Westerbeke BTD 7.5 KW 50H User manual

OPERATOR'S MANUAL
&
INSTALLATION GUIDE
WESTERBEKE CORPORATION
DIESEL GENERATORS
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

SAFETY PRECAUTIONS
The following symbols appear in this manual to call attention to and emphasize conditions potentially
dangerous to the operator.
IWARNING I
The above symbol is used in the manual to warn of possible serious personal injury or loss of life.
Ii CAUTION II
The above symbol is used in the manual to caution personnel of possible damage to equipment.
Read the manual carefully and thoroughly before attempting to operate the equipment. Know when
dangerous conditions 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 gasoline-fueled engine; ensure no
gasoline fumes are present before starting.
• Prevent Electric Shock
Shut offelectric power before accessing electrical equipment.
Use insulated mats whenever working on electrical equipment.
Make sure your clothing is dry, not damp (particularly shoes), and keep your skin surfaces dry when
handling electrical equipment.
Remove wristwatch andjewelry when working on electrical equipment.
Do not connect utility shore power
to vessel's AC circuits, except through a ship-to-shore double
throw transfer switch. Damage to vessel's
AC generator may result if this is not done.
Be e"tremely careful when working on electrical components. High voltage can cause injury or
death.
• Exhaust Gases Are Toxic
Ensure that exhaust system is adequate to expel gases discharged from the engine. Check exhaust
system regularly for leaks and make sure the exhaust manifolds are securely attached and no warping
exists.
Be sure the nnit and its surroundings are well-ventilated.
• 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.
1
WESTERBEKE GENERATORS

• Do Not Alter or Modifv the Fuel Svstem
Be sure all fuel supplies have a positive shut-offvalve.
Be certain fuel line fittings are adequately tightened and free ofleaks.
Make sure a fire extinguisher is installed nearby and is properly maintained. Be familiar with its
proper use. Extinguishers rated ABC
by the NFPA are appropriate for all applications encountered in
this environment.
• Use Extreme Care When Servicing Batteries
Wear rubber gloves, a rubber apron, and eye protection when servicing batteries.
Lead acid batteries emit hydrogen, a highly-explosive gas, which can be ignited by electrical arcing or
by a lighted cigarette, cigar, or pipe. Do not smoke or allow an open flame near the battery being
serviced. Shut offall electrical equipment in the vicinity to prevent electrical arcing during servicing.
• Avoid Moving Parts
Do not service the unit while it is running. If a situation arises in which it is absolutely necessary to
make operating adjustments, use extreme care to avoid moving parts and hot exhaust system
components.
Do not wear loose clothing
or jewelry when servicing equipment; avoid wearing loose jackets shirts
or sleeves, rings, necklaces, or bracelets that might
be caught in moving parts.
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 2

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
adjustment 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. 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's serial number and commission date.
3 WESTERBEKE GENERATORS

IMPORTANT
PRODUCT SOFTWARE DISCLAIMER
Product software of all kinds, such as brochures, drawings, technical data, operator's and workshop
manuals, parts lists and parts price lists, and other information, instructions and specifications provided
from sources 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 TIIE CONTENT OF SUCH SOFTWARE, MAKES NO WARRANTlES OR REPRESENTATIONS
WITH RESPECT TIIERETO, INCLUDING ACCURACY, TIMELINESS OR COMPLETENESS
TIIEREOF, AND WILL
IN NO EVENT BE LIABLE FOR ANY TYPE OF DAMAGES OR INJURY
INCURRED IN CONNECTION WITH, OR ARISING OUT OF, TIIE FURNISIDNG OR USE OF SUCH
SOFTWARE.
For example, components and subassemblies incorporated in Westerbeke's products and supplied by otbers
(such as engine blocks, fuel systems and components, transmissions, electrical components, pumps and
other products) are generally supported by their manufacturers with their own software, and 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.
Westerbeke customers should also keep in mind the time span between printings
of Westerbeke product
software, and the unavoidable existence
of earlier, non-current Westerbeke software editions in the field.
Additionally, most Westerbeke products include customer-requested special features that frequently do not
include complete documentation.
In summation, product software provided with Westerbeke products, 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 ofWesterbeke or
the supplier
in question be consulted to determine the accuracy and currentness of the product software
being consulted by the customer.
WESTERBEKE GENERATORS 4

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 GENERATOR SET GENERAL
SPECIFICATIONS 17
SYSTEM SPECIFICATIONS 18
BID 11.0 KW MARINE DIESEL GENERATOR SET GENERAL
SPECIFICATIONS 21
SYSTEM SPECIFICATIONS 22
BTD 12.5 KW MARINE DIESEL GENERATOR SET GENERAL
SPECIFICATIONS 25
SYSTEM SPECIFICATIONS 26
BIDA 12.5 KW MARINE DIESEL GENERATOR SET GENERAL
SPECIFICATIONS 29
SYSTEM SPECIFICATIONS 30
INSTALLATION CHECKS 34
OPERATION 41
FUEL SYSTEM 45
ELECTRICAL SYSTEM 48
COOLING SYSTEM 52
LUBRICATION SYSTEM 58
BTGENERATOR 60
GENERAL INFORMATION AND CARE OF THE GENERATOR 73
ENGINE CONTROL PANEL 75
ENGINE TROUBLESHOOTING 78
MAINTENANCE AND ADmSTMENTS 81
LAY-UP AND RECOMMISSIONING 89
5 WESTERBEKE GENERATORS

TABLE OF CONTENTS (CONTINUED)
TABLE OF STANDARD HARDWARE TIGHTENING TORQUES 92
SOUND GUARD INSTALLATION INSTRUCTIONS 94
POWER TAKE-OFF (PTO) ADAPTER KlTS 95
WESTERBEKE GENERATORS 6

Control Panel
20 Amp DC
Circuit Breaker
Block Drain
DC Charging
Alternator
Fresh Water
Circulating
Pump
Sea Water
BTD 8.0 KW Generator
Preheat Solenoid
Fuel Lift Pump
Fresh Water Fill
Oil Pressure Sender
8.0 KW BTD
xhaust Manifold
Intake Silencer
Charging
Alternator
Fuel Run
Solenoid
Switch
Zinc Anode
~ __ I'x<'h,,"ge,
Fresh Water Drain
Exhaust Temperature
itch
Unit Data Tag
Ground Connection
Starter with Solenoid
8.0 KW BTD
7 WESTERBEKE GENERATORS

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
WESTERBEKE GENERATORS
BTD 10.0 KW Generator
Preheat Solenoid
Intake Silencer
10.0 KW BTD
Emergency Shut
ide Oil Fill
DC Charging
rnatar
Run
__ ,4.nc Anode
Heat
Exchanger
-Exchanger
Fresh Water Drain
I Pressure Switch
rol Panel
-----'"' Exhaust
Starter with Solenoid
10.0 KW BTD
8
Elbow
DC Battery Ground
Connection

BTD 11.0 KW Generator
Top Engine Oil
Control Preheat Sollen<,id
AC Con,nec,tior"'~
Fresh Water Slock
Lube Oil Dip,stick'
Lube Oil Filter
11.0KW BTD
Fresh Water Air
Heat Exc;hang,,,/
11.0 KW BTD
9
Water Air Bleed
DC Charging
Pressure
Sender
Fitter
Shut-off Switch
Exhaust
Temperature
Switch
Elbow
DC Battery
Ground Connection
with Solenoid
WESTERBEKE GENERATORS

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 Engine Oil Fill
Fresh Water
I Fill
Thermostat
Heat Exchanger
Sea Water Pump
Fresh Water Block Drain
Lube Oil Dipstick
WESTERBEKE GENERATORS
10
DC Charging
i Pressure Switch
xhaust Manifold
mergency
Shut-off Switch
--""'U5t
Temperature
Switch
o Exhaust
Elbow
Battery
with Solenoid

....
....
:l=!
eo
[JJ
;j
~
eo
1:i
~
eo
z
~
o
0;
Control Panel
20 Amp DC Circuit Breaker
Lube Oil Filter ___ _
AC
Connections Outlet
Fresh Water Block Drain
Preheat Solenoid Air Intake Silencer
Side Oil Fill I DC Charging Alternator
Fuel Lift Pump
Oil Pressure Sender
12.5 BTDA
RIGHT SIDE
Fuel Filter
Fuel Injection Pump
Fuel Run Solenoid
Lube Oil Drain Hose
Oil Pressure Switch
Zinc Anode

~
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 Cap
12.5 BTDA
LEFT SIDE
Emergency Shut~off Switch
Exhaust Temperature Switch
45
0
Exhaust Elbow
Unit Data Tag
DC Battery Ground Connection
Starter with Solenoid

GENERAL
Introduction
This manual contains the equipment operating procednres as well as additional information needed to
help the operator keep the marine eqnipment in proper working order. Stndy and follow the instructions
carefully. A planned maintenance program is included in this manual; adhering to the program will
result in better equipment performance 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 Diesel Engine
The diesel engine closely resembles the gasoline engine, since the mechanism is essentially the same. The
cylinders are arranged above a closed crankcase; the crankshaft is of the same general type as that of a
gasoline engine; and the diesel engine has the same type ofvalves, camshaft, pistons, connecting rods and
lubricating system.
Therefore, to a great extent, a diesel engine requires the same preventive maintenance as a gasoline
engine. The most important factors are proper ventilation and proper maintenance of the fuel, lubricating
and cooling systems. Replacement of fuel and lubricating filter elements at the time periods specified is a
must, and frequent checking for contamination (that is, water, sediment, etc.) in the fuel system is also
essential. Another important factor is the use of the same brand of high detergent diesel lubricating oil
designed specifically for diesel engines.
The diesel engine does differ form the gasonline engine, however, in its method of handling and firing of
fuel. The carburetor and ignition systems are done away with and in their place is a single component -
the fuel injection pump -which performs the function of both.
Ordering Parts
When contacting your Westerbeke dealer, parts distributor, or the factory about your Westerbeke unit,
always provide the generator's complete model number, the engine's serial number and the generator's
serial number as they appear on the black and silver nameplate located on the generator end. You must
provide us with this information so we may properly 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 engine and facing in the same direction as the front
ofthe engine: the left side is atyour 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 ensnre dependable operation, long service, and a
satisfied owner.
Care at the factory during assembly, and thorough testing, have resulted in a Westerbeke diesel engine
driven generator capable of many thousands of hours of dependable service. However, the manufactnrer
cannot control the treatment the unit receives in the field. That part is up to the owner/operator.
13 WESTERBEKE GENERATORS

BTD 8.0 KW MARINE DIESEL GENERA TOR SET GENERAL SPECIFICATIONS
Engine Type
Governor
Combustion Chamber
Bore & Stroke
Pistion Displacement
Firing Order
Direction
of Rotation
Maximum Torque (at 1800 rpm)
Compression Ratio
Compression Pressure
Valve Timing
Valve Seat Angle
Valve Clearance
(engine cold)
Engine Speed
Dimensions
Weight
Fuel Consumption
Inclination
WESTERBEKE GENERATORS
Diesel, 4-cycle, 3-cylinder, fresh water-cooled
Vertical, in-line overhead valve mechanism
(14 hp
at 1800 rpms maximum)
Mechanical, centrifugal weight type
Swirl chamber type
2.87 x 3.07 inches (73 x 78 mm)
60 cubic inches (0.979 liters)
1-3-2
Clockwise, when viewed from the front
41.50 Ib-ft (5.73 kg-m)
23 : I
455.2 psi (32 kg/cm2)
at 280 rpm
Intake Opens 18°
BIDC
Intake Closes 46° ABDC
Exhaust Opens 46° BBDC
Exhaust Closes 18°
AIDC
Intake 45°
Exhaust 45°
Intake 0.0098 inches (0.25 mm)
Exhaust 0.0098 inches (0.25 mm)
1800 rpm 60 Hertz
1500 rpm 50 Hertz
Height: 21.80 inches (553.72mm)
Width: 17.00 inches (431.80 mm)
Length: 28.20 inches (716.28 mm)
450 Ibs (204.12 kgs)
0.9 gph (3.40 Iph) at full rated
output (approximate)
Continuous 15°
Temporary 20° (not to exceed 20 min.)
14

SYSTEM SPECIFICATIONS
FUEL SYSTEM:
GENERAL
FUEL
FUEL INJECTION PUMP
FUEL INJECTION TIMING
NOZZLE
INJECTORS
FUEL PUMP
FUEL FILTER( on engine)
AIR
CLEANER
AIRFLOW
COOLING SYSTEM:
GENERAL
OPERATING TEMPERATURE
FRESH WATER PUMP
SEA
WATER PUMP
SEAW
WATERFLOW, AT 1800 RPM
(measured before discharging into
exhaust elbow.)
SYSTEM CAPACITY(Fresh Water)
LUBRICATION SYSTEM:
GENERAL
OIL FILTER
SUMP CAPACITY
OPERATING OIL PRESSURE (engine hot)
OIL GRADE
Open flow, totally self-bleeding
No.2 Diesel oil (cetane rating of 45 or higher)
Nippon Denso (Bosch M type)
19° BIDC ±D.5 (static timing)
Throttle type
Pintle type
12-Volt DC; Electro-Magnetic type
Canister type, with replaceable element
Metal-screen type
32 cfm (.906 cmm)
Closed fresh water-cooled block, thermostatically
controlled with heat exchanger.
Centrifugal type, metal impeller, belt-driven
Positive displacement, rubber impeller, belt-driven
8.5 gpm (32.2Ipm)
5 quarts (4.73 liters)
Pressure type by Trichoid pump, gear driven with
e>.'lernal pressure reliefvalve
Full flow, paper element, spin-on type
3.3 quarts (3.12 liters)
40 -80 psi (2.8 -5.6 kg/cm2)
API specification CC or CD
15 WESTERBEKE GENERATORS

SYSTEM SPECIFICATIONS CONTINUED...
ELECTRICAL SYSTEM
STARTING BATfERY
BATfERY CAPACITY
DC CHARGING ALTERNATOR
REGULATOR
STARTING AID
STARTER
DC NO-LOAD CURRENT
DC CRANKING CURRENT
ACGENERATOR
GENERAL
VOLTAGE
RATING (Volts AC)
60 HERTZ (1800 rpm)
8.0KW
50 HERTZ (1500 rpm)
6.0KW
GENERATOR COOLING AIR
REQUIREMENTS, (60 Hertz), at
1800 rpm
12-Volt, ( - ) negative ground
300-400 CCA
12·volt DC, 50 Amp
Internal regulator built into alternator
Glow Plug, sheathed type
12·volt, 1.2 KW, reduction type, solenoid mounted
90 Amp (max.) at 11.5 Volts
175 -200 Amps (engine cold)
Brushless, four-pole, revolving field.
Pre·lubricated single-bearing design.
Reconnectable, single-phase transformer regulation
(optional solid-state voltage regulation)
120
or 1201240 Volts -60 Hertz
220 Volts -50 Hertz
Voltage regulation:± 5 % no load to full load
Frequency regulation: ± 3 % Hertz (5%) no load to
full load
120 Volts
1201240 Volts
220 Volts
66 Amps
66/33 Amps
27 Amps
175 -200 cfm (4.95 -5.66 cmm)
NOTE: Increase air supply 15 % for 50 Hertz operation 1500 rpm.
WESTERBEKE GENERATORS 16

SYSTEM SPECIFICATIONS CONTINUED...
ENGINE COMBUSTION AIR
REQUIREMENTS (60 Hertz) AT
1800 rpm
ENGINE COMPARTMENT COOLING
AIR
TUNE UP SPECIFIC A TlONS
INJECTORPRESSURE
ENGINE TIMING
32 cfm (.906 cmm)
100-200 cfm (2.83 -5.66 cmm)
1707 psi (120 kg/cm2 + 10 kg/cm2 - 0 kg/cm2)
19° BIDC
17 WESTERBEKE GENERATORS

BTD 10.0 KW MARINE DIESEL GENERATOR SET GENERAL SPECIFICATIONS
Engine Type
Governor
Combustion Chamber
Bore & Stroke
Pistion Displacement
Firing Order
Direction
of Rotation
Maximum Torque (at 1800 rpm)
Compression Ratio
Compression Pressure
Valve Timing
Valve Seat Angle
Valve Clearance
(engine cold)
Engine Speed
Dimensions
Weight
Fuel Consumption
Inclination
WESTERBEKE GENERATORS
Diesel, 4-cycle, 3-cylinder, fresh water-cooled
Vertical, in-line overhead valve mechanism
(16.5 hp at 1800 rpms maximum)
Mechanical, centrifugal weight type
Swirl chamber type
3.07 x 3.07 inches (78 x 78 mm)
68 cubic inches (1.12 liters)
1-3-2
Clockwise, when viewed from the front
47.7Ib-ft (6.6 kg-m)
23 : 1
483.5 psi (34 kg/cm2) at 230 rpm
Intake Opens 18°
BIDC
Intake Closes 46° ABDC
Exhaust Opens 46° BBDC
Exhaust Closes 18° A
IDC
Iutake 45°
Exhaust 45°
Intake 0.0098 inches (0.25 mm)
Exhaust 0.0098 inches (0.25 mm)
1800 rpm 60 Hertz
1500 rpm 50 Hertz
Height: 22.00 inches (558.7mm)
Width: 16.85 inches (427.9 mm)
Length: 32.56 inches (827.02 mm)
495 Ibs (224.5 kgs)
1.0 gph (3.78Iph) at full rated
output (approximate)
Continuous 15°
Temporary 20° (not to exceed 20 min.)
18