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 BT

Emergency Stop 20 Amp DC Circuit Srea AC Outlet Fresh Water Block Drain Lube Oil Filter Fuel Lift Fresh Water Coolant Sea Water Pump Heat Exchanger WE

BTD 11.0 KW Generator Top Engine Oil Control Preheat Sollen<,id A C Con,nec,tior"'~ Fresh Water Slock Lube Oil Dip,stick' Lube Oil

BTD 12.5 KW Generator 20 Amp DC Circuit Breaker Lube Oil Fil Fuel Filter Control AC Fuel Lift Lube Oil Filter 12.5 KW BTD Fresh Water Air Bleed Top E

... ... :l=! eo [JJ ;j ~ eo 1:i ~ eo z ~ o 0; Control Panel 20 Amp DC Circuit Breaker Lube Oil Filter ___ _ A C Connections Outlet Fresh Water Block

~ t"i rn ;.l ~ ~ ~ Z t"i ~ o ~ "" N Fresh Water Fill Cap Exhaust Manifold Belt Guard Raw Water Pump Heat Exchanger Lube Oil Fill C

GENERAL Introduction This manual contains the equipment operating procednres as well as additional information needed to help the operator

BTD 8.0 KW MARINE DIESEL GENERA TOR SET GENERAL SPECIFICATIONS Engine Type Governor Combustion Chamber Bore & Stroke Pistion Displacement Firing O

SYSTEM SPECIFICATIONS FUEL SYSTEM: GENERAL FUEL FUEL INJECTION PUMP FUEL INJECTION TIMING NOZZLE INJECTORS FUEL PUMP FUEL FIL TER( on engine) AIR CLEA

SYSTEM SPECIFICATIONS CONTINUED ... ELECTRICAL SYSTEM STARTING BATfERY BATfERY CAPACITY DC CHARGING ALTERNATOR REGULATOR STARTING AID STARTER DC NO-LO

SYSTEM SPECIFICATIONS CONTINUED ... ENGINE COMBUSTION AIR REQUIREMENTS (60 Hertz) AT 1800 rpm ENGINE COMPARTMENT COOLING AIR TUNE UP SPECIFIC A TlONS

BTD 10.0 KW MARINE DIESEL GENERATOR SET GENERAL SPECIFICATIONS Engine Type Governor Combustion Chamber Bore & Stroke Pistion Displacement Firing

SYSTEM SPECIFICATIONS FUEL SYSTEM: GENERAL FUEL FUEL INJECTION PUMP FUEL INJECTION TIMING NOZZLE INJECTORS FUEL PUMP FUEL FIL TER( on engine) AIR CLEA

SYSTEM SPECIFICATIONS CONTINUED ... ELECTRICAL SYSTEM STARTING BATfERY BATTERY CAPACITY DC CHARGING ALTERNATOR REGULATOR STARTING AID STARTER DC NO-LO

SYSTEM SPECIFICATIONS CONTINUED ... General - 3 Phase 10.0 KW -60 Hertz 7.5 KW - 50 Hertz Voltage - 3 Phase (60 Hertz) Voltage - 3 Phase (50 Hertz) Am

BTD 11.0 KW MARINE DIESEL GENERATOR SET GENERAL SPECIFICATIONS Engine Type Governor Combustion Chamber Bore & Stroke Pistion Displacement Firing O

SYSTEM SPECIFICATIONS FUEL SYSTEM: GENERAL FUEL FUEL INJECTION PUMP FUEL INJECTION TIMING NOZZLE INJECTORS FUEL PUMP FUEL Frr.. TER( on engine) AIR CL

SYSTEM SPECIFICATIONS CONTINUED ... ELECTRICAL SYSTEM STARTING BATTERY BATTERY CAPACITY DC CHARGING ALTERNATOR REGULATOR STARTING AID STARTER DC NO-LO

SYSTEM SPECIFICATIONS CONTINUED ... General - 3 Phase 11.0 KW - 60 Hertz 8.3 KW - 50 Hertz Voltage - 3 Phase (60 Hertz) Voltage - 3 Phase (50 Hertz)

BTD 12.5 KW MARINE DIESEL GENERATOR SET GENERAL SPECIFICATIONS Engine Type Governor Combustion Chamber Bore & Stroke Pistion Displacement Firing

SYSTEM SPECIFICATIONS FUEL SYSTEM: GENERAL FUEL FUEL INJECTION PUMP FUEL INJECTION TIMING NOZZLE INJECTORS FUEL PUMP FUEL FIL TER( on engine) AIR CLEA

SAFETY PRECAUTIONS The following symbols appear in this manual to call attention to and emphasize conditions potentially dangerous to the ope

SYSTEM SPECIFICATIONS CONTINUED ... ELECTRICAL SYSTEM STARTING BATTERY BATTERY CAPACITY DC CHARGING ALTERNATOR REGULATOR STARTING AID STARTER DC NO-LO

SYSTEM SPECIFICATIONS CONTINUED ... General - 3 Phase 12.5 KW - 60 Hertz 9.3 KW - 50 Hertz Voltage - 3 Phase ( 60 Hertz) Voltage - 3 Phase (50 Hertz)

BTDA 12.5 KW MARINE DIESEL GENERATOR SET GENERAL SPECIFICATIONS Engine Type Governor Combustion Chamber Bore & Stroke Pistion Displacement Firi

SYSTEM SPECIFICATIONS FUEL SYSTEM: GENERAL FUEL FUEL INJECTION PUMP FUEL INJECTION TIMING NOZZLE INJECTORS FUEL PUMP FUEL FIL TER( on engine) AIR CLEA

SYSTEM SPECIFICATIONS CONTINUED ... ELECTRICAL SYSTEM STARTING BATTERY BATTERY CAPACITY DC CHARGING ALTERNATOR REGULATOR STARTING AID STARTER DC NO-LO

SYSTEM SPECIFICATIONS CONTINUED ... General - 3 Phase 12.5 A KW - 60 Hertz 9.3 A KW - 50 Hertz Voltage -3 Phase (60 Hertz) Voltage -3 Phase (50 Hertz

INSTALLATION CHECKS General Because the crafts in which Westerbeke engines and generators are installed vary in design, installation procedures w

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.

J Sea Water Intal<e· Tnru· Hull F,n,nc Sea Waler '''''' The exhaust discharge from the water lift muftler sho

Exhaust Back-Pressure Exhaust back -pressure should be checked prior to putting a generator into service. (Refer to illustration.) Excessive

• 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 tighte

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 fitt

The best protection against carbon monoxide poisoning is a daily inspection of the complete exhaust system. Check for leaks around manifold

Generator (Ae Output) Make sure that the AC output connections within the generator's districution box are tight and in accordance

OPERATION This section of the manual provides the operator with preparation, initial starting, break-in, starting (cold or warm), and stopping procedu

Starting Procedure o o PREHEAT 4 ~ START @. ".-). -' STOP 4k ~ CENERATOJ:i o ELAfIl'S£OTM I plllmlll 0 II ... "'0 o NOTE:

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 volt

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 operat

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 ha

II CAUTION II Prolonged cranking intervals without the engine starting can result in filling the engine-mounted exhaust system with sea water c

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

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 ca

ELECTRICAL SYSTEM Engine 12-Volt DC Control Circuit The engine that drives the generator end has a 12-Volt DC electrical control circuit, as sh

9ATTERY(12VOC) DC CONTROL CIRCUIT WIRING DIAGRAM #36412 PAGEIOF2 A r ________ --"""o-'c,,""---_____________ ~ //,-,7:~ID

DC CONTROL CIRCUIT WIRING SCHEMATIC #36412 PAGE20F2 ,C) I PREH~AT SOL ;"b I t---:rca ,( 12CA -'f ! ~~: H"ERGE~CY , r: :;-:>~ 'O

The charging system consists of an alternator with an internal voltage regulator, an engine-mounted circuit breaker, and a battery and conn

COOLING SYSTEM Description Westerbeke marine diesel engines are designed and equipped for fresh water cooling. Heat produced in the engine by combus

ANTIFREEZE ADDITION DATA Antifreeze Concentration % 13 23 30 35 45 50 60 Freezing of 23 14 5 -4 -22 -40 -58 Temperature (0C) (-5) ( -10) (-15) (-2

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 a

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

Cooling System Illustrated below is a typical Westerbeke engine cooling system. Both fresh water and raw water flow through their independent

Exhaust Elbow Installation The Westerbeke Corporation offers a 450 and 900 exhaust elbow as well as an exhaust riser you can install on your propulsio

IMPORTANT PRODUCT SOFTWARE DISCLAIMER Product software of all kinds, such as brochures, drawings, technical data, operator's and workshop manuals

LUBRICATION SYSTEM Engine Oil For engine lubrication, use lubricating oil designated for diesel service. These oils are classified accord

2. Replacement of the Oil Filter When removing the used oil filter, cover the filter with a plastic bag containing a few cloth rags or

BT GENERATOR This generator is a brushless self-excited generator, which requires only the driving force of the engine to produce AC output. The c

GENERATOR AC DISTRIBUTION BOX BTD 10.0KW, 11.0KW, AND 12.SKW (A) Ye!lowM'hite 8tackNihile Optional AVA RedfWhite GreenNIhile Internal Wiring Sche

A + I ~;:; ~ ~ >-;-------------------1 , , , B : , . , , ( • • , ! I , b -()!-• , , , c , , , , -, , 2 , , , 2 , 3 ' ~-----------------~ e &

r--------, I C I r--------., I 0 I • ~---------------, I B 3' I • r=r-r.1' 11 B OlJl I 2 , ~ _______________ J 1 l i ! I , :!>

Optional Voltage Regulator An optional solid-state voltage regulator (board #34410) is available for use with the BT series generators. When installe

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 genera

TO FR .ME I I 120V 60Hz , 20/240V 60Hz 0 ( ) 0 0 0 TI N 110J;220V 50Hz = 0 ( ) T o FRAME 'II~ 0 ( ) , ) ~ 0 ~ :J L, N I: =< LO (OJ f==l 0

INTERNAL WIRING SCHEMA TIC 3 PHASE GENERATOR MODELS 10.0 BTD 11.0 BTD & 12.5 BTD r------l I C I FUSE I I 20 A. I STATOR : I i ., I. I ,-----.

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 GEN

LED'S Red Green Yellow HZ. AMP. VOLT VOLTAGE REGULATOR #038468 Single & Three Phase DOD 5 4 3 2 0 B + ]60HZ. The voltage regulator is of an

3. AmplHertz - These two adjustments are used in conjunction with the two protection circuits in the voltage regnlator that are indicated by

I PARALLEL WYE (STAR) 12 10 11 9 8 6 7 5 4 2 3 1 L-L 208 VAC 39 60 HZ L-N 120VAC 1060HZ l-L 190 VAC 3~ 50 HZ l-N 110 VAC 19 50 HZ 3 PHASE AC TERM

The illustration below shows the 3 phase AC generator backened with the louvered covers removed. Voltage Regulator 71 DC Charge Bridge Rectifier AC Te

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

GENERAL INFORMATION AND CARE OF THE GENERATOR Use of Electric Motors The power required to start an electric motor is considerably more than is requir

Load 4-Pole Frequency Generator Voltage Applied Speed (rpm) (Hertz) 120V (110) 240V (220) Plants Plants None 1830 62 122 240 (1530) (52) (112)

General This manually-controlled series of Westerbeke marine diesel gener-ators is equipped with toggle switches on the engine's control panel an

Engine Operation To start the engine, perform the following steps: 1. Preheat - Depress the PREHEAT switch. The voltmeter, panel lights, gauges a

A. Society Wire SI:r.., Standing Clreular DC WIRE SIZING CHART Stranded Conductors for 12 Volt Circuits 10% Voltage Drop oC Autonlotive Engineers Type

TABLE OF CONTENTS (CONTINUED) TABLE OF STANDARD HARDWARE TIGHTENING TORQUES 92 SOUND GUARD INSTALLATION INSTRUCTIONS 94 POWER TAKE-OFF (PTO) ADAPTER

ENGINE TROUBLESHOOTING Problem Probable Cause PREHEAT switch is depressed: Battery switch no panel indications, fuel solenoid, electric fuel pump

Problem Failure to stop. Engine stops. Battery not charging. Battery runs down. Probable Cause Fuel solenoid return spring. STOP switch failure. Fuel

Problem Probable Cause Battery runs down (continued). High resistance leak to ground. Low resistance leak. Alternator. WESTERBEKE GENERATORS 80 Veri

MAINTENANCE AND ADJUSTMENTS Introduction This section contains a scheduled preventive maintenance program and several adjustment procedures the owner/

5. Adjust the alternator and water pump drive belt tension, if required. 6. Adjust the engine's no-load speed, if required (Hertz). Please

Servicing After Every 800 Hours of Operation *1. Remove and check fuel injectors. Injector spray pressure: 1706 psi + 142 psi (120 kg/cm2 + 10 kg/cm2

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 rnr

ADmSTMENT OF VALVE CLEARANCE MODEL: BID 11.0 KW & BID (A) 12.5 KW II CAUTION n Adjust the valve clearance when the engine is cold. 0.010 inches (

Injection Timing Adjustment (BTD 8.0KW, IO.OKW, 11.OKW & 12.5KW) Incorrect fuel injection timing will result in hard engine starting and poor eng

If the specified (19° BID C) injection timing can-not be attained, adjust the timing by increasing or decreasing the thickness of the injection pump m

Control Panel 20 Amp DC Circuit Breaker Block Drain DC Charging Alternator Fresh Water Circulating Pump Sea Water BTD 8.0 KW Generator Preheat Solenoi

2. Adjust the engine's speed to obtain the frequency corresponding to the voltage selected by e,,'lending or shortening the Throttle Adjustm

LAY-UP AND RECOMMISSIONING General Many owners rely on their boatyards to prepare their craft, including engines and generators, for lay-up during

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. Car

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 replace

TABLE OF STANDARD HARDWARE TIGHTENING TORQUES Unless stated otherwise for a specific assembly, use the following torque values when tightening standa

TABLE OF TIGHTENING TORQUES FT - LBS (KG -M) 8.0 & 10.0 12.5 11.0 BTD AND BTD BTD 12.5 BTDA Crankshaft Pulley Nut 108.5-144.7 144.6-180.8 108.

SOUND GUARD INSTALLATION INSTRUCTIONS For a copy of the Sound Guard installation instructions required for your generator set, please contact your loc

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 ki