Westerbeke 25.0BTDAR 60HERTZ User manual

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 BEDR, 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

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. If you should need
further assistance, please contact the Westerbeke Master Distributor located nearest you
for technical advice.
Again, thank you for choosing a Westerbeke!
Sincerely,
WESTERBEKE CORPORATION
Westerbeke Generators

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
:1.6 .. 0
:I. .. () I
~.:jO
220
";"1') ••. .,
I .. : .. II l
::.:; ::? .. ()
:I. ~::.i () ()
CClN'r ..
)0 .. 0
:I.
6()
l.;.() II 0
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 2

BE SAFETY CONSCIOUS
A careless moment can cause an accident or fire. Here are basic DO's and DON'TS:
DO'S
• DO visual inspections before
starting your generator.
• DO check your engine once a
day. Keep eyes open and be
alert to people and obstacles.
3
DON'TS
•
•
DON'T touch any moving part on
your engine during operation.
DON'T touch hot engine parts such
as exhaust manifolds.
Westerbeke Generators

•
•
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.
If it comes in
contact with your skin, wash
it off at once with water.

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.
Westerbeke Generators

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.
DEFINITION OF LOCAL TERMS
The words "leftside", "rightside", "front", and "rear" are used in the senses
illustrated below:
Front
( Radiator
End)
Westerbeke Generators
Right
0000
Left
6
Rear
(Generator
End)

TABLE OF CONTENTS
GETTING TO KNOW YOUR GENERA TOR
SPECIFICATIONS (General and System)
15.0 BTDAR
20.0 BEDR
25.0 BEDR
32.0 BEDR
CONTROLS AND INSTRUMENTS
NEW GENERA TOR INITIAL INSPECTION
DAILY WALK AROUND CHECKS
DIESEL FUEL, ENGINE OIL, COOLING WATER
OPERA TING YOUR GENERA TOR
STARTING
WARMING UP
STOPPING
ROUTINE-SERVICE
SERVICE ITEMS
GENERAL RULES
SAFETY RULES
SERVICE SCHEDULE
ENGINE OIL & FILTER
CYLINDER HEAD BOLTS AND
VALVE ADJUSTMENTS
15.0 BTDAR & 20.0 BEDR
25.0 & 32.0 BEDR
INJECTOR SERVICING
AIR FILTRATION SYSTEM
FAN BELT
PAGE
9
17
22
27
32
38
40
41
42
44
44
45
45
46
46
46
47
50
50
51,52
52,53
54
54
55
7 Westerbeke Generators

ENGINE SERVICE ITEMS CONTINUED...
ENGINE COOLANT 55
GENERA
TOR ADJUSTMENTS 56
GENERA
TOR MAINTENANCE 57
ENGINE DC WIRING 58,59,60,61
GENERA
TOR DESCRIPTION -GENERAL 63
15.0 BTDAR SINGLE PHASE INTERNAL WIRING SCHEMATIC 65
20.0, 25.0, 32.0 BEDR SINGLE PHASE INTERNAL
WIRING SINGLE 66
BTDAR & BEDR INTERNAL WIRING SCHEMA
TIC
(THREE PHASE ONLY) 67
VOLTAGE REGULATOR ADJUSTMENTS 20,25,32 BEDR 68
15 BTDAR NO LOAD VOLTAGE ADJUSTMENT
(SINGLE PHASE ONLY) 69
AC VOLTAGE CONNECTIONS-ALL MODELS 70
15 BTDAR OPTIONAL VOLTAGE REGULATOR
(SINGLE PHASE ONLY) 71
ENGINE TROUBLESHOOTING 72
TORQUE SPECIFICATIONS 77,78
Westerbeke Generators 8

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:2
(t)
Ul
.....
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..,
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(t)
;><;"'
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(t)
::l
(t)
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po
.....
o
..,
Ul
Preheat Solenoid
Breaker
Emergency Shut-off Switch
Engine Oil Fill
Speed Sensor
DC Alternator Shield
Circuit Breaker Box
Fan/Belt Guard
AC Connections Outlet Exhaust Manifold
15.0 BTDAR GENERATOR
RIGHT SIDE

~
(I)
en
-
(I)
a-
(I)
;<;""
(I)
CJ
(I)
::l
(I)
P.l
-
o
..,
en
o
.Radiator _ ..
FanI Belt Guard
Injection Pump
Water Temperature Switch
Fuel Filter
Fuel Lift Pump
Oil Pressure Sender
Lube Oil Filter
15.0 BTDAR GENERATOR
LEFT SIDE
Start/Stop Panel
LED Lights
Unit Data Tag
DC Battery Ground
Starter with Solenoid

-
-
~
~
~
~
do
~
~
~
::s
~
~
o
..,
en
Preheat Solenoid
Emergency Stop Switch
Control Panel
LED Lights
DC Battery Ground Connection
20.0 BEDR
RIGHT SIDE
/Radia,or Fill Cap
;. ~
DC Charging Alternator
Lube Oil Drain Hose

~
~
(1)
8-
~
(1)
o
(1)
::l
(1)
g
o
..,
en
......
tv
Top Engine Oil Fill
Air Intake Silencer
Fuel Lift Pump
Actuator
. Radiator
Fuel Injection Pump
Oil Pressure Sender
20.0 BEDR
LEFT SIDE
Filter
Breaker
- Control Panel
AC Connections Outlet
Fresh Water Block Drain
Lube Oil Filter

13
Westerbeke Generators

Westerbeke Generators 14

15 Westerbeke Generators

Westerbeke Generators
16

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 (2.2 liters)
FIRING ORDER 1-3-4-2
DIRECTION OF ROTATION Clockwise, when viewed from the front
MAXIMUM TORQUE (AT 1800 RPM) 1171b-ft (16.18 kg-m)
COMPRESSION RATIO 21:1
COMPRESSION PRESSURE 427 psi (30 kglcm2) at 250 rpm
(Limit
of difference between cylinders) 47.2 psi (3.0 kglcm2)
VALVE TIMING Intake Opens 17° BTDC
Intake Closes 47° ABDC
VALVE SEAT ANGLE
VALVE CLEARANCE
(Engine Cold)
ENGINE SPEED
17
Exhaust Opens 51 ° BBDC
Exhaust Closes
13 ° ATDC
Intake 45°
Exhaust 30°
Intake 0.012 inches (0.3 mm)
Exhaust 0.012 inches (0.3 mm)
1800 rpm 60 Hertz
1500 rpm 50 Hertz
Westerbeke Generators