OPERATOR'S MANUAL WESTERBEKE BTG - 9 KW Marine Gasoline Generator Set Publication # 36710 Edition One June 1987 jr~ 'WESTERBEKE j • WESTERBEKE CORPORATION • MYLES STANDISH INDUSTRIAL PARK 150 JOHN HANCOCK ROAD, TAUNTON, MA 02780-7319 U.S.A.
Gasoline with an ETHANOL content higher than 10% (E10) is not allowed and may void warranty.
SAFETY PRECAUTIONS The following symbols appear in this manual to call attention to and emphasize conditions potentially dangerous to the operator or to the equipment. WARNING CAUTION • expros Do not fill running. fuel tank with engine Do not smoke or use open flame near the eng1ne or the fuel tank. This sy~bol is used in the manual to warn of possible serlOUS personal inJury or loss of life. Keep combustible materials away from the uni t.
IMPORTANT PRODUCT SOFTWARE DISCLAIMER Product software of all kinds, such as brochur es, dr awing s, technical data, operator's and workshop manuals, parts lists and parts price lists (and other related information), instruct ions and speci fica t ions prov ided from source s other than Westerbeke, is not within Westerbeke's control and, accordingly, is provided to Westerbeke customers only as a courtesy and service.
FOREWORD Thank you for selecting a Westerbeke marine product for your use. at Westerbeke are pleased to have you as a customer. We Read this manual carefully and observe all safety precautions included throughout.
TABLE OF CONTENTS Title GENERAL ..••••••••.•••••.••••••.••••.. 1 GENERAL SPECIFICATIONS ••••••••••••••• 3 SYSTEM SPECIFICATIONS ••••.•••.••.••. 4 TUNE-UP SPECIFICATIONS ••••••••••..•• 6 INSTALLATION ••••••••.••••••••.••••• 7 BT GENERATOR .•••••••••••.••••••••••• 18 OPERATION •.••••.•••.•..••••.••.•..•. 25 SERVICE AND MAINTENANCE .•••.•••••••• 28 ENGINE ADJUSTMENT •••••••••••••••.••• 32 DC CIRCUIT DESCRIPTION •••••••••••.•. 36 GENERAL INFORMATION AND CARE OF THE GENERATOR ••••...•.
GENERAL Introduction This manual contains the equipment operating procedures as well as information to assist the operator to maintain the equipment in proper working order. Study and follow the instructions carefully. A planned rna in tenance prog r am is included in th is manual; adher ing to the prog ram will result in better equipment per formance and longer equipment life. Proper diagnosis of a problem is the most important step to satisfactory repair; consequently, a troubleshooting table is included.
BTG 9 KW Gasoline Generator Set 2
GENERAL SPECIFICATIONS BTG 9 KW MARINE GASOLINE GENERATOR SET Engine Type Gasoline, 4-cycle, 3-cylinder, vertical, in-line Combustion Chamber Multi-sphere type Valve Mechanism Overhead camshaft, belt-driven Bor e 2.99 x 2.87 inches (76 X 73 mm) & Stroke Piston Displacement 60.6 cubic inches (0.993 liter) Firing Order 1-2-3 Direction of Rotation Clockwise, when viewed from the front Compression Ratio 9.5:1 Compression Pressure 177.8 psi (12.
SYSTEMS SPECIFICATIONS FUEL SYSTEM Fuel Unleaded or leaded gasoline (minimum octane 89) Carburetor Down-draft, single-barrel Governor Mechanical type, belt-driven Lift pump 12-Volt electric; lift capacity 6 ft (1.
ELECTRICAL SYSTEM Starting Battery (recommended) l2-Volt, 30 A-H (45 A-H cold areas) Starter l2-Volt, 1.2 kW, reduction type, solenoid-mounted DC No-load current 90 Amp (max.) at 11.
Engine Combustion Air Requirements, (60 Hertz), at 1800 rpm 32 cfm (0.906 cmm) TUNE-UP SPECIFICATIONS Spark P lug Gap 0.028 - .036 inch (0.7 - 0.9 rom) Contact Point Clearance 0.016 - .020 inch (0.4 - 0.5 mm) Dwell Angle 58' Condenser Capacity 0.27 microfarad Valve Clearance (warm eng ine) Intake 0.0079 inch (0.20 rom) Exhaust 0.0079 inch (0.
INSTALLATION General Proper location and installation of the generator set in the vessel are of prime importance. Factor s in the installation that must be considered are ventilation for the generator for proper cooling and engine combustion air; exhaust system to properly discharge raw cooling water, quiet the exhaust and expel exhaust gas; cooling water supply; fuel supply; and electrical connections.
ventilation The generator set needs fresh cool air for combustion within the engine cylinders, for generator cooling and to remove harmful or flammable gasoline fumes from around the generator set. The 9 KW BTG engine requires air flow of 32 cubic feet per minute (0.906 cubic meters per minute) and the generator end requires from 225 to 250 cubic feet per minute (6.37 to 7.08 cubic meters per minute) air flow.
Exhaust System Installations Flapper Cover_~.
CAUTION Overcranking with no engine start results in excessive amounts of cooling water pumped in to the exhaust system. Exhaust gas pressure may not always be sufficient to discharge accumulated water during periods of excessive cranking. Shut off thru-hull water supply until unit starts and then open once started. Investigate reason (s) for hard starting and correct. Fuel System WARNING Gasoline leakage in or around the generator compartment is a potential cause of fire and/or explosion.
Basic Fuel System Layouts with Anti-Siphon Protection FUEL LINE ALWAYS ABOVE FUEL TANK TOP LEVEL [UE ~ ~ T AN _=~~=-====:=.~~:.-:-__-::-='::=:-:=:-=-=~~-:-d TO P--DLE!!",V_E_L_-==....:!!:..=.=!",,"=,_.... NO ANTI·SIPHON DEVICE OR ELECTRICALLY OPERATED VALVE NEEDED 0-,.
Fuel system components must be compatible with oxygenate (butanes, alcohols) blended fuels.--pailure to ensure compatibility will result in the component failure and possible injury to the user. The use of check valves in place of the solenoid-type shut-off valves is discouraged. Check valves may tax the ability of the fuel lift pump on the eng ine to draw fuel through them. Also, they can trap debris under their seats, defeating their purpose.
Automatic Shutdown High Exhaust Temperature Shutdown Switch (normally closed) An exhaust temperature switch is located on the exhaust elbow and will open the ignition circuit should the switch sense excessive temperature, indicating a lack of proper sea water coolant flow. This switch opens at 260 - 270·F (127 - l32·C) and resets at approximately 22S·F (107·C).
DC Electrical Connections A common ground for negative (-) DC is found at the bellhousing of the generator, next to the starter, in the form of a threaded grounding stud. It is recommended that the battery ground be connected here. Connect battery positive for this connection. (+) to the starter solenoid terminal tagged CAUTION To avoid an overcharg ing condition, and poss ible equipment failure, do not disconnect the DC battery source while the engine is running.
::0 CD 8 rt CD rn rt IlJ 1"1 rt OPTIONAL R,MOn STAhT PANIL(RtJ\R VI'W) 'i:I IlJ PN 33703 ;J , - -- ----- - - - --- --- -- ---- -----------1 I CD ""IG lit.O I-' I I I I I ;J lO -\ tilfHO ,~ STOP I IN/PIJH "TR IPC ~ '>TAR! I o..... <;1::1:. '" .1 0: ::l 0.. 1 .~ T4-1 i \J1 ..... .....
g .... !!.!!ill:!&. ~ f.I'KU,T , ~~ ') T~~,~. ;t·.,. .- : :.- :."l1,Tl-llilUTOR 4----, bIlTO~ItD *'\T-EA~ I"NIT,ON COIL I TEMP I OPTIONAL ·'.Pvll./"'HT ~TII. I I "141'l'1I r x._____ ~lJL[N
~ (D 'r It ,.. , PI REMOTE INSTRUI'IENT PANEL (REAR VIE,,j) P[I(>i 0 9KW fe"oIl"'loIAL _ ()PClAie- '> GAGe t..JIllill!oIC, .Jl} ..lJ ASS'Y PN 33/02 r -- - - -- - ----- --- - - - -- - - -- - -------- -------------1 REo/W/PURPLf STRIPE I I I ~ r-$ I I 4KW BC 9KW BT TO T81- 2 TO TB3-2 ...... 6.!)KW BC SEE 0\'/6. 3!)<;39 . TO T2-1 TO T2-2 -...J TO T82-1 TO T2-3 TO T83-S TO T2-5' rt 1"'1 C :3 (D r-- rt I In.
BT GENERATOR This generator is a brushless self-excited generator, which requires only the driving force of the engine to produce AC output. Two permanent magnets in the exciter stator are responsible for the selfexciting feature of this generator. The magnetic field they produce causes an AC voltage to be induced into the related exciter rotor windings during rotation. Diodes located in the exciter rotor rectify this voltage to DC and supply it to the windings of the rotating field.
VOltage AaJustmen: Greer, YelloV'. Blacio\ 'fl..... o a=n 0 7 N~ 9 o-L, A 60 80 Blue 2 Blue ~ 3 0 100 L· Terminal BloCK COf"\nections 1201240V 60hz I Selector ~ ~ Compound +--+---Transtormer Opllonal Voltage Regulator Blue & White Illustration shows terminals connected for 120/240 volt 60 Hertz on compound transformer regulation G reen & Wh Ite Yellow & White t Regulator Plug ' I 'C":'-Blue & White - - " ..
BT Generator Internal Wiring Diagram r----------, : C r-----------, I I ,-------------------1 A + 2 ,"';;; , :», 00 ""~ QoQo ~~ ~I --< m--< '" I I I I I I I I I I a -{)t- 4 b - ~ 2 1 II 3 L _________________ J I ;z RED & WHITE )- '1 +r-- ) 1 - * '--- YELLOW & WHITE RED &!HITE +- BLACK & WHITE ... - ! F2 I I I I I I I 3 * - G I 11 • i I I I I ...
Optional voltage Regulator An optional solid-state voltage regulator (board :jj: 34410) is available for use with the 9 KW BTG generator. When installed, and the regulation switch is moved to the ELEC position, the regulator works together with the standard compound transformer regulator to regulate generator vol tage output. Installation 1. The regulator is mounted using existing tapped holes in generator case. Use (2) M4 x 0.7-mm screws, 15 rom long, with lock washers, to mount the regulator board. 2.
Load Connections The generator data plate gives voltage, current and frequency rating of the generator. An AC wiring decal is affixed to the inside of the louvered cover on the generator end. A diagram of the various AC vol tage connect ions is prov ided on the decal and is simi lar to the figure on the following page. The generator is single-phase, reconnectable 120 VAC two-wire or 120/240 VAC three-wire, at 60 Hertz~ or 110 VAC two-wire, 110/220 VAC three-wire, or 220 VAC two-wire, at 50 Hertz.
AC voltage Connections 120V 60Hz 0 120/240V 60Hz TO FRAME n
Shore Power Connections If the installer connects shore power to the vessel's AC circuit, this must be done by means of the SHORE POWER/OFF/SHIPS GEN, center posishown below. Use of this switch prevents tion-off transfer switch simultaneous connection of shore power to generator output. CAUTION Damage to the generator can result if utility shore power and generator output are connected. ~ ( N . _Generator __ NOTE: Diagram shows connections for twowire, 120-volt system.
OPERATION Prior to starting the generator, check the following: • • • • • • • • Lubricating oil level Coolant (fresh water) Fuel to engine Sea water connections Battery connections Generator AC electrical connections Exhaust connections Belt tensions (governor/fresh water pump) Engine Oil Use a good grade of oil API Spec. SD or SE, preferably SE. Refer to the specification section capacity. Use the proper SAE number which the unit will be operating.
A coolant recovery tank (*24977) is supplied with each engine and must be installed to allow coolant expansion and contraction without creating or introducing air into the cooling system. It should be used for monitor ing and adding coolant. NOTE: If coolant is lost through a leak in the system, it will be necessary to refill via the filler cap on the manifold and then refill the recovery tank. -Fuel Use clean, filtered unleaded gasoline line when available.
Starting ventilate the generator compartment for a minimum of 5 minutes before attempting to start the engine. The ventilating blowers remove potentially explosive fumes from the generator compartment and bilge. Starting sequence: 1. Depress the ON switch and hold. 2. Depress the START switch. When the engine starts, release the START switch only. Allow a few seconds to establish sufficient oil pressure and then release the ON switch. Check exhaust discharge for sea water coolant flow. NOTE: load.
SERVICE AND MAINTENANCE Regular inspection and servicing of the engine and generator increases the service life of the unit and reduces repair costs and down time.
Electric Fuel Pump The eng ine-moun ted electr ic fuel pump supplies fuel to the engine carburetor during engine operation. A cleanable filter screen is contained in its base. WARNING Shut off fuel service valve at engine when servicing fuel system. Take care to catch fuel when opening filter elemen ts. Do not allow any smoking, open flames, sparks or other sources of fire near the fuel system when servicing. Ensure proper ventilation when servicing the fuel system.
Cooling System Monitor system coolant (50/50 antifreeeze mixture) and, if rust or scale are evident, flush and clean system and replenish the antifreeze mixture. Use antifreeze that is compatible with aluminum engine components. Maintain proper belt tension on the fresh water circulating pump and sea water pump, three-eighths to one-half inch deflection along the belt's longest span. Replace if cracked or fr ayed. Do not overtighten as it is possible to bend the governor shaft by overtightening.
Valve clearance should time bolts are torqued. be checked and adjusted, if necessary, each Valve Clearance Adjustment (Both intake and exhaust): (Hot) (Cold) 0.0079 inch (0.20 rom) 0.0071 inch (0.18 rom) Valve Adjustment Procedure 1. Rotate the crankshaft in normal direction of rotation, placing No. 1 piston at the top of its compression stroke. Adjust the intake and exhaust valves for No.1 cylinder, the exhaust valve for for No. 2 cylinder and the intake valve for No.3 cylinder. 2.
ENGINE ADJUSTMENT Ignition Timing Attach a timing light to No. 1 spark plug and mark the front crankshaft pulley timing notch. Locate timing pointer on front gear caseand mark same. Use of white or yellow marking crayon helps greatly in referencing these two points with the timing light. Start the engine; allow it to warm up and stabilize engine speed. Check timing with an ignition timing light. Ensure engine is operating with no load on the generator (61.5 - 62.0 Hertz).
Electric Choke The electr ic choke uses a l2-Volt heating element which choke automatically once the engine starts and is running. Some hunting will be present when the choke, with no-load on the generator. generator is opens the started and on WARNING To avoid burns on fingers or hands, housing while engine is operating. before making choke adjustments. do not Allow touch the choke eng ine to cool The choke is adjusted with the engine off and at room temperature.
Carburetor Adjustment 1. Idle Mixture Jet Disconnect the throttle linkage arm from the governor control arm and reduce engine speed with the idle stop screw. Adjust the idle mixture screw: turn screw clockwise (in) until engine skips; back screw out (counterclockwise) slowly until engine smooths then skips again; turn screw clockwise (in) one-quarter to one-half turn. Idle mixture should be satisfactory.
sure this linkage moves freely and that the ball joint connectors are properly lubr icated. (Disconnect the ball joint and apply graphite lube to the inside of the joint.) 2. Hunting/Regulation If variation in engine speed between no load and full load is too great, adjust this eyescrew to draw the spring closer to the lever hub. The increase/decrease speed screw may need to be adjusted as well. I f the governor surges under load, the spring away from the lever hub. 3.
DC CIRCUIT DESCRIPTION: BTG 9 KW GASOLINE MARINE GENERATOR SET Safety Information This circuit is designed and manufactured in compliance with United States Coast Guard Standards (33 CFR PART 183). No modifications may be made to it by the installer or user. It is the installer's responsibility to assure that the installation of the generator set and any remote start panels or remote instrument panels are installed in compliance with the above Coast Guard Standards.
An optional remote instrument panel is available which includes start ing con troIs. This panel also includes a water temper ature gauge, oil pressure gauge, battery voltmeter, operating hourmeter, start-stop control switches, and senders to be installed on the engine for water temperature and oil pressure. Circuit Description The two-pole ON switch bypasses the protective shutdown switches during starting. The second pole provides a source of B+ to the START toggle switch.
GENERAL INFORMATION AND CARE OF THE GENERATOR Use of Electric Motors The power required to start an electr ic motor is considerably more than is required to keep it running after it is started. Some motors require much more current to start than others. Split-phase (AC) motors require more current to start, under similar circumstances, than other types. They are commonly used on easy-starting loads, such as washing machines, or where loads are applied after the motor is started, such as small power tools.
Load Applied 4-Pole Speed (rpm) Generator Voltage Frequency l20V (110) 240V (220) plants Plants (Hertz) None 1830 (1530) 62 (52 ) 122 (112 ) 244 (224 ) Half 1800 (1500) 60 (50) 120 (110) 240 (220) Full 1755 (1455 ) 59 (49 ) 110 (100) 220 (200 ) The output voltage should be checked periodically to ensure proper operation of the generating plant and the appliances it supplies.
ENGINE TROUBLESHOOTING Trouble Engine cranks but fails to start possible Cause 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. Engine does not crank 1. 2. 3. 4. 5. 6. 7. Engine starts, runs and shuts down 1. 2. 3. 4. 5. 6. 7. Backfire through carburetor 1. 2. 3. 4. 5. 6.
ENGINE TROUBLESHOOTING (continued) Trouble Engine overheating Possible Cause 1. 2. 3. 4. 5. 6. 7. 8. Coolant loss (Pressure test system) Belts loose or broken Sea water pump impeller faulty Sea water pump worn Faulty hose Thermostat stuck closed Exchanger clogged Faulty gauge (check with thermometer) Engine hunting 1. 2. 3. 4. 5. 6. 7. 8.
TABLE OF TIGHTENING TORQUES lb-ft kg-m Cylinder head hold-down bolts 36.2 - 43.4 5.0 - 6.0 Main bearing caps 39.0 - 47.7 5.4 - 6.6 Connecting rod bearing cap 15.2 - 21.0 2.1 - 2.9 Front crankshaft pulley 65.2 - 72.4 9.0 - 10.0 Flywheel retaining bolts 28.9 - 36.2 4.0 - 5.0 5.8 - 8 .7 0.8 - 1.2 10.8 - 15.9 1.5 - 2.2 Exhaust and intake manifold to cylinder head 7.2 - 11. 6 1.0 - 1.6 Camshaft timing belt pulley 21.7 - 32.5 3.0 - 4.5 2.9 - 5.1 0.
TABLE OF STANDARD HARDWARE TIGHTENING TORQUES unless stated otherwise for a specific assembly, torque values when tightening standard hardware. pitch use the following kg-m Ib-ft Grade 4T 6mm 8mm 10mm 10mm 12mm 12mm 12mm 13mm 14mm 14mm 16mm 16mm bolt/nut bolt/nut bolt/nut bolt/nut bolt/nut bolt/nut bolt/nut bolt/nut bolt/nut bolt/nut bolt/nut bolt/nut 1 1. 25 1. 25 1.5 1. 25 (ISO) 1.5 1. 75 1.5 1.5 2 1.5 2 2.9 7.2 13.7 13.0 25.3 25.3 21.7 32.5 36.2 34.0 54.2 51. 4 - 5.1 11.6 22.4 21. 7 39.8 39.
