Westerbeke BTDA 15.0, BTDA 12.0 Operator's Manual & Installation Manual

OPERATOR'S MANUAL

&

INSTALLATION GUIDE

WESTERBEKE

KW

BTDA 15.0 BTDA 12.0

- 60 Hertz

KW

- 50 Hertz

,~

MARINE

GENERATOR SET

Publication #038663

August 1990

DIESEL

Edition One

WESJ'ERBEKE

WESTERBEKECORPQRATJON

AVON INDUSTRIAL PARK,

AVON,,vA

02322.

T£L.:(5"")588-77oo

SAFETY PRECAUTIONS

The following symbols appear

to

attention dangerous to the operator.

and emphasize conditions potentially

in

this manual to call

nWARNINGjI

The above symbol possible serious personal injury or loss of

The above symbol personnel of possible damage to equipment.

Read

the manual carefully and thoroughly before attempting dangerous conditions can exist and take necessary precautions to protect personnel and equipment.

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

could

recommended procedures carefully. Always operate bilge blowers for at least five minutes

before starting a gasoline-fueled engine; ensure no

gasoline fumes are present before starting.

• prevent Electric Shock

to

resutt in serious personal injury or death. Follow

Shut off electric power before accessing electrical equipment.

Use

insulated mats whenever working on electrical

equipment.

is

used in the manual to warn of

life.

ICAUTIONI

is

used in the manual to caution

operate the equipment. Know when

are

potential hazards that

•

Use

Extreme Care When Handling Engine

(A

constant danger Do not fill fuel tank(s) while the engine Do

not smoke or use

or the fuel tank.

•

Do

Not Atter or Modify the

Be

sure all fuel supplies have a positive shut-off

valve. Be

certain fuel line fittings are adequately tightened

and free of leaks. Make sure a fire extinguisher

is

properly maintained. use. Extinguishers rated propriate for environment.

• Use Extreme Care When Servicing Batteries Wear rubber gloves, a rubber apron, and eye

protection when servicing batteries. Lead acid batteries emit hydrogen, a

plosive gas, which can be ignited by electrical cing or by a lighted cigarette, cigar, or pipe. smoke or allow serviced. vicinity to prevent electrical arcing during servicing.

Shut off all electrical equipment

of

explosion

an

open flame near the engine

Fuel

Be

ABC

all

applications encountered

an

open flame near the battery being

or

fire exists)

is

running.

System

is

installed nearby and

familiar with its proper

by the NFPA

highly-ex-

Fuel

are ap-

in

Do

in

this

ar-

not the

is

Make sure your clothing ly

shoes), and keep your skin surfaces dry when

handling electrical equipment. Remove wristwatch and jewelry when working on

electrical equipment. Do

not connect utility shore power to vessel's Circuits, except through a ship-to-shore doublethrow transfer switch. Damage to vessel's erator may resutt H this

Be

extremely careful when working on electrical components. High voltage can cause injury or death.

• Exhaust Gases Ensure that the exhaust system is adequate to expel

gases discharged from the engine. system regularly for leaks and make sure the haust manifolds ing exists.

Be

sure the unit and its surroundings

tilated.

Are

are

dry, not damp (particular-

AC

is

not done.

Toxic

Check exhaust

securely attached and no warp-

are

well-ven-

AC

gen-

ex-

• Ayoid

MOYing

Do

not service the unit while the unit is running; situation arises to make operating adjustments, use extreme care to avoid moving parts and hot exhaust system ponents.

Do

not wear loose clothing or jewelry when servicing equipment; avoid wearing loose jackets, shirts or sleeves, rings, necklaces, or bracelets that might caught in moving parts.

Make sure

tightened. Keep protective shields and guards in their respective place

Do

not check fluid levels or the drive-belt's tension

while the unit Do

not work on the equipment when mentally or

physically incapacitated by fatigue.

parts

in

which it is absolutely necessary

all attaching hardware is properly

at

all

times.

is

operating.

if

com-

be

a

15.0KWBTDA

1

Westerbeke Generators

FOREWORD

Thank you for selecting a Westerbeke marine product for your use.

We

at Westerbeke

are

pleased to have you as a customer.

Read this manual carefully and observe all of the safety precautions indicated. Operating procedures, periodic preventive maintenance procedures, installation checks, system descriptions and minor adjustment procedures are included so you can operate your equipment safely and properly, maintain the equipment at a high level of efficiency, and expect dependable performance and long service life in return.

Product Software Disclaimer

all

Product software of

kind; such as brochures, drawings, technical data, operator's and

workshop manuals, parts lists and parts price lists, and other information, instructions and

specifications provided from and; accordingly,

is

Sources

provided

Westerbeke cannot be responsible

or

representations with respect thereto, Including the accuracy, timeliness

In

thereof, and will

connection with,

no event be liable for any type of damages

or

arising out of, the furnishing or use

other than Westerbeke,

to

Westerbeke customers only as a courtesy and service.

for

the

content

of

is

not wtthin Westerbeke's control

such software, makes no warranties

or

completeness

or

Injury Incurred

of

such software.

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

as

by others (such

engine blocks, fuel systems and components, transmissions, electrical components, pumps and other products) are generally supported by their manufacturers with their own software, and Westerbeke must depend on such software for the design of Westerbeke's own product software.

by

changes made

Westerbeke's suppliers, of which Westerbeke rarely has notice in advance,

Such software may

be

outdated and no longer accurate. Routine

are frequently not reflected in the supplier's software until after such changes take place.

In

Westerbeke customers should also keep in mind the time span between printings of Westerbeke

product software and the unavoidable existence of earlier, non-current, Westerbeke software editions in the field. Additionally, most Westerbeke products include customer-requested special

features that frequently do not include complete documentation.

In

summation, product software provided with Westerbeke products, whether from Westerbeke or other suppliers, must not and cannot be relied upon exclusively as the definitive authority on the respective product.

It not only makes good sense but

representatives of Westerbeke or the supplier and currency of the product software being

Westerbeke Generators 2

is

imperative that appropriate

in

question be consulted to determine the accuracy

consulted by the customer.

15.0KWBTDA

Warranty Procedures

Should your unit require special attention, contact your Westerbeke dealer for assistance. The Westerbeke Service Organization

is

trained to provide the support necessary to ensure long-term

dependable performance.

If,

within

received a Customer Identification Card (figure

60

days of submitting the Warranty Registration Form for your unit, you have not

1.2)

registering your warranty, please contact

the factory in writing with model information, including the unit's serial number and commission

date.

tno:

IEST£RBEKE

AVOM nON,

Mall

CORPORHIOII

INDU$TlUAL

IIA

02122

To:

PARk

CUSTOMER IDENTIFICATION

.~

loIaph

Str

..

U 12234

III

'lbA

1nll9

t

Alolu. 140

.... 1 IS

hpi

....

Unit

1.0.

Plate

For

future repair or warranty erence,

service,

ref-

Westerbeke suggests that you fill the blank spaces in figure

1.3

with the infor-

mation

from

your

machine.

figure 1.2: Customer Indentification

in

•

figure 1.3: Unit I.D. Plate

Card

15.0KW BTDA

3

Westerbeke Generators

Table

Of

Contents

Section

SAFTEY PRECAUTIONS

FOREWORD PRODUCT SOFlWARE DISCLAIMER WARRANTY PROCEDURES

GENERAL INFORMATION

PROTECTING YOUR INVESTMENT

15.0

BTDA GENERAL SPECIFICATIONS

15.0

BTDA SYSTEM SPECIFICATIONS

INSTALLATION CHECKS

EXHAUST SYSTEM

RAW WATER INTAKE SYSTEM

COOLING SYSTEM

-

14

Page

1

2

3

11

12

13

• 16

18

23

27 28

ENGINE CONTROL

REMOTE

REMOTE PANEL

WIRING DIAGRAM # 36474

PREPARATIONS FOR STARTING

STARTING

STOPPING PROCEDURE

FUEL

LUBRICATION SYSTEM

DC CONTROL CIRCUIT WIRING DIAGRAM #36411

COOLING SYSTEM (FRESH WATER/RAW WATER)

BT

OPTIONAL VOLTAGE REGULATOR

OPERATION

PROCEDURE

SYSTEM

GENERATOR

PANEL

29

30

31

34

35

38

40

45

47

51

56

62

Weslerbeke Generators

4

15.0KW BTDA

Table

Of

Contents

(continued)

Section SHORE POWER CONNECTIONS 3 PHASE BT GENERATOR 3

PHASE VOLTAGE REGULATOR

ENGINE TROUBLESHOOTING

GENERATOR TROUBLESHOOTING

PERIODIC MAINTENANCE

TABLE

TIGHTENING TORQUES LAY-UP SPARE PARTS

OF

STANDARD HARDWARE

AND RECOMMISSIONING/WINTERIZING

-

AND ADJUSTMENTS

Page

64

68

69

74

77

78

64

86

90

1S.0KW BTDA

S

Westerbeke Generators

RIGHT SIDE OF GENERATOR

AC

Water Exhaust

Injected

Elbow

Exhaust

Manifold

Fresh

Water

Fill

Cap

Lube

Oil

Fill

Cap

Water

\

Temperature

Sender

DC

Charging

Alternator

Belt

Guard

Westerbeke Generators

6

15.0KW

BTDA

LEFT SIDE

OF

GENERATOR

Water

Fuel

Raw

Fuel Pressure Gauge

Temperature

Switch

Filter

Water

Pu

Oil

Pressure

___

~.

Sender

Lube

Oil

.------~

Oil Pressure Switch

Dipstick

..

---

Lube

Preheat

Oil

Solenoid

Filter

Starter

Control Panel

Generator

C

Battery

Ground

with

Solenoid

Switch

Data

Plate

Connection

15.0KW BTDA

7

Westerbeke Generators

(This

page intentionally left blank)

15.1

Westerbeke Generators

8

15.0KW

BTDA

(This page intentionally left blank)

15.0KW

BTDA

9

Westerbeke Generators

(This page intentionally left blank)

Westerbeke Generators

10

15.0KW

BTDA

15.0KW BTDA MARINE DIESEL GENERATOR SET GENERAL INFORMATION

Introduction

This manual contains equipment operating procedures and information to help the operator maintain the marine equipment carefully. A planned maintenance program

will

resuH

in

better equipment performance and longer equipment

problem

is

the most important step to satisfactory repair; therefore, a troubleshooting table

in

proper working order. Study and follow the instructions

is

included in this manual. Adhering to the program

me.

Proper diagnosis of a

is

included.

Service And Parts Manuals

For in-depth maintenance and repair, the service manual for the

15.0KW

BTDA

can be purchased

from your local dealer.

Product Description

The diesel engine closely resembles the gasoline engine since the mechanism is essentially

the same. The cylinders

are

arranged above a closed crankcase; the crankshaft

is

of the same general type as that of a gasoline engine; and the diesel engine has the same type of valves, camshaft, pistons, connecting rods, and lubricating system.

Therefore, to a great extent, a diesel engine requires the same preventive maintenance

gasoline engine. The most important factors

are

proper ventilation and proper maintenance of

as

the fuel, lubricating and cooling systems. Replacement of fuel and lubricating filter elements at

is

the time periods specified

manatory, and frequent checking for contamination (that

sediment, or algae) in the fuel system

is

also essential. Another important factor

is,

is

the use

water,

of the same brand of high detergent diesel lubricating oil designed specifically for diesel engines. Be

careful not to put gasoline in the diesel fuel tank(s). Gasoline does not have the same

lubricating qualities

as

diesel fuel; consequently, gasoline in the fuel lines will damage components

in the fuel injection pump and fuel injectors.

The diesel engine differs from the gasoline engine; however, in that the functions of the

carburetor and ignition system

are

performed by the fuel injection pump and the fuel injectors. Ignition results from a higher compression ratio which eliminates the need for spark plugs, but neccitates the use of a heavier block.

a

15.0KW BTDA

11

Westerbeke Generators

Protecting Your Investment

The five most important steps to insure

1.

Proper Installation.

In

particular, the use of

intrusion into the engine via the exhaust

2.

Avoid overcranking. This

3.

Change the lubricating

4.

Maintain the cooling system.

5.

Winterizing your Westerbeke product.

can

fill the engine with

oil.

long engine

elbow

Ine

are:

an

anti siphon break to preclude is

essential.

raw

water.

raw

water

Ordering Parts

Whenever you require (I.e.

15.0

~

BTDA)

the data

plates located on the exhaust manifold and on the generator end.

us with this information so

replacement parts, always provide the generator model number designation

, engine serial number, and generator serial number as they appear on

You

~

provide

we

may

properly identify your generator set.

In

addition, include a complete part description and part number for each part needed (see the separately furnished Parts List). or generic parts

Also,

be

sure to insist upon Westerbeke factory packaged parts because "will fit"

are

frequently not made to the same specifications as original equipment.

Note that component is

the pulley/drive are determined by the engine; imagine as the front of the engine: the

Westerbeke generator sets

locations in the manual are referenced from the front of the engine which

bett

end.

(The

flywheel/generator end

is

the rear end.) Left and right sides

straddling the engine and facing in the same direction

left side

are

thoroughly checked and given a final run under various load

is

at your

left,

the right side at your right.

conditions before leaving the factory. Test running the generator ensures dependable operation,

long service

Care at the factory during

life,

and a satisfied owner.

assembly and thorough testing has resulted in a Westerbeke diesel

engine-driven generator capable of many thousands of hours of dependable service. However,

the manufacturer cannot

in

which the unit

is

operated and serviced

control the installation of the generator in the vessel or the manner

in

the field. That part

is

up to the buyer/owner-operator.

Westerbeke Generators

12

15.0KW BTDA

15.0 KW BTDA General Specifications

Engine Type

Governor Combustion Chamber Bore

& Stroke

Piston Displacement Firing

Order Direction of Rotation

Maximum Torque

(at Compression Ratio

Compression Pressure

lim~

Valve

Timing

1800

rpm)

Diesel,

four·cycle, four-cylinder, fresh water-cooled, vertical in-line overhead valve mechanism (30

hp

at

1800 rpm maximum). Mechanical type (integral of the injection pump) Swirl type

3.50 x 3.50 inches (88.9 x

134.8 cubic inches (2.209

89

mm)

I~ers)

1-3-4-2 Clockwise, when viewed from the front

148

Ib-It

(20.46 kg-m)

21:1

2

47'

)

at 200 rpm

2

)

BTDC ABDC

427 psi 384

(30

kg/cm

psi (27.0 kg/cm

Intake Opens 17" Intake Closes

Valve

Seat Angle

Valve

Clearance

(engine cold)

Engine

Speed

Dimensions

Weight

Fuel

Consumption

Inclination

Exhaust Exhaust Closes

Intake Exhaust

Intake 0.012 inches Exhaust 0.012 inches (0.3

1800 rpm 1500 rpm

Opens 51'

45'

30'

60

Hertz

50

Hertz

13'

BBDC

ATDC

(0.3

mm)

Height: 25.74 inches (653.8 Width: 21.19 inches (538.2

mm)

Length: 39.63 inches (1006.6 765

Ibs

(347

kgs)

1.8

gph (6.81Iph) at full rated output

(approximate)

15'

Continuous

Temporary 20'

(not to exceed 20 min.)

mm)

15.0KW

BTDA

13 Westerbeke Generators

15.0 KW

BTDA

Fuel System

General

Fuel

Injection Pump

Fuel Injection Timing

System Specifications

Open flow,

No.

2 diesel oil (cetane rating of 45 or higher)

Distributor Type

0"

TDC

sen

priming·

(VE)

Diesel

(Top Dead Center)

one bleed point

KiKi

Nozzle

Fuel

Filter PN#024363

cleaner

Air

Air Flow (engine combustion)

Cooling System

General

Operating Temperature

Fresh Water Pump

Raw

Water Pump

Raw

Water

Flow,

at

1800 rpm (measured before discharging into exhaust

System Capacity

elbow)

(fresh water)

Throttle

type

Spin-on (Replaceable)

screen type - cleanable

Metal

cfm

(1.9

70.0

cmm)

Fresh water-cooled block, thermostatically-controlled

wtth heat exchanger.

170 - 190" F (77 - 88'

C)

Centrifugal type, metal impeller, bett-driven

Positive displacement, rubber impeller, gear-driven.

6.0 gpm (22.7

10.0 qts

Ipm)

(Itters)

Lubrication

General

Oil

Filter PN# 035828

Sump Capacity (not including filter)

Operating

Oil

Grade

Westerbeke Generators

System

Oil

Pressure (engine hot)

Pressure fed system

Full

flow,

paper element, spin-on type

5.3

U.S.

qts

(5.0

50 -65

API

psi

service

(3.5

CC -CD

14

Itters)

plus filter/cooler assembly

- 4.57 kg/cm

2

)

15.0KWBTDA

15.0

KW

BTDA System Specifications (continued)

Electrical System

Starting Battery

Battery Capacity

DC

Charging Alternator

12·Vott,

125

51

(-)

negative ground

ampere·Hours

Amp rated, belt·driven

Starter

Starting Aid

DC

No·Load Current

DC

Cranking Current

AC

Generator

General

12·Volt,

reduction

Glow plugs, sheathed type

± 2 % of rated Amps

280

Amps (engine cold)

Brushless, four·pole, revolving field. Pre·lubricated, single·bearing

design. Reconnectable, single·phase transformer regulation (optional solid·state voltage regulation).

Voltage120 220 Votts •

or 120/240 Volts •

50

Hertz.

60

Hertz

Voltage regulation: ±5% no load to full load.

Frequency regulation:

±3

Hertz

(5%)

no load

to full load.

Rating (Volts

AC)

15.0KW BTDA

60

Hertz (1800

50

Hertz

Generator Cooling (60

Hertz) at 1800 rpm

(1500

rpm)

Air

Requirements

NOTE: Increase air supply

Engine Combustion Air Requirements (60

Hertz),

at

1800

rpm

120 Volts125 Amps 120/240 Volts125/62.5 Amps

220 Volts60 Amps

225

• 250 cfm (6.37 • 7.08

15%

for

50

Hertz operation (1500 rpm).

70

cfm

(1.89

cmm)

15

cmm)

Westerbeke Generators

15.0

KW

BTDA System Specifications (continued)

Tune-up Specifications

Injector Pressure

Engine Timing

Governor

Generator Compartment

Ambient Temperature

NOTE: generator compartment ambient temperature below 104°

Forced ventilation should be provided

1920 +

Static timed - drop valve method

0.180 ± .005 inches

0°

1 mm of cam lift using measuring device for

injection pump.

Hydraulic mechanical type in the injection pump

104° F (40"

T.O.C.

71

- 0 psi

or

#1 cylinder.

C)

Maximum

as

(135

+ 5 - 0 kg/cm2)

BTDC

needed to maintain

F.

Westerbeke Generators

16

15.0KW BTDA

General

the boats on which Westerbeke generators are installed vary in design, installation

Since procedures will vary according to your boat's specific design. The intent of this section

not to advise boatyards or installers

However, the owner/operator must

on

procedures already well-developed and well-understood.

realize there are details of the installation which require

is

periodic checks to ensure the best operating conditions for the equipment and safe operating

conditions for the in

the vessel

personnel

are

of prime importance.

Factors in the installation that must

on

board. Proper location and installation of the diesel generator

be

considered

are:

(1)

ventilation; to aid in cooling the

generator end, to provide air for engine combustion and to remove heat produced by the

(2)

the

AC

e)(haust

expel exhausl

and

engine while operating, and to quiet the exhaust and to electrical connections; both supply of properly filtered fuel to the fuel pump

system; to properly discharge

gas,

(3)

the cooling water supply,

DC,

and

(5)

a fuel system that will provide

on

the engine.

~AOTIONI

raw

cooling water

an

unrestricted

(4)

the

Fill The Engine With

For safety reasons, the generator's engine oil

for shipment. Before leaving the factory, however, each generator

is

thoroughly tested

set things, provides

all

WITh

oil in

internal parts with a coating of

011

Before Starting

is

not filled with lubricating

ITS

engine. This testing, among other

oil.

This oil acts

as

a preservative, providing reliable protection against corrosion for at least

one year ~ the generator

is

properly stored.

Do

not overfill.

Inspection of Equipment

is

The generator equipment

shipped from the factory securely mounted and properly crated. Accessory

is

shipped

in

a separate small

box,

usually packed wtthin the generator's crate.

Before accepting shipment of the generator set from the transportation company, the crate

should

you

delivery receipt. sure that the proper notation are your protection against

be

opened and the contents inspected for concealed damage.

If

damage

is

noted,

should require the delivery agent sign "Received in damaged condition" on the proper

Also,

check the contents of the shipment against the packing list and make

is

made ~ any discrepancies exist. These noted discrepancies

loss

or

damage. Claims concerning loss or damage must

be

made to the carrier, not to Westerbeke Corporation.

15.0KW BTDA

17

Westerbeke Generators

Generator Mounting - Location

complete generator

The

un~

is

mounted on lightweight rails by means of four flexible isolatro

mouints that help prevent the transfer of vibration from the generator to the

generator mounting

several 1/2 inch boh holes so bohs can

be

employed to properly

rail

ahs

secure the generator to its mounting platform.

rails.

Eachj

figure 3.3:

The mounting location water and water from above cannot splash or drip engine and generator repairs to provide fresh

~nerator

Mounting

/llJ.lS1

be

/llJ.lS1

be

dry, above low-lying vapor

accessible for minor servicing and repairs. Access for major

should be given consideration

cooling air for the generator end, for engine combustion needs, and to remove

as

on

the generator or drive engine.

well.

The generator set

areas,

and

/llJ.lS1

in

heat produced by the engine while operating. The generator set needs fresh location

generator

be strong enough to support the generator during

in

the vessel ~ is

area.

The platform on which the generator and its mounting rails are located

installed. Hot generator discharge air

all

angles of vessel operation.

/llJ.lS1

1/2-

MOUNTING

HOLES

an

area where bilge

The

drive

be properly ventilated

cool air

be removed from the

in

whatever

/llJ.lS1

15.0KW BTDA

18

Westerbeke Generators

Generator Mounting - Rigging and Lifting

The generator

is

fitted with lifting eyes. Rope or chain slings capable of supporting the generator's weight should be attached to the eyes and the generator lifted by means of tackle attached to these slings. The lifting eyes have been designed to carry the full weight of the generator; therefore, auxiliary slings are not required or desired.

ICAUTION!

Sling Lifting Angle Must Not Exceed 10 Degrees Slings must not be so short as to place signfficant stress eyes.

Strain placed on the generator's lifting eyes by the lifting sling must not be in

excess

of

10

degrees from !he vertical plain.

10'

SLING LIFTING

ANGlE EXCEED

MUST

10'

LIFTING

NOT

on

the generator's lifting

EYE

ENGIME

figure 3.4: Lifting Angle

The general rule in moving generators

and firmly fixed in place. Move the engine a little at a time and see that

ported. Eliminate the possibility of accidents by avoiding haste.

tts

by

crankshaft pulley.

In

certain sttuations

tions other than the horizontal posttion. Certain sttuations exist

is

to see that all equipment used

Do

tt

may

be necessary to lift the engine in posi-

by

is

amply strong

tt

is

firmly sup-

not lift the generator

which the engine must be lowered endwise through a small hatchway which cannot be made larger. Under these conditions,

ff

the opening of the hatchway

is

extremely small,

tt

is

possible to reduce, to some extent, the outside dimensions of the generator by removing external components such

as

the cooling system's piping, the heat exchanger, certain filters, the mounting rails

and other obstructive equipment. This accessory equipment should be removed by a

competent mechanic and special care should be taken to avoid damage to any exposed parts. In

addition, be careful to prevent dirt from entering any opening created by the removal of equipment. Removed parts should be returned to their respective position once the ator

is

in

tts

In

case

installation

tt

becomes necessary to hoist the generator front -end upwards or generator-end upwards,

area.

Replace gaskets

as

needed for the parts that were removed.

gener-

the attachment of lifting slings must be done carefully to avoid the possibility of damaging the

parts

on

which the weight of the slings may bear. Special rigging work

is

best done by someone

experienced and competent in handling heavy machinery.

Westerbeke Generators

19

15.0KWBTDA

Ventilation

is

The ventilation requirements of the generator sets include the following: combustion air quired for the engine cylinder; cooling air

is

required for the generator end and also for

re-

removing the head produced by the generator's engine during operation; and ventilating air

is

required

the generator

Keep

to

clear the bilges below the generator, as well

is

located, of potentially toxic and flammable diesel vapors.

in

mind that hot air rises, so heated air should be removed from the upper area of the

as

the compartment in which

generator compartment and cool fresh air should be directed to the lower areas of the compartment. Ventilation should be accomplished with the aid of blowers especially when the

is

vessel

not underway. Refer to the

the airflow requirements of the

System

Fuel

ge,!1erator

"SYSTEM

set.

SPECIFICATIONS" section of this manual for

The generator

aJ.lW.

have

~s

own fuel supply line; in other words,

~

aJ.lW.

have

~s

own fuel tank pickup tube and primary filter/water separator. Do not tee off another engine's fuel supply. The fuel system should

installed

in

such a manner

as

to

allow the engine-

be

mounted fuel pump to pump and maintain a positive inlet pressure to the injection pump

all

under

operating conditions,1 1/2 - 2 p.s.i.. The minimum size of the fuel supply line and fuel return line is 1/4 inch, inside diameter, and there should be a primary fuel filter/ water separator installed between the fuel tank and the fuel pump.

on

stalled

the engine, between the fuel pump and the injection pump; this filter has a

Only one fuel filter

is

replaceable filter element.

The fuel tank's fuel pickup tube should

be

strainers should

incorporated in the fuel pickup tube.

clear and unobstructed.

No

screens or gauze

be

Make sure that the fuel supply and return lines are secruely anchored to prevent chafing

all

and that system has a positive shut-off valve; know

fittings are sufficiently tightened to prevent leaking. Also, make sure your fuel

ns

locaton and how ~ operates.

NOTE: in

Do

not use spring-loaded check valves

lieu

of mechanical shut-off valves. This type valve can create fuel

in

the fuel supply line

starvation problems for the engine's fuel system.

Fuel

tanks that

connection at the tank extending down into the tank

are

located below the engine's fuel system level must have their fuel return

in

the same manner as the pickup tube;

otherwise, air will replace fuel Siphoning out of the engine's fuel system through the return.

in-

Make sure the fuel tank filler awash. The fuel tank's vent should be routed so

Be

sure there

Be

familiar with its use.

applications

Westerbeke Generators

is

properly sealed to prevent water entry should it become

as

to prevent water enter

is

a fire extinguisher installed near the unit and that it

An

in

this environment.

extinguisher

w~h

the

NFPA

rating of

20

ABC

as

well.

is

properly maintained.

is

appropriate for

15.0KW BTDA

all

011

Drain Hose

An

oil sump drain hose is installed on the engine wtth the discharge end secured by a

bracket at the front of the engine.

cap and the discharge end of the hose from the support bracket and lowering the hose into a container. The hose cap

tended. or have a pup added, for easier removal of the old

Oil

fttting

may

is

1/4 inch

be

drained from this hose by removing the

NPT

(National Pipe Tap) and can

oil,

if desired.

be

ex-

Connecting Pressure Sensing Devices

Oil

pressure sensing devices, such engine's oil gallery wtth the use of extended nipples or tees. The reason continued engine vibration

If

these fittings fail during engine operation, lubricating oil will be lost and internal engine

damage will

When additional sensing devices such function on engine the oil gallery using an appropriated grade of lubricating oil hose. Any fittings used to con-

nect the hose to the gallery

be

not

Electrical System

The electrical system should

down with clamps or plastic ties and that enough to prevent chafing from vibration. are tight and that they are made to the appropriate terminals.

DC

Electrical Connections

resutt.

oil pressure, these devices

used for this application.

causes fatigue of the ftttings used to

mug

be

checked to make sure all wiring harnesses are properly tied

to

011

Gallerlos

as

senders and swttches, must not be connected to

is

simply that

make

such a connection.

as

swttched or sensors need to

mug

be bulkhead-mounted and connected to

be of steel or malleable iron composttion. Brass must

all

wiring harnesses

Check to make sure

are

all

be

installed that

spaced at intervals close

engine harness connections

an

A common ground for the negative of the generator, next to the starter, tery ground should be connected

Connect the battery's positive tion.

15.0KWBTDA

(+) connection to the starter solenoid tagged for this connec·

To

avoid

an

overcharging condition, and a possible equipment failure

do not disconnect the

(-)

DC

terminal connection

in

the form of a threaded grounding stud.

at

this stud.

is

found at the bellhousing

fAOTIONI

DC

battery source while the engine

21

The

bat-

is

running.

Westerbeke Generators

Generator

Make sure that the

correct and in acordance with the specific

this

leads

(AC

Output)

AC

output connections within the generator's

AC

Load Connections diagram found later in

manual.

are

(See

the "BT

protected against chafing as they exit the generator housing

GENERATOR"

section of this manual.) Make sure the

AC

terminal block

IWARNiNGI

Do not smoke or allow an open flame near batteries. Lead acid batteries emit hydrogen, a

Batteries

highly-explosive

gas.

are

AC

Make sure the positive the starting solenoid. The negative ground stud tagged at the rear of the engine

(+) battery connection

(-)

is

connected to the battery connection of

battery connection should be connected to the

block.

!WARNiNGJ

Protect Yourself When Servicing The Battery When servicing the battery of checking the rubber apron, and eye protection. Battery acid may eyes inadvertently when removing the

Check the battery's electrolyte level and specific gravity to ensure maximum engine starting efficiency. Make sure the battery's terminals

electorlyte

electrolyte caps.

level,

wear rubber gloves, a

splash on the skin or into the

are

clean and tight.

Westerbeke Generators

22

15.0KW BTDA

Exhaust System

Carbon monoxide is a dangerous and monoxide inhalation or poisoning

• Dizziness • Vomiting

• Intense Headache • Muscular Twitching

• Weakness and Sleepiness • Throbbing

Carbon monoxide gas Is deadlyl

is

potentially lethal. Some

tNAANiNGI

gas

that can cause unconsciousness

of

the symptoms or signs of carbon

are

listed below.

in

Temples

The generator should have its own separate exhaust installed so that the entry of

into the engine's exhaust or while the vessel is under sail or power rolling or pitching. Special atlention secure, tight and free

The

raw

water supply through-hull sea cock fittings scoop types or weed less scoop types must not of

raw

water through the cooling system filling

When a water lift type exhaust system is used (figure

mounted downward into the exhaust muffler. Loops exhaust elbow and the water lift muffler should

as close to the engine as practical.

manHold

of

leaks.

and cylinders is prevented while the engine is

in

~

which case the vessel

be

taken to

be

the

make

~

be

of

used,

as they tend to encourage siphoning

exhaust.

may

experience heeling,

certain the exhaust system is

the flush-hull type. High-speed

3.13.4), the exhaust muffler should be

The

exhaust discharge should always drop

in

the exhaust hose between the water-injected

be

avoided,

as

these

will

trap and hold water.

raw

nOl

water

running,

figure 3.13.4: Water Lift Exhaust System

Westerbeke Generators

23

15.0KWBTDA

u.n.",

II"

...

UUI_

IU'"

"I('

UI(

figure 3.13.5: Siphon Break

For installations where the exhaust manHold/water-injected exhaust elbow below the vessel's water line, provisions

ID~tallatioD

~

be

is

close

to

or

made to install a siphon-break or a vent in the raw water supply hose to the water-injected exhaust elbow. (figure 3.13.5) This stops the

flow of

exhaust and

~

be looped above the water line. This siphon-break or vent

the water line during

used,

~

empty of water when the engine to

prevent siphoning.

Dry

stack-type exhaust systems (figure 3.13.6)

exhaust

manHold supported and must be made for discharging the engine's

raw

water that runs through the

engine cylinders when the engine

raw

water cooling system from filling the

is

shut down. This

raw

water supply hose

~

always be above

all angles of vessel operation to prevent siphoning. The vent, when

have its vent hose or tube routed so it can remain above the water line and

is

shut down. This allows air to enter through this vent

must

be attached to the generator engine's

by means of a flexible connector pipe. This system

~

be properly

insulated to prevent water from entering into the engine's cylinders. Provisions

raw

cooling water .

..........

c.

c

....

c.

~

i I

15.0KWBTDA

"Z.C.

....

~~3

-

figure 3.13.6: Dry Stack Exhaust

c_

••••

,

pc.

LJ.C

•••

~E

..

•••

•

c.

_ ..

e.

J

.....

c ,.

....

ue

..

........

"Jrra

.. e

_

f'

.........

•• • S.C

a.c.

""""=="===~~~~~~~!:.=c.

24

~oc..7;;J--

........

_

)

..

e •

•••

Westerbeke Generators

Exhaust Elbow Installation

The Westerbeke Corporation offers a 7Z' exhaust elbow

can install on your engine's exhaust

the exhaust

elbow purchased for your generator.

manHold.

Refer to the instruction below when installing

NOTE: Fabricated exhaust elbows or risers attached to the exhaust manHold

1.

Coat only one side

shall not exceed 8 Ibs when unsupported.

of

the exhaust gasket with "High Tack" (Manufactured by Permatex Company, Brooklyn,

N.Y.) adhesive sealant. Place this coated surface against the exhaust manHold's

ex-

haust port flange (the gasket should

stick to the flange without falling off).

2. Place the clamp over the elbow's

flange. against the exhaust manHold's flange

Place your exhaust elbow

so the exhaust manHold's flange rests snug against the exhaust elbow's flange with the gasket centered between the two. Now

slip the exhaust clamp over

both flanges.

as

well

as

an

exhaust riser you

#38374

Elbow

3.14:

3.

A Tighten the clamp just enough

figure

so the exhaust elbow can remain attached to the

B.

The exhaust elbow discharge

~

be

directed downward

Exhaust Elbow Installation

manHold

and still be rotated.

so

the mixture of water and exhaust gases will flow/fall downward into the exhaust muffler which must be positioned hose connected between the exhaust and possibly allow water to flow back into the engine during starting or

4. Adjust the is

acquired.

5. Carefully tighten the clamp between 2 to 3

below the exhaust elbow. There should be no loops or rises in the exhaust

elbow by rotating

elbow and the muffler,

it

until the desired alignment with the exhaust piping

Ib-It,

or 24 to 35 Ib-in, or 0.27 to

as

these would trap water

at

shut down.

0.41 kg-m.

r.:;AOTIONj

3 Lb·Ft Torque Umlt

Approach the 3 Ib-It torque limit with caution. The clamp's threads will

H more than 3 Ib-It

break

If

a leak exists, correct it immediately .

is

applied to the clamp.

raw

. Westerbeke Generators

25

15.0KW BTDA

Exhaust Back-Pressure

The exhaust discharge hose and minimal run to prevent excessive exhaust pressure. Exhaust back-pressure should before a generator Excessive back-pressure will affect the engine's formance which affects generator

To measure manometer, a pressure gauge, or a water column. boatyard or marine mechanic should have a manometer or a pressure gauge. have a tapped hole in be

drilled and tapped for a 1/8 inch

dry area of the elbow.

Measure the engine's back-pressure at the exhaust elbow while the generator

Refer

to the pressure specifications listed below. \

A water column can be made

tube and taping one end of the tube along a yardstick and fitting the other end of the tube a 1/8 inch

NPT

is

for

back-pressure, use a mercury

(National

must be of adequate size

back-

be

checked

put into service (figure 3.15.1)

per-

AC

power output.

A

If the generator set does not

~s

exhaust elbow, one

NPT

f~ing

is

under a full-load.

by

taking a clear plastic figure 3.15.1: Exhaust Elbow Connections

Pipe

Tap) pipe fitting.

II!!.&:

in

the

w~h

..

"

H Exhaust

,n

..

~

~I

-Insulation

Exhaust

Elbow

Mercury

Manometer

Measure the engine's back-pressure in the dry area of the exhaust elbow while the generator

under a full-load.

NOTE: Dimension A (figure 3.15.5) cannot exceed 27 inches of water.

Back

pressure,

ment, should not exceed the following specifica-

tions:

2 inches of mercury 27 inches of water in a water column

15.6 ounces psi

1.0

1.11

psi

kg/cm

as

measured by a gauge instru-

2

"--.

is

1/8

NPT Plug

\

15.0KW BTDA

26

Westerbeke Generators

Exhaust System Failures

an

When the engine's raw water is fed into

exhaust system so that the full stream of this water strikes a surface, errosion takes place. This errosion may cause premature failures. The proper design of either a water jacketed or water injected

raw

requires that the not directly strike a surface.

be

as

low

as

possible, which can be achieved

water inlet be posttioned so that the entering stream of

In

addition, the veloctty of the entering

"wet" exhaust system to prevent this problem

raw

water does

raw

water stream should

by

having inlet fittings as big in diameter

as

possible.

is

The best protection against carbon monoxide poisoning

a daily inspection of the complete exhaust system. Check for leaks -around manifolds, gaskets, and welds. Make sure exhaust lines are not heating surrounding areas excessively.

If

situation immediately.

you notice a change

shut down the unit immediately and

in

the sound or appearance of the exhaust system,

have

the system inspected and repaired at once

excessive heat

is

present, correct the

by

If

qualified mechanic.

Make sure there are no unnecessary objects suspended from any portion of the exhaust lines. Exhaust risers installed off the exhaust manifold should not exceed 8

Ibs in total weight when rigidly constructed. Excessive weight could cause deflection or distortion of the manifold resulting in

damage and/or internal leaks. Inspect insulated portions of the exhaust system to ensure

there

is

no deterioration of the insulation.

a

ICAUtloN)

Do Not Overcrankl

resu~

Prolonged cranking intervals without the engine starting can

raw

filling the exhaust system with

raw

because the

water pump

water cooling system during cranking. This

engine's cylinders by

way

of the exhaust

system fills. Prevent this from happening by closing the

water coolant. This may happen

is

pumping

raw

water through the

raw

water can enter the

manHold

once the exhaust

raw

water supply

through-hull shut-off, drain the exhaust muffler, and correct the cause for the excessive engine cranking needed to obtain a start. Engine

raw

water entry

this in mind.

Raw Water

damage resulting from this type of

The owner/operator should

keep

Intake System

Make sure the intake system (raw water cooling system)

are

the hull inlet, sea cock and strainer

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 for cleaning while the vessel

be mounted below the water line to ensure

unobstructed. Sea cocks and strainers should be

self-priming. Inspect the

is

IlQ1

a warranted.

is

in

proper order. Check that

is

at

raw

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

The

there are no air leaks at any of the connections.

as

tioned at the vessel water line or below so

to

sea water strainer should

be

self primed.

in

raw

sea and should

water lines to

be

posi-

Westerbeke Generators

27

15.0KWBTDA

Cooling System

The

generator's engine water is used by

a raw water pump and is then injected into the exhaust discharge, carrying

as

the heat exchange's cooling

removed from the engine's fresh water Raw

water should be supplied to the

using a wire-reinforced hose between the through-hull fitting and the

raw

water should be directed through a visual-type raw water strainer and then delivered to

the pump. Hoses routed from the through-hull

pump should be wire-reinforced to prevent the hose from operation (suction from the pump should be mounted

is

fresh water-cooled

cooling

raw

may

collapse a non-reinforced hose).

at

or below the water line to

by

an

engine-mounted heat exchanger.

medium.

Raw

water is pumped into the exchanger

wtth

system.

water pump through a flush-type through-hull fttting

raw

water pump. This

fitting to the strainer and to the raw water

collapsing during the generator's

Raw

water strainers

make

sure the raw water line remains primed

alter shutdown.

!(?AOTlO~

Do

Not Use A Scoop-type Through·hull Fitting

Do not use a scoop-type through-hull fitting raw water to the generator. Water pressure against this type while the vessel

is

under

way,

can

push raw water past the raw water

pump's impeller into the generator's exhaust system, filling

as

well.

engine

Flush-type, and should be located during

all

angles of boat operation.

clear,

on

the hull so

through-hull fittings

as

a means

of

supplying

tt

are

recommended

as

to be below the waterline

fitting,

and the

tt

the heat

Raw

The use of common-type street elbows These generally have very restrictive inside diameters. Machined fittings

Coolant Recovery Tank, Recommended

A coolant recovery tank

kh

is supplied each Westerbeke diesel engine. of

this recovery tank is to allow for engine coolant expansion and contraction, during gine operation, whhout the loss and

wtthout introducing air into the cooling

The

of

is

not recommended for plumbing the

Installation

whh

purpose

en-

coolant

are

raw

water circutt.

preferred.

system.

be

in

wtth

installed

a loca-

a 30

UN

... , ......

This coolant recovery tank should at,

or above, engine manifold

tt

can

tion where where coolant

be easily monhored and

can

be easily added if needed

level,

(figure 3.19). A stainless steel mounting brack-

et

is

supplied

inch length

wtth

each

ktt

along

of

clear plastic hose and clamps to connect the hose between the engine's manifold

of

fitting to the hose spud

on

the base

the recovery tank. figure 3.19: Coolant Recovery Tank Installation

"

15.0KW BTDA

28

Westerbeke Generators

OPERATIONS

o

PREHEAT

o

~

START

@

~

o o

figure 4.1: Engine Mounted Instrument Panel

Engine Mounted Instrument Panel

The manually-operated series of Westerbeke generators are equipped with toggle switches and

optional remote panels. The Engine Mounted

in

which indicate water temperature

(OIL

PSI).

per square inch control circuit voltage and in 1/10 hours. The water temperature, the

ELAPSED

TIME

meter

This panel

(VOLTS)

is

degrees

and the generator's running time

not illuminated.

Instrument Panel (figure 4.1) includes two gauges

Fahrenhe~

is

also equipped with two meters which indicate

oil

pressure gauges and

(WATER

OF)

and oil pressure

(ELAPSED

DC

volt meter are illuminated;

TIME)

in

pounds

in

HOURS

DC

15KW BTDA

1.

PREHEAT: The PREHEAT fuel pump, bypasses the engine's oil pressure This switch

2.

START: The START the engine. This switch

and held at the same time.

3.

STOP: Power switch deactivates the fuel solenoid and shuts off fuel to the engine, causing the engine

to stop.

also energizes the START

is

provided to the fuel solenoid through the

NOTE: When the engine gauge and the oil pressure gauge will continue to register the last temperature and oil pressure readings indicated by the gauges before the electrical power was turned off. The temperature gauge and oil pressure gauge will return to zero once electrical power

sw~ch

switCh,

will

energizes the engine's glow plugs, activates the electric

sw~ch,

sw~ch.

when pressed, energizes the starter's solenoid which cranks

not operate electrically unless the PREHEAT switch

is

manually shut down, the water temperature

29 Westerbeke Generators

and activates the fuel run solenoid.

STOP

is

switch. Opening this

is

restored.

pressed

Remote Control Instrument Panel

The remote

on the engine-mounted Start/Stop panel (page

When starting at a remote location, the green

at approximately starting of the generator may not be audible from the remote location.

Start/Stop panel (figure 4.2) has three switches that serve the same functions

29). LED

600

rpm. This indicates when the START

0

GENERATOR

0

RELEASE

STARTER

PREHEAT

PRESS

"'"

1ST

•....

®

!.

-.::

,'.

It has a green

comes on when the generator

sw~ch

"''''-,

..

,--.

®

STOP

START

:

....

- I

®,,~'

. .

,-..,/

.

LED

can

0

2ND

as

light and no guages.

is

running

be released since the

Westerbeke Generators

0

WESTERBEKE

figure 4.2. Remote Control Instrument Panel

30

0

15KWBTDA

Instrument Panel Wiring

For

starting and stopping the generator at a remote iocation, three similar switches

The PREHEAT and START switches are connected in parallel with the engine mounted panel's

switches and serve the same functions. The STOP switch is connected in series with the local panel's STOP switch and serves the same function. The generator may be stopped and started from either engine mounted or remote positions.

are

used.

Remote

,

'

:

I I

~

__________

L

figure 4.3: Remote Control Insrument Panel Wiring Diagram

Control

r---------------------- --------------

Slop

Switch

114

Rr.d

_

________

19'10

StA

rt.

Switch

#14

P.N.

Panel

Red

21. 91. 3

(Rear

122

Rr.d

Blk

,v14

___________

_

View)

~5

"uuI'

15

~

@--',:..:'''' • ...;G:.;'.::n:.....+-i:::::::::Jc:::::t:::r-______

ii

N N

..

G

Red

Led

I

j

...

.Ul1p

",l

3 amps

.1

amps

1

"uup

UIl

55

nmp

15

amps

3

amps

__________

52

amp

15

amps

::J

amps

urgt:>

...

rlille

runnina

prt'ht'!tl.-L

9UTI:C

startln£

runnini

surce

Iiltartinl:

running

Oll

!Ottlrl

on

Red

Green

Purple

Red

st.nTt

~h!:e_

start

TBl-l

TBI-GND

TR2-2

TBl-2

TBl-4

Figure 4.3 illustrates the

control panel and a remote Start/Stop

Refer to the control circuit wiring diagram #036411 when installing the remote Start/Stop panel.

Refer

used between the engine control panel and the remote Start/Stop

coded

upon distance run and amperage flow through the wire during start.

15KWBTDA

to the

DC

wire sIzIng chart (figure

as

shown to comply with

DC

wifIng connections to

Panel.

4.4)

ABYC

standards and be sure to select the wire size dependent

31 Westerbeke Generators

on page

be

made between the engine mounted

31

when selecting the wire size to

Panel.

Use

the wire color

be

A.

::oocleTY

D.C. Wire Sizing Chari

Stranded Conductors For

UT

AUTOmOTIVe

t::nglneers I ype

Ul;

wore

::Olzlng

10% Voltage Drop

wore

l;nan

12

Volt

tI.

Circuits

NaTIOnal

t::leClTlCal

l;ooe

I ype

wore

191<291'9><27

1

j

I 86.7 140

29

2336 13702

130

43.3

17.3

16 14

,

Maximum Length Of Conductor In Feet From Power Source To

210

65 105 165 52 84 132

70 60

46.7 42 28 21

I

1

¥Vire

Size 18

tanding

116X30

ircular

Mill Area

ircuit

Current

nAMPS

1537

I

1.

i 174 260 285

2.

: 87

3.

i 58

4.

143.7

34.7

5.

6.

I

7.

i 24.7 37

8. t 21.7 32.7 52.7 82.7

9.

i 19.3 28.7

10. i 17.3 26

15.

20.

30.

I

40.

j

SO.

I

!

55.

60.

75.

90.

I

10

12

19><23

19><25

5833

9343

330

220 94.6

110

94

73.3 116 186 66

44

33 22

8 6

19><21

49><23

14810 25910

4

I

149><21

37360

i

262

I

210

. 57

175

279

ISO

240

131

210

105 j

70

52.7 83.7 35

26.3 21

300

168 271 28.3 45.3 112 180

56

42 67.3 107

33.7

30.7 49

285

135

211 22.7

90.3 142

54 85.3

77.7

45

71.3

36

57

47.3

2583 4107

16

14 12

19

6530

142

227 151

71

47.3 75.3 120

40.7 64.7

35.3 56.3

31.7

19

240

113 180

57

143

103 j

89.6

79.6

SO.3

72

30

48 36 24

10

19 19

10380

16510

285

232 190

303

163

260

143

227

127

202

114

182 289

76

121 193 306

57 38

60.7

28.3

45.3

23 36.3

8 6

262SO

Load And

91

96.3

57.7

33

52.3

38.3

4

61

37

41740

I

321

145

230 153 243 115

72

92 148 184

83.3 133

48

76.3 61 51

2 1

I

127 127

66370

Return

182

121 153

97.3 123 81

183690

306

230

167

102

The vottage drop for specific conductor lengths may

Voltage drop

When a drop

circu~,

at

the electrical device

circuit.

figure 4.4: D.C. Wire

Westerbeke Generators

be

calculated by the formula:

load in amperes

=

conductor length

=

conductor circular

=

in

mil

feet

area

=

lQZ:ixl

CM

X

L.

where:

I

L

CM

including the ground return, uses several different size conductors, the vottage

is

the

sum

of the drops calculated for each size segment of the

..

S,ZlOg

Chart

32

15KW BTDA

Description of Starting System

Westerbeke diesel engines use electric starters assisted by glow plugs for both normal and cold weather starting. The figure below shows a cross-sectional view of one

is

plug

located When the glow assists

in

This system

PREHEAT button

in

the combustion chamber so that

plug

is

energized

igniting the

is

fuel.

The

common to Westerbeke Diesels.

must

be

depressed for the time specified in the Preheat Table (figure 4.7.1).

by

resu~

~s

tip

is

in the injector nozzle's spray path.

the PREHEAT button, the plug glows

is

a rapid start with less wear

The

start circuitry

is

Then, while keeping the PREHEAT button engaged, the START button

cylinder. The glow

red

at

the tip and

on

the starter.

designed so that the

is

depressed to crank

the engine.

GLOW

PLUG

15KW BTDA

figure

4.5:

Combustion Chamber

NOTE: The START switch will not energize unless the PREHEAT button is

depressed.

the cylinder head are activated.

When

depressing the preheat switch, The glow plugs

Use

the preheat intermittently to avoid

overheating the glow plugs.

33

Westerbeke Generators

in

Preparation For Starting

stilPS

Take the

described below

shutdown or layup.

in

starting your engine for the first time or after a prolonged

Fill your engine with may have ing). oil

with

and

an

affect on the dipstick read-

Select readily available lubricating

an

API

specification of

an

SAE

number suitable for the

oil

up to or near the

CC

or

CD

upper

lim~

on the dipstick (the installation angle

temperature in your operating area. For the quantity of oil needed in your engine,

refer to the

tion of this

"System Specification: sec-

manual.

Upper Limit (Normal

Fill the fuel tank with a good grade of No.

2 diesel fuel and prime the fuel

Limit system up to the engine. When returning fuel

is

free of

is

bled and the engine

Each

un~

air,

the engine's fuel system

is

ready to start.

is

supplied with a coolant recovery

k~

(#24977)

as

standard equipment which must

be installed and the following applies:

A.

Remove the pressure cap from the engine's exhaust manifold and slowly fill the engine's cooling system with a mixture of water and antnreeze suitable for your temperature zone. Operate the engine and observe the the base of the filler neck. F),

make sure there

Once the engine reaches

is

no problem

coolant level in the

w~h

coolant flow through the manifold. Top off the

manUold.

~s

operating temperature (170 -

Maintain this level to

cooling system and install the pressure cap.

190'

B.

Make sure the plastic recovery tank

28), in a location where

be

mounted at manifold level or above. For installations that require

tank can be mounted

C.

Add coolant to the plastic coolant recovery tank once you have topped off the exhaust

manffold fold right to the filler neck top.

NOTE: This should pressurize the system and inspect for the cause. and air expelled, fill the recovery tank daily and add the

Make sure the Installation Checks "Installations and Installation Checks" section of this manual.

Westerbeke Generators

be

manifold

is

properly mounted near the unit (figure 3.19, page

~

can

be

monitored and filled easily. The recovery tank should

below the exhaust manffold's

is

a closed type cooling system and little or no coolant

lost from the system.

If

excessive coolant

level.

W~h

is

lost, artifically

the manifold filled

coolant recovery tank han full. Monitor this

coolant as needed. Periodically check that

is

full when cold.

have

been made

34 15KWBTDA

in

accordance with those specified

it,

the plastic recovery

in

the

Starting Procedure

1.

Depress and hold the preheat switch. Preheat according to the following chart:

Atmospheric Temperature

5°

41° F

+

F (+

41°

+

23° F (-5°

+

Lim~

of continuous use 30 seconds

figure 4.7.1: Preheat Table

2.

While still depressing the

runs,

engine

an

for

release the

additional 2 - 3 seconds. This allows the engine to build up enough oil pressure

(+

5°

C)

,?)

START

to close the oil pressure shutdown

NOTE: Should the engine not start when the START

10 - 12 seconds,

for the previous procedure. Never seconds

at

a time.

Preheating Time

or higher Approx. 10 sec.

to + 23° F

(-

5°

C)

Approx. 20

sec.

or lower Approx 30 sec.

before cranking.

PREHEAT

sw~ch,

depress the START switch.

switch but continue to hold the PREHEAT

release

sw~ch

both

and allow the engine to continue to

sw~ch

sw~ches

run

the starter motor for more than 30

and wait 30 seconds; repeat

is

depressed

As

soon

sw~ch

depressed

run.

as

the

Once the engine starts, allow ~ to engine's instruments are checked for proper attempt to engage the starter while the engine

15KWBTDA

3. Check

all

the instruments on the panel for proper operation and make sure

discharges with the exhaust discharge once the engine starts.

run

for a few minutes to warm up and stabilize while the

oil

pressure and battery charging voltage. Never

is

running.

NOTE: condition should smooth out the

Some unstable running

130 - 150° F (55 -

56°

may

occur

in

a cold engine, but this

as

the operating temperature moves into

C)

range.

35

raw

water

Westerbeke Generators

Proper glow plug function

vo~meter

by a

drop (figure 4.7.7) when the PREHEAT switch drop will be

vo~age

defective

slight but discernible.

drop is noted,

glow plugs or a

is

indicated

is

depressed. This

tt

may

indicate

fau~

preheat

If

circutt (check for loose connections).

no

figure 4.7.7: Voltage Drop From

I

CAUTION

Prolonged cranking can damage

I

the

englnel

Prolonged cranking intervals wtthout the engine starting can

wtth

raw

filling the engine mounted exhaust system may happen because the

raw

the

water cooling system during cranking. This

the engine's cylinders by

raw

water pump

way

of the exhaust manffold once the exhaust

system fills. Prevent this from happening by

is

pumping

closing the raw water supply

water coolant. This

raw

through-hull shut-off, drain the exhaust muffler, and correct the cause for the excessive engine cranking needed to obtain a start. Engine

raw

water entry is not a warrantable

Remote

Starting Procedure

The remote

damage resulting from this type of issue; the owner/operator

should keep this in mind.

Start/Stop panel (figure 4.2) has three switches that serve the same functions

on the engine-mounted Start/Stop panel (figure 4.1). it has a green

LED

When starting at a remote location, the green

600

rpm.

at approximately starting of the generator may not be

This indicates when the START switch

audible from the remote location.

comes on when the generator is running

Glow

Plug

resu~

in

water through

water can enter

LED

light and no gauges.

can

be released since the

as

A.

When the preheat switch illuminate. When the start light will dim. When the engine starts the START switch. Continue to hold the PREHEAT depressed for a pressure to build up and close the oil pressure safety switch that will be in the series path for

B. After the generator is started and the starter switch is released, the generator's starter will

not crank supplies voltage

Westerbeke Generators

is

depressed

swttch

12V

B + to the fuel run solenoid

is

at

the remote Start/Stop panel the

LED

light will

depressed and the starter cranks the engine this

LED

light will brighten signaling to release the

few

seconds to allow

until someone again operates the PREHEAT swttch first because this switch

10

the START swttch.

36

15KW

LED

oil

BTDA

Starting Under Normal Conditions

Follow

the procedure below for normal starting of the generator:

1.

Make sure there

is

sufficient fuel

on

board. Keep fuel tank(s)

as

full as possible. Check the fuel filters and water separators for the presence of contaminants and/or water. Drain and

clean them as needed.

2. Check the coolant

NOTE:

cooling system

a

level

in

the plastic recovery tank. Add coolant solution

Excessiv~

loss of coolant from the plastic recovery tank indicates

leak.

as

Check the entire cooling system and pressurize

needed.

the system using a common automotive radiator pressure tester to

3.

Check the

locate the be refilled

manual.

this

oil

level

leak.

In

cases of excessive coolant loss, the system must

as

outlined under the "Preparation For Starting" section of

in

the engine sump and look for fuel leaks, particularly H signs of such

leaks are found on the bottom of the engine or below the engine.

in

Start the generator

accordance with the "Starting Procedure" instructions

and allow the engine's operating temperature to reach into the 140 -

placing a load

on

it.

in

150·

F range before

this manual

Starting Under Cold Conditions

Under listed below when operating your engine

Lubricating

ratings for the prevailing atmospheric temperature. Refer of this

Voltage

minimize voltage drop across the battery terminals.

The

Enough -

whenever the temperature of the intake air

not rise enough. Refer to the preheat chart found in the "Starting Procedure" section of this manual.

15KWBTDA

extremely cold temperatures, the following conditions can occur. Follow the instructions

in

cold weather.

Oil

Turns

Viscous - Make certain that the lubricating oil used conforms with the

to

the "Lubrication System" section

manual for

Across

Temperature of

an

atmospheric/oil viscosity specification table.

the

Battery Terminal Drops - Make certain that the battery

the

Intake

Air is Low and

the

Compression Temperature does not Rise

is

fully charged to

Allow the glow plugs to operate sufficiently to aid in starting during the preheat period

is

low and when the compression temperature does

37

Westerbeke Generators

Stopping Procedure

AC

1. Remove the

electrical load from the generator and allow the generator to run for 3 to

5 minutes to stabilize its operating temperatures.

2. Depress the STOP switch (figure 4.1) and hold It until

the

generator Is completely

stopped.

3. Now

release the STOP switch.

Remote Stopping Procedure

To stop the generator, depress the STOP switch (figure 4.2) which opens the normally closed

B+

path for generator comes to a set

as

the

panel connection terminal board. (Refer to the wiring diagram in the "Electrical System"

vo~age

to the engine's run circuit. The STOP switch must be held open until the

complete stop. Remote start panels may be connected to the generator

indicated. A jumper has to be removed between the

TB

1-1

and

TB

1-2 connections at

section of this manual for remote Start/Stop panel connections.)

Automatic Shutdown

High

Exhaust

An

exhaust temperature switch indicate inadequate at

260 - 270

Temperature Shutdown Switch (normally closed)

is

located

an

excessive exhaust temperature, the switch will open and shut the generator off (an

on

the exhaust elbow. Should the switch's sensor

supply of raw water coolant causes high exhaust temperatures). This switch opens

0

F (127 -

13~

C)

and resets at approximately 225

0

F (10]0

C).

High

Water

Temperature Shutdown Switch (normally closed)

A high water temperature switch coolant's operating temperature reach approximately shut the generator

Low Oil Pressure Shutdown Switch (normally open)

A low oil pressure shutdown switch

monitors the engine's

switch will open and interrupt the run circut, shutting down the generator drive engine.

Westerbeke Generators

is

off.

This switch resets

located on the thermostat housing. Should the fresh water

0

205

at

1950 F (10]0

is

located off the engine's oil gallery. The switch's sensor

F (96

C).

0

C),

oil pressure. Should the engine's oil pressure fall to

38

the switch will open and

10

- 15 psi, the

15KWBTDA

Engine Break-In Procedure

Atthough your engine has experienced a minimum of one hour of test operations to make sure accurate assembly procedures were time is required. The service life of your engine is dependent upon how the engine

followed and that the engine operated properly, a break-in

is

operated

and serviced during its initial hours of use.

50

Your new engine requires approximately

each moving part in order to maximize the performance and service

this conditioning carefully, keeping

1.

Start the engine according to the "Starting Procedure" section.

checking that

2.

Start the generator and allow the engine to warm up untii the freshwater temperature gauge

moves into the

3.

Use

caution not to overload the generator. The presence of a gray or black exhaust with

all systen:s (raw water pump,

130" - 150" F range.

in

mind the following:

hours of initial conditioning operation to break

life

of the engine.

Run

the engine whiie

oii

pressure, battery charging)

are

functioning.

in

Perform

loss of engine rpm (hertz) are signs of a possible overload.

4.

Run

the generator

to 3/4 of its rated capacity. For the remainder of the break-in period, the generator

at

1/2 of its rated capacity for the first 10 hours then increase the load

may

be run at different load intervals.

Breaking-in a new engine

basically involves seating the piston rings to the cylinder

walls.

Excessive oil consumption and smoky operation may indicate that the rings have not properly

is

seated. Which

caused by overloading the generator or operating the generator with little

no load during the break-in period. (This can be confirmed with a compression test and

or

an

oil sample analysis.)

As

indicated above, operate the generator with a moderate load during the

(On

period.

one hand don't baby the engine, but on the other hand, don't abuse

50

hour break-in

it.)

1SKW BTDA

39

Westerbeke Generators

Fuel System

SYSTEMS

Figure

5.1

shows the 15.0

Priming

have a fuel

emergency

mounted on

anl5

filter

use.

the

KW

self

The main

engine.

BTDA's

bleel5ing!

with

bane

fuel system.

All

priming

engines

pump

source

coverec5

in

is

the

electric

by

beac5

this

casting

lift

JU.nual

for

pump

figure

5.1:

Diesel Fuel

Use

No.

2 diesel fuel

oil since these fuels do not

In

cold weather particularly, water vapor

the fuel

tank.

Westerbeke Generators

Fuel System

WITh

Keep'

fuel tank(s) full and completely free of dirt and water.

a cetane rating

have

the same lubricating properties as

of

45

or higher. Never

is

produced

by

use

kerosene or home heating

No.

2 diesel

condensation when air

fuel.

is

present

in

40 15.0KWBTDA

Fuel Fllter/Water Separators

A primary

fuel filter of the water separating type must

be installed between the fuel tank and the engine.

This

is

to remove water and other contaminants from

fuel before they can be carried to the fuel system

the on the engine.

/IN

Most

installers include with the generator installation

, .

, ,

package a type of fitter/water separator for they are

aware of the problems contaminants in the fuel

cause -

all

of which are not warrantable through

can

Westerbeke.

A typical

figure 5.3. This

fuel filter/water separator

is

the Raycor Model

in mind that ~ a water separator type filter

is

illustrated in

500MA.

Keep

is

not installed between the fuel supply tank and enginemounted fuel system, any water in the fuel will affect figure

fuel pump, engine filter, and injection equipment.

the

is

The owner/operator

is

equipment

free of impurities. This process

responsible for making certain the fuel reaching the engine's injection

is

accomplished by installing and maintaining a

5.3:

Fuel

Filter/Water Separator

proper filtration/separation system.

In

addition, any gasoline in the fuel system will damage the engine's fuel injection pump

as

assembly and injectors

gasoline does not have the same lubricating qualities as diesel

fuel.

Priming the Fuel System (One Bleed Point)

on

The in the

engine fuel system

on

engine fuel system to open for the removal of the housing for the spin on hex/slotted head screw that should area of the

fuel filter. Energizing the preheat switch for 10-20 seconds or by using the palm

is

nearly se" bleeding.

fuel fitter mounted

be

opened 1-2 turns

(See

figure

on

the engine. This bleed point

to

5.8).

There

air.

This bleed screw

remove air from the upper housing

is

one bleed point

is

located on

is

an

11

mm

of one's hand to slowly depress and release the primer pump on the top of the filter housing will force air

in

this area out through this bleed point. Once

all

air

is

expelled tighten the bleed

screw.

NOTE:

to bleed air from the

elements (glow plugs)

Do

not over tighten this screw.

fitter assembly, keep

are

being energized. Take care not to overheat

When

using the preheat function

in

mind that the preheat

them.

Once the

fuel filter assembly

is

bled of air and the bleed screw tightened again, depress the

preheat switch 10-20 seconds or slowly pump the primer on the fuel filter housing to force any

in

the system between the filter housing and the injection pump out of the system and

air back to the

fuel tank through the return.

15.0KWBTDA

41

Westerbeke Generators

Replacing

the

Fuel Filter Element

The spin-on type fuel

fitter (figure 5.8) mounted on the engine

(PN

#024343), should be changed aiter the initial 50 hours of operation and then every 200 hours of engine operation therafter. This the

fitter housing taking care to catch any diesel fuel that may spill while removing

fitter is easily removed with the

the replacement filter aiter placing some diesel fuel screw the filter

on

to the fitter housing, tightening it securely 1/2 to 3/4 turn more once the

sealing gasket contacts the housing. To bleed air from the fitter housing, see

System".

Fuel

NOTE: minor fuel system

Keep a fuel system hardware kit onboard to use in correcting

leak_s

and for maintenance needs.

aid

of

an

oil fitter wrench. Unscrew the fitter from

on

the sealing ring of the fitter. Carefully

it.

·Prlmlng

Install

The

Fuel Lift Pump

The engine mounted fuel pump filter element should be changed initially aiter the fisrt

50

hours

of engine operation and then every 200 hours or at least once a season.

Remove the fuel

base using a 17mm open end wrench. Take care in catching the filter element

pump's

Supply

(out)

V

DC

(+)

Cannection

and fuel within the pump. Install new element and sealing washer for the base. Ensure that the magnet located

in

the center of the

is

base, and then reinstall the locking base onto the ing pins

at

the base of the

secur-

pump.

Westerbeke Generators

figure 5.6: Fuel Lin Pump

I

WARNiNG

I

Fuel Leakage Is A Fire Hazard Fuel leakage at the fuel pump or its connections is a fire hazard and should be corrected. Make sure proper ventilation exists whenever servicing fuel system components.

42

15.0KWBTDA

Fuel Injection Pump

The fuel injection pump (figure

engine and, therefore,

pump has been

calls for the utmost caution

thoroughly bench·tested and should not be tampered with.

5.7)

is

one

of

the most important components of the diesel

in

handling. Furthermore, the fuel injection

Speed (hertz) and timing adjustment are the only adjustments the servicing dealer can perform on the injection pump. Other types

adjustments or repairs

~

be performed by a qualified

of

injection service shop.

figure

To free from impurities and maintain a good fikration and water separation system between the fuel tank and engine. Service this system regularly: the injection pump

own.

15.0KW BTDA

5.7:

Fuel

Injection Pump

NOTE: When servicing the injection pump, the injection shop must be

told that the pump is being used

to

shop will have attached

to

remove a timing shim located behind the oval cover

the lower side governor spring with a propulsion spring. Once the injector pump set up

to

propulsion specifications, the generator governor spring

(PN#024585) and the timing shim

in

a generator application. The injection

of

the injection pump and replace the

(PN#032021) are reinstalled

in

is

the injection pump and the pump remounted on the engine. Then set the throttle for proper engine no-load speed. (Hertz)

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

it

saves

will be your

43

Westerbeke Generators

is

Fuel Pressure Gauge

A fuel pressure gauge (figure 5.8)

incorporated

on

the engine-mounted fuel system. The

is

fuel pressure gauge is located on the outlet side of the engine-mounted fuel filter. The primary

is

purpose of this fuel pressure gauge supplies the engine's fuel injection pump will maintain a minimum) to the injection pump no matter what the load the fuel filter

is.

to help the installer ensure that the fuel system that

poshive inlet pressure (of 1.5

is

on the generator and how clean

psi,

NOTE: A positive inlet pressure of 1.5

supply should allow 2.5 to 3.5 psi to

The absence of positive pressure excessive fuel from the quently

be

flow restriction in the fuel piping

fuel tank to the engine. This

cured with larger lines and fewer and

usually indicates

can

fre-

pSI

IS

minimum.

be

present .

.-----------------------~

Fuel

Pressure

larger fittings. When the combination of distance

fitter

is

and lifting height for the primary for the

fuel lift pump on the engine to overcome

and maintain a positive pressure, then

booster

fuel pump and/or fuel day tank

Otherwise poor operating performance will

too great

an

auxiliary

is

required.

resutt.

Typical symptoms of the generator's engine run-

ning without positive fuel pressure at the inlet of

the injection pump are listed below.

A.

the presence of white exhaust smoke and

fuel-laden exhaust.

figure

B.

A rough running engine.

5.8:

C. Skipping and/or backfiring noises coming from the exhaust.

An

ideal fuel

Maual

Gauge

Primer

Fuel Pressure Gauge And Fuel Filter

D.

Loss of engine power and

E.

The inability of the engine to carry the generator's load.

The problems outlined above will and to the injector nozzles. This type of damage and that

rpm.

eventually cause internal wear damage to the injection pump

resutting from fuel contamination are

not warrantable issues.

NOTE: For fuel tanks that are located below the fuel lift pump, extend

the return line below the minimum fuel level in the tank. This will prevent

airation problems due to fuel syphoning out of the system through the

as

return, which causes operating problems such

A-E.

Weslerbeke Generators 44 15.0KW BTDA

Lubrication System

For engine lubrication, use lubricating according to the or higher

Engine

Use oil

SAE

(CD)

all

an oil having a viscosity best

10W-30

API

specijications into service grades

grades, made by well-known manufacturers

Viscosity

(SAE

w~h

minim~m

Number)

su~ed

viscosity change under different temperatures

Atmospheric Temperature

68" F (20"

F

41"

F(5"

41"

figure 5.10. Engme Od

(5"

C)

- 68" F

C)

- or lower

VISCOSity

or higher

(20"

oil

designated for diesel service. These oils are classified

CA,

ce,

CC

and

CD.

The use of

is

recommended.

to the atmospheric temperature. Use of

an

is

suggested.

all-season

Viscosity

SAE

30 or 10W-30

C)

SAE

20

or 10W-30

10W-30

CC

011

The

instrument panel (figure 4.1). During normal operation, the and

15.0KWBTDA

NOTE:

than

Do

30

not use

in

the engine.

an

engine lubricating

Pressure

engine's oil pressure, during operation,

55

psi.

NOTE: upwards of as

A newly started, cold engine can have

60

psi.

A warmed engine can have

low

as

35

psi.

These readings will vary depending upon the temperature

of the engine and the load placed

45

oil

w~h

an

SAE

number greater

is

indicated by the oil pressure gauge on the

oil

pressure will range between

an

oil pressure reading

an

oil pressure reading

on

the generator.

Westerbeke Generators

35

Engine

1.

011

Change (to Include filter)

Draining the

Oil

Sump

Discharge the old oil through the sump drain hose

to

(attached

is

still warm. Drain the old oil completely, replace the

in

hose Always observe the old

the front of the engine) while the engine

tts

bracket, and replace the

oil

as

tt

end

cap securely.

is

removed. A yellow/gray emulsion indicates the presence of water in the Although this condition

to

attention

in the

prevent serious damage.

oil,

call a competent mechanic.

in the oil can be the

is

rare,

resutt

it

does require prompt

If

water

is

Raw

water present

of

improper maintenance

of the exhaust system attached to the engine and/or

raw

siphoning through the

water cooling circutt into the ligure

engine, due to improper installation or overcranking.

oil.

present

5.12.1:

Sump

Drain

Hose

2. Replacement of the

When removing the used oil filter, you

Oil

Fitter

may

find

tt

helpful and cleaner to punch a hole in the upper and lower portion of the old

fitter to drain the oil from

container before removing

tt.

This helps to lessen spillage.

tt

into a

A small style automotive filter wrench should be helpful in

removing the old oil filter. Place some paper towels and a plastic bag around the filter when unscrewing to catch any

on

the engine reduces the engine's cooling ability.

Please

as

tt

is

gasket came off with the old oil filter.

oil

left in the filter.

(Oil

or any other fluid

keep your engine clean.) Inspect the old oil fitter

removed to make sure that the rubber sealing

If

this rubber

sealing gasket remains sealed against the engine block, gently remove requires no cleaning inside, so

When installing the new

tt.

The replaceable cartridge·type oil fitter

tt

may

be

disposed of properly.

oil

filter element, wipe the filter gasket's sealing surface

tt

ligure

5.12.2:

Oil Filter

engine block free of oil and apply a thin coat of clean engine oil to the rubber gasket

the new

oil

filter. Screw the filter onto the threaded oil filter stub, and then tighten the fitter

firmly by hand.

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

ttems

on

or diameters of important different from genuine parts. Immediately after

fill,

oil

there

run the engine to

are

no oil leaks around the new oil filter.

make

sure the

generic parts might be entirely

an

oil

fitter change and

oil

pressure

is

normal and that

3. Filling the Oil Sump

Change

on

the

on

Westerbeke Generators

46

15.0KWBTDA

5

Add new oil through the

side of the engine. After generator for a

few engine's oil pressure. Make sure there around the new oil fitter or from the and stop the generator. Then check the quantity oil

WITh

the lube oil dipstick. the high mark require

additional

on

oil.

oil

filler cap

refilling the

on

the top or

oil,

run

the

moments while checking the

is

no leakage

oil

drain system,

of

Fill

to, but not

over,

the dipstick, should the engine

Top

Oil

fill

Roeker

Oil

Dipstick

lower

figure 5.13.1: Oil Levels

C."er

'-_c--;::I

DC Electrical System

The

DC

circuIT

the generator dirve engine. The

#036411 for the

on the 15.0

model,

as

BTDA-614

circuIT

shown

on

(12.0BTDA-514)

is

best understood by reviewing the

figure

5.18.

functions to start, operate and stop

DC

schematic

The engine mounted

DC

control panel

has

three switches used

in

the starting and stop-

ping of the drive engine. Four gauges are mounted in the panel that show oil pressure,

DC

water temperature,

DC

The engine

circuITs.

basic

wiring

Preheat, start and

charging vottage and

is

designed to

run

be

circuIT.

an

hour meter to record operating time.

as

simple and straight forward as possible with 3

15.0KWBTDA 47 Westerbeke Generators

Engine 12-VoH

DC

Control ClrcuH

The Westcrbeke shown on wiring diagram electrical components on the engine.

Know the functioning of the three switches in this tion and fautts these switches

in

found

paragraph 4.13 to understand the oprating characteristics of the three switches.

Never Shut Off the Engine Battery Switch While

15.0 W

To

avoid damage to the battery charging circuit, never shut off the engine battery switch while the engine battery switch, however, to avoid electrical shorts when working

engine's electrical circuit.

BTDA

#036411.

generator has a 12-vott

can

Refer

pose

to this diagram when troubleshooting or servicing

in

this circuit. Refer to • Automatic Shutdown" text

I

CAUTION

DC

electrical run/control circuit, as

DC

circuit to better understand the opera-

I

the

Engine Is Running

is

running. Shut off the engine

on

the

Battery Specification

The minimum recommended capacity of the battery used in the engine's 12-volt

is

circuit

Westerbeke Generators

100 - 150 ampere-hours (minimum).

NOTE: Cold cranking amerage reqiurments

48

are

250 - 280 amps.

DC

control

15.0KWBTDA

15.0

..

KW

•

.'

BTOA

...

!.t

..

DC

Control Circuit Wiring Diagram #036411

page 1

~

<r

t'

~G'

(~

of

2

r---"~'------.

..

-

n~~T':'

J;i'-

..,

"""'.,

"'l

Oo~

""'SWIll

"""

9

<>-

~

•

.1

.'

I I

i!

~

"

• i

!

,

figure

15.0KWBTDA

5.17;

DC

Control Circuit Wiring Diagram #036411, Part 1

49

Westerbeke Generators

'.

15.0 KW BTDA DC Control Circuit Wiring Diagram #036411 Page 2

of

2

YDC

"

· ,

• 'SEE

i

!NOTtZ

:

~

_______________

" ,

: ):C.8.

~

.!IOA

~

i

[MEAGENCY

j STOP

:

, ,

· ,

,

, ,

,

SW.

ISTOP Sill.

-

SCHEMATIC

...

-J

~-.-

,

r

, ,

,

'PREHEAT

,

J

•

_.,

..

t,'T.

raw.

Sill.

DIAGRAM

STa"T SOLENOID

~F~"~

,

0,".""-

.

~

:

):

t J

____

C.F.

101

\o'.T.SW.

--{M~

.,

""

STARTER

G

.,

...

UZ-!

LIFT

fUn.

0

__

~

"'MIl'

p

SO~EHOIO

figure 5.18:

Westerbeke Generators

DC

Control Circuit Wiring Diagram #036411, Part 2

NOTE: This product located near the starter and as close possible. Excessive current draw anywhere in the instrument panel wiring or engine will cause the breaker to trip. will shut down because the opened breaker disconnects the fuel supply.

Therefore the builder/owner must

wiring and engine are installed to prevent contact between electrical devices and

NOTE: the starter from the battery in boat. Twelve when cranking. The duration of individual cranking cycles should not exceed

VDC will normally serve this function, but a swnch must never be

12 used to

raw

An

on-off switch should

vott diesel engine starters typically draw 200 to 300 amps

30 seconds. A swnch

"make" the starter circuit.

water.

is

protected by a manual reset circun breaker

to

the source of current

In

this event most generators

be

sure that the instrument panel

be

installed in this circun to disconnect

an

emergency and when leaving the

wnh

a continuous rating of 175 amps at

50 15.0KW BTDA

as

Cooling System

below

is

Illustrated

a typical Westerbeke engine cooling system. Both fresh water and flow through their independent cooling circuits. Refer to your generator's numbers and part descriptions

H you need to order cooling system parts for your engine.

'"IUtMOITA1

Parts

raw

water

Ust for part

15.0KW

,,,UH

WATEA

¢'

R

..

WWATU

figure

5.19.1:

Westerbeke marine diesel generators

produced

in

the engine by combustion and friction

throughout the engine. This circulating fresh water

.....

Typical Cooling

System

are

deSigned and equipped for fresh water cooling. Heat

is

transferred to fresh water which circulates

cools the engine block and its internal moving parts. The heat is transferred externally from the fresh water to raw water by means of

a heat exchanger; similar

of

tubes

the heat exchanger while fresh water flows around the tubes; engine heat transferred to the fresh water is conducted through the tube walls to the into the exhaust system where finally cooled by fresh water, the fresh water

in

function to

an

automotive radiator.

it

is

discharged overboard.

is

cooled by

raw

water,

Raw

water flows through the

raw

water which

In

other words, the engine is

is

then pumped

and the raw water carries the

transferred heat over the side through the exhaust system. The fresh water and raw water

of

circuits are independent

each other. Using only fresh water within the engine allows the

cooling water passages to stay clean and free from harmful deposits. The two independent

are

circuits and their components

BTDA

discussed

51

in

the following paragraphs.

Westerbeke Generators

Coolant from the engine, when heated during engine operation, will expand, lifting the spring-loaded manifold pressure cap, and enter the recovery tank by way of the hose connecting the recovery tank to the manifold.

is

When the engine by the contraction of the engine coolant, allowing some of the coolant in the recovery tank to be drawn back into the engine's cooling system, free of air and that the passage (figure 5.19.4) between the the manifold is clear so coolant can flow in either direction.

shut down and cools, a small check valve in the pressure cap

wtthout

90"

fitting on the mannold and the filler neck

loss.

Periodically check

is

opened

in

FUNCTION

From Coolant Tank

to

Coollnt Tank

figure 5.19.4: Manifold Pressure

OF

COOLANT RETRACTION

MANIFOLD

Cap

PRESSURE

CAP

Westerbeke Generators

52

15.0KWBTDA

Fresh Water Circuit

Fresh water is pumped through the engine by a

be~-driven

from the engine. The fresh water coolant circulates through the engine's block absorbing

circulating pump, absorbing heat

heat, then passes through the thermostat into the exhaust manifold, to the heat exchanger where it is cooled, and then circulating pump. When the engine is started cold, external fresh water flow the closed thermostat (although some fresh water flow

prevent the exhaust manifold from overheating).

is

returned to the engine block through the suction side of the fresh water

is

prevented by

is

bypassed around the thermostat to

As

the engine warms up, the thermostat gradually opens, allowing the engine's fresh water coolant to flow unrestricted to the external portion of the cooling system.

Fresh Water Pump Drive Belt Tension

Generator models come equipped with

the engine.

('Out of sight out of mind.' The bett guard

guards that cover over the beit(s)

is

not installed for that purpose.)

on

the front of

be~

Operators are advised that the inspection, service, and maintenance spoken of below should be followed.

M'ARNiNGI

Never attempt to adjust the drive

operation.

Check Water Pump Belt Drive Tensionl Excessive water pump drive beit and reduce the service life of the fresh water pump's bearings. Excessive slack or the presence of oil slipping resulting in high operating temperatures.

beWs

tension while the engine

PAOTIONI

be~

tension can cause rapid wear of the

on

the beit can cause beit

is

in

The water pump drive 3/8 inch and no more than 1/2 inch thumb at the midpoint between the two pulleys on the longest span of the

drive beit should be carried on board

Fresh Water Coolant (Antifreeze) Mixture.

A freshwater and antifreeze mixture should when it freezes, expands sufficiently to split the heat exchanger and crack the engine block. A water/antifreeze mixture of proper concentration will prevent freezing.

Use hard or foul water. Use of hard water or water containing impurities will lead to the collection

of scale in the engine and heat exchanger which will reduce the cooling system's efficiency.

15.0KWBTDA

bett

is

properly adjusted

(10

..

soft water with few impurities, such

if

mm,

the beit can

12

mm)

as the beit

be

deflected no less than

is

depressed with the

beit. A spare

be

used year-round

as

tap water (potable water) or rainwater. Never use

53

in

the cooling system.

Westerbeke Generators

Water,

Antifreeze of poor quality or wtthout rust inhibttors will cause corrosion wtthin the cooling system. Always use antifreeze which is compatible

wtth aluminum cooling system components and is

made by a reliable manufacturer. Never mix different brands of antifreeze. Make sure that the cooling system of the engine is well cleaned before adding antifreeze. Recommended antifreeze for year round use

In

order to control the concentration of the mixture. mix the antifreeze and freshwater thoroughly

is

ZEREX or PRESTONE wtth rust inhibttors.

before adding it to the cooling system.

ANTIFREEZE

CONCENTRATION

DATA

Antifreeze

%

13 23

(-5)

23

14

(-to) (-IS)

Concentration

Freezing

Temperature

• F

("

C)

NOTE: An antifreeze concentration should

a temperature which is about 10" F

(5"

30

35

45

5 -4

be

selected on the basis of

C)

lower than the actual

-22

(-20) (-30)

(-40)

60

50

-40 -58

(-58)

atmospheric temperature expected.

the

Filling

1.

Remove the pressure cap from the manifold.

Fresh Water System

2. Pour a clean. antifreeze mixture into the manifold and allow enough time for the coolant

to fill the fresh water cooling system.

3. Start the engine and allow it to come up to its operating temperature. Monttor the coolant

in the manifold and add antifreeze coolant as air is expelled. Once all air is expelled from

the system. fill the manifold to the filler neck and install the pressure cap.

4. Remove the plastic cap from the plastic coolant recovery tank and fill the tank wtth coolant

halfway between the ADD mark and the

5.

Run

the engine and observe the coolant's expansion flow into the plastic recovery tank.

6. Check for leaks between the pressure cap/filler neck and the plastic recovery tank. Stop

the engine and allow it to cool. Coolant should

as the engine's temperature comes down. Check the coolant passage in the filler neck to ensure

7. Add coolant to the recovery tank. as required. to top off the fresh water coolant system

and periodically check to see that the manifold cap when the engine is cold.

Westerbeke Generators

MAX

mark.

Replace the plastic cap.

be

drawn back into the cooling system

it

is

open

to

flow. Clean it

wtth

a heavy piece of wire. This

is

full of coolant by removing the pressure

54

is

passage • A".

15.0KW BTDA

Thermostat

are

Generally, thermostats

as

closes

the engine's temperature rises and falls. The second type has a bypass mechanism.

of two types.

Usually, this is a disc on the bottom of the thermostat which moves downward to close off internal bypass passage within the head. Since

n.

The

hole

is

punched through

a bypass to prevent the exhaust manifold from overheating

during the engine's warm-up. Replacement thermostats

One

is

simply a choking device which opens and

1980,

each type of thermostat has a hole

crumt

have this design characteristic.

an

Raw Water Circuit

raw

The

water flow

The pump draws raw water directly from the ocean through the sea cock and

and passes the water to the heat exchanger's

is

created

by

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

raw

water strainer

raw

water inlet. The

raw

water passes through

the heat exchanger's tubes, from which heat from the fresh water system that circulates around

is

these tubes

absorbed, and then the

overboard through the water-injected wet exhaust system.

the area inside of the heat exchanger where the zinc anode is

raw

water

is

discharged from the cooling system

Be

sure to clean zinc debris from

posnioned as this debris lays

in front of these tube ends and blocks them.

Zinc Anode

is

A zinc anode, or pencil,

located The purpose of the zinc anode raw

water cooling

the system. The

or replaced

circuIT,

condITion

as

required. Spare anodes should

thereby reducing the effects of electrolysis on other components of

of the zinc anode should be checked monthly and the anode cleaned

in

the

is

to sacrifice

raw

water cooling

ITseH

be

circuIT

wIThin

the heat exchanger.

to electrolysis action taking place in the

carried on board.

If

the zinc pencil needs replacement, hold the hex boss into which the zinc pencil threaded with a wrench while loosening the

anode with another wrench. This prevents

the hex boss from possibly tearing off the

exchanger shell. After removing the zinc,

note the condition of

condition, there

flakes within the exchanger.

of the heat exchanger and clean the inside of exchanger end gasket in case the present one becomes damaged when removing the end cover. Replace the gasket (refer to your figure 5.25: Zinc Anode

engine model's heat exchanger end gasket part number), cover, and

15.0KWBTDA

IT.

If

the zinc

are

probably a lot of zinc

all

zinc debris. Always have a spare heat

Remove

is

the end

install a new zinc pencil.

is

in poor

55

NEW

RNOOE

REPLRCE

CLERN

REPlACE

DR

REPlACE

Westerbeke Generators

Raw Water Pump

raw

The

water pump is a seff-priming, gear-driven, rotary pump with a non-ferrous housing and a neoprene impeller. The impeller has flexible vanes which wipe against a curved cam plate wnhin the impeller housing, producing the pumping action. On no account should this pump

be

run

dry. There should always be a spare impeller and impeller cover gasket aboard impeller (raw water)

warrantable and the operator

make sure Know your pump, know

kn).

Impeller failures occur when lubricant

is

not present. Such failures

is

cautioned to

raw

water flow

is

present at start-up.

ns

location

on

the engine

are

and know how to change the impeller in

Remove the cover and with the screwdrivers, (figure

5_26),

aid-

of two small

carefully pry the peller out of the pump. Install the impeller posnioning the hub shot to align with the

in

the drive shaft. Move the blades to conform

n.

not

im-

by

key

.......

".

(an

to the curved cam plate and push the impeller

into the pump's housing. Replace the gasket and install the cover.

figure 5.26: Raw Water Pump

BT Generator

en

...

c.u.<

This generator is a four-pole, brushless, self-excited generator which requires only the driving force of the engine to produce

are

responsible for the seff-exciting feature of this generator. The magnetic field produced

an

AC

causes

voltage to be induced into the related exciter rotor windings during rotation.

Diodes located in the exciter rotor rectify this

AC

output. The copper and laminated iron in the exciter stator

voltage to

DC

and supply it to the windings of the rotating field. This creates and electromagnetic field which rotates through the windings of the main stator, inducing is

connected in parallel to the the auxiliary windings of the transformer and main stator and bridge rectifier. The rectifier products a enabling the generator to produce a rated

an

AC

voltage which

AC

output of the main stator.

is

supplied to a load. A step down transformer

An

AC

voltage

is,

in turn, supplied to a full-wave

DC

voltage to further excite the exciter stator windings,

AC

output. (figure

5_28)

is

produced in

Westerbeke Generators

56

15.0KWBTDA

A

+

1-

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

-:

; t

'AEd:

11

________ : ______

'-

__

---,

:

___

L-----,-t----=_,I

,1-

F.

-.r.:-"C"'RE"."'"L-=1-1"l

I*Lij

G

-'+,

**

I

__

\

YELLDW

+

r--------,

I C I I 0 I

,.--------,

Il,! ; • ;, i

i I 2 I

1

I I 1 I I

I 3 I I

J

t

______

BLA.C'r RED B

Y>

V,..LOW

__

-l_t--

+

!!

J

______

2 :

3-=r""~

L!l!,~!--

___

U

--'

JIILI:

I

J

BLUE

IILUK

•

3

2

?

A'

T

E

R

M

J

•

A

l

B

l

0

,

®

S

T

U

0

G

+

~

______

,--

Fe I

\~

J~

J I

A.

EXCITER

A-1

and

(Selector in

C.

MAIN

STATOR

1.

Main Stator Windings

2.

Main Stator Windings

3. Main Stator Auxiliary Windings

F.

SELECTOR SWITCH F-1

SWITch

F-2

SWITch

~_~!*

CJe.1!:J:N

'YELLOW

Bl..ACX

STATOR WINDINGS 1 & 2

A-2

Exciter Stator Windings

COMP

in Compound Position in

Electronic and Compound

PosITion

BUC>

!V"-LOW

~

I

posITion)

I

+

!A.V.Rt

PIUI

Bl (To

(To

...

(To O ...

b/V.a

.....

/While

Pi

..

,8 T ...

a>..

Berta/YolL.

B.

1.

2.

Block)

Bar)

L~.J;;;:"'----4Y

EXCITER

Auxiliary Windings Diodes

ROTOR

(6)

......

(

__

r;;'-,"

Black/.hit.

A.V.R. PLUG

(A

Yen·

IT

..

- B -

..

S.ledol'

..

C)

3. Rotating Field Windings

4. Pozi Resistor

D.

COMPOUND TRANSFORMER

1.

Compound Transformer Windings

2.

Compound Transformer Windings

3. Compound Transformer Auxiliary Windngs

with

Vottage/Hertz Connection Bar

G.

BRIDGE

RECTIFIER

WIRING

)

I_hU.

Swncb)

figure 5.28: BT Generator Internal Wirmg Schemabc

Westerbeke Generators

57

15.0KWBTDA

No-Load Voltage Adjustment

Vottage adjustment is made with the generator regulation being governed by the compound transformer.

1.

The selector switch

2.

Operate the generator, apply a moderate load momentarily and remove

output from the generator's 120 be

between 121-124 volts

lIJJill

be

in

the COMP position.

vott

leg(S)

at

61.5 -

62

(220

vott

50

hertz). The no-load vottage should

hertz (222-228 votts at 51.5 -

it.

Note the vottage

52

hertz).

NOTE: The no-load off. Measure the transformer.

The load is removed the specified range, sut down the engine and adjust the

3.

To raise or lower the vottage, shims of varying thickness (non-conductive material) are

vottage should be adjusted with the engine shut

vottage alter applying a momentary load to excite the

-vottage produced by the generator alter this momentary is

no-load vottage.

If

this vottage does not fall within

vottage.

placed or removed from under the steel laminated bar on top of the compound transformer. The material used for shimming should not soften range. A small reduction in no-load vottage

(1

at temperatures in the 176" F

to 3 votts) can sometimes

be

accomplished by gently tapping the top of the laminated steel bar to reduce the gap between the existing shims and the transformer core.

"llu/.hal

Black/Whlh

La.ln.ted

St,,1

...

(80"

C)

figure

15.0KW BTDA

5.29:

Grlln/Whlt_

YoIt'gI/H,rh: Connection aar

Generator Wiring

and

Adjustments

58

11

.nd

U

Westerbeke Generators

Changing The Frequency

1.

Locate the

2.

Refer to (figure 5.29.).

3.

For

50

For

60

Vo~age/Hertz

Hz

operation wire in accordance wtth figure 5.30

Hz

operation wire in accordance

Of

Operation

Connection

Bar.

wtth

figure 5.30

A.

B.

figure

Place connect

Wire

5.30

Place connect

this

*6

I

To

AC

terminal

block

A:

50

this

wire

with

to

wire

"5

I

To terminal block

Hz Operation

wire

with

to

wire

AC

"5

"3

"6

*2

"1

Vo\lage/Hertz Connection Bar

figure 5.30

Westerbeke Generators

Wire

"6

I I

To

AC

terminal block

B:

60

Hz

Operation

"5

To

terminal block

AC

59

*3

Vo\tage/Hertz Connection

Bar

15.0KWBTDA

llOV

0 0

"

II~

6 7

,

N

50Hz

0

"

I.,

220V

IIr

0 0

2 0

(Q

•

Kl

~

50HZ

~

7

~

I

L,

120V

60Hz

II

0

2

0

7

•

3 8 3

0

N

Ll

120/240V

~

0

6

0

Ll

60Hz

0

1

9

I

~

111

-

N

figure 5.30.2: BT Generator

NOTE : The frame ground wire must be moved when changing output

vottage or frequency. For making connections to the

AC

Voltage Connections

AC

terminal block, use 1/4 inch studs that will accept mutti-strand copper wire sized for the amperage rating from the hot lead connection for terminal ends. The frame ground wire

is

white or white with a green strip.

It

connects

between the neutral stud and the generator frame.

4.

Frequency is a direct resutt of engine/generator speed: 1

=

50

hertz.

5. To change generator frequency:

A.

Connect the

AC

output leads to the

AC

terminal block (figure 5.30.2). Select the correct

BOO

rpm =

60

hertz; 1500 rpm

ground stud.

B.

Reposition the wire

(figure

C.

Start the engine, monitor vottage and adjust engine no-load speed. Adjust the throttle

arm

5.30

or the throttle stop screw to produce engine speed desired. (figure 5.36.1

A or

on

the vottage/hertz connection bar to correspond to the hertz selected.

5.30

B)

Frequency range:

60 50

hertz:

no-load frequency range no-ioad frequency range

61.5 - 62.0 hertz.

51.5 - 52.0 hertz.

15.0KW BTDA

D.

After the no-load hertz adjustment In

most cases, if the generator was producing the correct no-ioad vottage hertz setting, In

the event

it

would be correct at the changed hertz setting.

it

needs adjustment, adjust the shim thickness under the laminated steel

bar of the transformer. (figure

Frequency range:

60

hertz:

50

hertz:

is

made, the no-load vottage may need to be readjusted

5.29)

no-ioad

vottage, 121-124 votts.

no-load vottage, 111-114 votts.

222-22B volts.

60

at

the previous

Westerbeke Generators

..

E.

Load the generator to the rated output amperage corresponding to the frequency selected.

Rated Loaded frequency Range:

60

hertz: full load frequency range 58.5 - 59.0 hertz

50

hertz: full load frequency range 48.5 - 49.0 hertz

Minimum voltage acceptable at full rated output (amps)

60

hertz: 108 votts

50

hertz: 205 votts

Should the vottage drop below the minimum, excttation can be increased to raise this vottage by repOSitioning connections on the Vottage/Hertz Connection the two leads from

5.30.7).

(Z)

to M or

(Xl

will change the full load output vottage. (figure

Bar.

Reposttioning

r

,

Wire

"6

I

To

AC

terminal

block

5.30.3: Increasing Full Load Output Voltage

figure

#5

I

To terminal block

I I

"3

AC

_____

Connect

"2,

or

until

~ePtable

"2

to

wire

-1,

-:3

progressively

output

voltage

limits,

"1

VoltageiHertz Connection Bar

Is

Weslerbeke Generators

NOTE: No·load voltage may be effected requiring readjustment wtth the

nol

compound transformer. Do for overload conditions being placed tive-motor type loads). Loss of generator hertz/speed, as a overload, will cause a drop

use these adjustments to compensate

on

the generator/engine (induc-

in

vottage output.

61

resutt of

15.0KW BTDA

Optional Voltage Regulator

An

optional solid-state vottage regulator (board #34410) generators. When installed, and the regulator works together with the standard compound transformer regulator to regulate the generator's 1 exciter windings, and the transformer provides excitation to the group 2 exciter windings.

Installation

1.

The regulator

M4

2.

Connect the 6-prong generator plug to the receptacle on the regulator board.

vottage output.

x 0.7

-mm

is

mounted using existing tapped holes in the generator's case. Use two

screws, each 15 mm long, with lock washers to mount the regulator board.

In

the

regulation switch is moved to the

ELEC

mode, the regulator provides excitation to the group

is

available for use with the

ELEC

BT

series

position, the

(2)

NOTE: The direction.

3. Before moving the selector switch to the

the generator when

be

should

5.30.2.

4.

Move the selection switch into the

to set

- 52.0 Hertz). The regulator board and

adjusted down to between 114 - 118 volts following the procedures of paragraph

NO·Load voltage at 120 - 122 votts at 61.5 - 62.0 Hertz. (220 -

should maintain voltage output within

plug

is

keyed to engage the regulator receptacle in one

Check this and insert

in

the COMP position will have to be adjusted. The NO·Load vottage

ELEC

is

operating in parellel with the compound transformer

it

correctly.

ELEC

position the NO·Load vottage produced by

position. Adjust the regulator board potentiometer

224

±5

percent from NO·Load to FULL·Load.

votts at

51.5

15.0KW

BTDA

62

Westerbeke Generators

Engine Speed/Generator Hertz Adjustment

Engine speed

62.0 hertz

is

adjusted by poshioning the throttle lever against the adjustable throttle stop screw, lock wiring

is

maintained by the governor mechanism inside the fuel injection pump (61.5 -

at no-load and 58.5 -

59.0

hertz

at

full rated generator output). Engine no-load speed

h at that poshion, and tensioning the throttle stop screw against the throttle lever and securing h

whh

its lock nut.

Throttle

L.".r._-J~,~e~~~

figure 5.36.1: Engine Speed/Generator Hertz Adjustment

Viewing figure

and moving the throttle lever to the left lowers engine speed (hertz).

Westerbeke Generators

for Diesel Models with Distributor

5.36.1

- Moving the throttle lever to the right increases engine speed (hertz)

63

Injection

Type Injection Pumps

Pump

15.0KW BTDA

Shore Power Connections (60 Hertz)

If

the installer connects shore power to the vessel's of the figure 5.38 to generator output.

SHORE POWER/OFF/SHIPS

to

the

OFF

posnion. This swnch prevents

GEN

•.

Set the transfer swnch shown in figure 5.37 and

CAUTION

Do Not Connect Generator Output And Shore Power At The Same Tlmel

Damage to the generator can output is make sure

are

connected

not covered under the warranty; n is the installer's responsibility to

all

AC

at

connections are correct,

resu~

the same time. This type of generator damage

AC

circun, this must be done by means

simu~aneous

tl

utiltty shore power and generator

connection of shore power

Generator

]:

..

"

z

51

Shore

-,10

-\@@'

t

N I

,

Power

NOTE:

The

diagram two-wir., three-wlr. for

the

/ "

~_

, /

,

~r--+-=~~~N

~:::'.:;o~.:;:n"':=--

________ -lll'

shows

120-Volt

system

other

hot

system. us.

legs.

--,

I

I I

I

I I

I

L..-

.....

'----i~L1

Neutral

connections

dotted

L2

For

line.

Ship's

LOAD

for

Ship-To-Shore

(3

Pole)

PN

32008

40

Amps/Pole

PN

32008

80

Amps/Pole

PN

32010

126

PN

32133

200

Switch

Amps/Pole

15,OKWBTDA

figure

5.37:

120V/60Hz

Two

Wire Configuration

64

Westerbeke Generators

Switching Shore Power

Shut

Of

Heavy Loads Before Switching Shore To Generator Power Heavy motor loads should be shut off before switching shore power to generator power or vice-versa because switching with heavy components

Generator

G1

A

( H

to

Generator Power

AC

in

the generator.

NOTE:

The

•

generato,. with •

boat

ICAUTIONI

loads

diagram

two-wire.

system.

vottage surges induced by

may

cause damage to the exciter circuit

shows

120-Volt

connectlona

.ystem

thr

••

-wlre, 120-Volt

from

'or

the

/ "-

4 \

,

:E-t--j--.,

2 V

, /

L---I~L2

L-----I~L1

,

:E-r--+~~~~H

10

~=r=o=:n::::=--_+-

J

Neutral

(White)

____

;;;

i;

..

z

.---"G)

r--+--'<@)

~

j

~

\S2S1H

Shore

v

Power

figure 5.38: 120V/60Hz Three Wire Configuration

-lil'

Ship's

LOAD

Shlp-To-Shor.

(3

Pol.)

PH

32008

40

Amps/Pole

PH

32008

80

Amps/Pole

PH

32010

125

Amps/Pole

PH

32133

200

Amps/Pole

Switch

Westerbeke Generators

65

15.0KW

BTDA

Shlp-to-Shore Wiring Connections 220 Volt

BT

Generator

50

Hertz

Generator

Ground

220V

E9

o 0 0

o

o 0

Terminal

50Hz

0

E:])

L1

Generator/Shore

.:.:

()

co

iii

Block

Switch

...

-,

/

1

3 2 I

,

,_

Ship-To-Shore

,

~

L1

~\

/

.....

PN PN PN PN

Switch

32008 32009 32010

32133

Ship's

LOAD

figure

Note the repositioning of the white ground lead on the terminal block to the generator case,

1S,OKWBTDA

5.39:

l

L1

Shore

220V

220V/50Hz

--

/ "

'-------/-,

(Neutral)

,.......~..:....:.....:...:::....._7

NJ

T

-=

s

, /

.....

_

Shore

Ground

~'""~I

--

••

N

6 I

....

-

Power

50Hz

Two

Wire Configuration

66

Ship's

Ground

Westerbeke Generators

Shlp-to-Shore Wiring Connections 110 Volt 50 Hertz

,---

Generator

BT

Generator

....

>----+-\10

Generator

Terminal

110V

50Hz

02

O.

3 8 0

15

70

0

N

Ground

'---I"'i

r-----~--------~3

Block

L1

Ship-To-Shore

Generator/Shore

Switch

/

,

~

'-\\~)

--~~

@/

,

/

PN PN PN PN

Switch

32008 32009 32010 32133

L1

Ship's

LOAD

figure

5.40:

Note the

Westerbeke Generators

repos~ioning

I

L1

Shore

110V

nOV/50Hz

,-

/ "

L-----..J...(:s~)

(Neutral> )

,-----;-{7

, /

6 I

Shore

-

NJ

T

Ground

Power

50Hz

Two

Wire Configuration

of the white ground lead

67

on

the terminal block to the generator case.

N

-

Ground

Ship's

15.0KWBTDA

3 Phase BT Generator Wiring

r-------.,

I

I I

L.

A

EXCITER

.---+-------,

I I B I

+.

:

1

:1

I

-

I 1

-

I I

L

___

-----

I

.:~:

:: -1* 4

I I 2

+

_______

....

F

3:

b I

r------,

Ie

:

STATOR

!

rl---!!-

!

:

: :

:

I

..J

I I

•

---

•

,

•

,

•

I

......

·>I55>··--1

:

I I

•

FUSE

8.3"".

FOSE

20

A.

#'

S=OD

-1*

12

A "

e

1l

:

'n

B "

:

7 k

...

• L

:

4 B

:

: g

, "

E

+

~

m

~

A.

EXCITER

1. Exciter Stator Windings

C.

MAIN

STATOR

1.

Auxiliary Windings

2-7. Main Stator Windings

3. Auxiliary Windings

E.

DC

CONTROLLER

figure 5.50: 3 Phase BT Internal Wiring Schematic

UDJ

J

REGULATOR

lIE

I

jT

0

~

(DC

Charging Circuit)

(AC

to Regulator)

B.

D.

F.

ROTOR

1. Auxiliary Exciter Windings

2. Diodes (6)

3. Main Rotor Windings

4.

Pozi

Resistor

BRIDGE

VOLTAGE

RECTIFIER

REGULATOR

BOARD

(A

- B -

C)

Westerbeke Generators

68 15.0KW BTDA

3 Phase Voltage Regulator Adjustments

And

Protection Circuitry Adjustments

vottage regulator PN#038466

The ternator performacne.

operating conditions that could be detrimental to the

It

is equipped with complete protection circuitry to guard against

is

of

an

advanced design which ensures optimum

~j

o 0

:l

'c

C C

I

~

0

DoD

n

1"1"

Paten

LED'S

Red

Green

Yellow

tiolTIeters

Hz.

Axnp.

Stab.

Volt

AC

atternator.

IV

AC

al-

~]~6

Il

~'

;;'

~

~J

@

~J

mr©

0

5

4

3

2

1

0

B

+

-

J80

BII:.

figure 5.60.: BT 3 Phase Voltage Regulator

15,OKW BTDA

69

Westerbeke Generators

Adjustments To 3 Phase Regulator

Volts

This potentiometer is used to adjust output

output

vo~age

and from

Stability

should

powe~

factor 1.0 -

be

held

at

± 1 % from a no load condition

O.B

with engine drive speed variations of up to

vo~age.

At proper engine operating speed, the

to

full rated generator output

-6%.

This potentiometer permits variatiol) of the regulator's response to generator load changes so as to limit overcompensation and obtain a minimum recovery time to the normal vottage output.

Amp - Hertz

are

These two adjustments

regulator that are indicated by the illumination of a colored

1.

Delayed overload protection (yellow

2.

Low speed protection (red

Each system has

an

used in conjunction with the two protection circuits in the vottage

LED.

LED)

intervention threshold which

can

be adjusted using a potentiometer. Each of the two circuits reduces excitor vottage to safeguard the excitor windings and prevent overheating.

The overload protection system has a delay which permits temporary overloading of the generator

during times such has a third

LED

the regulator with the generator.

Westerbeke Generators

as

motor stan up or other similar load surge demands. The regulator also

(green), that glows during generator operation to indicate correct operation of

70

15.0KWBTDA

Regulator Sensing 3 Phase

WYE

and Delta Configurations

I

\

PARALLEL WYE (STAR)

10

12

8

4

1

L-L

208

L-H

120

L"L

!SID VAC

LooN

110

SERIES DELTA

L-L

L2,L3-H

L-L

L2.L3-H

240YAC

120YAC

nOYAe

HOYAt

3,

,.

39

"

9

5

1

60

60HZ

50 50

HZ

HZ HZ

11

6

2 3

VAC VAt

VAC

The

7

:Sf

eo

" eo

:til

50

'9

50

9

5

1

HZ HZ

L1

L2

L3

N

1

SERIES WYE

12

8 6

4

L-L

460

L

-N

26$

L-l

380

LooN

220

(STAR)

11

10

a:::::D

7

a:::::D

2 3

a:::::D

VAC

3,

VAC " 60

VAC

39

VAC " 50HZ

60HZ

50HZ

~

V

~

V

1

~

HZ

L1

L2

Q)

L3

N

regulator is equipped with seven numbered terminals and related brass jumpers. Figure

5.70.1 shows the connection points and jumpers for the 3 phase configuration of the generator. The

sensing leads connect between pin

#2

and

#0

on

the vonage regulator board.

NOTE: Series

Dena

board between terminal

requires the installation of a jumper

#1

Band

and pin

O.

#2

on

the

AC

terminal block and connection

on

the regulator

L1

L2

L3

N

15.0KWBTDA

170-27DV.rv

+

EXCITE~

--~

~

I SOH:.

D

figure 5.70.2: Voltage Regulator - 3 Phase

71

D

80-180V.,...,

--~

180Hz.

--~

Westerbeke Generators

Motor Starting Requirements

an

The power required to start

it

keep others. Split-phase than other types. They

machines, or where loads

tools. Because they require 5 to 7 times

should generator. Capacitor and repulsion-induction motors require from 2 to 4 times as much current to start connected to require more current than

In loads will

running after

be

avoided, whenever possible,

it.

general, the current required to start 115-volt motors connected to medium starting

be

approximately as follows:

it

is

started. Some motors require much more current to start than

(AC)

motors require more current to start, under similar Circumstances,

are

as

to

run.

An

electric motor connected to

electric motor

commonly used on easy-starting loads, such as washing

are

applied after the motor

if

The current required to start any motor varies with the load

a_

motor to which no load

is

considerably more than is required to

is

started, such as small power

as

much current to start

the electric motor

an

air compressor, for example, will

is

connected.

as

to

run,

their use

is

to be driven by a small

MOTOR

figure

6.0.2:

NOTE: for some small motors than for larger ones. The reason for this the hardest starting types (split-phase)

Because the heavy surge of current needed for starting motors instant, the generator will not few seconds.

and, H possible, reduce the load

loads

SIZE

(HP)

110

1/4

1/"

1/,

"/4

1

Startmg Loads

In

the above table the maximum "Amps for Starting"

be

damaged H

If

difficulty

is

experienced

AMPS FOR AMPS FOR

RUNNING (Amperes) (Amperes)

3.2

4.6 9.2 to

5.2

I."

lU."

1;;

are

not made

IT

can bring the motor up to speed in a

in

starting motors, turn off

on

the electric motor.

in

larger sizes.

STARTING

6.4

to 22.4'

10.4

to

14.4 to

"U.4

to 4U.1l

,0

to

is

more

is

that

is

required for only

all

other electrical

32.2'

{".Il·

"!!."

52

an

Westerbeke Generators

72

15.0KWBTDA

Required Operating Parameters

Although individual units may vary slightly, the normal voltage and frequency of typical engine-driven generators described

Run

the generator

loaded to

Load

tts

at

first with no load applied, then at haff the generator's capacity, and finally

full capactty

4 ",ole

as

Speed Frequency

in

this manual

are

shown below.

indicated on the generator's data plate.

vonage

120V (110)

Applied (rpm) (Hertz)

None

Half 1800

Full

figure

7_0.1:

Voltage

The output voltage should and the appliances

and

1830

(1530)

(1500)

1755

(1455)

Frequency

tt

supplies.

-

be

checked periodically to ensure proper operation of the generator

62

(52)

60

(50)

59

(49)

122 240

(112) (224)

120

(110) (220)

110

(100)

60-(50-)hertz

vonage

240V(220)

240

220

(200)

If

an

AC

voltmeter or ammeter

is

not installed to monitor voltage and load, check with a portable

meter.

NOTE: When the vessel in which the generator equipment of 120 volts only, AC

terminal block

be

configured to provide one 120 volt

it

is

for the vessel's distribution panel. This will ensure good motor starting response from the generator.

Preventive Maintenance (Generator)

1.

Keep the generator clean, dry and well-ventilated.

2.

Make

sure

all

connections

are

clean and tight and that cables carrying

properly supported and protected against chafing.

3.

The rear armature bearing If

the bearing becomes rough or noisy, replace

4.

Do

not overload.

5.

On

starting

up,

allow the engine to warm up with no load. Then apply the load

is

lubricated and sealed; therefore, no maintenance

is

installed contains

AC

recommended that the generator's

AC

hot leg

AC

n.

vo~age

is

required.

in

steps.

are

15.0KW BTDA

73

Westerbeke Generators

Troubleshooting

Engine Troubleshooting

tables which follow indicate troubleshooting procedures based upon certain problem

The

indicators, the probable causes of the problems, and the recommendations to overcome

these problems.

Note that the engine's manual reset circuit breaker located

forward of the generator's

is

de-energized when the emergency

control panel

PREHEAT switch

panel indications, fuel not

no solenoid, electric and preheat solenoid not energized. tripped. trips again, check preheat

~TART

no starter engagement.

is

depressed. Shutting down the engine.

Problem Probable Cause

switch

is

control system (electrical system) is protected by a 20-Ampere

on

a bracket on the right side of the engine, just

Elnd

plate.

The

fuel solenoid mounted in the injection pump

is

depressed:

fuel pump

depressed:

STOP

1.

Battery

20-Amp

2.

1.

Connection to solenoid faulty.

Faulty

2.

Faulty solenoid.

3.

switch located on the rear of the engine

Verification/Remedy

on.

START

SWITch

circuIT

breaker

SWITch.

1.

Check switch and/or battery connections.

2.

Reset breaker; if breaker

solenoid circuit and check circuIT

1.

Check connection.

2.

Check switch

for shorts to ground.

3. Check that

present at starter solenoid

connection.

12

WITh

Votts

ohmmeter

are

START

panel indications

start solenoid fuel solenoid not functioning.

Westerbeke Generators

switch

is

depressed:

OK;

4.

Loose battery connection.

Low

5.

1.

2.

batteries.

Poor

connections to

fuel solenoid.

Defective fuel solenoid.

74

4.

Check battery connection.

5.

Check battery charge state.

1.

Check connections.

2.

Check that present on the injection pump. Remove solenoid pump and test separately.

12

Votts

at

the fuel solenoid

from

15.0KWBTDA

are

the

Problem

No ignition: cranks,

but does not start;

fuel solenoid energized.

Failure to stop.

Probable Cause

1.

F aully fueling system.

1.

STOP

switch failure.

2.

Fuel solenoid

will not de-energize.

Verification/Remedy

1.

Check for fuel to generator engine.

2.

Check for air in fuel system. Bleed point on filter.

3.

Fuel lift pump faully.

I ers c

ogge.

ep filters and allow system to seH-bleed

only the

1.

Stop engine by depressing emergency

by depressing

PREHEAT

STOP

switch

engine or manually moving

lever

the shut off

on injection pump side. Test switch with ohmmeter.

2a.

Manually unplug the 12 Volt connection to the solenoid at the injection pump.

ac"

switch.)

on

the

Engine stops.

1.

Low oil pressure or overheated.

2.

Low

oil

pressure

switch opens.

3. High temperature

switchs open at too low a temperature. (water temperature) (exhaust temperature)

4.

2D-Amp

circuit breaker

tripping.

2b. Loosen high pressure

injector

lines at each

injector.

Beware of

1.

Check and sea water

2.

Check for satisfactory

fuel spray.

oil

level;

check fresh

cooling.

operation with switch bypassed. Check with ohmmeter.

3. Check for satisfactory

operation with switch

bypassed. Check with

ohmmeter.

4. Check for high

DC amperage draw during operation. Ensure switch not overly sensitive to heat which

would cause tripping.

an

is

15.0KW

BTDA

75

Westerbeke Generators

"roo,em

rooaDle \,;ause Verttlc8tton/nemeay

..

Engine stops. (cont.)

Battery not charging.

Battery runs down.

Emergency

5. switch or in

panel defective, opening fuel solenoid

Switches and/or wiring.

6.

STOP

run

circuIT.

-

1.

A~ernator

Oil

1.

D.C.

pressure switch.

SWITch

Check operation

5.

WITh

an ohmmeter.

Inspect

6.

all

of

wiring for

switch

short circuits and loose connections.

Inspect switches for proper operation.

1

a.

Check drive Be

sure

be~

tension.

a~ernator

turns

freely.

b.

Check for loose connections.

1

c.

Check output

1

d.

Ensure 12 Volts are present at

the R terminal

Observe if gauges and

1. panel lights when engine

WITh

are

activated

is

not running.

vo~meter.

Test the oil pressure switch.

Weslerbeke Generators

High resistance leak

2.

to ground. sensitive

3.

Low

Alternator.

4.

resistance

76

leak.

3. Check

4.

Check wiring. Insert

(0-.25

Amp)

meter

in

battery

start engine.)

lines.

(Do

Remove

not

connections and replace

is

all

wires for

located.

rise

to locate

at

after short

temperature

fau~.

the

Disconnect alternator output, after a good battery charging. remove

If

leakage stops,

a~ernator

and bench test. Repair or replace.

15.0KWBTDA

Generator Troubleshooting

complete and illustrated text

A

Technical Manual which

the

Troubleshooting Water Temperature and

If

the gauge reading

panel

is

energized, the first step

the Negative

Assuming there

following steps.

the

1.

Disconnect the sender wire

normal reading for this situation.

2.

Disconnect the ground connection at the gauge and see which

(B-)

is

the normal reading for this situation.

is

other than what

terminals of the gauge.

are

12

votts as required, leave the instrument panel energized and perform

on

troubleshooting the

is

available through your local dealer.

011

Pressure Gauges

is

normally indicated by the gauge when the instrument

is

to check for 12 votts

at

the gauge and see

BT

series of generators

DC

between the ignition (B+) and

ff

the gauge reads zero, which

ff

the gauge reads full scale,

is

furnished in

is

the

If both of the above gauge tests

either with the conductor from the sender to the gauge or with the sender.

lies

If

either of the above gauge tests

be

replaced.

Assuming the gauge the gauge for continuity.

Check that the engine terminals and

ground side will not necessarily

ff

is

OK,

block

the battery

check the conductor from the sender to the sender terminal

is

are

positive, the gauge

are

negative, the gauge

connected to the ground. Some starters

connected to the starter (both plus and minus terminals), the

be

connected to the block.

is

undoubtedly

is

probably defective and should

OK

and the problem

have

isolated ground

at

15.0KW BTDA

77

Westerbeke Generators

PERIODIC MAINTENANCE and ADJUSTMENTS

This section contains a scheduled preventive maintenance program and several adjustment

9.3 procedures the owner/operator can perform tools and instruments.

9.3.1 Preventive Maintenance

in

9.3.2 Perform the preventive maintenance

accordance with the schedules listed in the following

paragraphs. Adherence to these schedules will ensure the equipment

~

will

possible condition and that

(*) are recommended to be. performed

perform to expectations. Those items marked by an asterisk

by

Dally (before each use)

1.

Check the oil sump

Do

not overfill

2.

Check the coolant level in the plastic recovery tank. Maintain this level

level marked

ADD.

level.

Maintain the oil level

Periodically, check the coolant

to the top of the filler neck.

w~hout

the

benef~

of sophisticated and expensive

is

maintained in the best

an authorized dealer or distributor.

at

or near upper level mark on dipstick.

level

in the manifold.

at

or above the

It

should be filled

3.

Visually inspect the unit; check for loose

betts,

chafed or broken wires, loose brackets and

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

4.

Check the fuel supply.

5.

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

separator is optional, but strongly recommended engine from fuel contaminants

6.

Check the generator's gauges or lights for proper oil pressure, operating temperature,

staning battery charging

is

engine

7.

Check the generator's output meters (when installed) for proper

operating.

Fill

tank(s) with a good grade of No. 2 diesel fuel.

as

damage to fuel equipment

is

not warrantable.)

vottage and

pos~ive

fuel pressure to injection pump once the

(A

primary fitter/water

AC

voltage and output

frequency.

Monthly

1.

Check the condition of the zinc anode in the heat exchanger's sea water

Keep

replace the anode, as required.

the area inside the heat exchanger clean of zinc

circu~.

anode debris.

2.

Check siphon break operation when insttalled. Clean or replace

as

needed.

on

the

Clean or

15.0KW BTDA

78

Westerbeke Generators

Servicing After Initial 50 Hours of Operation

1.

Change the engine's lubrication oil and oil

2.

Replace the fuel filter element

filter element and clean the

in

the engine-mounted secondary fuel

fi~er/water

fi~er.

sedimentor, n a separator has been installed, and

n the model type permhs cleaning.

*3. Torque the cylinder head hold down bolts.

*4. Adjust valve clearances.

5.

Adjust the water pump drive

6.

Check electrical connections at the generator. Ensure they chaffe.

7.

Adjust the engine's no-load speed, n required (hertz) and make any

adjustments that maybe needed. adjustments during or after the generator's break-in.

be~

tension, n required.

Please

note that these adjustments are not warrantable

fi~er.

Change the fuel

are

tight and not subject to

vo~age

regulator

Servicing After Every

1.

Change the engine's lubrication oil and

2.

Adjust the water pump drive

Servicing After Every

1.

Replace the fuel filter element in the engine-mounted secondary fuel filter.

Servicing After Every

100 Hours of Operation

oil

filter.

be~

tension, n required.

250 Hours of Operation

500 Hours of Operation

*1. Torque the cylinder head bolts.

*2. Adjust the valve clearances.

3.

Drain, flush, and refill the fresh water cooling system. A block drain plug is found right side of the engine block adjustment to the backplate. Drain pet cocks are located on

the lower side of the heat exchanger.

on

the

*4. Check the condition of the starter motor drive pinion; lubricate the pinion.

Westerbeke Generators

79

15.0KWBTDA

5.

Check the resistance of the glow plugs (.4 to

engine and glowplug reinstalling.

6.

Check the internal condition of the water injected exhaust elbow. Inspect the exhaust and

water passages. Remove any carbon and/or corrosion build required.

7.

Check the

housing. Replace worn parts, them, as needed.

clean the carbon build up from the pencil end. Apply 12-Votts

to

ensure proper functioning. Use antiseize compound on the threads when

raw

water pump for internal wear. Examine the pump's cover,

as

needed. Check for leaks at seals or gaskets and repair

.6

ohm). Remove the glow plugs from the

DC

across the

up.

Clean or replace

cam,

and internal

as

NOTE:

competent mechanic.

Servicing After Every of Operation

*1. Remove and check

Injector spray pressure:

1920 psi ± 71psi (135

Eliminate undesirable injection conditions including after dripping.

*2. Check the engine's compression

pressure. Remove each and check each

pression pressure. The engine's cranking speed

Standard

427 psi

(30

kg/cm2)

Items highlighted by

800 Hours

fuel injectors.

2

kg/cm

±

5.0

kg/cm

cylinder's com-

2

glow plug figure

an

)

Minimum

384

psi

(27

kg/cm2) (Maximum difference between cylinders:

asterisk

9.8.1:

(*)

should be performed by a

Fuel

Injector Spray Pattern

is

at

280

rpm.

43 psi [3.0 kg/cm2])

POOR

GOOD

DC

*3. Check the

*4. Check the tightness of bolts, nuts, and clamps. Check

clean connections and that no chaffing of the wires

15.0KW BTDA 80 Westerbeke Generators

Charging Circuit for proper operation.

AC

is

occuring.

and

DC

wiring to ensure tight

Servicing After Every 1000 Hours of Operation

Remove, should be able to clean and test the heat exchanger.)

Torquing Cylinder Head Bolts

clean, and pressure test the primary heat exchanger.

NOTE: Operating in exchanger cleaning

silty and/or tropical waters may require that a heat

be

performed more olten than every 1000 hours.

.

Tighten the cylinder head Make sure the engine

~

then tighten in the sequence. Tighten the

between

bo~s

is

cold when this

80

to

85

Ib-It

RS

according to the sequence shown in the illustration below.

is

done, and loosen one head bold one-han turn and

(11.0

to 11.7 kgim). Then proceed to the next head

(rocker cover stud) securely.

4

1

5

(A

local automotive radiator shop

boH

15

<erentl

figure 9.10.1: Cylinder Head Bolt Pattern

11

2

Westerbeke Generators

81

15.0KW BTDA

Valve Clearance Adjustment

NOTE: Retorque the cylinder head botts before adjusting the engine's valves.

Adjust the valve clearance when the engine

cylinder in the firing order of the engine. Tighten the cylinder head

by bolts to the specified torque before adjusting the valves.

Pull

off the air breather

the

pipe from

rocker

cover, and take off the

rocker cover

botts and

the rocker cover to ex-

pose the rocker shaft and

valve assembly.

I

CAUTION

I

Adjust valves properly

is

'Wb.en

No. 1 c,.llnder

1.

cold. Valves are adjusted

at.

top

d.ead

cent.er

Position the

TOP Dead

at

(TOC) stroke and adjust the 1,

2,

3 and 6 valves (see

the

illustration

on

ITS

No.

1 piston

Center

compression

#

to

the

right).

PosITion

at

TOC

the

of

No.

its

4 piston

compres-

sion stroke and adjust

the

#

4,

5,

7 and 8 val- figure

ves.

The valves are num-

bered 1 to 8 from the

front of the engine to the

back.

Adjust

each

valve's

clearance by inserting a

0.012 inch (0.3 mm) feeler gauge between the rocker arm and the stem.

Make

sure to ad-

all

just inches (0.3 engine

valves to 0.012

mm)

is

cold.

valve

while the

9.11.4:

I

L_I

Valve

When

No.4-cylinder

Adjustment

Sequence

1.

at

t.op

st.", C"p

dead

oenter

15.0KW

BTDA

figure

9.11.6:

82

Westerbeke Generators

Injection Pump Timing

is

This Information

found in the engine technical manual and should only be performed

competent mechanic familiar with Diesel

Adjustments (Generator)

KiKi

injection equipment.

by

a

Once the diesel generator set has been placed for engine speed (hertz) during the engine's break-in period (first A no-load voltage adjustment may also

in

operation, there may be adjustments required

50

hours) or after this period.

be

required in conjunction with the engine's speed

adjustment. These are not warrantable adjustments as they relate to normal break-in and

maintenance.

!CAUTIONI

Switch When starting the generator, should be

sw~ched

cold climates, starts to warm caused by unanticipated operation of cold engine from stalling.

Off

AC

Load Before Starting Generator

all

AC

loads, especially large motors,

off until the engine has come up to speed and, in

up.

This precaution will prevent damage

AC

machinery and will prevent a

Westerbeke Generators

83

15.0KW

BTDA

Table

Of

Standard Hardware

Tightening

Torques

Unless stated otherwise for a specific assembly, use the following torque values when tightening standard hardware.

..

'3rade

4T

6mm Ilmm 1

Omm

lUmm

12mm

l"mm

12mm 13mm 14mm

14mm

16mm

bmm

lIcn

bo~

head/nut 1.0 2.9 -

Don

bo~

head/nut 1.25 13.7 - 22.4

Don

bo~

~,,,ut

.«0

.!>

1.25

(ISO)

0011

bo~

DOlt

bo~

Don

bo~

oOIT

head/nut

,"

"

1.75

1.5 32.5 - 50.6

1.5

2.U

1.5 "u

lo-n

5.1

1.«

- 11.0

3.~

-

«.7

25.3

"".~ -3~.1:>

21.7

36.2

34.U

39.B

36.2

- 57.9

-

"".1

54.2 79.6

"'.4

-

(1.(

Kg-m

0.4 - 0.7 U

-

1."

3.1

1.9

1.B

-

".U

3.5

- 5.5

3."

- 0.0

3.0 5.0

4."

5.0 -

.U

-

B.O

4.7 - 7.7

7.5 -

11.0

(.1 -

lU

. .,

~rade

6T

6mm bolt head/nut Ilmn 10mm

lUmm

0011

bo~

ooIT

~

I.

12mm bolt head/nut 1.25

,,,mm

DOll

neaa/nUl

12mm

~rade

6mm I:>mm 1 lUmn

7T,

8T and 8.8

bo~

0011

Omm

bo~

head/nut

head/nut 1.0

bolt

""aUI

nut 1.25

0011

~

12mm bolt head/nut 1.25

l«mn

Dan 12mm bolt head/nut 1.75 13mm 14mm 14mn 16mm 10mn

Don

bo~

,,~gvo

DOll

~m~

bo~

""aUI

~Oll

neaa/n~

"ut

nut

1.0 4.3 - 6.5 1

U.I:>

-

•

".~

3UA

"U.O

49.2

B.7

"'.f

39.B

;;I.t

75.9 0".

61.5 1l0.1l

.""

1.25 21.7 32.5

1."

(ISO)

1."

1

"."

36.2 - 57.9 "0.«

1.75 34.7

5.B

1.""

14."· 2B.9

1.0 (ISO)

1.0

"b.1:>

54.2 •

50.6 -

43.4

1.5 .57.H -

0.6 -

1."

3.0

".f

5.0 ".U -

4.B

O.B

2.U·

4.0·

3.f·

7.5

6.0 I:>.U • ''',U

I.U·

0.9

- 2.2

4.5

-

4." B.O

(.U

6.B

- 1.2

3.U

5.5

5.2

10.5

~.U

B.5

1.5 72.3 108.5 10.0 • 15.0

".U

1.5

".U

.,1>.1 • H; .3

10B.5 166.4

lUl.;;

• 1

,,~.

H.5

• 14.0

15.0 - 23.0

14.U

.

~.U

15.0KW BTDA

B4

Westerbeke

Generators

Grade 5 capscrew

!'lIen

lo-n

K~-m

1/4

UNC

1/"

UN.-

5/16

UNC

"flO

UN~

3/8

UNC

"It!

UNI

7/16

utilc

fllb

UN.-

1/2

UNC

1/2

UN~

~ngine

pylinder

~yllnaer

ponnecting rod cap JVlaln

~amshaft

",amsn a gear

die gear nlecllOn pump anve

"'ocker arm assembly

Imlng gear case

iming gear cover Hear Oil UII Water pump c..;ranKsnan

emperature gauge unit UI

f3low plug

nlectlon nozzle

njection pipe flare nut

ntaKe

xhaust manifold "xhaust elbow (to exhaust manifold) ClaCK

njector spray Pressure

pylinder Compression Pressure

Tightening Torque Table

head neaa cover

oeannQ

Oli

pan

pipe

pressure

mam

plate

cap

thrust plate

seal cap

(UII

pump)

ulley

sWltcn

010

Qear

9.0 -

11.0

18.0 -20.0

<!l.U

28.0 -

"u.u -"".u

44.0 -

ou.u

68.0 - 73.0

/".u

Ft-IO I\g-m

80 -

50

IlU

12

""

17

ai

80

1,

12 11

12

145

12

18 -

1,

12

,4

135

30

85

;j

"

54

-

1:l5

17

-

"1

23

-

51

- 85 11.0

11

17

15

-

5 -

0

9 -

!oj

7 -

9

17

-

1 III

13

-

1~

11

,

22

1

17

-

,,,,

+ 5 kg/cm

kg/m2 at

2

200

11.0

-

I".U

<!;;.U

-

33.0

49.0

-

OO.U

t!u.u

-

+

(1920

rpm (427

71/0

psO

11.0

'I.U

20.0

psO

u."

6.9

1.6

b."

2.3

4.u

1.b

1.6

1.5

0.7

U.t!

1.6

1.2

1.0

2.5

1.b

1.6

,"

1.2 -

1.0 - .t!

2.5 -

-

<!.9

3.7 -

4.

-

6.1

-

0.9

-

9.4 - 10.1

o

lU.

11.7

-

U.4"

7.5

-

,

1./

2.4

-

t.U

3.2

-

.U

11.7

-

<!.4

2.4

-

<!.U

-

1.2

-

1.,

2.4

-

,,,.u

1.8

-

,

.Il

-

1.5

-

,.4

3.0

-

2.4

-

"".U

1.5

2.8

".,

4.6

4.1l

6.8

f.O

11.1

Westerbeke Generators

85

15.0KWBTDA

LAY-UP

General

rely

Many owners for lay-up during the off-season or for long periods of inactivity.

lay-up preparation themselves.

on their boatyards to prepare their craft, including engines and generators,

AND RECOMMISSIONING

Others prefer to accomplish

The procedures which follow

as

or to use

These procedures should afford your engine protection during a lay-up and also help familiarize you with the maintenance

If you have any questions regarding lay-up procedures, call your local servicing dealer;

be

more than willing to provide assistance.

Fresh Water

50·50 solution of antifreeze and fresh water is recommended for use in the fresh water

A cooling system depending on the area's winter climate. Check the solution to make sure the antifreeze protection is

adequate.

Should more antifreeze add a more concentrated mixture. mixture of the solution's strength.

Lubrication System

WITh

the engine

oil

filter. (Place some paper towels and a plastic bag around the filter to catch the oil during

ITS

removal.)

a check list

Cooling System

at

all

times. This solution may require a higher concentration of antffreeze,

antffreeze concentration throughout the cooling system. Now recheck the antifreeze

warm,

will allow you to perform your own lay-up and recommissioning,

ff

others do the procedures.

n~eds

be

drain

of your engine.

needed, drain

Operate the engine to ensure a complete circulation and

all

the lubricating oil from the oil sump. Remove and replace the

an

appropriate amount from the engine block and

he

will

When installing the new oil filter, gasket at the base of the filter. (Refer to the of no leaks.

15.0KW BTDA

CC

be

sure to apply a small amount of

Fill

the sump

"System Specifications" section of this manual.)

or

CD.

Run

the generator and check for proper oil pressure and make

Remove

Do

not

leave

the engine's old lubricating oil in the sump over the lay-up

oil

period. Lubricating harmful chemicals which can reduce the life of your engine's internal parts.

and combustion

WITh

I

CAUTION

011

During Lay-Up

the correct amount of oil for your engine.

Use

I

depOSITS

combine to produce

86

oil

an oil with

Westerbeke Generators

on the rubber sealing

an

API

specification

sure

there are

Fuel System

Top off your fuel tanks with

be added additives used are the clean the separator sediment bowl.

Change the fuel filter element on the engine and bleed the fuel system, as needed. Start the engine and Check for any leaks that may have been created in the fuel system during this servicing, correcting them as needed. Operating the engine for of the treated

Raw Water

Close the end of this hose into a 5-gallon bucket of clean fresh water. Before starting the engine, check the zinc anode found in the primary heat exchanger on the engine and

as

a anode

Start the bucket stronger than needed for winter freeze protection in your area.

at

this time to control algae and condaion the fuel. Care should

compatible wah the primary fiher/water separator used in the system. Change

element in your primary fuel Mer/water separator, H the fuel system contains

allow it to run for 5 - 10 minutes to make sure no air

fuel through the injection equipment

Circuit

the through-hull sea cock.

required, and also clean any zinc debris from inside the heat exchanger where the zinc

is

located. Clean the raw water strainer, H one

the engine and allow the raw water pump to draw fresh water through the system. When

is

empty, stop the engine and refill the bucket with

No.2

diesel fuel.

Remove

the

Fuel

additives such as Sta-Bil and BioBor should

be

taken that the

is

left

in

the fuel system.

5-10

minutes will help allow movement

on

the engine

raw

water intake hose from the sea cock. Place

clean or replace

is

installed, in the inside of the hull.

an

antifreeze solution slightly

one,

and

Start the engine and allow all of this mixture to the bucket circuit from freezing during the winter

Remove the catch it in a bucket). Examine the gasket. cover and gasket.

Intake Manifold and Through-Hull Exhaust

Place a clean cloth, lightly soaked in lubricating block the opening.

an

and

Make a note to remove the cloth prior to start-up. The through-hull exhaust port can be blocked in the same manner.

is

empty, stop the engine. This antifreeze mixture should protect the

lay-up,

impeller from your

Do

not replace the impeller (into the pump) until recommissioning, but replace the

Do

not shove the cloth out of sight.

attempt is made to start the engine, you may need the assistance of a servicing dealer.)

raw

water pump (some antifreeze mixture will accompany

impeller. Acquire a replacement,

be

drawn through the

as

well

as

providing corrosion protection.

oil,

in the opening of the intake manifold to

(If

raw

water system. Once

if

needed, and a cover

it

is

not visible at recommissioning,

raw

water

it,

so

Westerbeke Generators

87

15.0KWBTDA

Generator End

Remove the louvered cover on the generator end. Check block

and those running to the bridge connections appear corroded, they all

AC

leads are properly cleaned and reconnected. Make sure

rectHier

making sure they are secure. Should these

should be removed, cleaned, and reconnected. Make sure

all

wire connections on the

all

AC

leads

AC

are

terminal

properly

supported and not chafing as they exit the generator housing.

Starter

Molor

Lubrication and cleaning of the starter drive pinion is advisable, H access to the starter permits its easy

removal. Make sure the battery connections

are

shut off before attempting to remove

the starter. Take care in properly replacing any electrical connections removed from the starter.

Cylinder Lubrication

It

is

not necessary to remove the glow plugs from the cylinder head to squirt light lubricating

oil

into the cylinders for the few months of normal lay-up. However, lay-up light oil

period (12 months or more),

in

the cylinders will prevent the piston rings from sticking to the cylinder walls. Make

we

recommended that this procedure be performed. The

ff

you anticipate a longer

sure you apply a light coat of anti-sieze on the threads of the glow plugs when reinstalling.

Spares

Lay-up time provides a good opportunity to inspect your Westerbeke engine items such as drive order items not zinc anodes. Refer to the

Batteries

If

batteries are to be left on board during the lay-up period, make sure they are fully charged,

and

batteries will not remain fully charged, or that they will be subjected to severe environmental conditions, remove the batteries and store them in a warmer, more compatible environment.

15.0KWBTDA

be~s

or coolant hoses need replacement. Check your basic spares kit and

on

hand, or replace those items used during the lay-up, such

"SPARE

PARTS"

section of this manual.

will remain that way, to prevent them from freezing.

88

to

see

ff

external

as

Mers

If

there exists any doubt that the

Westerbeke Generators

and

Recommissioning

The recommissioning of your Westerbeke engine after a seasonal lay-up generally follows the same procedures as those presented in the "Preparations For Starting" section regarding preparation for starting and normal starts. However, some of the lay-up procedures will need to be counteracted before starting the engine.

1.

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

2. Remove the

water pump impeller removed- during lay-up (or replacement, water pump cover

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. Check to make sure that the batteries

4. Check the condition of the zinc anode

anode as needed. Note that from the self-flush an

end of season or recommissioning service to inspect the area that the zinc

in

the heat exchanger and clear any and

at

raw

water pump cover and gasket and discard the old gasket. Install the

IT

required). Install the raw

wtth a new cover gasket.

are

fully-charged.

I

WARNING

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

batteries. Lead acid batteries

be

which can

or pipe. Do not smoke or allow serviced. electrical arcing during servicing.

raw

water coolant system. When the engine

in

a short period of time with no adverse affects. It

igntted

Shut off

by

all

electrical equipment in the vicintty to prevent

it

is

emtt

electrical arcing' or a lighted cigarette, cigar,

an

in

not necessary to flush the antifreeze/fresh water solution

I

hydrogen, a highly-explosive gas,

open flame near the battery being

the

raw

water circutt and clean or replace the

is

put into operation, the system will

is

adviseable to, as either

all

zinc debris from that area.

is

located

raw

5.

Start the engine

of this manual.

Westerbeke Generators

in

accordance with procedures in the "Preparations For Starting" section

89

15.0KWBTDA

SPARE

PARTS

Since a possibility exists port other than your home port, certain spare parts should be kept on board to help minimize delays spare parts. Usted below are those spare parts that should be carried on board at

in

your voyage. Please refer to your engine's Parts Ust for part numbers when ordering

Impeller

1. An PIN

2. A Fuel System Hardware PIN

3. A Secondary PIN

4.

A Water Pump

5. Hose Clamps. Select

K'n.

033104

032050

Fuel

024363

011672

from parts list

in

which the engine may need to be serviced at sea or while in a

Filter Element.

Bett.

ali times.

Ktt.

6.

7. A few Zinc Anodes and Heat Exchanger End Plate Gaskets.

8.

15.0KWBTDA

A Spare Oil Fitter wtth a Spare Quart of Diesel Service Engine Oil along with a Galion of

Premixed

PIN PIN

An

PIN 033348

Antnreeze.

035828

011885 Zinc 022851 Gasket

Oil Pressure Swttch.

90

Westerbeke Generators

Other parts (listed below), whose life expectancy cannot be accurately predetermined, should

be carried on board (in addition to those listed above) especially on

long ocean voyages.

Fuel

1.

Injectors.

032743

H the vessel is to be taken

2. Glow Plugs.

024353

3. Cooling System Hoses. Select from parts list

4.

A Starter.

030593

5.

A 20 Amp

DC

024683

Circutt Breaker.

6.

An

7. A

Electric

Raw

Fuel

024831

Water Pump.

016423

Pump.

8. Banery Terminal Connectors. Installer part

9. A Bridge

The spare parts listed directly above

long ocean voyages. have completed long ocean voyages

RectHier.

030809

You

may wish to

are

those

ask

as

to what spare parts they carried on board and what

we

recommend be carried on board during

other boat owners who have similar boats and who

parts were needed at specific times on the voyage. From the list provided directly above and

from these inquiries, you can determine what spare parts may be needed.

In

addition, H you are planning a long ocean voyage, consult your local Westerbeke dealer for a listing of the Westerbeke dealers located on your route.

Westerbeke Generators

91

1S.0KW BTDA

Westerbeke BTDA 15.0, BTDA 12.0 Operator's Manual & Installation Manual

Specifications and Main Features

Frequently Asked Questions

User Manual