Westerbeke BTG 10.0, Operator'S Manual

Page 1: ...0Kw BTG 50Hz 15 0Kw BTG 60Hz 12 0Kw BTG 50Hz MARINE GASOLINE GENERATORS PUBLICATION 035909 REVISIONS MARCH2018 _ rWESTERBEKE J WESTERBEKE CORPORATION 150JOHNHANCOCKROAD J MYLESSTANDISHINDUSTRIAL PARK...

Page 2: ...zziness NaiiSea Headache Weakness andSleepiness Throbbing in Temples Muscular Twitching Vomiting Inability to Think Coherently IF YOU ORANYONEELSEEXPERIENCEANYOF THESESYMPTOMS SETOUTINTO THEFRESHAIRIM...

Page 3: ...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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Page 5: ...FIRE IA WAJIIIIIIG F rB tljtlryDr 111 Prevent 6ash fires Do not smoke or permit flames or sparks to occur near the carburetor fuel line filter fuel pump or other potential sources of spilled fuel or...

Page 6: ...or into the eyes inadvertently when removing electrolyte caps TOXIC EXHAUST GASES A WARNING Carbon monoxide CO Is adeadlygas Ensure that the exhaust system is adequate to expel gases discharged from t...

Page 7: ...all safety procedures GASOLINE ENGINE AND GENERATOR INSTALLATIONS Preparations to install a gasoline engine or generator should begin with a thorough examination oftheAmerican Boat and Yacht Council...

Page 8: ...he 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...

Page 9: ...6 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 Belt Adjustment...

Page 10: ...LINE 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...

Page 11: ...NGER STARTER MOTOR LH SIDE AC CONNECTIONS PORT LUBE OIL DRAIN FUEL LIFT PUMP SIPHON BREAK CONNECTION WATER INJECTED DISTRIBUTOR AIR INTAKE FLAME ARRESTER RHSIDE GENERATOR COMPONENTS 20A CIRCUIT BREAKE...

Page 12: ...is operated and serviced in the field This is up to the buyer owner operator NOTE Six important steps to ensure long generator life Proper engine andgenerator installation and olignment An ejJicient...

Page 13: ...etic oils are used engine break in ust be perfor tn d using conveirtional oil on change tervals__must be as listed in the MAINTENANCE SCHEDULE section ofthis manua1 and notextendedifsYnthetic oils are...

Page 14: ...00 rpm s The purpose of the LED is to alert the operator to release the START switch It is also an indication that the engine generator is running REMOTE INSTRUMENT PANEL OPTIONAL An optiol al remote...

Page 15: ...panel is installed monitor the gauges for normal readings NOTE Some unstable running may occur in a cold engine This condition should smooth out as the engine warms up and when the generator loads ar...

Page 16: ...ting Since the generator operates at 1800 rpm to produce 60 hertz or at 1500 to produce 50 hertz control of the generators engine break in is governed by the current drawn from the generator NOTE Be a...

Page 17: ...ed offthe engine s oil gallery This switch s sensor monitors the engine s oil pres sure Should the engine s oil pressure fall to 5 10 psi 0 4 0 7 kg cD 2 this switch will activate a pulsating alann DI...

Page 18: ...electrical connections Keep bolts nuts tight remain cool Check for loose belt tension Spark Plugs D D D D D D Check gap inspect for burning and corrosion Generator if applicable D 0 0 D D D D Check th...

Page 19: ...ct the impeller for wear replace if needed Also replace the gasket Lubricate both when re assembling 0 0 Drain flush and refill cooling system with appropriate antifreeze mix 0 0 Check solenoid and mo...

Page 20: ...should be clean and well secured by the mo ting bolt to ensure proper pump operation The start sequence energizes the fuel lift pump as the piston in the pump operates it creates an audible ticking so...

Page 21: ...em Coolant Recovery Tank A coolant recovery tank allows for engine coolant expansion and contraction during engine operation without any signifi cant loss ofcoolant and without introducing air into th...

Page 22: ...oat of sealant on both sides ofthe gasket before pressing it into pi Do not over tighten the cap screws Replace the coolant in the manifold Run the engine and check for normal temperatures and that th...

Page 23: ...ping action On no account should this JlUr JP_ be run d rJ There should always be a spare impeller and impeller cover gasket aboard an impeller kit Raw water pump impeller failures occur when lubrican...

Page 24: ...DULE sectionofthis manual and not extended ifsjtnthetic oils are used NOTE The information above supersedes all previous statements regarding synthetic oil 16 CHANGING THE ENGINE OIL The engine oil sh...

Page 25: ...NNECTION AT THE REMOTE OIL ALTER APPLY ATHIN COAT OF CLEAN OIL TO THE D RING WHEN INSTALLING THIS KIT THREAD THE KIT ON THEN HAND TIGHTEN AN ADDmONAL3 4TURN AFTER THE D RING CONTACTS THE BASE NOTE Wes...

Page 26: ...n after the first 50 hours of operation every 100 hours from then on Clean the air screen in a water soluble cleaner such as GUNK FROM FUEL FILTER SEE ELECTRIC IN THIS MANUAL UNDER ENGINE ADJUSTMENTS...

Page 27: ...ine s front cover Each timing mark represents 2 2 Start the engine and warm the engine to its normal operating temperature 3 Using the timing light align the timing groove in the front ccim kshaft pul...

Page 28: ...After the initial break in period approximately 50 hours the cylinder head bolts should be re torques Loosen the cylinder head bolts one halfturn in the order shown The engine should be cold Then tig...

Page 29: ...n the belt can cause belt slipping resulting in high operating temperatures and the failure of the same components 1 To adjust the alternator and the engine coolant belts loosen the alternator mountin...

Page 30: ...hite lube to the inside of the joint 2 Hunting Regulation Adjustment If the variation in engine speed between no load and full loadis too great adjust this eye bolt to draw the spring closer to the le...

Page 31: ...p away ffDIII sheavesandbelts during testpmcedures A WARNING MOLT METERS ANDDC CIRCUITS DCandAC circuits are often mixed together in marine applfcatiiJIIS Always disconnect shore powercords Isolate DC...

Page 32: ...arging circuit nevershutoffthe enginebatteryswitch while the engine is mnning Shut off the engine batteryswitch however to avoidelectricalshorts when working on the engine s electricalcircuit BATTERY...

Page 33: ...ottle plate binding 6 AC generator issues 7 Air intake restricted 8 Exhaust restricted 9 Air in fuel system l 25 NOTE The engines control system electrical system is protected by a 8 Ampere manualfuse...

Page 34: ...re worn or unseated 6 Faulty engine bearings 7 Faulty oil filter Poor performance 1 Contaminates in fuel system at generator speed 2 Faulty fuel pump contaminated High oil pressure 1 Dirty oil or wron...

Page 35: ...l conditioner such as STABIL gasoline stabilizer should be added Change the element in your gasoline water separator and clean the metal bowl Re install and make certain there are no leaks Clean up an...

Page 36: ...RED PUR lit liED 0 114 flRH STOP 114 l ELIRED l SWITCH 114 RED P UR I llol PUR l 114 YEL IIE D IU IILIC l 11 1 1 1 1 11 liZ Y L IED FUSE 2 15 ANP 5 8 TB3 tte ILK FOR CONNECT ION TO REMOTE SfAU AND ft...

Page 37: ...iEIR REMOTE INSTRUMENT PANELS COMPLY wrrH 33CFR 183 2 THIS PRODUCT IS ROTECTED BY A MANUAL RESET CIRCUIT BREAKER LOCATED NEAR THE STARTER AND AS CLOSE AS POSSIBLE TO THE SOURCE OF CURRENT EXCESSIVE DR...

Page 38: ...D CIRCIJT ALTERNATOR 5 A OIL PRESSURE y QiQJ E IIIR DIPUR O r Ill R DIPUR JC IOIL PRESSURE D I liJiQll I L 1 Itt REDIPI Il 114 BL t J 112 TEL RED U2 Y L RE t ll P Ill BLit GP l 0 Ill Et __ 114 PUR c J...

Page 39: ...Ff IOM GASOUNE SOURCES IN ACCORDANCE WITH 33CFR 183 410 B ITIS TriE RESPONSIBIUTY OFntE BOAT MANUFACTURER TO ENSURE ntATntE INSTALLA TION OF ntESE GE ERATORS AND OPTIONAU Y ntEIR REMOtt INSTRUMENT PAN...

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Page 41: ...BLANK PAGE Engines Generators 33...

Page 42: ...E DWG 3G397 I TO T81 2 gt fCi s A t i TO TB3 211 TOT2 2 Qo f TO T62 111 TO T2 3 iiJ e 0 ill TOTB2 2 TO T2 4 TO TB3 S TO T2 S 16PURPLE IS PURPLE rG BLACk I 14 L T lll U E c PIIRPLE t iil 0 VOLTS w t 0...

Page 43: ...l G PU R PL E t lt Jt c t 14 P U R P I E __ TO TZ Z T4 2 l 2 AMP I I I I I I I I I I I I f G 1 1 14 BLACK L ____ TO T2 5 T4 5 j 2AMP I I I I TO TBI Z TO TB3 2 TO TB3 S 12 AMP STARTING 12 VEL w REO ST...

Page 44: ...AC terminal block be configured to provide one 120 voltAChot legfor the vessels distribution panel This will ensure good motor starting responsefrom the generator GENERATOR FREQUENCY ADJUSTMENT Freque...

Page 45: ...auxiliary windings of the transformer and the main stator and is in turn supplied to a full wave bridge rec tifier The rectifier produces a DC voltage to further excite the exciter stator windings ena...

Page 46: ...RY ROTOR WINDINGS A B C _1 0 1 2Q DIODES 6 11Q infinite ROTATING FIELD WINDINGS 7 0 S OQ POSt RESISTOR infinite C MAIN STATOR WINDINGS 20 22Q MAIN STATOR AUXIL1ARY WINDINGS_1 5 1 8Q 0 COMPOUND TRANSFO...

Page 47: ...1 TO SELECTOR SWITCH BLACXIWHITE fO 8111 G RECTIFIER CIRCUIT BREAKER BT GENERATOR SINGLE PHASE 10KW 15KW GENERATORS D COMPOUND TRANSFORMER 1 Compound Transformer Windings 2 Compound Transformer Windin...

Page 48: ...ause an adequate reduction in excitor voltage to safeguard the excitor windings and prevent their overheating The overload protection system has a delay which permits temporary overloading of the gene...

Page 49: ...basic repair tools with you on the initial trip to the problem equipment such as diodes and bridge rectifier so that if the problem should be found in one of these easily replaceable parts the problem...

Page 50: ...ove the rear generator carrier bearing NOTE These two model BTgenerators are used on models rated lower than the capabilities ofthe generator However the generator is rated according to the capabiliti...

Page 51: ...windings such as a short will cause the generator engine to load down and the shorted windings to eventually produce smoke as the excitation is continued 4 Voltage output greater than residual and les...

Page 52: ...istance value is measured between lifted lead 1 from the red insulated terminal stud below the transformer and lead 7 lifted off the AC terminal block NOTE No continuity should befound between either...

Page 53: ...g field windings The diOdes can be easily checked in place with the use of a common automotive 12 volt high beam headlight bulb some jumper leads and the generator s 12 volt starting battery A short o...

Page 54: ...ng at the regu lator will sense incorrect voltage and cause the generator to produce abnormally high output voltage CURRENT MODELS VOLTAGE HERTZ CONNECTION BAR REPOSffiON THIS WiRE FOR 50Hz TO 60Hz TE...

Page 55: ...output TO HERtz BAR YELLOW TO SELECTOR SWITCH TO BRIDGE RECnFIER A V R Plug and Connections L1230V50Hz j ___ L1120V60Hz 6 5 4 4 8 L s N 4 L2 240V 60Hz Terminal Block Wiring Connections Wiring connect...

Page 56: ...ain stator winding 2 Shorted pozi resistor on exciter rotor 3 Four or more shorted or open diodes on exciter rotor 1 Blown 6 AMP fuse auxiliary circuit AVR 2 Faulty voltage regulator 1 Open or shorted...

Page 57: ...1 7 I I 5 I I 1 l I I I 6 I I I bl J I 2 I c 6 I I I 4 I I I I I DIODES I 3 I I I I L r L _____ _j L 1 1 w EVOlTAGE REGULATOR YELLOW Q w a II F FUSE 6 3AMP GREEN Resistance Values A EXCITER STATOR 17...

Page 58: ...rmer auxiliary 2 Check continuity and connections of D 3 windings windings D 3 Low voltage 0 5volts at NIL with 1 Main statorwindings shorted C 1 C 2 1 Check continuity and resistance values of C 1 C...

Page 59: ...statatype with signal generatorand igniter 14mm x1 25 pitch Westerbeke partnumber033805 Down drafttype single barrel with USCG approved flame arrester General Oil Alter Sump Capacity not including fi...

Page 60: ...no load to full load Rating Volts AC 60Hz 1800rpm 120voHs 70amps 120 240 volts 70135 amps 50 Hz 1500 rpm AC Circuit Breaker Generator Cooling 220voHs 31 amps To be rated at 120 ofthe generators rated...

Page 61: ...e with signal generator and igniter 14mm x1 25 pitch Westerbeke part number 033805 Down draft type single barrel with USCG approved flame arrester General Oil Riter Sump Capacity not including filter...

Page 62: ...r 120 or 120 240 volts 60 hertz 220 Volts 50 Hertz 5 no load to full load 3Hertz 5 no load to full load 120 volts 104 amps 120 240 volts 104 52 amps 220 volts 47amps To be rated at 120 of the generato...

Page 63: ...with signal generatorand igniter 14mm x1 25 pitch Westerbeke part number 033805 Down drafttype single barrel with USCG approved flame arrester General Oil Riter Sump capacity not including filter Ope...

Page 64: ...240volts 60 hertz 220 Volts 50 Hertz 5 no load to full load 3 Hertz 5 no load to full load 120 volts 124 amps 120 240 volts 124 62 amps 220 volts 60amps To be rated at 120 of the generator s rated amp...

Page 65: ...Ounces Pounds lb x 454 Kilograms kg x 2 205 Pounds PRESSURE Pounds Per Sq In psi x6 895 Kilopascals kPa x 145 psi Inches of Mercury Hg x 4912 psi x 2 036 Hg Inches of Mercury Hg x 3 377 Kilopascals kP...

Page 66: ...ens meter l lmlm2 Multiolv Fuel Performance By To get eg_uivalent number of Miles oat CmDe aall 0 4251 Kilometerslliter_ J mfl Gallons mile Caat milel 2 3527 Liter kilometer 1Llkn l Multiolv Velocitv...

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