OPERATIONS & MAINTENANCE MANUAL WESTERBEKE DIESEL GENERATORS MOBILE & INDUSTRIAL MODEL 15.0 BTDAR, 20.0 BEDR, 25.0 BEDR & 32.0 BEDR 60 HERTZ MODEL 12.0 BTDAR, 16.0 BEDR, 20.0 BE DR, 25.0 BEDR 50 HERTZ SINGLE & THREE PHASE GENERATORS Publication # 039835 Edition Two May 1993 ~r-.
INTRODUCTION Thank you for purchasing a Westerbeke diesel generator. With proper care on a routine basis, your Westerbeke generator is designed to provide you with reliable and economical power for many years. This manual will help familiarize you with your engine. It covers initial service, operation, maintenance and troubleshooting in depth. It also contains important safety information, key specifications, and a wiring diagram. No manual can provide for every possible question or contingency.
ENGINE SERIAL NUMBER LOCATION The engine serial number and model designation are found on an LD. tag affixed to the generator's housing. An illustration of this I.D. tag is shown below. Take the time to fill in the model description, engine serial number and generator serial number in the appropriate blocks in the illustration below. These will provide quick reference when ordering spares, repair parts or when seeking technical information. '~79ELI. :1.6 .. 0 )0 .. 0 :1.6 .. 0 :I. .. () I ~.:jO :I.
BE SAFETY CONSCIOUS A careless moment can cause an accident or fire. Here are basic DO's and DON'TS: DO'S DON'TS • DO visual inspections before starting your generator. • DON'T touch any moving part on your engine during operation. • DO check your engine once a day. Keep eyes open and be alert to people and obstacles. • DON'T touch hot engine parts such as exhaust manifolds.
• • DO keep fuel away from your engine • at all times. Check for leaks regularly and correct them. DO check the capacity of sling hoist when lifting the unit. Use hangers and a wad of cloth in between sling and unit. Westerbeke Generators • 4 DON'T remove radiator filler cap immediately after shutting down engme. DON'T smoke near the battery Never use an open flame as a light anywhere on or around the battery. Battery gas is highly flammable. Sulfuric acid is destructive.
5 • DON'T work on an engine while it is running. If it is necessary to check the engine while running, use caution and beware of moving parts and the presence of AC voltage. • DON'T touch AC electrical connections while the unit is running. Lethal voltage is present at these connections.
NOTES, CAUTIONS AND WARNINGS NOTES, CAUTIONS, AND WARNINGS are used in this manual to emphasize important and critical instructions. They are used for the following conditions: An operating procedure, condition, etc. essential to notate. CAUTION Operating procedures, practices, etc. which if not strictly observed, will result in damage or destruction to your engine. WARNING Operating procedures, practices, etc. which if not correctly followed, will result in personal injury or loss of life.
TABLE OF CONTENTS PAGE GETTING TO KNOW YOUR GENERA TOR 9 SPECIFICATIONS (General and System) 15.0 BTDAR 20.0 BEDR 25.0 BEDR 32.
ENGINE SERVICE ITEMS CONTINUED ... ENGINE COOLANT GENERA TOR ADJUSTMENTS GENERA TOR MAINTENANCE ENGINE DC WIRING 55 56 57 58,59,60,61 GENERA TOR DESCRIPTION - GENERAL 63 15.0 BTDAR SINGLE PHASE INTERNAL WIRING SCHEMA TIC 65 20.0, 25.0, 32.
Preheat Solenoid Breaker Engine Oil Fill Emergency Shut-off Switch Speed Sensor \0 DC Alternator Shield Circuit Breaker Box Fan/Belt Guard :2 (t) Ul ..... .., (t) 0(t) A C Connections Outlet Exhaust Manifold ;><;"' (t) C) (t) ::l .., (t) po ..... o.., Ul 15.
~ -a(I) Water Temperature Switch en ( I) Fuel Filter (I) ;<;"" (I) CJ (I) Fuel Lift Pump ::l (I) - P.l o.., en Start/Stop Panel .Radiator _ .. LED Lights Unit Data Tag o DC Battery Ground Fan I Belt Guard Starter with Solenoid Injection Pump Lube Oil Filter Oil Pressure Sender 15.
Preheat Solenoid /Radia,or Fill Cap Emergency Stop Switch ;. ~ Control Panel DC Charging Alternator -LED Lights Lube Oil Drain Hose ~ ~ ~ ~ do ~ ~ ~ ::s DC Battery Ground Connection ~ ~ o .., en 20.
Top Engine Oil Fill ~ ~ (1) 8- Filter Air Intake Silencer ~ Breaker (1) o Fuel Lift Pump (1) ::l (1) g o.., en - Actuator Control Panel AC Connections Outlet ...... tv . Radiator Fresh Water Block Drain Oil Pressure Sender Lube Oil Filter Fuel Injection Pump 20.
13 Westerbeke Generators
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15 Westerbeke Generators
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15.0 BTDAR DIESEL GENERA TOR SINGLE PHASE & THREE PHASE GENERAL SPECIFICATIONS ENGINE TYPE Diesel, 4 cycle, 4 cylinder, fresh water cooled. Vertical, in-line overhead valve mechanism (30 hp at 1800 rpm maximum). GOVERNOR Electronic Governing COMBUSTION CHAMBER Swirl chamber type. BORE & STROKE 3.50 x 3.50 inches (88.9 x 88.9 mm) PISTON DISPLACEMENT 134.8 cubic inches (2.
GENERAL SPECIFICATIONS CONTINUED •.... DIMENSIONS Height: 28.50 inches (723 nun) Width: 24.8 inches (530 mm) Length: 49.6 inches (1260 nun) WEIGHT 870 lbs. (395 kgs) FUEL CONSUMPTION 2.0 gph (7.
15.0 BTDAR DIESEL GENERA TOR SINGLE PHASE & THREE PHASE SYSTEM SPECIFICATIONS FUEL SYSTEM: GENERAL Open flow, totally self-priming, 1 bleed point FUEL No.2 Diesel oil (cetane rating of 45 or higher) FUEL INJECTION PUMP Bosch Model VE Distributor FUEL INJECTION TIMING 0° TDC (Top Dead Center) NOZZLE Throttle type FUEL FILTER (on engine) Spin-on type, full flow AIR CLEANER Replaceable element AIR FLOW ( engine combustion) 70.0 dIn (l.
SUMP CAPACITY (not including filter) 5.3 quarts (5.0 liters) (plus filter/cooler assembly) OPERATING OIL PRESSURE (engine hot) 50 - 65 psi (3.5 - 4.5 kg/cm) OIL GRADE API SPECIFICATION OF CF OR CG-4 SAE 30, or 10W-30, 15W-40 ELECTRICAL SYSTEM: STARTING BATTERY 12 volt 170 A-H, (-) negative ground (recommended) (200 A-H in cold areas) BATTERY CAPACITY 400 - 600 cold cranking amps DC CHARGING ALTERNATOR 51 amp rated, belt driven STARTING AID Glow plug, sheathed type.
GENERATOR COOLING: 250 - 300 cfin (7.08 - 8.5 cmm) AIR REQUIREMENTS 60 Hertz at 1800 rpm NOTE: Increase air supply 15% for 50 hertz operation (1500 rpm) AC GENERATOR GENERAL: THREE PHASE ONLY Brushiess, six pole, revolving field. Sealed lubricated single-bearing design. 12 lead reconnectable for low voltage WYE, high voltage Delta. Solid State voltage regulator with protection circuitry.
20.0 BEDR DIESEL GENERA TOR SINGLE PHASE & THREE PHASE GENERALSPECnnCATIONS ENGINE TYPE Diesel, 4 cycle, 4 cylinder, fresh water cooled. Vertical, in-line overhead valve mechanism (40 hp at 1800 rpm maximum). GOVERNOR Electronic Governing COMBUSTION CHAMBER Swirl chamber type. BORE & STROKE 3.50 x 4.0 inches (88.9 x 101.6mm) PISTON DISPLACEMENT 154 cubic inches (2.
GENERAL SPECIFICA nONS CONTINUED.••.. DIMENSIONS Height: 28.50 inches (723.9 mm) Width: 22.0 inches (546.1 mm) Length: 45.79 inches (1163.3 mm) WEIGHT 7971bs. (361.5 kgs) FUEL CONSUMPTION 2.0 gph (7.
20.0 BEDR DIESEL GENERATOR SINGLE PHASE & THREE PHASE SYSTEM SPECIFICATIONS FUEL SYSTEM: GENERAL Open flow, totally self-priming, 1 bleed point FUEL No.2 Diesel oil (cetane rating of 45 or higher) FUEL INJECTION PUMP Bosch Model VB Distributor FUEL INJECTION TIMING 00 TDC (Top Dead Center) NOZZLE Throttle type FUEL FILTER (on engine) Spin-on type, full flow AIR CLEANER Replaceable element AIR FLOW ( engine combustion) 81.0 cfin (2.
SUMP CAPACITY (not including filter) 6.5 quarts (6.15 liters) (plus filter/cooler assembly) OPERATING all- PRESSURE (engine hot) 50 - 60 psi (3.5 - 4.2 kg/cm) Oll-GRADE API SPECIFICATION OF CF OR CG-4 SAE 30, or 10W-30, 15W-40 ELECTRICAL SYSTEM: STARTING BATTERY 12 volt (-) negative ground BATTERY CAPACITY 400 - 600 cold cranking amps DC CHARGING ALTERNATOR 51 amp rated, belt driven STARTING AID Glow plug, sheathed type.
GENERATOR COOLING: AIR REQUIREMENTS 60 Hertz at 1800 rpm 425 cfm (12.74 cmm) NOTE: Increase air supply 15% for 50 hertz operation (1500 rpm) AC GENERATOR GENERAL: THREE PHASE ONLY Brushless, six pole, revolving field. Sealed lubricated single-bearing design. 12 lead reconnectable for low voltage WYE, high voltage Delta. Solid State voltage regulator with protection circuitry.
25.0 BEDR DIESEL GENERATOR SINGLE PHASE & THREE PHASE GENERALSPECllITCATIONS ENGINE TYPE Diesel, 4 cycle, 4 cylinder, fresh water cooled. Vertical, in-line overhead valve mechanism (50 hp at 1800 rpm maximum). GOVERNOR Electronic Governing COMBUSTION CHAMBER Swirl chamber type. BORE & STROKE 3.74 x 4.13 inches (95 x 105 mm) PISTON DISPLACEMENT 182 cubic inches (2.
GENERAL SPECIFICAnONS CONTINUED .... DIMENSIONS Height: 28.6 inches(726.4 mm) Width: 23.3 inches (591.8 mm) Length: 49.9 inches (1140.5 mm) WEIGHT 752 Ibs. (345 kgs) FUEL CONSUMPTION 2.9 gph (10.
25.0 BEDR DIESEL GENERATOR SINGLE PHASE & THREE PHASE SYSTEM SPECIFICATIONS FUEL SYSTEM: GENERAL Open flow, self priming - 1 bleed point FUEL No.2 Diesel oil (cetane rating of 45 or higher) FUEL INJECTION PU1\1P Bosch Model VB Distributor FUEL INJECTION TIMING 0° TDC (Top Dead Center) NOZZLE Throttle type FUEL FILTER (on engine) Spin on type, full flow. AIR CLEANER Metal screen type clean able AIR FLOW ( engine combustion) 94.6 cfin (2.
SUMP CAPACITY (not including filter) 6.5 quarts (6.15 liters) plus filter/cooler assembly OPERATING OIL PRESSURE (engine hot) 50 - 60 psi (3.5 - 4.2 kg/cm) OIL GRADE API SPECIFICATION OF CF OR CG-4 SAE 30W or 10W-30, lSW-40 ELECTRICAL SYSTEM: STARTING BATTERY 12 volt (-) negative ground BATTERY CAPACITY 400 - 600 cold cranking amps DC CHARGING ALTERNATOR 51 Amp rated, belt -driven STARTING AID Glow plug, sheathed type.
AC GENERATOR GENERAL: GENERAL THREE PHASE ONLY Brushless, six pole, revolving field. Sealed lubricated single bearing design. 12 lead reconnectable for low voltage and high voltage WYE and for DELTA. Solid state voltage regulation with protection circuitry. Voltage - 3 Phase (60 Hertz) Low voltage WYE High voltage WYE DELTA 208 volts 480 volts 240 volts Voltage - 3 Phase (50 Hertz) High voltage WYE DELTA 380 volts 220 volts Amperage - 3 Phase (60 Hertz) .
32.0 BEDR DIESEL GENERATOR SINGLE PHASE & THREE PHASE GENERALSPEcnnCATIONS ENGINE TYPE Diesel, 4 cycle, 6 cylinder, fresh water cooled. Vertical, in-line overhead valve mechanism (67 hp at 1800 rpm maximum). GOVERNOR Electronic Governing COMBUSTION CHAMBER Swirl chamber type. BORE & STROKE 3.62 x 4.00 inches (92 x 101.6 mm) PISTON DISPLACEMENT 247.3 cubic inches (4.
GENERAL SPECIFICATIONS CONTINUED.... DIMENSIONS Height: 31.0 inches(787.4 nun) Width: 25.2 inches (640.3 nun) Length: 57.5 inches (1460.5 nun) WEIGHT 1250 Ibs. (567 kgs) FUEL CONSUMPTION 3.1 gph (11.
32.0 BEDR DIESEL GENERA TOR SINGLE PHASE & THREE PHASE SYSTEM SPECIFICATIONS FUEL SYSTEM: GENERAL Open flow, self priming - 1 bleed point FUEL No.2 Diesel oil (cetane rating of45 or higher) FUEL INJECTION PUMP Bosch Model VE Distributor FUEL INJECTION TIMING 0° TDC (Top Dead Center) NOZZLE Throttle type FUEL FILTER (on engine) Spin on type, full flow. AIR CLEANER Metal screen type clean able AIR FLOW ( engine combustion) 128.0 cfin (3.
OPERATING OIL PRESSURE (engine hot) 50 - 60 psi (3.5 - 4.2 kg/cm) OIL GRADE API SPECIFICATlON OF CF OR CG-4 SAE 30W or 10W-30, 15W-40 ELECTRICAL SYSTEM: STARTING BATTERY 12 volt (-) negative ground BATTERY CAPACITY 900-1000 COLD CRANKING AMPS DC CHARGING ALTERNATOR 51 Amp rated, belt-driven STARTING AID Glow plug, sheathed type.
AC GENERATOR GENERAL: GENERAL THREE PHASE ONLY Brushless, six pole, revolving field. Sealed lubricated single bearing design. 12 lead reconnectable for low voltage and high voltage WYE and for DELTA. Solid state voltage regulation with protection circuitry. Voltage - 3 Phase (60 Hertz) Low voltage WYE High voltage WYE DELTA 208 volts 480 volts 240 volts Voltage - 3 Phase (50 Hertz) High voltage WYE DELTA 380 volts 220 volts Amperage - 3 Phase ( 60 Hertz) .
YOUR NOTES 37 Westerbeke Generators
CONTROLS AND INSTRUMENTS o o INSTRUMENT PANEL The manually-operated series ofWesterbeke generators are equipped with toggle switches and optional remote panels. The instrument panel includes two gauges that indicate water temperature in degrees Fahrenheit (WATER OF) and oil pressure in pounds per square inch (OIL PSI). This panel is also equipped with two meters that indicate DC volts and hours of operations in 1I10ths.
DC VOLTMETER GAUGE 0 0 ~~ - ~ ~ ~9 ENGINE OIL PRESSURE 0 0 @~ ~ 0 ~. 0 0 ~e 0 Shows the amount the battery is being charged. Indicates the pressure of lube oil. The needle should indicate: 40-50 PSI (2.8-3.5 kg-cm) WATER TEMPERATURE GAUGE HOUR METER o o Indicates the temperature of engine coolant. The hour meter registers elapsed time and should be used as a guide for scheduled maintenance. During operation, it should be indicating 175° F - 195°F (80°- 91°C).
NEW GENERA TOR INITIAL INSPECTION Before starting your engine for the first time, check on the following items Appearance Electrical System DC Check for any missing part, loose bolt or nut, or any sign of damage. Check battery electrolyte level. Check connections for tightness and instruments for operation. Lubrication System Fuel System Check oil level in oil pan. Check for leaks. Check fuel level in tank. Check piping for leaks. Prime fuel system.
DAIL Y WALK-AROUND CHECKS For safety of operation and maximum service life of your engine, inspect the unit to make sure your answers to questions on these items are YES: Cooling System Battery Is coolant up to level in radiator filler? (Do not remove filler cap when engine is hot).
DIESEL FUEL. ENGINE OIL AND COOLING WATER DIESEL FUEL: Use fuel that meets the requirements or specifications of Class 2-D (ASTM). Cetane rating of#45 or better. CARE OF THE FUEL SUPPLY: Too much emphasis cannot be placed on the importance of using only clean diesel fuel. The clearance of the components in your fuel injection pump is very critical; invisible dirt particles which might pass through the filter can damage these finely finished parts. It is important to buy clean fuel, and keep it clean.
COOLING WATER: Use only water that is soft, or as free as possible from scale forming minerals. The use of an antifreeze mixture of 50/50 is recommended for year round use. Use an antifreeze brand such as "Prestone" that is compatible with aluminum engine components. Do not use straight water this can be deterimental to the aluminum engine and cooling system components. An antifreeze mixture will aid in cooling and protect against unexpected freeze.
OPERATING YOUR GENERATOR o C GENERATOR 0 ® STOP PRF;HUT ...... 0 mal~J\ ,., ~~ ____ ~_________o o Instrument Panel ~ :f~"UI W a ... WESTERBEKE o Start/Stop Panel 1. PREHEAT-Depress the PREHEAT switch. The voltmeter, panel lights, gauges and meters and fuel solenoid will be activated. The PREHEAT switch should be depressed in accordance with the chart presented below.
WARMING UP: Once the engine starts, check instruments for proper oil pressure, DC battery charge and generator AC output. Allow the engine to warm up for approximately 5 minutes before applying an amperage load. Note: There may be some unstable operation during warm up with a cold unit. Check that the engine/generator are operating without any abnormal noise or vibration.
ROUTINE SERVICE GENERAL RULES: 1. Before starting the generator for the day's run, be sure to carry out "walkaround checks". (See page 41.) 2. Service intervals in hours refer to the hour meter reading. On a daily basis, read the hour meter and record the reading in your log book. 3. Before attempting to service the engine, read the instructions in this manual thoroughly to get a full understanding of the extent and nature of routine service.
ROUTINE SERVICE SCHEDULE Rely on hour meter to schedule maintenance SERVICE ITEM EVERY 10 OPERATING HOURS OR DAILY See Page 41 1. Walk-around inspection. 2. Crankcase Check oil level in the sump. 3. Fuel Tank Check fuel level in the tank. 4. Radiator Check coolant level in the radiator and expansion tank. (Cold Engine) 5. Fuel FilterlWater Separator Check for any contaminants and clean as needed. 6. Starting battery Check electrolyte level and make sure cables have tight, clean connections.
ROUTINE SERVICE SCHEDULE CONTINUED•.. SERVICE ITEM EVERY 100 OPERATING HOURS 1. Lube Oil Change engine lube oil. 2. Lube oil filter Change lube oil filter 3. Air Filter Check, clean or replace as needed. 4. Fan Belt Adjust fan belt tension as needed. Check condition of belt. Replace as needed. EVERY 250 OPERATING HOURS 1. Fuel Filter(s) Replace fuel filter elements in electric fuel pump (if applicable) and in engine mounted cartridge filter. 2.
ROUTINE SERVICE SCHEDULE CONTINUED .... ITEM SERVICE EVERY 800 OPERA TING HOURS 1. Fuel injector(s) Remove, check and rebuild fuel injectors as needed. 2. Engine compression Check engine compression pressure. 3. DC alternator Check DC charge from alternator. Check pulley mounting and attachment of alternator to engine. 4. Engine parts Check security and tightness of nuts, bolts and wire connections. EVERY 1000 OPERATING HOURS 1.
SERVICE ITEMS 1. Engine Oil Change Remove the lubricating oil through the sump oil drain hose( this is attached to a bracket on the right forward side of the engine). The lube oil should be removed while the engine is still wann so it will flow easily out through the drain hose. o -Receiver When replacing the hose in its bracket be sure to securely reinstall the end cap. 2.
SERVICE ITEMS CONTINUED.... 3. Filling the Oil Sump Add fresh oil through the oil filter cap on the valve cover. After refilling with oil, run the engine for a few moments while checking the engine's oil pressure. Make sure there is no leakage around the new oil filter or from the oil drain system. Stop the engine. Wait a minute to allow the oil to settle. Then check the quantity of oil with the dipstick. Fill to, (but not over), the high mark on the dipstick, if the engine requires additional oil.
SERVICE ITEMS CONTINUED.... 5. Valve Clearance Adjustment (.012 inches - .3 mm cold, intake and exhuast) Note: Retorque the cylinder head bolts before adjusting the engine's valves. For the BTDAR 15 KW, BEDR 20 KW and 25 KW Engines: Position the No. 1 Piston at TOP DEAD CENTER (TDC) on its compression stroke and adjust the #1,2,3, and 6 valves (see the illustration to the right). 8 Position the No.4 piston at TDC of its compression stroke and adjust the #4, 5, 7 and 8 valves.
SERVICE ITEMS CONTINUED .... 7. Valve Clearance Adjustment Note: Retorque the cylinder head bolts before adjusting the engines valves. For the 32 BEDR engine: Position the No.1 piston at TOP DEAD CENTER (TDC) on its compression stroke and adjust the valve clearance: Intake Valve Cylinder # 1, #2 and #4 Exhaust Valve Cylinder #1, #3 and #5 Position the No.
SERVICE ITEMS CONTINUED .... 8. Injector Servicing r;-~C1&1 ~ ,. POOR. " '·:···~I .... . ,... Injector spray pressure: 1920 psi + 71 psi - 0 (135 kg/cm2 + 5 kg/cm2 - 0) I ~~~(H~~.:.ft."';:i~.-.....--~[jJj\ Eliminate undesirable injection conditions including after dripping. GOOD Check compression pressure. Remove each glow plug and check each cylinder's compression pressure. The engine's cranking speed is at 250 RPM.
SERVICE ITEMS CONTINUED... 10. Fan Belt Adjustment. Check visual condition of the fan belt. Replace as needed. Correct tension is reached with 3/8 - 1/2 inch deflection of the belt with 20 pounds of force. 11. Engine Coolant Change While the engine is cold, open the filler cap on the top of the radiator and then open drain petcock on the lower part of the radiator. (Drain and wash the plastic coolant recovery tank.) Open the engine block drain petcock located behind the lube oil filter.
SERVICE ITEMS CONTINUED..... 12. Radiator Pressure Cap Maintenance Periodically check the condition of the pressure cap. Ensure that the upper and lower rubber seals are in good condition. Check that the vacuum valve manually opens and closes tightly. 13. Electronic Governing System The system is composed of 3 basic components: 1. Controller - Mounted in the instrument panel. 2. Sensor - Installed on the bell housing over the flywheel ring gear. 3.
14. Generator Maintenance 1. Maintaining reasonable cleanliness is important. Connections of terminal boards and rectifiers may become corroded, and insulation surfaces may start conducting if saIts, dust, engine exhaust, carbon, etc., are allowed to build up. Clogged ventilation openings may cause excessive heating and reduced life of windings. 2. For unusually severe conditions, thin rust-inhibiting petroleum-base coatings should be sprayed or brushed over all surfaces to reduce rusting and corrosion.
ENGINE DC WIRING DIAGRAM r -, : ~ : BATTERY : SWITCH --' ~ ~ ________________________ START SOL. ~r~----~-~~ l.... ___ PREHEAT SOL. ________ STARTER ~M~ ____~ ~ 1 __________-+r-~---~_-~~,______~__________~GLOWPLUGS I I ' - ____ J ALTERNATOR r -, IOAI )1,' C·aL r -1 EMERGENCY : t 'STOP _JSWITCH ,. -, : : , _J SPEED ACTUATOR START SWITCH ~-- ---()j-I------~ _ _ _ _ oJ SPEED SENSOR i -i PREHEAT L _! SWITCH -+____________ L -__ : STOP : SWITCH _ J ~ K ~~ 87 W.T. SW. O.
DC Control CirC:Ji! Wiring Dia~ram -,. eve [f<.----------r-,'."I ~~ ....£.~. U ~ - ':"L!EL SOLENOID WATER TEMP. ..i SE~R ~ -r:~ GLOWP\.UGS .n ® .&(~~,~u~~::Jll ~D OIL PRESSURE SW. ! : ~~ . ~ ,-. -I".U OIL PRESS. ~ .~ .i II. ftl Lk~ ¥"'o .... .. ] ~ .,,,,,",,, III oJ .... L .. ... •. -rostED!."''' ", "I'" 1M ",t) .. .-- 'rOREC II "9W~f I I , I 4O~y.,.- J G&;,"RNQ9 C '!'Ro~ ~ 7 )\~\~ I '--- II.'" "'."'-'" '140Aw ·IO ..
DC WIRING DIAGRAM FOR REMOTE START/STOP PANEL. NOTE: For some applications, this panel may be mounted on the generator set and the instrument panel mounted at a remote location. REMOTE CONTROL PANEL (REAR VIEW) ,--------------------------------------------------------------i !! 55 A SURGE ~5/R~~ART RED :-----------------------------------------------------------------,------------------------- :____ 0 "" ~ i GREEN·.I TO TB I - I ~ TO TBI-GND .. STOP SWITCH ! i .
DC WIRING DIAGRAM CONTINUED ... ELECTRONIC GOVERNOR CIRCUIT TERMINAL BLOCK. MOUNTED INSIDE UNIT CONTROL PANEL.
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GENERATOR DESCRIPTION SUMlv1ARY BE-BRUSHLESS ELECTRONIC BT-BRUSHLESS TRANSFORMER Construction Type Brushless, four pole, revolving field, single bearing Speed: 60 Hz 50HZ 1800 RPM 1500 RPM* Phase 1 or 3 Ventilation Self - ventilated (fan cooled) Cooling Air Requirements 15 KW & 20 KW & 25 KW 450-500 CFM 32 KW 525-550 CFM Ambient Temp., Max. Insulation Class F Number of Poles 4 or 6 Stator Leads: 3 Phase 1 Phase 6 or 12 3 or 4 *Voltage and KW are 5/6 of rating at 1800 RPM.
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15.0 BTDARGENERATOR INTERNAL WIRING SCHEMATIC SINGLE PHASE A 1 - r--------, C r---------------, ,..--------., I 0 I I ;;';~l~·~!~~~~~i~~~ ~ jl=-:Btlj ~IlI~z~! ~!~:~2~:r:-'7 ,. :t I.. _______________ 2 "I I I 3 r_-I_-_-_-_._, J 1 I I t.! l!1lF_~ __ J 3;; ~~_RZI)=__. . I. G + I au: I II AC T E R M I M II L B L 5 o C K u ® S T U o G + Fe _-t::..h 1 r-- YnLOY ,--, I BUCK cJtRl'l 'YULOY ~,~U~ I BLACX Black/'lIt ... St •• /White (T. '-I . . , ... Sw"'e.l:t.) I . Y.
20,25,32.0 BEDR GENERATOR INTERNAL WIRING SCHEMATIC SINGLE PHASE r-----------------~N N > UJ V> €> <9 :x ::l N < :I: 0.. UJ \ole; J . ~M M r--- C) Z V> --, 0:: U) 0 J UJ l- ~ 1 cc· l- Q o IA. , I/) L ___ J: --..I 0::: • o 1-. N < 0::: UJ Z UJ r-----------, I 1 C) I I I .1 I I I· I I I g~ I- UJ 0- c::u.. 1 I I WI § J CIl c:: I J I -- J __ 1.., Q J 1 J I J I r---L----c:: ~o::: 0 -0 1 I 1 UII I IL _ _ _ xo ...., _ c::_ _ _ _ _ _ _ .
15.0 BTDAR 20, 25, 32.0 BEDR GENERATOR INTERNAL WIRING SCHEMATIC THREE PHASE ONLY - ---- ---, r --- cz: o .0\ ex:: ( ( - ( II(I) o 1 l. _ _ _ - - I- - - t- - _.J UJ cr. 03~ UJ U .....I co « (1)1- I- -.J« u UJ UJ~ QUJ z z ~3 ~- (I) 0:: oc.!) 1-::; «0:: 0:::_ UJ> Z LU.....I 0 NO U UJ oa::; c.t:r o I- e:! I I > UJ > I- 1 UJ ~ 2: Cl. .~ L~:J I I~ « I~. I 0 .0::. :J: 0.. 0:: 1'1"\ UJ )(::lIns r-----------,I UJ 0:: (I) 1-0:: NV 0:: (!;« >UJ z .....
Regulator Adjustments Volts: This potentiometer is used to adjust output voltage. At proper engine operating speed, the output voltage should be held at ± 2% from a no load condition to full rated generator output and from power factor l.0 - 0.8 with engine drive speed variations of up to -6%. Stability: This potentiometer permits variation of the regulator's response to generator load changes so as to limit over compensation and obtain a minimum recovery time to the normal voltage output.
BTDAR GENERATOR (Single Phase) NO LOAD VOLTAGE ADJUSTMENT Voltage adjustment is made with the generator regulation being governed by the compound transformer. 1. The selector switch must be in the COMP position. 2. Operate the generator, apply a moderate load momentarily and remove it. Note the voltage output from the generator's 120 volt leges) (220 volt 50 hertz). The no-load voltage should be between 121-124 volts at 60.0 hertz (222-228 volts at 50.0 hertz).
AC OUTPUT CONNECTIONS Single & Three Phase BT SINGLE PHASE AC CONNECTIONS FOR 220V 50HZ llOV 50Hz II ~ 0 2 0 5 0 2 0 5 r!'" 6 R (Q 6 0) 7 ~ 8 I I 7 N 120V 60Hz II LI L2 N 120/240V-GOHZ. AVR AVR 10 8 11 120V-f,O HZ. 12 8 5 J--I--L2 2 4 4 3 CL~D--+--- L -_ _ _ _ _ _ _ _ _ _ _ _ _ L-l 208 L-~ 120 L-l 190 L-~ 110 L3 [~l N -= VAC 3~ 60HZ VAC 1!J 60HZ VAC 3~ 50HZ VAC 1!1 50HZ NOTE - 0 7 3 0 8 o 6 3 o BE SINGLE PHASE AVR AVR 10 220V-50HZ.
BTDAR GENERA TOR (Single Phase) OPTIONAL VOLTAGE REGULATOR An optional solid-state voltage regulator (board #34410) is available to use with the BT series generators. When installed, and the regulation switch is moved to the ELEC position, the regulator works together with the standard compound transformer regulator to regulate the generator's voltage output.
ENGINE TROUBLESHOOTING Introduction The tables which follow indicate troubleshooting procedures based upon certain problem indicators, the probable causes of the problems, and the 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 a bracket on the right side of the engine, just forward of the generator's end plate.
PROBLEM PROBABLE CAUSE VERIFICAnONI REMEDY ST ART switch is depressed: Poor connections to fuel solenoid or no voltage Check for 12 volts to fuel solenoid on injection pump and connection. Engine cranks and does not start. No fuel to injectors. Defective fu'el solenoid. Check that 12 Volts are present on the injection pump. Remove solenoid from the pump and test separately No ignition: cranks but does not start; fuel solenoid energized. Faulty fueling system. 1.
PROBLEM PROBABLE CAUSE VERIFICATIONI REMEDY Engine Stops. Low oil pressure or overheated. Check oil level; check fresh water coolant. Check gauge reading for indication of cause. Low oil pressure switch opens. Check for satisfactory operation with switch bypassed. Check with ohmmeter. High water temperature switch opens at too low a temperature. Check for satisfactory operation with switch bypassed. Check with an ohmmeter. 20-Amp circuit breaker tripping.
PROBLEM PROBABLE CAUSE VERIFICATIONI REMEDY Battery not charging. Alternator drive. Check drive belt tension. Be sure alternator turns freely. Check for loose connections. Check output with voltmeter. Ensure 12 Volts are present at EXC terminal. Battery runs down. Oil pressure switch. Observe if gauges and panel lights are activated when engine is not running. Test the oil pressure switch. Battery runs down. High resistance leak to ground. Check wiring. Insert sensitive (0-.
PROBLEM PROBABLE CAUSE VERIFICATION/ REMEDY Engine slows and stops Fuel starvation Check fuel filter for contamination. Check operation of fuel pump. Check fuel tank vent is clear. Engine will not shut down when stop switch depressed. DC Circuit Fault. Check for DC feed through DC charging regulator. Disconnect exc. led. Then depress stop switch. Check for faulty stop switch.
TORQUE SPECIFICATIONS (lb-ft) Cylinder Head Cylinder Head Cover Connecting Rod Cap Main bearing Cap Camshaft thrust plate Camshaft gear Idler Gear Injection Pump Drive Gear Nut Rocker Arm Assembly Timing Gear Cover Bolts Rear Oil Seal Cap Oil Pan Bolts Oil Pump Cover Bolts Oil Pump Pipe Fresh Water Pump Bolts Crankshaft Pulley Nut Glow Plug Injector to Head Injection Nozzle to Body Injection Pipe Flare Nut Intake Manifold Nuts Exhaust Manifold Nuts Back Plate Bolts Flywheel Bolts Damper Bolts BTDR 15.
TABLE OF STANDARD HARDWARE TIGHTENING TORQUES Unless stated otherwise for a specific assembly, use the following torque values when tightening standard hardware. Pitch Ib-ft 6nun bolt head/nut Snun bolt head/nut 10 nun bolt head/nut 10 nun bolt head/nut 12 nun bolt head/nut 12 nun bolt head/nut 12 nun bolt head/nut 13 nun bolt head/nut 14 nun bolt head/nut 14 nun bolt head/nut 16 nun bolt head/nut 16 nun bolt head/nut 1 1.25 1.25 1.5 1.25 (ISO) 1.5 1.75 1.5 1.5 2 1.5 2 0.4 - .07 2.9 - 5.1 7.2 - 11.61.
