Westerbeke BTDA 15.0 User manual

OPERATOR'S MANUAL
&
INSTALLATION GUIDE
WESTERBEKE
BTDA 15.0
KW -60 Hertz
BTDA 12.0
KW -50 Hertz
MARINE DIESEL
GENERATOR SET
Publication #038663
Edition One
August 1990
,~ WESJ'ERBEKE
WESTERBEKECORPQRATJON
AVONINDUSTRIAL PARK, AVON,,vA 02322. T£L.:(5"")588-77oo

SAFETY PRECAUTIONS
The following symbols appear in this manual to call
attention
to and emphasize conditions potentially
dangerous to the operator.
nWARNINGjI
The above symbol is used in the manual to warn of
possible serious personal injury orloss of
life.
ICAUTIONI
The above symbol is used in the manual to caution
personnel of possible damage to equipment.
Read the manual carefully and thoroughly before at-
tempting 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 resutt 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 off electric power before accessing electrical
equipment.
Use insulated mats whenever working on electrical
equipment.
Make sureyourclothing
is dry, notdamp (particular-
ly shoes), and keep your skin surfaces dry when
handling electrical equipment.
Remove wristwatch and jewelry 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 gen-
erator may resutt Hthis is not done.
Be extremely careful when working on electrical
components. High voltage can cause injury or
death.
• Exhaust Gases Are Toxic
Ensurethatthe exhaust systemisadequateto expel
gases discharged from the engine. Check exhaust
system regularly for leaks and make sure the
ex-
haustmanifolds are securelyattached and nowarp-
ing exists.
Be sure the unit and its surroundings are well-ven-
tilated.
15.0KWBTDA 1
• Use Extreme Care When Handling Engine Fuel
(A constant danger of explosion or fire exists)
Do not fill fuel tank(s) while the engine
is running.
Do notsmoke oruse an openflame nearthe engine
orthe fuel tank.
• Do Not Atter or Modify the Fuel System
Be sure all fuel supplies have a positive shut-off
valve.
Be certain fuel linefittings are adequatelytightened
and free of leaks.
Makesure afire extinguisher
is installed nearby and
is properly maintained. Be familiar with its proper
use. Extinguishers rated
ABC by the NFPA are ap-
propriate 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-ex-
plosive gas, which can be ignited by electrical ar-
cing or by a lighted cigarette, cigar, or pipe. Do not
smokeorallow
an openflame nearthe battery being
serviced. Shut off all electrical equipment
in the
vicinity to prevent electrical arcing during servicing.
• Ayoid MOYing parts
Do not service the unit while the unit is running; if a
situation arises
in which it is absolutely necessary
to make operating adjustments, use extreme care
toavoid moving parts and hot exhaust system com-
ponents.
Do notwearlooseclothing orjewelrywhen servicing
equipment; avoid wearing loose jackets, shirts or
sleeves, rings, necklaces, orbraceletsthat might
be
caught in moving parts.
Make sure all attaching hardware is properly
tightened. Keep protective shields and guards in
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

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 of the safety precautions indicated. Operating
procedures, periodic preventive maintenance procedures, installation checks, system descriptions
and minor adjustment procedures are included 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.
Product Software Disclaimer
Product software of
all kind; 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 wtthin 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 subassemblies incorporated in Westerbeke's products and supplied
by others (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 of Westerbeke or the supplier
in question be consulted to determine the accuracy
and currency of the product software being consulted by the customer.
Westerbeke Generators 2 15.0KWBTDA

Warranty Procedures
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 (figure
1.2) registering your warranty, please contact
the factory in writing with model information, including the unit's serial number and commission
date.
tno: IEST£RBEKE CORPORHIOII
AVOM INDU$TlUAL PARk
nON, IIA 02122
Mall To:
CUSTOMER IDENTIFICATION
.~ loIaph Str .. t
Alolu. U 12234
140 .... 1 IS III 'lbA
hpi .... 1nll9
figure 1.2: Customer Indentification Card
Unit 1.0. Plate
For future service,
repair or warranty ref-
erence, Westerbeke
suggests that you fill in
the blank spaces in fig-
ure
1.3 with the infor-
mation from your
machine.
15.0KW BTDA
•
figure 1.3: Unit I.D. Plate
3 Westerbeke Generators

Table Of Contents
Section
SAFTEY PRECAUTIONS
FOREWORD
PRODUCT SOFlWARE DISCLAIMER
WARRANTY PROCEDURES
GENERAL INFORMATION -
PROTECTING YOUR INVESTMENT
15.0 BTDA GENERAL SPECIFICATIONS
15.0 BTDA SYSTEM SPECIFICATIONS
INSTALLATION CHECKS
EXHAUST SYSTEM
RAW WATER INTAKE SYSTEM
COOLING SYSTEM
ENGINE CONTROL PANEL
REMOTE OPERATION
REMOTE PANEL
WIRING DIAGRAM # 36474
PREPARATIONS FOR STARTING
STARTING PROCEDURE
STOPPING PROCEDURE
FUEL SYSTEM
LUBRICATION SYSTEM
DC CONTROL CIRCUIT
WIRING DIAGRAM #36411
COOLING SYSTEM (FRESH WATER/RAW WATER)
BT GENERATOR
OPTIONAL VOLTAGE REGULATOR
Weslerbeke Generators 4
Page
1
2
2
3
11
12
13
14 • 16
18
23
27
28
29
30
31
34
35
38
40
45
47
51
56
62
15.0KW BTDA

Table Of Contents (continued)
1S.0KW BTDA
Section
SHORE POWER CONNECTIONS
3 PHASE BT GENERATOR
3 PHASE VOLTAGE REGULATOR
ENGINE TROUBLESHOOTING -
GENERATOR TROUBLESHOOTING
PERIODIC MAINTENANCE AND ADJUSTMENTS
TABLE OF STANDARD HARDWARE
TIGHTENING TORQUES
LAY-UP AND RECOMMISSIONING/WINTERIZING
SPARE PARTS
S
Page
64
68
69
74
77
78
64
86
90
Westerbeke Generators

AC
Water Injected
Exhaust Elbow
Westerbeke Generators
RIGHT SIDE OF GENERATOR
Fresh Water Fill Cap
Exhaust Manifold
Lube Oil Fill Cap
6
Water Temperature
Sender
\DC
Charging
Alternator
Belt Guard
15.0KW BTDA

LEFT SIDE OF GENERATOR
Fuel Pressure Gauge Lube Oil Dipstick
Water Temperature
Switch ___ ~.
Fuel
Fuel Filter
Raw Water Pu
.------~ .. ---
Oil Pressure Sender
Oil Pressure Switch
15.0KW BTDA 7
Preheat Solenoid
Switch
Control Panel
Generator Data
Plate
C Battery
Ground Connection
Starter with Solenoid
Lube Oil Filter
Westerbeke Generators

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15.1
Westerbeke Generators 8
15.0KW BTDA

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15.0KW BTDA
9 Westerbeke Generators

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Westerbeke Generators
10
15.0KW BTDA

15.0KW BTDA MARINE DIESEL GENERATOR SET GENERAL INFORMATION
Introduction
This manual contains equipment operating procedures and information to help the operator
maintain the marine equipment in proper working order. Study and follow the instructions
carefully. A planned maintenance program
is included in this manual. Adhering to the program
will resuH in better equipment performance and longer equipment me. Proper diagnosis of a
problem is the most important step to satisfactory repair; therefore, a troubleshooting table is
included.
Service And Parts Manuals
For in-depth maintenance and repair, the service manual for the 15.0KW
BTDA can be purchased
from your local dealer.
Product Description
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 of valves,
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 manatory, and frequent checking for contamination (that is, water,
sediment, or algae) 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.
Be careful not to put gasoline in the diesel fuel tank(s). Gasoline does not have the same
lubricating qualities
as diesel fuel; consequently, gasoline in the fuel lines will damage components
in the fuel injection pump and fuel injectors.
The diesel engine differs from the gasoline engine; however, in that the functions of the
carburetor and ignition system
are performed by the fuel injection pump and the fuel injectors.
Ignition results from a higher compression ratio which eliminates the need for spark plugs, but
neccitates the use of a heavier block.
15.0KW BTDA
11
Westerbeke Generators

Protecting Your Investment
The five most important steps to insure long engine
Ine are:
1. Proper Installation. In particular, the use of an anti siphon break to preclude raw water
intrusion into the engine via the exhaust elbow
is essential.
2. Avoid overcranking. This can fill the engine with raw water.
3. Change the lubricating oil.
4. Maintain the cooling system.
5. Winterizing your Westerbeke product.
Ordering Parts
Whenever you require replacement parts, always provide the generator model number designation
(I.e. 15.0 ~ BTDA) , engine serial number, and generator serial number as they appear on
the data plates located on the exhaust manifold and on the generator end.
You ~ provide
us with this information so
we may properly identify your generator set. In addition, include a
complete part description and part number for each part needed (see the separately furnished
Parts List). Also, be sure to insist upon Westerbeke factory packaged parts because "will fit"
or generic parts
are frequently not made to the same specifications as original equipment.
Note that component locations in the manual are referenced from the front of the engine which
is the pulley/drive bett end. (The flywheel/generator 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 of the engine: the left side
is at your left, the right side at your right.
Westerbeke generator sets
are thoroughly checked and given a final run under various load
conditions before leaving the factory. Test running the generator ensures dependable operation,
long service life, and a satisfied owner.
Care at the factory during assembly and thorough testing has resulted in a Westerbeke diesel
engine-driven generator capable of many thousands of hours of dependable service. However,
the manufacturer cannot control the installation of the generator in the vessel or the manner
in which the unit is operated and serviced in the field. That part is up to the buyer/owner-operator.
Westerbeke Generators
12 15.0KW BTDA

15.0 KW BTDA General Specifications
Engine Type
Governor
Combustion Chamber
Bore & Stroke
Piston Displacement
Firing Order
Direction of Rotation
Maximum Torque
(at 1800 rpm)
Compression Ratio
Compression Pressure
lim~
Valve Timing
Valve Seat Angle
Valve Clearance
(engine cold)
Engine Speed
Dimensions
Weight
Fuel Consumption
Inclination
15.0KW BTDA
Diesel, four·cycle, four-cylinder, fresh water-cooled,
vertical in-line overhead valve mechanism
(30 hp at 1800 rpm maximum).
Mechanical type (integral of the injection pump)
Swirl type
3.50 x 3.50 inches (88.9 x 89 mm)
134.8 cubic inches (2.209 I~ers)
1-3-4-2
Clockwise, when viewed from the front
148 Ib-It (20.46 kg-m)
21:1
427 psi (30 kg/cm2) at 200 rpm
384 psi (27.0 kg/cm2)
Intake Opens 17" BTDC
Intake Closes 47' ABDC
Exhaust Opens 51'
BBDC
Exhaust Closes 13' ATDC
Intake 45'
Exhaust 30'
Intake 0.012 inches (0.3 mm)
Exhaust 0.012 inches (0.3 mm)
1800 rpm 60 Hertz
1500 rpm 50 Hertz
Height: 25.74 inches (653.8
mm)
Width: 21.19 inches (538.2 mm)
Length: 39.63 inches (1006.6 mm)
765 Ibs (347 kgs)
1.8 gph (6.81Iph) at full rated output
(approximate)
Continuous
15' Temporary 20'
(not to exceed 20 min.)
13 Westerbeke Generators

15.0 KW BTDA System Specifications
Fuel System
General
Fuel
Fuel Injection Pump
Fuel Injection Timing
Nozzle
Fuel Filter PN#024363
Air cleaner
Air Flow (engine combustion)
Cooling System
General
Operating Temperature
Fresh Water Pump
Raw Water Pump
Raw Water Flow, at 1800 rpm
(measured before discharging
into exhaust elbow)
System Capacity (fresh water)
Lubrication System
General
Oil Filter PN# 035828
Sump Capacity (not including filter)
Operating
Oil Pressure (engine hot)
Oil Grade
Westerbeke Generators
Open flow, sen priming· one bleed point
No. 2 diesel oil (cetane rating of 45 or higher)
Distributor Type
(VE) Diesel KiKi
0" TDC (Top Dead Center)
Throttle type
Spin-on (Replaceable)
Metal screen type -cleanable
70.0
cfm (1.9 cmm)
Fresh water-cooled block, thermostatically-controlled
wtth heat exchanger.
170 -190" F (77 -88' C)
Centrifugal type, metal impeller, bett-driven
Positive displacement, rubber impeller, gear-driven.
6.0 gpm (22.7 Ipm)
10.0 qts (Itters)
Pressure fed system
Full flow, paper element, spin-on type
5.3 U.S. qts (5.0 Itters) plus filter/cooler assembly
50 - 65 psi (3.5 -4.57 kg/cm2)
API service CC - CD
14 15.0KWBTDA

15.0 KW BTDA System Specifications (continued)
Electrical System
Starting Battery
Battery Capacity
DC Charging Alternator
Starter
Starting Aid
DC No·Load Current
DC Cranking Current
AC Generator
General
60 Hertz (1800 rpm)
50 Hertz (1500 rpm)
Generator Cooling Air Requirements
(60 Hertz) at 1800 rpm
12·Vott, (-) negative ground
125 ampere·Hours
51 Amp rated, belt·driven
12·Volt, reduction
Glow plugs, sheathed type
± 2 % of rated Amps
280 Amps (engine cold)
Brushless, four·pole, revolving field.
Pre·lubricated, single·bearing design.
Reconnectable, single·phase transformer
regulation (optional solid·state voltage regulation).
Voltage120 or 120/240 Volts •
60 Hertz
220 Votts • 50 Hertz.
Voltage regulation: ±5% no load to full load.
Frequency regulation: ±3 Hertz (5%) no load
to full load.
Rating (Volts AC)
120 Volts125 Amps
120/240 Volts125/62.5 Amps
220 Volts60 Amps
225 • 250 cfm (6.37 • 7.08 cmm)
NOTE: Increase air supply 15% for 50 Hertz operation (1500 rpm).
Engine Combustion Air Requirements
(60 Hertz), at 1800 rpm 70 cfm (1.89 cmm)
15.0KW BTDA
15
Westerbeke Generators

15.0 KW BTDA System Specifications (continued)
Tune-up Specifications
Injector Pressure
Engine Timing
Governor
Generator Compartment
Ambient Temperature
1920 + 71 - 0 psi (135 + 5 - 0 kg/cm2)
Static timed -drop valve method
0.180 ± .005 inches BTDC
or
0° T.O.C. #1 cylinder.
1mm of cam lift using measuring device for
injection pump.
Hydraulic mechanical type in the injection pump
104° F (40" C) Maximum
NOTE: Forced ventilation should be provided as needed to maintain
generator compartment ambient temperature below 104° F.
Westerbeke Generators
16
15.0KW BTDA

General
Since the boats on which Westerbeke generators are installed vary in design, installation
procedures will vary according to your boat's specific design. The intent of this section
is
not to advise boatyards or installers on procedures already well-developed and well-understood.
However, the owner/operator must 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. Proper location and installation of the diesel generator
in the vessel are of prime importance.
Factors in the installation that must
be considered are: (1) ventilation; to aid in cooling the
generator end, to provide air for engine combustion and to remove heat produced by the
engine while operating,
(2) the e)(haust system; to properly discharge raw cooling water
and to quiet the exhaust and to expel exhausl
gas, (3) the cooling water supply, (4) the
electrical connections; both AC and DC, and (5) a fuel system that will provide an unrestricted
supply of properly filtered fuel to the fuel pump on the engine.
15.0KW BTDA
~AOTIONI
Fill The Engine With 011 Before Starting
For safety reasons, the generator's engine is not filled with lubricating
oil for shipment. Before leaving the factory, however, each generator
set
is thoroughly tested WITh oil in ITS engine. This testing, among other
things, provides
all internal parts with a coating of oil. This oil acts as
a preservative, providing reliable protection against corrosion for at least
one year ~ the generator is properly stored. Do not overfill.
Inspection of Equipment
The generator
is shipped from the factory securely mounted and properly crated. Accessory
equipment
is shipped in a separate small box, usually packed wtthin the generator's crate.
Before accepting shipment of the generator set from the transportation company, the crate
should be opened and the contents inspected for concealed damage. If damage is noted,
you should require the delivery agent sign "Received in damaged condition" on the proper
delivery receipt.
Also, check the contents of the shipment against the packing list and make
sure that the proper notation
is made ~ any discrepancies exist. These noted discrepancies
are your protection against loss
or damage. Claims concerning loss or damage must be
made to the carrier, not to Westerbeke Corporation.
17
Westerbeke Generators

Generator Mounting -Location
The complete generator
un~ is mounted on lightweight rails by means of four flexible isolatro
mouints that help prevent the transfer of vibration from the generator to the rails. Eachj
generator mounting
rail ahs several 1/2 inch boh holes so bohs can be employed to properly
secure the generator to its mounting platform.
figure 3.3: ~nerator Mounting
1/2-
MOUNTING
HOLES
The mounting location /llJ.lS1 be dry, above low-lying vapor areas, and in an area where bilge
water and water from above cannot splash or drip on the generator or drive engine. The drive
engine and generator
/llJ.lS1 be accessible for minor servicing and repairs. Access for major
repairs should be given consideration
as well. The generator set /llJ.lS1 be properly ventilated
to provide fresh cooling air for the generator end, for engine combustion needs, and to remove
heat produced by the engine while operating. The generator set needs fresh cool air
in whatever
location in the vessel ~ is installed. Hot generator discharge air /llJ.lS1 be removed from the
generator
area. The platform on which the generator and its mounting rails are located /llJ.lS1
be strong enough to support the generator during all angles of vessel operation.
15.0KW BTDA 18
Westerbeke Generators