Westerbeke BTD 7.5 KW 60Hz, BTD A 9.4 KW 60Hz, BTD 10.0 KW 60Hz, BTD 11.0 KW 60Hz, BTD 6.0 KW 50Hz Operator's Manual
...
OPERATOR'S
MANUAL
&
INSTALLATION GUIDE
WESTERBEKE
CORPORATION
DIESEL
GENERA TORS
SINGLE
AND
THREE
PHASE
MODEL
BTD 8.0 KW, 10.0 KW, 11.0 KW
BTD & A 12.5 KW 60
HERTZ
MODEL
BTD 6.0 KW, 7.5 KW, 8.3 KW
BTD & A 9.4 KW 50
HERTZ
Publication # 036746
EDITION
THREE
February 1994
SAFETY PRECAUTIONS
The following symbols appear in this manual to call attention to and emphasize conditions potentially
dangerous to the operator.
I WARNING I
The above symbol is used in the manual
to
warn
of
possible serious personal injury or loss
of
life.
Ii
CAUTION
II
The above symbol is used in the manual
to
caution personnel
of
possible damage to equipment.
Read the manual carefully and thoroughly before attempting to operate the equipment. Know when
dangerous conditions can exist and take necessary precautions
to
protect personnel and equipment.
Fuels, exhaust gases, batteries, electrical equipment, and moving and hot parts are potential hazards that
could result in serious personal injury or death. Follow 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
Shut off electric power before accessing electrical equipment.
Use
insulated mats whenever working on electrical equipment.
Make sure your clothing is dry, not damp (particularly 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 AC circuits, except through a ship-to-shore double
throw transfer switch. Damage to vessel's
AC
generator may result
if
this is not done.
Be
e"tremely careful when working on electrical components. High voltage can cause injury or
death.
• Exhaust Gases
Are
Toxic
Ensure that exhaust system is adequate
to
expel gases discharged from the engine. Check exhaust
system regularly for leaks and make sure the exhaust manifolds are securely attached and no warping
exists.
Be sure the nnit and its surroundings are well-ventilated.
• Use
Extreme
Care
When Handling Engine Fucl(A constant
danger
of explosion
or
fire
exists)
Do
not fill fuel tank(s) while the engine is running.
Do not smoke or use an open flame near the engine or the fuel tank.
1
WESTERBEKE
GENERATORS
•
Do
Not Alter
or
Modifv the Fuel Svstem
Be sure all fuel supplies have a positive shut-off valve.
Be certain fuel line fittings are adequately tightened and free ofleaks.
Make sure a fire extinguisher is installed nearby and is properly maintained. Be familiar with its
proper use. Extinguishers rated ABC
by
the NFPA are appropriate for all applications encountered in
this
environment.
•
Use
Extreme
Care
When Servicing Batteries
Wear rubber gloves, a rubber apron, and eye protection when servicing batteries.
Lead acid batteries emit hydrogen, a highly-explosive gas, which can be ignited by electrical arcing or
by a lighted cigarette, cigar, or pipe. Do not smoke or allow an open flame near the battery being
serviced.
Shut off all electrical equipment in the vicinity to prevent electrical arcing during servicing.
• Avoid Moving
Parts
Do not service the unit while it is running.
If
a situation arises in which it is absolutely necessary
to
make operating adjustments, use extreme care to avoid moving parts and hot exhaust system
components.
Do not wear loose clothing
or
jewelry when servicing equipment; avoid wearing loose jackets shirts
or sleeves, rings, necklaces, or bracelets that might
be
caught in moving parts.
Make sure all attaching hardware is properly tightened. Keep protective shields and guards iu their
respective place at all times.
Do not check fluid levels or the drive belt's tension while the unit is operating.
Do not work on the equipment when mentally or physically incapacitated
by
fatigue.
WESTERBEKE GENERATORS 2
FOREWORD
Thank you for selecting a Westerbeke marine product for your
use.
We
at Westerbeke are pleased to have
you as a customer.
Read this manual carefully and observe all safety precautions included throughout Operating procedures,
periodic preventive maintenance procedures, installation checks, system descriptions and minor
adjustment procedures are included herein
so
you
can operate your equipment safely and properly,
maintain the equipment at a high level
of
efficiency, and expect dependable performance and long service
life in return. 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 60 days
of
submitting the Warranty Registration Form for your unit, you have not received a
Customer Identification Card (see below) registering your warranty, please contact the factory in writing
with Model information, including the unit's serial number and commission date.
3 WESTERBEKE GENERATORS
IMPORTANT
PRODUCT SOFTWARE DISCLAIMER
Product software
of
all kinds, such as brochures, drawings, technical data, operator's and workshop
manuals, parts lists and parts price lists, and other information, instructions and specifications provided
from sources other than Westerbeke, is not within Westerbeke's control and, accordingly, is provided to
Westerbeke customers only as a courtesy and service. WESTERBEKE
CANNOT BE RESPONSIBLE
FOR
TIIE CONTENT OF SUCH SOFTWARE, MAKES NO W ARRANTlES
OR
REPRESENTATIONS
WITH RESPECT TIIERETO, INCLUDING ACCURACY, TIMELINESS OR COMPLETENESS
TIIEREOF,
AND WILL
IN
NO EVENT BE LIABLE
FOR
ANY TYPE OF DAMAGES
OR
INJURY
INCURRED IN CONNECTION WITH, OR ARISING OUT OF, TIIE FURNISIDNG OR USE OF SUCH
SOFTWARE.
For example, components and subassemblies incorporated
in
Westerbeke's products and supplied by otbers
(such as 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. Such software may be
outdated
and
no longer accurate. Routine changes made by Westerbeke's suppliers,
of
which Westerbeke
rarely has notice in advance, are frequently not reflected
in
the supplier's software until after such changes
take place.
Westerbeke customers should also keep in mind the time span between printings
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 is imperative that appropriate representatives ofWesterbeke or
the supplier
in
question
be
consulted to determine the accuracy and currentness
of
the product software
being consulted by the customer.
WESTERBEKE GENERATORS
4
TABLE OF CONTENTS
GENERAL
12
BID
8.0
KW
MARINE DIESEL GENERATOR SET GENERAL
SPECIFICATIONS
13
SYSTEM SPECIFICATIONS
14
BTD 10.0
KW
MARINE DIESEL GENERATOR SET GENERAL
SPECIFICATIONS
17
SYSTEM SPECIFICATIONS
18
BID
11.0 KW MARINE DIESEL GENERATOR SET
GENERAL
SPECIFICATIONS
21
SYSTEM SPECIFICATIONS
22
BTD 12.5
KW
MARINE DIESEL GENERATOR SET GENERAL
SPECIFICATIONS
25
SYSTEM SPECIFICATIONS
26
BIDA
12.5
KW
MARINE DIESEL GENERATOR SET GENERAL
SPECIFICATIONS
29
SYSTEM SPECIFICATIONS
30
INSTALLATION CHECKS 34
OPERATION
41
FUEL SYSTEM
45
ELECTRICAL SYSTEM
48
COOLING SYSTEM
52
LUBRICATION SYSTEM 58
BTGENERATOR
60
GENERAL INFORMATION
AND
CARE OF THE GENERATOR
73
ENGINE CONTROL PANEL
75
ENGINE TROUBLESHOOTING
78
MAINTENANCE
AND
ADmSTMENTS
81
LAY-UP
AND
RECOMMISSIONING 89
5 WESTERBEKE GENERA TORS
TABLE OF CONTENTS (CONTINUED)
TABLE OF STANDARD HARDWARE TIGHTENING TORQUES
92
SOUND GUARD INSTALLATION INSTRUCTIONS
94
POWER TAKE-OFF (PTO) ADAPTER KlTS
95
WESTERBEKE GENERATORS
6
Control
Panel
20
Amp
DC
Circuit
Breaker
Block
Drain
DC
Charging
Alternator
Fresh
Water
Circulating
Pump
Sea
Water
BTD
8.0
KW
Generator
Preheat
Solenoid
Fuel
Lift
Pump
Fresh
Water
Fill
Oil
Pressure
Sender
8.0
KW
BTD
xhaust
Manifold
Intake
Silencer
Charging
Alternator
Fuel
Run
Solenoid
Switch
Zinc
Anode
~
__
I'x<'h,,"ge,
Fresh
Water
Drain
Exhaust
Temperature
itch
Unit
Data
Tag
Ground
Connection
Starter
with
Solenoid
8.0
KW
BTD
7
WESTERBEKE
GENERATORS
Emergency
Stop
20
Amp
DC
Circuit
Srea
AC
Outlet
Fresh
Water
Block
Drain
Lube
Oil
Filter
Fuel
Lift
Fresh
Water
Coolant
Sea
Water
Pump
Heat
Exchanger
WESTERBEKE GENERATORS
BTD
10.0
KW
Generator
Preheat
Solenoid
Intake
Silencer
10.0
KW
BTD
Emergency
Shut
ide
Oil
Fill
DC
Charging
rnatar
Run
__
,4.nc
Anode
Heat
Exchanger
-Exchanger
Fresh
Water
Drain
I
Pressure
Switch
rol
Panel
-----'"'
Exhaust
Starter
with
Solenoid
10.0
KW
BTD
8
Elbow
DC
Battery
Ground
Connection
BTD
11.0 KW Generator
Top Engine Oil
Control
Preheat Sollen<,id
A C
Con,nec,tior"'~
Fresh
Water
Slock
Lube
Oil
Dip,stick'
Lube Oil
Filter
11.0KW
BTD
Fresh
Water
Air
Heat
Exc;hang,,,/
11.0
KW
BTD
9
Water
Air
Bleed
DC
Charging
Pressure
Sender
Fitter
Shut-off
Switch
Exhaust
Temperature
Switch
Elbow
DC Battery
Ground Connection
with
Solenoid
WESTERBEKE GENERATORS
BTD 12.5 KW Generator
20
Amp
DC
Circuit
Breaker
Lube
Oil
Fil
Fuel
Filter
Control
AC
Fuel
Lift
Lube
Oil
Filter
12.5
KW
BTD
Fresh
Water
Air
Bleed
Top
Engine
Oil
Fill
Fresh
Water
I
Fill
Thermostat
Heat
Exchanger
Sea
Water
Pump
Fresh
Water
Block
Drain
Lube
Oil
Dipstick
WESTERBEKE GENERATORS
10
DC
Charging
i
Pressure
Switch
xhaust
Manifold
mergency
Shut-off
Switch
--""'U5t
Temperature
Switch
o
Exhaust
Elbow
Battery
with
Solenoid
....
....
:l=!
eo
[JJ
;j
~
eo
1:i
~
eo
z
~
o
0;
Control
Panel
20
Amp
DC
Circuit
Breaker
Lube
Oil
Filter
___
_
A
C
Connections
Outlet
Fresh
Water
Block
Drain
Preheat
Solenoid
Air
Intake
Silencer
Side
Oil
Fill
I
DC
Charging
Alternator
Fuel
Lift
Pump
Oil
Pressure
Sender
12.5
BTDA
RIGHT
SIDE
Fuel
Filter
Fuel
Injection
Pump
Fuel
Run
Solenoid
Lube
Oil
Drain
Hose
Oil
Pressure
Switch
Zinc
Anode
~
t"i
rn
;.l
~
~
~
Z
t"i
~
o
~
""
N
Fresh
Water
Fill
Cap
Exhaust
Manifold
Belt
Guard
Raw
Water
Pump
Heat
Exchanger
Lube
Oil
Fill
Cap
12.5 BTDA
LEFT
SIDE
Emergency
Shut~off
Switch
Exhaust
Temperature
Switch
450 Exhaust
Elbow
Unit
Data
Tag
DC
Battery
Ground
Connection
Starter
with
Solenoid
GENERAL
Introduction
This manual contains the equipment operating procednres as well as additional information needed
to
help the operator keep the marine eqnipment in proper working order. Stndy and follow the instructions
carefully. A planned maintenance program is included in this manual; adhering to the program will
result in better equipment performance and longer equipment life. Proper diagnosis
of
a problem
is
the
most important step
to
satisfactory repair; consequently, a troubleshooting table
is
included.
Understanding
the
Diesel Engine
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 as a gasoline
engine. The most important factors are proper ventilation and proper maintenance
of
the fuel, lubricating
and cooling systems. Replacement
of
fuel and lubricating filter elements at the time periods specified is a
must, and frequent checking for contamination (that is, water, sediment, etc.) in the fuel system is also
essential. Another important factor
is
the use
of
the same brand
of
high detergent diesel lubricating oil
designed specifically for diesel engines.
The diesel engine does differ form the gasonline engine, however, in its method
of
handling and firing
of
fuel. The carburetor and ignition systems are done away with and in their place is a single component the fuel injection pump - which performs the function
of
both.
Ordering
Parts
When contacting your Westerbeke dealer, parts distributor, or the factory about your Westerbeke unit,
always provide the generator's complete model number, the engine's serial number and the generator's
serial number as they appear on the black and silver nameplate located on the generator end. You must
provide us with this information
so
we
may
properly identify your unit.
Note that component locations in the manual are referenced from the front
of
the engine which
is
the
pulley/drive belt end. (The flywheel/generator or transmission end
is
the rear end.) Left and right sides
are determined
by
the engine; imagine straddling the engine and facing in the same direction as the front
ofthe
engine: the left side
is
at your left, the right side at your right.
Westerbeke engines and generator sets are thoroughly checked and given a final run under various load
conditions before leaving the factory. This
is
done
to
ensnre dependable operation, long service, and a
satisfied owner.
Care at the factory during assembly, and thorough testing, have resulted in a Westerbeke diesel engine
driven generator capable of many thousands
of
hours
of
dependable service. However, the manufactnrer
cannot control the treatment the unit receives in the field. That part
is
up to the owner/operator.
13
WESTERBEKE
GENERATORS
BTD 8.0
KW
MARINE DIESEL GENERA
TOR
SET
GENERAL
SPECIFICATIONS
Engine Type
Governor
Combustion Chamber
Bore
& Stroke
Pistion Displacement
Firing Order
Direction
of
Rotation
Maximum Torque (at
1800 rpm)
Compression Ratio
Compression Pressure
Valve Timing
Valve
Seat Angle
Valve Clearance
(engine cold)
Engine
Speed
Dimensions
Weight
Fuel Consumption
Inclination
WESTERBEKE
GENERATORS
Diesel, 4-cycle, 3-cylinder, fresh water-cooled
Vertical, in-line overhead valve mechanism
(14 hp
at
1800 rpms maximum)
Mechanical, centrifugal weight type
Swirl chamber type
2.87 x
3.07 inches (73 x 78 mm)
60 cubic inches (0.979 liters)
1-3-2
Clockwise, when viewed from the front
41.50 Ib-ft (5.73 kg-m)
23
: I
455.2 psi (32 kg/cm2)
at
280 rpm
Intake Opens
18°
BIDC
Intake Closes 46° ABDC
Exhaust Opens
46° BBDC
Exhaust Closes
18°
AIDC
Intake 45°
Exhaust 45°
Intake 0.0098 inches (0.25 mm)
Exhaust
0.0098 inches (0.25 mm)
1800 rpm 60 Hertz
1500 rpm
50
Hertz
Height:
21.80 inches (553.72mm)
Width:
17.00 inches (431.80 mm)
Length:
28.20 inches (716.28 mm)
450 Ibs (204.12 kgs)
0.9 gph (3.40 Iph) at full rated
output (approximate)
Continuous
15°
Temporary 20° (not to exceed 20 min.)
14
SYSTEM SPECIFICATIONS
FUEL
SYSTEM:
GENERAL
FUEL
FUEL INJECTION
PUMP
FUEL INJECTION TIMING
NOZZLE
INJECTORS
FUEL
PUMP
FUEL FIL TER(
on
engine)
AIR
CLEANER
AIRFLOW
COOLING
SYSTEM:
GENERAL
OPERATING TEMPERATURE
FRESH
WATER
PUMP
SEA
WATER
PUMP
SEAW
WATERFLOW,
AT 1800 RPM
(measured before discharging into
exhaust elbow.)
SYSTEM CAPACITY(Fresh Water)
LUBRICATION
SYSTEM:
GENERAL
OIL
FILTER
SUMP CAPACITY
OPERATING OIL PRESSURE (engine hot)
OIL GRADE
Open flow, totally self-bleeding
No.2
Diesel oil (cetane rating
of
45
or
higher)
Nippon Denso (Bosch M type)
19°
BIDC
±D.5
(static timing)
Throttle type
Pintle type
12-Volt DC; Electro-Magnetic type
Canister type, with replaceable element
Metal-screen type
32 cfm (.906 cmm)
Closed fresh water-cooled block, thermostatically
controlled with heat exchanger.
Centrifugal type, metal impeller, belt-driven
Positive displacement, rubber impeller, belt-driven
8.5 gpm
(32.2Ipm)
5 quarts (4.73 liters)
Pressure type by Trichoid pump,
gear
driven with
e>.'lernal pressure relief valve
Full flow, paper element, spin-on type
3.3 quarts (3.12 liters)
40 - 80 psi (2.8 - 5.6 kg/cm2)
API specification CC or CD
15
WESTERBEKE GENERATORS
SYSTEM
SPECIFICATIONS CONTINUED ...
ELECTRICAL
SYSTEM
STARTING
BATfERY
BATfERY
CAPACITY
DC
CHARGING ALTERNATOR
REGULATOR
STARTING AID
STARTER
DC
NO-LOAD CURRENT
DC CRANKING CURRENT
ACGENERATOR
GENERAL
VOLTAGE
RATING (Volts AC)
60 HERTZ (1800 rpm)
8.0KW
50 HERTZ (1500 rpm)
6.0KW
GENERATOR COOLING AIR
REQUIREMENTS, (60 Hertz), at
1800 rpm
12-Volt, ( - ) negative ground
300-400 CCA
12·volt DC,
50 Amp
Internal regulator built into alternator
Glow Plug, sheathed type
12·volt, 1.2 KW, reduction
type, solenoid mounted
90 Amp (max.) at 11.5 Volts
175
- 200 Amps (engine cold)
Brushless, four-pole, revolving field.
Pre·lubricated single-bearing design.
Reconnectable, single-phase transformer regulation
(optional solid-state voltage regulation)
120
or
1201240
Volts - 60 Hertz
220 Volts -
50 Hertz
Voltage regulation:± 5 % no load to full load
Frequency regulation: ± 3 % Hertz (5%) no load to
full load
120 Volts
1201240
Volts
220 Volts
66 Amps
66/33 Amps
27
Amps
175 -
200 cfm (4.95 - 5.66 cmm)
NOTE:
Increase
air
supply 15 %
for
50
Hertz
operation 1500
rpm.
WESTERBEKE
GENERATORS
16
SYSTEM SPECIFICATIONS CONTINUED ...
ENGINE COMBUSTION AIR
REQUIREMENTS (60 Hertz)
AT
1800
rpm
ENGINE COMPARTMENT COOLING
AIR
TUNE
UP
SPECIFIC A TlONS
INJECTOR PRESSURE
ENGINE TIMING
32 cfm (.906 cmm)
100-200 cfm (2.83 - 5.66 cmm)
1707 psi (120 kg/cm
2
+ 10 kg/cm
2
- 0 kg/cm2)
19°
BIDC
17 WESTERBEKE GENERATORS
BTD 10.0 KW MARINE DIESEL GENERATOR SET GENERAL SPECIFICATIONS
Engine Type
Governor
Combustion Chamber
Bore
& Stroke
Pistion Displacement
Firing Order
Direction
of
Rotation
Maximum Torque (at
1800 rpm)
Compression Ratio
Compression
Pressure
Valve Timing
Valve
Seat Angle
Valve Clearance
(engine cold)
Engine
Speed
Dimensions
Weight
Fuel Consumption
Inclination
WESTERBEKE GENERATORS
Diesel, 4-cycle, 3-cylinder, fresh water-cooled
Vertical, in-line overhead valve mechanism
(16.5 hp at
1800 rpms maximum)
Mechanical, centrifugal weight type
Swirl chamber type
3.07 x 3.07 inches (78 x 78 mm)
68 cubic inches (1.12 liters)
1-3-2
Clockwise, when viewed from the front
47.7Ib-ft (6.6 kg-m)
23
: 1
483.5 psi (34 kg/cm2) at
230 rpm
Intake Opens
18°
BIDC
Intake Closes 46° ABDC
Exhaust Opens
46° BBDC
Exhaust Closes
18° A
IDC
Iutake 45°
Exhaust 45°
Intake 0.0098 inches (0.25 mm)
Exhaust
0.0098 inches (0.25 mm)
1800 rpm 60 Hertz
1500 rpm
50
Hertz
Height:
22.00 inches (558.7mm)
Width: 16.85 inches (427.9 mm)
Length: 32.56 inches
(827.02 mm)
495
Ibs (224.5 kgs)
1.0 gph (3.78Iph) at full rated
output (approximate)
Continuous
15°
Temporary 20° (not to exceed 20 min.)
18
SYSTEM
SPECIFICATIONS
FUEL SYSTEM:
GENERAL
FUEL
FUEL INJECTION
PUMP
FUEL INJECTION TIMING
NOZZLE
INJECTORS
FUEL PUMP
FUEL FIL TER( on engine)
AIR CLEANER
AIRFLOW
COOLING SYSTEM:
GENERAL
OPERATING TEMPERATURE
FRESH WATER PUMP
SEA
WATER PUMP
SEAWWATERFLOW,
AT 1800 RPM
(measured before discharging into
exhaust elbow.)
SYSTEM CAPACITY(Fresh Water)
LUBRICATION SYSTEM:
GENERAL
OIL FILTER
SUMP CAPACITY
OPERATING OIL PRESSURE (engine hot)
OIL GRADE
Open flow, totally self-bleeding
No.2
Diesel oil (cetane rating
of
45
or
higher)
Nippon Denso (Bosch M Type)
19°
BIDC
±O.5
(static timing)
Throttle type
Pintle type
12-Volt DC; Electro-Magnetic type
Canister type, with replaceable element
Metal screen type-cleanable
48 cfm (1.36 cmm)
Closed fresh water-cooled block, thermostatically
controlled with heat exchanger.
170° - 190° F (77° - 88°
C)
Centrifugal type, metal impeller, belt-driven
Positive displacement, rubber impeller, belt-driven
7.2 gpm (27.25 Ipm)
8 quarts (7.6 liters)
Pressure type by Trichoid pump, gear driven with
external pressure relief valve
Full flow, paper element, spin-on type
4.76 (4.5 liters)
40 -
80
psi (2.8 - 5.6 kg/cm2)
API specification CC or CD
19
WESTERBEKE
GENERATORS
SYSTEM
SPECIFICATIONS
CONTINUED
...
ELECTRICAL
SYSTEM
STARTING
BATfERY
BATTERY CAPACITY
DC CHARGING ALTERNATOR
REGULATOR
STARTING AID
STARTER
DC NO-LOAD CURRENT
DC CRANKING CURRENT
ACGENERATOR
GENERAL
VOLTAGE
RATING (Volts AC)
60 HERTZ (1800 rpm)
1O.OKW
50
HERTZ (1500 rpm)
7.5KW
GENERATOR COOLING AIR
REQUIREMENTS, (60 Hertz), at
1800 rpm
12-Volt, ( - ) negative ground
350-450 CCA
12-volt DC,
50 Amp
Internal regulator built into alternator
Glow Plug, sheathed
type
12-volt, 1.6
KW,
reduction type, solenoid mounted
90 Amp (max.)
at
ll.5
Volts
175 -
200 Amps (engine cold)
Brushless, four-pole, revolving field.
Pre-lubricated single-bearing design.
Reconnectable, single-phase transformer regulation
(optional solid-state voltage regulation)
120 or
1201240
Volts - 60 Hertz
220 Volts -
50 Hertz
Voltage regulation:± 5 % no load to full load
Frequency regulation: ± 3 % Hertz (5%) no load to
full load
120 Volts
1201240
Volts
220 Volts
83.3 Amps
83.3/41.6 Amps
34.1 Amps
225-250 cfm (5.66 - 6.37 cmm)
NOTE:
Increase
air
supply
15 % for
50
Hertz
operation
1500
rpm.
WESTERBEKE
GENERATORS
20
SYSTEM SPECIFICATIONS CONTINUED ...
General - 3 Phase
10.0
KW -60
Hertz
7.5
KW
- 50 Hertz
Voltage - 3 Phase (60 Hertz)
Voltage - 3 Phase (50 Hertz)
Amperage -
3 Phase (60 Hertz)
Amperage -
3 Phase (50 Hertz)
AC
GENERATOR:
ENGINE COMBUSTION
AIR
REQUIREMENTS (60 Hertz) AT
1800
rpm
ENGINE COMPARTMENT COOLING
AIR
TUNE UPSPECIFICATIONS
INJECTOR PRESSURE
ENGINE TIMING
Brushless six pole, revolving field.
Sealed lubricated
single bearing design.
12 Lead reconnectable for
low voltage
WYE, high voltage Delta. Solid State
voltage regulator with protection circuitry.
Low voltage
WYE 208 volts
High voltage
WYE
480 volts
DELTA
240 volts
High voltage WYE 380 volts
DELTA
220 volts
Low voltage
WYE 35 Amps
High voltage
WYE
15
Amps
DELTA
30 Amps
High voltage
WYE
14
Amps
DELTA
24 Amps
32 cfm (.906 cmm)
100-200 cfm (2.83 - 5.66 cmm)
1707 psi (120 kg/cm
2
+
10
kg/cm
2
-
0 kg/cm
2
)
19'
BIDC
21 WESTERBEKE GENERATORS
BTD
11.0
KW
MARINE
DIESEL
GENERATOR
SET
GENERAL
SPECIFICATIONS
Engine Type
Governor
Combustion Chamber
Bore
& Stroke
Pistion Displacement
Firing
Order
Direction
of
Rotation
Maximum Torque (at
1800 rpm)
Compression Ratio
Compression Pressure
Valve Timing
Valve
Seat Angle
Valve Clearance
(engine cold)
Engine
Speed
Dimensions
Weight
Fuel Consumption
Inclination
WESTERBEKE
GENERATORS
Diesel, 4-cycle, 4-cylinder, fresh water-cooled
Vertical, in-line overhead valve mechanism
(18.4 hp at
1800 rpms maximum)
Mechanical, centrifugal weight type
Swirl chamber type
2.87 x 3.07 inches (73 x 78 mm)
80 cubic inches (1.305 liters)
1-3-4-2
Clockwise, when viewed from the front
54 Ib-ft (7.46 kg-m)
23
: I
455 psi (32 kg/cm2)
at
280 rpm
Intake
Opens 18°
BIDC
Intake Closes 46° ABDC
Exhaust
Opens 46° BBDC
Exhaust Closes
18°
AIDC
Intake 45°
Exhaust 45°
Intake 0.0098 inches (0.25 mm)
Exhaust
0.0098 inches (0.25 mm)
1800 rpm 60 Hertz
1500 rpm 50 Hertz
Height: 23.75 inches (603.25mm)
Width: 16.85 inches (427.99 mm)
Length: 34.56 inches (877.82 mm)
575 Ibs
(260.8 kgs)
1.2
gph (4.54 Iph) at full rated
output (approximate)
Continuous
15°
Temporary 20° (not to exceed 20 min.)
22
SYSTEM
SPECIFICATIONS
FUEL
SYSTEM:
GENERAL
FUEL
FUEL INJECTION
PUMP
FUEL INJECTION TIMING
NOZZLE
INJECTORS
FUEL PUMP
FUEL
Frr..
TER( on engine)
AIR CLEANER
AIRFLOW
COOLING
SYSTEM:
GENERAL
OPERATING TEMPERATURE
FRESH WATER PUMP
SEA
WATER PUMP
SEA
WATERFLOW, AT 1800 RPM
(measured before discharging into
exhanst elbow.)
SYSTEM CAPACITY(Fresh Water)
LUBRICATION
SYSTEM:
GENERAL
Orr..
Frr..
TER
SUMP CAPACITY
OPERATING OIL PRESSURE (engine hot)
OIL GRADE
Open flow, totally self-bleeding
No.2
Diesel oil (cetane rating
of
45 or higher)
Nippon Denso (Bosch M type)
19°
BIDC
±O.
5 (static timing)
Throttle
type
Pintle type
12-Volt DC; Electro-Magnetic type
Canister type, with replaceable element
Metal screen type-cleanable
42 cfm (1.2 cmm)
Closed fresh water-cooled block, thermostatically
controlled with heat exchanger.
170° - 190° F (77° - 88° C)
Centrifugal type, metal impeller, belt-driven
Positive displacement, rubber impeller, belt-driven
7.2 gpm (27.25 Ipm)
8 quarts (7.6 liters)
Pressure type
by
Trichoid pump, gear driven with
external pressure relief valve
Full flow, paper element, spin-on type
4.23 quarts (4.0 liters)
40 - 80 psi (2.8 - 5.6 kg/cm2)
API specification CC or CD
23
WESTERBEKE
GENERATORS
SYSTEM
SPECIFICATIONS
CONTINUED
...
ELECTRICAL
SYSTEM
STARTING BATTERY
BATTERY CAPACITY
DC
CHARGING ALTERNATOR
REGULATOR
STARTING AID
STARTER
DC
NO-LOAD CURRENT
DC
CRANKING CURRENT
ACGENERATOR
GENERAL
VOLTAGE
RATING (Volts AC)
60 HERTZ (1800 rpm)
11.0KW
50 HERTZ (1500 rpm)
8.3KW
GENERATOR COOLING AIR
REQUIREMENTS, (60 Hertz), at
1800 rpm
12-Volt, ( - ) negative ground
300-400
CCA
l2-volt DC, 50 Amp
Internal regulator built into alternator
Glow Plug, sheathed type
12-volt, 1.6 KW, reduction type, solenoid mounted
90 Amp (max.) at 11.5 Volts
175 -
200 Amps (engine cold)
Brushless, four-pole, revolving field.
Pre-lubricated single-bearing design.
Reconnectable, single-phase transformer regulation
(optional solid-state voltage regulation)
120 or 1201240 Volts - 60 Hertz
220 Volts - 50 Hertz
Voltage regulation:± 5 %
no
load to full load
Frequency regulation: ± 3 % Hertz (5%) no load to
full load
120 Volts
120/240 Volts
220 Volts
91.6 Amps
91.6/45.8 Amps
37.7 Amps
200 - 225 cfrn (5.66 - 6.37 cmm)
NOTE:
Increase
air
supply 15 %
for
50
Hertz
operation
1500
rpm.
WESTERBEKE
GENERATORS
24
SYSTEM
SPECIFICATIONS CONTINUED ...
General - 3 Phase
11.0 KW - 60 Hertz
8.3 KW - 50 Hertz
Voltage
- 3 Phase (60 Hertz)
Voltage - 3 Phase (50 Hertz)
Amperage
- 3 Phase (60 Hertz)
Amperage
- 3 Phase (50 Hertz)
AC
GENERA
TOR:
ENGINE COMBUSTION
AIR
REQUIREMENTS (60 Hertz) AT
1800 rpm
ENGINE COMPARTMENT COOLING
AIR
TUNE UP SPECIFlCATIONS
INJECTOR PRESSURE
ENGINE TIMING
Brushless six pole, revolving field.
Sealed lubricated
single bearing design.
12
Lead reconnectable for
low voltage WYE, high voltage Delta. Solid State
voltage regulator with protection circuitry.
Low voltage
WYE
208 volts
High voltage
WYE
480 volts
DELTA 240 volts
High voltage
WYE 380 volts
DELTA
220 volts
Low voltage WYE 38 Amps
High voltage WYE
16
Amps
DELTA
33
Amps
High voltage
WYE
15
Amps
DELTA
27
Amps
32 cfm (.906 cmm)
100-200 cfm (2.83 - 5.66 cmm)
1707 psi (120 kg/cm
2
+
10
kg/cm
2
- 0 kg/cm
2
)
19'
BIDC
25
WESTERBEKE
GENERATORS
BTD 12.5 KW MARINE DIESEL GENERATOR SET GENERAL SPECIFICATIONS
Engine Type
Governor
Combustion Chamber
Bore
& Stroke
Pistion Displacement
Firing Order
Direction
of
Rotation
Maximum Torque (at
1800 rpm)
Compression Ratio
Compression
Pressure
Valve Timing
Valve Seat Angle
Valve Clearance
(engine cold)
Engine Speed
Dimensions
Weight
Fuel Consumption
Inclination
WESTERBEKE GENERATORS
Diesel, 4-cycle, 4-cylinder, fresh water-cooled
Vertical, in-line overhead valve mechanism
(23 hp at
1800 rpms maximum)
Mechanical, centrifugal weight type
Swirl chamber
type
3.07 x 3.07 inches (78 x 78 mm)
91
cubic inches (1.49 liters)
1-3-4-2
Clockwise, when viewed from the front
67 Ib-ft (9.26 kg-m)
23
: 1
455 psi (32 kg/cm2)
at
280 rpm
Intake
Opens 20°
BIDC
Intake Closes 44° ABDC
Exhaust
Opens 44° BBDC
Exhaust Closes
20° A
IDC
Intake 45°
Exhaust 45°
Intake 0.0098 inches (0.25 mm)
Exhaust
0.0098 inches (0.25 mm)
1800 rpm 60 Hertz
1500 rpm 50 Hertz
Height: 25.34 inches
(643.60mm)
Width: 18.17 inches (461.50 mm)
Length: 37.25 inches (946.10 mm)
638
Ibs (289.4 kgs)
1.4 gph (5.29 Iph) at full rated
output (approximate)
Continuous
15°
Temporary 20° (not to exceed 20 min.)
26
SYSTEM SPECIFICATIONS
FUEL
SYSTEM:
GENERAL
FUEL
FUEL
INJECTION PUMP
FUEL INJECTION TIMING
NOZZLE
INJECTORS
FUEL PUMP
FUEL FIL
TER(
on engine)
AIR CLEANER
AIRFLOW
COOLING SYSTEM:
GENERAL
OPERATING TEMPERATURE
FRESH
WATER
PUMP
SEA
WATER PUMP
SEA
WATERFLOW,ATlS00RPM
(measured before discharging into
exhaust elbow.)
SYSTEM CAPACITY(Fresh Water)
LUBRICATION
SYSTEM:
GENERAL
OIL FILTER
SUMP CAPACITY
OPERATING OIL PRESSURE (engine hot)
OIL GRADE
Open flow, totally self-bleeding
No.2
Diesel oil (cetane rating
of
45 or higher)
Nippon Denso (Bosch M
type)
19°
BIDC
±O.
5 (static timing)
Throttle
type
Pintle type
12-Volt DC; Electro-Magnetic type
Canister type, with replaceable element
Metal screen type-cleanable
4S
cfm (1.2 cmm)
Closed fresh water-cooled block, thermostatically
controlled with heat exchanger.
Centrifugal type, metal impeller, belt-driven
Positive displacement, rubber impeller, belt-driven
7.2 gpm (27.25 Ipm)
8 quarts (7.6 liters)
Pressure type by Trichoid pump, gear driven with
exiernal pressure relief valve
Full flow, paper element, spin-on type
4.76 quarts (4.5 liters) plus filter/cooler assembly
40 -
SO
psi (2.S - 5.6 kg/cm2)
API specification CC or CD
27
WESTERBEKE GENERATORS
SYSTEM SPECIFICATIONS CONTINUED ...
ELECTRICAL
SYSTEM
STARTING BATTERY
BATTERY
CAPACITY
DC CHARGING ALTERNATOR
REGULATOR
STARTING AID
STARTER
DC NO-LOAD CURRENT
DC CRANKING CURRENT
AC
GENERATOR
GENERAL
VOLTAGE
RATING (Volts AC)
60 HERTZ (1800 rpm)
12.5 KW
50 HERTZ (1500 rpm)
9.3
KW
GENERA
TOR COOLING AIR
REQUIREMENTS,
(60 Hertz),
at
1800 rpm
12-Volt, (
-)
negative ground
300-400 CCA
12-volt DC,
50 Amp
Internal regulator built into alternator
Glow
Plug, sheathed type
12-volt, 1.6 KW, reduction type, solenoid mounted
90
Amp (max.) at 11.5 Volts
175 -
200 Amps (engine cold)
Brushless, four-pole, revolving field.
Pre-lubricated single-bearing design.
Reconnectable, single-phase transformer regulation
(optional solid-state voltage regulation)
120
or
1201240
Volts - 60 Hertz
220 Volts -
50
Hertz
Voltage regulation:±
5 % no load to full load
Frequency regulation: ± 3 % Hertz (5%) no load to
full load
120 Volts
1201240
Volts
220 Volts
104 Amps
104/52 Amps
42.3 Amps
200 - 225 cfm (6.37 - 7.08 cmm)
NOTE: Increase
air
supply 15 %
for
50
Hertz
operation 1500 rpm.
WESTERBEKE
GENERATORS 28
SYSTEM
SPECIFICATIONS
CONTINUED
...
General
- 3 Phase
12.5 KW - 60 Hertz
9.3 KW
- 50 Hertz
Voltage
- 3 Phase ( 60 Hertz)
Voltage
- 3 Phase (50 Hertz)
Amperage
- 3 Phase (60 Hertz)
Amperage
- 3 Phase (50 Hertz)
AC
GENERATOR:
ENGINE COMBUSTION AIR
REQUIREMENTS
(60 Hertz) AT
1800 rpm
ENGINE COMPARTMENT COOLING
AIR
TUNE UP SPECIFICATIONS
INJECTOR PRESSURE
ENGINE TIMING
Brushless six pole. revolving field.
Sealed lubricated
single bearing design.
12
Lead reconnectable for
low voltage WYE, high voltage Delta.
Solid State
voltage regulator with protection circuitry.
Low voltage WYE
208 volts
High voltage WYE
480 volts
DELTA
240 volts
High voltage WYE
380 volts
DELTA
220 volts
Low voltage WYE
43
Amps
High voltage WYE
18
Amps
DELTA
37 Amps
High voltage WYE
17
Amps
DELTA
30 Amps
32
cfm (.906 cmm)
100-200 cfm (2.83 - 5.66 cmm)
1707 psi (120 kg/cm
2
+
10
kg/cm2 - 0 kg/cm2)
29
WESTERBEKE
GENERATORS
BTDA 12.5
KW
MARINE DIESEL GENERATOR SET GENERAL SPECIFICATIONS
Engine Type
Governor
Combustion Chamber
Bore
& Stroke
Pistion
Displacement
Firing
Order
Direction
of
Rotation
Maximum Torque (at 1800 rpm)
Compression Ratio
Compression Pressure
Valve Tinting
Valve
Seat Angle
Valve Clearance
(engine cold)
Engine
Speed
Dimensions
Weight
Fuel Consumption
Inclination
WESTERBEKE
GENERATORS
Diesel, 4-cycle, 4-cylinder, fresh water-cooled
Vertical, in-line overhead valve mechanism
(23
hp at 1800 rpms maximum)
Mechanical, centrifugal weight
type
Swirl chamber type
3.07 x 3.07 inches (78 x 78 mm)
91
cubic inches (1.49 liters)
1-3-4-2
Clockwise, when viewed from the front
67 Ib-ft (9.26 kg-m)
23
: I
455 psi (32 kg/cm2)
at
280 rpm
Intake
Opens 20°
BIDC
Intake Closes 44° ABDC
Exhaust
Opens 44° BBDC
Exhaust Closes
20° A
IDC
Intake 45°
Exhaust 45°
Intake 0.0098 inches (0.25 mm)
Exhaust 0.0098 inches (0.25 mm)
1800 rpm
60 Hertz
1500 rpm
50
Hertz
Height: 25.34 inches (643.60mm)
Width: 18.17 inches (461.50 mm)
Length: 37.25 inches (946.10 mm)
638 Ibs (289.4 kgs)
1.1
gph (4.2 Iph) at full rated
output (approximate)
Continuous
15°
Temporary 20° (not to exceed 20 min.)
30
SYSTEM SPECIFICATIONS
FUEL SYSTEM:
GENERAL
FUEL
FUEL
INJECTION PUMP
FUEL INJECTION TIMING
NOZZLE
INJECTORS
FUEL PUMP
FUEL FIL TER( on engine)
AIR CLEANER
AIRFLOW
COOLING SYSTEM:
GENERAL
OPERATING TEMPERATURE
FRESH WATER PUMP
SEA
WATER PUMP
SEA
WATERFLOW,ATI800RPM
(measured before discharging into
exhaust elbow.)
SYSTEM CAPACITY(Fresh Water)
LUBRICATION SYSTEM:
GENERAL
OIL FILTER
SUMP CAPACITY
OPERATING OIL PRESSURE (engine hot)
OIL GRADE
Open flow, totally self-bleeding
No.2
Diesel oil (cetane rating
of
45 or higher)
Nippon Denso (Bosch M type)
19°
BIDC
±O.5
(static timing)
Throttle type
Pintle type
12-Volt DC; Electro-Magnetic type
Canister type, with replaceable element
Metal screen type-cleanable
48 cfm
(1.2 cmm)
Closed fresh water-cooled block, thermostatically
controlled with heat exchanger.
170° - 190° F (77° - 88°
C)
Centrifugal type, metal impeller, belt-driven
Positive displacement, rubber impeller, belt-driven
7.2 gpm (27.25 lpm)
8 quarts (7.6 liters)
Pressure type
by
Trichoid pump, gear driven with
external pressure relief valve
Full flow, paper element, spin-on type
4.76 quarts (4.5 liters) plus filter/cooler assembly
40 -
80
psi (2.8 - 5.6 kglcm2)
API specification CC or CD
31
WESTERBEKE GENERATORS
SYSTEM SPECIFICATIONS CONTINUED ...
ELECTRICAL
SYSTEM
STARTING
BATTERY
BATTERY
CAPACITY
DC
CHARGING ALTERNATOR
REGULATOR
STARTING AID
STARTER
DC
NO-LOAD CURRENT
DC
CRANKING CURRENT
ACGENERATOR
GENERAL
VOLTAGE
RATING
(Volts AC)
60
HERTZ
(1800 rpm)
12.5
KW
50
HERTZ
(1500 rpm)
9.3KW
GENERATOR COOLING AIR
REQUIREMENTS, (60 Hertz),
at
1800 rpm
12-Volt. (
-)
negative ground
300-400
CCA
12-volt
DC,
50
Amp
Internal regulator
built
into alternator
Glow Plug, sheathed type
12-volt, 1.6 KW, reduction type, solenoid mounted
90
Amp
(max.)
at
11.5 Volts
175 -
200 Amps (engine cold)
Brushless, four-pole, revolving field.
Pre-lubricated single-bearing design.
Reconnectable, single-phase transformer regulation
(optional solid-state voltage regulation)
120
or
1201240 Volts - 60 Hertz
220 Volts - 50 Hertz
Voltage regulation:± 5 % no load to
full load
Frequency regulation: ± 3 % Hertz (5%)
no
load to
full load
120 Volts
120/240 Volts
220 Volts
104 Amps
104/52 Amps
42.3 Amps
200 . 225 cfm (6.37 - 7.08 cmm)
NOTE:
Increase
air
supply 15 %
for
50
Hertz
operation 1500 rpm.
WESTERBEKE
GENERATORS 32
SYSTEM SPECIFICATIONS CONTINUED ...
General - 3 Phase
12.5 A
KW
- 60 Hertz
9.3 A
KW
- 50 Hertz
Voltage -
3 Phase (60 Hertz)
Voltage -
3 Phase (50 Hertz)
Amperage -
3 Phase (60 Hertz)
Amperage -
3 Phase (50 Hertz)
AC
GENERATOR:
ENGINE
COMBUSTION AIR
REQUIREMENTS (60 Hertz) AT
1800
rpm
ENGINE
COMPARTMENT
COOLING
AIR
TUNE UP SPEC/FlCA TIONS
INJECTOR
PRESSURE
ENGINE
TIMlNG
Brushless six pole. revolving field. Sealed lubricated
single bearing design.
12
Lead
reconnectable for
low voltage
WYE.
high
voltage Delta. Solid State
voltage regulator with protection circuitry.
Low voltage
WYE
208 volts
High voltage
WYE
480 volts
DELTA
240 volts
High voltage
WYE
380 volts
DELTA
220 volts
Low voltage
WYE
43 Amps
High
voltage
WYE
18 Amps
DELTA
37 Amps
High voltage
WYE
17 Amps
DELTA
30 Amps
32 cfm (.906 cmm)
100-200 cfm (2.83 - 5.66 cmm)
1707 psi (120 kglcm
2
+ 10 kglcm
2
-
0 kglcm
2
)
33
WESTERBEKE GENERATORS
INSTALLATION CHECKS
General
Because the crafts in which Westerbeke engines and generators are installed vary in design, installation
procedures will vary according to your craft's specific design.
It
is
not the intent
of
this section to advise
boatyards or installers on procedures already well-developed and well-understood. However, it
is
important that the owner/operator realize there are details of the installation which require periodic
checks
to
ensure the best operating conditions for the equipment and safe operating conditions for the
personnel on board.
Proper location and installation of the generator set in the vessel are
of
prime importance.
Factors
in
the installation that must
be
considered are ventilation,
so
as
to
cool
the generator and
to
provide air for engine combustion; exhaust system, to properly discharge raw cooling water, to quiet the
exhaust and to expel the exhaust gas; cooling water supply; fuel supply; and electrical connections.
Factors in the location that must
be
considered are proper support and access for servicing and repairs.
There are four II2-inch bolt holes in each generator mounting rail to properly secure the generator to its
mounting platform.
WESTERBEKE GENERATORS
34
Location
The location should be such that it
is
dry, above low-lying vapor areas, and away from being splashed
by
bile water or water from above.
It
should be properly ventilated and accessible for minor servicing and
repairs. Access for major repairs should
be
given consideration as well. The location must be properly
ventilated to provide the fresh cooling air for the generator end and for engine combustion. Hot generator
discharge air must be removed from the generator area. The platform on which the generator and its
mounting rails are located should be strong enough to support the generator unit during all angles
of
vessel operation.
Exhaust System
The exhaust system provides an outlet line
to
vent engine exhaust gases out
of
and away from the vessel.
The system also discharges sea water which has passed through the engine's sea water circuit by mixing it
with hot exhaust gases. This mixing helps to cool the exhaust gases and exhaust elbows and pipe. The
exhaust system and the sea water supply
to
the exhaust must be configured to prevent the siphoning
of
sea
water into the exhaust through the sea water cooling circuit and to prevent the entry
of
sea water into the
exhaust through the circuit's thm-hull discharge port.
If
not prevented, sea water entering through the
discharge port can fill the exhaust system's muffler and enter the
engine's
cylinders. This will prevent
proper starting and possibly cause damage
to
internal engine components.
PilCh
1E
......
.."t
lir'W!
Oow"
10
O'SC"
...
g<l!
'n
'nc"
~,
FOOl
Of
Ru'"
Dry
Stack
Exhaust
The sea water supply hose to the exhaust system's water injection elbow should be routed (looped) at least
12
inches above the vessel's water line. An anti-siphon break should be installed at the top
of
this loop
when the generator set is installed at or below the water line. The top
of
the loop should be placed high
enough above the vessel's water line
so
as
to
remain above the water line when the vessel is underway, no
matter what the angle
of
heel or roll may be.
The sea water supply thm-hull seacock fittings must be
of
the flush-hull type. High-speed scoop type
fittings should not be used, as they tend
to
encourage siphoning.
35
WESTERBEKE
GENERATORS
J
Sea
Water
Intal<e·
Tnru·
Hull
F,n,nc
Sea
Waler
''''''
The exhaust discharge from the water lift muftler should
be
routed well above the water line then
downward to the thru-hull discharge. This routing will prevent sea water from entering
if
the thru-hull
discharge fitting becomes submerged when the vessel heels or rolls while underway, or
is
subjected to
following sea conditions. Refer to the figures for recommended exhaust system installations.
WESTERBEKE GENERATORS
Sea
Waler
Inla-.e·
i"/'nJ-
MIA
Fn~C
36
Exhaust Back-Pressure
Exhaust back -pressure should be checked prior
to
putting a generator into service. (Refer to
illustration.) Excessive back-pressure will affect
the engine's performance and
the
generator's
power output.
To measure
the
engine's back-pressure, either a
mercury manometer
or
a water column must be
acquired. A boatyard or marine mechanic should
have a clear plastic tube and taping one end
to
a
yardstick and fitting the other end with a
114
inch
NPT (National
Pipe Tap) fitting. Fill the tube
half-full with water.
If
your generator set does not
have a tapped hole in its exhaust manifold, one
must
be
drilled and tapped
for a 114-inch
NPT
fitting.
Measure back -pressure at the exhaust elbow when
the generator is under a full load. Back-pressure,
as
measured
by
a manometer
or
water column,
should not be over the following specifications:
3 inches
of
mercury (0.104 kg/cm2)
39
inches of water in the column (.099 kg/cm2 at
4°
C)
22
ounces of psi
1
112
psi
"
\
' "
"
I~
::xhaust
::Ibow
~Exhaust
f\
Mercury
Manometer
\
\
NOTE: Other pressure gauges
may
be available to test for exhaust back-pressure.
Oil Drain
An
oil
sump drain hose
is
installed on the engine with
the
discharge end secured
by
a bracket at the front
of the engine. Oil may
be
drained from this
hose
by
removing the cap and the discharge end of the hose
from the support bracket and lowering the hose into a container. The hose cap fitting is
114
inch-NPT
(National
Pipe Tap) and can he extended,
or
have a pump added, for easier removal of the old oil,
if
desired.
Cooling System
The generator's engine is fresh water cooled
by
an engine-mounted heat exchanger. Sea water
is
used
as
the heat exchange's cooling medium.
Sea
water
is
pumped into the exchanger
by a sea
water pump and
is
then injected into the exhaust discharge, carrying with it the heat removed from the engine's fresh water
cooling system.
Sea water should
be
supplied to the sea water pump through a flush-type hull fitting using a wire-
reinforced hose between the thm-hull fitting and the sea water pump. This
sea
water should
be
directed
through a visual-type sea water strainer and then delivered
to
the pump. Hoses routed from the thm-hull
fitting
to
the strainer and to the
sea
water pump should
be
wire-reinforced
to
prevent the hose from
collapsing during the generator's operation (suction from the pump
may
collapse a non-reinforced hose.)
Sea water strainers should he mounted at or below the water line
to
make sure the sea water line remains
primed.
37
WESTERBEKE GENERATORS
UCAUTION
II
Do not nse a scoop-type thru-hull fitting as a means
of
supplying sea water to the generator.
Water pressure against this type fitting, while the vessel is under way, can push sea water past
the sea water pump's impeller into the generator's exhaust system, filling it and the engine as
well. Flush-type, clear, thru-hull fittings are recommended and should be located on the hull so
as to
be
below the waterline during all angles
of
boat operation.
The use
of
common-type street elbows is not recommended for plumbing the sea water circuit.
These generally have very restrictive inside diameters. Machined fittings are preferred.
Automatic Shutdown
High Exhaust Temperature Shutdown Switch (normally closed)
An exhaust temperature switch is located on the exhaust elbow. This switch will open and shut the fuel
solenoid
OFF (which turns OFF the engine) should the switch's sensor indicate an excessive exhaust
temperature (an inadequate supply
of
sea water coolant causes high exhaust temperatures). This switch
opens at
260
0
- 270
0
F (127 - 1320 C). This switch resets at
1950 F (107
0
C).
Low
Oil Pressure Shutdown Switch (normally open)
A low oil pressure shutdown switch is located off the engine's oil gallery. This switch's sensor monitors
the engine's oil pressure. Should the engine's oil pressure fall
to
10-15 psi, the switch will open shutting
OFF the fuel solenoid (which turns OFF the engine).
I WARNING I
Although diesel engine exhaust gases are not as toxic as exhaust fumes from gasoline engines,
carbon monoxide is present in diesel exhaust fumes. Carbon monoxide is a dangerous gas that
can cause unconsciousness and
is
potentially lethal. Some
of
the symptoms or signs
of
carbon
monoxide inhalation or poisoning are listed below.
• Dizziness
• Vomiting
• Intense headache • Muscular twitching
• Weakness and sleepiness • Throbbing in temples
If
you experience any
of
the above symptoms, get out into fresh air immediately.
WESTERBEKE
GENERATORS
38
The best protection against carbon monoxide poisoning
is
a daily inspection
of
the complete exhaust
system. Check for leaks around manifolds, gaskets, and
welds.
Make sure exhaust lines are not heating
surrounding areas excessively.
If
excessive heat is present, correct the situation immediately. If
you
notice a change in the sound
or
appearance of the exhaust system, shut down the unit immediately and
have the system inspected and repaired at once
by
a qualified mechanic.
Make sure there are
no
unnecessary objects suspended from any portion of the exhaust lines. Excessive
weight could cause deflection or distortion of the lines, resulting in damage leaks. Inspect insulated
portions of the exhaust system to ensure there
is
no
deterioration
of
the insulation.
Intake
System
Make sure the intake system (sea water cooling system)
is
in proper order. Check that the hull inlet,
seacock and strainer are unobstructed. Seacocks and strainers should be at least one size greater than the
inlet thread of sea water pump. The strainer should
be
of the type that
may
be
withdrawn for cleaning
while the vessel
is
at sea and should be mounted below the water line to ensure self-priming. Inspect the
sea water lines
to
ensure there are
no
collapsed sections, which would restrict water
flow.
Make sure there
are
no
air leaks at any of the connections.
Fuel
System
The generator must
have
its
own
fuel
supply; in other words, it must have its own pickup tube and
primary filter/water separator.
DO
NOT tee off another engine's fuel supply. The fuel system should
be
installed in such a manner
as
to
allow the engine-mounted
fuel
lift pump
to
maintain a positive inlet
pressure to the injection pump under all operating conditions. The minimum size of the fuel supply line
and
fuel
tank and the
fuel
lift pump. A secondary
fuel
filter has been installed on the engine between the
fuel lift pump and the injection pump; this filter has a replaceable filter element. Make sure that the
fuel
supply and return lines are securely anchored
to
prevent chafing and that all fittings are sufficiently
tightened
to
prevent leaking. Also make sure your
fuel
system has a positive shut-off valve; know its
location and
how
it operates.
NOTE: Ensure that the
fuel
pickup tubes in the
fuel
tank supplying the generator are clear of any gauze
or screen type strainers. These can easily clog and cause
fuel
starvation
to
the generator's engine.
DO
NOT use mechanical type check valves in lieu of a manual shut off valve.
Electrical
System
The electrical system should
be
checked to ensure that all wiring harnesses are properly tied down with
clamps or plastic ties and that all wiring harnesses are spaced at intervals close enough
to
prevent chafing
from vibration. Check to ensure that all engine harness connections are tight and that they are made to
the appropriate terminals.
39
WESTERBEKE GENERATORS
Generator
(Ae
Output)
Make sure that the AC output connections within the generator's districution box are tight and in
accordance with the specific
AC
Load Connections diagram found later
in
this manual. (See the "BT
GENERA TOR" section
of
this manaul.)
WARNING
DO NOT smoke or allow an open flame near batteries. Lead acid batteries emit hydrogen, a
highly-explosive gas.
Batteries
Make sure the positive (+) battery connection is connected to the battery connection
of
the starting
solenoid. The negative ( - ) battery connection should be connected
to
the system ground (engine block).
I
WARNING
I
When servicing the battery or checking electrolyte level, wear rubber gloves, a rubber apron, and
eye protection. Battery acid may splash on the skin or into the eyes inadvertently when removing
electrolyte caps.
Check the battery's electrolyte level ans specific gravity to ensure maximum engine starting efficiency.
Make sure the battery's terminals are clean and tight.
Ventilation
The ventilation requirements
of
the generator sets include the following: combustion air is required for the
engine cylinders; cooling air is required for the generator end; and ventilating air is required to clear the
bilges below the generator, as well as the compartment in which the generator is located,
of
potentially
toxic and flammable diesel fumes. Refer
to
the "SYSTEM SPECIFICATIONS" section
of
this manual for
the airflow requirements
of
the generator sets.
WESTERBEKE
GENERATORS
40
OPERATION
This section
of
the manual provides the operator with preparation, initial starting, break-in, starting (cold
or warm), and stopping procedures. Follow the procedures as presented, for the conditions indicated, and
your Westerbeke generator set will give you reliable performance and long service life.
Preparation for Starting
Take the steps described below in starting your engine for the first time or after a prolonged shutdown or
lay-up.
Fill your engine with oil up to or near the upper limit on the dipstick (the installation angle may have an
effect on the dipstick reading). Select a readily available lubricating oil with an API specification
of
CC
or CD and an SAE number suitable for the temperature in your operating area. For the quantity
of
oil
needed in your generator's engine, refer
to
the "SYSTEM SPECIFICATIONS" section
of
this manual,
located on pages
\3
through 33.
Each unit
is
supplied with a coolant recovery kit (part #24977) as standard equipment, to which 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 antifreeze suitable for your temperature zone. (See the "COOLING
SYSTEM" section
of
this manual.)
b.
Make sure the plastic recovery tank is properly mounted near the unit (with the bracket provided) in a
location where it can be monitored and filled easily. The recovery tank should be mounted at manifold
level or above.
c.
Coolant should be added to the plastic recovery tank after the engine has been filled and started. After
its operating temperature has been reached, ensure that all air
is
expelled out
of
the engine's cooling
system and manifold. With the manifold filled
to
the filler neck, install the pressure cap. Add coolant
mixture
to
the recovery tank to the half-full mark. Check recovery tank daily and add coolant as needed.
Very little coolant should be lost from this closed type
of
cooling system. Periodically check coolant level
in exhaust manifold; this should always be full to the filler cap
neck.
Fill the fuel tank with a good grade
of
No.2
diesel fuel and prime the fuel system up to the engine. The
engine's own fuel system
is
totally self-bleeding. Depress the PREHEAT switch for
15
to
30
seconds and
monitor the return fuel
flow.
When the returning fuel
is
free of air, the engine's fuel system is bled and
the engine
is
ready to start.
NOTE: When the PREHEAT switch
is
depressed, the glow plugs in the cylinder head are energized; use
the PREHEAT switch intermittently
to
prevent overheating the glow plugs.
Activating the PREHEAT switch energizes the fuel run solenoid, drawing the throttle arm into the preset
run position. Ensure that the arm moves rapidly and smoothly.
Ensure that the Installation Checks have been made in accordance with those specified in the
"INSTALLATION CHECKS" section
of
this manual (refer
to
page
35)
and that there
is
no
AC load on
the generator prior to starting the engine.
41
WESTERBEKE
GENERATORS
Starting
Procedure
o
o
PREHEAT
4
~
START
@
.
".-
).
-'
STOP
4k
~
CENERATOJ:i
o
ELAfIl'S£OTM
I
plllmlll
0
II
......
"'0
o
NOTE: When the generator
is
stopped after
use,
the water temperature and oil pressure gauges may stay
at their running readings.
When the generator
is
next used, depressing the PREHEAT switch will cause the water temperature and
oil pressure gauge indicators
to
return
to
zero (deflect to the left
of
the gauge). The DC voltmeter will
register system voltage. The electron on-engine fuel pump, glow plugs, and fuel run solenoid are also
energized.
Depress and hold the PREHEAT switch. Preheat according
to
the following chart:
Atmospheric Temperature Preheating Time
+41°F(+5°C)
orhip;her
Approx. 10 seconds
+41°F(+5°C)
to
+23°F(-5°C)
Approx. 20 seconds
+23
° F (_5°C) or lower Approx. 30 seconds
Limit
of
continuous use J minute
WESTERBEKE GENERATORS
42
Proper glow plug function is indicated
by
a voltmeter
drop when the
PREHEAT switch is depressed. This
drop will be slight but discernible.
If
no
voltage drop
is noted, it may indicate defective glow plugs or a faulty
preheat circuit (check for loose connections).
While holding the
PREHEAT switch depressed, depress
the
START switch. The starter motor will run, thereby
cranking the engine. As soon as the engine runs, release
the
START switch, but continue holding the PREHEAT
switch depressed for 2 or 3 seconds. Release the PREHEAT
switch when the oil pressure reaches approximately
20
psi.
This bypasses the Low
Oil Pressure shutdown until the
engine's
oil
pressure
rises
to
its
normal
running
pressure.
Now release the PREHEAT switch.
Should the engine not start when the START switch is
depressed for
10
to
20 seconds, release both switches
Proper Glow Plug Indication
and wait 30 seconds; repeat the procedure above. Never run the starter for more than 30 seconds.
II
CAUTION
n
Prolonged cranking intervals without the engine starting can result in filling the engine-mounted
exhaust system with sea water coolant. This may happen because the sea
water
pump
is
pumping
sea
water
through the sea
water
cooling system during cranking, This sea
water
can
enter
the
engine's cylinders
by
way of the exhaust manifold once the exhaust system fills. Prevent this from
happening
by
closing the sea 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 damage
resulting from this type of sea water entry is not a warrantable issue; the owner/operator should
keep this in mind.
Once the engine starts, check instruments for proper oil pressure and battery charging voltage. Never
attempt to engage the starter while the engine is running. Apply a light load to the generator and allow
the engine's operating temperature is reached (170
- 1900 F) and when a load is applied to the generator.
Stopping Procedure
Remove the AC electrical load from the generator and allow the generator
to
run for 3 - 5 minutes
to
stabilize its operating temperatures. Depress the STOP switch and hold it until the generator is
completely stopped. Now release the STOP switch.
Break-In Precautions
Because the generator set operates at 1800 rpm to produce 60 Hertz, or at 1500 rpm to produce 50 Hertz,
control
of
the generator's engine break-in is governed
by
the current drawn from the generator.
Do Not attempt
to
break-in your generator set
by
running it without a load.
43
WESTERBEKE GENERATORS
Upon starting the generator set, check for proper operation and then encourage a fast warm-up. For the
first
10
hours
of
the generator's operation, run the generator set between
20
and
60
percent
of
full load.
After the first
10
hours
of
the generator's operation, the load may be increased
to
the rated full-load
output. Periodically vary the load.
Be aware
of
motor starting loads and the high current draw required for starting motors (see page 69 for
an "Amps for Starting" chart).
Starting
Under
Normal Conditions
Follow the procedure below for routine starting
of
the generator:
Check the engine's lubricating oil level prior
to
each day's
use.
Add oil as needed and maintain the oil
level at the high mark on the dipstick.
Check the coolant level in the plastic recovery tank.
NOTE: Excessive loss
of
coolant from the plastic recovery tank indicates a cooling
system leak. Check the entire cooling system; pressurize the system
to
locate the leak.
In cases
of
excessive coolant loss, the system must be refilled as outlined under the
"Preparation for Starting" section of this manual.
Visually examine the unit; look for any abnormalities and correct them as needed.
Check to ensure that there
is
sufficient fuel in the tank and examine the filter/separator bowls for
contaminants. Clean and drain the bowls as needed.
Start the generator following the procedure given under "Starting Procedure," and allow the engine's
operating temperature to reach
140
- 1500 F (60 - 660 C) before placing the generator under a heavy load.
Starting
Under
Cold Conditions
Under extremely cold temperatures, the following conditions can occur. Follow the instructions listed
below when operating your generator set in cold weather.
LUBRICATING OIL TURNS VISCOUS - Make certain that the lubricating oil used conforms with the
ratings for the prevailing atmospheric temperature. Refer to the "LUBRICATION SYSTEM" section
of
this manual, page 46, for an atmosphericalioil viscosity specification table.
VOLT AGE ACROSS BATTERY TERMINALS DROPS - Make certain that the battery
is
fully charged
to
minimize voltage drop across the battery terminals.
THE TEMPERATURE OF THE INTAKE AIR
IS
LOW
AND
THE COMPRESSION TEMPERATURE
DOES NOT RISE ENOUGH -Allow the glow plugs to operate sufficiently
to
aid in starting during the
preheat period whenever the temperature
of
the intake air
is
low
and when the compression temperature
does not rise enough. Refer to the preheat chart found in the "Starting Procedure" section
of
this manual,
page
30.
WESTERBEKE
GENERATORS
44
FUEL SYSTEM
Diesel Fuel
Use
No.2
diesel fuel with a cetane rating
of
45
or higher. Never use kerosene or home heating oil since
these fuels
do
not have the same lubricating properties as
No.2
diesel fuel.
In
cold weather particularly, water vapor is produced
by
condensation when air is present in the fuel tank.
Keep fuel tank(s) full and completely free
of
dirt and water.
Fuel FilterlW
ater
Separators
A primary fuel filter
of
the water separating type must be
installed between the fuel tank and the engine. This is to
remove water and other contaminants from the fuel before
they can be carried
to
the fuel system on the engine.
Most installers include with the generator installation
package a rype
of
filter/water separator for they are aware
of
the problems contaminants in the fuel can cause - all
of
which are not warrantable through Westerbeke.
A rypical fuel filter/water separator is illustrated
at
the right.
This is the Raycor Model
220 F. Keep in mind that
if
a water
separator rype filter is not installed between the fuel supply
tank and engine-mounted fuel system, any water in the fuel
will affect the fuel pump, engine filter, and injection equipment. The owner/operator is responsible for making certain
the fuel reaching the engine's injection equipment is free
of
impurities. This process is accomplished by installing and
maintaining a proper filtration/separation system.
In
addition, any gasoline in the fuel system will damage the
engine's fuel injection pump assembly and injectors as gasoline does not have the same lubricating qualities as diesel
fuel.
Priming
the Fuel System (Self-Bleeding)
The Westerbeke self-bleeding fuel system is semiautomatic in operation. The self-bleeding feature
of
the
fuel system allows for easy servicing
of
the fuel filters. Simply remove and replace the filter element (take
care in catching any fuel that may drain out
of
the fuel filtering assembly) as described in the "Replacing
the Fuel Filter Element" section. Energize the
PREHEAT switch and allow the electric fuel pump to
operate for
20
to 30 seconds to prime and bleed air from the system. (No fittings should be opened.)
Then proceed to start the engine as you normally would.
If
the engine does not start, stop and wait a
few
moments, and then repeat the bleed procedure as indicated above. When the PREHEAT switch is
depressed, the preheat elements (the glow plugs) are energized,
so
take care not to over heat them.
45
WESTERBEKE
GENERATORS
II
CAUTION
II
Prolonged cranking intervals without the engine starting can result in filling the engine-mounted
exhaust system with sea water coolant. This may happen because the sea water pump
is
pumping
sea
water
through
the
sea water cooling system during cranking. This sea water can
enter
the
engine's cylinders
by
way of the exhaust manifold once the exhaust system fills. Prevent this from
happening by closing the sea 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 damage
resulting from this type of sea water entry
is
not a warrantable issue; the owner/operator should
keep this in mind.
Replacing the
Fuel Filter Element
While it is unlikely that the operator will
be
forced
to
service the system at sea, the possibility
does
exist.
Therefore, it is recommended that baojo washers, injectors seat washers, a fuel system hardware kit, fuel
filter and gasket be carried
on
board at all times. Select the parts
for
your engine
from
the Parts List and
purchase spares from your local Westerbeke Dealer or Distributor. For example,
fuel
filter kit #30200
includes replacement elements with gaskets (items
#21
and
20).
If
a leak should develop at a
fuel
banjo or
sealing washer location that cannot
be
remedied
by
a slight tightening, the sealing washers and banjo
bolts contained in the
fuel
system hardware kit for your particular
model
will
come
in handy
to
remedy
these leaks.
After the first
50
hours operation, loosen retainer ring
#23
and discard filter element
#21.
Clean bowl
#22
and install a
new
filter using a
new
#20
gasket. Be careful to catch any fuel
that
may spill from within
these fuel filter assemblies.
After the first
50-hour change, the change period
may
be
increased
to
200 hours or once per season.
The fuel pump has
no
filter element
within it. The only maintenance it
requires
is
to
ensure
the
connections
to
itm, both
fuel
and electrical, are
secure and tight and that
fuel
supplied
to
this pump
is
free of impurities.
13
WESTERBEKE GENERATORS
Fuel
Supply
(out)
12
V DC
(+)
Connection
Ground
Wire
46
Fuel
Pum.p
Fuel
Supply
(in)
(In..ta.ller'.
Connection)
Fuel Injection Pump
The fuel injection pump
is
one
of
the most important components
of
the diesel engine and therefore calls
for the utmost caution in handling. Furthermore, the fuel injection pump has been thoroughly benchtested and should not be tampered with.
Running speed and timing adjustment are the only adjustments the servicing dealer can perform on the
injection pump. Other types
of
adjustments or repairs must be performed
by
a qualified injection service
shop.
Typical Fuel System
To obtain long and satisfactory service from the injection pump, always use fuel which is free from
impurities and maintain a good filtration and water separation system between the fuel tank and generator
engine. Service this system regularly: the injection pump
is
saves may be your
own.
47
WESTERBEKE GENERATORS
ELECTRICAL SYSTEM
Engine 12-Volt DC Control Circuit
The engine that drives the generator end has a 12-Volt DC electrical control circuit, as shown on the
wiring diagrams which are illustrated on the following pages. Refer to these diagrams when
troubleshooting or servicing electrical components on the engine.
II
CAUTION
II
To avoid damage to the battery's charging circuit, never shut off the engine's battery
switch while the engine is running.
However, shut off the engine's battery switch to avoid electrical shorts when working on
the engine's electrical circuit.
Battery Specification
The minimum recommended capacity
of
the battery used in the engine's
12-
Volt DC control circuit
is
90
-
125
Ampere-Hours (minimum) for the generator sets covered
by
this manual.
II
CAUTION
II
When quick-charging the battery with an external charger, be sure to disconnect the
battery cables from the battery. Leaving the charging circuit connected while quickcharging will damage the alternator's diodes.
Alternator
II
CAUTION
II
When testing the alternator circuit (charging circuit),
do
not
use
a high-voltage tester
such as a megger; damaged diodes could result.
When operating the generator,
do
not disconnect the positive terminal
of
the battery
from the B terminal
of
the alternator, nor disconnect the negative terminal
of
the battery
from the ground.
When cleaning the engine/generator with a steam cleaner, be careful to keep steam away
from the DC and
AC
alternators.
WESTERBEKE GENERATORS
48
9ATTERY(12VOC)
DC CONTROL CIRCUIT WIRING DIAGRAM #36412
PAGEIOF2
A
r
________
--"""o-'c,,""---
_____________
~
//,-,7:~ID";"I-_-,.-_
,,-0-"-"-0-0-'
',4RED!PUA
5TR'»E
"J
ML
.~"'"
"
wt.TER
,
WATER
"1---'-;£
EXHAUST
TEMP. SWITCIi
O,l
RED
~
~
•
,
TEMF-_':'
a
TEMP
SENDER
a:o
SWITCH
1
r:UEL
SJLENOID
CIRCUIT
BREAKER
.'
-
o~
;
pj:lEHEAT
.~
SOLENOID
GgJ
CIRCUIT
0
SREAKER
,
.
GROUN~I~
TO
-I
ENGINE
'"
BLOCK
ffi
.
.-
~,o
RED
"O"'HT
•
~
~
,
~
e
.
.-
'140RN
·,4
VEL I
-1-0
\;
\;
~
~~
- -
0
"
,~
.-
OIL
PRESSURE
SWITCH
EMERGENCY
STOP
sw.
s'op
SWITCH
"
e
.,
£t-
OIL PRESSURE
SENDER
'"
~un
rgpu~p
,
.
STANDARD
I
NSTRlilViE0iT
PANEL
1________
__
_
__
-.J
49
WESTERBEKE GENERATORS
DC CONTROL CIRCUIT WIRING SCHEMATIC #36412
PAGE20F2
,C)
I
PREH~AT
SOL
;"b
I
t---
:rca
,(
12CA
-'f
!
~~:
H"ERGE~CY
,
r:
:;-:>~
'Ow
,
!"
- ,
'~:5TOPSW
•
',PREH~AT
SI-I
+----{
p
EXHAUST
TfMP
51.,'
,~
!
O_~
GAUGE
FU~l
SOL
VOLTMETER
1
START'I.t.LWf-..VS
PUSH
PREHi:AT
5WiTO<
FIRST_HOLD
FOR
15
TO
60
SECONDS AS
REQ'u.
2.WHILE
C;::'HINUI:>jG
Te!
PUSH
PR[HEAT
SWITCH \ PUSH
START
SWITCH.
:;,WI-'_EN
GE,'l[H\TOR
STAfHS,r{ELEIlSE
START
SWiTCH
ONLY.
4,WHECl
01:'"
P"
The charging system consists
of
an alternator with an internal voltage regulator, an engine-mounted
circuit breaker, and a battery and connecting wires.
Because
of
the use
ofle's
(integrated circuits), the electronic voltage regulator
is
very compact and
is
built
into the rear bracket
of
the alternator.
Charging
Voltage Test
If
you suspect that the alternator is not producing enough voltage
to
charge the engine's battery, perform
the following voltage test.
L
R
AHPHETER
;-----------~~~A
e
Interconnections
lor
Charging Voltage Test
1.
Using a voltmeter, connect the voltmeter's red wire clip to the B output terminal on the alternator.
Refer to the schematic shown above.
2.
Connect the other voltmeter wire clip to a ground on the engine.
3.
Start the generator and record the reading given by the voltmeter.
The voltage reading for a properly operating alternator should be between 13.5
to
14.5
volts.
If
your
alternator
is
over or under charging, have it replaced or rebuilt
by
a reliable service shop. Before
removing the alternator for repair or replacement, enSure that 12-Volts excitation is present at the R
terminal should the above test show only battery voltage at the B output terminal.
51
WESTERBEKE
GENERATORS
COOLING SYSTEM
Description
Westerbeke marine diesel engines are designed and equipped for fresh water cooling. Heat produced in
the engine
by
combustion and friction
is
transferred
to
the fresh water which circulates throughout the
engine. This circulating fresh water cools the engine block and its internal moving parts. The heat is
transferred externally from the fresh water
to
sea water
by
means
of
a heat exchanger, similar in function
to an automotive radiator. Sea water flows through the tubes
of
the heat exchanger while fresh water
flows around the tubes; engine heat transferred
to
fresh water
is
conducted through the tube walls to the
sea water which is pumped into the exhaust system and discharged overboard. In basic terms, the engine
is cooled by fresh water, the fresh water
is
cooled
by
sea water, and the sea water carries the transferred
heat over the side through the exhaust system. The fresh water and sea water circuits are independent
of
each other. Using only fresh water within the engine allows the cooling water passages to stay clean and
free from harmful deposits. The two independent circuits and their components are discussed in the
following paragraphs.
Fresh
Water
Circuit
NOTE: Refer
to
paragraphs a and b in this section on the recommended antifreeze and
water mixture to be used as the fresh water coolant, and for information on filling the
fresh water system.
Fresh water is pumped through the engine
by
a belt-driven circulating pump, absorbing heat from the
engine. The fresh water coolant circulates through the engine's block absorbing heat, then passes through
the thermostat into the exhaust manifold. then
to
the heat exchanger where it is cooled, and then is
returned
to
the engine block through the suction side
of
the fresh water circulating pump. When the
engine
is
started cold, external fresh water
flow
is
prevented
by
the closed thermostat (although some
fresh water flow
is
bypassed around the thermostat
to
prevent the exhaust manifold from overheating). 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.
a. Fresh Water Coolant (Antifreeze) Mixture.
It
is
recommended that a fres water and antifreeze mixture be used year-round. Water, when it freezes,
expands suffiCiently
to
split the heat exchanger and crack the engine block. A water/antifreeze mixture
of
proper concentration will prevent feeling (see page
41
for an antifreeze/water mixture chart).
Use soft water with
few
impurities, such as tap water (potable water) or rainwater. Never 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.
Antifreeze
of
poor quality or without rust inhibitors will cause corrosion within the cooling system.
Always use antifreeze which
is
compatible
Witll
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
is
ZEREX or PRESTONE with rust inhibitors.
In order
to
control the concentration
of
the mixture, mix the antifreeze and fresh water thoroughly before
adding it to the cooling system.
WESTERBEKE
GENERATORS
52
ANTIFREEZE ADDITION DATA
Antifreeze
Concentration
%
13
23
30 35
45
50
60
Freezing
of
23
14
5
-4
-22
-40
-58
Temperature
(0C)
(-5) ( -10) (-15) (-20) (-30) (-40) (-58)
b. Filling the Fresh Water System
A coolant recovery tank kit
is
supplied with each Westerbeke diesel generator. The purpose
of
this
recovery tank is to allow for engine coolant expansion and contraction, during engine operation, without
the loss
of
coolant and without introducing air into the cooling system.
This coolant recovery tank should be installed at, or above, engine manifold level, in a location where it
can be easily monitored and where coolant can be easily added
if
needed (see the figure below). A
stainless steel mounting bracket
is
supplied with each kit along with a 30-inch length
of
clear plastic hose
and clamps to connect the hose between the engine's manifold fitting to the hose spud on the base
of
the
recovery tank.
COOLANT
RECOVERY
TANK
PRESSURE CAP
COOLANT
PASSAGE
EXHAUST
MANIFOLD
Coolant Recovery Tank, Recommended Installation
Coolant from the engine, when heated during the engine's operation, will expand, lift the spring-loaded
manifold pressure cap, and enter the recovery tank via the hose connecting the recovery tank
to
the
manifold.
When the engine
is
shut down and cools, a small check valve in the pressure cap
is
opened
by
the
contraction
of
the engine's coolant, allowing some
of
the coolant in the recovery tank
to
be drawn back
into the engine's cooling system, free
of
air and without loss.
53
WESTERBEKE
GENERATORS
Fill the fresh water system as follows:
I.
Remove the pressure cap from the manifold.
2.
Pour a clean, fresh water coolant mixture into the manifold and allow enough time for the coolant to
fill the fresh water cooling system.
3.
Replace the pressure cap on the manifold.
4. Remove the plastic cap from the coolant recovery tank and fill the tank with coolant halfway between
the
ADD mark and the
MAX
mark. Replace the cap.
S.
Start and run the engine long enough for the engine
to
warm up
so
that the thermostat will open,
allowing the coolant
to
flow through the engine block and to the rest
of
the fresh water coolant
system.
6. Add coolant
to
the recovery tank, as required,
to
top off the fresh water coolant system.
Thermostat
Generally, thermostats are
of
two types. One is simply a choking device which opens and closes as the
engine's temperature rises and falls. The second type has a bypass mechanism. Usually this is a disc on
the bottom
of
the thermostat which moves downward to close off an internal bypass passage within the
head. Since 1980, each type ofthermostat has a hole punched through it. The hole is a bypass to prevent
the exhaust manifold from overheating during the engine's warm-up. Replacement thermostats must have
this design characteristic.
Sea Water Circuit
The sea water flow is created
by
a gear-driven, positive displacement, neoprene impeller pump. The
pump draws sea water directly from the ocean through the sea cock and sea water strainer and passes the
water to the heat exchanger's sea water inlet.
The sea water passes through the heat
exchanger's tubes, from which heat from the
fresh water system is absorbed, and then is
discharged from the cooling system
overboard through the water-injected wet
exhaust system.
A zinc anode, or pencil, is located in the sea
water cooling circuit within the heat exchanger.
The purpose
of
the zinc anode is to sacrifice
itself
to
electrolysis on other components
of
the system. The condition
of
the zinc anode
should be checked monthly and the anode
cleaned or replaced, as required.
Spare anodes
should be carried on board.
WESTERBEKE GENERATORS
..~
~
-j'
"
..
'
,.
New
Anod.,
54
Replace
Replace
Zinc Anode Conditions
Clean
or
Replace
Raw
Water
Pump
The raw water pump
is
a self-priming, gear-driven, rotary pump with a non-ferrous housing and a
neoprene impeller. The impeller has flexible vanes which wipe against a curved cam plate within the
impeller housing, producing the pumping action.
On
no account should this pump be
run
dry. There
should always
be
a spare impeller and impeller cover gasket aboard (an impeller kit). Impeller failures
occur when lubricant (raw
water)
is
not present. Such failures are not warrantable and the operator's are
cautioned to make sure raw water flow
is
present at start-up. Know your pump, know its location on the
engine and know how to change the impeller in it.
SLOTTED
DRIVE
RAW WATER
PUMP
Hue
PIN
NEOPRENE
IMPELLER
CURVED
CAM
PLATE
SCREWDRIVER
Remove the impeller with the aid
of
two small screwdrivers, as illustrated, and carefully pry the impeller
out
of
the pump. Install the impeller by positioning the hub pin to align with the slot in the drive shaft.
Move the blades to conform
to
the curved cam plate and push the impeller into the pump's housing.
Water
Pump
Drive Belt Tension
Generator models come equipped with belt guards that cover over the belt(s) on the front
of
the engine.
("Out
of
sight-out
of
mind" The belt guard
is
not installed for that purpose.) Operators are advised that
the inspection, service, and maintenance spoken
of
below should be followed.
I
WARNING
I
Never attempt
to
adjust the drive belt's tension while the engine
is
in operation.
II
CAUTION
II
Excessive water pump drive belt tension can cause rapid wear
of
the belt and reduce the
service life
of
the fresh water pump's bearings. Excessive slack or the presence
of
oil on
the belt can cause belt slipping, resulting in high operating temperatures.
The water pump drive belt
is
properly adjusted
if
the belt can be deflected no less than 3/8 inch and no
more than
112
inch (10 mm,
12
mm) as the belt
is
depressed with the thumb at the midpoint between the
two pulleys on the longest span
of
the belt. A spare drive belt should be carried on board.
55
WESTERBEKE
GENERATORS
Cooling System
Illustrated below is a typical Westerbeke engine cooling system. Both fresh water and raw water flow
through their independent cooling circuits. Refer
to
your generator's Parts List for part numbers and part
descriptions
if
you need to order cooling system parts for your engine.
f
'{' --------
,
----------
WATER '
____
_ PRESSURE CAP
.'
INJECTED
ELBOW
--
__
_
COOLANT
RECOVERY
TANK
INCOMING
RAW
WATER
RAW
WATER
PUMP
FRESH
WATER
~
RAW
WATER
*
WESTERBEKE
GENERATORS
EXHAUST
MANIFOLD
,
\
THERMOSTAT
WATER
~~--~~~--TEMPERATURE
~~'1
SWITCH
\
HEAT
EXCHANGER
FRESH WATER
DRAIN
RAW
WATER
DRAIN
Typical Cooling System
56
Exhaust
Elbow Installation
The Westerbeke Corporation offers a
450 and
900 exhaust
elbow as well as
an
exhaust riser you can install on your
propulsion engine. Refer to the instructions below when
installing the exhaust elbow purchased for your generator.
NOTE: Fabricated exhaust elbows or risers attached to the
exhaust manifold shall not exceed 8 Ibs when unsupported.
1.
Coat only one side
of
the exhaust gasket with "High Tack"
adhesive sealant. Place this coated surface against the
exhaust manifold's exhaust port flange (the gasket should
stick to the flange without falling off).
2.
Place the clamp over the elbow's flange. Place your exhaust
elbow against the exhaust manifold's flange so the exhaust
manifold'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.
3.A. Tighten the clamp just enough
so
the exhaust elbow
can remain attached to the manifold and still be rotated.
B. The exhaust elbow discharge must be directed
downward
so the mixture
of
raw water and exhaust gases
will flow/fall downward into the exhaust muffler which
must
be positioned below the exhaust elbow. There should
be no loops or rises in the exhaust hose between the exhaust
elbow and the muffler, as these would trap water and possibly
allow water to flow back into the engine during starting or at
shut down causing internal damage to the engine.
4. Adjust the elbow by rotating it until the desired alignment
with the exhaust piping is acquired.
ELBOW
FL.
...
NGE
ELBOW
FLANGE
<
..
,.,,'OT
GASKET
4S0ELBOW
<
..
,.".T
CL....
Kit'"
037402
."IA","
MANIFOLD
FLANGE
EXHAUST GASKET
EXHAUST
CLAMP
•
t
90"
ELBOW
Kit"'037401
5.
Carefully tighten the clamp between 8 to
10
Ib-ft, or
Uto
1.3 kg-m.
UCAUTION
II
Approach thelO Ib-ft torque limit with caution. The clamp's
threads will break if more than
10
Ib-ft
is
applied to the
clamp.
If
a leak exists, correct it immediately.
'Manufactured by
Perrnatex Company, Brooklyn, N.Y.
57
EXHAUST
FLANGE
EXHAUST RISER
Kit"
037403
EXHAUST GASKET
"'
..
""
CLAMP
mUllS'
MANIFOLD FLANGE
WESTERBEKE
GENERATORS
LUBRICATION
SYSTEM
Engine Oil
For engine lubrication, use lubricating oil designated for diesel service. These oils are classified
according to the API specifications into service grades CA, CB, CC and CD. The use
of
CCor higher
(CD) grades made
by
well-known manufacturers
is
recommended. The oil selected should be used
thereafter.
Engine
Oil Viscosity (SAE Number)
Use oil having a viscosity best suited to the atmospheric temperature. Use
of
an all-season oil SAE 10W-
30 with minimum viscosity change under different temperatures is suggested.
Atmospheric Temperature
68° F (20°C) or higher
41° F (5° C) - 68° F (20° C)
41° F (5° C) - or lower
Viscosity
SAE 30 or lOW - 30
SAE 20
or lOW - 30
SAE
lOW
- 30
NOTE:
Do not use engine lube oil with an SAE number greater than
30
in generator engines.
Oil
Pressure
The engine's oil prcssure is indicated
by
the oil pressure gauge.
During normal operation, the engine's oil pressure will range between
35
and 70 psi (engine hot).
NOTE: A newly started, cold cngine can have
an
oil pressure reading upwards
of
60 to
80 psi. A warmed engine can have an oil pressure reading as low as
35
psi. These
readings may also vary depending upon the load that is placed on the generator.
Your generator set is fitted with an oil pressure switch.
Should your engine's oil pressure drop below a
safe operating pressure, the switch will open and shut the engine
OFF
to
prevent any internal damage
to
your generator's engine from occurring.
Engine
Oil Change (to include filter)
1.
Draining the Oil Sump
Discharge the old oil through the sump drain hose (attached at the front
of
the engine) while the engine is
still warm. Drain the old oil completely, replace the hose in its bracket and replace the end cap securely.
Always observe the old oil as it is removed. A yellow/gray emulsion indicates the presence
of
water in the
oi!.
Although this condition is rare, it does require prompt attention to prevent serious damage. Call a
competent mechanic should water be present in the oi!.
Sea water present in the oil can be the result
of
a
fault in the exhaust system attached
to
the engine andlor a syphoning through the sea water cooling circuit
into the exhaust, filling it up into the engine (refer
to
the installation illustrations in this manua!.)
WESTERBEKE
GENERATORS
58
2.
Replacement
of
the Oil Filter
When removing the used oil filter, cover the filter
with a plastic bag containing a
few
cloth rags or
paper towels. This will allow both the filter element
and spilled oil
to
be collected cleanly without
spilling oil on the engine or in the bilge. (Oil or any
other fluid on the engine reduces the engine's
cooling ability. Please keep your generator's engine
clean.)
The replaceable cartridge-type oil filter requires
no
cleaning inside.
When installing the oil filter element, apply a thin
coat of clean engine oil to the rubber gasket on the
oil filter, screw the filter onto the threaded oil filter
stub, and then tighten the filter firmly
by
hand. (See
page
79
for the proper tightening specification for oil
filters.)
OIL fILTER.
OIL
PRESSURE
SENOER
Oil
Filter and
Oil
Drain System
NOTE: Operators are advised that replacement oil filters supplied by Westerbeke Corporation may
vary in size from the original oil filter supplied with the engine (i.e.- replacement filter
is
larger).
This
is
due
to
commonizing
of
oil filters between engine models. The smaller original oil filters on
some models are there only for the initial break-in period.
NOTE: Generic filters are not recommended, as the material standards or diameters
of
important items on generic parts might be entirely different from genuine parts.
NOTE: Immediately after an oil filter change and oil fill, run the engine to ensure that the
oil pressure
is
normal and that there are no oil leaks around the new oil filter.
3.
Filling the Oil Sump
Add fresh oil through the oil fillter cap on the valve cover. Afier refilling the oil, run the engine for a
few
moments while checking the engine's oil pressure. Ensure there
is
no leakage around the new oil filter or
from the oil drain system, and then stop the engine. Then check the quantity
of
oil with the dipstick. Fill
to,
but not over, the high mark on the dipstick, should the engine require additional oil.
59
WESTERBEKE
GENERATORS
BT GENERATOR
This generator is a brushless self-excited generator, which requires only the driving force
of
the engine to
produce AC output. The copper and laminated iron in the exciter stator are responsible for the self-
exciting feature
of
this generator. The magnetic field produced causes
an
AC voltage to be induced into
the related exciter rotor windings during rotation. Diodes located
in
the exciter rotor rectify this voltage
to
DC
and supply it to the windings
of
the rotating field. This creates
an
electromagnetic field which
rotates through the windings
of
the main stator, inducing
AC
voltage which is supplied to a load. A
transformer is connected
in
parallel to the
AC
output
of
the main stator.
An
AC voltage is produced in
the auxiliary windings
of
the transformer and main stator and
is,
in
tum,
supplied to a full-wave bridge
rectifier. The rectifier produces a DC voltage to further excite the exciter stator windings, enabling the
generator to produce a rated AC output.
An optional solid-state voltage regulator is available to work in tandem with the transformer regulator to
produce a more stable AC output.
No-Load
Adjustment
Voltage adjustment is made with the compound transformer governing generator regulation.
1.
The seletor switch must be
in
the COMP position.
2.
Operate the generator and apply a moderate load momentarily; then remove the load. Note the voltage
output from the generator's l20-Volt leg(s) (220 Volts at
50
Hertz). The no-load voltage should be
between 118 - 128 Volts at 61.5 - 62 Hertz (218 - 228 Volts at 51.5 -
52
Hertz).
NOTE:
The no-load voltage should be adjusted to the voltage produced by the
generator when : the generator is started, a momentary load is applied to excite the
transformer, and then removed. The voltage produced by the generator alier this
momentary load is removed is the no-load Voltage.
3.
To raise or lower the voltage, non-conductive shims
of
varying thickness are inserted or removed from
under the laminated steel
bar
that is situated on top
of
the compound transformer. The material used for
shimming should not soften
at
temperatures in the 1760 F (80
0
C) range. A small reduction in no-load
voltage
(I
to 3 volts) sometimes can be accomplished by gently tapping the top
of
the laminated steel
bar
to reduce the air gap between the existing shims and the transformer core.
II
CAUTION
II
Under no circumstances attempt to increase the no-load voltage
by
increasing the gap
between the laminated steel bar and the transformer core without the use
of
shims.
Magnetic forces created within the transformer during the generator's operation may
close the air gap and reduce the no-load voltage output.
4. To remove the laminated steel bar, remove the two upper securing bolts from the compound
transformer and lift the bar from the transformer. The addition
of
shim thickness will raise the no-load
voltage and conversely, the removal
of
the shim thickness will lower the no-load voltage.
Varying shim thickness by .001 inch (0.025 mm) will change the no-load voltage
by 4 to
6 Volts.
WESTERBEKE
GENERATORS
60
GENERATOR AC DISTRIBUTION BOX
BTD 10.0KW, 11.0KW,
AND
12.SKW
(A)
Ye!lowM'hite
8tackNihile
Optional
AVA
RedfWhite
GreenNIhile
Internal
Wiring
Schematic for
12
Stud
BT
Model
with Voltage Regulator Circuit Removed
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61
WESTERBEKE
GENERATORS
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18)
Early Model
BID
8.0KW Generator's Internal Wiring Diagram with
A.
V.
R Circuit
A.
EXCITER STATOR WINDINGS
I. Exciter Stator Windings
2.
Exciter Stator Windings
B. EXCITER
ROTOR
I.
Auxiliary Windings (a-b-c)
2.
Diodes (6)
3.
Rotating Field Windings
4.
Pozi Resistor
C. MAIN STATOR
I.
Main
Stator Windings
2.
Main
Stator Windings
3.
Main
Stator Auxiliary Windings
D.
COMPOUND TRANSFORMER
I.
Compound Transformer Windings
2.
Compound Transformer Windings
3.
Compound Transformer Auxiliary
Windings
E.
SELECTOR SWITCH
I.
Compound
2.
Electronic
and
Compound
G.
BRIDGE RECTIFIER
(Optional
A.
VR. - Automatic Voltage Regulator)
WESTERBEKE
GENERATORS
62
r--------,
I C I
r--------.,
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•
~---------------,
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3'
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IO.OKW,
BTD I
LOKW,
& BTD 12.5KW (A) Generator's Internal Wiring Diagram
A EXCITER STATOR WINDINGS
L Exciter Stator Windings
2.
Exciter Stator Windings
B.
EXCITER ROTOR
L Auxiliary Windings (a-b-c)
2.
Diodes (6)
3.
Rotating Field Windings
4.
Pozi Resistor
C.
MAIN STATOR
L Main Stator Windings
2.
Main Stator Windings
3.
Main Stator Auxiliary Windings
D.
COMPOUND TRANSFORMER
L Compound Transformer Windings
2.
Compound Transformer Windings
3.
Compound Transformer Auxiliary
Windings
E.
SELECTOR SWITCH
L Compound
2.
Electronic and Compound
G.
BRIDGE RECTIFIER
(Optional
AY.R. - Automatic Voltage Regulator)
63
WESTERBEKE
GENERATORS
S
1
U
0
Optional Voltage Regulator
An optional solid-state voltage regulator (board #34410)
is
available for use with the BT series generators.
When installed, and the regulation switch
is
moved
to
the ELEC position, the regulator works together
with the standard compound transformer regulator
to
regulate the generator's voltage output. In the
ELEC mode, the regulator excitation to the group I exciter windings, and the transformer provides
excitation to the group 2 exciter windings.
Installation
I.
The regulator is mounted using existing tapped holes in the generator's case. Use two (2) M4 x 0.7
rum
screws, each
15
mm long, with lock washers to mount the regulator board.
2.
Connect the 6-prong generator plug
to
the receptacle on the regulator board. Note: The plug is keyed
to engage the regulator receptacle in one direction. Check this and insert it correctly.
3.
Before moving the selector switch
to
ELEC, ensure that the no-load voltage produced
by
the generator
is
properly adjusted. The no-load voltage desired with the selector switch in the COMP position must be
slightly lower than the voltage desired with the regulator in the circuit.
(i.e. 120 volts 60 Hertz no-load voltage in COMP 116 -
118
volts for 50 Hertz 216 - 218 volts.)
4.
With the no-load voltage adjusted in COMP move the selector switch
to
ELEC position. Adjust the
regulator potentiometer
to
bring the no-load voltage up
to
120
volts at
60
Hertz and 220 volts at 50 Hertz.
The potentiometer adjustment must not be used
to
force the no-load voltage down.
Generator
Frequency
Frequency
is
a direct result
of
engine/generator speed:
1800 RPM -
60
Hertz
1500 RPM -
50
Hertz
To
change the generator's frequency, refer to the "Maintenance and Adjustments" section
of
this manual.
Load Connections
The generator's data plate gives the voltage, current and frequency rating
of
the generator. An
AC
wiring
decal is affixed to the inside
of
the louvered cover on the generator end. A diagram
of
the various
AC
voltage connections
is
provided on the decal. The information on the decal
is
similar to the figure shown
on the following page.
The generator
is
a single-phase, reconnectable
120
Volts
AC
two-wire or
1201240
Volts
AC
three-wire at
60
Hertz; or 220 Volts
AC
two-wire at 50 Hertz. Refer
to
the "System Specifications" section
of
this
manual for ratings.
WESTERBEKE
GENERATORS 64
NOTE:
We
recommend that the installer provide
AC
ampmeters (optional)
so
that the
operator can observe the load being taken off each leg
of
the generator.
A circuit breaker should be installed between the generator and the AC load. This circuit breaker should
be rated for the generator's
AC
output and be able
to
react quickly to overloads, subject to motor starting
considerations.
120V 60Hz
1201240V
60Hz
50}+-
2 5
Os
Os
7lUl-i-...,
03
H
110V
50Hz
110/22BV 50Hz
22BV
50Hz
02
sO
50
sO
'1
r
OS
7P
Os
¥3
80
Q3
8 Q
I
I
I
H
l 1
l 2
AC
Voltage Connections
(6
Stud Terminal Block)
(Used with the BTD 100KW, 11.0KW, and the 12.5KW(A) (Generator Sets.)
NOTE: The frame ground wire must be moved when changing from
110
Volts,
50
Hertz
to
220 Volts,
50
Hertz.
For making connections to the
AC
terminal block,
use
1/4
inch terminal ends that will accept multi-strand
wire sized for the number
of
conductors in the bundle, the rating
of
the conductor's insulation, and
amperage that will be drawn through the conductor(s). (Refer
to
the generator's scarlet and gold data
plate for generator amperage ratings.
65
WESTERBEKE
GENERATORS
TO
FR
.ME
I
I
120V 60Hz
,
20/240V 60Hz
0
( )
0
0
0
TI
N
110J;220V
50Hz
= 0
( )
T
o
FRAME
'II~
0
( )
, )
~
0
~
:J
L,
N I:
=<
LO
(OJ
f==l
0
0 0
0
0 0
0
l.-
n
L,
110VSOHz
220V
50Hz
= 0
=
0
o 0 0 0 0
0
0
=
(6)
RO
Tn
'n
c ~ .....
t
U
U
N
L,
AC Voltage Connections (12 Stud Tenninal Block)
(Used only with the BTD 8.0 KW Generator
Set.)
NOTE:
The frame ground wire must be moved when changing from 110 Volts, 50 Hertz to
1220
Volts, 50 Hertz.
For
making connections to the AC terminal block, use tenninal ends for #10 studs which will accept #6 or
#8 multi-strand wire.
WESTERBEKE
GENERATORS
66
INTERNAL
WIRING
SCHEMA TIC
3 PHASE
GENERATOR
MODELS 10.0 BTD 11.0 BTD & 12.5 BTD
r------l
I C I
FUSE
I
I
20
A.
I
STATOR
: I
i
.,
I.
I
,-----.c
i
I
EXCITF~
____
.1
___________
-,
I I : B I
I
I
2
:
I
:
3
:
I + I a i a I
: 1
II
:I-C*
4
3!
I I I b I
:
,
:
:
:
5
I
i
I
I
•
I
:
:
:
:
:
: : :
~ROTOR
:
i
r---=-I
1 I 2
II
I I
!
,
.J.
I I I I
I L
_____
T-
__________
J
L_I-
________
--.l
I
I
L
F
REGULATOR
A.
Exciter
1.
Exciter Stator Windings
B.
Rotor
1.
Auxiliary Exciter Windings (a-b-c)
2.
Diodes (6)
3.
Main Rotor Windings
4.
Pozi Resistor
C.
Main Stator
1.
Auxiliary Windings (DC Charging Circuit)
2-7. Main Stator Windings
3.
Auxiliary Windings (AC
to
Regulator)
D.
Bridge Rectifier
E. DC Controller
F.
Voltage Regulator Board
#
,
I
I
----
j
FUSE
6,3A.
12
BiJ:
A
11
C
10
T
9
E
R
8
M
7
I
6
N
A
5
L
4
8
3
L
2
0
c
1
K
67
WESTERBEKE
GENERATORS
LED'S
Red
Green
Yellow
HZ.
AMP.
VOLT
VOLTAGE REGULATOR #038468
Single &
Three
Phase
DOD
5
4
3
2
0
B
+
]60HZ.
The voltage regulator
is
of
an
advanced design which ensures optimum AC alternator performance. The
regulator is equipped with complete protection circuitry to guard against operating conditions that could
be detrimental to the AC alternator.
Adjustments:
I. Volts - This potentiometer
is
used to adjust AC output voltage.
It
has an additional range
of
± 25-30
volts. At proper engine operating speed the output voltage should be held at
± 1 % from a no-load
condition to full rated generator output and from power factor
1.0 - 0.8 with engine drive speed variation
of
up to -6%.
2.
Stability - This potentiometer permits variation
of
the regulators response to generator load changes
so
as to limit over-compensation and obtain a minimum recovery time to the normal voltage output.
WESTERBEKE
GENERATORS
68
3.
AmplHertz - These two adjustments are used
in
conjunction with the two protection circuits in the
voltage regnlator that are indicated
by
illumination
of
a colored LED.
I) Delayed overload protection (YELLOW RED)
2)
Low
speed protection (RED LED)
Each
of
these two protection circuits reduces exciter voltage to safegnard the exciter windings and prevent
overheating
of
the
AC
alternator. These two potentiometers are factory adjusted and sealed and should
not be tampered with.
4.
Proper Generator Operation (GREEN LED) - The overload protection system has a delay which
permits temporary overloading
of
the generator during times such as motor start-up or other similar load
surge demands.
69
WESTERBEKE GENERATORS
I
PARALLEL
WYE
(STAR)
12
10
11
9
8 6 7
5
4 2 3 1
L-L
208
VAC
39
60
HZ
L-N
120VAC
1060HZ
l-L
190
VAC
3~
50
HZ
l-N
110
VAC
19
50
HZ
3 PHASE AC TERMINAL BLOCK CONNECTIONS
FOR
WYE AND DELTA CONFIGURATION
SERIES
WYE
(STAR)
SERIES
DELTA
L1
L2
1
L3
N
12
10
11
9
a:::=J)
8 6 7 5
a:::=J)
~
4
2 3
1
a:::=J)
~
L - L
460
VAC
31J
60
HZ
L - N
265
VAC
1"
60
HZ
L-L
380
VAC
39
SO
HZ
L-N
220
VAC
19
SO
HZ
L1
L2
Q)
L3
N
®-
L-L
240VAC
3~
L2,L3-N
120VAC
'.
L-L 220VAC
3~
L2,L3-N
llQVAC
, .
9
5
60
HZ
60
HZ
50
HZ
SO
HZ
The regulator is equipped with 7 uumbered terminals and related brass jumpers. The illustration below
shows
the connection points and jumpers for the 3 phase configuration
of
the generator. The sensing
leads connect between pin # 1 and pin
#2
on the
AC
terminal block and connection
#2
and
#0
on the
regulator board.
NOTE: Series DELTA requires the installation of a jumper on the regulator board between terminal B
andO.
r--------------------~
I ,
,
'---(----\-----------~
I
SO-160v
........
~
1
:~~nLJ
n'
--~
.OM,.
U~
, \
l..
___________________
...
I I
~--~-----~----------~
WYE
DELTA
WESTERBEKE GENERATORS
70
L1
L2
L3
N
The illustration below shows the 3 phase
AC
generator backened with the louvered covers removed.
Voltage
Regulator
71
DC
Charge Bridge
Rectifier
AC
Terminal Block
WESTERBEKE GENERATORS
Shore
Power
Connections
If
the installer connects shore power to the vessel's AC circuit, this must be done by means
of
the SHORE
POWER/OFF/SHIPS
GEN, center position-off transfer switch as shown below. Use
of
this switch
prevents simultaneous connection
of
shore power to generator output.
II
CAUTION
II
Damage to the generator can result
if
utility shore power and generator output are connected at the same
time. This type
of
generator damage is not covered under the warranty;
it
is the installer's respnsibility to
ensure that all
AC connections are correct.
IIOT£: II,"'U"
SHOIIS
COlirCTIONS
FOil
''10-
( N
Gl
"'t
.=.
IIiRE.
12'-IIOLT
SYSTUII.
fOI
TKIH-WlltE
SYSHIi
uS(
DCllHD
tIMES
FDa
111£
01NU
NOl
LEGS.
'--------,
I
I
/-',
L
____
~
~\
.
~-
r-----\~
-"
,
'.
I
,
,
I
--,
L-+-+----+.'G;
\
--,
I
I
I
I
I
I
I
~~l
,
,
,
l
-,~
"J"'.'
'f7'
'--/)
""
~
"O;"""'.,."','-----''---_---i
I '
...
\52
s'
"
"-,,,,,,
5I11P-10-5110R£
SWITCH
C]
POlEl
PII
32
...
(U
IIMPS/POtE)
'11
)2'"
ell
AMPS/POLE)
PI
3211.
(t2S
IWPS'POLfl
PM
32131
(211
IIMPS/PotO
r N
Gl
~
t
NOTE,
OIAGRAM
SHOWS
CONNECTIONS
FOR R TWO-
WIRE.
129-VOlT
SYSTEM
FROM
THE
GENERRTOR.
f
.,
e
~
~
z
WJlH
THREE-WIRE.
129-VOll
BORT
SYSTEM.
/
/
,
,
~'
(j.
~
,
,
,
..
,
,
,
,
,
/
,
-_/
z
g
•
Q
~
/
.--
.....
,
L--_
u
r;
~'--+-"~"~"~'-
..
"
(WHT,
,
/
-_/
.;G~"~''''''!!-_O-
____
I'·
(GRN)
\
52
51.
N
Sh'p'5load
Na.
N02~o.",0II.
'-'
Shore Power Switch Connection Diagrams
WESTERBEKE
GENERATORS
72
....
32118&
(.e
l:u.P6/POLE)
PM
32889
(Bill
AMPS/POLE)
"W
3281111
(,1.25 A ..
P6/POLf;l
PM
32133
(ZIIII
POOPS/POLC,
GENERAL INFORMATION
AND
CARE
OF
THE
GENERATOR
Use
of
Electric Motors
The power required to start an electric motor
is
considerably more than is required to keep it running after
it
is
started. Some motors require much more current to start than others. Split-phase (AC) motors
require more current
to
start, under similar circumstances, than other types. They are commonly used on
easy-starting loads, such as washing machines,
or
where loads are applied after the motor is started, such
as small power tools. Because they require S
to
7 times as much current to start as
to
run, their use should
be avoided, whenever possible,
if
the electric motor is
to
be driven
by
a small generator. Capacitor and
repulsion-induction motors require from 2 to 4 times as much current to start as
to
run. The current
required
to
start any motor varies with the load connected to it.
An
electric motor connected
to
an air
compressor, for example, will require more than a motor
to
which no load
is
connected.
In general, the current required to start l1S-Volt motors connected medium starting loads will be
approximately as follows:
MOTOR
AMPS FOR
AMPS FOR
SIZE RUNNING STARTING
(HP) (Amperes) (Amperes)
1/6 3.2 6.4
to
22.4*
114
4.6
9.2
to 32.2*
113
S.2
10.4 to 72.8*
112
7.2 14.4 to 29.2
3/4 10.2 20.4 to 40.8
1
13
26
to 52
*Note that in the above table the maximum "Amps for Starting"
is
more for some small
motors than for larger ones. The reason for this
is
that the hardest starting types (split-
phase) are not made in larger sizes.
Because the heavy surge
of
current needed for starting motors
is
required for only an instant, the generator
will not be damaged
if
it can bring the motor up
to
speed in a
few
seconds.
If
difficulty
is
experienced in
starting motors, turn off all other electrical loads and,
if
possible, reduce the load on the electric motor.
Required
Operating
Speed
Although individual units may vary slightly, the normal voltage and frequency
of
typical 60-(50-) Hertz
engine-<iriven generators described in this manual are approximately as follows: run first with no load
applied, then at half the generator's capacity, and finally loaded
to
its full capacity as indicated on the
generator's data plate.
See the rpmlHertzifrequency chart
on
the next page.
73
WESTERBEKE
GENERATORS
Load
4-Pole Frequency
Generator
Voltage
Applied
Speed (rpm) (Hertz) 120V (110)
240V (220)
Plants Plants
None 1830
62
122
240
(1530) (52) (112)
(224)
Half
1800 60
120
240
(1500)
(50) (110)
(220)
Full 1755
59
110
220
(1455) (49) (100) (200)
The output voltage should
be
checked periodically
to
ensure proper operation of the generating plant and
the appliances it supplies.
If an
AC
voltmeter or ampmeter
is
not installed to monitor voltage and load, check it with a portable
meter and amp-probe.
Preventive Maintenance (Generator)
Maintenance
on
the
generator
is
minimal.
1.
Keep the generator clean, dry and well-ventilated.
2.
Ensure that all connections are clean and tight and that cables carrying
AC
voltage are properly
supported and protected against chafing.
3.
The rear armature bearing
is
lubricated and sealed; therefore,
no
maintenance
is
required. If the
bearing becomes rough or noisy, replace
it.
Generator
Troubleshooting
A complete and illustrated text on troubleshooting the
BID
series of generators
is
furnished in the
Technical Manual which
is
available through your local dealer.
WESTERBEKE GENERATORS
74
General
This manually-controlled series
of
Westerbeke marine diesel gener-
ators is equipped with toggle
switches
on
the
engine's
control
panel and, optionally, at remote
panels. The following instructions
and methods
of
correcting minor
problems apply only
to
such toggle
switch controls.
All three switches are momentary
contact type and serve the following functions:
1.
PREHEAT: The PREHEAT toggle switch is a double-pole, singlethrow switch. The switch serves
two purposes: preheating the
engine for easy starting and defeating
or
bypassing the engine's pro-
tective oil pressure sensor. The
defeat function turns on the fuel
solenoid, instrument power, alter-
ENGINE CONTROL PANEL
Standard Instrument Panel
0
o
'R(lEAT
®
st.""
~
$TO'
®
,"",
.. " ...
TOII
0
o
nator excitation and provides power to the START switch.
2.
START:
The START toggle switch is a double-pole, single-throw switch. The switch, when
activated, energizes the starter solenoid for starting the engine. This switch will not operate electrically
unless the
PREHEAT switch is depressed and held at the same time.
3.
STOP:
The STOP toggle switch is a sinle-pole, single-throw, normally-closed switch. This switch
provides power to the fuel solenoid, instrument cluster and alternator excitation, after the oil pressure
switch has closed upon starting. Opening
of
this switch opens the power circuit
to
the fuel solenoid, thus
stopping the flow
of
fuel
to
the engine and stopping the engine.
4.
In addition
to
the three switches above, the Standard Instrument Panel used with Westerbeke diesel
generator sets includes two gauges, which indicate water temperature in degrees Fahrenheit (WATER
OF)
and oil pressure in pounds per square inch (OIL PSI), and two meters, which indicate DC control circuit
voltage
(VOLTS) and generator running time (ELAPSED TIME) in HOURS and
1110
hours. The Water
Temperature and
Oil Pressure gauges, and the DC Voltmeter are illuminated; the ELAPSED TIME meter
is not.
75
WESTERBEKE GENERATORS
Engine
Operation
To
start the engine, perform the following steps:
1.
Preheat - Depress the PREHEAT switch. The voltmeter, panel lights, gauges and meters and fuel
solenoid will be activated. The
PREHEAT switch should be depressed in accordance with the chart
in
the
It
OPERA
TrONI! section under "Starting Procedure" section.
2.
Start - While still depressing the PREHEAT switch, depress the START switch. This will engage the
start solenoid.
Panel power and the fuel solenoid will be activated. Upon engine firing, release the
START switch. Do not release the
PREHEAT switch until the oil pressure reaches
15
psi.
Then
as long
as the high water temperature, low oil pressure and exhaust temperature protective circuits do not activate,
the set will remain energized and continue to run.
3.
Stop - Depress the STOP switch to stop the engine. This opens the power feed to the fuel solenoid,
stopping the fuel flow to the engine. The
STOP switch must be held depressed until the generator stops
rotating.
Remote
Operation
For remote operation
of
the generator system, the same three switches are used. The PREHEAT
and
START switches are connected
in
parallel with the local panel's switches
and
serve the same functions as
in
the local panel. The STOP switch is in series with the local panel's STOP switch, and serves the same
functions as
in
the local panel. The generator may be stopped from local or remote positions.
Rf~O!E
CONTROL P.o.N(L IREAII VIEW)
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WESTERBEKE
GENERATORS
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100[lum WESTER8(KE CORPORATION
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...
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A.
Society
Wire
SI:r..,
Standing
Clreular
DC WIRE SIZING CHART
Stranded Conductors for 12 Volt Circuits
10%
Voltage Drop
oC
Autonlotive
Engineers
Type
Wire
B.
National
"
,.
"
"
10
•
•
,
16
"
16x3O
1Silx29
19x27
19;(25
lb23
19x21
49)(23
49",21
" "
ElectricaJ
Code
Type
Wire
"
10
• •
, ,
1
"
,.
"
37
.,
'"
'"
Mil Area
1537
2336
3702
5833
93'3
)-41110
25910
37360
2583
4'07
Ei530
10380
16510
26250
-4'''0
66370
83690
Circuli
Current
MaxilTlurn
Length
of
Conductor
in
Feel
CroIn
Power
SOUTce
to
Load
and
Return
In
AMPS
1.
m 260
'"
2.
"
130
210
330
'"
227
3.
••
86.7
"0
220
9".6
,.,
,.0
,.
43.7
••
lOS
16.
"'"
7'
"3
,.0 2 ••
••
3".7
.,
"
132
210
.7
.7
"3
232
••
29
43.3
70
"0
".
279
47.3
75.3
120
'90
303
7.
2·(.7
37
8O
..
,.0
2<0
40.7
6
....
7
'03
'.3
,.0
••
21.7
32.7
52.7
82.7
,,,
210
35.3
56.3
89.6
,.,
227
••
1S.3 28.7
46.7
73.3
".
lB.
300
31.7
50.3
79.6
127
20'
321
'0.
17.3
,.
"
6.
lOS
,
..
271
2B.3
45.3
72
'"
,.,
,
..
lS.
17.3
"
"
70
'"
,.0
'"
19
30
,.
76
'"
193
20.
21
33
52.7
83.7
135
'"
22.7
36
.7
91
,,,
30.
22
35
..
90.3
'"
"
..
60.7
96.3
'0.
26.3
"
67.3
'07
28.3
45.3
72
.0.
"
33.7
..
85.3
23
36.3
57.7
•••
30.7
..
77.7
33
52.3
60.
"
71.3
"
75.
36
.7
38.3
90.
.(7.3
The
voltage
drop
for
:'Ipecific
conductor
lengths
may
be
calculated
by
the
formula:
Voltage
drop
10.75
x I x L
CM
where:
L
CM
load
in
amperes
conductor
length
in
feel
conductor
circular
MIL
arca
When
Ii
circuit..
including
the
ground
return.
U9CS
several
different.
size
conductors,
the
voltage
drop
at
the
electrical
device
i!'J
the
sum
of
the
drops
calculaled
for
ea.ch
size
segrnent
of
the
circuit.
ENGINE TROUBLESHOOTING
Introduction
30'
230
,.3
,,,
"
83.3
76.3
.,
.,
The tables which follow indicate troubleshooting procedure based upon certain problem indicators, the
probable causes
of
the problems, and the recommendations to overcome these problems.
Note that the engine's control system (electrical system) is protected
by
a 20-Ampere manual reset circuit
breaker located on a bracket on the right side
of
the engine, just forward
of
the generator's end plate. The
preheat solenoid is close
by.
as is the emergency STOP switch, which may be mounted on the same
bracket or on the back
of
the standard instrument panel, depending upon the model.
77
WESTERBEKE
GENERATORS
'"
182
,,,
133
,,,
S7.3
"
306
230
",
"7
153
'"
'02
ENGINE TROUBLESHOOTING
Problem Probable Cause
PREHEAT switch is depressed: Battery switch
no
panel indications, fuel
solenoid, electric fuel pump and
preheat solenoid not energized. 20-Amp circuit breaker tripped.
START switch is depressed: Connection to solenoid faulty.
no
starter engagement
START switch is depressed:
panel indication
OK; start
solenoid
OK; fuel solenoid not
functioning.
Faulty
START switch.
Faulty solenoid.
Loose battery connection.
Low batteries.
Poor connections to fuel
solenoid.
Defective fuel solenoid.
No
ignition: cranks, but does not Faulty fueling system.
start; fuel solenoid energized.
WESTERBEKE GENERATORS
78
VerificationiRemedy
Check switch and/or battery
connections.
Reset breaker;
if
breaker trips
again, check preheat solenoid
circuit
and
run
circuit
for
shorts
to
ground.
Check connection.
Check switch with ohmmeter.
Check that
12
volts is present at
solenoid connection.
Check battery connection.
Check battery charge state.
Check connections.
I.
Check mechanical
positioning
of
fuel solenoid for
plunger bottoming.
2.
Manually check movement
of
fuel solenoid plunger and
throttle arm.
3.
Check for voltage drop at
solenoid during PREHEAT.
Check wire size from remote
panels.
I.
Check for fuel
to
generator
engine.
2.
Check for air in fuel system.
Allow system
to
self-bleed.
3.
Fuel lift pump faulty.
4.
Filters clogged.
(Replace filters and allow
system
to
self-bleed
by
depressing only the PREHEAT
switch.
Problem
Failure to stop.
Engine stops.
Battery not charging.
Battery runs down.
Probable Cause
Fuel solenoid return spring.
STOP switch failure.
Fuel injection pump failure.
Low oil pressure.
Low oil pressure.
High water temperature switch
opens at too
Iowa
temperature.
20-Amp circuit breaker tripping.
High exhaust temperature
switch opens at too
Iowa
temperature.
Emergency
STOP switch or
STOP switch
in
panel defective,
opening fuel run solenoid
circuit.
Alternator drive.
Oil pressure switch.
79
Verification/Remedy
Stop engine manually
by
moving the throttle lever to shut
off.
That failing, shut off fuel
and air. Check fuel solenoid
linkage and repair for free
movement.
Stop engine by depressing
emergency
STOP switch on
engine
or
manually moving
throttle to shut off. Test switch
with ohmmeter.
Depress emergency
STOP
switch on engine. Stop engine
by opening the high pressure
injector lines at the injectors and
stop air intake.
Check oil level; check fresh and
sea water cooling.
Check for satisfactory operation
with switch depressed. Check
with ohmmeter.
Check for satisfactory operation
with switch bypassed. Check
with an ohmmeter.
Same
as
above.
Same as above.
Inspect all wiring for loose
connections
and
short
circuits.
Inspect switches for proper
operation.
Check drive belt tension. Be
sure alternator turns freely.
Check for loose connections.
Check output with voltmeter.
Ensure
12
Volts present at
regulator terminal.
Observe
if
gauges and panel
lights are activated when engine
is not running. Test the oil
pressure switch.
WESTERBEKE GENERATORS
Problem Probable Cause
Battery runs down (continued). High resistance leak to ground.
Low resistance leak.
Alternator.
WESTERBEKE GENERATORS
80
VerificationlRemedv
Check wiring. Insert sensitive
(0-.25 Amp) meter in battery
lines. (Do not start engine.)
Remove connections
and
replace
after short is located.
Check all wires for temperature
rise to locate fault.
Disconnect alternator
at
output,
after a good battery charging.
If
leakage stops, remove alternator
and
bench
test. Repair
or
replace.
MAINTENANCE AND ADJUSTMENTS
Introduction
This section contains a scheduled preventive maintenance program and several adjustment procedures the
owner/operator can perform without the benefit
of
sophisticated and expensive tools and instruments.
Preventive
Maintenance
(Engine)
Perform the preventive maintenance in accordance with the schedules listed in the following paragraphs.
Adherence to these schedules will ensure the equipment is maintained in the best possible condition and
that it will perform
to
expectations. Those items marked
by
an asterisk (*) are recommended.
to
be
performed
by
an authorized dealer or distributor.
Daily (before each use)
1.
Check oil sump level. Maintain the oil level at or near upper level mark on dipstick.
2.
Check coolant level in plastic recovery tank. Maintain at or above the level marked ADD.
3.
Visually inspect the unit; check for loose belts, chafed or broken wires, loose brackets and fittings,
damaged hoses, loose clamps, andother equipment not properly secured.
4.
Check fuel supply. Fill tank(s) with a good grade
of
No.2 diesel fuel,
if
required.
5.
Check the primary filter/water separator. Drain and service as required. (A primary filter/water
separator is optional, but strongly recommended.)
6.
Check the engine's gauges for proper oil pressure, operating temperature, and starting battery charging
voltage once the engine is operating.
7.
Check the generator's output meters (when installed) for proper AC voltage and output frequency.
Monthly
Check the condition
of
the zinc anode in the heat exchanger's sea water circuit. Clean or replace the
anode, as required. Keep the area inside the heat exchanger clean
of
zinc anode debris.
Servicing
After
Initial 50
Hours
of
Operation
1.
Change the engine's lube oil and oil filter.
2.
Replace the fuel filter elements in the electric fuel lift pump and in the engine-mounted filter
assembly.
*3. Torque the cylinder head hold-down bolts.
*4. Adjust valve clearances.
81
WESTERBEKE
GENERATORS
5.
Adjust the alternator and water pump drive belt tension,
if
required.
6.
Adjust the engine's no-load speed,
if
required (Hertz). Please note that this adjustment
is
not a
warrantable adjustment during or after the unit's break
in.
7.
Lubricate the ball joint linkage between the run solenoid and the throttle arm.
Servicing
After
Every 100 Hours of Operation
I. Change the engine's lube oil and filter.
2.
Adjust the alternator and water pump drive belt tension,
if
required.
3.
Lubricate the ball joint linkage between the run solenoid and the throttle arm.
4.
Inspect siphon-break assembly for proper operation (when installed).
Servicing
After
Every
250
Hours of Operation
Replace the fuel filter elements in the electric fuel lift pump and in the engine-mounted filter assembly.
Servicing
After
Every 500 Hours of Operation
* I. Torque the cylinder head hold-down bolts.
*2.
Adjust the valve clearances.
3.
Drain, flush, and refill the fresh water cooling system. For an illustration showing the heat
exchanger and block drain locations, see model photos with call outs at the beginning
ofthis
manual.
*4.
Check the condition
of
the starter motor drive pinion; lubricate pinion.
5.
Check the resistance
of
the glow plus. Check circuit operation. 1.0 -
1.2
ohms.
6.
Check raw water pump for internal wear. Examine the pump's cover, cam and internal housing.
Replace worn parts as needed. Check for leaks at seals or gaskets and make repairs as needed. Do not
neglect.
7.
Check external and internal condition
of
the water injected exhaust elbow. Inspect exhaust and water
passages in the elbow. Remove any carbon and/or corrosion build
up.
Replace the elbow should its
condition be questionable.
WESTERBEKE
GENERATORS
82
Servicing
After
Every 800 Hours of Operation
*1.
Remove and check fuel injectors.
Injector spray pressure:
1706 psi + 142 psi
(120 kg/cm
2
+
10
kg/cm2)
Eliminate undesirable injection conditions
including after dripping.
*2. Check compression pressure. Remove each
glow plug and check each cylinder's compression
pressure. The engine's cranking speed
is
at 250 rpm.
8.0
KW,
10.0
KW,
11.0
KW,
12.5
KW
Standard
Minimum
4GJl35l*-s
JdI)
...
~..
II
,
POOR
455
psi
(32 kg/cm2l
370
psi
(26 kg/cm2)_ (Maximum difference between cylinders: 35.5 psi (2.5 kg/cm
2
l
*3.
Check the battery-charging alternator for proper operation,
*4.
Check the tightness
of
bolts, nuts, and clamps.
Servicing
After
Every 1000 Hours of Olleration
1.
Remove, clean, and pressure test the primary heat exchanger. (A local automotive radiator shop
should be able to clean and test the heat exchanger.
*2.
Check thc injection pump's timing.
Preventive Maintenance (Generator)
Maintenance
on
the
generator
end
is
minimal:
I. Keep the generator clean, dry and well-ventilated.
2.
Ensure that all connections are clean and tight, and that cables carrying
AC
voltage are properly
supported and protected against chafing.
*3.
The rear armature bearing
is
lubricated and sealed:
no
maintenance
is
required. However,
if
the
bearing becomes noisy or rough-sounding, have it replaced.
83
WESTERBEKE
GENERATORS
ADJUSTMENT OF VALVE CLEARANCE
MODEL:
BID
8.0KW & 10.0 KW
II
CAUTION
II
Adjust the valve clearance when the engine is cold.
0.010 inches (0.25 rnrn)
Tighten the cylinder head bolts to the specified
torque.
1.
Pull
off
the
air
breather pipe from the rocker cover,
and
take
off
the rocker cover bolts. Adjust the valve
clearances
at
IDC
(Top Dead Center) for each cylinder
when they are
on
their compression stroke (see below).
2.
Align the timing marks
on
the gear case and on the
crankshaft pulley as shown. In this position, the No.1
cylinder is
at
its top Timing Mark while dead center on
its compression stroke.
Check both intake and exhaust
valve clearances
of
the cylinder.
If
the valves have no
specified clearance, adjust
by
means
of
the adjusting
screws. Remember to align the timing marks properly;
if
not, the valve may be pushed up by the piston,
depending on position
of
the cam lobe.
3.
Next, the piston
of
No. 3 cylinder comes
IDC.
Turn
the crankshaft 2400 clockwise from the above position,
aligning the timing mark
of
the crankshaft with that
of
the gear case. Then check and adjust the valve clearance.
4.
To check the
No.2
cylinders valve clearance, turn the
crankshaft another 2400 clockwise, and then align the
Front
-
0
No 3 top
Timing
Mark
0 0
0 0
9
1
5
11
10
4
,
8
0 0
0
0
o Z
01
0 3
timing marks; check and adjust the valve clearance
in
a 3
Cylinder
Head
Bolt
Tightening
~quence
similar
manner.
Note: Retighten the cylinder head bolts before the valve clearance is adjusted. Note:
rnrn
size shown are
sockets size for holddown bolts. Rocker
Shaft Holddown Bolts: (14mm 3.4 kg-m) 24.5 ft-lbs.
BTD 8.0 KW and
10.0 KW
Bolts #4,5,6,7,8,9,10
&
II
(17 mm 11-12.5 kg-m)
83.2 -
90.4 ft-Ibs
Bolts #1,2,
& 3
(14 mm 6.5 - 8 kg-m)
47.0 - 57.9 ft-Ibs
WESTERBEKE GENERATORS
84
ADmSTMENT
OF VALVE CLEARANCE
MODEL:
BID
11.0 KW &
BID
(A) 12.5 KW
II
CAUTION
n
Adjust the valve clearance when the engine is cold.
0.010 inches (0.25 mm)
Tighten the cylinder head bolts to the specified torque.
1.
Pull off the air breather pipe from the rocker cover,
and take off the rocker cover bolts.
2. Adjust the valve clearances at
IDC
(Top Dead
Center) for each cylinder when they are on their
compression stroke.
3.
Make sure that the timing mark
on
the gear case and
the timing mark
on
the crankshaft pulley are exactly
aligned;
if
not, the valve will interfere with the piston
because
of
improper cam positioning. (Refer to page
71
another illustration showing crankshaft timing marks.)
NOTE: Retighten the cylinder head bolts before the valve
clearance is adjusted.
BID
II.OKW &
BIDA
12.5KW
BOLTS 5,6,7,8,9,10,11,12,13&14
(I7MM
11.5 - 12.5 kg/m)
83.1
- 86.7 ft-Ibs
BOLTS 1,2,3, & 4
(I4MM
6.5 - 8.0 kg/m)
47.0 - 57.8 ft-Ibs
NOTE: mm size shown are socket size for holddown bolts
BTD
II.OKW &
BIDA
12.5 KW
Rocker Shaft Holddown Bolts
14mm
(4.0-5.5 kg/m) 28.9 - 39.8 ft-Ibs
10mm (0.8-1.2 kg/m) 5.8 - 8.7 ft-Ibs
85
~
Front
b
o
I
13
L
g
3
0
Nos, 1 and 4 piston
T.O.C.
mark
I
Timing
Mark
0
0
7
5
9
6
0
1
0
0
2
0
Injection timing
{I.T.)
mark
0
10
8
0
4
0
0
12
14
0
Cylinder Head
Bolts
Tightening Sequence
BID
12.5KW
BOLTS 5,6,7,8,9,10,11,12,13 &14
(22MM 15-16 kg/m)
108.4
- 115.7 ft-Ibs
BOLTS 1,2,3, & 4
(22MM
11-12
kg/m)
79
-
86
ft-Ibs
BID
12.5KW
Rocker Shaft Holddown Bolts
14mm (4.0-5.5 kg/m)28.9-39.8ft-lbs
10mm
(0.8-1.2 kg/m) 5.8 - 8.7 ft-Ibs
Revised
August 1994
WESTERBEKE
GENERATORS
I
Injection Timing Adjustment (BTD 8.0KW,
IO.OKW,
11.OKW
& 12.5KW)
Incorrect fuel injection timing will result in hard engine starting and poor engine performance. Adjust the
injection timing as follows:
NOTE: The fuel lever (throttle) must
be
in the Run position while making the
adjustment or
no
fuel will
flow
to the
fuel
injection pump.
Refer to the cutaway view
of
the fuel injection pump and remove the high-pressure fuel line from the
No.
I fuel delivery valve holder. Remove the
No.1
fuel delivery valve holder and remove the delivery valve
spring beneath the holder. Reinstall the delivery valve holder and reattach the fuel line. Disconnect the
opposite
end
of
the
No.
I fuel line (from the
No.
I fuel injector) and
tum
the fitting away from the
injector, in order to catch the fuel as the pump operates.
Rotate the crankshaft clockwise (as viewed from the front), catching the fuel from the No. I fuel line, until
the instant the fuel completely stops flowing (no drips). At this instant, the
19°
BTDC timing mark on
the crankshaft pulley should be directly aligned with the timing indicator on the front
of
the cylinder block
(see the illustration on the next page).
DELIVERY VAlVE HOLDER
DELIVERY
VALVE
SPRING
DELIVERY
VALVE
CONTROL PINION
PLlJNC;ER
SPRING
AIR
BLEEDING
SCREW
CONTROL
RACK
TAPPET
Cutaway View of 3-Cylinder Fuel Injection Pump
WESTERBEKE GENERATORS
86
If
the specified (19°
BID
C)
injection timing can-
not be attained, adjust the timing
by
increasing
or decreasing the thickness
of
the injection pump
mounting shim. Changing the shim thickness
by
0.004 inch (O.Olmm) changes the injection timing
by approximately one degree. To advance the
timing, decrease the shim !hichness, as required.
To retard the timing, increase the shim thickness,
as required.
Adjustments
(Generator)
'.
".
'
...
_';-,_
..
,
.,.
_____
TDC
.
\0
;.···_·19'
r·:,:·---"
.
~
..
Crankshaft Pulley Timing Marks
Once the diesel generator set has been placed in operation, there may be adjustments required for engine
speed (Hertz) during the engine's break-in period (first
50 hours) or after this period. A no-load voltage
adjustment may also be required in conjunction with the engine's speed adjustment.
II
CAUTION
II
When starting the generator, it
is
recommended that all
AC
loads, especially large
motors, be switched OFF until the engine has come up
to
speed and, in cold climates,
starts to warm
up.
This precaution will prevent damage caused
by
unanticipated
operation
of
AC
machinery and will prevent a cold engine from stalling.
Generator
Frequency Adjustment
Frequency is a direct result
of
engine/generator speed, as indicated
by
the following:
When the generator is run at
1800 rpm, the
AC
voltage output frequency is 60 Hertz. When the generator
is run at
1500 rpm, the
AC
voltage output frequency is 50 Hertz.
Therefore, to change the generator's frequency, the generator's speed must be changed. To accomplish the
frequency change, perform the following:
1.
Connect the
AC
output leads
to
the
AC
terminal block in accordance with the
AC
Voltage
Connections diagram specified for your generator set, which appears in the "BT GENERA TOR" section
ofthis
manual.
87
WESTERBEKE
GENERATORS
2.
Adjust the engine's speed to obtain the frequency corresponding to the voltage selected by e,,'lending or
shortening the Throttle Adjustment Linkage. Make sure the solenoid's plunger is completely bottomed in
the solenoid.
(See figure below.)
II
CAUTION n
Failure
of
the solenoid to bottom
in
the solenoid will result in a failed solenoid.
To avoid failure
of
the solenoid, ensure that the solenoid plunger bottoms in the
solenoid. Check the solenoid's operation at the initial start-up.
Periodically lubricated
linkage joints between the solenoid plunger and the throttle arm will eliminate binding.
NOTE: The solenoid plunger must move smoothly and rapidly into the solenoid when
the solenoid is electrically energized, drawing the engine's throttle arm into the
Set
SpeedlRun
position.
To arrive at the appropriate frequency, either monitor the speed
of
the engine/generator with a
tachometer, or monitor the frequency with a frequency meter, the latter method being the more precise of
the two.
Solenoid and Throttle with Linkage
BID
8.0KW,
IO.OKW,
11.0KW & 12.5 KW
WESTERBEKE GENERATORS
88
LAY-UP AND
RECOMMISSIONING
General
Many owners rely on their boatyards
to
prepare their craft, including engines and generators, for lay-up
during the off-season or for long periods
of
inactivity. Others prefer
to
accomplish lay-up preparation
themselves.
The procedures which follow will allow you to perform your own lay-up and recommissioning, or
to
use
as a check list
if
others
do
the procedures.
These procedures should afford your engine protection during a lay-up and also help familiarize
you
with
the maintenance needs
of
your engine.
If
you have any questions lay-up procedures, call your local servicing dealer; he will be more than willing
to provide assistance.
Fresh
Water
Cooling System
A
SO-50
solution
of
antifreeze and fresh water is recommended for use in the fresh water cooling system at
all times. This solution may require a higher concentration
of
antifreeze, depending on the area's winter
climate. Check the solution
to
ensure that the antifreeze protection is adequate.
Should more antifreeze be needed, drain an appropriate amount from the engine block and add a more
concentrated mixture.
Operate the engine
to
ensure a complete circulation and mixture
of
the antifreeze
concentration throughout the cooling system. Now recheck the antifreeze solution's strength.
Lubrication
System
With the engine warm, drain all the lubricating oil from the oil sump. Remove and replace the oil filter.
(place some paper towels and a plastic bag around the filter
to
catch the oil during its removal.)
When installing the new oil filter, be sure to apply a small amount of oil on the rubber sealing gasket at
the base
of
the filter. Fill the sump with the correct amount
of
oil for your engine model. (Refer to the
"SYSTEM SPECIFICATIONS" section
of
this manual for the amount
of
oil each model's oil sump should
contain.)
Use an oil with an API specification
of
CC-CD, Run the engine, check for proper oil pressure
and ensure there are no leaks.
II
CAUTION
II
Do not leave the engine's old lubricating oil in the sump over the lay-up period.
Lubricating oil and combustion deposits combine
to
produce harmful chemicals which
can reduce the life
of
your engine's internal parts.
89
WESTERBEKE
GENERATORS
Fuel System
Top off your fuel tanks with
No.2
diesel fuel. Fuel additives should be added at this time
to
control algae
and condition the fuel. Care should be taken that the additives used are compatible with the primary
filter/water separator used in the system. Change the element in your primary fuel filter/water separator,
if
the fuel system contains one, and clean the separator sediment
bowl.
Change the fuel filter elements on the engine and bleed the fuel system, as needed. Start the engine and
allow it to run for 5 -
10
minutes
to
ensure that no air
is
left in the fuel system. Check for any leaks that
may have been in the fuel system during this servicing, correcting them as needed.
Sea
Water
Circuit
Close the thru-hull seacock. Remove the sea water intake hose from the seacock. Place 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 clean
or
replace it as required. Clean the sea strainer,
if
one
is
installed in the inside
of
the hull.
Start the engine and allow the sea water pump to draw fresh water through the system. When the bucket
is empty, stop the engine and refill the bucket with an antifreeze solution slightly stronger than needed for
winter
freeze protection
in
your
area.
Start the engine and allow all
of
this mixture
to
be drawn through the sea water system. Once the bucket
is empty, stop the engine. This antifreeze mixture should protect the sea water circuit from freezing
during the winter lay-up, as well as providing corrosion protection.
Remove the impeller from your sea water pump (some antifreeze mixture will accompany it,
so
catch it in
a bucket). Examine the impeller. Acquire a replacement,
if
needed, and a cover gasket. Do not replace
the impeller (into the pump) until recommissioning, but replace the cover and gasket.
Intake
Manifold and Through-Hull Exhaust
Place a clean cloth, lightly soaked in lubricating oil, in the opening
of
the intake manifold to block the
opening. Do not shove the cloth out
of
sight. (If
it
is
not visible at recommissioning, and an attempt is
made to start the engine,
you
may need the assistance
of
a servicing dealer.) Make a note to remove the
cloth prior to start-up. The through-hull exhaust part can be blocked in the same manner.
Starter
Motor
Lubrication and cleaning
of
the starter drive pinion is advisable,
if
access to the starter permits its easy
removal. Ensure that 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,
if
you anticipate a longer lay-up period (12
months or more),
we
recommended that this procedure
be
performed. The light oil in the cylinders will
prevent the piston rings from sticking
to
the cylinder walls. Apply a small amount
of
anti-seize to the
glow plugs threads when reinstalling.
WESTERBEKE
GENERATORS
90
Spares
Lay-up time provides a good opportunity
to
inspect the equipment to see
if
external items such as drive
belts
or
coolant hoses need replacement. Check your basic spares kit and order items not on hand, or
replace those items used during the lay-up, such as filters and zinc anodes.
Batteries
If
batteries are
to
be left on board during the lay-up period, ensure that they are fully charged, and will
remain that way,
to
prevent them from freezing. If there exists any doubt that the batteries will
no
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.
Recommissioning
The recommissioning
of
your Westerbeke unit after a seasonal lay-up generally follows the same
procedures as those presented in the "Preparation 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 sea water pump cover and gasket. Discard the gasket. Install the sea water pump impeller
removed during lay-up (or a replacement,
if
required). Install the sea water pump cover with a new cover
gasket.
WARNING
Wear rubber gloves, a rubber apron, and
eye
protection when servicing batteries.
Lead acid batteries emit hydrogen, a highly-explosive gas, which can be ignited
by
electrical arcing or a lighted cigarette, cigar, or pipe. Do not smoke or allow an open
flame near the battery being serviced.
Shut off all electrical equipment in the vicinity to
prevent
electrical
arcing
during
servicing.
3.
Reinstall the batteries that were removed during the lay-up, and reconnect the battery cables, making
sure the terminals are clean and that the connections are tight. Check
to
ensure that the batteries are !iIlly
charged.
4.
Check the condition
of
the zinc anode in the sea water circuit and clean
or
replace the anode as needed.
Note that it is not necessary
to
flush the antifreeze/fresh water solution from the sea water coolant system.
When the input is put into operation, the system will self-flush in a short period
of
time with no adverse
effects.
5.
Start the unit in accordance with procedures in the "Preparation for Starting" section of this manual.
91
WESTERBEKE
GENERATORS
TABLE OF STANDARD HARDWARE TIGHTENING TORQUES
Unless
stated
otherwise
for
a specific assembly, use
the
following
torque
values when tightening
standard
hardware.
Pitch
Ib-ft kg-m
Grade
4
6mm
bolt head/nut
1 2.9 - 5.1
0.4
- .07
8mm
bolt head/nut
1.25
7.2 - 11.61.0 - 1.6
10
mm
bolt head/nut
1.25 13.7 - 22.4
1.9 - 3.1
10
mm
bolt head/nut
1.5 13.0
-21.7
1.8 -
3.0
12
mm
bolt head/nut
1.25
(ISO)
25.3 - 39.8 3.5 - 5.5
12
mm
bolt head/nut
1.5 25.3 - 39.8 3.5 - 5.5
12
mm
bolt head/nut
1.75
21.7
- 36.2
3.0 - 5.0
13
mm
bolt head/nut
1.5 32.5 - 50.6 4.5 -
7.0
14 mm bolt head/nut
1.5
36.2-57.9
5.0 -
8.0
14
mm
bolt head/nut
2 34.0 - 55.7
4.7
-7.7
16
mm
bolt head/nut
1.5
54.2 - 79.6
7.5-11.0
16
mm
bolt head/nut
2
51.4
-76.7
7.1
-10.6
Grade
6T
6mm
bolt head/nut
1 4.3 - 6.5
0.6 -
0.9
8mm bolt head/nut
1.25
10.8 - 15.9 1.5 - 2.2
10
mm
bolt head/nut
1.25
21.7
- 32.5 3.0 - 4.5
10
nun
bolt head/nut
1.5 19.5 - 30.4
2.7 - 4.2
12
mm
bolt head/nut
1.25 (ISO) 36.2 - 57.9
5.0 - 8.0
12
mm bolt head/nut
1.5
36.2 - 50.6 5.0 -
7.0
12
mm
bolt head/nut
1.75
34.7 -
49.2
4.8 -6.8
Grade
7T,
8T
and 8.8
6mm
bolt head/nut
1
5.8 - 8.7
0.8
- 1.2
8mm
bolt head/nut
1.25 14.5 -
21.7
2.0 - 3.0
10
mm
bolt
head/nut
1.25 28.9 - 39.8
4.0
- 5.5
10
nun
bolt
head/nut
1.5 26.8 - 37.6
3.7 - 5.2
12
mm
bolt head/nut
1.25
(ISO)
54.2 - 75.9 7.5 - 10.5
12
mm
bolt head/nut
1.5 50.6 -65.1
7.0
- 9.0
12
mm
bolt head/nut
1.75
43.4
-61.5
6.0
- 8.5
13 mm bolt head/nut
1.5
57.9 - 86.8
8.0 - 12.0
14 mm bolt head/nut
1.5
72. 3
-108.5
10.0 - 15.0
14
mm bolt head/nut
2
68.7
-101.3
9.5 - 14.0
16 mm bolt head/nut
1.5
108.5 - 166.4
15.0 -
23.0
16 mm bolt head/nnt
2
101.3-159.1
14.0 -
220
Grade 5 cap
screw
1/4 UNC
9 -
11
1.2 - 1.5
114
UNF
11
- 13 1.5 - 1.8
5116
UNC
18 -
20 2.5 - 2.8
5116
UNF
21
- 23
2.9 - 3.2
3/8 UNC
28 - 33
3.7
- 4.6
3/8
UNF
30 - 35
4.1-4.8
7116
UNC
44 - 49
6.1 -
6.8
7116
UNF
50 - 55
6.9
- 7.6
112
UNC
68 - 73
9.4 - 10.1
112
UNF
73 - 80
10.1-11.1
WESTERBEKE GENERATORS
92
TABLE OF TIGHTENING TORQUES
FT - LBS (KG -
M)
8.0 & 10.0 12.5
11.0 BTD AND
BTD BTD
12.5 BTDA
Crankshaft Pulley Nut
108.5-144.7
144.6-180.8 108.5-144.7
(15-20)
(20-25) (15-20)
Main bearing cap bolt
36.2-39.8
SAME SAME
(5.0-5.5)
Connecting rod cap nut 23.1-25.3
39.7-43.3 23.1-25.3
(3.2-3.5) (5.5-6.0)
(3.2-3.5)
Flywheel bolt - with separate
83.2-90.4
SAME
SAME
washers
(11.5-12.5)
Flywheel bolt washer 94.0-101.3
SAME SAME
attached (13.0-14.0)
Oil pan drain plug 36.2-43.4 SAME SAME
(5.0-6.0)
Oil filter 8.0-9.4 SAME SAME
(1.1-1.3)
Delivery valve holder 28.9-36.2
SAME SAME
(injection pump) (4.0-50)
Holder mounting bolt, nozzle
10.8-14.5
SAME SAME
(15-2.0)
Holder body and retaining nut, 43.4-57.9
SAME SAME
nozzle
(6.0-8.0)
Glow plug 10.8-14.5
SAME SAME
(1.5-2.0)
93
WESTERBEKE GENERATORS
SOUND GUARD INSTALLATION INSTRUCTIONS
For a copy
of
the Sound Guard installation instructions required for your generator set, please contact your
local Westerbeke dealer. A four page installation brochure is available which covers all current Sound
Guard model assembly/installations.
WESTERBEKE GENERATORS
94
POWER
TAKE-OFF
(PTO) ADAPTER
KITS
The generator housing
of
the Generators is machined
to
accept an optional power take-off (PTO) adapter
kit. This kit allows the user
to
mount and to operate a hydraulic pump (or similar device) while the
generator is operating.
The operator is advised that the generator's drive engine produces a specific amount
of
horsepower at
1800 rpm. This horsepower can be ntilized either for generator
AC
amperage output or to operate the
PTO device.
It
cannot do both; that
is,
it cannot produce
AC
amperage and furnish horsepower to operate
the PTO device, simultaneously.
When mounting a PTO device using the optional adapter kit listed below, ensure
good
alignment
of
the
device to the spline coupling and ensure that
if
additional support
is
needed, it is added. When in doubt,
provide e"ira support.
CCHERAT
:lR
HOUSXHC
P.LO.
ADAPTER
KIT
SPLINE
COUPLIHC
AOAP"rER
CRPSCRCW
(3)
LOCICW"::;"'En
(:3)
lOTUD
(41
I,.OCICWRSHER
14)
NUT
C"')
BTO
8.
8KW
KIT
PM.
34786
8TO
10.9I(W.
1l.IH:W.
AHD
12.Sk'W
KIT
PM.
37134
HVORAU1.IC
PU~P
HVORECO
1122l.8A481R
'
.........
_,,'
..
'._
..
,._...
(PUMP
SOURCE)
H ...
DREca
PUMPS
KALAMAZOO.
HXCK.
(6l.6)
:349-l.5.1.1
NOTE: Provisions should be made
to
prevent the PTO device from overloading the generator's engine.
Install a pressure relief valve on the hydraulic pump to limit maximum pumping pressure.
95
WESTERBEKE
GENERATORS
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