Westerbeke BTDA 12.0, Operator'S Manual & Installation Manual

Page 1: ...ALLATION 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 AVON INDUSTRIAL PARK AVON vA 02322 T L 5 588 77oo ...

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Page 3: ...the ex haust manifolds are securely attached and no warp 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 not smoke or use an open flame near the engine or the fuel tank Do Not Atter or Modify the Fuel System Be sure all f...

Page 4: ...ftware 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...

Page 5: ... 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 ...

Page 6: ... 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...

Page 7: ...E 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 ...

Page 8: ... 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 ...

Page 9: ...k 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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Page 13: ...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...

Page 14: ...aged 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 ...

Page 15: ...echanical 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...

Page 16: ...essure 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 drive...

Page 17: ...d 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 Amp...

Page 18: ...5 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 ...

Page 19: ... 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 protec...

Page 20: ... 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 ...

Page 21: ...o lift the engine in posi tions other than the horizontal posttion Certain sttuations exist by which the engine must be lowered endwise through a small hatchway which cannot be made larger Under these conditions ff the opening of the hatchway is extremely small tt is possible to reduce to some extent the outside dimensions of the generator by removing external components such as the cooling system...

Page 22: ...eter and there should be a primary fuel filter water separator installed between the fuel tank and the fuel pump Only one fuel filter is in stalled on the engine between the fuel pump and the injection pump this filter has a replaceable filter element The fuel tank s fuel pickup tube should be clear and unobstructed No screens or gauze strainers should be incorporated in the fuel pickup tube Make ...

Page 23: ... engine oil pressure these devices mug be bulkhead mounted and connected to the oil gallery using an appropriated grade of lubricating oil hose Any fittings used to con nect the hose to the gallery mug be of steel or malleable iron composttion Brass must not be used for this application Electrical System The electrical system should be checked to make sure all wiring harnesses are properly tied do...

Page 24: ...re the positive battery connection is connected to the battery connection of the starting solenoid The negative battery connection should be connected to the ground stud tagged at the rear of the engine block WARNiNGJ Protect Yourself When Servicing The Battery When servicing the battery of checking the electorlyte level wear rubber gloves a rubber apron and eye protection Battery acid may splash ...

Page 25: ...erience heeling rolling or pitching Special atlention be taken to make certain the exhaust system is secure tight and free of leaks The raw water supply through hull sea cock fittings be of the flush hull type High speed scoop types or weedless scoop types must not be used as they tend to encourage siphoning of raw water through the cooling system filling the exhaust When a water lift type exhaust...

Page 26: ... always be above the water line during all angles of vessel operation to prevent siphoning The vent when used have its vent hose or tube routed so it can remain above the water line and empty of water when the engine is shut down This allows air to enter through this vent to prevent siphoning 15 0KWBTDA Dry stack type exhaust systems figure 3 13 6 must be attached to the generator engine s exhaust...

Page 27: ... two Now slip the exhaust clamp over both flanges 3 A Tighten the clamp just enough 38374 Elbow figure 3 14 Exhaust Elbow Installation so the exhaust elbow can remain attached to the manHold and still be rotated B The exhaust elbow discharge be directed downward so the mixture of raw water and exhaust gases will flow fall downward into the exhaust muffler which must be positioned below the exhaust...

Page 28: ...e the engine s back pressure at the exhaust elbow while the generator is under a full load Insulation Exhaust Elbow H Exhaust n I Mercury Manometer Refer to the pressure specifications listed below A water column can be made by taking a clear plasticfigure 3 15 1 Exhaust Elbow Connections tube and taping one end of the tube along a yardstick and fitting the other end of the tube w h a 1 8 inch NPT...

Page 29: ...ng in damage and or internal leaks Inspect insulated portions of the exhaust system to ensure there is no deterioration of the insulation ICAUtloN Do Not Overcrankl Prolonged cranking intervals without the engine starting can resu in filling the exhaust system with raw water coolant This may happen because the raw water pump is pumping raw water through the raw water cooling system during cranking...

Page 30: ...essure against this type fitting while the vessel is under way can push raw water past the raw water pump s impeller into the generator s exhaust system filling tt and the engine as well Flush type clear through hull fittings are recommended and should be located on the hull so as to be below the waterline during all angles of boat operation The use of common type street elbows is not recommended ...

Page 31: ...he engine s glow plugs activates the electric fuel pump bypasses the engine s oil pressure sw ch and activates the fuel run solenoid This switch also energizes the START sw ch 2 START The START switCh when pressed energizes the starter s solenoid which cranks the engine This switch will not operate electrically unless the PREHEAT switch is pressed and held at the same time 3 STOP Power is provided...

Page 32: ...ges When starting at a remote location the green LED comes on when the generator is running at approximately 600 rpm This indicates when the START sw ch can be released since the starting of the generator may not be audible from the remote location 0 GENERATOR 0 0 RELEASE STARTER STOP PREHEAT START PRESS 1ST I 2ND 0 WESTERBEKE 0 figure 4 2 Remote Control Instrument Panel Westerbeke Generators 30 1...

Page 33: ...TI C on st nTt 15 amps startln 3 amps runnini L 114 Rr d 14 Red _____________________j__________ h e_ 52 amp surce on start 15 amps Iiltartinl _ _ _ _ _ _ _ _ _ _ J amps running P N 21 91 3 figure 4 3 Remote Control Insrument Panel Wiring Diagram TBl l TBI GND TR2 2 TBl 2 TBl 4 Figure 4 3 illustrates the DC wifIng connections to be made between the engine mounted control panel and a remote Start S...

Page 34: ...63 260 8 t 21 7 32 7 52 7 82 7 131 210 35 3 56 3 89 6 143 227 9 i 19 3 28 7 46 7 73 3 116 186 300 31 7 SO 3 79 6 127 202 321 10 i 17 3 26 42 66 105 j 168 271 28 3 45 3 72 114 182 289 15 17 3 28 44 70 112 180 285 19 30 48 76 121 193 306 20 21 33 52 7 83 7 135 211 22 7 36 57 91 145 230 30 I 22 35 56 90 3 142 24 38 60 7 96 3 153 243 306 40 j 26 3 42 67 3 107 28 3 45 3 72 115 182 230 SO I 21 33 7 54 8...

Page 35: ... resu is a rapid start with less wear on the starter This system is common to Westerbeke Diesels The start circuitry is designed so that the PREHEAT button must be depressed for the time specified in the Preheat Table figure 4 7 1 Then while keeping the PREHEAT button engaged the START button is depressed to crank the engine 15KW BTDA GLOW PLUG figure 4 5 Combustion Chamber NOTE The START switch w...

Page 36: ...ve the coolant level in the manUold Maintain this level to the base of the filler neck Once the engine reaches s operating temperature 170 190 F make sure there is no problem w h coolant flow through the manifold Top off the cooling system and install the pressure cap B Make sure the plastic recovery tank is properly mounted near the unit figure 3 19 page 28 in a location where can be monitored an...

Page 37: ...engine to continue to run NOTE Should the engine not start when the START sw ch is depressed for 10 12 seconds release both sw ches and wait 30 seconds repeat the previous procedure Never run the starter motor for more than 30 seconds at a time 3 Check all the instruments on the panel for proper operation and make sure raw water discharges with the exhaust discharge once the engine starts Once the...

Page 38: ...or should keep this in mind Remote Starting Procedure The remote Start Stop panel figure 4 2 has three switches that serve the same functions as on the engine mounted Start Stop panel figure 4 1 it has a green LED light and no gauges When starting at a remote location the green LED comes on when the generator is running at approximately 600 rpm This indicates when the START switch can be released ...

Page 39: ... the Starting Procedure instructions in this manual and allow the engine s operating temperature to reach into the 140 150 F range before placing a load on it Starting Under Cold Conditions Under extremely cold temperatures the following conditions can occur Follow the instructions listed below when operating your engine in cold weather Lubricating Oil Turns Viscous Make certain that the lubricati...

Page 40: ... Exhaust Temperature Shutdown Switch normally closed An exhaust temperature switch is located on the exhaust elbow Should the switch s sensor indicate an excessive exhaust temperature the switch will open and shut the generator off an inadequate supply of raw water coolant causes high exhaust temperatures This switch opens at 260 2700 F 127 13 C and resets at approximately 2250 F 10 0 C High Water...

Page 41: ...ntii the freshwater temperature gauge moves into the 130 150 F range 3 Use caution not to overload the generator The presence of a gray or black exhaust with loss of engine rpm hertz are signs of a possible overload 4 Run the generator at 1 2 of its rated capacity for the first 10 hours then increase the load to 3 4 of its rated capacity For the remainder of the break in period the generator may b...

Page 42: ...ric lift pump mounted on the engine figure 5 1 Fuel System Diesel Fuel Use No 2 diesel fuel WITh a cetane rating of 45 or higher Never use kerosene or home heating oil since these fuels do not have the same lubricating properties as No 2 diesel fuel In cold weather particularly water vapor is produced by condensation when air is present in the fuel tank Keep fuel tank s full and completely free of...

Page 43: ...bly and injectors as gasoline does not have the same lubricating qualities as diesel fuel Priming the Fuel System One Bleed Point The on engine fuel system is nearly se bleeding See figure 5 8 There is one bleed point in the on engine fuel system to open for the removal of air This bleed screw is located on the housing for the spin on fuel fitter mounted on the engine This bleed point is an 11 mm ...

Page 44: ...ep a fuel system hardware kit onboard to use in correcting minor fuel system leak_s and for maintenance needs Fuel Lift Pump The engine mounted fuel pump filter element should be changed initially aiter the fisrt 50 hours of engine operation and then every 200 hours or at least once a season Remove the fuel pump s base using a 17mm open end wrench Take care in catching the filter element and fuel ...

Page 45: ... used in a generator application The injection shop will have to remove a timing shim located behind the oval cover attached to the lower side of the injection pump and replace the governor spring with a propulsion spring Once the injector pump is set up to propulsion specifications the generator governor spring PN 024585 and the timing shim PN 032021 are reinstalled in the injection pump and the ...

Page 46: ... the engine to overcome and maintain a positive pressure then an auxiliary booster fuel pump and or fuel day tank is required Otherwise poor operating performance will resutt Typical symptoms of the generator s engine run ning without positive fuel pressure at the inlet of the injection pump are listed below A the presence of white exhaust smoke and fuel laden exhaust B A rough running engine Maua...

Page 47: ...68 F 20 C or higher SAE 30 or 10W 30 41 F 5 C 68 F 20 C SAE 20 or 10W 30 41 F 5 C or lower SAE 10W 30 figure 5 10 Engme Od VISCOSity NOTE Do not use an engine lubricating oil w h an SAE number greater than 30 in the engine 011 Pressure The engine s oil pressure during operation is indicated by the oil pressure gauge on the instrument panel figure 4 1 During normal operation the oil pressure will r...

Page 48: ...ould be helpful in removing the old oil filter Place some paper towels and a plastic bag around the filter when unscrewing tt to catch any oil left in the filter Oil or any other fluid on the engine reduces the engine s cooling ability Please keep your engine clean Inspect the old oil fitter as tt is removed to make sure that the rubber sealing gasket came off with the old oil filter If this rubbe...

Page 49: ...r Oil Dipstick lower figure 5 13 1 Oil Levels The DC circuIT on the 15 0 BTDA 614 12 0BTDA 514 functions to start operate and stop the generator dirve engine The circuIT is best understood by reviewing the DC schematic 036411 for the model as shown on figure 5 18 The engine mounted DC control panel has three switches used in the starting and stop ping of the drive engine Four gauges are mounted in...

Page 50: ...aragraph 4 13 to understand the oprating characteristics of the three switches I CAUTION I Never Shut Off the Engine Battery Switch While the Engine Is Running To avoid damage to the battery charging circuit never shut off the engine battery switch while the engine is running Shut off the engine battery switch however to avoid electrical shorts when working on the engine s electrical circuit Batte...

Page 51: ...figure 5 17 15 0KWBTDA 15 0 KW BTOA DC Control Circuit Wiring Diagram 036411 page 1 of 2 t r n T r J i t G l Oo SWIll I I 9 i i 1 DC Control Circuit Wiring Diagram 036411 Part 1 49 Westerbeke Generators ...

Page 52: ...the breaker to trip In this event most generators will shut down because the opened breaker disconnects the fuel supply Therefore the builder owner must be sure that the instrument panel wiring and engine are installed to prevent contact between electrical devices and raw water NOTE An on off switch should be installed in this circun to disconnect the starter from the battery in an emergency and w...

Page 53: ...from the fresh water to raw water by means of a heat exchanger similar in function to an automotive radiator Raw water flows through the tubes of the heat exchanger while fresh water flows around the tubes engine heat transferred to the fresh water is conducted through the tube walls to the raw water which is then pumped into the exhaust system where finally it is discharged overboard In other wor...

Page 54: ... by the contraction of the engine coolant allowing some of the coolant in the recovery tank to be drawn back into the engine s cooling system free of air and wtthout loss Periodically check that the passage figure 5 19 4 between the 90 fitting on the mannold and the filler neck in the manifold is clear so coolant can flow in either direction FUNCTION OF MANIFOLD PRESSURE CAP From Coolant Tank COOL...

Page 55: ...d M ARNiNGI Never attempt to adjust the drive beWs tension while the engine is in operation PAOTIONI Check Water Pump Belt Drive Tensionl Excessive water pump drive be tension can cause rapid wear of the beit and reduce the service life of the fresh water pump s bearings Excessive slack or the presence of oil on the beit can cause beit slipping resulting in high operating temperatures The water pu...

Page 56: ...he manifold and allow enough time for the coolant to fill the fresh water cooling system 3 Start the engine and allow it to come up to its operating temperature Monttor the coolant in the manifold and add antifreeze coolant as air is expelled Once all air is expelled from the system fill the manifold to the filler neck and install the pressure cap 4 Remove the plastic cap from the plastic coolant ...

Page 57: ...hanger where the zinc anode is posnioned as this debris lays in front of these tube ends and blocks them Zinc Anode A zinc anode or pencil is located in the raw water cooling circuIT wIThin the heat exchanger The purpose of the zinc anode is to sacrifice ITseH to electrolysis action taking place in the raw water cooling circuIT thereby reducing the effects of electrolysis on other components of th...

Page 58: ...mp s housing Replace the gasket and install the cover BT Generator en c u figure 5 26 Raw Water Pump This generator is a four pole brushless self excited generator which requires only the driving force of the engine to produce AC output The copper and laminated iron in the exciter stator are responsible for the seff exciting feature of this generator The magnetic field produced causes an AC voltag...

Page 59: ... Stator Windings 2 Main Stator Windings 3 Main Stator Auxiliary Windings F SELECTOR SWITCH F 1 SWITch in Compound Position Bl While To Pi 8 T a Block To Berta YolL Bar Yen I_hU L J 4Y __r IT S ledol Swncb Black hit A V R PLUG B EXCITER ROTOR 1 Auxiliary Windings A B C 2 Diodes 6 3 Rotating Field Windings 4 Pozi Resistor D COMPOUND TRANSFORMER 1 Compound Transformer Windings 2 Compound Transformer ...

Page 60: ...y the generator alter this momentary load is removed is no load vottage If this vottage does not fall within the specified range sut down the engine and adjust the vottage 3 To raise or lower the vottage shims of varying thickness non conductive material are placed or removed from under the steel laminated bar on top of the compound transformer The material used for shimming should not soften at t...

Page 61: ...e in accordance wtth figure 5 30 B Place this wire to connect with wire 5 Wire 6 5 3 I I To AC To AC terminal terminal block block figure 5 30 A 50 Hz Operation Place this wire to connect with wire 6 Wire 6 5 3 I I To AC To AC terminal terminal block block figure 5 30 B 60 Hz Operation Westerbeke Generators 59 2 1 Vo lage Hertz Connection Bar Vo tage Hertz Connection Bar 15 0KWBTDA ...

Page 62: ... figure 5 30 2 Select the correct ground stud B Reposition the wire on the vottage hertz connection bar to correspond to the hertz selected figure 5 30 A or 5 30 B C Start the engine monitor vottage and adjust engine no load speed Adjust the throttle arm or the throttle stop screw to produce engine speed desired figure 5 36 1 Frequency range 60 hertz 50 hertz no load frequency range no ioad freque...

Page 63: ...sttioning the two leads from Z to M or Xl will change the full load output vottage figure 5 30 7 Wire 6 I To AC terminal block Connect to wire 1 2 or 3 progressively until output voltage Is r _____ ePtable limits I I 5 3 2 1 I To AC terminal block VoltageiHertz Connection Bar figure 5 30 3 Increasing Full Load Output Voltage NOTE No load voltage may be effected requiring readjustment wtth the comp...

Page 64: ...e regulator board 2 Connect the 6 prong generator plug to the receptacle on the regulator board NOTE The plug is keyed to engage the regulator receptacle in one direction Check this and insert it correctly 3 Before moving the selector switch to the ELEC position the NO Load vottage produced by the generator when in the COMP position will have to be adjusted The NO Load vottage should be adjusted d...

Page 65: ...le throttle stop screw lock wiring h at that poshion and tensioning the throttle stop screw against the throttle lever and securing h whh its lock nut Throttle L r _ J e Injection Pump figure 5 36 1 Engine Speed Generator Hertz Adjustment for Diesel Models with Distributor Type Injection Pumps Viewing figure 5 36 1 Moving the throttle lever to the right increases engine speed hertz and moving the ...

Page 66: ... shore power and generator output are connected at the same time This type of generator damage is not covered under the warranty n is the installer s responsibility to make sure all AC connections are correct Generator NOTE The diagram shows connections for two wir 120 Volt system For three wlr system us dotted line for the other hot legs 10 _ I I I I I I I I I L L2 i L1 Neutral r N t o n ________...

Page 67: ... to the exciter circuit components in the generator Generator A H G1 NOTE The diagram shows connectlona or two wire 120 Volt ystem from the generato with thr wlre 120 Volt boat system i z G 4 E t j r 2 V L I L2 L I L1 Neutral E r H 10 White j r o n _ ____ lil S2S1H J v Shore Power figure 5 38 120V 60Hz Three Wire Configuration Westerbeke Generators 65 Ship s LOAD Shlp To Shor Switch 3 Pol PH 32008...

Page 68: ... Switch PN 32008 PN 32009 PN 32010 PN 32133 Generator Shore Switch co iii 1 3 2 I _ L1 Ship s LOAD s I N Neutral _7 6 I _ l L1 NJ T Shore Power 220V 50Hz Shore Ground Ship s Ground figure 5 39 220V 50Hz Two Wire Configuration Note the repositioning of the white ground lead on the terminal block to the generator case 1S OKWBTDA 66 Westerbeke Generators ...

Page 69: ...To Shore Switch PN 32008 PN 32009 PN 32010 PN 32133 Generator Shore Switch I i L1 r 3 Ship s LOAD L J s N Neutral 7 6 I I L1 NJ T Shore Power 110V 50Hz Shore Ground figure 5 40 nOV 50Hz Two Wire Configuration Ship s Ground Note the repos ioning of the white ground lead on the terminal block to the generator case Westerbeke Generators 67 15 0KWBTDA ...

Page 70: ...gs DC Charging Circuit 2 7 Main Stator Windings 3 Auxiliary Windings AC to Regulator E DC CONTROLLER r I e I FOSE E STATOR I 20 A S OD rl I55 1 1 12 A I I B ROTOR I I FUSE 8 3 1l e n B 7 k L 4 B g 1 Auxiliary Exciter Windings A B C 2 Diodes 6 3 Main Rotor Windings 4 Pozi Resistor D BRIDGE RECTIFIER F VOLTAGE REGULATOR BOARD figure 5 50 3 Phase BT Internal Wiring Schematic Westerbeke Generators 68 ...

Page 71: ...l ternator performacne It is equipped with complete protection circuitry to guard against operating conditions that could be detrimental to the AC atternator j 6 5 l Il 4 o 0 LED S 3 Red c 0 DoD 2 Green C J 1 Yellow C 0 B Paten tiolTIeters I Hz n Axnp Stab J Volt J80 BII 1 1 IV 0mr figure 5 60 BT 3 Phase Voltage Regulator 15 OKW BTDA 69 Westerbeke Generators ...

Page 72: ...njunction with the two protection circuits in the vottage regulator that are indicated by the illumination of a colored LED 1 Delayed overload protection yellow LED 2 Low speed protection red LED Each system has an intervention threshold which can be adjusted using a potentiometer Each of the two circuits reduces excitor vottage to safeguard the excitor windings and prevent overheating The overloa...

Page 73: ...0YAC 60HZ L L nOYAe 39 50 HZ L2 L3 H HOYAt 50 HZ The regulator is equipped with seven numbered terminals and related brass jumpers Figure 5 70 1 shows the connection points and jumpers for the 3 phase configuration of the generator The sensing leads connect between pin 1 and pin 2 on the AC terminal block and connection 2 and 0 on the vonage regulator board 15 0KWBTDA NOTE Series Dena requires the...

Page 74: ...o it An electric motor connected to an air compressor for example will require more current than a_ motor to which no load is connected In general the current required to start 115 volt motors connected to medium starting loads will be approximately as follows MOTOR SIZE AMPS FOR AMPS FOR HP RUNNING STARTING Amperes Amperes 110 3 2 6 4 to 22 4 1 4 4 6 9 2 to 32 2 1 5 2 10 4 to Il 1 I 14 4 to 4 lU ...

Page 75: ...ies If an AC voltmeter or ammeter is not installed to monitor voltage and load check with a portable meter NOTE When the vessel in which the generator is installed contains AC equipment of 120 volts only it is recommended that the generator s AC terminal block be configured to provide one 120 volt AC hot leg for the vessel s distribution panel This will ensure good motor starting response from the...

Page 76: ...o panel indications fuel not on battery connections solenoid electric fuel pump and preheat solenoid not 2 20 Amp circuIT breaker 2 Reset breaker if breaker energized tripped trips again check preheat solenoid circuit and check circuIT for shorts to ground TART switch is depressed 1 Connection to solenoid 1 Check connection no starter engagement faulty 2 Faulty START SWITch 2 Check switch WITh ohm...

Page 77: ... ogge ep ac filters and allow system to seH bleed by depressing only the PREHEAT switch 1 Stop engine by depressing emergency STOP switch on engine or manually moving the shut off lever on the injection pump side Test switch with ohmmeter 2a Manually unplug the 12 Volt connection to the solenoid at the injection pump 2b Loosen high pressure injector lines at each injector Beware of fuel spray 1 Ch...

Page 78: ...heck output WITh vo meter 1d Ensure 12 Volts are present at the R terminal Battery runs down 1 Oil pressure switch 1 Observe if gauges and panel lights are activated when engine is not running Test the oil pressure switch 2 High resistance leak 2 Check wiring Insert to ground sensitive 0 25 Amp meter in battery lines Do not start engine Remove connections and replace after short is located 3 Low r...

Page 79: ... zero which is the normal reading for this situation 2 Disconnect the ground connection at the gauge and see ff the gauge reads full scale which is the normal reading for this situation If both of the above gauge tests are positive the gauge is undoubtedly OK and the problem lies either with the conductor from the sender to the gauge or with the sender If either of the above gauge tests are negati...

Page 80: ...It should be filled to the top of the filler neck 3 Visually inspect the unit check for loose betts chafed or broken wires loose brackets and fittings damaged hoses loose clamps and other equipment not properly secured 4 Check the fuel supply Fill tank s with a good grade of No 2 diesel fuel 5 Check the primary filter water separator Drain and service as required A primary fitter water separator i...

Page 81: ...aybe needed Please note that these adjustments are not warrantable adjustments during or after the generator s break in Servicing After Every 100 Hours of Operation 1 Change the engine s lubrication oil and oil filter 2 Adjust the water pump drive be tension nrequired Servicing After Every 250 Hours of Operation 1 Replace the fuel filter element in the engine mounted secondary fuel filter Servicin...

Page 82: ...tems highlighted by an asterisk should be performed by a competent mechanic Servicing After Every 800 Hours of Operation 1 Remove and check fuel injectors Injector spray pressure 1920 psi 71psi 135 kg cm2 5 0 kg cm2 Eliminate undesirable injection conditions including after dripping POOR GOOD 2 Check the engine s compression pressure Remove each glow plug figure 9 8 1 Fuel Injector Spray Pattern a...

Page 83: ...rmed more olten than every 1000 hours Torquing Cylinder Head Bolts Tighten the cylinder head bo s according to the sequence shown in the illustration below Make sure the engine is cold when this is done and loosen one head bold one han turn and then tighten between 80 to 85 Ib It 11 0 to 11 7 kgim Then proceed to the next head boH in the sequence Tighten the RS rocker cover stud securely 4 1 5 15 ...

Page 84: ... Position the No 1 piston at TOP Dead Center TOC on ITS compression stroke and adjust the 1 2 3 and 6 valves see the illustration to the right PosITion the No 4 piston Wb en No 1 c llnder 1 at top d ead cent er at TOC of its compres When No 4 cylinder 1 at t op dead oenter sion stroke and adjust the 4 5 7 and 8 val figure 9 11 4 Valve Adjustment Sequence ves The valves are num bered 1 to 8 from th...

Page 85: ... period A no load voltage adjustment may also be required in conjunction with the engine s speed adjustment These are not warrantable adjustments as they relate to normal break in and maintenance CAUTIONI Switch Off AC Load Before Starting Generator When starting the generator all AC loads especially large motors should be sw ched off until the engine has come up to speed and in cold climates star...

Page 86: ... u 4 1 1 lU rade 6T 6mm bolt head nut 1 0 4 3 6 5 0 6 0 9 Ilmn 0011 1U I 1 2 2 10mm bo I 1 25 21 7 32 5 3 0 4 5 lUmm ooIT 1 1 3UA f 4 12mm bolt head nut 1 25 ISO 36 2 57 9 5 0 B O mm DOll neaa nUl 1 0 U O U U 12mm bo head nut 1 75 34 7 49 2 4 B 6 B rade 7T 8T and 8 8 6mm bo head nut 1 0 5 B B 7 O B 1 2 I mm 0011 1 14 f 2 U 3 U 1Omm bolt aUI nut 1 25 2B 9 39 B 4 0 5 5 lUmn 0011 1 0 b 1 I t 3 f 5 2 ...

Page 87: ...U die gear 17 23 2 3 3 2 nlecllOn pump anve Qear ai 51 4 u U ocker arm assembly 80 85 11 0 11 7 Imlng gear case 1 11 1 b 4 iming gear cover 12 17 1 6 2 4 Hear Oli seal cap 11 15 1 5 U Oil pan 5 9 0 7 1 2 UII pipe UII pump 0 9 U t 1 Water pump 12 17 1 6 2 4 c ranKsnan ulley 145 1III 20 0 u emperature gauge unit 9 13 1 2 1 8 UI pressure sWltcn oj 1 1 2 Il f3low plug 7 11 1 0 1 5 nlectlon nozzle 12 1...

Page 88: ...quate Should more antifreeze be needed drain an appropriate amount from the engine block and add a more concentrated mixture Operate the engine to ensure a complete circulation and mixture of the antffreeze concentration throughout the cooling system Now recheck the antifreeze solution s strength Lubrication System WITh the engine warm drain all the lubricating oil from the oil sump Remove and rep...

Page 89: ...heat exchanger where the zinc anode is located Clean the raw water strainer H one is installed in the inside of the hull Start the engine and allow the raw water pump to draw fresh water through the system When the bucket is empty stop the engine and refill the bucket with an antifreeze solution slightly stronger than needed for winter freeze protection in your area Start the engine and allow all ...

Page 90: ...nths of normal lay up However ff you anticipate a longer lay up period 12 months or more we recommended that this procedure be performed The light oil in the cylinders will prevent the piston rings from sticking to the cylinder walls Make sure you apply a light coat of anti sieze on the threads of the glow plugs when reinstalling Spares Lay up time provides a good opportunity to inspect your Weste...

Page 91: ...rged I WARNING I Wear rubber gloves a rubber apron and eye protection when servicing batteries Lead acid batteries emtt hydrogen a highly explosive gas which can be igntted by electrical arcing or a lighted cigarette cigar or pipe Do not smoke or allow an open flame near the battery being serviced Shut off all electrical equipment in the vicintty to prevent electrical arcing during servicing 4 Che...

Page 92: ... spare parts that should be carried on board at ali times 1 An Impeller K n PIN 033104 2 A Fuel System Hardware Ktt PIN 032050 3 A Secondary Fuel Filter Element PIN 024363 4 A Water Pump Bett PIN 011672 5 Hose Clamps Select from parts list 6 A Spare Oil Fitter wtth a Spare Quart of Diesel Service Engine Oil along with a Galion of Premixed Antnreeze PIN 035828 7 A few Zinc Anodes and Heat Exchanger...

Page 93: ...s Installer part 9 A Bridge RectHier PIN 030809 The spare parts listed directly above are those we recommend be carried on board during long ocean voyages You may wish to ask other boat owners who have similar boats and who have completed long ocean voyages as to what spare parts they carried on board and what parts were needed at specific times on the voyage From the list provided directly above ...

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