Westerbeke BTG 8.5 User manual

OPERATORS MANUAL
. - .. ·,
- 8~:5;!Kw. BTG 50Hz ·6.8Kw BTG 50Hz
8.5Kw BTGA 6,0Hz 6.8Kw BTGA 50Hz
12.5Kw BTG 60Hz 10.0Kw BTG 50Hz
15.0Kw BTG 60Hz . 12.0Kw BTG 50Hz
MARINE GASOLINE GENERATORS
PUBLICATION #035909
REVISIONS
-MARCH2018
~,.._. rWESTERBEKE
J WESTERBEKE CORPORATION •150JOHN HANCOCK ROAD
J MYLES STANDISH INDUSTRIAL PARK • TAUNTON MA 02TBo
WEBSITE: WWW.WESTERBEKE.COM
am.,_.
NAIHA Member Ntditmal Marine MllnufacturersAssoclaJion
...... .

CALIFORNIA PROPOSITION 65
WARNING
Exhaust gas from diesel and
gasoline engines (and some of
its constituents) are known to
the state of California to cause
cancer, birth defects, and other
reproductive harm.
A WARNING:
Exhaust gasses contain Carbon Monoxide, an odorless and
colorless gas. carbon Monoxide is poisonoiiS and can cause
unconsciousness and death. SympfDms of Carbon Monoxide
exposure can include:
•Dizziness
•NaiiSea.
•Headache
• Weakness and Sleepiness
• Throbbing in Temples
• Muscular Twitching
• Vomiting
•Inability to Think Coherently
IF YOU OR ANYONE ELSE EXPERIENCE ANY OF THESE SYMPTOMS,
SET OUT INTO THE FRESH AIR IMMEDIAmY. If symptiJ!US persist,
seek medical attention. Shut down the unit and do not restart
until it bas been inspected and repaired.
A WARNING DECAL is provided by WESTERBEKE and
should be fixed to a bulkhead near your engine or
generator.
WESTERBEKE also recommends installing CARBON
MONOXIDE DETECTORS in the living/sleeping quarters
of your vessel. They are inexpensive and easily
obtainable at your local marine store.

Gasoline with an ETHANOL content
higher than 10°/o (E10) is not allowed
·and may void warranty.
AJ~ •WESTERBEKE™
~ Engines & Generators

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SAFETY INSTRUCTIONS
'INTRODUCTION
Read this safety manuol carefully. Most accidents are
causedbyfoilure to follow fundamental rules and
precautions. Know when dangerous conditions exist and
.toke the necessary precautions to protect yourself, your
perso~eJ.~ your machinBr!: _ .. _ _
As the.dftmer or ope(8toF, always~ the following ,safe#¥ roles
and advisories provided for your c:onvenience. 1his safely information
Is in af1g11menfwitft the~ Boat and Yacht Cormcil ( ABYC)
· stimdatd8; hovrevel; safety riSks are not limited to the lnfonnation
in the followilg pages. The responsNlyforthe ldenfilication of
potential E!rKI ar;:tual risks for comp(tanCe with all safety~~
l'1lfiln1enarlce aCiMlies. and other conditions belong eXClusiVely·
to the QWRef/operator.
:PREVENT ELECTRIC SHOCK
A WARNING: Do not. trlllt:h Ai: electrical CtJIIIIectitms
wblle engine is ruDlling, or when oolmecteil tD shore
power.l.etha/ voltage is present at th~ titJDllections!
1111 Do not operate tbis machinery withoutelectrical
enclosures and covers
in place.
111 Shut offelectrical ,power before accessing electrical
equipment
111 Use ilisulatedmats whenever working on electrical
equipment
111 Make sure yourclothing and skin are dry, not damp
(particularly shoes) when handling electrical equipment
Ill Remove wristwatch and all jewelry when working on
electrlca1 equipment
PREVENT BURNS- HOT ENGINE
A WARNING: Do llot-tDut:h hot engl11e parts or
exhallst system components. A tullning engine gets very
hot!
111 Monitor engine antifreeze coolant level at the plastic
coolant recovery tankandperiodically
at the filler cap
location on the waterjacketed exhaust manifold, but only
when the engine
is COLD.
A WARNING: Steam can cause injury or death!
1111 Incase of an engine overheat, allow the engine to cool
before touching the engine orchecking the coolant.
PREVENT BURNS- FIRE
IA WAJIIIIIIG: F/rB .......... /tljtlry Dr-
111 Prevent :6ash fires. Donot smoke orpermit flames or
sparks to occur nearthe carburetor, fuel line,
filter, fuel
pump, orother potential
sources of spilled fuel orfuel
vapors. Use a suitable container to catch all fuel when
removing the fuel line, carburetor, orfuel filters.
111 Do not operate with the air cleaner/silemcer removed.
Backfire can cause severe injury ordeath.
Ill Do not smoke orpermit flames or sparks to occur near
the fuel system.
Keep the compamnent and the
engine/generatorclean and free of debris to minimize the
chan~ of fire; Wipe up all spilled fuel and engine oil.
1111 Be aware- diesel fuel will burn.
PREVENT BURNS- EXPLOSION
.A WARNING: ExploslollS from fuel 'llllfJOI'S t:a11 t:aiiSII
injury or death!
1111 •Follow n>-fueling safety instructi.OJ:!S. Keepthe vessel's
hatches closed when fueling. Open
and ventilate cabin
afterfueling. Check below forfumes/vapor before
running
the blower. Run the blow~ for four minutes
before starting your engine. ··
111 All fuel vapors are highly explosive. Use extreme care
when handling and storing fuels. Store fuel ina well-
ventilated area away from spark-producing equipment
and
out of the reach of children.
-
Ill Donot fill the fuel tank(s) while theengine is running.
111 Shut'·off the fuel service valve atthe engine when servicing
the fue~ system. Thke care in ca~b4J.g any fuel that might
spill. DO NOT allow any smoKing, open flames, orother
SQl.n"ceS of fire near the fuel system or engine when
servicing. Ensure properventilation exists when servicing
the fuel system.
Ill Do not alter or modify the fuel system.
Ill Be sure all fuel supplies have a positive shutoff valve.
Ill Be certain fuel line fittings are adequately tightened and
free ofleaks.
1111 Make sure a fire extinguisheris installed nearby and is
properly maintained. Befamiliar with its
proper use.
Extinguishers ratedABC by the NFPA are apptopriate
for all applications encountered in ~ environment
Engines & Generators
i

SAFETY INSTRUCTIONS
ACCIDENTAL STARTING
A WARNING: Accidental starting can cause injury
or death!
• Thm OFF the DC breaker on the control panel or tum the
unit's battery selector switch to OFF before servicing the.
engine.
• Make certain all personnel are clear ofthe engine before
starting.
• Make certain all covers, guards, and hatches are
re-installed before starting the engine.
BAnERY EXPLOSION
A WARNING: Battery explosion can cause Injury
or death!
• Do not smoke or allow an open flame near the battery
being serviced. Lead
acid batteries emit hydrogen, a
highly explosive
gas, which can be ignited by ele~cal
arcing or by lit tobacco products. Shut off all electncal
equipment in the
vicinity to prevent electrical arcing
during servicing.
• Never connect the negative(-) battery cable to the
positive (+) connection terminal of the starter solenoi?.
Do not test the battery condition by shorting the termmals
together. Sparks could ignite battery gases or fuel vapors.
Ventilate any compartment containing batteries to prevent
accumulation ofexplosive
gases. To avoid sparks, do not
disturb the battery charger connections
while the battery
is being charged.
• Avoid contacting the terminals with tools, etc., to prevent
burns or sparks that could cause
an explosion. Remove
wristwatch, rings,
and any otherjewelry before handling
the battery.
• Always turn the battery charger off before disconnecting
the battery connections .. Remove the negative lead first
and reconnect it last when servicing the battery.
BATTERY ACID
A WARNING: Sulfuric acid in batteries can cause
severe injury or death!
• When servicing the battery orchecking the electrolyte
level, wear rubber gloves, a rubber apron, and eye
protection. Batteries contain sulfuric acid which is
destructive. If it comes in contact with your skin, wash
it offat once with water. Acid may splash on the skin or
into the
eyes inadvertently when removing electrolyte
caps.
TOXIC EXHAUST GASES
A WARNING: Carbon monoxide (CO} Is a deadly gas!
• Ensure that the exhaust system is adequate to expel gases
discharged from the engine. Check the exhaust system
regularly for leaks and make sure the exhaust manifold/
water-injected
elbow is securely attached.
• Be sure the unit and its surroundings are well ventilated.
Run blowers when running the generator set or engine.
• Do not run the generator set or engine unless the boat is
equipped with a functioning marine carbon monoxide
detector that complies with ABYC A-24. Consult your
boat builder ordealer for installation of approved
detectors.
• For additional information, refer to ABYC TH-22
(educational information on Carbon Monoxide).
A WARNING: Carbon monoxide (CD} is an invisible
odorless gas. Inhalation produces flu·llke symptoms,
nausea or death!
• Do not use copper tubing in diesel exhaust systems.
Diesel fumes can rapidly destroy copper tubing in exhaust
systems. Exhaust sulfur causes rapid deterioration of
copper tubing resulting in exhaust/water leakage.
• Do not install exhaust outlet where exhaust can be drawn
through portholes, vents, or air conditioners. If the engine
exhaust discharge outlet is near the waterline, water could
enter the exhaust discharge outlet and close or restrict the
flow ofexhaust. Avoid overloading the craft.
• Although diesel engine exhaust gases are not as toxic as
exhaust fumes from gasoline engines, carbon monoxide
gas is present in diesel exhaust fume~. S?me of. the
symptoms or signs of carbon monoXlde mhalation or
poisoning are:
Vomiting
Dizziness
Headache
Inability
to think coherently
Throbbing in temples
Muscular twitching
Nausea
Weakness and sleepiness
AVOID MOVING PARTS
A WARNING: Rotating parts can cause injury
or death!
• Do not service the engine while it is running. If a
situation arises in
which it is absolutely necessary to
make operating adjustments, use extreme care to avoid
touching moving parts and hot exhaust system
components.
Engines & Generators
ii

SAFETY INSTRUCTIONS
1!11 Do not wear loose clothing or jewelry when servicing
equipment; tie back long hair and avoid wearing loose
jackets, shirts, sleeves, rings, necklaces or bracelets that
could be caught in moving parts.
1:1 Make sure all attaching hardware is properly tightened.
Keep protective shields and guards in their respective
places at all times.
19 Do not check fluid levels or the drive belt's tension while
the engine is operating.
!1il Do not allow any swimming or activity around or near
the exhaust discharge opening for the generator while the
generator is operating. Carbon Monoxide poisoning or
death can occur.
4kW:«\RNING: High noise levels can cause hearing
I(J~!
II Never operate an engine without its muffler installed.
1'1 Do not run the engine with the air intake (silencer) or
flame arrester removed.
1!11 Do not run engines for long periods with their enclosures
open {when installed).
A WARNING: Do not work on machinery when you are
mentally or physically incapacitated by fatigue!
OPERATORS MANUAL
Many of the preceding safety tips and warnings are repeated
in your Operators Manual along with other <;autions and
notes to highlight critical information. Read yoU:r manual
carefully, maintain your equipment, and follow all safety
procedures.
GASOLINE ENGINE AND GENERATOR INSTALLATIONS
Preparations to install agasoline engine or generator should
begin with a thorough examination oftheAmerican Boat and
Yacht Council's (ABYC) standards. These standards are· from
a combination of sources tnc~uding the USCG and the NFPA.
Sections ofthe ABYC standards ofparticular interest are:
H-2 Ventilation .for Boats using Gasoline
· H-24 Gasoline Fuel' Systems
P-1 Installation of Exhaust Systems
for Propulsion and Auxiliary Engines
P-4 ;M:arine Inboard Engines and Transmissions
EllAC
and DC Electrical Systems on Boats
All installations must comply with the Federal Code of
Regulations (FCR).
www.abycinc.org
ABYC, NFPA AND USCG PUBLICATIONS FOR
INSTALLING ENGINES AND GENERATORS
Read the following ABYC, NFPA and USCG publications
for safety codes and standards. Follow their recommenda-
tions .when installing your engine.
AB:YC (American Boat and Yacht Council)
"Standards and Technical Information Reports for Small
Craft"
Order from:
ABYC
613 Third Street, St1ite 10
Aprtapolis, MD 21403
www.abycinc.org
NFPA- No.302 (National Fire Protection Association)
"Pleasure and Commercial Motor Craft"
Order
from:
National Fire Protection Association
Battery Match Park
Quincy, MA02269
USCfl(Uritted States Coast Guard)
"regulatedions are under titles
CFR33 and CFR46 of the
Code ofRegulations"
Order from:
U.S. Government Printing Office
Washington, D.C. 20404
Engines & Generators
iii

INSTALLATION
When installing WESTERBEKE engines and generators it is important that strict
attention be paid to the
following information:
CODES AND REGULATIONS
Strict federal regulations, ABYC guidelines, and safety codes must be complied with
when installing engines and generators in a marine environment.
SIPHON-BREAK
For installations where the exhaust manifold/water injected exhaust elbow is close to
or
will be below the vessel's waterline, provisions must be made to install a siphon-
break in the raw water supply hose to the exhaust elbow. This hose must be looped a
minimum of 20" above the vessel's waterline. Failure to use a siphon-break when
the exhaust manifold injection port is at or below the load waterline wiU result in
raw water damage to the engine and possible flooding of the boat.
If you have any doubt about the position of the water-injected exhaust elbow relative ·
to the vessel's waterline under the vessel's various operating conditions, instaU a
siphon-break.
•.
NOTE: A siphon-break requires periodic inspection and cleaning to ensure proper
operation. Failure to properly maintain a siphon-break can result in catastrophic
engine damage. Consult the siphon-break manufacturer for proper maintenance.
AVAILABLE FROM
YOUR WESTERBEKE
'DEALER
EXHAUST SYSTEM
:·s/PHON4fREAiWirif STAINLESS
LOOP'
The exhaust system's hose MUST be certified for marine use. Corrugated Marine
Exhaust
Hose is recommended. The use of this type ofhose allows for extreme bends
and turns without the Iieed ofadditional fitting and clamps to accomplish these bends
and turns. In this regard, a single length of corrugated exhaust hose can be used. The
system MUST be designed to prevent the entry of water into the exhaust system
under any sea conditions and at any angle of vessels heel.
A detailed Marine Installation Manual covering gasoline and diesel,
engines and generators, is supplied with each unit. A pdf is available
to download from our website at www.westerbeke.com.
Engines & Generators
iv

TABLE OF CONTENTS
Parts Identification .................................................... 2
Introduction ................................................................ 4
Fuel, Engine 011, and Engine Coolant ........................ s
Control Panels ............................................................ 6
Operating Instructions ................................................ 7
Generator Break·ln Procedure ................................... 8
The Dally Routine ....................................................... 8
Alarms and Circuit Breakers ...................................... 9
Maintenance Schedule ............................................. 10
Fuel System .............................................................. 12
Fuel Lift Pumps.....................................................
12
Gasoline/Water Separator......................................12
Cooling System ......................................................... 13
Changing Coolant..................................................13
Heat Exchanger .....................................................14
Replacing the Thermostat......................................14
Raw Water Intake Strainer ....................................15
Raw Water Pump...................................................15
Engine Lubricating Oil .............................................. t6
Changing the Oil Filter..........................................16
Remote 011 Filter ...................................................... 17
Carburetor Adjustments ........................................... 18
Engine Adjustments .................................................. 19
Electric Choke.......................................................19
Engine Compression..............................................19
Ignition Wires ........................................................19
Valve Clearance.....................................................20
Oil Pressure ...........................................................20
Spark Plugs............................................................21
Drive BeltAdjustment...........................................21
Govemor................................................................
22
Alternator Testing .................................................... 23
12 Volt DC Circuit................................................. 23
Engine Troubleshooting ............................................ 25
Lay-up and Recommissioning ................................. .27
Wiring Diagrams and Schematics ....................... 28-3S
Generator Information .............................................. 36
BT Generator Description ......................................... 37
12 Stud Internal Wiring Schematic ......................... 38
BT Single Phase Wiring Schematic .......................... 39
Voltage Regulator Adjustments ............................... 40
BT Generator Troubleshooting ............................ 41-50
BTGJBTGA 8.5Kw Speclfications .............................. S1
BTG 12.5Kw Specifications ........................................ 53
BTG 15.0Kw Speclficatlons ........................................ ss
Metric Conversion Data .............................................. 57
Engines & Generators
1

J.D. PLATE
RAW WATER PUMP
FRONT
STARTER
12.5KW BTG 15.0KW BTG
GASOLINE GENERATOR
AC CONNECTIONS PORT
RH SIDE
PARTS IDENTIFICATION
AIR INTAKE
FLAME
LUBE OIL FILL
LH SIDE
OIL FILTER
SIPHON BREAK
CONNECTION
LUBE OIL FILL
Engines & Generators
2
DISTRIBUTOR
WATER INJECTED
ELBOW
BT GENERATOR
REAR
20A CIRCUIT
BREAKER
ANODE
HEAT EXCHANGER