Single phase gasoline carburetor models (53 pages)
Summary of Contents for Westerbeke 15.0BTD60-HERTZ
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12.0 BTD 50 - HERTZ MARINE DIESEL GENERA TOR SETS SINGLE & THREE PHASE Publication #36856 Edition Two May 1995 rWESTERBEKE j'-..Y" WESTERBEKE CORPORATION MYLES. STANDISH INDUSTRIAL PARK 150 JOHN HANCOCK ROAD, TAUNTON, 02780-7319 U.S.A. • TEL: (508)823-7677 FAX: (508)884-9688 WEBSITE: WWW.WESTERBEKE.COM...
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SAFETY PRECAUTIONS The following symbols appear in this manual to call attention • Use Extreme Care When Handling Engine Fuel to and emphasize conditions potentially dangerous to the (A constant danger of explosion or fire exists) operator. not fill fuel tank(s) while the engine is running. not smoke or use an open flame near the engine or the IIWARNINGI fuel tank.
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It not only makes good sense, but is imperative that appropriate representatives of Westerbeke or the sup- plier in question be consulted to determine the accuracy and currency of the product software being con-...
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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 adjust- ment 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.
TABLE OF CONTENTS Section ................. Page GENERAL ................2 BTD 15.0KW GENERAL SPECIFICATIONS ...... 3 SYSTEM SPECiFiCATIONS ..........4 INSTALLATION CHECKS ........... 7 OPERATION ..............14 FUEL SYSTEM ..............18 ELECTRICAL SYSTEM ............. 21 DC CONTROL CIRCUIT WIRING DIAGRAM ... 22 &...
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BTD 15.0 KW Generator Water Injected Fresh Water Fill Cap Lube Oil Fill Cap Exhaust Elbow I.D. Plate Control Panel DC Charging Alternator Heat Exchanger -----:.;:~ Lube Oil Filter Lube Oil Drain Hose Oil Pressure Switch Zinc Anode Lube Oil Dipstick Oil Pressure Sender 15KW BTD...
Westerbeke engines and generator sets are thoroughly checked and given a final run under various load conditions before leaving the factory. This is done to ensure dependable operation, long service, and a satis- fied owner.
SYSTEM SPECIFICATIONS FUEL SYSTEM General Open flow, totally self-bleeding Fuel No.2 Diesel oil (cetane rating of 45 or higher) Fuel Injection Pump CAY DPA Injection pump Fuel Injection Timing BTDC (static timing) ± Nozzle Throttle type Bosch type Injectors 12-Volt; lift capacity 6 (1.8 m) Lift Pump Fuel Filter (on engine)
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Operating Pressure (engine hot) 35 - 45 psi (2.8 - 3.5 kg/cm CF OR CG-4 Grade API specification ELECTRICAL SYSTEM Starting Battery 12-Volt,(-) negative ground Battery Capacity(C. C.A.) 300 - 400 cold cranking Amps DC Charging Alternator 12-Volt DC, 50 Amp Regulator Internal regulator built into alternator Starting Aid...
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General 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. Rating - Three Phase 15KW - 60 Hertz 12KW - 50 Hertz Voltage - 3 Phase (60 Hertz) Low voltage WYE 208 volts...
INSTALLATION CHECKS General Because the crafts in which Westerbeke engines and generators are installed vary in design, installation pro- It is not the intent of this section to advise cedures will vary according to your craft's specific design. 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.
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Location dry, The location should be such that it is above low-lying vapor areas, and away from being splashed by bilge 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 ven- tilated to provide the fresh cooling air for the generator end and for engine combustion.
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Generator BeloN Water Line The exhaust discharge from the water lift muffler should be routed well above the water line then downward to the thru-hull discharge. This routing will prevent sea water from entering if the thru-hull discharge fitting becomes submerged when the vessel heels or rolls while underway, or is subjected to following sea condi- tions.
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2 inches of mercury 27 inches of water in a water column 15.6 ounces PSI 1.0 PSI NOTE: Other pressure gauges may be available to test for exhaust back-pressure. 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.
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High Water Temperature Shutdown Switch (normally closed) A high water temperature switch is located on the thermostat housing. This switch will open and shut the fuel solenoids OFF (which turns OFF the engine) should the fresh water coolant's operating temperature reach approximately 205 F (96 C).
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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 in- jection pump under all operating conditions.
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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 and specific gravity to ensure maximum engine starting efficiency. Make sure the battery's terminals are clean and tight.
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.
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Starting Procedure PREHEAT .~'. START ...' . "."'- '-." STOP ELAPSED TIME " ' . ' I mllUDI!I Hours GENERATOR Standard Instrument Panel, Switches and Gauges NOTE: When the generator is stopped after use, the water temperature and oil pressure gauges may stay at their running readings.
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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 defec- tive glow plugs or a faulty preheat circuit (check for loose con- nections).
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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.
Westerbeke warranty. Although most boatbuilders supply a water trap/filter, some do not. Westerbeke offers a sedimenter/water trap/filter as an optional extra at moderate cost. The filter is supplied with fittings for either hose or metal' tubing fuel lines.
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The figure also illustrates the self-bleeding and priming system used by Westerbeke. The Westerbeke self-bleeding fuel system is semiautomatic in operation. 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 banjo washers, injector seat washers, electric lift pump filter and gasket, fuel filter and gasket be carried on board at all times.
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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 bench-tested and should not be tampered with. Running speed (Hertz) and timing adjustment are the only adjustments the servicing dealer can perform on the injection pump.
ELECTRICAL SYSTEM Engine 12-Volt DC Control Circuit The engine that drives the generator end has a 12-Volt DC electrical control circuit, as shown on the wiring diagrams which follow on pages 22 and 23. Refer to these diagrams when troubleshooting or servicing electrical components on the engine.
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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 of IC's (integrated circuits), the electronic voltage regulator is very compact and is built into the rear bracket of the alternator.
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 en- gine. 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 automo- tive radiator.
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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.
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Fill the fresh water system as follows: 1. Remove the pressure cap from the manifold. 2. Pour a clean, fresh water coolant mixture into the manifold and allow enough time for the coolant to fill the fresh water cooling system. 3.
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Sea Water Pump The sea 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 on board (an impeller kit).
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The following illustration shows the location of the zinc anode in the BTD 1S.0KW's heat exchanger unit. ZINC AHODE Heat Exchanger Unit of the BTD 1S.0KW Generator Set...
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Illustrated below is a typical Westerbeke engine's cooling system. Both fresh water and sea water flow through their independent cooling circuits. TO HOT WATER TAN!( OVEflHEAT ALARM PUMP II[OMII6 SEA VATER Typical Cooling System...
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 CC, CD CF AND CG-4. THE USE OF THE IDGHEST GRADE AVAILABLE IS RECOMMENDED. THE OIL YOU SELECT SHOULD BE USED ON A REGULAR BASIS WHEN POSSmLE.
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2. Replacement of the Oil Filter When removing the used oil filter, cover the filter with a plastic bag containing a few cloth rags or paper towels. This will allow both the filter ele- ment and spilled oil to be collected cleanly without spilling oil on the engine or in the bilge.
BT GENERATOR This generator is a four-pole, brushless, self-excited generator which requires only the driving force of the engine to produce AC output. The copper and laminated iron in the exciter stator are responsible for the self-exciting feature of this generator. The magnetic field produced causes an AC voltage to be induced into the related exciter rotor windings during rotation.
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YellowfWhite Optional AVR BlackIWhite Generator AC Distribution Box BTD 15.0KW Generator Set CAUTION Under no circumstances attempt to increase the no-load voltage by increasing the gap be- tween the laminated steel bar and the transformer core without the use of shims. Magnetic forces created within the transformer during the generator's operation may close the air gap and reduce the no-load voltage output.
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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 provides excitation to the group 1 exciter windings, and the transformer provides excitation to the group 2 exciter windings.
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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 con- siderations.
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Shore Power Connections If the installer connects shore power to the vessel's AC circuit, this must be done by means of the SHORE POWER/OFF/SHIPS GEN, center position-off transfer switch as shown below. Use of this switch prevents simultaneous connection of shore power to generator output. CAUTION Damage to the generator can result utility shore power and generator output are connected...
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.
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4-Pole Generator Voltage Load Frequency 120V(110) 240V (220) Speed Applied (rpm) (Hertz) Plants Plants None 1830 (1530) (52) (112) (224) Half 1800 (1500) (50) (110) (220) Full 1755 (1455) (49) (100) (200) The output voltage should be checked periodically to ensure proper operation of the generating plant and the appliances it supplies.
4. In addition to the three switches above, the Standard Instrument Panel used with Westerbeke diesel gen- erator sets includes two gauges, which indicate water temperature in degrees Fahrenheit (WATER...
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Engine Operation To start the engine, perform the following steps: I. 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 "OPERA- TION"...
ENGINE TROUBLESHOOTING Introduction The tables which follow indicate troubleshooting procedures 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 the rear lifting eye bracket.
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ENGINE TROUBLESHOOTING Problem Probable Cause Verification/Remedy PREHEAT switch is de- Battery switch Check switch and/or pressed: no panel in- not on. battery connections. dications, fuel sole- noid, electric fuel 20-Amp circuit pump and preheat sole- breaker tripped. Reset breaker; if noid not energized.
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probable Cause problem Verification/Remedy Faulty fueling system. 1. Check for fuel No ignition: cranks, to generator engine. but does not start; fuel solenoid energized. 2. Check for air in fuel system. Allow system to self-bleed. 3. Fuel lift pump faulty. 4.
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Verification/Remedy problem probable Cause Engine Stops (continued). High water tempera- Check for satisfactory ture switch opens at operation with switch bypassed. Check with too Iowa temperature. an ohmmeter. 20-Amp circuit breaker Same as above. tripping. High exhaust tempera- Same as above. ture switch opens at too Iowa temperature.
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Problem Probable Cause VerificationlRemedy Battery runs down (continued). High resistance leak Check wiring. Insert to ground. 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.
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.
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belt tension, if required. 5. Adjust the alternator and water pump drive 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. Servicing After Every 100 Hours of Operation 1.
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Servicing After Every 800 Hours of Opera- tion *1. Remove and check fuel injectors Injector spray pressure: 1706 psi 142 psi (120 kglcm 10 kglcm Eliminate undesirable injection conditions in- cluding after dripping. ~~+; ~lIi'lliiiN"""_.--~o1i\ ..*2.
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Adjustments (Engine) Valve Clearance Adjustment Pull the air breather hose off of the rocker cover; loosen and remove the rocker cover bolts. - Exhaust Side - - Intake Side - Cylinder Head Bolt Tightening Sequence 1. Tighten the cylinder head bolts in the sequence shown above. The engine should be cold. Loosen each bolt 1/8 to 1/4 turn when tightening in the sequence shown.
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B. In this position, adjust the valve's clearance in the conventional manner of the intake and exhaust valve of the number 1 cylinder, the intake valve of the number 2 cylinder, and the exhaust valve of the num- ber 3 cylinder. C.
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Injection Pump Timing BTD 15.0KW Incorrect fuel injection timing will result in hard engine starting and poor engine performance. Adjust the in- jection timing as follows: 1. Locate the timing pointer on the front gear cover. This pointer is located at about the 10:00 o'clock position when viewing the front crankshaft pulley.
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5. Inside the opening in the injection pump is a circlip and the rotor body of the pump. The rotor body has a scribe mark on it with the letter stamped above it. The scribed mark should align with the top, flat surface of the circlip.
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Adjustments (Generator) Once the diesel generator set has been placed in operation, there is no adjustment required by the AC gen- erator. The only adjustment that would be required is the speed adjustment made to the linkage between the fuel solenoid and the throttle arm in the event of a change of operating frequency between 50 and 60 Hertz.
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.
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Fuel System Top off your fuel tanks with No.2 diesel fuel. Fuel additives should be added at this time to control algae and condition the fuel. Care should be taken that the additives used are compatible with the primary fil- ter/water separator used in the system.
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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, page 14, regarding preparation for starting and normal starts. However, some of the lay-up procedures will need to be counteracted before starting the en- gine.
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. SOUND ABSORBENT . .
TORQUE SPECIFICATIONS l..b:ft Kg::m. Cylinder head bolt Exhaust side 83.2 -90.5 11.5 -12.5 Intake side 72.4 -79.6 10.0 -11.0 (See the "Cylinder Head Bolt Tightening Sequence" diagram on page 51.) Crankshaft pulley nut 285.7 -292.9 39.5 - 40.5 8.0 -9.0 Main bearing cap bolt 57.9 -65.2 Connecting rod bearing caps...
INDEX Adjustments, Engine ....................... 51 Injection Pump Timing ....................53 No-Load Speed ......................54 No-Load Voltage ......................33 Valve Clearance ......................51 Adjustment, Generator ......................55 Frequency ........................55 Alternator ..........................21 Alternator and Water Pump Drive Belt Tension ..............28 ANTIFREEZE ADDITION DATA (Chart) ..................
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& Diagram 36411, DC Control Circuit ................22 Diesel Engine, Understanding the .................... 2 Diesel Fuel ..........................18 Draining the Oil Sump ......................31 Drive Belt Tension, Alternator and Water Pump ..............28 ELECTRICAL SYSTEM ......................21 Electric Motors, Use of ......................39 Engine Adjustments ..........
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GENERAL ..........................2 General Specifications ......................3 Generator AC Output........................12 Adjustments ........................55 Frequency ........................36 Frequency Adjustment....................55 General Information ...................... 39 Preventive Maintenance ....................40 Specifications ........................5 Troubleshooting ......................40 GENERATOR, BT ........................33 Injection System, Fuel ....................
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