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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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