Westerbeke BTG-9KW Operator's Manual
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Westerbeke BTG-9KW Operator's Manual

Westerbeke BTG-9KW Operator's Manual

Marine gasoline generator set
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OPERATOR'S MANUAL
WESTERBEKE
BTG -
9 KW
Marine Gasoline
Generator Set
Publication
#
36710
Edition One
June 1987
jr~
'WESTERBEKE
j
WESTERBEKE CORPORATION • MYLES STANDISH INDUSTRIAL PARK
•
150 JOHN HANCOCK ROAD, TAUNTON,
MA
02780-7319 U.S.A.

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  • Page 1 OPERATOR'S MANUAL WESTERBEKE BTG - 9 KW Marine Gasoline Generator Set Publication 36710 Edition One June 1987 'WESTERBEKE WESTERBEKE CORPORATION • MYLES STANDISH INDUSTRIAL PARK • 150 JOHN HANCOCK ROAD, TAUNTON, 02780-7319 U.S.A.
  • Page 2 Gasoline with an ETHANOL content higher than 10% (E10) is not allowed and may void warranty. Engines & Generators...
  • Page 3 SAFETY PRECAUTIONS • following symbols appear this Care When Handllne Extreme manual call attention (A c'onstant danger of Enoine Fuel. expros emphasize conditions potentially ioner fire exists.) dangerous operator Do not fill fuel tank with engine equipment. running. Do not smoke or use open flame near WARNING This sy~bol...
  • Page 4 Wester beke' s supplier s, wh ich Wester beke rarely notice advance, frequently reflected supplier's software until after such changes take place. Westerbeke customers should also keep in mind the time span between pr intings of Westerbeke product software, unavoidable existence earlier,...
  • Page 5 FOREWORD Thank you for selecting a Westerbeke marine product for your use. 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-...

  • Page 6: Table Of Contents

    TABLE OF CONTENTS Title GENERAL ..••••••••.•••••.••••••.••••.. 1 GENERAL SPECIFICATIONS ••••••••••••••• 3 SYSTEM SPECIFICATIONS ••••.•••.••.••. 4 TUNE-UP SPECIFICATIONS ••••••••••..•• 6 INSTALLATION ••••••••.••••••••.••••• 7 BT GENERATOR .•••••••••••.••••••••••• 18 OPERATION •.••••.•••.•..••••.••.•..•. 25 SERVICE AND MAINTENANCE .•••.•••••••• 28 ENGINE ADJUSTMENT •••••••••••••••.••• 32 DC CIRCUIT DESCRIPTION •••••••••••.•. 36 GENERAL INFORMATION AND CARE OF THE GENERATOR ••••...•.

  • Page 7: General

    Order ing Parts When contacting your Westerbeke dealer, parts distributor, or the fac- tory about your Westerbeke unit, always provide the model number and serial number as they appear on the nameplate (located on the surface of the exhaust manifold/coolant tank).
  • Page 8 BTG 9 KW Gasoline Generator Set...

  • Page 9: General Specifications

    GENERAL SPECIFICATIONS BTG 9 KW MARINE GASOLINE GENERATOR SET Engine Type Gasoline, 4-cycle, 3-cylinder, vertical, in-line Combustion Chamber Multi-sphere type Overhead camshaft, belt-driven Valve Mechanism Bor e Stroke 2.99 x 2.87 inches (76 X 73 mm) & Piston Displacement 60.6 cubic inches (0.993 liter) Firing Order 1-2-3 Clockwise, when viewed from the front...

  • Page 10: System Specifications

    SYSTEMS SPECIFICATIONS FUEL SYSTEM Fuel Unleaded or leaded gasoline (minimum octane 89) Carburetor Down-draft, single-barrel Governor Mechanical type, belt-driven Lift pump 12-Volt electric; lift capacity 6 ft (1.8 m) Air Cleaner Metal screen type - cleanable COOLING SYSTEM General Fresh water-cooled block, thermostatically-controlled with sea water exchanger system Operating temperature...
  • Page 11 ELECTRICAL SYSTEM Starting Battery l2-Volt, 30 A-H (recommended) (45 A-H cold areas) Starter l2-Volt, 1.2 kW, reduction type, solenoid-mounted DC No-load current 90 Amp (max.) at 11.5 Volts and DC Cranking Current 175 Amp (eng ine cold) DC Charging Alternator 35-Amp belt-driven, with internal regulator and without isolation diodes...

  • Page 12: Tune-Up Specifications

    Engine Combustion Air Requirements, (60 Hertz), at 1800 rpm 32 cfm (0.906 cmm) TUNE-UP SPECIFICATIONS .036 inch (0.7 Spark P lug Gap 0.028 rom) Contact Point Clearance 0.016 .020 inch (0.4 0.5 mm) Dwell Angle Condenser Capacity 0.27 microfarad 0.0079 inch (0.20 Valve Clearance Intake rom)

  • Page 13: Installation

    INSTALLATION General Proper location and installation of the generator set in the vessel are of prime importance. Factor s in the installation that must be considered are ventilation generator proper cooling engine combustion air; exhaust system to properly discharge raw cooling water, quiet the exhaust and expel...
  • Page 14 ventilation generator set needs fresh cool combustion within engine cylinders, for generator cooling and to remove harmful or flam- mable gasoline fumes from around the generator set. The 9 KW BTG en- gine requires air flow of 32 cubic feet per minute (0.906 cubic meters per minute) and the generator end requires from 225 to 250 cubic feet per minute (6.37 to 7.08 cubic meters per minute) air flow.
  • Page 15 Exhaust System Installations Flapper Cover_~.f SUPpor1 Hangers - RawWaler Pump Dry Slack Exhaust AawWater Pump Generator Above Water Lme AawWater Pump Generator Below Water Lme...
  • Page 16 CAUTION Overcranking with engine start results excessive amounts cooling water pumped in to exhaust system. Exhaust pressure always sufficient discharge accumulated water during periods excessive cranking. Shut off thru-hull water supply until unit starts and then open once started. Investigate reason (s) for hard starting and correct.
  • Page 17 Basic Fuel System Layouts with Anti-Siphon Protection FUEL LINE ALWAYS ABOVE FUEL TANK TOP LEVEL _=~~=-====:=.~~:.-:- -::-='::=:-:=:-=-=~~-:-d T AN TO P--DLE!!",V_E_L_-==..:!!:..=.=!",,"=,_ ..NO ANTI·SIPHON DEVICE OR ELECTRICALLY OPERATED VALVE NEEDED ANTI·SIPHON DEVICE OR ELECTRICALLY 0-,.---- OPERATED FUEL STOP VALVE - - - - - - ; p FUEL TANK TOP LEVEL FUEL liNE BELOW FUEL TANK TOP LEVEL ANTI·SIPHON DEVICE OR ELECTRICALLY OPERATED FUEL STOP...
  • Page 18 Fuel system components must be compatible with oxygenate (butanes, alcohols) blended fuels.--pailure to ensure compatibility will result in the component failure and possible injury to the user. The use of check valves in place of the solenoid-type shut-off valves is discouraged. Check valves may tax the ability of the fuel lift pump on the eng ine to draw fuel through them.
  • Page 19 Automatic Shutdown High Exhaust Temperature Shutdown Switch (normally closed) An exhaust temperature switch is located on the exhaust elbow and will open ignition circuit should switch sense excessive tem- perature, indicating a lack of proper sea water coolant flow. This switch opens at 260 - 270·F (127 - l32·C) and resets at approximately 22S·F (107·C).
  • Page 20 DC Electrical Connections A common ground for negative (-) DC is found at the bellhousing of the generator, next to the starter, in the form of a threaded grounding stud. It is recommended that the battery ground be connected here. Connect battery positive to the starter solenoid terminal tagged for this connection.
  • Page 21 1"1 'i:I OPTIONAL R,MOn STAhT PANIL(RtJ\R VI'W) PN 33703 , - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1 ""IG lit.O ::E;...
  • Page 22 ..I"."I-;;::::;:;C;o N· TI''''''"' ..L ..' .-1;:;-""1 "' ..,.ri ..r-·~-,§'\ !!.!!ill:!&. ~t!!=:MA!l£ [)t"t>RA~ ~ll~DC .._________ -IOvIiN :n' ' ' ' . 11 ~l~~; ~~{-.-------- G;'ttn-o ,-----~ j[:~ ~~~~, ----'Cf)';{--·-----~ ..""I~/' :(:(8 " : . ' " ~ (Hlll<E;(l,\f,.flJ f.I'KU,T b~[A"ER...
  • Page 23 P[I(>i 0 9KW fe"oIl"'loIAL _ .Jl} '> ..lJ ,.. , PI ()PClAie- GAGe t..JIllill!oIC, 33/02 REMOTE INSTRUI'IENT PANEL (REAR VIE,,j) ASS'Y PN r - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1 ::;l REo/W/PURPLf STRIPE...

  • Page 24: Bt Generator

    BT GENERATOR This generator is a brushless self-excited generator, which requires only the driving force of the engine to produce AC output. Two perma- nent magnets exciter stator responsible self- exciting feature of this generator. The magnetic field they produce causes an AC voltage to be induced into the related exciter rotor win- dings during rotation.
  • Page 25 VOltage AaJustmen: Greer, Blacio\ YelloV'. ' f l..o-L, 80 Blue Blue 3 0 100 Selector L· Terminal BloCK COf"\nections 60hz 1201240V Compound +--+---Transtormer Opllonal Voltage Regulator Regulator Plug Blue & White I 'C":'-Blue & White Illustration shows terminals " .. Yellow Black &...
  • Page 26 BT Generator Internal Wiring Diagram r----------, r-----------, ,-------------------1 " 1==: -{)t- • L _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ J =TF= BLACK WHITE & ~f~ tI3--L---J "';;; & WHITE GREEN _________ 0 :»,...
  • Page 27 Optional voltage Regulator An optional solid-state voltage regulator (board 34410) is available :jj: for use with the 9 KW BTG generator. When installed, and the regulation switch is moved to the ELEC position, regulator works together with the standard compound transformer regulator to regulate generator vol tage output.
  • Page 28 Load Connections The generator data plate gives 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 vol tage connect ions is prov ided on the decal and is simi lar to the figure on the following page.
  • Page 29 AC voltage Connections 120V 60Hz 120/240V 60Hz TO FRAME <l TO FRAME 60 Hertz, 1800 rpm , ,O/220V 50Hz 50Hz 220V 50Hz TO FRAME --,-----<L .. _ .. J - - - --'---~- 50 Hertz 1500 rpm NOTE: The frame ground wire must be moved when changing from 110 Volts, 50 Hertz to 110/220 Volts, 50 Hertz.
  • Page 30 Shore Power Connections shore power to the vessel's AC circuit, this If the installer connects must be done by means of the SHORE POWER/OFF/SHIPS GEN, center posi- tion-off transfer switch shown below. Use of this switch prevents shore power to generator output. simultaneous connection of CAUTION Damage to the generator can result if utility shore power and...

  • Page 31: Operation

    OPERATION Prior to starting the generator, check the following: • Lubricating oil level • Coolant (fresh water) • Fuel to engine • Sea water connections • Battery connections • Generator AC electrical connections • Exhaust connections • Belt tensions (governor/fresh water pump) Engine Oil Use a good grade of oil API Spec.
  • Page 32 A coolant recovery tank (*24977) is supplied with each engine and must be installed to allow coolant ex- pansion contraction without creating introducing into the cooling system. It should be used monitor ing adding coolant. NOTE: coolant lost through a leak the system, it will be necessary to refill...
  • Page 33 Starting ventilate the generator compartment for a minimum of 5 minutes before attempting to start the engine. The ventilating blowers remove poten- tially explosive fumes from the generator compartment and bilge. Starting sequence: Depress the ON switch and hold. (No load on generator). Depress START switch.

  • Page 34: Service And Maintenance

    SERVICE AND MAINTENANCE Regular inspection and servicing of the engine and generator increases the service life of the unit and reduces repair costs and down time. Table of Scheduled Maintenance Daily Hrs. Hrs. Hrs. Hrs. visually inspect unit Check lube oil level Check coolant level Check fuel supply Clean air screen (flame arrestor)
  • Page 35 Electric Fuel Pump eng ine-moun ted electr ic fuel pump supplies fuel engine carburetor during engine operation. A cleanable filter screen con- tained in its base. WARNING Shut off fuel service valve at engine when servicing fuel Filter Screen system. Take care catch...
  • Page 36 Cooling System Monitor system coolant (50/50 antifreeeze mixture) and, if rust scale are evident, flush and clean system and replenish the antifreeze mixture. Use antifreeze that is compatible with aluminum engine com- ponents. Maintain proper belt tension on the fresh water circulating pump and sea water pump, three-eighths to one-half inch deflection along the...
  • Page 37 Valve clearance should be checked and adjusted, necessary, each time bolts are torqued. Valve Clearance Adjustment (Both intake and exhaust): (Hot) 0.0079 inch (0.20 rom) (Cold) 0.0071 inch (0.18 rom) Valve Adjustment Procedure Rotate the crankshaft normal direction of rotation, placing 1 piston at the top of its compression stroke.

  • Page 38: Engine Adjustment

    ENGINE ADJUSTMENT Ignition Timing Attach a timing light to No. 1 spark plug and mark the front crank- shaft pulley timing notch. Locate timing pointer on front gear case- and mark same. Use of white or yellow marking crayon helps greatly in referencing these two points with the timing light.
  • Page 39 Electric Choke electr ic choke uses l2-Volt heating element which opens choke automatically once the engine starts and is running. Some hunting will present when the generator started and on choke, with no-load on the generator. WARNING avoid burns fingers hands, touch choke...
  • Page 40 Carburetor Adjustment Idle Mixture Jet Disconnect the throttle linkage arm from the governor control arm and reduce engine speed with the idle stop screw. Adjust the idle mixture screw: turn screw clockwise (in) until engine skips; back screw out (counterclockwise) slowly until engine smooths then skips again;...
  • Page 41 sure this linkage moves freely and that the ball joint connectors are properly lubr icated. (Disconnect ball joint and apply graphite lube to the inside of the joint.) Hunting/Regulation If variation in engine speed between no load and full load is too great, adjust this eyescrew to draw the spring closer to the lever hub.

  • Page 42: Dc Circuit Description

    DC CIRCUIT DESCRIPTION: BTG 9 KW GASOLINE MARINE GENERATOR SET Safety Information This circuit is designed and manufactured in compliance with United States Coast Guard Standards (33 CFR PART 183). No modifications may be made to it by the installer or user. It is the installer's respon- sibility to assure that the installation of the generator set and any remote...
  • Page 43 optional remote instrument panel available which includes start ing con troIs. This panel also includes water temper ature gauge, oil pressure gauge, battery voltmeter, operating hourmeter, start-stop control switches, and senders to be installed on the engine for water temperature and oil pressure. Circuit Description two-pole switch...

  • Page 44: General Information And Care Of The Generator

    GENERAL INFORMATION AND CARE OF THE GENERATOR Use of Electric Motors The power required to start an electr ic motor considerably more than is required to keep it running after it is started. Some motors require much more current start than others.
  • Page 45 4-Pole Generator Voltage Load Speed Frequency l20V (110) 240V (220) Applied plants (rpm) (Hertz) 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.

  • Page 46: Engine Troubleshooting

    ENGINE TROUBLESHOOTING Trouble possible Cause Engine cranks but fails Out of fuel to start Engine flooded Filters clogged by contaminated fuel voltage drop at on overspeed switch Worn or faulty spark plugs Bad ignition coil High-tension leads grounding (system wet) Automatic shutdown switch faulty Fuel pump inoperative, filter clogged...
  • Page 47 ENGINE TROUBLESHOOTING (continued) Trouble Possible Cause Engine overheating Coolant loss (Pressure test system) Belts loose or broken Sea water pump impeller faulty Sea water pump worn Faulty hose Thermostat stuck closed Exchanger clogged Faulty gauge (check with thermometer) Engine hunting Throttle linkage binding Dirty fuel filter Defective fuel pump...

  • Page 48: Tightening Torques

    TABLE OF TIGHTENING TORQUES lb-ft kg-m Cylinder head hold-down bolts 36.2 43.4 Main bearing caps 39.0 47.7 Connecting rod bearing cap 15.2 21.0 Front crankshaft pulley 65.2 72.4 10.0 Flywheel retaining bolts 28.9 36.2 Rocker cover cap nuts 8 .7 Spark plugs 10.8 15.9...
  • Page 49 TABLE OF STANDARD HARDWARE TIGHTENING TORQUES following specific assembly, stated otherwise unless torque values when tightening standard hardware. kg-m pitch Ib-ft Grade 4T 6mm bolt/nut 11.6 1. 25 8mm bolt/nut 13.7 22.4 10mm bolt/nut 1. 25 21. 7 1. 8 - 10mm bolt/nut 13.0 1.

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