Page 1: ...RTZ MARINE DIESEL GENERATOR SETS SINGLE THREE PHASE Publication 36856 Edition Two May 1995 j Y rWESTERBEKE WESTERBEKE CORPORATION 0 MYLES STANDISH INDUSTRIAL PARK j 150 JOHN HANCOCK ROAD TAUNTON MA 02...
Page 2: ...leaks and make sure the exhaust manifolds are securely attached and no warping exists Be sure the unit and its surroundings are well ventilated Use Extreme Care When Handling Engine Fuel A constant d...
Page 3: ...y their manufacturers with their own software and Westerbeke must depend on such software for the design of Westerbeke s own product software Such software however may be outdated and no longer accura...
Page 4: ...pecial attention contact your Westerbeke dealer for assistance The Westerbeke Service Organization is trained to provide the support necessary to ensure long term dependable perfor mance If within 60...
Page 5: ...DC CONTROL CIRCUIT WIRING DIAGRAM 22 23 COOLING SySTEM 25 LUBRICATION SYSTEM 31 BT GENERATOR 33 GENERAL INFORMATION AND CARE OF THE GENERATOR 39 ENGINE CONTROL PANEL 41 ENGINE TROUBLESHOOTING 43 MAINT...
Page 6: ...ol Panel Heat Exchanger Zinc Anode BTD 15 0 KW Generator Lube Oil Fill Cap Lube Oil Dipstick Oil Pressure Sender 15KW BTD 1 Fresh Water Fill Cap I D Plate DC Charging Alternator Lube Oil Filter Lube O...
Page 7: ...oil designed specifically for diesel engines The diesel engine does differ from the gasoline engine however in its method of handling and firing of fuel The carburetor and ignition systems are done aw...
Page 8: ...pms maximum Mechanical centrifugal weight type Swirl chamber type 3 307 x 3 701 inches 84 x 94 mm 128 cubic inches 2 1 liters 1 3 4 2 Clockwise when viewed from the front 79 6 Ib ft 11 kg m at 1900 rp...
Page 9: ...elf bleeding No 2 Diesel oil cetane rating of 45 or higher CAY DPA Injection pump 230 BTDC 0 50 static timing Throttle type Bosch type 12 Volt lift capacity 6 ft 1 8 m Spin on replaceable cartridge Me...
Page 10: ...cranking Amps 12 Volt DC 50 Amp Internal regulator built into alternator Glow plug sheathed type 12 Volt 1 6KW reduction type solenoid mounted 90 Amp max at 11 5 Volts 225 250 Amps engine cold Brushi...
Page 11: ...ts High voltage WYE 480 volts DELTA 240 volts High voltage WYE 380 volts DELTA 220 volts Low voltage WYE 99 Amps High voltage WYE 43 Amps DELTA 86 Amps High voltage WYE 43 Amps DELTA 75 Amps 225 250 d...
Page 12: ...e equipment and safe operating conditions for the personnel on board Proper location and installation of the generator set in the vessel are of prime importance Factors in the installation that must b...
Page 13: ...t system and the sea water supply to the exhaust must be configured to prevent the siphoning of sea water into the exhaust through the sea water cooling circuit and to prevent the entry of sea water i...
Page 14: ...the engine s performance and the generator s power output To measure the engine s back pressure either a mer cury manometer or a water column must be acquired A boatyard or marine mechanic should have...
Page 15: ...he thru hull fitting to the strainer and to the sea water pump should be wire reinforced to prevent the hose from collapsing during the generator s operation suction from the pump may collapse a non r...
Page 16: ...iately The best protection against carbon monoxide poisoning is a daily inspection of the complete exhaust sys tem Check for leaks around manifolds gaskets and welds Make sure exhaust lines are not he...
Page 17: ...can easily clog and cause fuel starvation to the generator s engine DO NOT use mechanical type check valves in lieu of a manual shut off valve Be sure there is a fire extinguisher installed near the...
Page 18: ...battery s terminals are clean and tight Ventilation The ventilation requirements of the generator sets include the following combustion air is required for the engine cylinders cooling air is require...
Page 19: ...c recovery tank is properly mounted near the unit with the bracket provided in a location where it can be monitored and filled easily see page 26 The recovery tank should be mounted at manifold level...
Page 20: ...AT switch will cause the water temperature and oil pressure gauge indicatorsto return to zero deflectto the left ofthe gauge The DC voltmeter will register system Voltage The electric on engine fuel p...
Page 21: ...can enter the engine S cylinders via the exhaust manifold once the exhaust system fills Prevent this from happening by closing the sea water supply thru hull shutoff drain the exhaust muffler and corr...
Page 22: ...Start ing section of this manual page 14 Visually examine the unit look for any abnormalities and correct them as needed Checkto ensure thatthere is sufficient fuel in the tank and examine the filter...
Page 23: ...c tion pump and injectors with damag ing results and the possibility of expensive repairs Remember water damage to the engine s fuel system is not covered under the Westerbeke warranty Although most b...
Page 24: ...fitting replace the washers with one of those in the kit Replacing Filter Elements After the first 50 hours of operation replace the filter element located in the base of the electric fuel pump Remov...
Page 25: ...djustments the servicing dealer can perform on the injection pump Other types of adjustments or repairs must be performed by a qualified injection service shop ELECTRIC LIFT PUMP INCOMING FUEL INJECTO...
Page 26: ...ty of the battery used in the engine s 12 Volt DC control circuit is 90 125 Ampere Hours minimum for the generator set covered by this manual CAUTION When quick charging the battery with an external c...
Page 27: ...I 0 I I GROUND I TO BLOCK STARTER 1t 2REO CIRCUIT BREAKER BATTERY 12V IG sRN CIRCUIT Q BREAKERU 4 PUR wHT 12YEL RED o T 8 a r 4REO EMERGENCY STOP SWITCH EXHAUST TEMP S JITCH r l G H t 30 COONECTING A...
Page 28: ...CATED NEAR THE STARTER AND AS CLOSE TO THE SOuRCE OF CURRE I AS POSSIBLE EXCESSivE CURRENT DRAW ANYWHERE IN THE INSTRl fvlENT PANEL WIRING OR ENGINE WILL CAUSE THE BREAKER TO TRH I J THIS EVENT MOST G...
Page 29: ...ns for Charging Voltage Test 1 Using a voltmeter connect the voltmeter s red wire clip to the B output terminal on the alternator Refer to the schematic shown above 2 Connect the other voltmeter wire...
Page 30: ...passes through the thermostat into the exhaust manifold then to the heat exchanger where it is cooled and then is returned to the engine block through the suction side of the fresh water circulating...
Page 31: ...location where it can be easily monitored and where coolant can be easily added if needed see the figure below A stainless steel mounting bracket is supplied with each kit along with a 30 inch length...
Page 32: ...head Since 1980 each type of thermostat has a hole punched through it The hole is a bypass to prevent the exhaust manifold from overheating during the engine s warm up Replacement thermostats must ha...
Page 33: ...ation CAUTION Excessive alternator and water pump drive belt tension can cause rapid wear of the belt and reduce the service life of the fresh water pump and alternator shaft bearings Excessive slack...
Page 34: ...The following illustration shows the location of the zinc anode in the BTD 1S 0KW s heat exchanger unit ZINC AHODE Heat Exchanger Unit of the BTD 1S 0KW Generator Set 29...
Page 35: ...belowis a typical Westerbeke engine s cooling system Both fresh waterand sea waterflow through their independent cooling circuits TO HOT WATER TAN OVEflHEAT ALARM PUMP II OMII6 SEA VATER Typical Cooli...
Page 36: ...f 60 to 80 psi Awarmed engine can have an oil pressure reading as low as 35 psi These readings may also vary depending upon the load that is placed on the generator Your generator set is fitted with a...
Page 37: ...n tighten the filter firmly by hand A Oil Filter and Oil Drain System NOTE Generic filters are not recommended as the material standards or diameters of im portant items on generic parts might be enti...
Page 38: ...able AC output see the top of page 34 No Load Voltage Adjustment Voltage adjustment is made with the compound transformer governing generator regulation 1 The selector switch must be in the CaMP posit...
Page 39: ...d within the transformer during the generator s operation may close the air gap and reduce the no load voltage output 4 To remove the laminated steel bar remove the two upper securing bolts from the c...
Page 40: ...c SOcyc BTD 15 0KW Generator s Internal Wiring Diagram A EXCITER STATOR WINDINGS 1 Exciter Stator Windings 2 Exciter Stator Windings B EXCITER ROTOR 1 Auxiliary Windings a b c 2 Diodes 6 3 Rotating Fi...
Page 41: ...lowing the procedures for No Load Voltage Adjustment page 33 4 With the generator s no load voltage properly adjusted move the selector switch into the ELEC position Adjust the regulator board potenti...
Page 42: ...40V 60Hz II Os 7 5 03 8 110V 50Hz 1101220V 50Hz 220V 50Hz sO sO 02 sO II Os 70 II AC Voltage Connections 6 Stud Terminal Block 15 0KW Generator Set NOTE The frame ground wire must be moved when changi...
Page 43: ...installer s responsibility to ensure that all AC connections are correct Generator HOTE i z tT _ I I L r D r Q I I I I I I I I I I I I I I I L_L2 Ship S LOAD SHIP TO SHORE SWITCH 3 POLE PH 32888 48 AM...
Page 44: ...to start 115 Volt motors connected to medium starting loads will be ap proXimately as follows MOTOR AMPS FOR AMPS FOR SIZE RUNNING STARTING HP Amperes Amperes 1 6 3 2 6 4 to 22 4 1 4 4 6 9 2 to 32 2...
Page 45: ...th a portable meter and amp probe Preventive Maintenance Generator Maintenance on the generator is minimal 1 Keep the generator clean dry and well ventilated 2 Ensure that all connections are clean an...
Page 46: ...witch The switch when activated ener gizes the starter solenoid for starting the engine This switch will not operate electrically unless the PREHEAT switch is depressed and held at the same time 3 sIQ...
Page 47: ...e STOP switch to stop the engine This opens the power feed to the fuel solenoid stop ping the fuel flow to the engine The STOP switch must be held depressed until the generator stops rotat ing Remote...
Page 48: ...e recommendations to overcome these problems Note that the engine s control system electrical system is protected by a 20 Ampere manual reset circuit breaker located on the rear lifting eye bracket Th...
Page 49: ...connection Low batteries Poor connections to fuel solenoid Defective fuel sole noid 44 Verification Remedy Check switch and or battery connections Reset breaker if breaker trips again check preheat s...
Page 50: ...throttle lever to shut off That failing shut off fuel and air Check fuel solenoid linkage and repair for free movement STOP switch failure Stop engine by depres sing emergency STOP switch on engine o...
Page 51: ...of or STOP switch in switch with an panel defective ohmmeter opening fuel run sole noid circuit Switches and or Inspect all wiring wiring for loose connections and short circuits Inspect switches for...
Page 52: ...lRemedy Check wiring Insert sensitive 0 25 Amp meter in battery lines Do not start engine Remove connections and replace after short is located Check all wires for temperature rise to locate fault Dis...
Page 53: ...for loose belts chafed or broken wires loose brackets and fittings damaged hoses loose clamps and other equipment not properly secured 4 Check the fuel supply Fill with a good grade of No 2 diesel fu...
Page 54: ...e pinion lubricate pinion 5 Check for proper operation ofpreheat circuit and glow plugs 6 Check the generator for proper operation Also check the generator s AC output connections for security make su...
Page 55: ...d clamps Servicing After Every 1000 Hours of Operation 1 Remove clean and pressure testthe primary heat exchanger A local automotive radiator shop should be able to clean and test the heat exchanger N...
Page 56: ...the intake manifold where it is attached to the head Head Bolt Tightening Torque Exhaust Side 12 0 kg m 86 Ib ft Intake Side 10 5 kg m 76Ib ft 2 Tighten each rocker shaft bracket bolt to 11 Ib ft 1 5...
Page 57: ...valve of the num ber 3 cylinder C Rotate the crankshaft in the normal direction of rotation one full turn 360 and stop D In this position adjust the valve clearances of the intake and exhaust valve of...
Page 58: ...degree increments Lo cate the 20 and 25 marks and place a visible mark halfway between the two points to represent 23 3 Rotate the engine by hand to position the number 1 piston on its compression st...
Page 59: ...m the injection pump Connect the high pressure injector lines between the injection pump and the injectors Do not cross or mix up these lines Engine No Load Speed Adjustment BTD 15 0KW The no load eng...
Page 60: ...ts to warm up This precaution will prevent damage caused by the unanticipated operation of AC machinery and will prevent a cold engine from stalling Generator Frequency Adjustment Frequency is a direc...
Page 61: ...reeze protection is adequate Should more antifreeze be needed drain an appropriate amount from the engine block and add a more con centrated mixture Operate the engine to ensure a complete circulation...
Page 62: ...This antifreeze mixture should protect the sea water circuit from freezing during the winter lay up as well as providing corrosion protection Remove the impeller from your sea water pump some antifree...
Page 63: ...rough hull exhaust port 2 Remove the sea water pump cover and gasket Discard the gasket Install the sea water pump impeller removed during lay up or a replacement if required Install the sea water pum...
Page 64: ...ad nut 1 25 21 7 32 5 3 0 4 5 10mm bolt head nut 1 5 19 5 30 4 2 7 4 2 12mm bolt head nut 1 25 ISO 36 2 57 9 5 0 8 0 12mm bolt head nut 1 5 36 2 50 6 5 0 7 0 12mm bolt head nut 1 75 34 7 49 2 4 8 6 8...
Page 65: ...t your local Westerbeke dealer A four page installation brochure is available which covers all current Sound Guard model assembly installations SOUND ABSORBENT INSULATION WITH MYLAR FACING An easy to...
Page 66: ...rod bearing caps 36 2 43 4 5 0 6 0 Rocker shaft bracket 7 2 14 5 1 0 2 0 Front plate bolts 5 1 10 8 0 7 1 5 Timing gear cover 5 1 10 8 0 7 1 5 Camshaft thrust plate 10 8 16 6 1 5 2 3 Idle thrust plat...
Page 67: ...16 BT GENERATOR 33 BT Generator s Internal Wiring Diagram BTD 15 0KW Figure 35 c Care of the Generator 39 Charging Voltage Test Alternator 24 Circuit Engine 12 Volt DC Control 21 Fresh Water 25 Sea W...
Page 68: ...1 Engine Oil Change 31 Viscosity SAE Number 31 Engine Operation 42 Engine Preventive Maintenance 48 ENGINE TROUBLESHOOTING Table 44 Exhaust System Installation Check 8 F Filling the Fresh Water System...
Page 69: ...7 Instrument Panel Standard Figure 41 Intake Manifold 57 Intake System 11 Internal Wiring Diagram BT Generator Figure 35 L LAY UP AND RECOMMISSIONING 56 Load Connections 36 Lubrication Cylinder during...
Page 70: ...Precautions Break in 16 Preparation for Starting 14 Pressure Oil 31 Preventive Maintenance 48 Engine 48 Generator 40 Procedure Starting 15 Stopping 16 Pump Sea Water 28 R Recommissioning 56 Regulator...
Page 71: ...32 Switch Connection Diagram Shore Power Figure 38 T TABLE OF STANDARD HARDWARE TIGHTENING TORQUES 59 TORQUES SPECiFiCATION 61 Test Voltage Charging Alternator 24 Tension Drive Belt Alternator and Wa...
Page 72: ...w Water Pump Alternator Drive Belt Tension 28 Wiring Diagram 36411 DC Control Circuit Figure 22 23 Wiring Diagram Internal BT Generator Figure 35 67...
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