Westerbeke BTG-9KW User manual

OPERATOR'S MANUAL

WESTERBEKE

BTG - 9

Marine Gasoline

Generator Set

Publication # 36710

Edition One

June 1987

jr~

'WESTERBEKE

WESTERBEKE

CORPORATION

•

MYLES

STANDISH

INDUSTRIAL

PARK

•

150

JOHN HANCOCK

ROAD,

TAUNTON,

02780-7319

U.S.A.

Gasoline with an ETHANOL content

higher than 10% (E10) is not allowed

and may void warranty.

Engines & Generators

SAFETY PRECAUTIONS

The

following

symbols

appear

manual

call

attention

emphasize

conditions

potentially

dangerous

the

operator

equipment.

this

and

the

WARNING

CAUTION

This

sy~bol

used

the

manual

warn

possible

serlOUS

personal

inJury

loss

life.

This

symbol

used

the

manual

caution

per-

sonnel

possible

damage

equipment.

Read

the

manual

carefully

and

thoroughly

before

attempting

operate

the

equlp-

ment.

Know

when

dangerous

condi

ions

can

exist

and

take

necessary

precautions

protect

personnel

and

equIpment.

Fuels,

exhaust

gases,

batteries,

electrical

equipment,

and

moving

and

hot

parts

are

potential

hazards

that

could

result

serious

personal

injury

death.

recommended

procedures

carefully.

Always

operate

bilge

blowers

for

least

five

minutes

before

starting

oasoline-fueled

enoine;

ensure

oaso-

line

fumes

are

present

before

starting.

•

Prevent

Electric

Shut

off

electric

power

before

accessing

electrical

equ1pment.

Use

insulated

mats

whenever

working

electrical

equipment.

Make

sure

clothing

dry,

not

damp

(particularly

shoes;,

and

keep

sk1n

surfaces

dry

when

handling

electri-

cal

equipment.

Remove

wristwatch

and

jewelry

when

working

electrical

equ1pment.

not

connect

utility

shore

power

vessel's

circuits,

except

through

ship-to-shore

double-throw

transfer

switch.

Damaoe

vessel's

generator

may

resul~.

extremely

careful

when

workinc

electrical

components.

High

vol~age

can

cause

injury

death.

Exhaust

!£tiE

Ensure

that

the

exhaust

system

adequate

expel

gases

discharged

from

the

engine.

Check

exhaust

system

regularly

for

leaks

and

make

sure

exhaust

manifolds

are

securely

attached

and

warping

exists.

sure

the

unit

and

its

surround-

ings

are

well-ventilated.

•

Use

Extreme

Enoine

Fuel.

expros

ioner

not

fill

running.

Care

When

Handllne

c'onstant

danger

fire

exists.)

fuel

tank

with

engine

not

smoke

use

open

flame

near

the

eng1ne

the

fuel

tank.

Keep

combustible

materials

away

from

the

uni

sure

all

fuel

supplies

have

positive

shutoff

valve.

certain

adequately

leaks.

fuel

line

tightened

fittinos

are

and

free

Make

sure

fire

extinouisher

installed

nearby

and

properly

maintained.

familiar

with

its

proper

use.

Extinguishers

rated

ABC

the

NFPA

appropr

iate

for

all

applications

encountered

this

environment.

Use

Extreme

Care

When

Servicing

'b"atterles.

Wear

rubber

gloves,

and

eye

protection

batteries.

rubber

apron,

when

serv1cing

Leac

acid

batteries

emit

hvdrooen,

hiohlv-explosive

oas,

wh-ich -

can

1clniced

b\'

electrical

arC1nc

11ghted

cig~rette,

cigar,

pipe.

not

smoke

allo'"

open

flame

near

batten'

beino

serviced.

Snut

off

all

electr

ical

equipment

the

vicinity

prevent

electrical

arcing

dur1ng

servicing.

Avoid

Parts.

not

service

unit

while

unit

running;

absolutely

necessary

make

operating

adjustments,

use

ex-

treme

care

avoid

moving

parts

and

hot

exhaust

system

components.

not

wear

loos~

clothing

jewel-

when

servicing

equipment;

avoid

loose

jackets,

shirts

sleeves,

rings,

necklaces,

bracelets

that

might

caught

moving

parts.

Make

sure

all

attaching

hardware

properly

tightened

and

keep

protec-

tive

shields

and

guards

place

all

times

.•

not

check

fluid

levels

drive-

belt

tension

while

unit

opera-

t1ng.

not

work

equipment

when

men-

tally

physically

incapacitated

fatigue.

IMPORTANT

PRODUCT

SOFTWARE

DISCLAIMER

Product

software

all

kinds,

such

brochur

es,

awing

technical

data,

operator's

and

workshop

manuals,

parts

lists

and

parts

price

lists

(and

other

information),

instruct

ions

and

speci

fica

ions

prov

ided

from

source

other

than

Westerbeke,

not

within

Westerbeke's

control

and,

accordingly,

provided

Westerbeke

customers

only

courtesy

and

service.

WESTERBEKE

CANNOT

RESPONSIBLE

FOR

THE

CONTENT

SUCH

SOFTWARE,

MAKES

WARRANTIES

REPRESENTATIONS

WITH

RESPECT THERETO, INCLUDING

THE

ACCURACY,

TIMELINESS

COMPLETENESS

THEREOF,

AND

WILL

EVENT

LIABLE

FOR

ANY

TYPE

DAMAGES

INJURY

INCURRED

CONNECTION

WITH,

ARISING

OUT

OF,

THE

FURNISHING

USE

SUCH

SOFTWARE.

For

example,

components

and

sub-assemblies

incorporated

into

Westerbeke's

products

and

supplied

others

(such

engine

blocks,

fuel

systems

and

components,

transmissions,

electri-

cal

components,

pumps

and

other

products)

are

generally

sup-

ported

their

manufacturers

with

their

own

software,

and

Westerbeke

m'ust

depend

such

software

for

the

design

Westerbeke's

own

product

software.

Such

software,

however,

may

outdated

and

longer

accurate.

Routine

changes

made

Wester

beke'

supplier

ich

Wester

beke

rarely

has

notice

advance,

are

frequently

not

reflected

the

supplier's

software

until

after

such

changes

take

place.

Westerbeke

customers

should

also

keep

mind

the

time

span

between

intings

Westerbeke

product

software,

and

the

unavoidable

existence

earlier,

non-current

Westerbeke

software

i t

ions

the

field.

Addi

ionally,

most

Westerbeke

products

include

customer-requested

special

fea

tur

that

equen

tly

not

include

complete

documen-

tation.

summation,

product

software

provided

with

Westerbeke

pro-

ducts,

whether

from

Westerbeke

other

suppliers,

must

not

and

cannot

relied

upon

exclusively

the

definitive

authority

the

respective

product.

not

only

makes

good

sense,

but

imperative

that

appropriate

representatives

Westerbeke

the

supplier

question

consulted

deter-

mine

the

accuracy

and

currency

the

product

software

being

consulted

the

customer.

FOREWORD

Thank

you

for

selecting

Westerbeke

marine

product

for

your

use.

Westerbeke

are

pleased

have

you

customer.

Read

this

manual

carefully

and

observe

all

safety

precautions

included

throughout.

Operating

procedures,

periodic

preventive

maintenance

procedures,

installation

checks,

system

descriptions

and

minor

adjust-

ment

procedures

are

included

herein

that

you

can

operate

your

equipment

safely

and

properly,

maintain

the

equipment

high

level

efficiency,

and

expect

dependable

performance

and

long

service

life

return.

Should

your

unit

require

special

attention,

contact

your

Westerbeke

dealer

for

assistance.

The

Westerbeke

Service

Organization

trained

provide

the

support

necessary

ensure

long-term

dependable

performance.

If,

within

days

submitting

the

Warranty

Registration

Form

for

your

unit,

you

have

not

received

Customer

Identification

Card

(see

below)

registering

your

warranty,

please

contact

the

factory

writing

with

Model

information,

including

the

unit

serial

number

and

commission

date.

from: J.H. Westerbeke Corp.

Avon

Industrial

Park

Avon, MA 02322

•

r'~jr

WESTERBEKE

•

AV(JfoINOUS'kll"L

I>A/iiI,

AV(h

10.1,1.023.'1.

'I.

,~",~

,'()(

rutx

~/"'''''.'~A¥

lel',~~"3~_"CA&1

wfsrc~p

CUSTOMER IDENTIFICATION

Adam

Smith

Mail

To:

Maple

Street

Alden,

12234

ModeJ_

B'TG

9KW

Ser.#1234C706

Expires

7/7/88

TABLE

CONTENTS

Title

GENERAL

..••••••••.•••••.••••••.••••..

GENERAL

SPECIFICATIONS

•••••••••••••••

SYSTEM

SPECIFICATIONS

••••.•••.••.••.

TUNE-UP

SPECIFICATIONS

••••••••••..••

INSTALLATION

••••••••.••••••••.•••••

GENERATOR

.•••••••••••.•••••••••••

OPERATION

•.••••.•••.•..••••.••.•..•.

SERVICE

AND

MAINTENANCE

.•••.••••••••

ENGINE

ADJUSTMENT

•••••••••••••••.•••

CIRCUIT DESCRIPTION

•••••••••••.•.

GENERAL

INFORMATION

AND

CARE

THE

GENERATOR

••••...•.

ENGINE TROUBLESHOOTING

••.•••••••.••.

TIGHTENING

TORQUES

••••••.••••••••.••

GENERAL

Introduction

This

manual

contains

the

equipment

operating

procedures

well

information

assist

the

operator

maintain

the

equipment

proper

working

order.

Study

and

the

instructions

carefully.

planned

rna

tenance

prog

included

manual;

adher

ing

the

prog

ram

will

result

better

equipment

per

formance

and

longer

equipment

life.

Proper

diagnosis

problem

the

most

important

step

satisfactory

repair;

consequently,

troubleshooting

table

included.

Understanding

the

Gasoline

Powered

Generator

The

gasoline

engine

driving

the

generator

many

ways

similar

automobile

engine.

The

cylinders

are

vertical

and

in-line,

with

belt-driven,

overhead

camshaft.

The

engine

utilizes

breaker

points

and

condenser

type

distributor

which

horizontally-mounted

and

camshaft-driven,

pressure

type

lubrication

system,

and

thermostatically-controlled

water-cooled

engine

block

with

ex-

changer

system.

great

extent,

the

gasoline

engine

used

drive

the

generator

~equires

the

same

preventive

maintenance

that

any

responsible

operator

would

give

the

gasoline

engine

his

automobile.

The

most

important

factors

contributing

the

long

life

the

unit

are

proper

ven-

tilation

and

maintenance

the

fuel

system,

ignition

system,

cooling

system,

and

the

generator

end.

Order

ing

Parts

When

contacting

your

Westerbeke

dealer,

parts

distributor,

the

fac-

tory

about

your

Westerbeke

unit,

always

provide

the

model

number

and

serial

number

they

appear

the

nameplate

(located

the

surface

the

exhaust

manifold/coolant

tank).

This

information

necessary

order

identify

your

unit.

Note

that

component

locations

the

manual

are

referenced

from

the

front

the

engine

which

the

pulley/drive

belt

end.

(The

flywheel/generator

transmission

end

the

rear

end.)

Left

and

right

sides

are

determined

the

engine;

imagine

straddling

the

eng

ine

and

facing

the

same

dir

ection

the

front

the

eng

ine:

the

left

side

your

left,

the

right

side

your

right.

Westerbeke

engines

and

generator

sets

are

thoroughly

checked

and

given

final

run

under

various

load

conditions

before

leaving

the

factory.

This

done

ensure

dependable

operation,

long

service,

and

satisfied

owner.

record

this

test

maintained

the

factory.

Care

the

factory

during

assembly,

and

thorough

testing,

have

resulted

Westerbeke

gasoline

engine-driven

generator

capable

many

thousands

hours

dependable

service.

However,

the

manufac-

turer

cannot

control

the

treatment

the

unit

receives

the

field.

That

part

the

owner/operator.

BTG

Gasoline

Generator

Set

GENERAL

SPECIFICATIONS

BTG

MARINE

GASOLINE

GENERATOR

SET

Engine

Type

Combustion

Chamber

Valve

Mechanism

Bor

e &

Stroke

Piston

Displacement

Firing

Order

Direction

Rotation

Compression

Ratio

Compression

Pressure

Valve

Timing

Valve

Seat

Angle

Valve

Clearance

(eng

ine

warm)

Eng

ine

Speed

Dimensions

Gasoline,

4-cycle,

3-cylinder,

vertical,

in-line

Multi-sphere

type

Overhead

camshaft,

belt-driven

2.99

2.87

inches

(76

mm)

60.6

cubic

inches

(0.993

liter)

1-2-3

Clockwise,

when

viewed

from

the

front

9.5:1

177.8

psi

(12.5

kg/cm

350

rpm

Intake

Opens

19·

BTDC

Intake

Closes

51·

ABDC

Exhaust

Opens

51·

BBDC

Exhaust

Closes

19·

ATDC

Intake

45·

Exhaust

45·

Intake

0.0079

inch

(0.20

mm)

Exhaust

0.0079

inch

(0.20

rom)

1800

rpm

(belt-driven

mechanical

governor)

Height:

Width:

Length:

23.38

inches

(593.85

rom)

18.69

inches

(474.73

rom)

28.25

inches

(717.55

mm)

Weight

386

(175.0

kg)

Sea

Water

Flow,

1800

rpm

4.5

5.0

gpm

(17.03

18.92

lpm)

(measured

discharge

from

heat

exchanger)

Fuel

Consumption

1.5

gph

(5.68

lph)

full

rated

output

(approximate)

FUEL

SYSTEM

Fuel

Carburetor

Governor

Lift

pump

Air

Cleaner

COOLING

SYSTEM

SYSTEMS

SPECIFICATIONS

Unleaded

leaded

gasoline

(minimum

octane

89)

Down-draft,

single-barrel

Mechanical

type,

belt-driven

12-Volt

electric;

lift

capacity

(1.8

Metal

screen

type

cleanable

General

Fresh

water-cooled

block,

thermostatically-controlled

with

sea

water

exchanger

system

Operating

temperature

130-lS0·F

(55·

66·C)

Fresh

Water

Pump

Centrifugal

type,

metal

impeller,

belt-driven

Sea

Water

Pump

positive

displacement

rubber

impeller,

belt-driven

Sea

Water

Flow,

1800

rpm

4.75

5.0

gpm

(17.98

18.92

Ipm)

(measured

discharge

from

heat

exchanger)

System

Capacity

5.7

qts

(5.39

liters)

(fresh

water)

LUBRICATION

SYSTEM

General

Oil

Filter

Sump

Capacity

(filter

not

included)

Oil

Pressure,

1800

rpm

(engine

hot)

Oil

Grade

Pressure

type

with

trochoid

pump,

chain-driven

through

balance

shafts

Full

flow,

paper

element,

spin-on

type.

3.0

qts

(2.841

liters)

psi

(3.5

4.9

kg/cm

API

spec

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