Westerbeke 25.0 BEDR 50 HERTZ, 20.0BEDR 60HERTZ, 16.0 BEDR 50 HERTZ, 20.0BEDR 50 HERTZ, 25.0BEDR 60HERTZ Operation And Maintenance Manual

OPERATIONS & MAINTENANCE

MANUAL

WESTERBEKE

DIESEL GENERATORS

MOBILE

MODEL

25.0 BEDR & 32.0 BEDR

MODEL

SINGLE &

& INDUSTRIAL

15.0 BTDAR, 20.0 BEDR,

60

HERTZ

12.0 BTDAR, 16.0 BEDR,

20.0 BE DR, 25.0 BEDR
50

HERTZ

THREE

Publication # 039835

PHASE GENERATORS

~r-.v-

~

Edition Two

May 1993

'WESTERBEKE

WESTERBEKECORPORATION
MYLES
150

STANDISH

JOHN HANCOCK

INDUSTRIAL

ROAD,

PARK

TAUNTON,

MA

02780-7319

INTRODUCTION

Thank you for purchasing a Westerbeke diesel generator. With proper care on a routine
basis, your Westerbeke generator
power for many years.

is

designed to provide you with reliable and economical

This manual will help familiarize you with your engine.

in

maintenance and troubleshooting

It

also contains important safety information, key specifications, and a wiring diagram.

No manual can provide for every possible question
further assistance, please contact the Westerbeke Master Distributor located nearest you
for technical advice.

Again, thank you for choosing a Westerbeke!

Sincerely,

WESTERBEKE

CORPORATION

depth.

It

covers initial service, operation,

or

contingency.

If

you should need

Westerbeke Generators

ENGINE

SERIAL

NUMBER

LOCATION

The engine serial number and model designation are found

An

generator's housing.

illustration

of

this I.D.

tag

is shown below.

on

an LD.

tag

Take

affixed

to

the time to

the

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

or

ordering spares, repair parts

when seeking technical information.

'~79ELI.

:1.6

..

0

)0

..

:1.6

..

0

:I.

..

~.:jO

()

CClN'r

I

0

:I.

6()

..

220

";"1')

••.

.,

I

.. : ..

II

l

fill

The engine serial number can also be found stamped into the engine block on a smooth
rectangular surface above the injection pump.
the generator housing

on

Westerbeke Generators

::.:;

::?

..

()

:I.

~::.i

()

()

The

generator serial number is stamped into

the flat surface above the rear

2

l.;.()

II

0

generator

bearing.

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.

DON'TS

•

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.

3

•

DON'T touch hot engine parts such

as exhaust manifolds.

Westerbeke Generators

DO

•

keep fuel away from your engine •

at

all

and correct them.

times. Check for leaks regularly

DON'T remove radiator filler cap
immediately after shutting down
engme.

•

Westerbeke Generators

DO check the capacity
hoist when lifting the unit.
hangers and a wad
between sling and unit.

of

of

cloth

sling

Use

in

4

•

DON'T smoke near the battery
Never use an open flame as a

or

light anywhere on
battery. Battery gas is highly
flammable. Sulfuric acid is
destructive.
contact with your skin, wash
it

off

at once with water.

If

around the

it comes

in

• DON'T work on an engine while it is
running.

it is necessary

to

check

If

the engine while running, use caution

of

and beware
presence

moving parts and the

of

AC voltage.

• DON'T touch AC electrical

is

connections while the unit

is

Lethal voltage

present at these

running.

connections.

5

Westerbeke Generators

NOTES, CAUTIONS AND WARNINGS

NOTES, CAUTIONS, AND WARNINGS are used

and critical instructions. They are used for the following conditions:

An

operating procedure, condition, etc. essential

CAUTION

Operating procedures, practices, etc. which

in

result

damage

or

destruction

to

your engine.

WARNING

Operating procedures, practices, etc. which

in

result

The words "leftside", "rightside", "front", and "rear" are used
illustrated below:

personal injury

or

loss

of

DEFINITION

life.

OF

LOCAL TERMS

in

this manual to emphasize important

to

notate.

if

not strictly observed, will

if

not correctly followed, will

in

the senses

Front
(

Radiator
End)

Westerbeke Generators

Right

0000

Left

6

Rear

(Generator

End)

TABLE OF CONTENTS

PAGE

GETTING

SPECIFICATIONS

CONTROLS

NEW

DAILY

DIESEL

OPERA

TO

AND INSTRUMENTS

GENERA

WALK

FUEL,

TING

YOUR

KNOW

TOR

AROUND

ENGINE

YOUR

(General

15.0

20.0

25.0

32.0

INITIAL

GENERA

STARTING
WARMING

STOPPING

and

BTDAR
BEDR
BEDR
BEDR

CHECKS

OIL,

GENERA

System)

INSPECTION

COOLING

TOR

UP

TOR

WATER

9

17
22
27
32

38

40

41

42

44

44
45
45

ROUTINE-SERVICE

SERVICE

ITEMS

GENERAL
SAFETY

SERVICE

ENGINE
CYLINDER
VALVE ADJUSTMENTS

INJECTOR

AIR

FILTRATION

FAN

BELT

RULES

RULES

SCHEDULE

OIL & FILTER

HEAD

15.0 BTDAR & 20.0

25.0 & 32.0

SERVICING

7

BOLTS

SYSTEM

AND

BEDR

BEDR

Westerbeke Generators

46
46
46

47

50

50

51,52

52,53

54
54

55

ENGINE SERVICE ITEMS CONTINUED ...

ENGINE

GENERA
GENERA

COOLANT 55

TOR

ADJUSTMENTS 56

TOR

MAINTENANCE

57

ENGINE DC WIRING 58,59,60,61

GENERA

15.0 BTDAR SINGLE

20.0, 25.0, 32.0 BEDR SINGLE

BTDAR
(THREE PHASE ONLY)

TOR

DESCRIPTION - GENERAL 63

PHASE INTERNAL WIRING SCHEMA TIC 65

PHASE INTERNAL

& BEDR INTERNAL WIRING SCHEMA

WIRING

TIC

SINGLE 66

67

VOLTAGE REGULATOR ADJUSTMENTS 20,25,32 BEDR 68

15 BTDAR
(SINGLE

AC

VOLTAGE CONNECTIONS-ALL MODELS 70

NO LOAD VOLTAGE ADJUSTMENT

PHASE ONLY) 69

15

BTDAR OPTIONAL VOLTAGE REGULATOR

(SINGLE PHASE ONLY)

ENGINE TROUBLESHOOTING

71

72

TORQUE SPECIFICATIONS 77,78

Westerbeke Generators

8

\0

:2

(t)

Ul

.....

(t)

..,

0-

(t)

;><;"'

(t)

C)

(t)

::l

(t)

..,

po

.....

o

..,

Ul

Preheat

Solenoid

Breaker

Emergency

Shut-off

Switch

Engine

Oil

Fill

Speed

Sensor

DC

Alternator

Shield

Circuit

Breaker

Box

Fan/Belt

Guard

A C

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 _

..

Fan I

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

GENERAL

PHASE & THREE

SPECIFICATIONS

PHASE

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

DIRECTION

MAXIMUM

ORDER 1-3-4-2

OF ROTATION Clockwise, when viewed from the front

TORQUE (AT 1800 RPM) 1171b-ft (16.18 kg-m)

COMPRESSION RATIO 21:1

COMPRESSION PRESSURE 427 psi (30 kglcm2)
(Limit

VALVE TIMING Intake

VALVE SEAT ANGLE

of

difference between cylinders) 47.2 psi (3.0 kglcm2)

Opens 17° BTDC

Intake Closes

47° ABDC

Exhaust Opens
Exhaust Closes

Intake

45°

51

° BBDC

13

° ATDC

Exhaust 30°

VALVE CLEARANCE
(Engine Cold)

ENGINE SPEED

Intake 0.012 inches (0.3
Exhaust 0.012 inches (0.3 mm)

1800 rpm 60 Hertz
1500 rpm 50 Hertz

at

250 rpm

mm)

17

Westerbeke Generators

GENERAL

SPECIFICATIONS

CONTINUED

•....

DIMENSIONS

WEIGHT

FUEL

INCLINATION

CONSUMPTION

Height: 28.50 inches (723

nun)
Width: 24.8 inches (530 mm)
Length: 49.6 inches (1260 nun)

870

lbs. (395 kgs)

2.0 gph (7.571ph) at

full

rated output

( approximate)

Continuous
Temporary 200 (not

15

0

to

exceed 20

min)

Westerbeke Generators

18

FUEL SYSTEM:

15.0 BTDAR DIESEL GENERA

TOR

SINGLE PHASE & THREE PHASE

SYSTEM SPECIFICATIONS

GENERAL

FUEL

FUEL INJECTION

FUEL INJECTION TIMING

NOZZLE

FUEL FILTER (on engine)

AIR CLEANER

AIR

FLOW ( engine combustion)

PUMP

COOLING SYSTEM·

GENERAL

Open flow, totally self-priming, 1 bleed point

No.2

Diesel oil (cetane rating

or

higher)

Bosch Model VE Distributor

0°

TDC (Top Dead Center)

Throttle type

Spin-on type,

Replaceable element

70.0

dIn

Closed fresh water-cooled block,

thermostatically controlled with radiator

(l.9

full

cmm)

flow

of

45

OPERATING TEMPERATURE

FRESH WATER PUMP

SYSTEM

CAPACITY (Fresh Water)

LUBRICATION SYSTEM:

GENERAL

OIL FILTER

19

Centrifugal type, metal impeller,

belt-driven.

11.5 quarts (10.88 liters) approximately

Pressure fed system

Full flow, paper element, spin-on type

Westerbeke Generators

SUMP CAPACITY (not including filter) 5.3 quarts (5.0 liters) (plus filter/cooler

assembly)

OPERATING OIL PRESSURE 50 - 65 psi (3.5 - 4.5 kg/cm)
(engine hot)

OIL GRADE API SPECIFICATION OF

or

SAE 30,

10W-30, 15W-40

ELECTRICAL SYSTEM:

STARTING BATTERY

BATTERY

DC

CHARGING ALTERNATOR

STARTING AID

STARTER

DC

NO-LOAD CURRENT

DC

CRANKING CURRENT

AC

GENERATOR GENERAL:

CAPACITY

12

volt 170 A-H, (-) negative ground

(200

(recommended)

400 - 600 cold cranking amps

51

amp rated, belt driven

Glow plug, sheathed type.

12 volt, 3 KW, reduction type

±

2%

of

rated Amps

250-300 amps ( engine cold)

A-H

CF

OR

CG-4

in cold areas)

SINGLE PHASE ONLY

VOLTAGE (Single Phase)

RATING

Westerbeke Generators

(Volts AC)

Hertz (1800

60

15KW

50 Hertz (1500 RPM)

12KW

RPM)

Brushless, four pole, revolving field.

Sealed lubricated single-bearing design.

Reconnectable, single phase for

volts with solid state voltage regulator.

120

OR

120/240 volts- 60 Hertz

220 volts - 50 Hertz

±

2%

Voltage regulation

Frequency regulation:

to

full

load

120 volts 125 amps
120/240 Volts 125/62.5 amps

220 volts 54.5 amps

20

load.

no

.3

Hertz (.005%) no

load

120/240

to

full

load

GENERATOR COOLING:

AIR

REQUIREMENTS

60

Hertz

at 1800

NOTE:

AC

GENERATOR GENERAL:

THREE

Voltage - 3 Phase

Voltage - 3

Amperage -

PHASE

.8

Increase air supply 15% for 50 hertz operation (1500 rpm)

ONLY

(60

Hertz)

Phase

(50

Hertz)

3 Phase (60 Hertz)

Powerfactor

rpm

250 -300

Brushiess, six pole, revolving field.
Sealed lubricated single-bearing design.

12 lead reconnectable for

high

regulator with protection circuitry.

Low
High voltage
DELTA

High voltage
DELTA

Low
High voltage
DELTA

cfin (7.08 - 8.5 cmm)

low

voltage WYE,

voltage Delta. Solid State voltage

voltage

voltage

WYE

WYE

WYE

WYE

WYE

208 volts
480

volts

240

volts

380

volts

220

volts

52.1 Amps

22.1 Amps
45 Amps

Amperage - 3 Phase (50

.8

Powerfactor

TUNE

Inj

Engine Timing

ector

UP

SPECIFICATIONS:

Pressure

Hertz)

High voltage
DELTA

1920 + 71-0 psi (135 +

Static timed -

0.205 ± .005 inches

WYE

drop

valve method

22.8 Amps

39.4

Amps

5-0

kglcm2)

BTDC

21

Westerbeke Generators

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 (2.5 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
(Limit

of

difference between cylinders) 47.2

psi

VALVE TIMING Intake

Intake

Exhaust
Exhaust Closes 13°

VALVE SEAT ANGLE

Intake 45°
Exhaust

VALVE CLEARANCE
(Engine Cold)

ENGINE

SPEED

Intake 0.012 inches (0.3 mm)
Exhaust 0.012 inches (0.3 mm)

1800 rpm 60 Hertz
1500 rpm 50 Hertz

(30 kglcm2) at 250 rpm

psi

(3.0 kglcm2)

Opens 17° BTDC
Closes 47° ABDC

Opens

51

° BBDC

AIDC

30°

Westerbeke Generators

22

GENERAL

SPECIFICA

nONS

CONTINUED

.••..

DIMENSIONS

WEIGHT

FUEL

CONSUMPTION

INCLINATION

Height: 28.50 inches (723.9 mm)

Width: 22.0 inches (546.1
Length: 45.79 inches (1163.3

mm)

mm)

7971bs. (361.5 kgs)

2.0 gph (7.571ph) at

full

rated output

(approximate)

Continuous

15°

Temporary 20° (not to exceed 20 min)

23

Westerbeke Generators

20.0

BEDR

DIESEL GENERA

TOR

SINGLE PHASE &

FUEL SYSTEM:

GENERAL

FUEL

FUEL INJECTION PUMP

FUEL INJECTION TIMING

NOZZLE

FUEL FILTER (on engine)

AIR CLEANER

AIR

FLOW ( engine combustion)

THREE

PHASE

SYSTEM SPECIFICATIONS

Open flow, totally self-priming, 1 bleed point

No.2

Diesel oil (cetane rating

or

higher)

Bosch Model VB Distributor

0

0

TDC (Top Dead Center)

Throttle type

Spin-on type, full flow

Replaceable element

81.0 cfin (2.29 cmm)

of

45

COOLING SYSTEM:

GENERAL

OPERATING TEMPERATURE

FRESH WATER PUMP

SYSTEM CAPACITY (Fresh Water)

LUBRICATION SYSTEM:

GENERAL

OIL FILTER

Closed fresh water-cooled block,

thermostatically controlled with radiator

170

0

-

1900 F (77

0

0

-

88

C)

Centrifugal type, metal impeller,
belt-driven.

11.5 quarts (10.88 liters) approximately

Pressure fed system

Full flow, paper element, spin-on type

Westerbeke Generators

24

SUMP CAPACITY (not including filter) 6.5 quarts (6.15 liters) (plus filter/cooler

assembly)

OPERATING

all-

PRESSURE 50 - 60 psi (3.5 - 4.2 kg/cm)

(engine hot)

Oll-GRADE

ELECTRICAL SYSTEM:

STARTING BATTERY

BATTERY CAPACITY

DC

CHARGING ALTERNATOR

STARTING AID

STARTER

DC

NO-LOAD CURRENT

DC CRANKING CURRENT

API SPECIFICATION OF

CF

SAE 30, or 10W-30, 15W-40

12

volt (-) negative ground

400 - 600 cold cranking amps

51

amp rated, belt driven

Glow plug, sheathed type.

12 volt, 3 KW, reduction type

± 2%

of

rated Amps

250-300 amps ( engine cold)

OR

CG-4

AC

GENERATOR GENERAL:

SINGLE PHASE ONLY

VOLTAGE

(Single Phase)

RATING (Volts AC)

60 Hertz (1800 RPM)
20KW

50 Hertz (1500 RPM)

16KW

Brushless, four pole, revolving field.

Sealed lubricated single-bearing design.

Reconnectable, single phase for

1201240

volts with solid state voltage regulator.

120 OR 120/240 volts- 60 Hertz
220 volts - 50 Hertz
Voltage regulation

Frequency regulation:

load to

full

load.

± 2% no load to

.3

Hertz (.005%) no

full

120 volts 166 amps

1201240

Volts 166/83 amps

220 volts 72.7 amps

load

25

Westerbeke Generators

GENERATOR COOLING:

AIR

REQUIREMENTS

60

Hertz

at 1800 rpm

NOTE: Increase air supply 15% for 50 hertz operation (1500 rpm)

AC

GENERATOR GENERAL:

THREE

Voltage - 3 Phase (60 Hertz)

Voltage - 3 Phase

Amperage - 3 Phase (60 Hertz)

PHASE

.8 Powerfactor

ONLY

(50

Hertz)

425 cfm (12.74 cmm)

Brushless, six pole, revolving field.
Sealed lubricated single-bearing design.

low

12 lead reconnectable for
high voltage Delta. Solid State voltage
regulator with protection circuitry.

Low

voltage
High voltage
DELTA

High voltage
DELTA

Low

voltage
High voltage
DELTA

WYE

WYE

WYE

WYE

WYE

208 volts
480
240

380
220

69.4 Amps

30.1 Amps
60 Amps

voltage WYE,

volts
volts

volts
volts

Amperage - 3 Phase

.8

Powerfactor

TUNE

Injector Pressure

Engine Timing

Westerbeke Generators

UP

SPECIFICATIONS:

(50 Hertz)

High voltage
DELTA

1920

+ 71-0 psi (135 + 5-0 kg/cm

Static timed - drop valve method

0.205 ± .005 inches

26

WYE

30.4 Amps

52.5 Amps

BTDe

2

)

25.0

BEDR

DIESEL

GENERA

TOR

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 (2.98 liters)

FIRING

DIRECTION

ORDER 1-3-4-2

OF ROTATION Clockwise, when viewed from the front

MAXIMUM TORQUE (AT 1800 RPM) 1481b-ft (20.46 kg-m)

COMPRESSION RATIO 21: 1

COMPRESSION PRESSURE 427

of

(Limit

VAL

VAL

difference between cylinders) (47.2 psi (3.0 kg/cm2)

VB TIMING Intake Opens

VB

SEAT ANGLE

psi

(30 kg/cm2) at 250 rpm

Intake Closes

Exhaust

Opens

Exhaust Closes

Intake

45°

17°

BTDC

47° ABDC

510 BBDC

13°

ATDC

Exhaust 30°

VAL

VB

CLEARANCE

(Engine Cold)

ENGINE

SPEED

Intake 0.012 inches (0.3 mm)

Exhaust

0.012 inches (0.3 mm)

1800 rpm 60 Hertz
1500 rpm 50 Hertz

27

Westerbeke Generators

GENERAL

SPECIFICA

nONS

CONTINUED ....

DIMENSIONS

WEIGHT

FUEL

CONSUMPTION

INCLINATION

Height: 28.6 inches(726.4 mm)
Width: 23.3 inches (591.8 mm)
Length: 49.9 inches (1140.5

752

Ibs.

(345 kgs)

2.9

gph

(10.9Iph) at

full

mm)

rated output

(approximate)

Continuous
Temporary 20° (not

15°

to

exceed 20

min)

Westerbeke Generators

28

25.0

BEDR

DIESEL GENERA

TOR

FUEL SYSTEM:

GENERAL

FUEL

FUEL

FUEL

NOZZLE

FUEL

AIR

AIR

INJECTION

INJECTION TIMING

FILTER

CLEANER

FLOW

(on engine)

( engine combustion)

SINGLE PHASE &

SYSTEM

PU1\1P

THREE

PHASE

SPECIFICATIONS

Open flow, self priming - 1 bleed point

No.2

Diesel oil (cetane rating

or

higher)

Bosch Model VB Distributor

0°

TDC

(Top Dead Center)

Throttle type

Spin

on

type, full flow.

Metal screen type clean able

94.6

cfin (2.7 cmm)

of

45

COOLING SYSTEM:

GENERAL

OPERATING

FRESH

SYSTEM

WATER

TEMPERATURE

PU1\1P

CAPACITY (Fresh Water)

LUBRICATION SYSTEM:

GENERAL

OIL

FILTER

Closed fresh water-cooled block,
thermostatically controlled with radiator

Centrifugal type, metal impeller,
belt-driven.

11. 5 quarts

Pressure fed system

Full flow, paper element, spin-on type

(10. 88 liters) approximately

29

Westerbeke Generators

SUMP CAPACITY (not including filter) 6.5 quarts (6.15 liters) plus filter/cooler

assembly

OPERATING OIL PRESSURE 50 - 60 psi (3.5 - 4.2 kg/cm)
(engine hot)

API

OIL GRADE

SPECIFICATION

SAE 30W

or

10W-30, lSW-40

OF

CF

OR CG-4

ELECTRICAL SYSTEM:

STARTING BATTERY

BATTERY CAPACITY

DC

CHARGING ALTERNATOR

STARTING AID

STARTER

DC

NO-LOAD CURRENT

DC

CRANKING CURRENT

AC

GENERATOR GENERAL:

SINGLE PHASE ONLY

12

volt (-) negative ground

400 - 600 cold cranking amps

51

Amp rated, belt -driven

Glow plug, sheathed type.

12

volt, reduction type

± 2%

of

rated Amps

250 - 300 amps (engine cold)

Brushless, four pole, revolving field.
Pre-lubricated single-bearing design.

Reconnectable, single phase for

volts with solid state voltage regulation.

120/240

VOLTAGE (Single Phase)

RATING (Volts AC)

60 Hertz (1800 RPM)

25.0KW

50 Hertz (1500 RPM)

20.0

KW

Westerbeke Generators

120 OR 120/240 volts- 60 Hertz
220 volts - 50 Hertz
Voltage regulation

Frequency regulation:

load to

120 volts 208 amps

120/240

220 volts

30

full load.

208/104 amps

91

± 2% no load

amps

.3

Hertz (.005%) no

to

full

load

AC

GENERATOR GENERAL:

GENERAL THREE PHASE ONLY

Voltage - 3 Phase (60 Hertz)

Voltage - 3 Phase

Amperage - 3 Phase

(50 Hertz)

(60 Hertz)

.8 Powerfactor

Amperage - 3 Phase

.8

Powerfactor

GENERATOR

(50 Hertz)

COOLING:

12

Sealed

lead

Brushless, six pole, revolving field.
lubricated single bearing design.

reconnectable for low voltage and high
voltage WYE and for DELTA.

Solid state

voltage regulation with protection circuitry.

Low voltage WYE
High voltage WYE
DELTA

High voltage WYE
DELTA

Low voltage WYE
High voltage WYE
DELTA

High voltage WYE
DELTA

208 volts
480 volts
240 volts

380 volts

220 volts

86.6 amps

37.6 amps

75.2 amps

38.0 amps

65.5 amps

AIR REQUIREMENTS
60 Hertz at 1800 rpm

NOTE: Increase air supply 15% for 50 hertz operation (1500 rpm)

TUNE-UP

INJECTOR PRESSURE

ENGINE TIMING

SPECIFICATIONS:

1.0 Power Factor 450

1920 +

70

- 0 psi (135 + 5-0 kg/cm

din

(12.74 cmm)

Static timed - drop valve method

0.180 ± .005 inches

BIDC

2

)

31

Westerbeke Generators

32.0 BEDR DIESEL GENERA

TOR

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 (4.05 liters)

FIRING

ORDER 1-5-3-6-4-2

DIRECTION OF ROTATION Clockwise, when viewed from the front

MAXIMUM TORQUE (AT

1800 RPM) 1951b-ft (26.97 kg-m)

CO:MJ>RESSION RATIO 21: 1

CO:MJ>RESSION PRESSURE 427 psi (30 kg!cm2) at 250 rpm
(Limit

VALVE TIMING Intake

of

difference between cylinders) (47.2 psi (3.0 kg! cm2})

Opens 14°

BIDC

Intake Closes 44° ABDC
Exhaust
Exhaust Closes

Opens 48° BBDC

10° A

IDC

VALVE SEAT ANGLE Intake 45°

Exhaust 30°

VALVE CLEARANCE
(Engine Cold)

ENGINE

SPEED

Intake
Exhaust 0.012 inches (0.3 mm)

1800 rpm 60 Hertz

0.012 inches (0.3 mm)

1500 rpm 50 Hertz

Westerbeke Generators

32

GENERAL

SPECIFICATIONS

CONTINUED

....

DIMENSIONS

WEIGHT

FUEL

CONSUMPTION

INCLINATION

Height: 31.0 inches(787.4 nun)

Width: 25.2 inches (640.3 nun)
Length: 57.5 inches (1460.5

1250

Ibs.

(567 kgs)

73

3.1 gph (11.

Iph) at

full

nun)

rated output

(approximate)

Continuous
Temporary 20° (not

15°

to

exceed 20 min)

33

Westerbeke Generators

32.0

BEDR

DIESEL

GENERA

TOR

SINGLE

SYSTEM

FUEL SYSTEM:

GENERAL

FUEL

FUEL INJECTION

FUEL INJECTION TIMING

NOZZLE

FUEL FILTER ( on engine)

AIR CLEANER

AIR FLOW ( engine combustion)

PUMP

PHASE & THREE

SPECIFICATIONS

Open flow, self priming - 1 bleed point

No.2

Diesel oil (cetane rating

or

higher)

Bosch Model VE Distributor

0° TDC (Top Dead Center)

Throttle type

Spin on type, full flow.

Metal screen type clean able

128.0 cfin (3.7 cmm)

PHASE

of45

COOLING SYSTEM:

GENERAL

OPERATING TEMPERATURE

FRESH WATER PUMP

SYSTEM CAPACITY (Fresh Water)

Closed fresh water-cooled block,
thermostatically controlled with radiator

Centrifugal type, metal impeller,
belt-driven.

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 34

OPERATING OIL PRESSURE
(engine hot)

50 - 60 psi (3.5 - 4.2 kg/cm)

OIL GRADE

ELECTRICAL SYSTEM:

STARTING BATTERY

BATTERY CAPACITY

DC CHARGING

STARTING AID

STARTER

DC

NO-LOAD CURRENT

DC CRANKING CURRENT

AC

GENERATOR GENERAL:

SINGLE PHASE ONLY

ALTERNATOR

API SPECIFICA

SAE 30W

12

volt (-) negative ground

900-1000 COLD CRANKING AMPS

51

Amp rated, belt-driven

TlON

OF

or

10W-30, 15W-40

CF

OR

CG-4

Glow plug, sheathed type.

12 volt, reduction type

± 2%

of

rated Amps

350-400 AMPS (ENGINE COLD)

Brushiess, four pole, revolving field.
Pre-lubricated single-bearing design.
Reconnectable, single phase for

1201240

volts with solid state voltage regulation.

VOLTAGE (Single Phase)

RATING (Volts AC)

60 Hertz (1800 RPM)

32.0KW

50 Hertz (1500 RPM)

25.0 KW

35

120

OR

120/240 volts­220 volts - 50 Hertz
Voltage regulation

± 2% no load

Frequency regulation:

to

full

load

load.

120 volts 266 amps
120/240 266/133 amps

220 volts 113.6 amps

Westerbeke Generators

60

Hertz

to

full

.3

Hertz .005% no

load

AC

GENERATOR GENERAL:

GENERAL THREE

Voltage - 3 Phase (60 Hertz)

Voltage -

Amperage -

3 Phase (50 Hertz)

3 Phase ( 60 Hertz)

PHASE

ONLY

.8 Powerfactor

Amperage - 3 Phase (50 Hertz)

.8 Powerfactor

GENERATOR COOLING:

Brushless, six pole, revolving field. Sealed
lubricated single bearing design. 12 lead
reconnectable for low voltage and high
voltage
voltage regulation with protection circuitry.

Low
High voltage
DELTA

High voltage
DELTA

Low
High voltage WYE
DELTA

High voltage WYE

DELTA

WYE

voltage

voltage WYE

and for DELTA. Solid state

WYE

WYE

WYE

208 volts
480 volts

240 volts

380 volts
220 volts

111.0 amps

48.1 amps

96.2 amps

47.5 amps

82.0 amps

AIR

REQUIREMENTS

60 Hertz at 1800 rpm

NOTE: Increase air supply 15% for 50 hertz operation (1500 rpm)

TUNE-UP SPECIFICATIONS:

INJECTOR PRESSURE

ENGINE

TIMING

Power Factor 480

1.0

+ 70 - 0 psi (135 + 5-0 kglcm

1920

Static timed - drop valve method

0.230 ± .005 inches

din

BIDC

(13.59 cmm)

2

)

Westerbeke Generators

36

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

in

temperature

(OIL PSI). This panel is also equipped with two meters that indicate DC volts and

inch

of

hours
voltmeter are illuminated; the

START/STOP panel functions

degrees Fahrenheit (WATER

operations

in

1I10ths. The water temperature,

ELAPSED TIME meter

in

the same manner

OF)

and oil pressure

is

as

the instrument panel, but does not

in

pounds per square

oil

pressure gauge and DC

not illuminated. The

include gauges. Either panel can be engine or remote mounted.

1.

PREHEAT.
activates the electric
activates the

The

PREHEAT
fuel

pump, bypasses the engine's

fuel

run solenoid. This switch also feeds power to the

switch energizes the engine's glow plugs,

oil

pressure switch, and

START

switch.

2.

START. The

START

switch, when pressed, energizes the starter's solenoids
which cranks the engine. This switch will not operate electrically unless the
PREHEA

3.

STOP. Power

Opening this switch deactivates the

T switch is pressed and held at the same time.

is

provided to the

fuel

solenoid through the

fuel

solenoid and shuts

off

STOP

the

fuel

switch.

to the

engine, causing the engine to stop.

NOTE: When the engine

pressure gauge will continue
readings indicated before the electrical power was turned

oil

gauge and

pressure gauge will return to zero once electrical power

is

shut down, the water temperature gauge and the

to

register the last temperature and oil pressure

off.

The temperature

is

restored.

oil

Westerbeke Generators

38

DC

VOLTMETER

GAUGE

ENGINE

OIL PRESSURE

0

~~

-

~

0

~

~9

0

Shows the amount the battery is being
charged.

WATER

TEMPERATURE GAUGE

0

0

-

~.

@~

~

~e

0

Indicates the pressure

The needle should indicate:

(2.8-3.5 kg-cm)

PSI

HOUR

METER

of

lube oil.

0

0

40-50

o

Indicates the temperature

During operation, it should be indicating

175° F - 195°F (80°- 91°C).

of

engine coolant.

39

o

The hour meter registers elapsed
time and should be used as a guide
for scheduled maintenance.

Westerbeke Generators

NEW GENERA

TOR

INITIAL INSPECTION

Before starting your engine for the first time, check on the following items

Appearance

Check for any missing
part, loose bolt

sign

of

damage.

or

nut,

or

Lubrication System

Check oil level in oil pan.
Check for leaks.

any

Electrical System

DC

Check battery electrolyte level. Check
connections for tightness and instruments
for operation.

Fuel System

Check fuel level in tank. Check
piping for leaks.

Prime fuel system.

Cooling System

Check coolant level
Vent air out

of

system.

Westerbeke Generators

in

radiator

40

For

safety

of

operation and maximum service life

sure your answers

DAIL Y WALK-AROUND CHECKS

to

questions on these items are YES:

of

your engine, inspect the unit to make

Cooling System

Is coolant up to level

in
radiator filler? (Do not remove
filler cap when engine

is

hot).

Others

Are electrical connections
OK? Are you sure there are no
oil

or

water leaks? Are bolts and

nuts tight?

Battery

Are cables tight on terminal
posts?

Is there enough fuel for the day's
operation?

Engine

Oil

Is the oil level up to the FULL
mark on the dipstick?

41

Westerbeke Generators

DIESEL FUEL:

Use

fuel that meets the requirements

rating

of#45

or

better.

DIESEL FUEL. ENGINE

AND

COOLING

or

specifications

WATER

of

OIL

Class 2-D (ASTM). Cetane

CARE

Too
The clearance
particles which might pass through the filter can damage these finely finished parts.
important
unsatisfactory by careless handling
going into
advisable.

OF

THE

FUEL SUPPLY:

much emphasis cannot be placed

of

the components

to

buy clean fuel, and keep it clean. The best fuel can be rendered

the

tank for

Purchase a well-known brand

Install and regularly service a good, visual type, filter/water separator between

the fuel tank and the generator drive engine. Raycor

of

such a filter.

your

engine's daily use is clean and pure, the following practice

on

the importance

in

your fuel injection pump is very critical; invisible dirt

or

improper storage facilities.

of

fuel.

of

using only clean diesel fuel.

To

assure that fuel

220

or

225 is a good example

ENGINE LUBRICATING OIL:

Use

a heavy duty engine oil with
after an initial
For

recommended oil viscosity see the chart below.

50 hours

of

break-in operation and thereafter, every 100 hours

API

classification

ofCC

or

better. Change the engine oil

of

operation.

It

is

is

Operating Temperature

Above
41

Below 41° F (5°C)

CAUTION:
contains its
to

Westerbeke Generators

68° F, (20° C)

- 68° F (5 - 20° C)

Do

own

produce properties harmful

not allow two

additives; additives

or

to

your engine.

Oil

Viscosity

SAE 30
SAE

more brands

of

different brands could react in the mixture

42

or

10W-30

20

or

10W-30

SAE 10W-30

of

engine oil

to

mix. Each brand

COOLING

Use

only

The

use

Use

an antifreeze brand such as "Prestone" that is compatible with aluminum engine
components.
and

cooling system components.

An

antifreeze mixture will aid in cooling and protect against unexpected freeze.
Antifreeze mixtures are beneficial
and

scale formation and are beneficial

seal.

WATER:

water

that is soft,

of

an antifreeze mixture

Do

not

use straight

or

as free as possible from scale forming minerals.

of

50/50 is recommended for year round use.

water

this can be deterimental

to

the engine's cooling system in that they retard rust

to

the service life

of

to

the aluminum engine

the freshwater circulating pump

Antifreeze Concentration

Freezing Temperature

ANTIFREEZE

%

13

23
(-5) (-10) (-15) (-20) (-30) (-40) (-58)

PROTECTION

23

30

CHART

35 45

50

60

14 5 -4 -22 -40 -58

43

Westerbeke Generators

OPERATING

YOUR

GENERATOR

o

~~

____

~_________o

Instrument Panel

1.

PREHEAT-Depress

the

PREHEAT

switch. The voltmeter, panel lights, gauges and
meters and fuel solenoid will be activated. The
accordance with the chart presented below.

to

Preheat according

the following chart:

Atmospheric Temperature
+41°F (+5°C)
+41°F (+5°C)
+23°F(-5°C)
Limit

of

or

higher

to

+23°F

or

lower

continuous use

(-SOC)

C

GENERATOR

PRF;HUT

...... 0

mal~J\

,.,

~

WESTERBEKE

o

Start/Stop Panel

PREHEAT

switch should be depressed in

Preheating Time
Approx.
Approx. 20 seconds
Approx. 30 seconds
One minute

0

®

STOP

:f~"UI

a

W

...

o

10 seconds

2.

STARTING:

While still depressing the PREHEAT switch, depress the
the start solenoid. Panel power and the fuel solenoid will be activated.
firing, release the

ST ART switch.
pressure reaches 15 psi. Then as long as the high
protective circuits

do

not activate, the set will remain energized and continue

Should the engine not start when the S T ART switch
release both switches and wait
starter for more than 30 seconds.

Westerbeke Generators 44

START switch. This will engage

Upon engine

Do

not release the

PREHEAT

water

temperature and low oil pressure

is

depressed for 10

switch until the oil

to

run.

to

20 seconds,

30 seconds; repeat the procedure above. Never run

the

WARMING

UP:

Once the engine starts, check instruments

for proper oil pressure,

and generator

AC

Allow the engine to warm

DC battery charge

output.

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.

STOPPING:

Remove the AC electrical load from the
generator and allow the generator
run for 3 to 5 minutes
operating temperatures. Depress the
STOP switch and hold
generator
Now

is

completely stopped.

release the STOP switch.

to

stabilize its

it

until the

45

to

Apply a light amperage load to the generator
and allow the engine operating temperature
to come up to

140

0

- 150

0

F (60

0

- 65

0

C)

before applying a heavy load.

Westerbeke Generators

GENERAL RULES:

1.

Before starting the generator for the day's run, be sure

around checks". (See page

2.

Service intervals

read the hour meter and record the reading

3.

Before attempting

thoroughly

to

Some service jobs are simple while the others are not; for complicated or difficult

of

kinds

service, rely on expert knowledge

facilities at your local truck and generator service center.

4.

Warm-Up. Once the unit has started on the initial cold start

the engine

to

Note: Some unstable running may occur in a cold engine. This condition should
abate as normal operating temperature is reached and when a load

DO

Note:

NOT operate the generator unit for lengthy periods

load being placed on the generator.

ROUTINE SERVICE

to

carry out "walk-

41.)

in

get a

hours refer

to

service the engine, read the instructions

full

understanding

to

the hour meter reading. On a daily basis,

in

your log book.

in

this manual

of

the extent and nature

of

service engineers, and service

of

routine service.

of

the day, allow

warm up for 5-10 minutes before applying any heavy loads.

is

applied.

of

time without a

5.

Loading. Apply loads systematically, not

to each load before applying the next

6.

Stopping. Remove major loads f['.nr.

to

unit

run loaded for approximate:}
Depress the stop switch and hold it
stop, then release the switch.

SAFETY RULES:

1.

Never attempt

2.

Wear the proper safety equipment such as goggles for example as called for

each special job. Use only the right kinds

3.

When servicing DC electrical equipment, be sure

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.

5.

Do

not attempt

all

4t

once. Allow the unit to adjust

bad.

the::

gene~';"!'~or

~:

R'

mi:.1utes

ciet-'ressed

to

perform any service while the engine

of

to

service the

AC

generator with the engine running.

to

until the engine comes

hand tools.

one at a time. Allow the

stabilize engine temperatures.

to

a complete

is

running.

to

disconnect the battery.

Use with proper ventilation.

by

Westerbeke Generators

46

ROUTINE

Rely on

hour

SERVICE

meter

to schedule maintenance

SCHEDULE

ITEM

EVERY

1.

Walk-around inspection.

2.

Crankcase

3.

Fuel Tank

4.

Radiator

5.

Fuel FilterlWater Separator

6.

Starting battery

1.

Lube Oil

SERVICE

10 OPERATING HOURS OR

FIRST

See Page

Check

Check

Check coolant level
expansion tank. (Cold Engine)

Check for any contaminants and clean
as needed.

Check electrolyte level and make sure
cables have tight, clean connections.

50

OPERATING HOURS

Initial lube oil change should be performed.

oil

fuel

41

level

level

DAILY

in

the sump.

in

the tank.

in

the radiator and

2.

Lube oil filter

3.

Generator

4.

Fuel filter element

5.

Engine no load speed

6.

Fan Belt

7.

Air cleaner

47

Initial

Check that AC connections are clean and
secure. Check that

Initial change

Check engine no load speed and adjust
necessary. (61.5 - 62.0 Hertz)

Adjust fan belt tension 1/2 - 3/8 inch
deflection.

Check and clean element.

oil

filter change should be performed.

AC

leads are not chaffing.

of

engine fuel filter element(s).

Westerbeke Generators

if

ROUTINE SERVICE SCHEDULE CONTINUED

•..

ITEM

1.

Lube Oil

2.

Lube

oil

3. Air Filter

4. Fan Belt

1.

Fuel Filter(s)

2.

Radiator

filter

EVERY

EVERY

SERVICE

100 OPERATING HOURS

Change engine lube

Change lube oil filter

or

Check, clean

Adjust fan belt tension as needed. Check
condition

replace as needed.

of

belt. Replace as needed.

250 OPERATING HOURS

Replace
fuel pump (if applicable) and

mounted cartridge filter.

Clean any obstructions from radiator
Check radiator hoses and tighten clamps.

fuel

filter elements

oil.

in

electric

in

engine

fins.

EVERY

1.

Cylinder Head Maintenance Retorque cylinder head and rocker shaft,

2.

Cooling System

3.

Starter Motor

4. Preheat circuit

Westerbeke Generators

500 OPERATING HOURS

hold down bolts and adjust valve clearances.

Check antifreeze/water mixture. Add
antifreeze
mixture.

Remove and lubricate pinion drive.

Check operation

Remove and clean glow plugs, check

resistance

48

as

needed. Check condition

of

(.4 - .6 ohms).

preheat solenoid.

of

ROUTINE SERVICE SCHEDULE CONTINUED ....

ITEM

1.

Fuel injector(s)

2.

Engine compression

3.

DC alternator

4. Engine parts

1.

Radiator

EVERY

EVERY

SERVICE

800 OPERA TING HOURS

Remove, check and rebuild
as needed.

Check engine compression pressure.

Check DC charge from alternator.
Check pulley mounting and attachment
of

alternator to engine.

Check security and tightness
bolts and wire connections.

1000 OPERATING HOURS

Remove radiator, have professionally

cleaned and pressure tested. Repair or
replace as needed. Replace coolant mixture
if needed.

fuel

of

injectors

nuts,

49

Westerbeke Generators

1.

Engine Oil Change

SERVICE ITEMS

Remove
through
is attached
forward side
oil should be removed while the engine
is still
through

When replacing the hose in its bracket
be sure

2.

Replacement

When removing the used oil filter, cover
the filter with a plastic bag containing a few

cloth rags

both the filter element and spilled oil

collected cleanly without spilling oil
engine.
reduces
keep

The replaceable cartridge-type oil filter
requires no cleaning inside.

the

lubricating oil

the

sump oil drain hose( this

to

a bracket on the right

of

the engine). The lube

wann

so it will flow easily

the

drain hose.

to

securely reinstall the end cap.

of

the Oil Filter

or

paper towels. This will allow

(Oil

or

any other fluid on the engine

the

engine's cooling ability. Please

your

generator's engine clean.)

out

to

on

be
the

OlL

P~ESSu~E

SENDER

o

~=~

-Receiver

®

OIL PRESSURE SWITCH

~

~

When installing the oil filter element,
apply a thin coat
the rubber gasket
filter onto the threaded oil filter stub, and
then tighten the filter firmly by hand.

NOTE: Generic filters are not recommended. The material standards
tolerances
genuine parts.

Westerbeke Generators

of

on

of

important items on generic parts might be entirely different from

clean engine oil

the oil filter, screw the

to

50

OIL

Oil Filter and Oil Drain System

or

DIU.'H

SYSTEW

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

oil filter

is

no leakage around the new

or

from the oil drain system.

Stop the engine. Wait a minute to allow

the oil

of

to

settle. Then check the quantity

oil with the dipstick. Fill to, (but not over),

the high mark on the dipstick,

engine requires additional

4.

Torquing Cylinderhead Bolts

SERVICE ITEMS CONTINUED ....

if

the

oil.

UPPER

(HoNHnL

LOWER

LIMIT

L£un)

LIMIT

Tighten the cylinder head bolts according
Make sure the engine
then tighten

it

between
25KW, or 80-85 Ib-ft (11.0
next head bolt

in

is

cold when this

85

to 90 Ib-ft. (11.8 to 12.5 kg/m) for the

to

the sequence.

is

11.8 kg/m) for the BTDAR

to

the sequence shown in the illustration below.

done, and loosen one head bolt one-half turn and

BED

20KW AND

15

KW. Then proceed

to

the

51

Westerbeke Generators

5.

Valve Clearance Adjustment
(.012 inches -

.3

mm cold, intake and exhuast)

Note: Retorque the cylinder head bolts before adjusting the engine's valves.

SERVICE

ITEMS

CONTINUED ....

For the

Position

BTDAR

the

CENTER (TDC)

15

KW, BEDR 20 KW and 25 KW Engines:

No. 1 Piston at TOP DEAD

on

its compression stroke
and adjust the #1,2,3, and 6 valves (see the
illustration to the right).

Position

the

No.4

piston at TDC

of

its

compression stroke and adjust the #4, 5, 7

to

and 8 valves. The valves are numbered 1

of

from the front

6.

Torquing Cylinderhead Bolts 32

the engine

to

the back

BEDR

8

Tighten the cylinder head bolts according to the sequence shown

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)

in

the illustration. Make

8

Westerbeke Generators 52

7.

Valve Clearance Adjustment

Note: Retorque the cylinder head bolts before adjusting the engines valves.

For the 32 BEDR engine:

SERVICE ITEMS CONTINUED ....

Position the No.1 piston at

TOP DEAD
CENTER (TDC) on its compression stroke and
adjust the valve clearance:

1,

Intake Valve Cylinder #
Exhaust Valve Cylinder #1,

Position the

No.6

piston at the TOP DEAD

#2 and #4

#3

and #5

CENTER (TDC) on its compression stroke
and adjust the valve clearance:

Intake Valve ­Exhaust Valve

Cylinder # 3,

Cylinder #2, #4 and #6

#5

and #6

Valve Clearance:

15

BTDAR, 20 BEDR, 25 BEDR and 32 BEDR

Adjust

all

valves

to

.012 inches (0.3 mm)

with the engine cold.

\ I I

r

"

:.

, -

:'--------

; I I

0.012

53

J L

I I

-----

II

OJ30mm

:

-.-.~::;.

.J'

--

--~-

cold

..

"

~:

II

,

......

-.:.,'

I I

... -....

.'----,

.'

"

I • -

Westerbeke Generators

8.

Injector Servicing

Injector spray pressure:

1920 psi +

(135 kg/cm

71

psi - 0

2

+ 5 kg/cm

SERVICE ITEMS CONTINUED ....

'·:···~I

~

....

2

0)

-

r;-~C1&1

.

,-

...

,.

I

POOR.

"

Eliminate undesirable injection

conditions including after dripping.

Check compression pressure.
Remove each glow plug and check each
cylinder's compression pressure. The
engine's cranking speed

Standard

427 psi

(30 kg/cm2)

Maximum difference between cylinders:

42.7 psi

9.

Air Cleaner Element

Various air filtration systems may be incorporated with your generator depending on the
application.

NOTE:
INSTALLED. INTERNAL
INGESTION

DO

(3.0 kg/cm2)

Proper servicing

NOT

OPERATE

OF ROAD DEBRIS.

is

at 250 RPM.

Minimum

384 psi

(27 kg/cm2)

is

imperative. Check the air filtration system frequently.

THE

UNIT WITHOUT

ENGINE

DAMAGE WILL RESULT

~~~(H~~.:.ft.

THE

"';:i~.-

.....

--~[jJj\

GOOD

AIR CLEANER ELEMENT

FROM

THE

Westerbeke Generators

54

10.

Fan Belt Adjustment.

SERVICE ITEMS CONTINUED ...

Check visual condition
Replace as needed. Correct tension is
reached with 3/8 - 1/2 inch deflection
of

the belt with 20 pounds

11.

Engine Coolant Change

While the engine
cap on the top
drain petcock on the lower part
radiator. (Drain and wash the plastic
coolant recovery tank.)

Open the engine block drain petcock
located behind the lube

When the system
clean water.
drained, close the two pet cocks securely.

Fill the radiator with a
clean water and antifreeze. NOTE: Mix
before adding.

of

the fan belt.

of

force.

is

cold, open the filler

of

the radiator and then open

of

oil

filter.

is

drained, flush with

Once flushed and

50/50 mixture

the

of

Start the engine and observe the coolant

in

mixture
expelled.
ature.

radiator

the radiator. Add coolant as air is

Observe engine operating temper-

Once the system

full

and install the pressure cap.

plastic coolant recovery tank

is

purged

55

112

of

full.

air,

fill

Fill

the

the

Westerbeke Generators

SERVICE ITEMS CONTINUED .....

12. Radiator Pressure

Cap

Periodically check the condition

pressure cap. Ensure that the upper and lower
rubber seals are in
that the vacuum valve manually opens and
closes tightly.

13. Electronic Governing

The system is composed

1.

Controller - Mounted in the instrument panel.

2.

Sensor - Installed on the bell housing over

the flywheel ring gear.

3.

Actuator - Mounted at the front

engine and attached with linkage to the
throttle arm

ofthe

Controller Adjustments:

1.

Speed - This adjustment

raise

or

lower engine speed

hertz.

Maintenance

of

good

condition. Check

System

of

3 basic components:

injection pump.

is

used

to

the desired

the

of

to

the

Typical Wiring e

Diagram

(all

units)

~

COlo!

11'0111

code on

01

!=Onlrtlue:.

o

-:-ID

t..-..-

g::...m

'---'-;;;;;;;;;;~~.J=""i

=~'@

CO

....

T1tO~::1

PHi. 303006

.t

<t"

2. Gain - This adjustment affects the
of

reaction time

the actuator

generator/engine load changes.

Note: A high gain adjustment can

induce an oscillating

producing a hunting mode. In such

cases, lessen the gain adjustment.

Westerbeke Generators

to

of

the actuator

the

56

s::uo~

'HI

C39l7Z

Unezr

·A::tUZ1I)f

c·

I

I

14.

Generator Maintenance

1.

Maintaining reasonable cleanliness is important. Connections

rectifiers may become corroded, and insulation surfaces

engine exhaust, carbon, etc., are allowed to build up.

of

cause excessive heating and reduced life

2.

For unusually severe conditions, thin rust-inhibiting petroleum-base coatings should be

or

sprayed

brushed over

suggested are Ashland "Tectyle

3.

In addition to periodic cleaning, the generator should be inspected for (a) tightness

all

connections, (b) evidence

4.

The drive discs on single bearing generators should

of

for tightness
be allowed
the drive disc

screws and for any evidence

to

become rusty because rust

to

the generator shaft must

radial marks, one at each

5.

Examine bearing at periodic intervals.

is

when force
of

bearing socket outside bearing has occurred. Repair must be made quickly

applied.

all

surfaces to reduce rusting and corrosion. Typical materials

506" and Daubert Chemical Co. "Nox-Rust AC-410."

of

overheated terminals and (c) loose

of

the 6 comers

If

side motion

windings.

of

incipient cracking failure. Discs should not

may

accelerate cracking. The bolts which fasten

be

hardened steel SAE grade

of

the head.

No

side movement

is

detectable, bearings area wearing

may

Clogged ventilation openings may

be

checked periodically

of

terminal boards and

start conducting

or

damaged wires.

if

saIts, dust,

if

8,

identified by 6

of

shaft should be detected

or

wear on shaft

or

possible

major

components will rub and cause major damage to generator.

of

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

box for additional strength to resist vibration.

in

57 Westerbeke Generators

ENGINE DC WIRING

DIAGRAM

r

-,

1 : BATTERY

: :

SWITCH

~

--'

~

________________________

~

__________

r

-1

EMERGENCY

: 'STOP

t

_JSWITCH

-,

STOP

SWITCH

L-

,.

: :
: :

, _ J

PREHEAT

SOL.

-+r-~---~_-~~,

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____

START

SWITCH

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____

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_!

SWITCH

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I

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~

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r

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STARTER

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____

SPEED

ACTUATOR

SPEED

SENSOR

SOL.

~

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________

o.P.

SNDR.

Westerbeke Generators

.-

____________

W.T.
SNDR.

~~

58

________

~

__

~~~8~5

K

~8~~

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Wiring

Dia~ram

-,.

eve

~

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[f<.----------r-,'."

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STANDARD
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PANEL

Westerbeke Generators

DC

WIRING

DIAGRAM

FOR REMOTE

START/STOP

PANEL.

NOTE:
applications,

may
generator
the
at a remote

,--------------------------------------------------------------i

For

some

this

be

mounted

set

instrument

location.

REMOTE

and

panel

panel

on

the

CONTROL

mounted

PANEL

(REAR

VIEW)

:-----------------------------------------------------------------,-------------------------

: i

~

____

0

.

,

,

STOP

SWITCH

I 10 BLACK

""

GREEN·.I

r-------------

·

·

·

! 55 A

SURGE

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..

~

RED

TO

TO

TB

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TBI-GND

!

i

i I A

~-------------------------

PURPLE

TO

TB2-2

START

SWITCH

."

RED

."

, ! n

, t

L

______________________________________________________________________

'-

______________________________________________________________

P.N.

Westerbeke

Generators

RED

2490

PREljEAT

SWITCH

_____________

55 A SURGE

15 A START

i

_3

__

A_

!~~

______________

R_Ep

__

TO

TBI-2

!

."

REO

60

i:

~

mg~

l

3 A

RUN

•

________________________

J

WHITE

_

TO

TBI-4

DC

WIRING

DIAGRAM

CONTINUED

...

VOLT

IVIETER

12

VDC

SENSOR

ELECTRONIC
MOUNTED

DC+

DC-

BLACK

INSIDE

RED

BLACK

,

or

RED

GOVERNOR

UNIT

CIRCUIT
CONTROL

WIRE

TERMINAL
PANEL.

BLOCK.

RED

BLACK

BLACK/WHI

WHITE

TE

n

0

:z

--i

::::::J

0

r
r

rl

::::::J

PURPLE

ACTUATOR

PURPLE

61

PURPLE

I

PURPLE

Westerbeke Generators

THIS PAGE LEFT BLANK INTENTIONALLY.

Westerbeke Generators

62

GENERATOR

BE-BRUSHLESS

BT-BRUSHLESS

DESCRIPTION SUMlv1AR Y

ELECTRONIC

TRANSFORMER

Construction Type

Speed: 60 Hz

50HZ

Phase

Brushless, four pole, revolving field, single bearing

1800 RPM
1500 RPM*

1 or 3

Ventilation Self - ventilated (fan cooled)

Cooling

Air Requirements

15

KW

& 20

32

KW

KW

& 25

KW

450-500 CFM
525-550 CFM

Ambient Temp., Max.

Insulation

Number

of

Poles

Stator Leads: 3 Phase

1 Phase

Class F

4

or

6

6

or

12

3 or 4

*Voltage and

At

1500 RPM, any given generator will provide a voltage and KW rating equal
rating at
50

HZ

(1500 RPM).

KW

are 5/6

of

rating at 1800 RPM.

1800 RPM. Consult manufacturer

if

a higher voltage

of

KW rating is needed at

63 Westerbeke Generators

to

5/6

the

THIS PAGE

IS

LEFT BLANK INTENTIONALLY

Westerbeke Generators

64

15.0 BTDARGENERATOR

INTERNAL WIRING SCHEMATIC

SINGLE PHASE

A r---------------,

~

jl=-:Btlj

-

,.

1

Fe I

I 2 I

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A.

EXCITER STATOR WINDINGS 1 & 2

A-1

and A·2 Exciter Stator Windings

(Selector in

C.

MAIN STATOR

1.

Main Stator Windings

2.

Main Stator Windings

3.

Main Stator Auxiliary Windings

F.

SELECTOR SWITCH

F-'

Switch in Compound Position

F-2 Switch in Electronic and Compound

COMP position)

Position

65

A.V.R.

PLUG

B.

EXCITER ROTOR

1. Auxiliary Windings

2.

Diodes

3.

Rotating Field Windings

4.

Pozi Resistor

D.

COMPOUND TRANSFORMER

1.

Compound Transformer Windings

2.

Compound Transformer Windings

3.

Compound Transformer Auxiliary Windngs

with Voltage/Hertz Connection Bar

G.

BRIDGE RECTIFIER WIRING

(6)

J

(A

- B - C)

Westerbeke Generators

20,25,32.0

BEDR GENERATOR

INTERNAL WIRING SCHEMATIC

SINGLE PHASE

r-----------------~N

UJ

V>

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Westerbeke Generators

66

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15.0 BTDAR

20, 25, 32.0 BEDR GENERATOR

INTERNAL WIRING

SCHEMATIC

THREE PHASE ONLY

-

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CD

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67

Westerbeke Generators

Volts:

is

used

to

This potentiometer

adjust output voltage. At proper engine operating speed,

the output voltage should be held

output and from power factor

l.0

Stability:

Regulator Adjustments

at

± 2% from a

no

load condition to full rated generator

- 0.8 with engine drive speed variations

of

up

to

-6%.

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.

Amp-Hertz: (Adjustment sealed)

These two adjustments are used
voltage regulator that are indicated

1.

Delayed overload protection (yellow LED)

2.

Low

speed protection (red LED)

conjunction with the two protection circuits

by

the illumination

of

a colored LED.

in

the

in

Each system has an intervention threshold which can be adjusted using a potentiometer.
Each

of

the two circuits reduces excitor voltage to safeguard the excitor windings and

prevent overheating.

of

The overload protection system has a delay which permits temporary overloading

as

generator during times such

motor start up or other similar load surge demands. The

the

regulator also has a third LED (green), that glows during operation to indicate correct

of

operation

the regulator with the generator.

Note: When changing from

50 hertz operation, remove the 60

to
hertz jumper bar from the regulator
board. Regulator

20 BEDR, 25 BEDR and the

the

PN# 039640

32 BEDR.

Westerbeke Generators 68

60 hertz

is

for

LEC·S

Rod

"".lIow

AMP.

STAB.

VOLT

4

3

o

B

+

]aOHZ.

BTDAR

NO LOAD

GENERATOR

VOLTAGE

(Single Phase)

ADJUSTMENT

Voltage adjustment is made with the generator regulation being governed by the
compound transformer.

1.

The selector switch must be

2.

Operate the generator, apply a moderate load momentarily and remove it. Note the
voltage output from the generator's 120 volt
voltage should be between 121-124 volts at

in

the COMP position.

leges) (220 volt 50 hertz). The no-load

60.0 hertz (222-228 volts at 50.0 hertz).

NOTE: The no-load voltage should

be

adjusted with the engine shut

off.

the voltage after applying a momentary load to excite the transformer. The

is

voltage produced by the generator after this momentary load

If

voltage.

this voltage does not

fall

within the specified range, shut down the

removed

engine and adjust the voltage.

3.

To raise or lower the voltage, shims
placed or removed from under the steel laminated bar on top

of

varying thickeness (nonconductive material) are

of

the compound

transformer. The material used for shimming should not soften at temperatures

176°F (80°C) range. A small reduction

by

accomplished

gently tapping the top

between the existing shims and the transformer core.

in

no-load voltage

of

the laminated steel bar to reduce the gap

(l

to 3 volts) can sometimes be

(.001 inch

of

shim thickness will vary

voltage 4-6 volts AC.)

Measure

is

no-load

in

the

69

Westerbeke Generators

II

~

llOV

0

2

r!'"

6

~

N

I

AC OUTPUT CONNECTIONS

AC

CONNECTIONS

50Hz

0

5

R

7

8

I

AC

220V

0

(Q

6

II

N

CONNECTIONS

Single

50HZ

2

& Three Phase

FOR

BT

120V

t"i"t(.

0

0)

5

7

LI

1/

2

0

6

3

0

FOR

SINGLE

60Hz

-»-

5

0

7

8

I

BE

SINGLE

t-

PHASE

120!24-0V

o

6

3

o

PHASE

60Hz

II

PARALLEL

12

10

8 6

4

L-

_____________

L-l

208

L-~

120

L-l

190

L-~

110

AVR

LI

L2

120/240V-GOHZ.

WYE

(STAR)

11

9

CT-O--+---

7 5

J--I--L2

2 3

CL~D--+---

VAC

3~

60HZ

VAC

1!J

60HZ

VAC

3~

50HZ

VAC

1!1

50HZ

AVR AVR

N

LI

N

AC

CONNECTIONS

L 1

L3

[~l

N

120V-f,O HZ.

FOR

SERIES

12

10

8 6 7 5

a::=o

4

a=:D

-=

I

L-L

460

L-~

265

L-L

380

L-N

220

AVR

NU

BT & BE

WYE

(STAR)

11

a::::D

2

3

VAC

3~

VAC 1!J
VAC

3~

VAC

'950HZ

AVR

220V-50HZ.

A

~

1

0

60HZ
60HZ
50HZ

AVR

II

THREE

Ll

L2

Q)

L3

N

AVR

N

IIOV

PHASE

SERIES

L-l

L2

.l3-~

L-L

L2.l3-N

50HZ.

(12

DELTA

240VAC
120VAC
220

VAC

,'0

VAC

IWR

WIRE)

3~

1!J

3~

1!1

9

60
60
50HZ
50

HZ
HZ

HZ

Ll

L2

L3

N

NOTE

-

INSTALLER
NEUTRAL

TERMINAL

INSTALLED.

Westerbeke Generators 70

TO

ENSURE

TO

THAT
THE

THE

GENERATOR

GROUND

CASE

LEAD

IS

FROM

THE

PROPERLY

BTDAR

OPTIONAL

An

optional solid-state voltage regulator (board #34410) is available to use with the BT

series generators. When installed, and the regulation switch

GENERA

VOLTAGE

TOR

(Single Phase)
REGULATOR

is

moved to the ELEC
position, the regulator works together with the standard compound transformer regulator
to

regulate the generator's voltage output. In the ELEC mode, the regulator provides

excitation to the group 1 exciter windings, and the transformer provides excitation

to

the

group 2 exciter windings.

Installation

1.

The regulator is mounted using existing tapped holes

(2) M4 x 0.7 mm screws, each

15

mm

long, with lock washers to mount the regulator

in

the generator's case. Use two

board.

2.

Connect the 6 prong generator plug to the receptacle on the regulator board.

NOTE: The plug

is

keyed to engage the regulator receptacle

in

one direction.

Check this and insert it correctly.

3. Before moving the selector switch
produced by the generator when

LOAD

voltage should be adjusted down to between 114 -118 volts following the

to

the ELEC position the NO-LOAD voltage

in

the COMP position will have

to

be adjusted. The NO-

procedures for BTDAR Generator No Load Voltage Adjustment.

4. Move the selection switch into the ELEC position. Adjust the regulator board
potentiometer to set No-load voltage at 120-122 volts at 60 hertz (220 - 224 volts at 50

in

hertz). The regulator board is operating
should maintain voltage output within

parallel with the compound transformer and

± 5 percent from No-load

to

Full-rated.

71

Westerbeke Generators

ENGINE TROUBLESHOOTING

Introduction

The tables which follow indicate troubleshooting procedures based upon certain problem
indicators, the probable causes

the problems, and the recommendations

to

overcome

of

these problems.

Note that the engine's control system (electrical system) is protected by a 20-Ampere

of

manual reset circuit breaker located on a bracket on the right side

of

forward

the generator's end plate. The preheat solenoid

STOP switch, which may be mounted on the same bracket

is

close by, as

or

on the back

the engine, just

is

the emergency

of

the standard

instrument panel, depending upon the model.

PROBLEM

PREHEAT

switch is
depressed: no panel
indications, fuel solenoid
electric fuel pump and
preheat solenoid not

energized.

START switch

is
depressed: no starter
engagement.

PROBABLE CAUSE

Battery switch not on.

20-Amp circuit
breaker tripped

Connection

to

solenoid

faulty.

Faulty

START switch.

Faulty solenoid.

VERIFICATION/

REMEDY

Check switch and/or
battery connections.

Reset Breaker;

if
breaker trips again,
check preheat

solenoid circuit and
run circuit for shorts

to

ground.

Check connection.

Check switch with

ohmmeter.

12

Check that

Volts
are present at starter
solenoid connection.

Westerbeke Generators

Loose battery connection.

Low batteries.

72

Check battery

connection.

Check battery
charge state.

PROBLEM

PROBABLE CAUSE

VERIFICA
REMEDY

nONI

Poor

ST ART switch is
depressed:

Engine cranks and Defective

connections to

fuel solenoid or no voltage

fu'el

solenoid.
does not start. No fuel
to injectors.

No ignition: cranks but Faulty fueling system.
does not start; fuel solenoid
energized.

Check for

12

volts to
fuel solenoid on
injection pump and
connection.

12

Check that

Volts
are present on the
injection pump.
Remove solenoid
from the pump and

test separately

1.

Check for fuel to

generator engine.

2.

Check for air

in
fuel system. Allow
system to self-bleed.

3.

Fuel lift pump

faulty. Check for

12VDC at pump.
Check ground
connection.

Failure to stop.

STOP switch failure.

73

4.

Filters clogged.
(Replace filters and
allow system to self­bleed by depressing
only the PREHEAT

switch).

by

Stop engine

de­pressing emergency
STOP switch on
engine or manually
unplugging
connection to fuel
solenoid on injection
pump.

Westerbeke Generators

PROBLEM

PROBABLE

CAUSE

VERIFICATIONI
REMEDY

Engine

Stops.

Engine stops.

Low

oil pressure

or

overheated.

Low

oil pressure

switch opens.

High water temperature
switch opens at

too

low

a temperature.

20-Amp circuit breaker
tripping.

Check oil level; check
fresh water coolant.
Check gauge reading
for indication

of

cause.

Check for satisfactory
operation with switch
bypassed. Check with
ohmmeter.

Check for satisfactory
operation with switch
bypassed. Check with
an ohmmeter.

Check for high DC
amperage draw during
operation. Ensure

switch is not overly

to

sensitive

heat which

would cause tripping.

Emergency
or

STOP switch in panel

STOP switch

defective, opening fuel run

solenoid circuit.

Switches and/or wiring.

Check operation

of
switch with an
ohmmeter.

all

Inspect

wiring

for loose connections

and short circuits.
Inspect switches for
proper operation

Westerbeke Generators

74

PROBLEM

PROBABLE CAUSE

VERIFICA TIONI

REMEDY

Battery not charging.

Battery runs down.

Battery runs down.

Alternator drive.

Oil

pressure switch.

High resistance leak to
ground.

Check drive belt
tension. Be sure
alternator turns freely.
Check for loose
connections.

Check
output with voltmeter.
Ensure
present at

12

Volts are

EXC

terminal.

Observe

if

gauges and
panel lights are
activated when engine
is not running. Test
the oil pressure
switch.

Check wiring. Insert
sensitive

(0-.25 Amp)
meter in battery lines.
(Do not start engine.)
Remove connections
and replace after short
is located.

Low resistance leak.

Alternator

75

Check

all

wires for
temperature rise to
locate fault.

Disconnect alternator
at output, after a good
battery charging.

If
leakage stops, remove
alternator and bench
test. Repair

or

replace

Westerbeke Generators

PROBLEM

PROBABLE CAUSE

VERIFICATION/
REMEDY

Engine slows and stops

Engine will not shut
down when stop switch
depressed.

Fuel starvation

DC Circuit Fault.

Check fuel filter for
contamination. Check

of

operation

fuel
pump. Check fuel
tank vent is clear.

Check for

DC

feed
through DC charging
regulator. Disconnect
exc. led. Then
depress stop switch.
Check for faulty stop
switch.

Westerbeke Generators

76

TORQUE

BTDR BEDR BEDR BEDR

15.0KW

SPECIFICATIONS

(lb-ft)

20.0KW 25.0KW

32.0KW

Cylinder
Cylinder

Head
Head

Connecting Rod

Main

bearing
Camshaft
Camshaft

Idler

Gear
Injection
Rocker
Timing
Rear

Arm

Gear

Oil Seal

Cap
thrust
gear

Pump

Assembly 80-85

Cover Bolts 12-17 12-17

Cap

Cover

Cap

plate 12-17 12-17 12-17

Drive

Gear

Nut

80-85 85-90 85-90
2-3

2-3

2-3
50-54 59-65 59-65
80-85 80-85 80-85

45-51 46-69 46-69
17-23 17-23 17-23
29-51

29-51 29-51 29-51
80-85 80-85

12-17 12-17

11-15

11-15 11-15 11-15
Oil Pan Bolts 5-9 12-17 12-17
Oil

Pump

Oil

Pump
Fresh
Crankshaft
Glow
Injector
Injection Nozzle to Body 58-72
Injection
Intake
Exhaust Manifold Nuts
Back
Flywheel Bolts 95-137
Damper

Cover

Bolts 6-9

Pipe 6-9 6-9

Water

Pump

Bolts 12-17 12-17 12-17

Pulley Nut 145-181

Plug

to

Head

Pipe

Flare

Nut

7-11 7-11

'"

18-22

Manifold Nuts 12-17

12-17 12-17

Plate Bolts

Bolts

24-35

14-20

6-9 6-9 6-9

6-9

253-289 253-289 282-304

7-11

*

** **

29-36 58-72

18-22 18-22
12-17

12-17 18-22

20-24
24-35 24-35
80-85 95-137 95-137

14-20 14-20 14-20

80-85
2-3
55-60
80-85

12-17

45-51

17-23

80-85

12-17

6-9

12-17

7-11

29-36

18-22

20-24
24-35

*BEDR 25KW and BTDR 15KW generator sets use injector screwed into the head for

which the torque value

**BEDR 20KW and 32KW generator sets use an injector bolted to the head for which

the torque value

is

12

is

42 to

51

lb-ft.

to

17

lb-ft per bolt, tightened evenly.

77

Westerbeke Generators

TABLE OF STANDARD HARDWARE TIGHTENING TORQUES

Unless stated otherwise for a specific assembly, use the following torque values when tightening standard hardware.

Grade 4

6nun bolt head/nut

bolt head/nut

Snun
10 nun bolt head/nut 1.25
10 nun bolt head/nut 1.5
12

nun bolt head/nut 1.25 (ISO)

12

nun bolt head/nut

12

nun bolt head/nut 1.75

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

Grade6T

6nun bolt head/nut

bolt head/nut

Snun
10

nun bolt head/nut 1.25
10 nun bolt head/nut
12

nun bolt head/nut 1.25 (ISO)
12

nun bolt head/nut
12

nun bolt head/nut

Grade ?T. 8T and 8.8

6nun bolt head/nut
Snun bolt head/nut 1.25
10

nun bolt head/nut
10

nun bolt head/nut
12

nun bolt head/nut 1.25 (ISO)
12

nun bolt head/nut 1.5
12

nun bolt head/nut 1.75
13

nun bolt head/nut
14

nun bolt head/nut 1.5
14

nun bolt head/nut
16

nun bolt head/nut
16 nun bolt head/nut

Pitch

1

1.25

1.5

1.5

1.5

2

1.5

2 51.4

1 4.3 - 6.5

1.25

1.5

1.5

1.75 34.7

1

1.25

1.5 26.8 - 37.6

1.5

2

1.5

2

Ib-ft kg-m

5.1

2.9 -

7.2 -

11.61.0 - 1.6

13.7 - 22.4
\3.0 - 21.7 1.8 - 3.0

25.3 - 39.8 3.5 - 5.5

25.3 - 39.8 3.5 - 5.5

21.7 - 36.2

32.5 - 50.6

36.2 - 57.9

34.0 - 55.7 4.7 - 7.7

54.2

-79.6

-76.7

10.8 - 15.9

21.7-32.5

19.5 -

30.4 2.7 - 4.2

36.2 - 57.9

36.2 - 50.6 5.0

-49.2

5.8 - 8.7

14.5 - 21.7

2S.9 - 39.8

54.2 - 75.9 7.5 - 10.5

50.6 -65.1

43.4 -61.5

57.9 - 86.8

72. 3 - 108.5

68.7 - 101.3

108.5 - 166.4

101.3 - 159.1 14.0 - 22.0

0.4 - .07

1.9-3.1

3.0 - 5.0

4.5 - 7.0

5.0 -

S.O

7.5 - 11.0

7.1

- 10.6

0.6 - 0.9

1.5 - 2.2

3.0 - 4.5

5.0 - 8.0

-7.0

4.8 - 6.S

0.8 - 1.2

2.0 - 3.0

4.0 - 5.5

3.7 - 5.2

7.0 - 9.0

6.0 - 8.5

8.0 - 12.0

10.0 - 15.0

14.0

9.5 -

15.0 - 23.0

Grade 5 cap screw

1I4UNC
114

UNF

5116

UNC

5116

UNF

3/8 UNC
3/8 UNF

7116

UNC

7116

UNF

1/2

UNC

112

UNF

Westerbeke Generators

78

11

9 ­11-\3

18

- 20 2.5 - 2.8

21 -23

33

28 ­30 -

35

44

-49

50 -

55

68

-73

73 -80

1.2

1.5 - 1.8

2.9 - 3.2

3.7-4.6

4.1

6.1

6.9 - 7.6

9.4 -

10.1-11.1

- 1.5

-4.8

- 6.8

10.1