Westerbeke BTD 8.0 KW 60Hz Operator's Manual
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Westerbeke BTD 8.0 KW 60Hz Operator's Manual

Westerbeke BTD 8.0 KW 60Hz Operator's Manual

Diesel, single and three phase generators
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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

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  • Page 1 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 & A 12.5 KW 60 HERTZ MODEL BTD 6.0 KW, 7.5 KW, 8.3 KW A 9.4 KW 50 HERTZ &...
  • Page 3 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. WESTERBEKE GENERATORS...
  • Page 4 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...
  • Page 5 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...
  • Page 6 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 Such software may be outdated and no longer accurate.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.

  • Page 7: Table Of Contents

    BIDA 12.5 KW MARINE DIESEL GENERATOR SET GENERAL SPECIFICATIONS SYSTEM SPECIFICATIONS INSTALLATION CHECKS OPERATION FUEL SYSTEM ELECTRICAL SYSTEM COOLING SYSTEM LUBRICATION SYSTEM BTGENERATOR GENERAL INFORMATION AND CARE OF THE GENERATOR ENGINE CONTROL PANEL ENGINE TROUBLESHOOTING MAINTENANCE AND ADmSTMENTS LAY-UP AND RECOMMISSIONING WESTERBEKE GENERA TORS...
  • Page 8 TABLE OF CONTENTS (CONTINUED) TABLE OF STANDARD HARDWARE TIGHTENING TORQUES SOUND GUARD INSTALLATION INSTRUCTIONS POWER TAKE-OFF (PTO) ADAPTER KlTS WESTERBEKE GENERATORS...
  • Page 9 Fresh Water Drain Oil Pressure Sender Fuel Lift Pump 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 KW BTD WESTERBEKE GENERATORS...
  • Page 10 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...
  • Page 11 DC Charging Control Con,nec,tior"'~ Fresh Water Slock Pressure Sender Lube Oil Dip,stick' Fitter Lube Oil Filter 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 WESTERBEKE GENERATORS...
  • Page 12 12.5 KW BTD Fresh Water Top Engine Oil Fill xhaust Manifold Fresh Water Air Bleed Fill mergency Shut-off Switch --""'U5t Temperature Switch Thermostat Exhaust Elbow Battery Heat Exchanger with Solenoid Sea Water Pump Lube Oil Dipstick Fresh Water Block Drain WESTERBEKE GENERATORS...
  • Page 13 Preheat Solenoid Air Intake Silencer 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=! A C Connections Outlet Zinc Anode Fresh Water Block Drain Fuel Filter...
  • Page 14 Fresh Water Fill Cap Lube Oil Fill Cap t"i Shut~off Emergency Switch Exhaust Manifold t"i Exhaust Temperature Switch Belt Guard Exhaust Elbow "" Unit Data Tag Raw Water Pump DC Battery Ground Connection Heat Exchanger Starter with Solenoid 12.5 BTDA LEFT SIDE...

  • Page 15: General

    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.

  • Page 16: Bid 8.0 Kw Marine Diesel Generator Set General Specifications

    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...

  • Page 17: System Specifications

    OIL FILTER Full flow, paper element, spin-on type SUMP CAPACITY 3.3 quarts (3.12 liters) 40 - 80 psi (2.8 - 5.6 kg/cm 2 ) OPERATING OIL PRESSURE (engine hot) OIL GRADE API specification CC or CD WESTERBEKE GENERATORS...
  • Page 18 50 HERTZ (1500 rpm) 220 Volts 27 Amps 6.0KW 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...
  • Page 19 1800 32 cfm (.906 cmm) ENGINE COMPARTMENT COOLING 100-200 cfm (2.83 - 5.66 cmm) TUNE UP SPECIFIC A TlONS 1707 psi (120 kg/cm 2 10 kg/cm 2 - 0 kg/cm 2 ) INJECTOR PRESSURE ENGINE TIMING 19° BIDC WESTERBEKE GENERATORS...

  • Page 20: Btd 10.0 Kw Marine Diesel Generator Set General Specifications

    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...
  • Page 21 OIL FILTER Full flow, paper element, spin-on type SUMP CAPACITY 4.76 (4.5 liters) 40 - 80 psi (2.8 - 5.6 kg/cm 2 ) OPERATING OIL PRESSURE (engine hot) OIL GRADE API specification CC or CD WESTERBEKE GENERATORS...
  • Page 22 83.3/41.6 Amps 50 HERTZ (1500 rpm) 220 Volts 34.1 Amps 7.5KW GENERATOR COOLING AIR REQUIREMENTS, (60 Hertz), at 1800 rpm 225-250 cfm (5.66 - 6.37 cmm) NOTE: Increase air supply 15 % for 50 Hertz operation 1500 rpm. WESTERBEKE GENERATORS...
  • Page 23 REQUIREMENTS (60 Hertz) AT 1800 rpm 32 cfm (.906 cmm) ENGINE COMPARTMENT COOLING 100-200 cfm (2.83 - 5.66 cmm) TUNE UPSPECIFICATIONS 1707 psi (120 kg/cm 2 10 kg/cm 2 - 0 kg/cm 2 ) INJECTOR PRESSURE 19' BIDC ENGINE TIMING WESTERBEKE GENERATORS...
  • Page 24 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...

  • Page 25: System Specifications

    Orr.. Frr.. TER Full flow, paper element, spin-on type SUMP CAPACITY 4.23 quarts (4.0 liters) 40 - 80 psi (2.8 - 5.6 kg/cm 2 ) OPERATING OIL PRESSURE (engine hot) OIL GRADE API specification CC or CD WESTERBEKE GENERATORS...

  • Page 26: System Specifications

    50 HERTZ (1500 rpm) 220 Volts 37.7 Amps 8.3KW GENERATOR COOLING AIR REQUIREMENTS, (60 Hertz), at 1800 rpm 200 - 225 cfrn (5.66 - 6.37 cmm) NOTE: Increase air supply 15 % for 50 Hertz operation 1500 rpm. WESTERBEKE GENERATORS...
  • Page 27 REQUIREMENTS (60 Hertz) AT 1800 rpm 32 cfm (.906 cmm) ENGINE COMPARTMENT COOLING 100-200 cfm (2.83 - 5.66 cmm) TUNE UP SPECIFlCATIONS 1707 psi (120 kg/cm 2 10 kg/cm 2 - 0 kg/cm 2 ) INJECTOR PRESSURE ENGINE TIMING 19' BIDC WESTERBEKE GENERATORS...

  • Page 28: Btd 12.5 Kw Marine Diesel Generator Set General Specifications

    Height: 25.34 inches (643.60mm) Dimensions 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...
  • Page 29 OIL FILTER Full flow, paper element, spin-on type SUMP CAPACITY 4.76 quarts (4.5 liters) plus filter/cooler assembly 40 - SO psi (2.S - 5.6 kg/cm 2 ) OPERATING OIL PRESSURE (engine hot) OIL GRADE API specification CC or CD WESTERBEKE GENERATORS...
  • Page 30 50 HERTZ (1500 rpm) 220 Volts 42.3 Amps 9.3 KW GENERA TOR 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...
  • Page 31 REQUIREMENTS (60 Hertz) AT 1800 rpm 32 cfm (.906 cmm) ENGINE COMPARTMENT COOLING 100-200 cfm (2.83 - 5.66 cmm) TUNE UP SPECIFICATIONS 1707 psi (120 kg/cm 2 10 kg/cm 2 - 0 kg/cm 2 ) INJECTOR PRESSURE ENGINE TIMING WESTERBEKE GENERATORS...
  • Page 32 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...

  • Page 33: System Specifications

    OIL FILTER Full flow, paper element, spin-on type SUMP CAPACITY 4.76 quarts (4.5 liters) plus filter/cooler assembly 40 - 80 psi (2.8 - 5.6 kglcm 2 ) OPERATING OIL PRESSURE (engine hot) OIL GRADE API specification CC or CD WESTERBEKE GENERATORS...

  • Page 34: System Specifications

    104/52 Amps 50 HERTZ (1500 rpm) 220 Volts 42.3 Amps 9.3KW 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...
  • Page 35 (60 Hertz) AT 1800 32 cfm (.906 cmm) ENGINE COMPARTMENT COOLING 100-200 cfm (2.83 - 5.66 cmm) TUNE UP SPEC/FlCA TIONS 1707 psi (120 kglcm 2 10 kglcm 2 - 0 kglcm 2 ) PRESSURE INJECTOR ENGINE TIMlNG WESTERBEKE GENERATORS...

  • Page 36: Installation Checks

    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. is not the intent of this section to advise boatyards or installers on procedures already well-developed and well-understood.
  • Page 37 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. WESTERBEKE GENERATORS...
  • Page 38 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 i"/'nJ- Inla-.e· Fn~C WESTERBEKE GENERATORS...
  • Page 39 (suction from the pump may collapse a non-reinforced hose.) Sea water strainers should mounted at or below the water line to make sure the sea water line remains primed. WESTERBEKE GENERATORS...
  • Page 40 • Dizziness • Vomiting • Intense headache • Muscular twitching • Weakness and sleepiness • Throbbing in temples If you experience any of the above symptoms, get out into fresh air immediately. WESTERBEKE GENERATORS...
  • Page 41 Check to ensure that all engine harness connections are tight and that they are made to the appropriate terminals. WESTERBEKE GENERATORS...
  • Page 42 Refer to the "SYSTEM SPECIFICATIONS" section of this manual for the airflow requirements of the generator sets. WESTERBEKE GENERATORS...

  • Page 43: 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.
  • Page 44 Depress and hold the PREHEAT switch. Preheat according to the following chart: Atmospheric Temperature Preheating Time +41°F(+5°C) orhip;her Approx. 10 seconds +41°F(+5°C) to +23°F(-5°C) Approx. 20 seconds +23 ° F (_5°C) or lower Approx. 30 seconds Limit of continuous use minute WESTERBEKE GENERATORS...
  • Page 45 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. WESTERBEKE GENERATORS...
  • Page 46 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...

  • Page 47: Fuel System

    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"...
  • Page 48 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).
  • Page 49 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. WESTERBEKE GENERATORS...

  • Page 50: Electrical System

    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...
  • Page 51 • " SENDER GROUN~I~ • '" rgpu~p ENGINE '" " BLOCK 9ATTERY(12VOC) EMERGENCY STOP '140RN "O"'HT ·,4 VEL -1-0 \; \; STANDARD I NSTRlilViE0iT PANEL s'op SWITCH 1 _ _ _ _ _ _ _ _ _ _ WESTERBEKE GENERATORS...
  • Page 52 Wf-IEN CPAr-.K!~G.THE D;JRATlO\J OF 'NDtVID.Jt..L CRfI~KI\JG CYCLES SHOULD S£CC~DS. EX:::EED :;C A SWITCH WITH A CO'lT;·,"UOUS t\I<T'NG ::: .• ;75 AMPS AT NC"MI\~\Y r~UST 12VJC >'I,LL SEHvE. THI':> FU:-<CTlOr-.,8:JTA S\\!TCH NEVER BE USEr, Tf~ 1~t.KE THE "TAI;T!:r, CIRCUIT. WESTERBEKE GENERATORS...
  • Page 53 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. WESTERBEKE GENERATORS...

  • Page 54: Cooling System

    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.
  • Page 55 Temperature 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.
  • Page 56 The condition of the zinc anode Replace Replace Replace Anod., should be checked monthly and the anode cleaned or replaced, as required. Spare anodes should be carried on board. Zinc Anode Conditions WESTERBEKE GENERATORS...
  • Page 57 112 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. WESTERBEKE GENERATORS...
  • Page 58 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.
  • Page 59 Exhaust Elbow Installation The Westerbeke Corporation offers a 45 and 90 exhaust elbow as well as an exhaust riser you can install on your ELBOW propulsion engine. Refer to the instructions below when FL..NGE installing the exhaust elbow purchased for your generator.

  • Page 60: Lubrication System

    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...
  • Page 61 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.

  • Page 62: Btgenerator

    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) change the no-load voltage by 4 to 6 Volts. will WESTERBEKE GENERATORS...
  • Page 63 4 3: i>t =7"P== L _ _ _ _ _ _ _ _ _ _ _ _ _ IweT/S,". L..!l-"H--I-- --'- - __ J WHT IGREEN • ORANGE BLACK 0L-__ -K}- GREEN YELLOW COMPONENTS LISTED ON FOLLOWING PAGE. WESTERBEKE GENERATORS...
  • Page 64 2. Diodes (6) 2. Electronic and Compound 3. Rotating Field Windings 4. Pozi Resistor C. MAIN STATOR G. BRIDGE RECTIFIER I. Main Stator Windings 2. Main Stator Windings 3. Main Stator Auxiliary Windings A. VR. - Automatic Voltage Regulator) (Optional WESTERBEKE GENERATORS...
  • Page 65 2. Diodes (6) 2. Electronic and Compound 3. Rotating Field Windings 4. Pozi Resistor C. MAIN STATOR G. BRIDGE RECTIFIER L Main Stator Windings 2. Main Stator Windings 3. Main Stator Auxiliary Windings (Optional AY.R. - Automatic Voltage Regulator) WESTERBEKE GENERATORS...
  • Page 66 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...
  • Page 67 (Refer to the generator's scarlet and gold data plate for generator amperage ratings. WESTERBEKE GENERATORS...
  • Page 68 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...
  • Page 69 2. Diodes (6) 3. Main Rotor Windings 4. Pozi Resistor 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 WESTERBEKE GENERATORS...
  • Page 70 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...
  • Page 71 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. WESTERBEKE GENERATORS...
  • Page 72 NOTE: Series DELTA requires the installation of a jumper on the regulator board between terminal B andO. '---(----\-----------~ r--------------------~ SO-160v ..:~~nLJ .OM,. ~--~-----~----------~ l.. _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ ... DELTA WESTERBEKE GENERATORS...
  • Page 73 The illustration below shows the 3 phase AC generator backened with the louvered covers removed. DC Charge Bridge Rectifier AC Terminal Block Voltage Regulator WESTERBEKE GENERATORS...
  • Page 74 .-- .., L - - _ "W 3281111 ~'--+-"~"~"~'- .. " (,1.25 A .. P6/POLf;l Sh'p'5load (WHT, 32133 N02~o.",0II. (ZIIII POOPS/POLC, ____ I'· .;G~"~''''''!!-_O- ' - ' (GRN) \ 52 51. N Shore Power Switch Connection Diagrams WESTERBEKE GENERATORS...

  • Page 75: General Information And Care Of The Generator

    See the rpmlHertzifrequency chart on the next page. WESTERBEKE GENERATORS...
  • Page 76 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...

  • Page 77: Engine Control Panel

    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.
  • Page 78 TO Til I - I ..D {> ~TOTIlI-(jHO '10 GU[":.I ... STOP SWI TCH f' N. 2HO 100[lum WESTER8(KE CORPORATION Q~lH AVO" "4 ::"i ~7auG GrMr~AIOR :::O<;Lif' DIAGRAM, OI(Hl ...:::" 1,P _II' RfIlOl[ COIITROL ... " .." WESTERBEKE GENERATORS...

  • Page 79: Engine Troubleshooting

    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. WESTERBEKE GENERATORS...
  • Page 80 I. Check for fuel to generator start; fuel solenoid energized. 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...
  • Page 81 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. WESTERBEKE GENERATORS...
  • Page 82 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...

  • Page 83: Maintenance And Admstments

    Servicing After Initial 50 Hours of Operation 1. Change the engine's lube oil and oil filter. 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. WESTERBEKE GENERATORS...
  • Page 84 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...
  • Page 85 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. WESTERBEKE GENERATORS...
  • Page 86 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...
  • Page 87 BTD II.OKW & BIDA 12.5 KW BID 12.5KW Rocker Shaft Holddown Bolts Rocker Shaft Holddown Bolts 14mm (4.0-5.5 kg/m) 28.9 - 39.8 ft-Ibs 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 10mm (0.8-1.2 kg/m) 5.8 - 8.7 ft-Ibs Revised August 1994 WESTERBEKE GENERATORS...
  • Page 88 (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...
  • Page 89 Connect the AC output leads to the AC terminal block in accordance with the AC Voltage Connections diagram specified for your generator set, which appears in the "BT GENERA TOR" section ofthis manual. WESTERBEKE GENERATORS...
  • Page 90 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...

  • Page 91: Lay-Up And Recommissioning

    CAUTION 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. WESTERBEKE GENERATORS...
  • Page 92 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...
  • Page 93 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.
  • Page 94 3.7 - 4.6 3/8 UNF 30 - 35 4.1-4.8 7116 UNC 44 - 49 6.1 - 6.8 7116 UNF 50 - 55 6.9 - 7.6 112 UNC 68 - 73 9.4 - 10.1 112 UNF 73 - 80 10.1-11.1 WESTERBEKE GENERATORS...
  • Page 95 Oil filter 8.0-9.4 SAME SAME (1.1-1.3) Delivery valve holder 28.9-36.2 SAME SAME (injection pump) (4.0-50) 10.8-14.5 Holder mounting bolt, nozzle SAME SAME (15-2.0) Holder body and retaining nut, 43.4-57.9 SAME SAME nozzle (6.0-8.0) Glow plug 10.8-14.5 SAME SAME (1.5-2.0) WESTERBEKE GENERATORS...
  • Page 96 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 current Sound Guard model assembly/installations. WESTERBEKE GENERATORS...
  • Page 97 (PUMP SOURCE) H ... DREca PUMPS KALAMAZOO. HXCK. (6l.6) :349-l.5.1.1 NOTE: Provisions should be made to prevent the PTO device from overloading the generator's engine. Install a pressure relief valve on the hydraulic pump to limit maximum pumping pressure. WESTERBEKE GENERATORS...

This manual is also suitable for:

Btd 7.5 kw 60hzBtd a 9.4 kw 60hzBtd 12.5 kw 60hzBta 12.5 kw 60hzBtd 8.3 50hzBtd 9.4 kw 50hz ... Show all

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