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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-.v-
'WESTERBEKE
WESTERBEKECORPORATION
~
MYLES STANDISH INDUSTRIAL PARK
150 JOHN HANCOCK ROAD, TAUNTON, MA 02780-7319
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Related Manuals for Westerbeke 25.0BTDAR 60HERTZ
Summary of Contents for Westerbeke 25.0BTDAR 60HERTZ
- Page 1 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...
- Page 2 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.
- Page 3 The engine serial number can also be found stamped into the engine block on a smooth rectangular surface above the injection pump. The generator serial number is stamped into the generator housing on the flat surface above the rear generator bearing. Westerbeke Generators...
- Page 4 DON'T touch any moving part on starting your generator. your engine during operation. • DO check your engine once a • DON'T touch hot engine parts such day. Keep eyes open and be as exhaust manifolds. alert to people and obstacles. Westerbeke Generators...
- Page 5 Battery gas is highly flammable. Sulfuric acid is destructive. If it comes in contact with your skin, wash it off at once with water. Westerbeke Generators...
- Page 6 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. Westerbeke Generators...
- Page 7 Operating procedures, practices, etc. which if not correctly followed, will result in personal injury or loss of life. DEFINITION OF LOCAL TERMS The words "leftside", "rightside", "front", and "rear" are used in the senses illustrated below: Right Front Rear 0000 ( Radiator (Generator End) End) Left Westerbeke Generators...
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Page 8: Table Of Contents
STOPPING ROUTINE-SERVICE GENERAL RULES SAFETY RULES SERVICE SCHEDULE SERVICE ITEMS ENGINE OIL & FILTER CYLINDER HEAD BOLTS AND VALVE ADJUSTMENTS 51,52 15.0 BTDAR & 20.0 BEDR 25.0 & 32.0 BEDR 52,53 INJECTOR SERVICING AIR FILTRATION SYSTEM FAN BELT Westerbeke Generators... -
Page 9: Btdar
BTDAR & BEDR INTERNAL WIRING SCHEMA TIC (THREE PHASE ONLY) VOLTAGE REGULATOR ADJUSTMENTS 20,25,32 BEDR 15 BTDAR NO LOAD VOLTAGE ADJUSTMENT (SINGLE PHASE ONLY) AC VOLTAGE CONNECTIONS-ALL MODELS 15 BTDAR OPTIONAL VOLTAGE REGULATOR (SINGLE PHASE ONLY) ENGINE TROUBLESHOOTING TORQUE SPECIFICATIONS 77,78 Westerbeke Generators... - Page 10 Preheat Solenoid Breaker Engine Oil Fill Emergency Shut-off Switch Speed Sensor DC Alternator Shield Circuit Breaker Box Fan/Belt Guard ..A C Connections Outlet Exhaust Manifold ;><;"' 15.0 BTDAR GENERATOR ..RIGHT SIDE...
- Page 12 Water Temperature Switch ( I) Fuel Filter ;<;"" Fuel Lift Pump Start/Stop Panel .Radiator _ LED Lights Unit Data Tag DC Battery Ground Fan I Belt Guard Starter with Solenoid Injection Pump Oil Pressure Sender Lube Oil Filter 15.0 BTDAR GENERATOR LEFT SIDE...
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Page 14: Bedr
Preheat Solenoid /Radia,or Fill Cap Emergency Stop Switch Control Panel DC Charging Alternator LED Lights Lube Oil Drain Hose DC Battery Ground Connection 20.0 BEDR RIGHT SIDE... -
Page 15: Bedr
Top Engine Oil Fill Filter Air Intake Silencer Breaker Fuel Pump Lift Control Panel Actuator AC Connections Outlet ..Radiator Fresh Water Block Drain Oil Pressure Sender Lube Oil Filter Fuel Injection Pump 20.0 BEDR LEFT SIDE... - Page 16 Westerbeke Generators...
- Page 17 Westerbeke Generators...
- Page 18 Westerbeke Generators...
- Page 19 Westerbeke Generators...
- Page 20 Exhaust Opens 51 ° BBDC Exhaust Closes 13 ° ATDC VALVE SEAT ANGLE Intake 45° Exhaust 30° VALVE CLEARANCE Intake 0.012 inches (0.3 mm) (Engine Cold) Exhaust 0.012 inches (0.3 mm) 1800 rpm 60 Hertz ENGINE SPEED 1500 rpm 50 Hertz Westerbeke Generators...
- Page 21 Height: 28.50 inches (723 nun) Width: 24.8 inches (530 mm) Length: 49.6 inches (1260 nun) WEIGHT 870 lbs. (395 kgs) full FUEL CONSUMPTION 2.0 gph (7.571ph) at rated output ( approximate) INCLINATION Continuous 15 min) Temporary 20 (not to exceed 20 Westerbeke Generators...
- Page 22 Closed fresh water-cooled block, thermostatically controlled with radiator OPERATING TEMPERATURE FRESH WATER PUMP Centrifugal type, metal impeller, belt-driven. SYSTEM CAPACITY (Fresh Water) 11.5 quarts (10.88 liters) approximately LUBRICATION SYSTEM: GENERAL Pressure fed system OIL FILTER Full flow, paper element, spin-on type Westerbeke Generators...
- Page 23 2% no load to load Frequency regulation: .3 Hertz (.005%) no full load to load. RATING (Volts AC) 60 Hertz (1800 RPM) 120 volts 125 amps 15KW 120/240 Volts 125/62.5 amps 50 Hertz (1500 RPM) 220 volts 54.5 amps 12KW Westerbeke Generators...
- Page 24 Amperage - 3 Phase (50 Hertz) High voltage WYE 22.8 Amps .8 Powerfactor DELTA 39.4 Amps TUNE UP SPECIFICATIONS: 5-0 kglcm 2 ) Inj ector Pressure 1920 71-0 psi (135 Engine Timing Static timed - drop valve method ± 0.205 .005 inches BTDC Westerbeke Generators...
- Page 25 Exhaust Opens 51 ° BBDC Exhaust Closes 13° AIDC VALVE SEAT ANGLE Intake 45° Exhaust 30° VALVE CLEARANCE Intake 0.012 inches (0.3 mm) (Engine Cold) Exhaust 0.012 inches (0.3 mm) ENGINE SPEED 1800 rpm 60 Hertz 1500 rpm 50 Hertz Westerbeke Generators...
- Page 26 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 (7.571ph) at full rated output (approximate) INCLINATION Continuous 15° Temporary 20° (not to exceed 20 min) Westerbeke Generators...
- Page 27 OPERATING TEMPERATURE F (77 FRESH WATER PUMP Centrifugal type, metal impeller, belt-driven. SYSTEM CAPACITY (Fresh Water) 11.5 quarts (10.88 liters) approximately LUBRICATION SYSTEM: GENERAL Pressure fed system OIL FILTER Full flow, paper element, spin-on type Westerbeke Generators...
- Page 28 2% no load to load Frequency regulation: .3 Hertz (.005%) no full load to load. RATING (Volts AC) 60 Hertz (1800 RPM) 120 volts 166 amps 20KW 1201240 Volts 166/83 amps 50 Hertz (1500 RPM) 220 volts amps 72.7 16KW Westerbeke Generators...
- Page 29 Amperage - 3 Phase (50 Hertz) High voltage WYE 30.4 Amps .8 Powerfactor DELTA 52.5 Amps TUNE UP SPECIFICATIONS: 5-0 kg/cm 2 ) Injector Pressure 1920 71-0 psi (135 Engine Timing Static timed - drop valve method ± 0.205 .005 inches BTDe Westerbeke Generators...
- Page 30 BBDC Exhaust Closes 13° ATDC VAL VB SEAT ANGLE Intake 45° Exhaust 30° VAL VB CLEARANCE Intake 0.012 inches (0.3 mm) (Engine Cold) Exhaust 0.012 inches (0.3 mm) ENGINE SPEED 1800 rpm 60 Hertz 1500 rpm 50 Hertz Westerbeke Generators...
- Page 31 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) full FUEL CONSUMPTION 2.9 gph (10.9Iph) at rated output (approximate) INCLINATION Continuous 15° min) Temporary 20° (not to exceed 20 Westerbeke Generators...
- Page 32 OPERATING TEMPERATURE FRESH WATER PU1\1P Centrifugal type, metal impeller, belt-driven. SYSTEM CAPACITY (Fresh Water) 11. 5 quarts (10. 88 liters) approximately LUBRICATION SYSTEM: GENERAL Pressure fed system OIL FILTER Full flow, paper element, spin-on type Westerbeke Generators...
- Page 33 2% no load to full load Frequency regulation: .3 Hertz (.005%) no load to full load. RATING (Volts AC) 60 Hertz (1800 RPM) 120 volts 208 amps 25.0KW 120/240 208/104 amps 50 Hertz (1500 RPM) 220 volts 91 amps 20.0 KW Westerbeke Generators...
- Page 34 NOTE: Increase air supply 15% for 50 hertz operation (1500 rpm) TUNE-UP SPECIFICATIONS: 5-0 kg/cm 2 ) INJECTOR PRESSURE 1920 70 - 0 psi (135 ENGINE TIMING Static timed - drop valve method ± 0.180 .005 inches BIDC Westerbeke Generators...
- Page 35 Exhaust Opens 48° BBDC Exhaust Closes 10° A IDC VALVE SEAT ANGLE Intake 45° Exhaust 30° VALVE CLEARANCE Intake 0.012 inches (0.3 mm) (Engine Cold) Exhaust 0.012 inches (0.3 mm) ENGINE SPEED 1800 rpm 60 Hertz 1500 rpm 50 Hertz Westerbeke Generators...
- Page 36 Height: 31.0 inches(787.4 nun) Width: 25.2 inches (640.3 nun) Length: 57.5 inches (1460.5 nun) 1250 Ibs. (567 kgs) WEIGHT 3.1 gph (11. 73 Iph) at full rated output FUEL CONSUMPTION (approximate) INCLINATION Continuous 15° Temporary 20° (not to exceed 20 min) Westerbeke Generators...
- Page 37 FRESH WATER PUMP Centrifugal type, metal impeller, belt-driven. SYSTEM CAPACITY (Fresh Water) 18.5 quarts (17.5 liters) approximately LUBRICATION SYSTEM: GENERAL Pressure fed system OIL FILTER Full flow, paper element, spin-on type SUMP CAPACITY (not including filter) 14.0 quarts (13.2 liters) Westerbeke Generators...
- Page 38 2% no load to full load Voltage regulation Frequency regulation: .3 Hertz .005% no load to full load. RATING (Volts AC) 60 Hertz (1800 RPM) 120 volts 266 amps 32.0KW 120/240 266/133 amps 50 Hertz (1500 RPM) 220 volts 113.6 amps 25.0 KW Westerbeke Generators...
- Page 39 NOTE: Increase air supply 15% for 50 hertz operation (1500 rpm) TUNE-UP SPECIFICATIONS: 5-0 kglcm 2 ) INJECTOR PRESSURE 1920 70 - 0 psi (135 Static timed - drop valve method ENGINE TIMING ± 0.230 .005 inches BIDC Westerbeke Generators...
- Page 40 YOUR NOTES Westerbeke Generators...
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Page 41: Controls And Instruments
NOTE: When the engine is shut down, the water temperature gauge and the oil pressure gauge will continue to register the last temperature and oil pressure readings indicated before the electrical power was turned off. The temperature gauge and oil pressure gauge will return to zero once electrical power is restored. Westerbeke Generators... - Page 42 WATER TEMPERATURE GAUGE HOUR METER 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). Westerbeke Generators...
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Page 43: New Genera Tor Initial Inspection
Lubrication System Fuel System Check oil level in oil pan. Check fuel level in tank. Check Check for leaks. piping for leaks. Prime fuel system. Cooling System Check coolant level in radiator Vent air out of system. Westerbeke Generators... -
Page 44: Daily Walk Around Checks
Is there enough fuel for the day's OK? Are you sure there are no operation? oil or water leaks? Are bolts and nuts tight? Engine Oil Is the oil level up to the FULL mark on the dipstick? Westerbeke Generators... -
Page 45: Diesel Fuel, Engine Oil, Cooling Water
Below 41° F (5°C) SAE 10W-30 CAUTION: Do not allow two or more brands of engine oil to mix. Each brand contains its own additives; additives of different brands could react in the mixture to produce properties harmful to your engine. Westerbeke Generators... - Page 46 Antifreeze mixtures are beneficial to the engine's cooling system in that they retard rust and scale formation and are beneficial to the service life of the freshwater circulating pump seal. ANTIFREEZE PROTECTION CHART Antifreeze Concentration Freezing Temperature (-5) (-10) (-15) (-20) (-30) (-40) (-58) Westerbeke Generators...
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Page 47: Operating Your Generator
Should the engine not start when the S T ART switch is depressed for 10 to 20 seconds, release both switches and wait 30 seconds; repeat the procedure above. Never run the starter for more than 30 seconds. Westerbeke Generators... -
Page 48: Warming Up
Remove the AC electrical load from the generator and allow the generator to run for 3 to 5 minutes to stabilize its operating temperatures. Depress the STOP switch and hold it until the generator is completely stopped. Now release the STOP switch. Westerbeke Generators... -
Page 49: Routine-Service
4. Highly inflammable liquids are often used as cleaning fluids. When using such fluids, be sure to make necessary provisions for avoiding fire hazards. Good commercial, nonflammable solvents are preferred. Use with proper ventilation. 5. Do not attempt to service the AC generator with the engine running. Westerbeke Generators... -
Page 50: Fan Belt
Initial change of engine fuel filter element(s). 5. Engine no load speed Check engine no load speed and adjust if necessary. (61.5 - 62.0 Hertz) 6. Fan Belt Adjust fan belt tension 1/2 - 3/8 inch deflection. 7. Air cleaner Check and clean element. Westerbeke Generators... - Page 51 Check antifreeze/water mixture. Add antifreeze as needed. Check condition of mixture. 3. Starter Motor Remove and lubricate pinion drive. 4. Preheat circuit Check operation of preheat solenoid. Remove and clean glow plugs, check resistance (.4 - .6 ohms). Westerbeke Generators...
- Page 52 4. Engine parts Check security and tightness of nuts, bolts and wire connections. EVERY 1000 OPERATING HOURS 1. Radiator Remove radiator, have professionally cleaned and pressure tested. Repair or replace as needed. Replace coolant mixture if needed. Westerbeke Generators...
- Page 53 NOTE: Generic filters are not recommended. The material standards or tolerances of important items on generic parts might be entirely different from genuine parts. Westerbeke Generators...
- Page 54 85 to 90 Ib-ft. (11.8 to 12.5 kg/m) for the BED 20KW AND 25KW, or 80-85 Ib-ft (11.0 to 11.8 kg/m) for the BTDAR 15 KW. Then proceed to the next head bolt in the sequence. Westerbeke Generators...
- Page 55 Tighten the cylinder head bolts according to the sequence shown in the illustration. Make sure the engine is cold when this is done. Loosen one bolt at a time one-half turn, then apply the torque. Tightening Torque: 80-85Ib-ft (11.0-11.7 kg-m) Westerbeke Generators...
- Page 56 15 BTDAR, 20 BEDR, 25 BEDR and 32 BEDR Adjust all valves to .012 inches (0.3 mm) with the engine cold. -.:.,' -.-.~::;..I ... - .." . J ' -- " --~- .'----, I • :'-------- I I ----- " 0.012 OJ30mm cold Westerbeke Generators...
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Page 57: Air Filtration System
Various air filtration systems may be incorporated with your generator depending on the application. Proper servicing is imperative. Check the air filtration system frequently. NOTE: DO NOT OPERATE THE UNIT WITHOUT THE AIR CLEANER ELEMENT INSTALLED. INTERNAL ENGINE DAMAGE WILL RESULT FROM THE INGESTION OF ROAD DEBRIS. Westerbeke Generators... -
Page 58: Engine Coolant
Add coolant as air is expelled. Observe engine operating temper- ature. Once the system is purged of air, fill the radiator full and install the pressure cap. Fill the plastic coolant recovery tank 112 full. Westerbeke Generators... - Page 59 Note: A high gain adjustment can Unezr induce an oscillating of the actuator ·A::tUZ1I)f producing a hunting mode. In such cases, lessen the gain adjustment. s::uo~ c· C39l7Z Westerbeke Generators...
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Page 60: Genera Tor Maintenance
6. Examine control box at periodic intervals to detect cracks from engine and generator vibration. If cracks in box are seen, engine vibration may be severe and require bracing in box for additional strength to resist vibration. Westerbeke Generators... - Page 61 ~-- --- ()j-I------~ 'STOP _ _ _ _ oJ _JSWITCH SPEED i -i SENSOR PREHEAT SWITCH -+ ____________ L -__ : STOP : SWITCH W.T. O.P. FUEL SOL. ________ . -____________ ________ ~~~8~5 ~8~~ o.P. W.T. SNDR. SNDR. Westerbeke Generators...
- Page 62 OIL PRESSURE SW. -I".U OIL PRESS. II. ftl oJ ..L .. •..-rostED!."''' ¥"'o 'rOREC ", "I'" "9W~f .,,,,,",,, ",t) 4O~y.,.- G&;,"RNQ9 '!'Ro~ )\~\~ ' - - - II.'" "'."'-'" '140Aw ·IO .. ",'T STANDARD INSTRUMENT PANEL Westerbeke Generators...
- Page 63 15 A START ______________ A_ !~~ _____________ i _3 _ _ R_Ep __ TO TBI-2 . " RED . " . " RED ~ mg~ 3 A RUN WHITE L ______________________________________________________________________ • ________________________ _ TO TBI-4 '-______________________________________________________________ J P.N. 2490 Westerbeke Generators...
- Page 64 DC WIRING DIAGRAM CONTINUED ... ELECTRONIC GOVERNOR CIRCUIT TERMINAL BLOCK. MOUNTED INSIDE UNIT CONTROL PANEL. VOLT IVIETER 12 VDC BLACK BLACK BLACK WIRE BLACK/WHI SENSOR ::::::J WHITE ::::::J PURPLE PURPLE ACTUATOR PURPLE PURPLE Westerbeke Generators...
- Page 65 THIS PAGE LEFT BLANK INTENTIONALLY. Westerbeke Generators...
- Page 66 1800 RPM. At 1500 RPM, any given generator will provide a voltage and KW rating equal to rating at 1800 RPM. Consult manufacturer if a higher voltage of KW rating is needed at 50 HZ (1500 RPM). Westerbeke Generators...
- Page 67 THIS PAGE IS LEFT BLANK INTENTIONALLY Westerbeke Generators...
- Page 68 2. Main Stator Windings 2. Compound Transformer Windings 3. Main Stator Auxiliary Windings 3. Compound Transformer Auxiliary Windngs with Voltage/Hertz Connection Bar F. SELECTOR SWITCH G. BRIDGE RECTIFIER WIRING F-' Switch in Compound Position F-2 Switch in Electronic and Compound Position Westerbeke Generators...
- Page 69 - - . . I 0::: • < 0::: r-----------, I· I- UJ c::u.. § ..-- J < r---L----- 1.., ..I ~o::: 0::: _ _ _ _ _ _ _ _ _ _ _ .J .., 0::: < .., V> ----------------~ Westerbeke Generators...
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Page 70: Btdar
_1- _ _ _ ..I .::l c.!) ·1 L.::;;:-~-'- ..-"- . . · 0 _____ ~J.lj.4j.4~IY I· 1010113.1. l . - _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ Westerbeke Generators... -
Page 71: Bedr
Note: When changing from 60 hertz to 50 hertz operation, remove the 60 hertz jumper bar from the regulator board. Regulator PN# 039640 is for LEC·S the 20 BEDR, 25 BEDR and the 32 BEDR. "".lIow AMP. STAB. VOLT ]aOHZ. Westerbeke Generators... - Page 72 176°F (80°C) range. A small reduction in no-load voltage (l to 3 volts) can sometimes be accomplished by gently tapping the top of the laminated steel bar to reduce the gap between the existing shims and the transformer core. (.001 inch of shim thickness will vary voltage 4-6 volts AC.) Westerbeke Generators...
- Page 73 50HZ 220 VAC 50HZ 110 VAC 1!1 50HZ L-N 220 VAC '950HZ L2.l3-N ,'0 VAC 1!1 50 HZ NOTE - INSTALLER TO ENSURE THAT THE GROUND LEAD FROM THE NEUTRAL TERMINAL TO THE GENERATOR CASE IS PROPERLY INSTALLED. Westerbeke Generators...
- Page 74 No-load voltage at 120-122 volts at 60 hertz (220 - 224 volts at 50 hertz). The regulator board is operating in parallel with the compound transformer and ± should maintain voltage output within 5 percent from No-load to Full-rated. Westerbeke Generators...
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Page 75: Engine Troubleshooting
Check connection. depressed: no starter faulty. engagement. Faulty START switch. Check switch with ohmmeter. Faulty solenoid. Check that 12 Volts are present at starter solenoid connection. Loose battery connection. Check battery connection. Low batteries. Check battery charge state. Westerbeke Generators... - Page 76 (Replace filters and allow system to self- bleed by depressing only the PREHEAT switch). Failure to stop. STOP switch failure. Stop engine by de- pressing emergency STOP switch on engine or manually unplugging connection to fuel solenoid on injection pump. Westerbeke Generators...
- Page 77 Emergency STOP switch Check operation of or STOP switch in panel switch with an defective, opening fuel run ohmmeter. solenoid circuit. Switches and/or wiring. Inspect all wiring for loose connections and short circuits. Inspect switches for proper operation Westerbeke Generators...
- Page 78 Low resistance leak. Check all wires for temperature rise to locate fault. Alternator Disconnect alternator at output, after a good battery charging. If leakage stops, remove alternator and bench test. Repair or replace Westerbeke Generators...
- Page 79 Check fuel tank vent is clear. Engine will not shut DC Circuit Fault. Check for DC feed down when stop switch through DC charging depressed. regulator. Disconnect exc. led. Then depress stop switch. Check for faulty stop switch. Westerbeke Generators...
- Page 80 *BEDR 25KW and BTDR 15KW generator sets use injector screwed into the head for which the torque value is 42 to 51 lb-ft. **BEDR 20KW and 32KW generator sets use an injector bolted to the head for which the torque value is 12 to 17 lb-ft per bolt, tightened evenly. Westerbeke Generators...
- Page 81 28 - 33 3.7-4.6 3/8 UNF 30 - 35 4.1 -4.8 7116 UNC 44 -49 6.1 - 6.8 7116 UNF 50 - 55 6.9 - 7.6 1/2 UNC 68 -73 9.4 - 10.1 112 UNF 73 - 80 10.1-11.1 Westerbeke Generators...