Westerbeke BTD 7.5 KW 50H 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 WARRANTlES 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
SPECIFICATIONS
GENERAL
17
SYSTEM SPECIFICATIONS
18
BID 11.0 KW MARINE DIESEL GENERATOR SET GENERAL
SPECIFICATIONS
21
SYSTEM SPECIFICATIONS
22
BTD 12.5 KW MARINE DIESEL GENERATOR SET GENERAL
SPECIFICATIONS
25
SYSTEM SPECIFICATIONS
26
BIDA 12.5 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
BTD 8.0 KW Generator
Control Panel
Intake Silencer
Preheat Solenoid
Charging
Alternator
20 Amp DC
Circuit Breaker
Fuel Run
Solenoid
Switch
Zinc Anode
Block Drain
~
__ I'x<'h,,"ge,
Fresh Water Drain
Fuel Lift Pump
Oil Pressure Sender
8.0 KW BTD
Fresh Water Fill
xhaust Manifold
Exhaust Temperature
DC Charging
itch
Alternator
Fresh Water
Circulating
Pump
Unit Data Tag
Sea Water
Ground Connection
Starter with Solenoid
8.0 KW BTD
7
WESTERBEKE GENERATORS
BTD 10.0 KW Generator
Preheat Solenoid
Emergency Stop
ide Oil Fill
Intake Silencer
DC Charging
rnatar
20 Amp DC Circuit
Srea
AC
Outlet
Run
__,4.nc Anode
Heat
Exchanger
Fresh Water
Block Drain
-Exchanger
Fresh Water Drain
Lube Oil Filter
Fuel Lift
I Pressure Switch
10.0 KW BTD
Emergency Shut
rol Panel
Fresh Water Coolant
- - - - - ' " ' Exhaust
Elbow
Sea Water
Pump
DC Battery Ground
Connection
Heat Exchanger
Starter with Solenoid
10.0 KW BTD
WESTERBEKE GENERATORS
8
BTD 11.0 KW Generator
Water Air Bleed
Top Engine Oil
Control
DC Charging
Preheat Sollen<,id
A C Con,nec,tior"'~
Fresh Water Slock
Pressure
Sender
Lube Oil Dip,stick'
Lube Oil Filter
Fitter
11.0KW BTD
Fresh Water Air
Shut-off Switch
Exhaust
Temperature
Switch
Elbow
Heat Exc;hang,,,/
DC Battery
Ground Connection
with Solenoid
11.0 KW BTD
9
WESTERBEKE GENERATORS
BTD 12.5 KW Generator
20 Amp DC Circuit Breaker
Fuel Filter
Lube Oil Fil
DC Charging
Control
AC
Fuel Lift
i Pressure Switch
Lube Oil Filter
12.5 KW BTD
Top Engine Oil Fill
Fresh Water Air Bleed
Fresh Water
I
Fill
xhaust Manifold
mergency
Shut-off Switch
--""'U5t
Temperature
Switch
Thermostat
o Exhaust
Elbow
Battery
Heat Exchanger
with Solenoid
Sea Water Pump
Fresh Water Block Drain
WESTERBEKE GENERATORS
10
Lube Oil Dipstick
Preheat Solenoid
Air Intake Silencer
I
Side Oil Fill
DC Charging Alternator
Control Panel
20 Amp DC Circuit Breaker
Fuel Injection Pump
Fuel Run Solenoid
Lube Oil Filter ____
....
....
Lube Oil Drain Hose
Oil Pressure Switch
:l=!
eo
[JJ
;j
~
A C Connections Outlet
Zinc Anode
eo
1:i
~
Fresh Water Block Drain
eo
z
~
o
0;
Fuel Filter
Fuel Lift Pump
Oil Pressure Sender
12.5 BTDA
RIGHT SIDE
~
Fresh Water Fill Cap
t"i
Lube Oil Fill Cap
rn
;.l
~
~
Emergency
Exhaust Manifold
Shut~off
Switch
~
Z
t"i
~
Exhaust Temperature Switch
Belt Guard
o
~
0
45 Exhaust Elbow
""
N
Unit Data Tag
Raw Water Pump
DC Battery Ground Connection
Heat Exchanger
Starter with Solenoid
12.5 BTDA
LEFT SIDE
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
Diesel, 4-cycle, 3-cylinder, fresh water-cooled
Vertical, in-line overhead valve mechanism
(14 hp at 1800 rpms maximum)
Governor
Mechanical, centrifugal weight type
Combustion Chamber
Swirl chamber type
Bore & Stroke
2.87 x 3.07 inches (73 x 78 mm)
Pistion Displacement
60 cubic inches (0.979 liters)
Firing Order
1-3-2
Direction of Rotation
Clockwise, when viewed from the front
Maximum Torque (at 1800 rpm)
41.50 Ib-ft (5.73 kg-m)
Compression Ratio
23 : I
Compression Pressure
455.2 psi (32 kg/cm2) at 280 rpm
Valve Timing
Intake Opens 18° BIDC
Intake Closes 46° ABDC
Exhaust Opens 46° BBDC
Exhaust Closes 18° AIDC
Valve Seat Angle
Intake 45°
Exhaust 45°
Valve Clearance
(engine cold)
Intake 0.0098 inches (0.25 mm)
Exhaust 0.0098 inches (0.25 mm)
Engine Speed
1800 rpm 60 Hertz
1500 rpm 50 Hertz
Dimensions
Height: 21.80 inches (553.72mm)
Width: 17.00 inches (431.80 mm)
Length: 28.20 inches (716.28 mm)
Weight
450 Ibs (204.12 kgs)
Fuel Consumption
0.9 gph (3.40 Iph) at full rated
output (approximate)
Inclination
Continuous 15°
Temporary 20° (not to exceed 20 min.)
WESTERBEKE GENERATORS
14
SYSTEM SPECIFICATIONS
FUEL SYSTEM:
GENERAL
Open flow, totally self-bleeding
FUEL
No.2 Diesel oil (cetane rating of 45 or higher)
FUEL INJECTION PUMP
Nippon Denso (Bosch M type)
FUEL INJECTION TIMING
19° BIDC ±D.5 (static timing)
NOZZLE
INJECTORS
Throttle type
Pintle type
FUEL PUMP
FUEL FILTER(on engine)
12-Volt DC; Electro-Magnetic type
Canister type, with replaceable element
AIR CLEANER
Metal-screen type
AIRFLOW
32 cfm (.906 cmm)
COOLING SYSTEM:
GENERAL
Closed fresh water-cooled block, thermostatically
controlled with heat exchanger.
OPERATING TEMPERATURE
FRESH WATER PUMP
Centrifugal type, metal impeller, belt-driven
SEA WATER PUMP
Positive displacement, rubber impeller, belt-driven
SEAW WATERFLOW, AT 1800 RPM
(measured before discharging into
exhaust elbow.)
8.5 gpm (32.2Ipm)
SYSTEM CAPACITY(Fresh Water)
5 quarts (4.73 liters)
LUBRICATION SYSTEM:
GENERAL
Pressure type by Trichoid pump, gear driven with
e>.'lernal pressure relief valve
OIL FILTER
Full flow, paper element, spin-on type
SUMP CAPACITY
3.3 quarts (3.12 liters)
OPERATING OIL PRESSURE (engine hot)
40 - 80 psi (2.8 - 5.6 kg/cm2 )
OIL GRADE
API specification CC or CD
15
WESTERBEKE GENERATORS
SYSTEM SPECIFICATIONS CONTINUED ...
ELECTRICAL SYSTEM
STARTING BATfERY
12-Volt, ( - ) negative ground
BATfERY CAPACITY
300-400 CCA
DC CHARGING ALTERNATOR
12·volt DC, 50 Amp
REGULATOR
Internal regulator built into alternator
STARTING AID
Glow Plug, sheathed type
STARTER
12·volt, 1.2 KW, reduction type, solenoid mounted
DC NO-LOAD CURRENT
90 Amp (max.) at 11.5 Volts
DC CRANKING CURRENT
175 - 200 Amps (engine cold)
ACGENERATOR
GENERAL
Brushless, four-pole, revolving field.
Pre·lubricated single-bearing design.
Reconnectable, single-phase transformer regulation
(optional solid-state voltage regulation)
VOLTAGE
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
RATING (Volts AC)
60 HERTZ (1800 rpm)
8.0KW
120 Volts
1201240 Volts
66 Amps
66/33 Amps
50 HERTZ (1500 rpm)
6.0KW
220 Volts
27 Amps
GENERATOR COOLING AIR
REQUIREMENTS, (60 Hertz), at
1800 rpm
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
32 cfm (.906 cmm)
ENGINE COMPARTMENT COOLING
AIR
100-200 cfm (2.83 - 5.66 cmm)
TUNE UP SPECIFICA TlONS
INJECTOR PRESSURE
1707 psi (120 kg/cm2 + 10 kg/cm2 - 0 kg/cm2)
ENGINE TIMING
19° BIDC
17
WESTERBEKE GENERATORS
BTD 10.0 KW MARINE DIESEL GENERATOR SET
GENERAL SPECIFICATIONS
Engine Type
Diesel, 4-cycle, 3-cylinder, fresh water-cooled
Vertical, in-line overhead valve mechanism
(16.5 hp at 1800 rpms maximum)
Governor
Mechanical, centrifugal weight type
Combustion Chamber
Swirl chamber type
Bore & Stroke
3.07 x 3.07 inches (78 x 78 mm)
Pistion Displacement
68 cubic inches (1.12 liters)
Firing Order
1-3-2
Direction of Rotation
Clockwise, when viewed from the front
Maximum Torque (at 1800 rpm)
47.7Ib-ft (6.6 kg-m)
Compression Ratio
23 : 1
Compression Pressure
483.5 psi (34 kg/cm2) at 230 rpm
Valve Timing
Intake Opens 18° BIDC
Intake Closes 46° ABDC
Exhaust Opens 46° BBDC
Exhaust Closes 18° AIDC
Valve Seat Angle
Iutake 45°
Exhaust 45°
Valve Clearance
(engine cold)
Intake 0.0098 inches (0.25 mm)
Exhaust 0.0098 inches (0.25 mm)
Engine Speed
1800 rpm 60 Hertz
1500 rpm 50 Hertz
Dimensions
Height: 22.00 inches (558.7mm)
Width: 16.85 inches (427.9 mm)
Length: 32.56 inches (827.02 mm)
Weight
495 Ibs (224.5 kgs)
Fuel Consumption
1.0 gph (3.78Iph) at full rated
output (approximate)
Inclination
Continuous 15°
Temporary 20° (not to exceed 20 min.)
WESTERBEKE GENERATORS
18
SYSTEM SPECIFICATIONS
FUEL SYSTEM:
GENERAL
Open flow, totally self-bleeding
FUEL
No.2 Diesel oil (cetane rating of 45 or higher)
FUEL INJECTION PUMP
Nippon Denso (Bosch M Type)
FUEL INJECTION TIMING
19° BIDC ±O.5 (static timing)
NOZZLE
INJECTORS
Throttle type
Pintle type
FUEL PUMP
FUEL FILTER( on engine)
12-Volt DC; Electro-Magnetic type
Canister type, with replaceable element
AIR CLEANER
Metal screen type-cleanable
AIRFLOW
48 cfm (1.36 cmm)
COOLING SYSTEM:
GENERAL
Closed fresh water-cooled block, thermostatically
controlled with heat exchanger.
OPERATING TEMPERATURE
170° - 190° F (77° - 88° C)
FRESH WATER PUMP
Centrifugal type, metal impeller, belt-driven
SEA WATER PUMP
Positive displacement, rubber impeller, belt-driven
SEAWWATERFLOW, AT 1800 RPM
(measured before discharging into
exhaust elbow.)
7.2 gpm (27.25 Ipm)
SYSTEM CAPACITY(Fresh Water)
8 quarts (7.6 liters)
LUBRICATION SYSTEM:
GENERAL
Pressure type by Trichoid pump, gear driven with
external pressure relief valve
OIL FILTER
Full flow, paper element, spin-on type
SUMP CAPACITY
4.76 (4.5 liters)
OPERATING OIL PRESSURE (engine hot)
40 - 80 psi (2.8 - 5.6 kg/cm2)
OIL GRADE
API specification CC or CD
19
WESTERBEKE GENERATORS
SYSTEM SPECIFICATIONS CONTINUED ...
ELECTRICAL SYSTEM
STARTING BATfERY
12-Volt, ( - ) negative ground
BATTERY CAPACITY
350-450 CCA
DC CHARGING ALTERNATOR
12-volt DC, 50 Amp
REGULATOR
Internal regulator built into alternator
STARTING AID
Glow Plug, sheathed type
STARTER
12-volt, 1.6 KW, reduction type, solenoid mounted
DC NO-LOAD CURRENT
90 Amp (max.) at ll.5 Volts
DC CRANKING CURRENT
175 - 200 Amps (engine cold)
ACGENERATOR
GENERAL
Brushless, four-pole, revolving field.
Pre-lubricated single-bearing design.
Reconnectable, single-phase transformer regulation
(optional solid-state voltage regulation)
VOLTAGE
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
RATING (Volts AC)
60 HERTZ (1800 rpm)
1O.OKW
50 HERTZ (1500 rpm)
7.5KW
GENERATOR COOLING AIR
REQUIREMENTS, (60 Hertz), at
1800 rpm
120 Volts
1201240 Volts
83.3 Amps
83.3/41.6 Amps
220 Volts
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
Brushless six pole, revolving field. Sealed lubricated
single bearing design. 12 Lead reconnectable for
low voltage WYE, high voltage Delta. Solid State
voltage regulator with protection circuitry.
Voltage - 3 Phase (60 Hertz)
Low voltage WYE 208 volts
High voltage WYE 480 volts
DELTA
240 volts
Voltage - 3 Phase (50 Hertz)
High voltage WYE 380 volts
DELTA
220 volts
Amperage - 3 Phase (60 Hertz)
Low voltage WYE
High voltage WYE
DELTA
Amperage - 3 Phase (50 Hertz)
High voltage WYE
DELTA
35 Amps
15 Amps
30 Amps
14 Amps
24 Amps
AC GENERATOR:
ENGINE COMBUSTION AIR
REQUIREMENTS (60 Hertz) AT
1800 rpm
32 cfm (.906 cmm)
ENGINE COMPARTMENT COOLING
AIR
100-200 cfm (2.83 - 5.66 cmm)
TUNE UPSPECIFICATIONS
INJECTOR PRESSURE
1707 psi (120 kg/cm 2 + 10 kg/cm 2 - 0 kg/cm 2)
ENGINE TIMING
19' BIDC
21
WESTERBEKE GENERATORS
BTD 11.0 KW MARINE DIESEL GENERATOR SET GENERAL SPECIFICATIONS
Engine Type
Diesel, 4-cycle, 4-cylinder, fresh water-cooled
Vertical, in-line overhead valve mechanism
(18.4 hp at 1800 rpms maximum)
Governor
Mechanical, centrifugal weight type
Combustion Chamber
Swirl chamber type
Bore & Stroke
2.87 x 3.07 inches (73 x 78 mm)
Pistion Displacement
80 cubic inches (1.305 liters)
Firing Order
1-3-4-2
Direction of Rotation
Clockwise, when viewed from the front
Maximum Torque (at 1800 rpm)
54 Ib-ft (7.46 kg-m)
Compression Ratio
23 : I
Compression Pressure
455 psi (32 kg/cm2) at 280 rpm
Valve Timing
Intake Opens 18° BIDC
Intake Closes 46° ABDC
Exhaust Opens 46° BBDC
Exhaust Closes 18° AIDC
Valve Seat Angle
Intake 45°
Exhaust 45°
Valve Clearance
(engine cold)
Intake 0.0098 inches (0.25 mm)
Exhaust 0.0098 inches (0.25 mm)
Engine Speed
1800 rpm 60 Hertz
1500 rpm 50 Hertz
Dimensions
Height: 23.75 inches (603.25mm)
Width: 16.85 inches (427.99 mm)
Length: 34.56 inches (877.82 mm)
Weight
575 Ibs (260.8 kgs)
Fuel Consumption
1.2 gph (4.54 Iph) at full rated
output (approximate)
Inclination
Continuous 15°
Temporary 20° (not to exceed 20 min.)
WESTERBEKE GENERATORS
22
SYSTEM SPECIFICATIONS
FUEL SYSTEM:
GENERAL
Open flow, totally self-bleeding
FUEL
No.2 Diesel oil (cetane rating of 45 or higher)
FUEL INJECTION PUMP
Nippon Denso (Bosch M type)
FUEL INJECTION TIMING
19° BIDC ±O. 5 (static timing)
NOZZLE
INJECTORS
Throttle type
Pintle type
FUEL PUMP
FUEL Frr..TER( on engine)
12-Volt DC; Electro-Magnetic type
Canister type, with replaceable element
AIR CLEANER
Metal screen type-cleanable
AIRFLOW
42 cfm (1.2 cmm)
COOLING SYSTEM:
GENERAL
Closed fresh water-cooled block, thermostatically
controlled with heat exchanger.
OPERATING TEMPERATURE
170° - 190° F (77° - 88° C)
FRESH WATER PUMP
Centrifugal type, metal impeller, belt-driven
SEA WATER PUMP
Positive displacement, rubber impeller, belt-driven
SEA WATERFLOW, AT 1800 RPM
(measured before discharging into
exhanst elbow.)
7.2 gpm (27.25 Ipm)
SYSTEM CAPACITY(Fresh Water)
8 quarts (7.6 liters)
LUBRICATION SYSTEM:
GENERAL
Pressure type by Trichoid pump, gear driven with
external pressure relief valve
Orr.. Frr..TER
Full flow, paper element, spin-on type
SUMP CAPACITY
4.23 quarts (4.0 liters)
OPERATING OIL PRESSURE (engine hot)
40 - 80 psi (2.8 - 5.6 kg/cm 2)
OIL GRADE
API specification CC or CD
23
WESTERBEKE GENERATORS
SYSTEM SPECIFICATIONS CONTINUED ...
ELECTRICAL SYSTEM
STARTING BATTERY
12-Volt, ( - ) negative ground
BATTERY CAPACITY
300-400 CCA
DC CHARGING ALTERNATOR
l2-volt DC, 50 Amp
REGULATOR
Internal regulator built into alternator
STARTING AID
Glow Plug, sheathed type
STARTER
12-volt, 1.6 KW, reduction type, solenoid mounted
DC NO-LOAD CURRENT
90 Amp (max.) at 11.5 Volts
DC CRANKING CURRENT
175 - 200 Amps (engine cold)
ACGENERATOR
GENERAL
Brushless, four-pole, revolving field.
Pre-lubricated single-bearing design.
Reconnectable, single-phase transformer regulation
(optional solid-state voltage regulation)
VOLTAGE
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
RATING (Volts AC)
60 HERTZ (1800 rpm)
11.0KW
50 HERTZ (1500 rpm)
8.3KW
GENERATOR COOLING AIR
REQUIREMENTS, (60 Hertz), at
1800 rpm
120/240 Volts
91.6 Amps
91.6/45.8 Amps
220 Volts
37.7 Amps
120 Volts
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
Brushless six pole, revolving field. Sealed lubricated
single bearing design. 12 Lead reconnectable for
low voltage WYE, high voltage Delta. Solid State
voltage regulator with protection circuitry.
Voltage - 3 Phase (60 Hertz)
Low voltage WYE 208 volts
High voltage WYE 480 volts
DELTA
240 volts
Voltage - 3 Phase (50 Hertz)
High voltage WYE 380 volts
DELTA
220 volts
Amperage - 3 Phase (60 Hertz)
Low voltage WYE
High voltage WYE
DELTA
Amperage - 3 Phase (50 Hertz)
High voltage WYE
DELTA
38 Amps
16 Amps
33 Amps
15 Amps
27 Amps
AC GENERA TOR:
ENGINE COMBUSTION AIR
REQUIREMENTS (60 Hertz) AT
1800 rpm
32 cfm (.906 cmm)
ENGINE COMPARTMENT COOLING
AIR
100-200 cfm (2.83 - 5.66 cmm)
TUNE UP SPECIFlCATIONS
INJECTOR PRESSURE
1707 psi (120 kg/cm2 + 10 kg/cm2 - 0 kg/cm2)
ENGINE TIMING
19' BIDC
25
WESTERBEKE GENERATORS
BTD 12.5 KW MARINE DIESEL GENERATOR SET GENERAL SPECIFICATIONS
Engine Type
Diesel, 4-cycle, 4-cylinder, fresh water-cooled
Vertical, in-line overhead valve mechanism
(23 hp at 1800 rpms maximum)
Governor
Mechanical, centrifugal weight type
Combustion Chamber
Swirl chamber type
Bore & Stroke
3.07 x 3.07 inches (78 x 78 mm)
Pistion Displacement
91 cubic inches (1.49 liters)
Firing Order
1-3-4-2
Direction of Rotation
Clockwise, when viewed from the front
Maximum Torque (at 1800 rpm)
67 Ib-ft (9.26 kg-m)
Compression Ratio
23 : 1
Compression Pressure
455 psi (32 kg/cm2) at 280 rpm
Valve Timing
Intake Opens 20° BIDC
Intake Closes 44° ABDC
Exhaust Opens 44° BBDC
Exhaust Closes 20° AIDC
Valve Seat Angle
Intake 45°
Exhaust 45°
Valve Clearance
(engine cold)
Intake 0.0098 inches (0.25 mm)
Exhaust 0.0098 inches (0.25 mm)
Engine Speed
1800 rpm 60 Hertz
1500 rpm 50 Hertz
Dimensions
Height: 25.34 inches (643.60mm)
Width: 18.17 inches (461.50 mm)
Length: 37.25 inches (946.10 mm)
Weight
638 Ibs (289.4 kgs)
Fuel Consumption
1.4 gph (5.29 Iph) at full rated
output (approximate)
Inclination
Continuous 15°
Temporary 20° (not to exceed 20 min.)
WESTERBEKE GENERATORS
26
SYSTEM SPECIFICATIONS
FUEL SYSTEM:
GENERAL
Open flow, totally self-bleeding
FUEL
No.2 Diesel oil (cetane rating of 45 or higher)
FUEL INJECTION PUMP
Nippon Denso (Bosch M type)
FUEL INJECTION TIMING
19° BIDC ±O. 5 (static timing)
NOZZLE
INJECTORS
Throttle type
Pintle type
FUEL PUMP
FUEL FILTER(on engine)
12-Volt DC; Electro-Magnetic type
Canister type, with replaceable element
AIR CLEANER
Metal screen type-cleanable
AIRFLOW
4S cfm (1.2 cmm)
COOLING SYSTEM:
GENERAL
Closed fresh water-cooled block, thermostatically
controlled with heat exchanger.
OPERATING TEMPERATURE
FRESH WATER PUMP
Centrifugal type, metal impeller, belt-driven
SEA WATER PUMP
Positive displacement, rubber impeller, belt-driven
SEA WATERFLOW,ATlS00RPM
(measured before discharging into
exhaust elbow.)
7.2 gpm (27.25 Ipm)
SYSTEM CAPACITY(Fresh Water)
8 quarts (7.6 liters)
LUBRICATION SYSTEM:
GENERAL
Pressure type by Trichoid pump, gear driven with
exiernal pressure relief valve
OIL FILTER
Full flow, paper element, spin-on type
SUMP CAPACITY
4.76 quarts (4.5 liters) plus filter/cooler assembly
OPERATING OIL PRESSURE (engine hot)
40 - SO psi (2.S - 5.6 kg/cm2)
OIL GRADE
API specification CC or CD
27
WESTERBEKE GENERATORS
SYSTEM SPECIFICATIONS CONTINUED ...
ELECTRICAL SYSTEM
STARTING BATTERY
12-Volt, ( -) negative ground
BATTERY CAPACITY
300-400 CCA
DC CHARGING ALTERNATOR
12-volt DC, 50 Amp
REGULATOR
Internal regulator built into alternator
STARTING AID
Glow Plug, sheathed type
STARTER
12-volt, 1.6 KW, reduction type, solenoid mounted
DC NO-LOAD CURRENT
90 Amp (max.) at 11.5 Volts
DC CRANKING CURRENT
175 - 200 Amps (engine cold)
AC GENERATOR
GENERAL
Brushless, four-pole, revolving field.
Pre-lubricated single-bearing design.
Reconnectable, single-phase transformer regulation
(optional solid-state voltage regulation)
VOLTAGE
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
RATING (Volts AC)
60 HERTZ (1800 rpm)
12.5 KW
50 HERTZ (1500 rpm)
9.3 KW
GENERATOR COOLING AIR
REQUIREMENTS, (60 Hertz), at
1800 rpm
120 Volts
104/52 Amps
220 Volts
42.3 Amps
200 - 225 cfm (6.37 - 7.08 cmm)
NOTE: Increase air supply 15 % for 50 Hertz operation 1500 rpm.
WESTERBEKE GENERATORS
104 Amps
1201240 Volts
28
SYSTEM SPECIFICATIONS CONTINUED ...
General - 3 Phase
12.5 KW - 60 Hertz
9.3 KW - 50 Hertz
Brushless six pole. revolving field. Sealed lubricated
single bearing design. 12 Lead reconnectable for
low voltage WYE, high voltage Delta. Solid State
voltage regulator with protection circuitry.
Voltage - 3 Phase (60 Hertz)
Low voltage WYE 208 volts
High voltage WYE 480 volts
240 volts
DELTA
Voltage - 3 Phase (50 Hertz)
High voltage WYE 380 volts
220 volts
DELTA
Amperage - 3 Phase (60 Hertz)
Low voltage WYE
High voltage WYE
DELTA
43 Amps
18 Amps
37 Amps
Amperage - 3 Phase (50 Hertz)
High voltage WYE
DELTA
17 Amps
30 Amps
AC GENERATOR:
ENGINE COMBUSTION AIR
REQUIREMENTS (60 Hertz) AT
1800 rpm
32 cfm (.906 cmm)
ENGINE COMPARTMENT COOLING
AIR
100-200 cfm (2.83 - 5.66 cmm)
TUNE UP SPECIFICATIONS
INJECTOR PRESSURE
1707 psi (120 kg/cm2 + 10 kg/cm2 - 0 kg/cm2)
ENGINE TIMING
29
WESTERBEKE GENERATORS
BTDA 12.5 KW MARINE DIESEL GENERATOR SET GENERAL SPECIFICATIONS
Engine Type
Diesel, 4-cycle, 4-cylinder, fresh water-cooled
Vertical, in-line overhead valve mechanism
(23 hp at 1800 rpms maximum)
Governor
Mechanical, centrifugal weight type
Combustion Chamber
Swirl chamber type
Bore & Stroke
3.07 x 3.07 inches (78 x 78 mm)
Pistion Displacement
91 cubic inches (1.49 liters)
Firing Order
1-3-4-2
Direction of Rotation
Clockwise, when viewed from the front
Maximum Torque (at 1800 rpm)
67 Ib-ft (9.26 kg-m)
Compression Ratio
23 : I
Compression Pressure
455 psi (32 kg/cm2) at 280 rpm
Valve Tinting
Intake Opens 20° BIDC
Intake Closes 44° ABDC
Exhaust Opens 44° BBDC
Exhaust Closes 20° AIDC
Valve Seat Angle
Intake 45°
Exhaust 45°
Valve Clearance
(engine cold)
Intake 0.0098 inches (0.25 mm)
Exhaust 0.0098 inches (0.25 mm)
Engine Speed
1800 rpm 60 Hertz
1500 rpm 50 Hertz
Dimensions
Height: 25.34 inches (643.60mm)
Width: 18.17 inches (461.50 mm)
Length: 37.25 inches (946.10 mm)
Weight
638 Ibs (289.4 kgs)
Fuel Consumption
1.1 gph (4.2 Iph) at full rated
output (approximate)
Inclination
Continuous 15°
Temporary 20° (not to exceed 20 min.)
WESTERBEKE GENERATORS
30
SYSTEM SPECIFICATIONS
FUEL SYSTEM:
GENERAL
Open flow, totally self-bleeding
FUEL
No.2 Diesel oil (cetane rating of 45 or higher)
FUEL INJECTION PUMP
Nippon Denso (Bosch M type)
FUEL INJECTION TIMING
19° BIDC ±O.5 (static timing)
NOZZLE
INJECTORS
Throttle type
Pintle type
FUEL PUMP
FUEL FILTER(on engine)
12-Volt DC; Electro-Magnetic type
Canister type, with replaceable element
AIR CLEANER
Metal screen type-cleanable
AIRFLOW
48 cfm (1.2 cmm)
COOLING SYSTEM:
GENERAL
Closed fresh water-cooled block, thermostatically
controlled with heat exchanger.
OPERATING TEMPERATURE
170° - 190° F (77° - 88° C)
FRESH WATER PUMP
Centrifugal type, metal impeller, belt-driven
SEA WATER PUMP
Positive displacement, rubber impeller, belt-driven
SEA WATERFLOW,ATI800RPM
(measured before discharging into
exhaust elbow.)
7.2 gpm (27.25 lpm)
SYSTEM CAPACITY(Fresh Water)
8 quarts (7.6 liters)
LUBRICATION SYSTEM:
GENERAL
Pressure type by Trichoid pump, gear driven with
external pressure relief valve
OIL FILTER
Full flow, paper element, spin-on type
SUMP CAPACITY
4.76 quarts (4.5 liters) plus filter/cooler assembly
OPERATING OIL PRESSURE (engine hot)
40 - 80 psi (2.8 - 5.6 kglcm2)
OIL GRADE
API specification CC or CD
31
WESTERBEKE GENERATORS
SYSTEM SPECIFICATIONS CONTINUED ...
ELECTRICAL SYSTEM
STARTING BATTERY
12-Volt. ( -) negative ground
BATTERY CAPACITY
300-400 CCA
DC CHARGING ALTERNATOR
12-volt DC, 50 Amp
REGULATOR
Internal regulator built into alternator
STARTING AID
Glow Plug, sheathed type
STARTER
12-volt, 1.6 KW, reduction type, solenoid mounted
DC NO-LOAD CURRENT
90 Amp (max.) at 11.5 Volts
DC CRANKING CURRENT
175 - 200 Amps (engine cold)
ACGENERATOR
GENERAL
Brushless, four-pole, revolving field.
Pre-lubricated single-bearing design.
Reconnectable, single-phase transformer regulation
(optional solid-state voltage regulation)
VOLTAGE
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
RATING (Volts AC)
60 HERTZ (1800 rpm)
12.5 KW
120 Volts
120/240 Volts
104 Amps
104/52 Amps
50 HERTZ (1500 rpm)
9.3KW
220 Volts
42.3 Amps
GENERATOR COOLING AIR
REQUIREMENTS, (60 Hertz), at
1800 rpm
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
Brushless six pole. revolving field. Sealed lubricated
single bearing design. 12 Lead reconnectable for
low voltage WYE. high voltage Delta. Solid State
voltage regulator with protection circuitry.
Voltage - 3 Phase (60 Hertz)
Low voltage WYE 208 volts
High voltage WYE 480 volts
DELTA
240 volts
Voltage - 3 Phase (50 Hertz)
High voltage WYE 380 volts
DELTA
220 volts
Amperage - 3 Phase (60 Hertz)
Low voltage WYE
High voltage WYE
DELTA
43 Amps
18 Amps
37 Amps
Amperage - 3 Phase (50 Hertz)
High voltage WYE
DELTA
17 Amps
30 Amps
AC GENERATOR:
ENGINE COMBUSTION AIR
REQUIREMENTS (60 Hertz) AT
1800 rpm
32 cfm (.906 cmm)
ENGINE COMPARTMENT COOLING
AIR
100-200 cfm (2.83 - 5.66 cmm)
TUNE UP SPEC/FlCA TIONS
INJECTOR PRESSURE
1707 psi (120 kglcm2 + 10 kglcm2 - 0 kglcm2)
ENGINE TIMlNG
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
~, FOOl Of Ru'"
'nc"
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 Waler
''''''
Sea Water
Intal<e· Tnru·
Hull F,n,nc
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.
Sea Waler
Inla-.e· i"/'nJMIA Fn~C
WESTERBEKE GENERATORS
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.
::xhaust
::Ibow
\
I~
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:
~Exhaust
"
"
' "
f\
Mercury
Manometer \
\
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
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 wirereinforced 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 - 132 0 C). This switch resets at 195 0 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
• Intense headache
• Weakness and sleepiness
• Vomiting
• Muscular twitching
• 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
GENERATOR" section of this manaul.)
WARNING
DO NOT smoke or allow an open flame near batteries. Lead acid batteries emit hydrogen, a
highly-explosive gas.
Batteries
Make sure the positive (+) battery connection is connected to the battery connection of the starting
solenoid. 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
~
ELAfIl'S£OTM
Iplllmlll 0 II
......
"'0
CENERATOJ:i
o
o
NOTE: When the generator is stopped after use, the water temperature and oil pressure gauges may stay
at their running readings.
When the generator is next used, depressing the PREHEAT switch will cause the water temperature and
oil pressure gauge indicators to return to zero (deflect to the left of the gauge). The DC voltmeter will
register system voltage. 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
+41°F(+5°C) to +23°F(-5°C)
+23 ° F (_5°C) or lower
Approx. 10 seconds
Approx. 20 seconds
Approx. 30 seconds
J minute
Limit of continuous use
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.
Proper Glow Plug Indication
Should the engine not start when the START switch is
depressed for 10 to 20 seconds, release both switches
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 - 190 0 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 - 150 0 F (60 - 66 0 C) before placing the generator under a heavy load.
Starting Under Cold Conditions
Under extremely cold temperatures, the following conditions can occur. Follow the instructions listed
below when operating 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.
VOLTAGE 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.
Fuel Supply (out)
12 V DC (+) Connection
Fuel Pum.p
Fuel Supply (in)
(In..ta.ller'. Connection)
Ground Wire
13
WESTERBEKE GENERATORS
46
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
DC CONTROL CIRCUIT WIRING DIAGRAM #36412
PAGEIOF2
A
r ________--"""o-'c,,""---_____________~
//,-,7:~ID";"I-_-,.-_,,-0-"-"-0-- '
"J ML
',4RED!PUA 5TR'»E
wt.TER ,
TEMF-_':'
SENDER
a
a:o
.~"'"
"
0
"1---'-;£
WATER
TEMP
SWITCH
1
r:UEL
SJLENOID
TEMP. SWITCIi
-
.'
CIRCUIT
BREAKER
EXHAUST
.-
o~
;
pj:lEHEAT
.~
OIL PRESSURE
SWITCH
SOLENOID
O,l RED
£t-
GgJ
CIRCUIT
0
.,
SREAKER
~
•~
OIL PRESSURE
SENDER
"e
,
.,
~
~
GROUN~I~
TO
-I
•
,
e
.-. .-.
ENGINE
~
'"
ffi
BLOCK
'"
0
~un
rgpu~p
"
,~
.,
9ATTERY(12VOC)
EMERGENCY
STOP
'140RN
·,4 VEL
~,o
I
sw.
RED
"O"'HT
-1-0 \; \;
~
~~
-
-
STANDARD
I NSTRlilViE0iT
PANEL
s'op
SWITCH
1________ __
_
49
__
-.J
WESTERBEKE GENERATORS
DC CONTROL CIRCUIT WIRING SCHEMATIC #36412
PAGE20F2
,C)
I
PREH~AT
;"b
SOL
I
t---
:rca
,(
12CA
-'f
!
~~: H"ERGE~CY
,r:
,-!",
:;-:>~
'Ow
'~:5TOPSW
',PREH~AT SI-I
•
+----{ p
EXHAUST
TfMP 51.,'
FU~l
SOL
,~
!
O_~
GAUGE
VOLTMETER
1
PUSH PREHi:AT 5WiTO< FIRST_HOLD FOR 15 TO 60 SECONDS AS REQ'u.
START'I.t.LWf-..VS
2.WHILE
:;,WI-'_EN
C;::'HINUI:>jG Te!
PUSH
PR[HEAT SWITCH \ PUSH START SWITCH.
GE,'l[H\TOR STAfHS,r{ELEIlSE
START SWiTCH ONLY.
4,WHECl 01:'" P"![SSURE REI\Ct-<ES :'PPRQXIMATEL, 20 PSI,RELEASE PREHEAT
SIVITCH (THe ","[H[AT SWiTCH
~O\" OIL ?RESSuR[ SHUT-DOWN
CVERR\D[':, THE
ClilC.UITj.
STOP'.
PUSH NW hOLD Tr'.t ",SP ",'WITCH 'JNTlL T--i[
LTfi:':> PROD'le' 1'-, PHOTECTlD BY A
NEAP THE. STARTEI, AN!)
EXCESSIVE
C0I<RE1,~
A~
~lANl!AL
GENERATOR :,"OPS COMPLETELY.
RESET
ClnCUIT
Cl0SE TO THE SCURCE OF
BREAKER LOCATED
ClJRRE~T
Dflr,w ANYWHU<[ I.," TilE I'<STP:UME'lT
"r,GINE W;LL cr,USE THE
BREAKER ro TRIP. Ir>; THIS EVENT ~OS"
WILL SI-t.;T [;owr; BE.CIIUSE
THE
OPENED
~L1:.CTRICAL
OR
'~ENERATORS
BREAKER DISCCNNECTS THE FUEL
SUPF-LY. THEREfOP:E THE 6uILOER/OW\lER I~UST 8E SURE THI\T
"'ANEL,WIRI.'lG AND ENGINE
AS POSSIBLE.
PANE,-,'NlRI~G
"'''E INSTALLED
~O
THE INSTRUMENl
PREVENT CONTACT BETWEEN
Df'v"_ES ':"No St.LT WATER
2A\' ON-OFF ,-,WITCH SHOl·LD RE INSTALLED ,', THIS CRe'.)IT TO DISCONNECT THE
STARTEiC
HIC:LVE
Wf-IEN
FRO'" THE BATTERY IN M; EMERGENCY AI\O WHEN LEAVI"lG THE 80AT
VQLT u!ESEL ::\JG NE "TARTER';' TYP:cr.LLY r;Rr,\,
CPAr-.K!~G.THE
EX:::EED :;C
S£CC~DS.
D;JRATlO\J OF 'NDtVID.Jt..L
~OO
CRfI~KI\JG
TO 300 M·1PS
CYCLES SHOULD
~OT
A SWITCH WITH A CO'lT;·,"UOUS t\I<T'NG :::.• ;75 AMPS AT
12VJC >'I,LL NC"MI\~\Y SEHvE. THI':> FU:-<CTlOr-.,8:JTA S\\!TCH r~UST NEVER BE
USEr,
Tf~ 1~t.KE
WESTERBEKE GENERATORS
THE "TAI;T!:r,
CIRCUIT.
50
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.
AHPHETER
;-----------~~~A e
L
R
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
Freezing
Temperature
%
13
23
30
35
45
50
60
of
23
(-5)
14
(-10)
5
(-15)
-4
(-20)
-22
(-30)
-40
(-40)
-58
(-58)
(0C)
b. Filling the Fresh Water System
A coolant recovery tank kit is supplied with each Westerbeke diesel generator. The purpose of this
recovery tank is to allow for engine coolant expansion and contraction, during engine operation, without
the loss of coolant and without introducing air into the cooling system.
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.
..~
~
"
..
-j'
'
,.
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
Clean
or
New
Anod.,
Replace
Replace
Zinc Anode Conditions
54
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 - - _ _ _
EXHAUST MANIFOLD
,
\
THERMOSTAT
WATER
~~--~~~--TEMPERATURE
~~'1
SWITCH
\
COOLANT RECOVERY TANK
INCOMING
RAW WATER
RAW WATER
PUMP
FRESH WATER
RAW WATER
HEAT EXCHANGER
*
~
FRESH WATER DRAIN
RAW WATER DRAIN
Typical Cooling System
WESTERBEKE GENERATORS
56
Exhaust Elbow Installation
The Westerbeke Corporation offers a 45 0 and 90 0 exhaust
elbow as well as an exhaust riser you can install on your
propulsion engine. Refer to the instructions below when
installing the exhaust elbow purchased for your generator.
ELBOW
FL.... NGE
NOTE: Fabricated exhaust elbows or risers attached to the
exhaust manifold shall not exceed 8 Ibs when unsupported.
1. Coat only one side of the exhaust gasket with "High Tack"
adhesive sealant. 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.
,.,,'OT GASKET
< ..
4S0ELBOW
,.".T CL....
Kit'" 037402
<..
."IA","
MANIFOLD FLANGE
•
ELBOW
FLANGE
t
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.
EXHAUST GASKET
90" ELBOW
EXHAUST CLAMP
Kit"'037401
4. Adjust the elbow by rotating it until the desired alignment
with the exhaust piping is acquired.
5. Carefully tighten the clamp between 8 to 10 Ib-ft, or Uto 1.3 kg-m.
UCAUTION
II
EXHAUST
FLANGE
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.
EXHAUST RISER
Kit" 037403
If a leak exists, correct it immediately.
EXHAUST GASKET
'Manufactured by Perrnatex Company, Brooklyn, N.Y.
" '.. " " CLAMP
mUllS' MANIFOLD FLANGE
57
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 10W30 with minimum viscosity change under different temperatures is suggested.
Viscosity
Atmospheric Temperature
SAE 30 or lOW - 30
SAE 20 or lOW - 30
SAE lOW - 30
68° F (20°C) or higher
41° F (5° C) - 68° F (20° C)
41° F (5° C) - or lower
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
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.
OIL
PRESSURE SENOER
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
Oil Filter and Oil Drain System
filters.)
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 selfexciting feature of this generator. The magnetic field produced causes an AC voltage to be induced into
the related exciter rotor windings during rotation. Diodes located in the exciter rotor rectify this voltage
to DC and supply it to the windings of the rotating field. 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 176 0 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
AC
r--------------,
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COMPONENTS LISTED ON FOLLOWING PAGE.
61
WESTERBEKE GENERATORS
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PLUG
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
D. COMPOUND TRANSFORMER
I. Compound Transformer Windings
2. Compound Transformer Windings
3. Compound Transformer Auxiliary
Windings
B. EXCITER ROTOR
I. Auxiliary Windings (a-b-c)
2. Diodes (6)
3. Rotating Field Windings
4. Pozi Resistor
E. SELECTOR SWITCH
I. Compound
2. Electronic and Compound
C. MAIN STATOR
I. Main Stator Windings
2. Main Stator Windings
3. Main Stator Auxiliary Windings
G. BRIDGE RECTIFIER
(Optional A. VR. - Automatic Voltage Regulator)
WESTERBEKE GENERATORS
62
A
1
r--------.,
I
I
C
I
~---------------,
•
B
I
I
•
r--------,
2
I~
r=r-r.1' 1
OlJl ,
•
11
3'
l
i
B
2
,
_______________ J
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AC
6
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BID 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
D. COMPOUND TRANSFORMER
L Compound Transformer Windings
2. Compound Transformer Windings
3. Compound Transformer Auxiliary
Windings
B. EXCITER ROTOR
L Auxiliary Windings (a-b-c)
2. Diodes (6)
3. Rotating Field Windings
4. Pozi Resistor
E. SELECTOR SWITCH
L Compound
2. Electronic and Compound
C. MAIN STATOR
L Main Stator Windings
2. Main Stator Windings
3. Main Stator Auxiliary Windings
G. BRIDGE RECTIFIER
(Optional AY.R. - Automatic Voltage Regulator)
63
WESTERBEKE GENERATORS
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
50}+-
2
Os
Os
60Hz
5
7lUl-i-...,
03
H
110V
'1 r
50Hz
110/22BV 50Hz
02
sO
OS
7P
¥3
80
22BV 50Hz
50
sO
Os
Q3
I
I
I
H
l 1
l 2
8
Q
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
120V 60Hz
0
( )
, 20/240V 60Hz
( )
0
I
0
0
0
0
0
0
'II~
TO FR .ME
I
~ :J
L,
NI:
(
)
)
~
=<
0
f==l
(OJ
LO
l.-
0
0
0
0
n
TIN
L,
110J;220V 50Hz
=
,
To FRAME
110VSOHz
=
0
o
0
220V 50Hz
0
=
0
0
0
0
=
0
RO
Tn
c
~
..... t
U
N
0
(6)
'n
U
L,
AC Voltage Connections (12 Stud Tenninal Block)
(Used only with the BTD 8.0 KW Generator Set.)
NOTE: The frame ground wire must be moved when changing from 110 Volts, 50 Hertz to 1220
Volts, 50 Hertz.
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
I
I
I STATOR
,-----.c
I
EXCITF~
:I I
i
____ .1 ___________ -,
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FUSE
20 A.
.J.
#
12 A
11 C
10 T
9 E
8
7
6
5
4
3
2
1
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M
I
N
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L
8
L
0
c
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FUSE
6,3A.
REGULATOR
A. Exciter
1. Exciter Stator Windings
B. Rotor
1.
2.
3.
4.
Auxiliary Exciter Windings (a-b-c)
Diodes (6)
Main Rotor Windings
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
67
WESTERBEKE GENERATORS
VOLTAGE REGULATOR #038468
Single & Three Phase
5
4
LED'S
3
Red
Green
Yellow
HZ.
2
DOD
0
B
+
AMP.
VOLT
]60HZ.
The voltage regulator is of an advanced design which ensures optimum AC alternator performance. The
regulator is equipped with complete protection circuitry to guard against operating conditions that could
be detrimental to the AC alternator.
Adjustments:
I. Volts - This potentiometer is used to adjust AC output voltage. It has an additional range of ± 25-30
volts. 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
3 PHASE AC TERMINAL BLOCK CONNECTIONS
FOR WYE AND DELTA CONFIGURATION
PARALLEL WYE (STAR)
12
10
11
12
L1
8
6
7
5
8
L2
4
2
3
SERIES DELTA
SERIES WYE (STAR)
9
1
4
L3
I
N
L-L 208 VAC 39 60 HZ
L-N 120VAC 1060HZ
l-L 190 VAC 3~ 50 HZ
l-N 110 VAC 19 50 HZ
1
10
11
a:::=J)
9
9
L1
L1
6
7
a:::=J)
~
5
2
3
a:::=J)
~
5
L2
Q)
1
L3
L3
®-
N
L - L 460 VAC 31J 60
L - N 265 VAC 1" 60
L-L 380 VAC 39 SO
L-N 220 VAC 19 SO
HZ
HZ
HZ
HZ
L-L
L2,L3-N
L- L
L2,L3-N
240VAC
120VAC
220VAC
llQVAC
'..
3~ 60 HZ
,
3~
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
U~
n'
,
I
DELTA
WYE
WESTERBEKE GENERATORS
\I
:~~nLJ
--~ .OM,.
~--~-----~----------~
l.. _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ ...
70
L2
N
The illustration below shows the 3 phase AC generator backened with the louvered covers removed.
DC Charge Bridge
Rectifier
AC Terminal Block
Voltage
Regulator
71
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.
prevents simultaneous connection of shore power to generator output.
Use of this switch
II CAUTION II
Damage to the generator can result if utility shore power and generator output are connected at the same
time. 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.
( N Gl
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SHOIIS COlirCTIONS FOil ''10IIiRE. 12'-IIOLT SYSTUII. fOI TKIH-WlltE
SYSHIi uS( DCllHD tIMES FDa 111£
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"J"'"".'
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(t2S IWPS'POLfl
PM 32131
(211 IIMPS/PotO
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Shore Power Switch Connection Diagrams
72
l:u.P6/POLE)
PM 32889
(Bill AMPS/POLE)
51. N
WESTERBEKE GENERATORS
32118&
(.e
.-- . . . ,
-_/
\ 52
'11
NOTE, OIAGRAM SHOWS CONNECTIONS FOR R TWOWIRE. 129-VOlT SYSTEM FROM THE GENERRTOR.
WJlH THREE-WIRE. 129-VOll
BORT SYSTEM.
"-,,,,,,
r
-,~
"O;"""'.,."','-----''---_---i I '
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5I11P-10-5110R£ SWITCH
3281111
(,1.25
PM
A ..P6/POLf;l
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:
(HP)
AMPS FOR
RUNNING
(Amperes)
AMPS FOR
STARTING
(Amperes)
1/6
114
113
112
3/4
1
3.2
4.6
S.2
7.2
10.2
13
6.4 to 22.4*
9.2 to 32.2*
10.4 to 72.8*
14.4 to 29.2
20.4 to 40.8
26 to 52
MOTOR
SIZE
*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 (splitphase) 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
Applied
4-Pole
Speed (rpm)
Frequency
(Hertz)
Generator
120V (110)
Plants
Voltage
240V (220)
Plants
None
1830
(1530)
62
(52)
122
(112)
240
(224)
Half
1800
(1500)
60
(50)
120
(110)
240
(220)
Full
1755
(1455)
59
(49)
110
(100)
220
(200)
The output voltage should be checked periodically to ensure proper operation of the generating plant and
the appliances it supplies.
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
ENGINE CONTROL PANEL
General
This manually-controlled series of
Westerbeke marine diesel generators is equipped with toggle
switches on the engine's control
panel and, optionally, at remote
panels. The following instructions
and methods of correcting minor
problems apply only to such toggle
switch controls.
Standard Instrument Panel
0
o
®
st.""
~
All three switches are momentary
contact type and serve the following functions:
1. 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-
'R(lEAT
$TO'
®
,"", .. " ...TOII
o
0
tective oil pressure sensor. The
defeat function turns on the fuel
solenoid, instrument power, alternator 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)
..
..
..
,
I
,
..
..It ...
..
i
:
H
"
...
M""""''''
1..'·· ... ••
111~G(
! ~~/'M~!UT
:---------------------. --".-----------." -----.-----------"." ------r-----·
--------.".-.. ----:
i
{>
REP
~
.... D
'10 GU[":.I ...
!
STOP
SWI TCH
G
TO Til I - I
~TOTIlI-(jHO
!
!
i
i
i
i
f' N.
2HO
100[lum
WESTER8(KE CORPORATION
AVO" "4
Q~lH
:::O<;Lif'::"i ,n ~7auG
...:::" 1,P _II'
" ~
.
... '...."...
WESTERBEKE GENERATORS
76
-
DIAGRAM, OI(Hl
RfIlOl[ COIITROL
...........
GrMr~AIOR
DC WIRE SIZING CHART
Stranded Conductors for 12 Volt Circuits
10% Voltage Drop
B. National ElectricaJ Code Type Wire
A. Society oC Autonlotive Engineers Type Wire
"
Wire SI:r..,
,.
16x3O 1Silx29
Standing
Clreular
1537
Mil Area
"
19x27
"
19;(25
2336 3702 5833
Circuli
Current
In AMPS
10
lb23
,
• •
19x21
16
"
49",21
49)(23
93'3 )-41110 25910
37360
2583
"
"
"
"
4'07
Ei530
,.
10
10380
• 37• .,, , 1
"
'" '"
-4'''0
16510
26250
66370 83690
MaxilTlurn Length of Conductor in Feel CroIn Power SOUTce to Load and Return
m
1.
2.
3.
260
130
"•• ••
.,
,.
86.7
43.7
3".7
••
••
7.
••••
'0.
29
2·(.7
21.7
1S.3
17.3
lS.
20.
43.3
37
32.7
28.7
,.
17.3
30.
'0.
.0.
210
"0
330
220
"
132
lOS
70
8O
52.7
46.7
16.
227
9".6
.
"'210"
".
,.0
,,,
6.
lOS
"0
82.7
73.3
"
"21 "33
'"
'" ,.,
7'
.7
279
2<0
210
". ,lB...
70
52.7
35
26.3
22
"
•••
300
271
." .
.."
'"
83.7
,.0
135
90.3
67.3
33.7
75.3
19
30
6 ....7
56.3
50.3
45.3
22.7
'"'07
77.7
71.3
.7
.(7.3
36
90.
47.3
40.7
35.3
31.7
2B.3
85.3
30.7
60.
75.
'"
'"
"3
.7
,.0
,.0
"3
2••
232
120
'03
'90
303
,.0
'.3
,.,
227
321
127
20'
,.,
,
'"
193
76
30'
.7 '"91 ,,,
230
36
306
,.3
96.3
,,,
182
230
" 2328.3 45.3
'"
,,,
57.7
36.3
",
"
133
52.3
33
"7
76.3 ,,,
153
..
89.6
79.6
72
,. .
60.7
72
.,.,
83.3
"
38.3
The voltage drop for :'Ipecific conductor lengths may be calculated by the formula:
load in amperes
Voltage drop
10.75 x I x L
where:
CM
CM
When
Ii
L
circuit.. including the ground return.
U9CS
conductor length in feel
conductor circular MIL arca
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
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
S7.3
'"
" '02
ENGINE TROUBLESHOOTING
Problem
Probable Cause
VerificationiRemedy
PREHEAT switch is depressed:
no panel indications, fuel
solenoid, electric fuel pump and
preheat solenoid not energized.
Battery switch
Check switch and/or battery
connections.
20-Amp circuit breaker tripped.
Reset breaker; if breaker trips
again, check preheat solenoid
circuit and run circuit for shorts
to ground.
START switch is depressed:
no starter engagement
Connection to solenoid faulty.
Check connection.
Faulty START switch.
Check switch with ohmmeter.
Faulty solenoid.
Check that 12 volts is present at
solenoid connection.
Loose battery connection.
Check battery connection.
Low batteries.
Check battery charge state.
Poor connections to fuel
solenoid.
Check connections.
Defective fuel solenoid.
I. Check mechanical
positioning of fuel solenoid for
plunger bottoming.
START switch is depressed:
panel indication OK; start
solenoid OK; fuel solenoid not
functioning.
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.
No ignition: cranks, but does not
start; fuel solenoid energized.
Faulty fueling system.
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.
WESTERBEKE GENERATORS
78
Problem
Probable Cause
Verification/Remedy
Failure to stop.
Fuel solenoid return spring.
Stop engine manually by
moving the throttle lever to shut
off. That failing, shut off fuel
and air. Check fuel solenoid
linkage and repair for free
movement.
STOP switch failure.
Stop engine by depressing
emergency STOP switch on
engine or manually moving
throttle to shut off. Test switch
with ohmmeter.
Fuel injection pump failure.
Depress emergency STOP
switch on engine. Stop engine
by opening the high pressure
injector lines at the injectors and
stop air intake.
Low oil pressure.
Check oil level; check fresh and
sea water cooling.
Low oil pressure.
Check for satisfactory operation
with switch depressed. Check
with ohmmeter.
High water temperature switch
opens at too Iowa temperature.
Check for satisfactory operation
with switch bypassed. Check
with an ohmmeter.
20-Amp circuit breaker tripping.
Same as above.
High exhaust temperature
switch opens at too Iowa
temperature.
Same as above.
Emergency STOP switch or
STOP switch in panel defective,
opening fuel run solenoid
circuit.
Inspect all wiring for loose
connections and short circuits.
Inspect switches for proper
operation.
Battery not charging.
Alternator drive.
Check drive belt tension. Be
sure alternator turns freely.
Check for loose connections.
Check output with voltmeter.
Ensure 12 Volts present at
regulator terminal.
Battery runs down.
Oil pressure switch.
Observe if gauges and panel
lights are activated when engine
is not running. Test the oil
pressure switch.
Engine stops.
79
WESTERBEKE GENERATORS
Problem
Probable Cause
VerificationlRemedv
Battery runs down (continued).
High resistance leak to ground.
Check wiring. Insert sensitive
(0-.25 Amp) meter in battery
lines. (Do not start engine.)
Remove connections and replace
after short is located.
Low resistance leak.
Check all wires for temperature
rise to locate fault.
Alternator.
Disconnect alternator at output,
after a good battery charging. If
leakage stops, remove alternator
and bench test. Repair or
replace.
WESTERBEKE GENERATORS
80
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.
separator is optional, but strongly recommended.)
(A primary filter/water
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:
4GJl35l*-s JdI)
... ~..
II
, POOR
1706 psi + 142 psi
(120 kg/cm2 + 10 kg/cm2)
Eliminate undesirable injection conditions
including after dripping.
*2. Check compression pressure. Remove each
glow plug and check each cylinder's compression
pressure. The engine's cranking speed is at 250 rpm.
8.0 KW, 10.0 KW, 11.0 KW, 12.5 KW
Standard
455 psi
(32 kg/cm2l
Minimum
370 psi
(26 kg/cm2)_ (Maximum difference between cylinders: 35.5 psi (2.5 kg/cm2l
*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.
No 3 top
Timing Mark
-0
Front
3. Next, the piston of No. 3 cylinder comes IDC. Turn
the crankshaft 240 0 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 240 0 clockwise, and then align the
timing marks; check and adjust the valve clearance in a
0
0
9
1
10
4
0
0
o
3
Z
0
0
5
11
,
8
0
01
0
0
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
3
ADmSTMENT OF VALVE CLEARANCE
MODEL: BID 11.0 KW & BID (A) 12.5 KW
II
CAUTION
Nos, 1 and 4 piston T.O.C. mark
I
Injection timing
{I.T.) mark
n
Adjust the valve clearance when the engine is cold.
0.010 inches (0.25 mm)
Tighten the cylinder head bolts to the specified torque.
Timing Mark
1. Pull off the air breather pipe from the rocker cover,
and take off the rocker cover bolts.
I
2. Adjust the valve clearances at IDC (Top Dead
Center) for each cylinder when they are on their
compression stroke.
~
b
I
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.)
Front
o
13
L
g
3
0
0
7
9
0
0
5
0
10
6
1
0
0
2
8
0
0
0
12
4
14
0
0
NOTE: Retighten the cylinder head bolts before the valve
clearance is adjusted.
Cylinder Head Bolts Tightening Sequence
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
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
NOTE: mm size shown are socket size for holddown bolts
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
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
Revised
August 1994
85
WESTERBEKE GENERATORS
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
AIR BLEEDING
SCREW
CONTROL RACK
CONTROL PINION
TAPPET
PLlJNC;ER SPRING
Cutaway View of 3-Cylinder Fuel Injection Pump
WESTERBEKE GENERATORS
86
If the specified (19° BID C) injection timing cannot be attained, adjust the timing by increasing
or decreasing the thickness of the injection pump
mounting shim. Changing the shim thickness by
0.004 inch (O.Olmm) changes the injection timing
by approximately one degree. To advance the
timing, decrease the shim !hichness, as required.
To retard the timing, increase the shim thickness,
as required.
'.
".
'
..._';-,_ ..
,
.,. _____ TDC
. \0
;.···_·19'
r·:,:·---"
.
..
~
Crankshaft Pulley Timing Marks
Adjustments (Generator)
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 GENERATOR" 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
n
CAUTION
Failure of the solenoid to bottom in the solenoid will result in a failed solenoid.
To avoid failure of the solenoid, ensure that the solenoid plunger bottoms in the
solenoid. Check the solenoid's operation at the initial start-up. 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
6mm bolt head/nut
8mm bolt head/nut
10 mm bolt head/nut
10 mm bolt head/nut
12 mm bolt head/nut
12 mm bolt head/nut
12 mm bolt head/nut
13 mm bolt head/nut
14 mm bolt head/nut
14 mm bolt head/nut
16 mm bolt head/nut
16 mm bolt head/nut
1
1.25
1.25
1.5
1.25 (ISO)
1.5
1.75
1.5
1.5
2
1.5
2
2.9 - 5.1
0.4 - .07
7.2 - 11.61.0 - 1.6
13.7 - 22.4
1.9 - 3.1
13.0 -21.7
1.8 - 3.0
25.3 - 39.8
3.5 - 5.5
25.3 - 39.8
3.5 - 5.5
3.0 - 5.0
21.7 - 36.2
32.5 - 50.6
4.5 - 7.0
36.2-57.9
5.0 - 8.0
34.0 - 55.7
4.7 -7.7
54.2 - 79.6
7.5-11.0
7.1 -10.6
51.4 -76.7
6mm bolt head/nut
8mm bolt head/nut
10 mm bolt head/nut
10 nun bolt head/nut
12 mm bolt head/nut
12 mm bolt head/nut
12 mm bolt head/nut
1
1.25
1.25
1.5
1.25 (ISO)
1.5
1.75
4.3 - 6.5
10.8 - 15.9
21.7 - 32.5
19.5 - 30.4
36.2 - 57.9
36.2 - 50.6
34.7 - 49.2
0.6
1.5
3.0
2.7
5.0
5.0
4.8
1
1.25
1.25
1.5
1.25 (ISO)
1.5
1.75
1.5
1.5
2
1.5
5.8 - 8.7
14.5 - 21.7
28.9 - 39.8
26.8 - 37.6
54.2 - 75.9
50.6 -65.1
43.4 -61.5
57.9 - 86.8
72. 3 -108.5
68.7 -101.3
108.5 - 166.4
101.3-159.1
0.8 - 1.2
2.0 - 3.0
4.0 - 5.5
3.7 - 5.2
7.5 - 10.5
7.0 - 9.0
6.0 - 8.5
8.0 - 12.0
10.0 - 15.0
9.5 - 14.0
15.0 - 23.0
14.0 - 220
9 - 11
11 - 13
18 - 20
21 - 23
28 - 33
30 - 35
44 - 49
50 - 55
68 - 73
73 - 80
1.2 - 1.5
1.5 - 1.8
2.5 - 2.8
2.9 - 3.2
3.7 - 4.6
4.1-4.8
6.1 - 6.8
6.9 - 7.6
9.4 - 10.1
10.1-11.1
kg-m
Grade 4
Grade 6T
Grade 7T, 8T and 8.8
6mm bolt head/nut
8mm bolt head/nut
10
10
12
12
12
13
14
mm bolt head/nut
nun bolt head/nut
mm bolt head/nut
mm bolt head/nut
mm bolt head/nut
mm bolt head/nut
mm bolt head/nut
14 mm bolt head/nut
16 mm bolt head/nut
16 mm bolt head/nnt
2
-
0.9
2.2
4.5
4.2
8.0
7.0
6.8
Grade 5 cap screw
1/4 UNC
114 UNF
5116 UNC
5116 UNF
3/8 UNC
3/8 UNF
7116 UNC
7116 UNF
112 UNC
112 UNF
WESTERBEKE GENERATORS
92
TABLE OF TIGHTENING TORQUES
FT - LBS (KG - M)
8.0 & 10.0
BTD
12.5
BTD
11.0 BTD AND
12.5 BTDA
Crankshaft Pulley Nut
108.5-144.7
(15-20)
144.6-180.8
(20-25)
108.5-144.7
(15-20)
Main bearing cap bolt
36.2-39.8
(5.0-5.5)
SAME
SAME
Connecting rod cap nut
23.1-25.3
(3.2-3.5)
39.7-43.3
(5.5-6.0)
23.1-25.3
(3.2-3.5)
Flywheel bolt - with separate
washers
83.2-90.4
(11.5-12.5)
SAME
SAME
Flywheel
attached
94.0-101.3
(13.0-14.0)
SAME
SAME
Oil pan drain plug
36.2-43.4
(5.0-6.0)
SAME
SAME
Oil filter
8.0-9.4
(1.1-1.3)
SAME
SAME
Delivery valve holder
(injection pump)
28.9-36.2
(4.0-50)
SAME
SAME
Holder mounting bolt, nozzle
10.8-14.5
(15-2.0)
SAME
SAME
Holder body and retaining nut,
nozzle
43.4-57.9
(6.0-8.0)
SAME
SAME
Glow plug
10.8-14.5
(1.5-2.0)
SAME
SAME
bolt
washer
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.
P.LO. ADAPTER KIT
SPLINE
AOAP"rER
CRPSCRCW
34786
1l.IH:W. AHD 12.Sk'W KIT PM.
37134
(:3)
(41
I,.OCICWRSHER
NUT
8TO 10.9I(W.
(3)
LOCICW"::;"'En
lOTUD
BTO 8. 8KW KIT PM.
COUPLIHC
14)
C"')
CCHERAT :lR
HOUSXHC
PU~P
HVORAU1.IC
HVORECO
1122l.8A481R
'........._,,' ..'._..,._...
(PUMP SOURCE)
H ... DREca
PUMPS
KALAMAZOO.
(6l.6)
HXCK.
: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