Westerbeke BTG-9KW User manual

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.

Gasoline with an ETHANOL content
higher than 10% (E10) is not allowed
and may void warranty.
Engines & Generators

SAFETY PRECAUTIONS
The following symbols appear in
manual to call attention to
emphasize conditions potentially
dangerous to the operator or to
equipment.
this
and
the
WARNING
CAUTION
This sy~bol is used in the
manual to warn of possible
serlOUS personal inJury or
loss of life.
This symbol is used in the
manual to caution per-
sonnel of possible damage
to equipment.
Read the manual carefully and thoroughly
before attempting to operate the equlp-
ment. Know when dangerous condi t ions
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
oasoline-fueled enoine; ensure no oaso-
line fumes are present before starting.
•
•
Prevent Electric ~
Shut off electric power before
accessing electrical equ1pment.
Use insulated mats whenever working
on electrical equipment.
Make sure clothing is dry, not damp
(particularly shoes;, and keep sk1n
surfaces dry when handling electri-
cal equipment.
Remove wristwatch and jewelry when
working on electrical equ1pment.
Dc not connect utility shore power
to vessel's AC circuits, except
through a ship-to-shore double-throw
transfer switch. Damaoe to vessel's
AC generator may resul~.
Be extremely careful when workinc on
electrical components. High vol~age
can cause injury or death.
Exhaust ~ ~ !£tiE .
Ensure that the exhaust system is
adequate to expel gases discharged
from the engine. Check exhaust
system regularly for leaks and make
sure exhaust manifolds are securely
attached and no warping exists.
Be sure the unit and its surround-
ings are well-ventilated.
•
•
•
Use Extreme
Enoine Fuel.
expros ioner
Do not fill
running.
Care When Handllne
(A c'onstant danger of
fire exists.)
fuel tank with engine
Do not smoke or use open flame near
the eng1ne or the fuel tank.
Keep combustible materials away from
the uni t.
Be sure all fuel supplies have a
positive shutoff valve.
Be certain
adequately
leaks.
fuel line
tightened
fittinos are
and free of
Make sure a fire extinouisher is
installed nearby and ii properly
maintained. Be familiar with its
proper use. Extinguishers rated
ABC by the NFPA ar e appropr iate for
all applications encountered in this
environment.
Use Extreme Care When Servicing
'b"atterles.
Wear rubber gloves,
and eye protection
batteries.
a rubber apron,
when serv1cing
Leac acid batteries emit hvdrooen,
c hiohlv-explosive oas, wh-ich - can
be 1clniced b\' electrical arC1nc or
c 11ghted cig~rette, cigar, or pipe.
Dc not smoke or allo'" an open flame
near batten' beino serviced. Snut
off all electr ical equipment in the
vicinity to prevent electrical
arcing dur1ng servicing.
Avoid ~ Parts.
Do not service unit while unit is
running; if absolutely necessary to
make operating adjustments, use ex-
treme care to avoid moving parts and
hot exhaust system components.
Do not wear loos~ clothing or jewel-
ry when servicing equipment; avoid
loose jackets, shirts or sleeves,
rings, necklaces, or bracelets that
might be caught in moving parts.
Make sure all attaching hardware is
properly tightened and keep protec-
tive shields and guards in place at
all times .•
Do not check fluid levels or drive-
belt tension while unit is opera-
t1ng.
Do not work on equipment when men-
tally or physically incapacitated by
fatigue.

IMPORTANT
PRODUCT SOFTWARE DISCLAIMER
Product software of all kinds, such as brochur es, dr awing s,
technical data, operator's and workshop manuals, parts lists
and parts price lists (and other related information),
instruct ions and speci fica t ions prov ided from source s 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
THE CONTENT OF SUCH SOFTWARE, MAKES NO WARRANTIES OR
REPRESENTATIONS WITH RESPECT THERETO, INCLUDING THE ACCURACY,
TIMELINESS OR COMPLETENESS THEREOF, AND WILL IN NO EVENT BE
LIABLE FOR ANY TYPE OF DAMAGES OR INJURY INCURRED IN
CONNECTION WITH, OR ARISING OUT OF, THE FURNISHING OR USE OF
SUCH SOFTWARE.
For example, components and sub-assemblies incorporated into
Westerbeke's products and supplied by others (such as engine
blocks, fuel systems and components, transmissions, electri-
cal components, pumps and other products) are generally sup-
ported by their manufacturers with their own software, and
Westerbeke m'ust depend on such software for the design of
Westerbeke's own product software. Such software, however,
may be outdated and no longer accurate. Routine changes made
by Wester beke' s supplier s, of wh ich Wester beke 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 pr intings of Westerbeke product software, and the
unavoidable existence of earlier, non-current Westerbeke
software ed i t ions in the field. Addi t ionally, most
Westerbeke products include customer-requested special
fea tur es that fr equen tly do not include complete documen-
tation.
In summation, product software provided with Westerbeke pro-
ducts, 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 of
Westerbeke or the supplier in question be consulted to deter-
mine the accuracy and currency of the product software being
consulted by the customer.

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 that 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 serial number and
commission date.
from: J.H. Westerbeke Corp.
Avon Industrial Park
Avon, MA 02322
•
r'~jr WESTERBEKE
•
AV(JfoINOUS'kll"L I>A/iiI, AV(h 10.1,1.023.'1. 'I. ,~",~ ,'()(
rutx ~/"'''''.'~A¥ lel',~~"3~_"CA&1 wfsrc~p
CUSTOMER IDENTIFICATION
Adam Smith
Mail To:
85 Maple Street
Alden, IN 12234
ModeJ_ B'TG 9KW
Ser.#1234C706
~ Expires 7/7/88
~
~

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 ••••...•. 38
ENGINE TROUBLESHOOTING ••.•••••••.••. 40
TIGHTENING TORQUES ••••••.••••••••.•• 42

GENERAL
Introduction
This manual contains the equipment operating procedures as well as
information to assist the operator to maintain the equipment in proper
working order. Study and follow the instructions carefully. A
planned rna in tenance prog r am is included in th is manual; adher ing to
the prog ram will result in better equipment per formance 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 Gasoline Powered Generator
The gasoline engine driving the AC generator is in many ways similar
to an automobile engine. The cylinders are vertical and in-line, with
a belt-driven, overhead camshaft. The engine utilizes a breaker
points and condenser type distributor which is horizontally-mounted
and camshaft-driven, a pressure type lubrication system, and a
thermostatically-controlled water-cooled engine block with an ex-
changer system.
To a great extent, the gasoline engine used to drive the AC generator
~equires the same preventive maintenance that any responsible operator
would give the gasoline engine in his automobile. The most important
factors contributing to the long life of the unit are proper ven-
tilation and maintenance of the fuel system, ignition system, cooling
system, and the generator end.
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). This information is necessary
in order to 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
eng ine and facing in the same dir ection as the front of the eng ine:
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 ensure dependable operation, long service, and a
satisfied owner. A record of this test is maintained at the factory.
Care at the factory during assembly, and thorough testing, have
resulted in a Westerbeke gasoline engine-driven generator capable of
many thousands of hours of dependable service. However, the manufac-
turer cannot control the treatment the unit receives in the field.
That part is up to the owner/operator.
1

BTG 9 KW Gasoline Generator Set
2

GENERAL SPECIFICATIONS
BTG 9 KW
MARINE GASOLINE GENERATOR SET
Engine Type
Combustion Chamber
Valve Mechanism
Bor e & Stroke
Piston Displacement
Firing Order
Direction of Rotation
Compression Ratio
Compression Pressure
Valve Timing
Valve Seat Angle
Valve Clearance
(eng ine warm)
Eng ine Speed
Dimensions
Gasoline, 4-cycle, 3-cylinder, vertical,
in-line
Multi-sphere type
Overhead camshaft, belt-driven
2.99 x 2.87 inches (76 X 73 mm)
60.6 cubic inches (0.993 liter)
1-2-3
Clockwise, when viewed from the front
9.5:1
177.8 psi (12.5 kg/cm
2
), at 350 rpm
Intake Opens 19· BTDC
Intake Closes 51· ABDC
Exhaust Opens 51· BBDC
Exhaust Closes 19· ATDC
Intake 45·
Exhaust 45·
Intake 0.0079 inch (0.20 mm)
Exhaust 0.0079 inch (0.20 rom)
1800 rpm (belt-driven mechanical
governor)
Height:
Width:
Length:
23.38 inches (593.85 rom)
18.69 inches (474.73 rom)
28.25 inches (717.55 mm)
Weight 386 lb (175.0 kg)
Sea Water Flow, at 1800 rpm 4.5 - 5.0 gpm (17.03 - 18.92 lpm)
(measured at discharge
from heat exchanger)
Fuel Consumption 1.5 gph (5.68 lph) at full rated
output (approximate)
3

FUEL SYSTEM
Fuel
Carburetor
Governor
Lift pump
Air Cleaner
COOLING SYSTEM
SYSTEMS SPECIFICATIONS
Unleaded or leaded gasoline
(minimum octane 89)
Down-draft, single-barrel
Mechanical type, belt-driven
12-Volt electric;
lift capacity 6 ft (1.8 m)
Metal screen type - cleanable
General Fresh water-cooled block,
thermostatically-controlled
with sea water exchanger system
Operating temperature 130-lS0·F (55· - 66·C)
Fresh Water Pump Centrifugal type, metal
impeller, belt-driven
Sea Water Pump positive displacement rubber
impeller, belt-driven
Sea Water Flow, at 1800 rpm 4.75 - 5.0 gpm (17.98 - 18.92 Ipm)
(measured at discharge from heat
exchanger)
System Capacity 5.7 qts (5.39 liters)
(fresh water)
LUBRICATION SYSTEM
General
Oil Filter
Sump Capacity
(filter not included)
Oil Pressure, at 1800 rpm
(engine hot)
Oil Grade
Pressure type with trochoid pump,
chain-driven through balance shafts
Full flow, paper element, spin-on
type.
3.0 qts (2.841 liters)
50 - 70 psi (3.5 - 4.9 kg/cm
2)
API
spec SD or SE
4