careful

When

to

keep steam away from

the alternator.

21

DC

fJ

~'FTPUMP

~~===':'4:P:U::R~

....

V. SOLENOID

~I'

·,0

CRN

~Ll

SEl~~~-2

r-t=7-lf

I 0

b(

I

GROUND'

I

TO

BLOCK

~

BATTERY-12V

STARTER

r---;~

-----t---+------,/0~

L

'----+-+--+-i0

RED

1t'2REO

CIRCUIT

~

BREAKER~

·IG

sRN

'-)4

PUR/wHT

*12YEL/RED

~

--:;~

30

""'-1--

50

r--~t::=

I

'-

________

"4PUR

r'~'4~B~R~N

'--

"'10

____

-t'.,,'4'-'0"'"""'--,

t-""'4-"'E,\

~

Control Circuit Wiring Diagram #36411

page 1

or

2

~

'4

FUEL

PUR

__________________________

- \ )

~TE~'P

-".

(~-;"

GLOWPLUGS

WATER

,~R

'I~

(~"

'~,o~o~e~N

"14 PuR

WATE~

sw.

TEMP

OIL

PRESSuRE

(~"

CIRCUIT Q

BREAKERU

EMERGENCY

STOP

SWITCH

o

T

8-\

a:

"4REO

l~G~~~~

:"H~~t

COONECTING

REMOTE

PANEL

____________

SLK

I I

~

r---

~~

~~'*------'

A

e30t:------+-----t---~

~

I'-f::::=:::l

!

~€><I:::-I"--Jt--j---~

~

f--

+

____

+-~

·10

REO

·r'O:..:;W-"HT.:...

+-

__

---'

Z

~

TB~:~9

Rg

TEMP

AL

0

L)

____

01

L PRESSuRE

SENDER

~

EXHAUST

S\'JITCH

_~

SW,

~

TERNATOR

z

~

o

;.

I

~L

PRESS-:;;

I

I I

I

L

w

.:~

-

~

8

)(

'"

~ ~

" 0 0

.-

,.-

_____

22

?REHEAT

SWITCH

START SW

ITCH

STep

SWITCH

-.1

~

I

STANDARD

[INSTRUMENT

I

PANEL

I

'.

DC

Control Circuit Wiring Diagram #36411

page 2

PREHEAT

SOLENOI

t>

j.------~'

:

):

C.8.

,

t"0A

; j STOP

SW.

r"'""~"

, 1

,

: STOP

SW.

,

~

~'

~~::::===l

I

rSJ~t'~

c-L

PREHEAT

E,T,

:

S"'.

5w.

o p

5w.

of2

C.fl,

10 "

W_T.

G

B

---.::~

fB2-3

liFT

PUMP

P

SW.

FUEL

SOU.NOIO

STARTING

START:I.ALWAYS

STOP, PUSH AND HOLD THE

I.

THIS AND IN

THE

MOST GENERATORS WILL SHUT

SUPPLY.

ANO

E'JGINE

2.AN

ON-OFF i=ROM ENGINE

INDIVIDUAL CONTI,..UOUS

A

SWITCH

ANU

STOI"PING

PUSH

PRE-HEAT

2.WHILE

CONTINUING

3,WHEN

GENERATOR

4. WHEN

OIL

(THE

PRODUCT

AS

INSTRl

THE

PRESSURE

PRE-HEi\T

SWITCH OVERRIDES

IS

PROTECTED

CLOSE

TO

THE

SOuRCE

fvlENT PANEL

THEREFORE

STARTERS

THE

ARE

INSTALLED

SWITCH

SHOUl\)

BATTEf..<'( :N AN E(.1ERGENCY AND WHEN

TYPICALLY

CRANKINr~

CYCLES

RATING

r-'iUST \lEV(r-.( BE

OF

SWITCH

TO

PUSH

STARTS,

RELEASE

REACH

ES

STOP

SWITCH

BY A MANUAL

OF

CURRE"I

WIRING

OR

ENGINE

DOw~

TO

Pi\EVE\JT

BE

INSTALLED

QRAW .::'00

SHOULD

1PS I\T 12VDC

uSED

TO"MAy-e"Tf1E

BECAUSE

BUILDER/OWNER

175 M ...

INSTRUCTIO'JS

FIPST.

HOLD

FOt::

I:'

TO

PRE.

HEAT SWITCH, PUSH START

START

SWITCH

ONLY.

APP~lOx

I M ATLY

20

"HE

LOW

UNTIL

THE GENERATOR STOPS COMPLETELY.

RE':·ET

AS

WILL

THE

MUST

CONTACT

IN

THIS

TO

300

NOT

EXCEE.D

WILL

P.S.I., RELEASE THE PRE-HEAT

OIL

PRESSUE

CIRCUIT

POSSIBLE.

BE

STAR:TE~

BREAKER

EXCESSivE

CAUSE

THE

OPENED BREAKER

SURE

THAT

BETWEE'\I

ELECTRICAL

CIRCUIT TO

LEAVING

THE

A:v1PS

WHE:-.J

30

SECC'\\lDS. A

NORMALLY

CIRCUIT.

E.O

SECCND<:::.

A~

REQUIRED.

SWitCH.

SHUTDOWN

BREAKER

THE

DISCON'\IECT

BOAT.TWELVE

CRANKI:'IIG.

SERvE

CIRCUIT.)

LOCATED

NEAR

CURRENT

DRAW

TO

TRH~

I'J

DEVICES

THE

VOLT

THE

WITH A

FUNCTION,

THIS

THE FUEL

PANEL

ANO

'3TARTER

DURATION

DISCONNECTS

1;'I./SH"l.U~lENT

SWITCH

THIS

SW

ITCH.

THE

STARTER

ANYWHERE

EVENT

WIRiNG

SALT

DIESEL

OF

BUT

WATER.

23

The charging system consists

of

an alternator with an internal voltage regulator, an engine-mounted circuit

breaker, and a battery and connecting wires.

Because into the rear bracket

Charging

of

the use of IC's (integrated circuits), the electronic voltage regulator is very compact and is built

of

the alternator.

Voltage

Test

If you suspect that the alternator is not producing enough voltage the following voltage test.

AMPMETER

r-------......-'®""{

L

R

A e

to

charge the engine's battery, perform

Interconnections

1.

Using a voltmeter, connect the voltmeter's red wire clip

for

the schematic shown above.

2.

Connect the other voltmeter wire clip

3.

Start the generator and record the reading given

The voltage reading

nator is over

or alternator for repair above test show

for

a properly operating alternator should be between 13.5

under charging, have it replaced

or

replacement, ensure that 12-Volts excitation is present at the R terminal should the

only battery voltage at the B output terminal.

to

a ground on the engine.

or

Charging Voltage Test

to

the B output terminal on the alternator. Refer to

by

the voltmeter.

rebuilt

by

a reliable service shop. Before removing the

to

14.5 volts. If your alter-

24

Description

COOLING SYSTEM

Westerbeke marine diesel engines are designed and equipped for fresh water cooling. Heat produced the engine

by

combustion and friction is transferred

to

the fresh water which circulates throughout the en-

in

gine. This circulating fresh water cools the engine block and its internal moving parts. The heat is transferred externally from the fresh water

tive radiator.

Sea water flows through the tubes

tubes; engine heat transferred

pumped into the exhaust system and discharged overboard. In basic terms, the engine is cooled water, the fresh water is cooled

to

sea water

to

fresh water is conducted through the tube walls

by

sea water, and the sea water carries the transferred heat over the side

by

means of a heat exchanger, similar in function

of

the heat exchanger while fresh water flows around the

to

the sea water which is

to

an automo-

by

fresh

through the exhaust system. The fresh water and sea water circuits are independent of each other. Using only fresh water within the engine allows the cooling water passages deposits. The

Fresh Water

NOTE: Refer mixture

two

independent circuits and their components are discussed in the following paragraphs.

Circuit

to

paragraphs a and b

to

be used as the fresh water coolant, and

in

this section on the recommended antifreeze and water

for

information on filling the fresh water

to

stay clean and free from harmful

system.

Fresh water is pumped through the engine

by

a belt-driven circulating pump, absorbing heat from the engine. The fresh water coolant circulates through the engine's block absorbing heat, then passes through the thermostat into the exhaust manifold, then to

the engine block through the suction side cold, external fresh water flow is prevented bypassed around the thermostat up, the thermostat ternal portion

gradually opens, allowing the engine's fresh water coolant

of

the cooling system.

to

prevent the exhaust manifold from overheating). As the engine warms

to

the heat exchanger where it is cooled, and then is returned

of

the fresh water circulating pump. When the engine is started

by

the closed thermostat (although some fresh water flow is

to

flow unrestricted

to

the ex-

a. Fresh Water

Coolant (Antifreeze) Mixture.

It is recommended that a freshwater and antifreeze mixture be used year-round. Water, when it freezes, ex-

to

pands sufficiently proper concentration will prevent freezing (see page 26

Use soft water with few impurities, such as tap water (potable water) water. Use

of

hard water

heat exchanger which will reduce the

Antifreeze

of

poor use antifreeze which is compatible with aluminum cooling system components and is made manufacturer. Never mix different brands

Make sure that the

Recommended antifreeze for year round use is

I n order

ding it

to

control the concentration

to

the cooling system.

split the heat exchanger and crack the engine block. A water/antifreeze mixture

for

an antifreeze/water mixture chart).

or

rainwater. Never use hard

or

quality

water containing impurities will lead

COOling

or

without rust inhibitors will cause corrosion within the cooling system. Always

system's efficiency.

to

the collection

of

scale in the engine and

by

of

antifreeze.

cooling system

of

the engine is well cleaned before adding antifreeze.

ZEREX

of

the mixture, mix the antifreeze and fresh water thoroughly before ad-

or

PRESTONE with rust inhibitors.

or

foul

a reliable

25

of

Antifreeze

Concentration

% 13

ANTIFREEZE ADDITION DATA

23

30 35

45

50

60

Freezing

Temperature

NOTE: ture which is about

b.

Filling the Fresh Water System

coolant recovery tank kit is supplied with each Westerbeke diesel generator. The purpose

A tank is coolant and without introducing air into the cooling system.

This coolant recovery tank should be installed at, be easily monitored and where steel

mounting bracket is supplied with each kit along with a 30-inch length

to

connect the hose between the engine's manifold fitting

COOLANT

RECOVERY TANK

It is advisable that the antifreeze concentration be selected on the basis of a tempera-

to

allow

for

° F 23 14 5 -4 -22 -40 -58

e

C)

(-5)

(-10) (-15) (-20) (-30) (-40) (-58)

10° F (5°

engine coolant expansion and contraction, during engine operation, without the loss of

C)

lower than the actual atmospheric temperature expected.

coolant can be easily added if needed (see the figure below). A stainless

or

above, engine manifold level,

to

the hose spud on the base of the recovery tank.

PRESSURE

CAP

of

this recovery

in

a location where it can

of

clear plastic hose and clamps

COOLANT

Coolant Recovery Tank, Recommended Installation

Coolant from the engine, when heated during the engine's operation, will expand, lift the spring-loaded manifold

When the engine is shut down and cools, a small check valve in the pressure cap is opened tion

cooling system, free of air and without loss.

pressure cap, and enter the recovery tank via the hose connecting the recovery tank

of

the engine's coolant, allowing some coolant in the recovery tank

to

be drawn back into the engine's

to

by

PASSAGE

the manifold.

the contrac-

26

Fill the fresh water system as follows:

1.

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

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

MAX

ADD mark and the

5.

Start and run the engine long enough for the engine

ing the coolant

6.

Add coolant

Thermostat

to

the recovery tank, as required,

mark. Replace the cap.

flow through the engine block and

to

top

to

warm up so that the thermostat will open, allow-

to

the rest

off the fresh water coolant system.

of

the fresh water coolant system.

to

fill

Generally, thermostats are of two types. One engine's temperature rises and

the bottom of the thermostat which moves downward

Since 1980, each type of thermostat has a hole punched through

head.

the exhaust manifold from overheating during the engine's warm-up. Replacement thermostats must have

this design characteristic.

Sea Water

The sea water flow is created

draws sea water directly from the ocean through the sea cock and sea water strainer and passes the water

to

the heat exchanger's sea water inlet.

The sea water passes through the heat

exchanger's tubes, from which heat from the fresh water system is absorbed, and then tem overboard jected wet exhaust system.

A zinc anode,

sea water cooling circuit within the heat exchanger. The purpose anode is action taking place in the sea water cooling circuit, thereby reducing the effects of electrolysis on other components system. The condition of the zinc anode

should be checked monthly and the anode cleaned Spare anodes should be carried on

board.

Circuit

is

discharged from the cooling sys-

through

or

pencil, is located in the

to

sacrifice itself

or

replaced, as required.

falls. The second type has a bypass mechanism. Usually this is a disc on

by

a gear-driven, positive displacement, neoprene impeller pump. The pump

the

water-in-

of

the zinc

to

electrolysis

of

the

is

simply a choking device which opens and closes as the

to

close off an internal bypass passage within the

it.

The hole

is

a bypass

to

prevent

~

New

Anode

~

Rep~ace

Zinc Anode Conditions

Rep~ace

C~ean

or

Replace

27

Sea Water Pump

The sea water

impeller. The impeller has flexible vanes which wipe against a curved cam plate within the impeller housing, producing the pumping action. impeller and impeller cover gasket on board (an impeller kit).

pump

is a self-priming, gear-driven rotary

On no account should this

pump

with a non-ferrous housing and a neoprene

pump

be run dry. There should always be a spare

Alternator (DC) and Water Pump Drive Belt Tension

Never attempt

Excessive alternator and water pump drive belt tension can cause rapid wear

reduce the service

or

the presence

tures, as

The alternator and water

inch and

tween the

ried on board.

no

more than 1/2 inch

two

to

adjust the drive belt's tension while the engine is in operation.

CAUTION

of

the belt and

life of the fresh water pump and alternator shaft bearings. Excessive slack

of

oil on the belt can cause belt slipping, resulting in high operating tempera-

we"

as insufficient alternator output.

pump

drive belt is properly adjusted if the belt can be deflected

(10

mm, 12 mm) as the belt is depressed with the

pulleys on the longest span of the belt. (See figure below.) A spare drive belt should be car-

thumb

no

less than 3/8

at the midpoint be-

Alternator and Water Pump Belt Tension

28

The

following illustration shows the location of the zinc anode

ZINC

in

AHODE

the

BTD

1S.0KW's

heat

exchanger

unit.

Heat Exchanger Unit of the

29

BTD

1S.0KW

Generator

Set

Illustrated

their

below

is a typical Westerbeke engine's cooling system. Both fresh

independent cooling circuits.

water

and sea water

flow

through

TO

HOT

WATER TAN!(

OVEflHEAT ALARM

Typical Cooling System

30

II[OMII6

SEA

PUMP

VATER

LUBRICATION SYSTEM

Engine Oil

FOR

ENGINE LUBRICATION, USE LUBRICATING OIL DESIGNATED THESE OILS ARE CLASSIFIED ACCORDING GRADES RECOMMENDED. THE OIL POSSmLE.

Engine Oil Viscosity (SAE Number)

Use

CC,

CD

CF

AND

CG-4. THE USE

YOU

SELECT SHOULD BE USED

oil

having a viscosity best suited to the atmospheric temperature.

TO

THE API SPECIFICATIONS INTO SERVICE

OF

THE IDGHEST GRADE AVAILABLE IS

with minimum viscosity change under different temperatures

FOR

DIESEL SERVICE.

ON

A REGULAR BASIS WHEN

Use

of

an

all-season

is

suggested.

oil

SAE

10W-30

Atmospheric Temperature

NOTE:

Oil Pressure

The

engine's

Do

not

oil

pressure

68° F (20° 41° F (5°

41° F (5°

use

engine lube

is

indicated by the oil

C) or higher

C) -68° F (20° C)

During normal operation, the engine's

NOTE: A warmed engine vary depending upon the

Your generator set

operating

A newly started, cold

can

is

fitted with

pressure,

the sensor will shut the engine

have

an

engine

an

oil

load that

oil

engine from occurring.

- or lower

oil

with

an

oil

pressure will

can

pressure

is

placed

pressure

C)

SAE

pressure

have

an

reading

on

sensor.

OFF

Viscosity

SAE

30

or

10W-30

SAE

20

or

10W-30

SAE

10W-30

number greater than

30

in

generator

engines.

gauge.

range

between

oil

pressure reading upwards of

as

low

as

35

psi.

and

55

These

psi

(engine

60

to

hot).

80

psi.

readings may also

the generator.

Should your engine's

oil

pressure drop below a

to prevent any internal damage to your generator's

safe

Engine Oil Change (to include filter)

1.

Draining the

Discharge the old still

warm.

Always

oil.

observe the old oil

Although this condition

Oil

Drain

Sump oil

through the sump drain

the old

oil

completely, replace the

as

is petent mechanic should water in

the exhaust system attached to the engine and/or a siphoning through the

exhaust,

the

filling it up into the engine (refer to the installation illustrations

hose

(attached at the front of the

hose

in

its bracket

it

is

removed.

rare,

it does require prompt attention to prevent serious

be

present

A yellow/gray emulsion indicates the presence of water

in

the

oil.

Sea

water present

31

and

in

engine)

replace the

the

oil

can

sea

water cooling circuit into

on

pages 8 and

while the engine

end

cap securely.

damage.

be

the result of a fault

Call

9).

in

the

a com-

is

2.

Replacement

When removing the used oil filter, cover the filter with a plastic bag containing a few cloth rags paper towels. This will allow both the filter element and spilled oil without spilling oil on the engine

(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.

of

the Oil Filter

to

or

be collected cleanly

or

in the bilge.

When installing the oil filter element, apply a thin

coat

of

clean engine oil the oil filter, screw the filter onto the threaded oil filter stub, and then tighten the filter firmly hand.

NOTE: Generic filters are not recommended, as the material standards

portant items

NOTE: Immediately after an oil filter change and oil fill, run the engine

pressure is normal and that there are

3.

Filling the Oil Sump

Add fresh oil through the oil filler cap on the valve cover. After refilling the oil, run the engine ments while checking the engine's oil pressure. Ensure there is the

oil drain system, and then stop the engine. Then check the quantity

not over, the high mark

to

the rubber gasket on

.~~

by

~

on

generic parts might be entirely different from genuine parts.

no

oil leaks around the new oil filter.

on

the dipstick, should the engine require additional oil.

A

Oil Filter and Oil Drain System

or

diameters

to

ensure that the oil

no

leakage around the new oil filter

of

oil with the dipstick. Fill to, but

of

for

im-

a few mo-

or

from

32

BT

GENERATOR

This generator is a four-pole, brushless, self-excited generator which requires

engine self-exciting feature

the related exciter

DC and supply it through the windings is connected in parallel ings

produces a rated

to

produce AC output. The

of

this generator. The magnetic field produced causes an AC voltage

rotor

windings during rotation. Diodes located in the exciter

to

the windings

of

the main stator, inducing an AC voltage which is supplied

to

the AC

of

the transformer and main stator and is, in tum, supplied

DC voltage

to

further excite the exciter stator windings, enabling

copper

of

the rotating field. This creates an electromagnetic field

output

and laminated iron in the exciter stator are responsible

of

the main stator. An AC voltage is produced in

AC output.

to

a full-wave bridge rectifier. The rectifier

only

the

driving force

to

be induced into

rotor

rectify this voltage

which

to

a load. A transformer

the

auxiliary wind-

the

generator

to

of

the

for

the

to

rotates

produce a

An optional solid-state voltage regulator is available

produce a

No-Load

more

Voltage

stable AC

Adjustment

output

(see the

top

of

to

work

page 34).

in tandem with the transformer regulator

Voltage adjustment is made with the compound transformer governing generator regulation.

1.

The selector switch must be in the

2.

Operate the generator and

apply output from the generator's tween

121

- 123 Volts

at

61.5 - 62 Hertz

NOTE: The no-load voltage should be adjusted when: the generator is started, a momentary load is applied then removed. The voltage produced

CaMP

position.

a moderate load momentarily; then remove the load. Note the voltage

120-Volt leg(s) (110 Volts

(111

- 113 Volts at 51.5 - 52 Hertz).

by

the generator after this momentary load is removed

at

50 Hertz). The no-load voltage should be be-

to

the voltage produced

to

excite the transformer, and

by

the generator

is the no-load voltage.

3.

To

raise

or

lower

the voltage, non-conductive shims under the laminated steel bar that is situated shimming should age

(1

to

3 Volts) sometimes can be accomplished

reduce

the

air

not

soften at temperatures in

gap

between the existing shims and the transformer core.

on

the

of

varying thickness are inserted

top

of

the compound transformer. The material used

or

1760 F (800 C) range. A small reduction in no-load volt-

by

gently tapping the

top

of

the laminated steel

to

removed from

for

bar

to

See the next page

for

an

illustration

of

the generator's AC distribution box.

33

YellowfWhite

BlackIWhite

Optional

AVR

Generator

BTD

Under no circumstances attempt

to tween the laminated steel bar and the transformer core without the use of shims. Magnetic forces created within the transformer during the generator's operation may close the air gap and reduce the no-load voltage output.

4.

To remove the laminated steel bar, remove the two upper securing bolts from the compound transformer

and lift the bar from the transformer. The addition of shim thickness will raise the no-load voltage and, conversely, the removal of shim thickness will lower the no-load voltage.

Varying shim thickness by.001 inch (0.025 mm) will change the no-load voltage

AC

Distribution Box

15.0KW Generator Set

CAUTION

increase the no-load voltage

34

by

increasing the gap be-

by 4 to

6 Volts.

r-

+

-

Black

YIYeliow

1[=

I

-

I

1-

_____________

Green

Red

F

I ,

Green

Red

/f<'

Green

I \ Yellow

I Black

'l+~

Black Yellow

-{>I-

+'----

/

*-

/

-L--

--------1

'---11-'

I

I I

2 !

I

-.J

3

- -

c

~

e

G

m

Black Red

+

'---:l

IAVR.,

PLUG

-

C I I 0 I

-!~i

---

r--------,

I I

--+-!

I

4

•

I

:

I

2

1

I I

•

I

I I

3==7'r==

I

I I

..J

~~~~I--

_J

-

1010101171101

Yellow/Red

Green

Black

-r

I

i

I I

I

-:

Blue Blue

_6

3

2

7

'---

__

~t

60

cyc.

SOcyc.

CI>

'" '"

10 10

-s

AC

T B

E L

-7

~

8

~

A

L

K

-8

---.J

CI>

BTD

15.0KW

A.

EXCITER

B.

EXCITER

C.

MAIN

STATOR

1.

Exciter Stator Windings

2.

Exciter Stator Windings

WINDINGS

ROTOR

1.

Auxiliary Windings

2.

Diodes

3.

Rotating

4.

Pozi

(6)

Field

Resistor

Windings

STATOR

1.

Main

Stator Windings

2;

Main

Stator Windings

3.

Main

Stator Auxiliary Windings

(Optional

(a

- b -

A.V.R

Generator's Internal Wiring Diagram

D.COMPOUNDTRANSFORMER

1.

Compound Transformer Windings

2.

Compound Transformer Windings

3.

Compound Transformer Auxiliary Windings

F.

SELECTOR

1.

c)

G.

Compound

2.

Electronic

BRIDGE

RECTIFIER

-Automatic Voltage Regulator)

SWITCH

and

Compound

Optional

Voltage

Regulator

An optional solid-state voltage regulator (board #34410) is available When

installed, and

the

standard compound transformer regulator

the

regulator provides excitation

the

group

2 exciter windings.

the

regulation switch is moved

to

the

group

to

the ELEC position, the regulator works together with

to

regulate the generator's voltage output. In the ELEC mode,

1 exciter windings, and the transformer provides excitation

for

use with the BT series generators.

Installation

1.

The regulator is mounted using existing tapped holes in the generator's case. Use

screws, each 15

2.

Connect the 6-prong generator plug

NOTE: The plug is keyed insert it

3.

Before moving

properly adjusted, with the

mm

correctly.

the

selector switch

long, with

lock

washers

to

the receptacle on the regulator board.

to

engage the regulator receptacle in one direction. Check this and

to

ELEC, ensure that the no-load voltage produced

selector in COMP position,

to

mount

the

regulator board.

by

following the procedures

two

(2)

M4 x 0.7 -mm

by

the generator is

for

"No-Load Voltage

Adjustment," page 33.

4.

With the generator's no-load voltage properly adjusted, move the selector switch into the ELEC position. Adjust the

regulator board potentiometer

51.5 - 52 Hertz). The generator's voltage output should be within

to

set no-load voltage at 120 Volts, 61.5 - 62 Hertz (110 Volts,

±5

percent from no-load

to

full-load.

to

Generator

Frequency is a direct result

To

change the generator's frequency, refer

Frequency

1800

RPM

1500

RPM

of

engine/generator speed:

- 60 Hertz

- 50 Hertz

to

the "MAINTENANCE AND ADJUSTMENTS" section

manual, page 48.

Load

Connections

The generator's data plate gives the voltage, current and frequency rating

decal is affixed

to

the inside

of

the louvered cover on the generator end. A diagram

of

the generator. An AC wiring

age connections is provided on the decal. The information on the decal is similar

following page.

The generator is a

Hertz;

or

110 Volts AC two-wire, 110/220 Volts AC three-wire,

single-phase, reconnectable 120 Volts AC two-wire

the "SYSTEM SPECIFICATIONS" section

of

this manual

or

220 Volts AC two-wire, at 50 Hertz. Refer

for

ratings, page 5.

or

120/240 Volts AC three-wire, at 60

of

the various AC volt-

to

the figure shown on the

of

this

to

36

NOTE: We recommend that the installer provide AC ampmeters (optional)

of

can observe the load being taken off each leg

the generator.

so

that the operator

A circuit breaker should be

rated

for

the generator's AC output and be able

siderations.

installed between the generator and the AC load. This circuit breaker should be

to

120V

60Hz

II

Os 7

03

110V

50Hz 1101220V 50Hz

(5

8

sO

react quickly

sO

to

overloads, subject

1281240V

60Hz

220V

02

50Hz

sO

to

motor starting con-

II

AC Voltage Connections (6 Stud

15.0KW Generator Set

NOTE: 220 Volts, 50 Hertz.

For making connections wire sized that will be drawn through the conductor(s). (Refer

ator amperage ratings.)

The frame ground wire must be moved when changing from 110 Volts, 50 Hertz

to

the AC terminal block, use 1/4 inch terminal ends that will accept multi-strand

for

the number of conductors in the bundle, the rating of the conductor's insulation, and amperage

Os

70)

II

Terminal

to

the generator's scarlet and gold data plate

Block)

to

for

gener-

37

Shore Power Connections

If the installer connects

POWER/OFF/SHIPS

shore

GEN,

simultaneous connection of

Damage at the

to the generator

same

time.

This

installer's responsibility to

~

i

z

power to the vessel's

AC

circuit, this

center position-off transfer switch

shore

power to generator output.

CAUTION

can

result if utility

type of generator

ensure

Generator

t

T<---_----,

I

L------r-<D

r-----\Q)

I

that

/""--

,

....../

all

HOTE:

shore

damage

AC

.....

~\

....

-

I

power

is

connections

---,

I

L_L2

must

as

shown

and

generator output

be done by

below.

means

Use

of this switch

are

connected

not covered under the warranty; it

are

correct.

SHIP-TO-SHORE SWITCH

[3

POLE]

PH

32888

[48

AMPS/POLE]

PH

32an

[BB

AMPS/POLE]

PH

32818

Ship'S

LOAD

1125 AMPS/POLE]

PH

32133

[288

AMPS/POLE]

of

is

the

SHORE

prevents

the

IN

~

'!

ii

Z

Generator

Gl~

t

..J

!!\t

"

NOTE:

....

/

.

.!,

.......

\

'-

~r

4-

~

....

:"...

l

....

.

~

.....

~

-_

J[i

Shore

.::;:Grou~nd::---4

Power

DIAGRAM WIRE. WITH BOIlT

-

....

,

~\

/

....

(GRN)

SHOWS

12B-VOLT THREE-WIRE, SYSTEM

_-t--,N~eutr~al'--.N

J

___

SYSTEM

12B-UOLT

.

L2

(WHT)

--Illt.

Switch Connection

CONNECTIONS

FOR A TWO-

FROM

Ship·l0-Sh0re

Ship'Slcad

Note

NO

24(].Vol1

equipment

Diagrams

THE

(48

PH

(Blil

PH

(.125

PM

(28B

38

GENERATOR,

Sw~ch

(3

Pole)

PH

32BBB AMPS/POLE)

32890

AMPS/POLE)

328111

AMPS/POLE)

32133

AMPS/POLE)

Use

of

Electric

GENERAL INFORMATION AND CARE OF THE GENERATOR

Motors

The power required it is started.

Some motors require much more current more current starting loads, such as washing machines, small power tools. Because they require 5

to

start an electric motor is considerably more than is required

to

start, under similar circumstances, than other types. They are commonly used on easy-

or

where loads are applied after the motor is started, such as

to

7 times as much current

avoided, whenever possible, if the electric motor is

sion-induction motors require from 2 start any

motor

varies with the load connected

example, will require more current than a motor

In general, the current required

to

4 times as much current

to

start 115-Volt motors connected

proXimately as follows:

MOTOR AMPS

SIZE RUNNING STARTING

(HP) (Amperes) (Amperes)

1/6

1/4 1/3 1/2

3/4

1

to

start than others. Split-phase

to

start as

to

be driven

by

a small generator. Capacitor and repul-

to

start as

to

run. The current required

it. An electric motor connected

which

no

load is connected.

to

medium starting loads will be ap-

FOR

AMPS

3.2 6.4

4.6 9.2

5.2 10.4

7.2 14.4

10.2 13

20.4 26

FOR

to

22.4*

to

32.2* to to to

t052

72.8*

29.2

40.8

to

keep it running after

(AC)

motors require

to

run, their use should be

to

an air compressor,

to

for

* Note that in the above table the maximum "Amps for Starting" is more for some small motors

than

for

larger ones. The reason

for

this is that the hardest starting types (split-phase) are not

made in larger sizes.

Because the heavy surge of current needed will not be damaged

if it can bring the motor up

starting motors, turn off all other electrical loads and,

for

starting motors is required for only an instant, the generator

to

speed

in

a few seconds. If difficulty is experienced in

if possible, reduce the load on the electric motor.

Required Operating Speed

Although individual units may vary slightly, the normal voltage and frequency driven generators described at half the generator's capacity, and finally loaded

in

this manual are approximately as follows: run first with

to

its full capacity as indicated on the generator's data

of

typical 60-(50-) Hertz engine-

plate.

See the rpm/Hertz/frequency chart on the next page.

no

load applied, then

39

4-Pole Generator Voltage

Load

Applied

Speed

(rpm) (Hertz) Plants Plants

Frequency 120V(110) 240V (220)

None 1830 62 122 244

(1530)

(52)

(112) (224)

Half

Full 1755

The output voltage should be checked periodically

1800

60

120 240

(1500) (50) (110)

110 220

(100) (200)

(1455)

59

(49)

to

ensure proper operation of the generating plant and

(220)

the appliances it supplies.

If an AC voltmeter

or

ampmeter is not installed

to

monitor voltage and load, check it with a portable meter

and amp-probe.

Preventive

Maintenance

(Generator)

Maintenance on the generator is minimal.

1.

Keep the generator clean,

2.

Ensure that all connections are clean and tight and that cables carrying AC voltage are properly supported

dry

and well-ventilated.

and protected against chafing.

3.

The rear armature bearing is lubricated and sealed; therefore,

becomes rough

or

noisy, replace it.

no

maintenance is required. If the bearing

Generator

Troubleshooting

A complete and illustrated text on troubleshooting the

Manual which is available through

your

local dealer.

40

BTD

series

of

generators is furnished in the Technical

ENGINE CONTROL PANEL

General

Standard Instrument Panel

manually-controlled series of

This

Westerbeke marine ators

is

equipped

switches on the engine's control

panel

and, optionally, at remote

panels. The following instructions

and methods of correcting minor

problems apply only gle switch controls.

diesel gener-

with

toggle

to

such

tog-

o

~

PREHEAT

START

4

three switches are momentary

All contact type and serve

ing functions:

1.

PREHEAT: The PREHEAT

gle

switch single-throw switch. The switch serves

ing the engine

and defeating

engine's protective sensor. The defeat

turns on the fuel solenoid, instrument power, alternator excitation and provides power

is a

two

purposes: preheat-

the

follow-

double-pole,

for

easy starting

or

bypassing the

oil pressure

function

tog-

~

STOP

A

~

QiNERATOR

o

to

the START switch.

2.

SIABI:

gizes the starter PREHEAT switch is depressed and

3..sIQE.:

provides power switch has stopping the

4.

In addition

erator sets

and oil pressure in pounds per square inch (OIL PSI), and voltage (VOLTS) and generator running time (ELAPSED TIME) in HOURS and 1/10 hours. The Water Temperature and

is not.

The STARTtoggle switch is a double-pole, single-throw switch. The switch, when activated, ener-

solenoid

The STOP toggle switch is a single-pole, single-throw, normally-closed switch. This switch

to

the fuel solenoid, instrument cluster and alternator excitation, after the oil pressure

closed upon starting. Opening

flow

of

to

the three switches above, the Standard Instrument Panel used with Westerbeke diesel gen-

includes

Oil Pressure gauges, and the DC Voltmeter are illuminated; the ELAPSED TIME meter

for

starting the engine. This switch will not operate electrically unless the

held at the same time.

of

this switch opens the power circuit

fuel

to

the engine and stopping the engine.

two

gauges, which indicate water temperature in degrees Fahrenheit (WATER 0

two

meters, which indicate DC control circuit

to

the fuel solenoid, thus

F)

41

Engine Operation To

start

the

engine,

I.

Preheat -Depress

will

be

activated.

TION"

2.

3.

section under

Start

-

While solenoid. switch.

water

temperature,

will

remain

Stop -

Depress

ping

the

still

Panel

Do

not

energized

fuel

flow to the

ing.

perform

the

PREHEAT

The

PREHEAT

"Starting

depressing

power

release

the

low

and

the

STOP

engine.

the

following

switch.

switch

Procedure,"

the

PREHEAT

and

the

fuel

PREHEAT

oil

pressure

continue to

switch to stop

The

steps:

The

should

page

solenoid switch

and

exhaust

run.

the

STOP

switch

voltmeter,

be

depressed

15.

switch,

will

until

the

temperature

engine.

must

panel

depress

be

activated.

oil

pressure

This

opens

be

lights,

in

accordance

the

START

Upon

reaches

gauges

and

with

switch.

engine

15

psi.

protective circuits do not

the

power

feed

held

depressed

until

meters the

chart

This firing,

Then

to

the

generator

and

will

engage

release

as

activate,

fuel

in

the

"OPERA-

the

long

as

solenoid,

stops

solenoid

the

start

START

the

high

the

set

stoprotat-

Remote For

START in functions

Operation

remote

the

,-------------------------------------------------'

, ,

" : 55 A

, , 3 A

i

I : I

" : :

:

!

,

operation of

switches

local

as

are

panel.

in

the

REMOTE

r--------------------------------------------------~-------------------~

!..---

0 '

the

connected

The

STOP

local

panel.

CONTROL

STOP

SWITCH

generator

in

parallel

switch

The

generator

PANEL

(REAR

system,

is

in

series

VIEW)

with

the

with

may

same

local

the

be

stopped

three

panel's

local

panel's

switches

from

,

22 A

i,

are

STOP

local

SURGE START

RUM

used.

and

serve

switch,

or

remote

m::::[J-!!ll!-

! I

I I i

, : ®

! ,

I

, "

"

r---

I I I I

110

BLACK

!

:---,..-------------r--------------------

:

I I ,

___________

I:!

i

,

RED/WHITE

~-~L----------.P.!'!!p.g-

! i

i,

I

PREHEAT

SW

ITCH

___________

,:

55 A

SURGE

, 22 A

START

~~-A-~U!-----------R.!~--

The

PREHEAT

the

same

and

serves

positions.

RED

TOT81-1

TO

lBl-6ND

TO

T82-1

TO

T82-2

TO

T81-2

and

functions

the

same

as

114

i,

,

RED

114

RED

! i

l

__

=~~_=_~=~~_=_~=~~_=_~=~~_=_~=~~~_~=~~~_~

P.N.

24943

','

'

,

48 A SURGE

-

-.

~~_=_~~=~~~J

~5_

~

oS!

~~T

- - - - - - - _!H

11E_

TO

T81- 4

42

ENGINE

TROUBLESHOOTING

Introduction The

tables which follow indicate troubleshooting procedures

probable

causes

of the problems,

and

the

recommendations to overcome

based

upon certain problem indicators, the

these

problems.

Note that the engine's control

on

the

rear

breaker located

switch,

ing

which

may

upon the model.

be

lifting

mounted

system

eye

on

the

(electrical

bracket.

same

bracket or

system)

The

preheat solenoid

on

the back of

is

protected by a

is

the

20-Ampere

close

by,

standard

manual

as

is

the emergency

instrument

reset

panel,

circuit

STOP

depend-

43

ENGINE TROUBLESHOOTING

Problem

PREHEAT

switch is de-

pressed: no panel in-

dications, fuel sole-

noid, electric fuel pump

and preheat sole-

noid not energized.

5T

ART

switch is de-

no

pressed:

starter

engagement.

Probable Cause

Battery switch not on.

20-Amp circuit breaker tripped.

Connection

to

solenoid faulty.

Faulty

START

switch.

Faulty solenoid.

Verification/Remedy

Check switch and/or battery connections.

Reset breaker; if

breaker trips again,

check preheat sole-

noid circuit and run

for

circuit to

ground.

shorts

Check connection.

Check switch with ohmmeter.

Check that 12 Volts is present at solenoid connection.

START switch is depressed:

panel indications OK; start solenoid OK; fuel solenoid

not func-

tioning.

Loose battery connection.

Low batteries.

Poor connections fuel solenoid.

Defective fuel solenoid.

to

Check battery connection.

Check battery charge state.

Check connections.

1.

Check mechanical positioning solenoid

of

for

fuel

plunger

bottoming.

2.

Manually check

movement

of

fuel solenoid plunger and throttle arm.

3.

Check for voltage

drop

at solenoid

during

PREHEAT.

Check wire size

from remote panels.

44

problem

No ignition: cranks,

not

but does

start;

fuel solenoid energized.

probable Cause

Faulty fueling system.

Verification/Remedy

1.

Check

to

2. Check

for

fuel

generator engine.

for

air in fuel system. Allow system

3. Fuel lift

to

self-bleed.

pump

faulty.

4.

Filters clogged.

(Replace filters

and allow system

self-bleed

by

to

depressing only the PREHEAT switch.)

Failure

to

stop.

Fuel solenoid return spring.

Stop engine ually moving the

throttle lever

by

to

man-

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

Depress emergency

failure. STOP switch on engine.

Stop engine

by

opening the high pressure injector lines

at

the injectors and stop air intake.

Engine stops. Low oil pressure

or

overheated.

Check oil level; check fresh and sea water cooling.

Low oil pressure

Check

for

satisfactory

switch opens. operation with switch

bypassed. Check with ohmmeter.

45

problem

probable Cause

Verification/Remedy

Engine

Stops (continued).

High water temperature switch opens at too

Iowa

temperature.

Check operation with switch bypassed. Check with

for

satisfactory

an ohmmeter.

20-Amp circuit breaker Same as above. tripping.

High exhaust tempera-

Same as above.

ture switch opens at too

Iowa

temperature.

Emergency

or

STOP switch in

STOP switch

Check operation switch with an

panel defective, ohmmeter.

opening

fuel run sole-

noid circuit.

Switches and/or

wiring.

Inspect all wiring for

loose connections and short circuits. Inspect switches proper operation.

of

for

Battery not charging.

Battery runs down.

Alternator drive. Check drive belt ten-

sion. Be sure

alternator turns freely. Check

for

loose conn-

ections. Check output

with

voltmeter. Ensure

Volts present at

12 regulator terminal.

Oil pressure switch.

Observe if gauges and panel lights are activated when engine is not running. Test the oil pressure

switch.

46

Problem

Battery runs down (continued).

Probable Cause

VerificationlRemedy

High resistance leak

to

ground.

Low resistance leak.

Alternator.

Check wiring. Insert

sensitive (0-.25 Amp)

meter in battery lines. (Do not start engine.) Remove connections and replace after short is

located.

Check all wires for

temperature rise

to

locate fault.

Disconnect alternator at output, after a good battery charging. If leakage stops, remove alternator and bench test. Repair

or

replace.

47

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

Perform the preventive maintenance in accordance with the schedules listed Adherence that it will perform

by

an authorized dealer

Daily

1.

Check the oil sump's level. Maintain the oil level at

2.

Check coolant level in plastic recovery tank. Maintain at

3.

Maintenance

to

these schedules will ensure the equipment is maintained in the best possible condition and

to

(Engine)

expectations. Those items marked

or

distributor.

(before each use)

Visually inspect the unit; check

for

loose belts, chafed

in

the following paragraphs.

by

an asterisk (*) are recommended

or

near upper level mark on dipstick.

or

above the level marked ADD.

or

broken wires, loose brackets and fittings,

to

be performed

damaged hoses, loose clamps, and other equipment not properly secured.

4.

Check the fuel supply. Fill with a good grade of

5.

Check the primary filter/water separator. Drain and service as required.

No.2

diesel fuel,

if

required.

(A

primary filter/water separator

is optional, but strongly recommended.)

6.

Check the engine's gauges for proper oil pressure, operating temperature, and starting battery charging voltage once the engine is operating.

7.

Check the generator's output meters (when installed) for proper AC voltage and output frequency.

Monthly

Check the condition of the zinc anode

in

the heat exchanger sea water circuit. Clean

or

replace the anode,

as required. Keep the area inside the heat exchanger clean of zinc anode debris.

After

Initial

50

Servicing

1.

Change the engine's lube oil and oil filter.

2.

Replace the fuel filter elements in the electric fuel lift pump and in the engine-mounted filter assembly.

Hours

of

Operation

*3. Torque the cylinder head hold-down bolts.

*4. Adjust valve clearances.

48

5. Adjust the alternator and water pump drive belt tension,

6.

Adjust the engine's no-load speed,

adjustment during

or

after the unit's break-in.

if

required (Hertz). Please note that this adjustment is not a warrantable

if

required.

Servicing After Every 100 Hours

1.

Change the engine's lube oil and oil filter.

2.

Adjust the alternator and water pump drive belt tension,

3. Check siphon break operation (when installed).

Servicing After Every 250 Hours

Replace the fuel filter elements in the electric fuel lift pump and in the engine-mounted filter assembly.

Servicing After Every 500 Hours

*1. Torque the cylinder head hold down bolts.

*2. Adjust the valve clearances.

3. Drain, flush, and refill the fresh water cooling system.

of

*4. Check the condition

5. Check for proper operation

*6. Check the generator for proper operation. Also check the generator's sure that these connections are not chafing.

the starter motor drive pinion; lubricate pinion.

of

Operation

of

Operation

of

Operation

of

preheat circuit and glow plugs.

if

required.

AC

output connections for security make

7.

Check the outside

engine inhibits the engine's ability

8.

Check the condition

secure

and that the alternator's voltage output is correct.

9. Check the condition

internal wear

10. Check water injected exhaust elbow for carbon andlor corrosion build-up

needed.

11. Inspect sea water pump drive. Remove the pump and check drive tank and pump shaft. Replace as needed.

of

the engine. Make sure that any oil on the engine's surface is cleaned.

to

remain cooL Please keep th engine clean.

of

the DC battery charging alternator making sure that all the connections are clean and

of

the sea water pump making sure that the pump's impeller is serviceable. Check the

the pump, and replace worn components as needed.

Any

dirt

or

oil on the

on

inside passages. Clean/replace as

49

Servicing tion

*1. Remove and check fuel injectors

After

Every

800

Injector spray pressure:

Hours

of

Opera-

1706 psi + 142 psi (120

Eliminate undesirable injection conditions in-

cluding after dripping.

*2. Check compression pressure. Remove

each cylinder's compression pressure. The engine's cranking speed is at 250 rpm.

Standard

440 psi

(31

*3. Check the battery-charging alternator

*4. Check the tightness

Servicing

2

kglcm

+ 10

glow

BTD15.0KW

2

)

After

Every

plug

2

kglcm

(25 kg/cm

)

and

check

Minimum

355.5 psi

1000

2

)

of

bolts, nuts, and clamps.

Hours

of

each

Maximum difference between cylinders: 35.5 psi (2.5 kg/cm

Operation

for

proper operation.

~~~

..

~~+;

......

~lIi'lliiiN"""_.--~o1i\

GOOD

2

)

1.

Remove, clean, and pressure test the primary heat exchanger.

be able

*2. Check the injection pump's timing.

Preventive

Maintenance on the generator end is

1.

Keep the generator clean, dry, and well-ventilated.

2.

Ensure that all connections are clean and tight, and that cables carrying AC voltage are properly supported and protected against chafing.

*3. The rear armature bearing is

ing becomes noisy

to

clean and test the heat exchanger.)

NOTE: Operating in silty and/or tropical waters may require that a heat exchanger cleaning be performed more often than every

Maintenance

(Generator)

lubricated and sealed;

or

rough-sounding, have it replaced.

1000 hours.

minimal:

no

(A

local automotive radiator shop should

maintenance is required. However, if the bear-

50

Adjustments (Engine)

Valve Clearance Adjustment

Pull the air breather hose off

o

8

of

the rocker cover; loosen and remove the rocker cover bolts.

- Exhaust Side -

10

14

12

o 0

4

11

o 0

13

15

o 0

5

o

@J

2

- Intake Side -

1

3

@

o

q

Cylinder Head Bolt Tightening Sequence

1.

Tighten the cylinder head bolts in the sequence shown above. The engine should be cold. Loosen each

bolt 1/8

the intake manifold where it is attached

2.

Tighten each rocker shaft bracket bolt

3.

Adjust the valves' clearances with the engine cold after the cylinder head bolts have been re-torqued as described in step

A.

to

1/4 turn when tightening in the sequence shown. Note that bolt # 4 and 5 are located under

Exhaust

Intake Side

#1.

Slowly rotate

(as viewed from the front that when this is done, the valves ves are closed.

the

crankshaft in its normal direction of rotation

of

the engine)

to

the head.

Head Bolt Tightening Torque

Side - 12.0 kg-m (86 Ib-ft)

- 10.5 kg-m (76Ib-ft)

to

11

Ib-ft (1.5 kg-m).

to

bring the piston

to

Top dead Center

of

the number 4 cylinder are in a position

(TOC)

of

the number 1 cylinder

its compression stroke. Observe

of

overlap; that

is,

both val-

51

B.

In this position, adjust the valve's clearance in the conventional manner

of the number 1 cylinder, the intake valve

ber 3 cylinder.

C.

Rotate the crankshaft in the normal direction of rotation one full turn (360°) and stop.

D.

In this position, adjust the valve clearances

the exhaust valve

of

the number 2 cylinder, and the intake valve

of

the number 2 cylinder, and the exhaust valve

of

the intake and exhaust valve

of

the intake and exhaust valve

of

the number 3 cylinder.

Exhaust valves

Inlet valves

of

the num-

the number 4 cylinder,

Valve Clearance (engine cold)

.010 inches (0.25 mm)

52

Injection Pump Timing

BTD

15.0KW

Incorrect fuel injection timing will result in hard engine starting and poor engine performance. Adjust the injection timing as follows:

1. Locate the timing pointer on the front gear cover. This pointer is located at about the 10:00 o'clock position when viewing the

front crankshaft pulley.

2. The front crankshaft pulley has timing marks embossed on its circumference from

to

(Top Dead Center)

40° BTDC (Before Top

0° TDC

Dead Center) in five-degree increments. Locate the visible mark halfway between the to

represent 23°.

3. Rotate the engine number Continue rotating the engine

20° and 25° marks and place a

two

points

by

hand

to

position the

1 piston on its compression stroke.

to

align the 23° mark on the crankshaft with the timing pointer and stop.

On the side of the injection pump body is an

4.

to

oval cover plate mounted by

two

screws that are wired together. Cut

the pump body

the connecting lock wire and remove the screws and cover plate, including the gasket.

Timing

pointer

Front

pulley

(Note:

Some fuel will be lost from inside the pump when this cover is removed. Be

prepared

to

catch it

in

a container.)

53

5.

Inside the opening in the injection pump is a

circlip and the rotor body of the pump. The rotor body has a scribe mark on it with the letter

II E II

stamped above

mark

should align with the top, flat surface of

circlip. If the mark does not align, loosen

the

it.

The scribed

the injection pump's securing nuts and gently

rotate the injection pump's body up

down

to

align the scribe mark with the circlip

flat. The pump is now statically timed

engine.

flange,

Secure the pump

replace the pump's side cover and

gasket, and

bolts.

ing

lock-wire the side cover's attach-

to

its mounting

to

or

the

(Note: cover's attaching

Do

not

over-tighten

bolts.)

the

side

Reattach the fuel supply and return lines run-

to

ning

and the injectors. Do not cross

The

and from the injection pump. Connect the high-pressure injector lines between the injection pump

or

mix up these lines.

Engine No-Load Speed Adjustment

BTD

15.0KW

no-load engine speed adjustment is set, wired, and

sealed at the factory.

This adjustment is

accomplished

throttle lever, located on the

by

positioning the

top

of the fuel injection

pump, so that the engine's speed is at 61.5 -62.0 Hertz

#2

when contact with the

adjustment screw takes

place.

This adjustment screw can be repositioned ing the locknut and screwing it in

to

level

move

should

a slower speed,

to

a faster speed. Once set, the # 2 locknut

be tightened. Next, lock-wire the # 2 locknut

or

.out

on the # 2 adjustment screw. The internal pump's governor system

should maintain the engine's rpm

within 3 Hertz from no-load up

rated output.

by

to

move the throttle

to

allow the throttle

to

the generator's full

loosen-

to

54

Adjustments (Generator)

Once the diesel generator set has been placed in operation, there is erator. The the

fuel solenoid and the throttle arm in the event of a change

only adjustment that would be required is the speed adjustment made

no

adjustment required

to

of

operating frequency between 50 and 60

by

the AC gen-

the linkage between

Hertz. This adjustment is given below.

CAUTION

When starting the generator, it is recommended that all AC loads, especially large motors, be switched This precaution will prevent damage caused and will prevent a

OFF until the engine has come up

cold engine from stalling.

to

speed and, in cold climates, starts

by

the unanticipated operation

to

warm up.

of

AC machinery

Generator Frequency Adjustment

Frequency is a direct

result of engine/generator speed, as indicated

by

the following:

When the generator is run at 1800 rpm, the AC voltage output frequency is 60 Hertz. When the generator

is run at

Therefore,

1500 rpm, the AC voltage output frequency is 50 Hertz.

to

change

the

generator's frequency, the generator's speed must be changed.

To

accomplish

the frequency change, perform the following:

Connect the AC output leads

nections diagram which appears in the

to

the AC terminal block in accordance with the AC Voltage Con-

"ST GENERATOR" section

of

this manual, page

37.

55

LAY-UP

AND

RECOMMISSIONING

General Many

owners rely

the off-season or for The

procedures which follow will allow you to perform your

on

their boatyards to prepare their craft, including engines

long periods of inactivity. Others prefer to accomplish lay-up preparation

a check list if others do the procedures. These

procedures should afford your engine protection during a lay-up

needs

maintenance If you

have

any questions regarding lay-up procedures,

of your

engine.

call

willing to provide assistance.

and

generators, for lay-up during

own

lay-up

and

recommissioning, or to

and

also help familiarize you with the

your local servicing dealer;

he

themselves.

will

be

use

more

as

than

Fresh Water

A

50-50

all

times.

climate. Check the solution to Should more antifreeze

Cooling System

solution of antifreeze

This

solution may require a higher concentration of

be

needed,

and

fresh

ensure

water

that the antifreeze protection

drain centrated mixture. Operate the engine to centration throughout the

Lubrication With

the engine

some When

base

of the filter. SPECIFICATIONS" the engine

System

warm,

paper towels

and

installing the new

Fill

the sump with the correct amount of

section of this

and

check for proper

drain

a plastic

cooling

oil

system.

all

the lubricating

bag

filter,

be

sure

manual,

oil

pressure

around the filter to catch the

is

recommended for

an

appropriate amount from the engine block

ensure

a complete circulation

use

in

antifreeze,

is

adequate.

and

the fresh water cooling

depending

mixture of the antifreeze con-

Now recheck the antifreeze solution's strength.

oil

from the

to apply a

page

4.)

and

ensure

small

Use

oil

sump.

Remove

oil

during its

amount of

oil

for your engine model.

an

oil

that there

with

oil

on the rubber sealing gasket at the

an

API

are

no

leaks.

and

replace the

removal.)

specification of

CAUTION

system

on

the area's winter

and add a more

oil

filter. (place

(Refer

to

the"SYSTEM

CC

or

CD.

at

con-

Run

Do

not

leave

the engine's old lubricating

oil

and

combustion deposits combine to produce

of your engine's internal

parts.

oil

in

the sump over the lay-up period. Lubricating

harmful

chemicals which

can

reduce the life

56

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 fil-

ter/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. Start the engine and allow it

to

run

for

5 -

10

minutes

to

ensure that no air is left in the fuel system. Check

for

any leaks that may

have been created in the fuel system during this servicing, correcting them as needed.

Sea Water

Close the thru-hull seacock. Remove the sea water intake hose from the seacock. Place the end

hose into a 5-gallon bucket

the primary heat exchanger on the engine and clean

is

installed in the inside of the hull.

Start is empty, stop the engine and refill the bucket with an antifreeze solution slightly stronger than needed

winter freeze protection

Start the engine and allow all of this mixture is empty, stop the engine. This antifreeze mixture

Circuit

of

clean fresh water. Before starting the engine, check the zinc anode found

the engine and allow the sea water pump

in

your area.

to

of

this

or

replace it as required. Clean the sea strainer, if one

to

draw fresh water through the system. When the bucket

for

be drawn through the sea water system. Once the bucket

should protect the sea water circuit from freezing during

the winter lay-up, as well as providing corrosion protection.

in

Remove the bucket). Examine the

impeller from your sea water pump (some antifreeze mixture will accompany it, so catch it in a

impeller. Acquire a replacement, if needed, and a cover gasket. Do not replace the

impeller (into the pump) until recommissioning, but replace the cover and gasket.

Intake

Place a clean cloth, lightly soaked in lubricating oil, in the opening of the intake manifold

Manifold

and

Through-Hull

Exhaust

to

block the opening. Do not shove the cloth out of sight. (If it is not visible at recommissioning, and an attempt is made start the engine, you may need the assistance to

start-up. The through-hull exhaust part can be blocked in the same manner.

Starter

Lubrication and cleaning

Motor

of

the starter drive pinion is advisable, if access removal. Ensure that the battery connections are shut off before attempting in

properly replacing any electrical connections removed from the starter.

Cylinder

It is not necessary cylinders or

more), we recommended that this procedure be performed. The light oil in the cylinders will prevent the

pistons rings from sticking

Lubrication

to

remove the fuel injectors from the cylinder head

for

the few months of normal lay-up. However, if you antiCipate a longer lay-up period (12 months

to

the cylinder walls. Ensure that you have replacements for the injector and

of

a servicing dealer.) Make a note

to

squirt light lubricating oil into the

to

remove the cloth prior

to

the starter permits its easy

remove the starter. Take care

return line sealing washers.

to

57

Spares

Lay-up time provides a good opportunity or

coolant hoses need replacement. Check your basic spares kit and order items not on hand,

those items used during the lay-up, such as filters and zinc anodes.

to

inspect the equipment

to

see if external items such as drive belts

Batteries

If batteries are

that way,

charged,

them in a warmer, more compatible environment.

to

be left on board during the lay-up period, ensure that they are fully charged, and will remain

to

prevent them from freezing. If there exists any

or

that they will be subjected

to

severe environmental conditions, remove the batteries and store

doubt

that the batteries will not remain fully

Recommissioning

The recommissioning of as those presented in the "Preparation

normal starts. However, some of the lay-up procedures will need gine.

1.

Remove the oil-soaked cloths from the intake manifold and from the through-hull exhaust port.

2.

Remove the sea water removed during lay-up (or a replacement, if required). Install the sea water gasket.

your

Westerbeke unit after a seasonal lay-up generally follows the same procedures

for

Starting" section, page 14, regarding preparation

to

be counteracted before starting the en-

pump

cover and gasket. Discard the gasket. Install the sea water

pump

cover with a new cover

or

for

starting and

pump

replace

impeller

Wear rubber gloves, a rubber apron, and eye protection when servicing batteries.

by

Lead acid batteries emit hydrogen, a highly-explosive gas, which can be ignited

or

arcing tery being serviced. during servicing.

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. charged.

4.

Check the condition of the zinc anode in the sea water circuit and clean

Note that it is not necessary When the unit is put into operation, the system will self-flush in a short period fects.

5.

Start the unit in accordance with procedures in the "Preparation

14.

a lighted cigarette, cigar,

Shut off all electrical equipment in the vicinity

to

flush the antifreeze/fresh water solution from the sea water coolant system.

or

pipe. Do not smoke

or

allow an open flame near the bat-

to

prevent electrical arcing

Check

to

ensure that the batteries are fully-

or

replace the anode as needed.

of

for

Starting" section of this manual, page

electrical

time with

no

adverse af-

58

TABLE

OF

STANDARD HARDWARE TIGHTENING TORQUES

Unless stated otherwise

ard hardware.

Graden

6mm bolt head/nut

8mm bolt head/nut 10mm bolt head/nut 10mm bolt head/nut 12mm bolt head/nut 12mm bolt head/nut 12mm bolt head/nut 13mm bolt head/nut 14mm bolt head/nut 14mm bolt head/nut 16mm bolt head/nut 16mm bolt head/nut

Grade6I

6mm bolt head/nut

8mm bolt head/nut

10mm

bolt head/nut 10mm bolt head/nut 12mm bolt head/nut 12mm bolt head/nut 12mm bolt head/nut

for

a specific assembly, use the following torque values when tightening stand-

Pitch

1

1.25

1.5

1.25

1.5

1.75

1.5

1.5 2

1

1.25

1.5

1.25

1.5

1.75

(ISO)

Ib-ft

2.9 -

5.1

7.2 - 11.6

13.7 - 22.4

13.0 - 21.7

25.3 - 39.8

21.7 - 36.2

50.6

32.5 -

36.2 - 57.9

34.0 - 55.7

54.2 - 79.6

51.4 - 76.7

4.3 - 6.5

10.8 - 15.9

21.7 - 32.5

19.5 - 30.4

36.2 - 57.9

36.2 - 50.6

34.7 - 49.2

kg-m

0.4 - 0.7

1.0 - 1.6

1.9 -

3.1

3.0

1.8 -

3.5 - 5.5

3.0 - 5.0

4.5 - 7.0

5.0 - 8.0

4.7 - 7.7

7.5-11.0

7.1

-10.6

0.6 - 0.9

1.5 - 2.2

3.0 - 4.5

2.7 - 4.2

5.0 - 8.0

- 7.0

5.0

4.8 - 6.8

Grade

7T,

aI

aDd

6mm bolt head/nut

8mm bolt head/nut 10mm bolt head/nut 10mm bolt head/nut 12mm bolt head/nut 12mm bolt head/nut 12mm bolt head/nut 13mm bolt head/nut 14mm bolt head/nut 14mm bolt head/nut 16mm bolt head/nut 16mm bolt head/nut

5

caJ;lScrew

1/4 UNC 1/4 UNF

UNC

5/16 5/16 UNF 3/8

UNC 3/8 UNF 7/16

UNC 7/16 UNF 1/2 UNC 1/2 UNF

a a

1

1.25

1.5

1.25 (ISO)

1.5

1.75

1.5

1.5 2

5.8 - 8.7

14.5 - 21.7

28.9 - 39.8

26.8 - 37.6

54.2 - 75.9

50.6 -

43.4 - 61.5

57.9 - 86.8

72.3 -108.5

68.7 -101.3

108.5 - 166.4

101.3 -159.1

65.1

11

9 -

11

- 13

18 - 20

21

- 23

28 -

33

30 -

35

44-

49

50

-

55

68 -

73

73 -

80

0.8 - 1.2

2.0 - 3.0

4.0 - 5.5

3.7 - 5.2

7.5

-10.5

7.0 - 9.0

6.0 - 8.5

8.0 -12.0

10.0 -15.0

9.5

-14.0

15.0 - 23.0

14.0 - 22.0

1.2 - 1.5

1.5 - 1.8

2.5 - 2.8

2.9 - 3.2

3.7 - 4.6

4.1

- 4.8

6.1

- 6.8

6.9 - 7.6

9.4

-10.1

10.1

-11.1

59

SOUND GUARD INSTALLATION INSTRUCTIONS

For a

copy

of the Sound Guard installation instructions required local Westerbeke dealer. A four page installation brochure is available which covers all current Sound Guard model assembly/installations.

SOUND

ABSORBENT

INSULATION

MYLAR

..

WITH

FACING

for

your

generator set, please contact your

An

easy sound all

Westerbeke

to

assemble

enclosure

to

fit

generators.

ALUM.INUM

OlE

CAST

EXTRUSION

CORNERS

FRAME

FOR

ACCURACY

ALUMINUM

WITH

HANDLES

60

TORQUE SPECIFICATIONS

Cylinder head bolt

(See the "Cylinder Head Bolt Tightening Sequence" diagram on page 51.)

Crankshaft

Main bearing cap bolt 57.9

Connecting rod bearing caps

Rocker shaft bracket

Front plate bolts

Timing gear cover

Camshaft thrust plate 10.8

Idle thrust plate

pulley nut

Exhaust side

Intake side

83.2

72.4

285.7 -292.9 39.5 - 40.5

36.2

7.2

5.1

21.7 - 28.9

l..b:ft

-90.5

-79.6

-65.2

-43.4

-14.5

-10.8

-10.8 0.7

-16.6

Kg::m.

11.5

-12.5

10.0

-11.0

8.0

-9.0

5.0 - 6.0

1.0 - 2.0

0.7

-1.5

1.5 - 2.3

3.0 - 4.0

Backplate

Rear oil seal

Flywheel bolts 57.9

Oil pan bolts

Banjo bolt - oil drain hose 68.7

Injector retaining nut 32.5

Injection

to

block

pump

delivery valve holder

21.7 - 25.3

18.1

3.0 - 3.5

2.9 0.4

-65.2

5.1

-75.9

-39.8

- 25.3 2.5

8.0 - 9.0

9.5

4.5

0.7

-10.5

-5.5

-3.5

61

A

INDEX

Adjustments, Engine ...............................................................................................................

Injection Pump Timing .................................................................................................. 53

No-Load No-Load

Valve Clearance ............................................................................................................

Adjustment, Generator ............................................................................................................ 55

Frequency ..................................................................................................................... 55

Alternator .................................................................................................................................

Alternator and Water Pump Drive Belt Tension ..................................................................... 28

ANTIFREEZE ADDITION DATA (Chart) .................................................................................. 26

Speed .................................. ~ .......................................................................... 54

Voltage ........................................................................................................... 33

51

21

B

Batteries

Electrical System Installation Checks ..........................................................................

Lay-up and Recommissioning ...................................................................................... 56

Battery Specification ...............................................................................................................

Break-in Precautions ............................................................................................................... 16

BT GENERATOR .................................................................................................................... 33

BT Generator's

Internal Wiring Diagram, BTD 15.0KW (Figure) ........................................... 35

12

21

c

Care of the Generator ............................................................................................................. 39

Charging Circuit

Connection Diagram, Connections

Control Circuit .........................................................................................................................

Coolant (Antifreeze) Mixture, Fresh Water ............................................................................. 25

COOLING SYSTEM ................................................................................................................ 25

Cylinder Lubrication ................................................................................................................ 57

Voltage Test (Alternator) ......................................................................................... 24

Engine

Fresh Water ................................................................................................................... 25

Sea Water ...................................................................................................................... 27

Wiring Diagram, DC

AC

Load ............................................................................................................................... 36

Shore Power .................................................................................................................. 38

Engine 12-Volt DC .........................................................................................................

Wiring Diagram #36411 (Figure) ........................................................................ 22 & 23

Description .................................................................................................................... 25

Fresh Water (Lay-up/Recommissioning) ..................................................................... 56

12-Volt DC Control ...........................................................................................

Control #36411 (Figure) .................................................... 22 & 23

Shore Power Switch (Figure) ............................................................. 38

Voltage (Figure) ...................................................................................................... 37

21

21 21

62

D

Diagram # 36411, Diesel

Engine,

Diesel

Fuel ...............................................................................................................................

Draining Drive

the

Belt

Tension,

DC

Control

Understanding

Oil

Sump

............................................................................................................

Alternator

Circuit ............................................................................ 22 &

the ............................................................................................ 2

and

Water

Pump ....................................................................

E

ELECTRICAL Electric Engine

Injection No-Load No-Load

Valve ENGINE Engine

Engine

Change ..........................................................................................................................

Viscosity

Engine Engine ENGINE Exhaust

SYSTEM

Motors,

Adjustments ................................................. ; ..............................................................

Use

Pump

Speed .............................................................................................................

Voltage ........................................................................................................... 33

Clearance

CONTROL

12-Volt

DC

..........................................................................................................

of

...........................................................................................................

Timing ..................................................................................................

............................................................................................................

PANEL

Control

...................................................................................................

Circuit ..........................................................................................

Oil

(SAE

Number)

Operation .................................................................................................................... 42

Preventive

Maintenance .............................................................................................

TROUBLESHOOTING

System

Installation

.................................................. :

(Table) .................................................................................

Check .......................................................................................... 8

...

.........................................

23

18 31 28

21 39 51 53 54

51

41

21

31

48

44

F

Filling

the

Fresh

Water

System ...............................................................................................

Filling

the

Oil

Sump .................................................................................................................

Filter

Elements,

Oil, Frequency Frequency, Fresh

Water

Coolant

Cooling

System,

Replacing

Replacing ................................................................................................................

Adjustment,

Generator

Circuit

....

(Antifreeze) System

Filling

.....................................................................................................

Generator .........................................................................................

............................................................................................................

.........................................................................................................

Mixture

(Lay-up) ..............................................................................................

the

........................................................................................................

........................................................................................

Fuel

Diesel ............................................................................................................................. 18

Filters .............................................................................................................................

FUEL Fuel

Injection SYSTEM

System

Installation Lay-Up Notes

System

...........................................................................................................

........................................................................................................................

Check

and

on ........................................................................................................................ 19

.........................................................................................................

Recommissioning

.....................................................................................

....

26 32

19 32 55 36 25 25

56

26

18

19

18

12 56

G

63

GENERAL General

.................................................................................................................................. 2

Specifications .............................................................................................................. 3

Generator

AC

Output. .....................................................................................................................

Adjustments ..................................................................................................................

Frequency .....................................................................................................................

Frequency Adjustment. .................................................................................................

General Preventive

Information ......................................................................................................

Maintenance ................................................................................................

Specifications .................................................................................................................. 5

Troubleshooting ............................................................................................................

GENERATOR,

BT

....................................................................................................................

12 55 36 55 39 40

40 33

Injection

System,

Fuel

....................................................................................................

19 & 20

Injection Pump Timing ............................................................................................................

INSTALLATION

Instrument

CHECKS

Panel,

.......................................................................................................... 7

Standard

(Figure)

......................................................................................

Intake Manifold ........................................................................................................................

Intake

System

Internal Wiring

..........................................................................................................................

Diagram,

BT

Generator

(Figure)

....................................................................

L

LAY-UP Load

AND

RECOMMISSIONING

.......................................................................................

Connections ...................................................................................................................

Lubrication, Cylinder (during lay-up) ......................................................................................

LUBRICATION Lubrication

SYSTEM

System

.........................................................................................................

(during lay-up) ........................................................................................

M

MAINTENANCE Maintenance,

AND

ADJUSTMENTS

Preventive

..................................................................................

.........................................................................................................

Engine ............................................................................................................................

Generator ......................................................................................................................

Motors, Electric,

Use

of ...........................................................................................................

Motor, Starter ..........................................................................................................................

53 41

57

11

35

56 36 57 31 56

48 48 48 40 39 57

N

No-Load

Speed

Adjustment ...................................................................................................

No-Load Voltage Adjustment .................................................................................................

Notes

on

the

Fuel

System

.......................................................................................................

54 33 19

64

o

Oil Change, Engine .................................................................................................................

Oil, Engine ...............................................................................................................................

Oil Filter Replacement ............................................................................................................ 32

Oil Pressure .............................................................................................................................

Oil Sump

Drain ..............................................................................................................................

Fill .................................................................................................................................. 32

Oil Viscosity (SAE Number), Engine ......................................................................................

Operating Speed, Required .................................................................................................... 39

Operation

Engine ........................................................................................................................... 42

Remote .......................................................................................................................... 42

OPERATION ............................................................................................................................ 14

Optional Voltage Regulator .................................................................................................... 36

Ordering Parts ........................................................................................................................... 2

31 31

31

P

Parts, Ordering .......................................................................................................................... 2

Power Connections,

Precautions, Break-in ............................................................................................................. 16

Preparation Pressure,

Preventive Maintenance ......................................................................................................... 48

Procedure

Pump,

for

Oil ............................................................................................................................

Engine ........................................................................................................................... 48

Generator ......................................................................................................................

Starting .......................................................................................................................... 15

Stopping ........................................................................................................................ 16

Sea Water .................................................................................................................... 28

Shore .................................................................................................... 38

Starting .......................................................................................................... 14

31

40

R

Recommissioning ................................................................................................................... 56

Regulator, Voltage, Optional .................................................................................................. 36

Remote Replacement

Replacing Filter Elements ....................................................................................................... 19

Required

Operation .................................................................................................................. 42

of

Oil Filter ........................................................................................................ 32

Operating Speed ..................................................................................................... 39

S

SAE

Number

SAFETY PRECAUTIONS .............................................................................. Inside Front Cover

Sea Water Circuit

Description .................................................................................................................... 27

Lay-up Procedure ......................................................................................................... 56

Sea Water

Shore Power Connections ..................................................................................................... 38

(Engine Oil Viscosity) .......................................................................................

Pump

..................................................................................................................... 28

31

65

Shore Spares Specification, Battery (Electrical SPECIFICATION, SPECIFICATIONS, Speed,

Power Switch Connection

......................................................................................................................................

TORQUE

SySTEM

Operating, Standard Instrument

Starter Motor (gear check during lay-up) ...............................................................................

Starting

Preparation for ..............................................................................................................

Procedure ......................................................................................................................

Under

Under Normal Conditions .............................................................................................

Stopping Procedure ................................................................................................................

Sump,

Switch Connection

Oil

Draining .........................................................................................................................

Filling .............................................................................................................................

T

Required

Panel

Cold

Conditions .................................................................................................

Diagram,

Diagram

System)

....................................................................................................

..................................................................................................... 4

...................................................................................................

(Figure)

Shore

(Figure)

..............................................................................

.......................................................................................

Power

(Figure)

..............................................................

.............................................................

38 58 21 61

39 41 57

14 15 17 17 16

31 32 38

TABLE TORQUES Test

Tension,

Thermostat ..............................................................................................................................

Through-Hull Exhaust .............................................................................................................

Timing, Injection TROUBLESHOOTING Troubleshooting, Engine

Troubleshooting, Generator ...................................................................................................

OF

STANDARD

SPECiFiCATION

Voltage,

Charging (Alternator) ......................................................................................

Drive

Belt,

HARDWARE

...................................................................................................

Alternator

Pump

...........................................................................................................

.............................................................................................................

(Table)

TIGHTENING

and

Water

Pump

............................................................................................

TORQUES

...................................................................

...........................................

u

Understanding the

Use

of Electric Motors .............................................................................................................

Diesel

Engine

............................................................................................. 2

v

Valve

Clearance Adjustment. ..................................................................................................

Ventilation ................................................................................................................................

Viscosity, Engine

Voltage Adjustment, No-Load ................................................................................................

Voltage Voltage

Regulator, Test,

Oil

(SAE

Number)

Optional ....................................................................................................

Charging (Alternator) ........................................................................................

......................................................................................

59

61 24

28 27 57 53 43 44 40

39

51

13 31 33 36 24

66

w

Water

Pump/Alternator Wiring Wiring

Diagram Diagram,

#36411,

Internal,

Drive

DC

BT

Belt

Tension

Control

Generator

Circuit

............................................................................

(Figure)

................................................... 22 &

...................................................................

28 23 35

67

Westerbeke 15.0BTD60-HERTZ, 12.0BTD50-HERTz Operator's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual