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Westerbeke 20.0 BEDA - User Manual

Westerbeke 20.0 BEDA
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OPERATORS
MANUAL
.MARINE
DIESEL
GENERATORS
20.0
BEDA
60
Hz
16.0
BEDA
50
Hz
25.0
BED
60Hz;
20·
..
BED
50
Hz
32.0
BEDA
60
Hz
25.0
BEDA
50
Hz
·
Single
and
Three
Phase
·
PUBLICATION. N0.039685
REVISIONS
AUGUST 2017
WcSTERBEKECORPORATiON
•1SOJ0HNHANCOCK
ROAD
MYLES
STAND{.S,f!
INDUSTRIAL
PARK
TAUNTON
MA
02780
'WEBSITE; WWW.WESTERBEKE.COM '
,«"""'
.....
.....,'A(1f.A
Member
National
Marine
Manufacturers
Association

Table of Contents

Question and Answer IconNeed help?

Do you have a question about the Westerbeke 20.0 BEDA and is the answer not in the manual?

Summary

Safety Instructions and Precautions

Introduction to Safety Guidelines

Manual's introduction to safety rules and compliance with ABYC standards.

Electrical Safety Procedures

Guidelines to prevent electric shock when working with the generator.

Burn and Fire Prevention

Precautions against burns from hot engine parts and fire/explosion hazards.

Engine Start-up and Battery Safety

Safety measures for accidental starting, battery explosions, and acid hazards.

Hazardous Gas and Moving Part Safety

Warnings about toxic exhaust gases and risks from moving parts.

Noise Hazards and Personal Condition

Safety regarding hazardous noise levels and operator's condition.

Installation Standards and References

Information on ABYC, NFPA, USCG publications for installations.

Installation Procedures and Regulations

Codes and Regulations Compliance

Importance of complying with federal, ABYC, and safety codes for marine environments.

Siphon-Break Requirements

Mandatory installation of siphon-breaks for exhaust elbows below waterline.

Exhaust System Guidelines

Requirements for marine exhaust hose and preventing water entry.

Manual Introduction and Engine Basics

Product Software Disclaimer

Disclaimer regarding third-party product software accuracy and liability.

Warranty Procedures and Identification

Information on warranty registration and customer identification.

Notes, Cautions, and Warnings Explained

Explanation of symbols used for critical information in the manual.

Serial Number Location and Interpretation

How to locate and interpret engine and generator serial numbers for date codes.

Understanding the Diesel Engine

Comparison of diesel engines to gasoline engines and key differences.

Ordering Parts and Spares

Information on how to order replacement parts and accessories.

Control Panel Operation

Main Panel Controls

Description of toggle switches on the engine's control panel.

Remote Start;Stop Panel

Explanation of controls for remote operation of the generator system.

Fluid Management: Fuel, Oil, and Coolant

Diesel Fuel Requirements and Care

Specifications for diesel fuel quality and fuel supply care.

Engine Oil Specifications and Change

Recommended engine oil grade, viscosity, and oil change intervals.

Engine Coolant and Antifreeze

Details on coolant mixture, properties, and antifreeze selection for diesel engines.

Coolant Recovery Tank System

Function and installation notes for the coolant recovery tank.

Starting and Stopping Procedures

Initial Start-Up Preparations

Pre-start inspection checklist and generator voltage verification.

Engine Starting System Operation

Explanation of the starting system, including glow plugs and preheat.

Starting and Stopping the Generator

Procedures for starting, stopping, remote operation, and cold weather starts.

Safety Shutdown Switch Functions

Description of automatic shutdown switches: exhaust temp, water temp, oil pressure.

Generator Break-In and Daily Operation

Generator Break-In Procedure

Guidelines for initial conditioning and break-in of the engine and generator.

Daily Operation Checklist

Daily checks to perform before starting the generator.

Starting and Stopping the Generator Daily

Procedures for daily starting, warm-up, and stopping the generator.

Scheduled Maintenance Tasks

Daily and Hourly Maintenance Checks

Maintenance checks to be performed daily, weekly, and at specific operating hours.

Preventative Maintenance Schedule

Detailed schedule for preventative maintenance based on operating hours.

Engine Cooling System Details

Cooling Circuit Description

Overview of the fresh water and raw water cooling circuits.

Fresh Water Circuit Management

Details on coolant circulation, thermostat, and recovery tank.

Coolant Change and Refill Procedures

Step-by-step guide for changing and refilling engine coolant.

Thermostat Function and Replacement

Information on thermostat operation, testing, and replacement.

Raw Water Cooling System

Explanation of the raw water circuit, pump, and heat exchanger.

Raw Water Pump and Impeller Service

Procedure for changing the raw water pump impeller and its care.

Heat Exchanger and Zinc Anode Maintenance

Maintenance for the heat exchanger and regular inspection of zinc anodes.

Fuel System Maintenance and Operation

Diesel Fuel and Filtration

Requirements for diesel fuel and the importance of fuel/water separators.

Fuel Lift Pump and Injection Pump

Information on fuel lift pumps and the critical fuel injection pump.

Fuel Filter Replacement Procedures

Instructions for changing fuel filters on different generator models.

Fuel System Bleeding;Priming

Procedures for bleeding air from the fuel system for 20/25 KW and 32 KW models.

Fuel Pressure and Additives

Details on fuel pressure requirements and recommended fuel additives.

Engine Oil and Filter Change

Oil Draining and Filter Replacement

Steps for draining used oil and replacing the oil filter.

Refilling Oil and Pressure Check

Procedure for adding new oil and checking for leaks and oil pressure.

Oil Pressure Monitoring

Information on normal operating oil pressure readings.

Optional Remote Oil Filter Installation

Remote Oil Filter Kit Installation

Instructions for installing an accessory remote oil filter kit.

DC Electrical System Overview

12-Volt DC Control Circuit

Description of the engine's 12-volt DC control circuit and wiring.

Battery Care and Specification

Recommendations for starting battery capacity, care, and maintenance.

Glow Plugs and Air Intake Heater

Information on glow plug operation and the 32 KW air intake heater.

Alternator and Charging System

Components of the charging system and basic troubleshooting.

Alternator Testing Procedures

Steps for testing the alternator's output and charging circuit.

Electronic Governor System

Governing System Components

Description of the electronic governor's controller, sensor, and actuator.

Controller Adjustments and Calibration

Procedures for adjusting speed, gain, and calibrating the governor.

Troubleshooting the Electronic Governor

Table of common governor problems, causes, and remedies.

Engine Mechanical Adjustments

Valve Clearance Adjustment

Procedure for adjusting valve clearance when the engine is cold.

Drive Belt Tension Adjustment

Guidelines for checking and adjusting drive belt tension.

Cylinder Head Bolt Torquing

Sequence and torque values for tightening cylinder head bolts.

Engine Compression Testing

Method for checking cylinder compression pressure.

Fuel Injector Testing and Pattern

Procedure for testing fuel injector spray pattern and pressure.

General Engine Troubleshooting

Troubleshooting Engine Start;Stop Issues

Common problems related to starting, stopping, and engine run issues.

Troubleshooting Charging and Fuel Issues

Common issues with battery charging, fuel supply, and system leaks.

Troubleshooting Overheating and Smoking

Diagnosing overheating, high exhaust temperature, and exhaust smoke problems.

Troubleshooting Gauges (Temp & Oil Pressure)

Procedure for checking water temperature and oil pressure gauges.

Generator Operation and Maintenance

Using Electric Motors with Generator

Considerations for starting electric motors with generator power.

Generator Frequency and Speed Adjustment

How engine speed affects generator frequency and voltage regulator settings.

Generator Cleaning and Inspection

Maintaining generator cleanliness, checking connections, and windings.

The BE Generator: Design and Wiring

BE Generator Description (Single;Three Phase)

Overview of the BE generator's four-pole, brushless, self-excited design.

Circuit Breaker Function

Explanation of the automatic circuit breaker for overload protection.

Internal Wiring Schematics

Diagrams showing internal wiring for single and three-phase generators.

Generator AC Voltage Connections

How to connect the AC output for single-phase configurations.

Three Phase Voltage Regulator Connections

Connection points and jumpers for three-phase voltage regulator configurations.

Voltage Regulator Calibration

Voltage and Stability Adjustments

Adjusting output voltage and regulator stability for optimal performance.

Amp-Hertz and Protection Settings

Setting overload and underspeed protection using potentiometers and LEDs.

BE Generator AC Troubleshooting

Troubleshooting No;Low;Unstable AC Output

Diagnosing common AC output faults in the BE generator.

Shore Power Transfer Switch Installation

Shore Power Connection Diagrams

Wiring diagrams for connecting shore power and generator power.

Switching Shore Power Safely

Cautionary advice on switching between shore and generator power.

Seasonal Lay-Up and Recommissioning

General Lay-Up Procedures

Overview of procedures for engine protection during off-season storage.

Lay-Up Procedures by System

Specific lay-up tasks for cooling, lube, and fuel systems.

Specific Lay-Up Tasks (Engine Components)

Lay-up procedures for starter motor, cylinders, batteries, and transmission.

Spare Parts for Lay-Up

Recommendations for spare parts to inspect and replace during lay-up.

Recommissioning Steps

Procedures for preparing the engine for operation after lay-up.

20 KW BEDA Generator Specifications

Engine and General Specs

Engine type, bore, stroke, dimensions, weight, and fuel consumption.

Fuel System Specs

Specifications for fuel type, injection pump, and filters.

Cooling System Specs

Details on cooling system components, operating temperature, and water flow.

Lubrication System Specs

Specifications for oil filter, sump capacity, and oil pressure.

Electrical System Specs

Specifications for starting battery, DC charging alternator, and starter.

AC Generator (3 Phase) Specs

Specifications for 3-phase AC generator voltage and amperage ratings.

AC Generator (Single Phase) Specs

Specifications for single-phase AC generator voltage and amperage ratings.

Generator Cooling Specs

Generator cooling air requirements and engine combustion air.

25 KW BED Generator Specifications

Engine and General Specs

Engine type, bore, stroke, dimensions, weight, and fuel consumption.

Fuel System Specs

Specifications for fuel type, injection pump, and filters.

Cooling System Specs

Details on cooling system components, operating temperature, and water flow.

Lubrication System Specs

Specifications for oil filter, sump capacity, and oil pressure.

Electrical System Specs

Specifications for starting battery, DC charging alternator, and starter.

AC Generator (3 Phase) Specs

Specifications for 3-phase AC generator voltage and amperage ratings.

AC Generator (Single Phase) Specs

Specifications for single-phase AC generator voltage and amperage ratings.

Generator Cooling Specs

Generator cooling air requirements and engine combustion air.

32 KW BEDA Generator Specifications

Engine and General Specs

Engine type, bore, stroke, dimensions, weight, and fuel consumption.

Fuel System Specs

Specifications for fuel type, injection pump, and filters.

Cooling System Specs

Details on cooling system components, operating temperature, and water flow.

Lubrication System Specs

Specifications for oil filter, sump capacity, and oil pressure.

Electrical System Specs

Specifications for starting battery, DC charging alternator, and starter.

AC Generator (3 Phase) Specs

Specifications for 3-phase AC generator voltage and amperage ratings.

AC Generator (Single Phase) Specs

Specifications for single-phase AC generator voltage and amperage ratings.

Generator Cooling Specs

Generator cooling air requirements and engine combustion air.

Parts Identification: 20 KW BE Generator

Left Side View Identification

Identifies major components on the left side of the 20KW generator.

Right Side View Identification

Identifies major components on the right side of the 20KW generator.

Parts Identification: 25 KW BE Generator

Left Side View Identification

Identifies major components on the left side of the 25KW generator.

Right Side View Identification

Identifies major components on the right side of the 25KW generator.

Parts Identification: 32.0 BEDA Generator

Front;Rear View Identification

Identifies components on the front and rear of the 32.0 BEDA generator.

Left Side View Identification

Identifies major components on the left side of the 32.0 BEDA generator.

Right Side View Identification

Identifies major components on the right side of the 32.0 BEDA generator.

Torque Specifications

20.0 KW BEDA Torque Specs

Torque values for components of the 20.0 KW BEDA generator.

25.0 KW BED Torque Specs

Torque values for components of the 25.0 KW BED generator.

32.0 KW BEDA Torque Specs

Torque values for components of the 32.0 KW BEDA generator.

Standard Hardware Torque Values

Bolt and Screw Torque Charts

Torque values for various standard bolts, screws, and hardware.

Sealant Applications

Recommendations for sealant usage on specific threaded components.

Metric Conversion Tables

Length and Weight Conversions

Tables for converting inches to millimeters and pounds to kilograms.

Volume and Temperature Conversions

Tables for converting gallons to liters and Fahrenheit to Celsius.

Recommended Spare Parts

Individual Spare Parts Identification

Visual identification of common spare parts like filters, impellers, and anodes.

Spare Parts Kits

Description of available spare parts kits for basic and extensive use.

Summary

Safety Instructions and Precautions

Introduction to Safety Guidelines

Manual's introduction to safety rules and compliance with ABYC standards.

Electrical Safety Procedures

Guidelines to prevent electric shock when working with the generator.

Burn and Fire Prevention

Precautions against burns from hot engine parts and fire/explosion hazards.

Engine Start-up and Battery Safety

Safety measures for accidental starting, battery explosions, and acid hazards.

Hazardous Gas and Moving Part Safety

Warnings about toxic exhaust gases and risks from moving parts.

Noise Hazards and Personal Condition

Safety regarding hazardous noise levels and operator's condition.

Installation Standards and References

Information on ABYC, NFPA, USCG publications for installations.

Installation Procedures and Regulations

Codes and Regulations Compliance

Importance of complying with federal, ABYC, and safety codes for marine environments.

Siphon-Break Requirements

Mandatory installation of siphon-breaks for exhaust elbows below waterline.

Exhaust System Guidelines

Requirements for marine exhaust hose and preventing water entry.

Manual Introduction and Engine Basics

Product Software Disclaimer

Disclaimer regarding third-party product software accuracy and liability.

Warranty Procedures and Identification

Information on warranty registration and customer identification.

Notes, Cautions, and Warnings Explained

Explanation of symbols used for critical information in the manual.

Serial Number Location and Interpretation

How to locate and interpret engine and generator serial numbers for date codes.

Understanding the Diesel Engine

Comparison of diesel engines to gasoline engines and key differences.

Ordering Parts and Spares

Information on how to order replacement parts and accessories.

Control Panel Operation

Main Panel Controls

Description of toggle switches on the engine's control panel.

Remote Start;Stop Panel

Explanation of controls for remote operation of the generator system.

Fluid Management: Fuel, Oil, and Coolant

Diesel Fuel Requirements and Care

Specifications for diesel fuel quality and fuel supply care.

Engine Oil Specifications and Change

Recommended engine oil grade, viscosity, and oil change intervals.

Engine Coolant and Antifreeze

Details on coolant mixture, properties, and antifreeze selection for diesel engines.

Coolant Recovery Tank System

Function and installation notes for the coolant recovery tank.

Starting and Stopping Procedures

Initial Start-Up Preparations

Pre-start inspection checklist and generator voltage verification.

Engine Starting System Operation

Explanation of the starting system, including glow plugs and preheat.

Starting and Stopping the Generator

Procedures for starting, stopping, remote operation, and cold weather starts.

Safety Shutdown Switch Functions

Description of automatic shutdown switches: exhaust temp, water temp, oil pressure.

Generator Break-In and Daily Operation

Generator Break-In Procedure

Guidelines for initial conditioning and break-in of the engine and generator.

Daily Operation Checklist

Daily checks to perform before starting the generator.

Starting and Stopping the Generator Daily

Procedures for daily starting, warm-up, and stopping the generator.

Scheduled Maintenance Tasks

Daily and Hourly Maintenance Checks

Maintenance checks to be performed daily, weekly, and at specific operating hours.

Preventative Maintenance Schedule

Detailed schedule for preventative maintenance based on operating hours.

Engine Cooling System Details

Cooling Circuit Description

Overview of the fresh water and raw water cooling circuits.

Fresh Water Circuit Management

Details on coolant circulation, thermostat, and recovery tank.

Coolant Change and Refill Procedures

Step-by-step guide for changing and refilling engine coolant.

Thermostat Function and Replacement

Information on thermostat operation, testing, and replacement.

Raw Water Cooling System

Explanation of the raw water circuit, pump, and heat exchanger.

Raw Water Pump and Impeller Service

Procedure for changing the raw water pump impeller and its care.

Heat Exchanger and Zinc Anode Maintenance

Maintenance for the heat exchanger and regular inspection of zinc anodes.

Fuel System Maintenance and Operation

Diesel Fuel and Filtration

Requirements for diesel fuel and the importance of fuel/water separators.

Fuel Lift Pump and Injection Pump

Information on fuel lift pumps and the critical fuel injection pump.

Fuel Filter Replacement Procedures

Instructions for changing fuel filters on different generator models.

Fuel System Bleeding;Priming

Procedures for bleeding air from the fuel system for 20/25 KW and 32 KW models.

Fuel Pressure and Additives

Details on fuel pressure requirements and recommended fuel additives.

Engine Oil and Filter Change

Oil Draining and Filter Replacement

Steps for draining used oil and replacing the oil filter.

Refilling Oil and Pressure Check

Procedure for adding new oil and checking for leaks and oil pressure.

Oil Pressure Monitoring

Information on normal operating oil pressure readings.

Optional Remote Oil Filter Installation

Remote Oil Filter Kit Installation

Instructions for installing an accessory remote oil filter kit.

DC Electrical System Overview

12-Volt DC Control Circuit

Description of the engine's 12-volt DC control circuit and wiring.

Battery Care and Specification

Recommendations for starting battery capacity, care, and maintenance.

Glow Plugs and Air Intake Heater

Information on glow plug operation and the 32 KW air intake heater.

Alternator and Charging System

Components of the charging system and basic troubleshooting.

Alternator Testing Procedures

Steps for testing the alternator's output and charging circuit.

Electronic Governor System

Governing System Components

Description of the electronic governor's controller, sensor, and actuator.

Controller Adjustments and Calibration

Procedures for adjusting speed, gain, and calibrating the governor.

Troubleshooting the Electronic Governor

Table of common governor problems, causes, and remedies.

Engine Mechanical Adjustments

Valve Clearance Adjustment

Procedure for adjusting valve clearance when the engine is cold.

Drive Belt Tension Adjustment

Guidelines for checking and adjusting drive belt tension.

Cylinder Head Bolt Torquing

Sequence and torque values for tightening cylinder head bolts.

Engine Compression Testing

Method for checking cylinder compression pressure.

Fuel Injector Testing and Pattern

Procedure for testing fuel injector spray pattern and pressure.

General Engine Troubleshooting

Troubleshooting Engine Start;Stop Issues

Common problems related to starting, stopping, and engine run issues.

Troubleshooting Charging and Fuel Issues

Common issues with battery charging, fuel supply, and system leaks.

Troubleshooting Overheating and Smoking

Diagnosing overheating, high exhaust temperature, and exhaust smoke problems.

Troubleshooting Gauges (Temp & Oil Pressure)

Procedure for checking water temperature and oil pressure gauges.

Generator Operation and Maintenance

Using Electric Motors with Generator

Considerations for starting electric motors with generator power.

Generator Frequency and Speed Adjustment

How engine speed affects generator frequency and voltage regulator settings.

Generator Cleaning and Inspection

Maintaining generator cleanliness, checking connections, and windings.

The BE Generator: Design and Wiring

BE Generator Description (Single;Three Phase)

Overview of the BE generator's four-pole, brushless, self-excited design.

Circuit Breaker Function

Explanation of the automatic circuit breaker for overload protection.

Internal Wiring Schematics

Diagrams showing internal wiring for single and three-phase generators.

Generator AC Voltage Connections

How to connect the AC output for single-phase configurations.

Three Phase Voltage Regulator Connections

Connection points and jumpers for three-phase voltage regulator configurations.

Voltage Regulator Calibration

Voltage and Stability Adjustments

Adjusting output voltage and regulator stability for optimal performance.

Amp-Hertz and Protection Settings

Setting overload and underspeed protection using potentiometers and LEDs.

BE Generator AC Troubleshooting

Troubleshooting No;Low;Unstable AC Output

Diagnosing common AC output faults in the BE generator.

Shore Power Transfer Switch Installation

Shore Power Connection Diagrams

Wiring diagrams for connecting shore power and generator power.

Switching Shore Power Safely

Cautionary advice on switching between shore and generator power.

Seasonal Lay-Up and Recommissioning

General Lay-Up Procedures

Overview of procedures for engine protection during off-season storage.

Lay-Up Procedures by System

Specific lay-up tasks for cooling, lube, and fuel systems.

Specific Lay-Up Tasks (Engine Components)

Lay-up procedures for starter motor, cylinders, batteries, and transmission.

Spare Parts for Lay-Up

Recommendations for spare parts to inspect and replace during lay-up.

Recommissioning Steps

Procedures for preparing the engine for operation after lay-up.

20 KW BEDA Generator Specifications

Engine and General Specs

Engine type, bore, stroke, dimensions, weight, and fuel consumption.

Fuel System Specs

Specifications for fuel type, injection pump, and filters.

Cooling System Specs

Details on cooling system components, operating temperature, and water flow.

Lubrication System Specs

Specifications for oil filter, sump capacity, and oil pressure.

Electrical System Specs

Specifications for starting battery, DC charging alternator, and starter.

AC Generator (3 Phase) Specs

Specifications for 3-phase AC generator voltage and amperage ratings.

AC Generator (Single Phase) Specs

Specifications for single-phase AC generator voltage and amperage ratings.

Generator Cooling Specs

Generator cooling air requirements and engine combustion air.

25 KW BED Generator Specifications

Engine and General Specs

Engine type, bore, stroke, dimensions, weight, and fuel consumption.

Fuel System Specs

Specifications for fuel type, injection pump, and filters.

Cooling System Specs

Details on cooling system components, operating temperature, and water flow.

Lubrication System Specs

Specifications for oil filter, sump capacity, and oil pressure.

Electrical System Specs

Specifications for starting battery, DC charging alternator, and starter.

AC Generator (3 Phase) Specs

Specifications for 3-phase AC generator voltage and amperage ratings.

AC Generator (Single Phase) Specs

Specifications for single-phase AC generator voltage and amperage ratings.

Generator Cooling Specs

Generator cooling air requirements and engine combustion air.

32 KW BEDA Generator Specifications

Engine and General Specs

Engine type, bore, stroke, dimensions, weight, and fuel consumption.

Fuel System Specs

Specifications for fuel type, injection pump, and filters.

Cooling System Specs

Details on cooling system components, operating temperature, and water flow.

Lubrication System Specs

Specifications for oil filter, sump capacity, and oil pressure.

Electrical System Specs

Specifications for starting battery, DC charging alternator, and starter.

AC Generator (3 Phase) Specs

Specifications for 3-phase AC generator voltage and amperage ratings.

AC Generator (Single Phase) Specs

Specifications for single-phase AC generator voltage and amperage ratings.

Generator Cooling Specs

Generator cooling air requirements and engine combustion air.

Parts Identification: 20 KW BE Generator

Left Side View Identification

Identifies major components on the left side of the 20KW generator.

Right Side View Identification

Identifies major components on the right side of the 20KW generator.

Parts Identification: 25 KW BE Generator

Left Side View Identification

Identifies major components on the left side of the 25KW generator.

Right Side View Identification

Identifies major components on the right side of the 25KW generator.

Parts Identification: 32.0 BEDA Generator

Front;Rear View Identification

Identifies components on the front and rear of the 32.0 BEDA generator.

Left Side View Identification

Identifies major components on the left side of the 32.0 BEDA generator.

Right Side View Identification

Identifies major components on the right side of the 32.0 BEDA generator.

Torque Specifications

20.0 KW BEDA Torque Specs

Torque values for components of the 20.0 KW BEDA generator.

25.0 KW BED Torque Specs

Torque values for components of the 25.0 KW BED generator.

32.0 KW BEDA Torque Specs

Torque values for components of the 32.0 KW BEDA generator.

Standard Hardware Torque Values

Bolt and Screw Torque Charts

Torque values for various standard bolts, screws, and hardware.

Sealant Applications

Recommendations for sealant usage on specific threaded components.

Metric Conversion Tables

Length and Weight Conversions

Tables for converting inches to millimeters and pounds to kilograms.

Volume and Temperature Conversions

Tables for converting gallons to liters and Fahrenheit to Celsius.

Recommended Spare Parts

Individual Spare Parts Identification

Visual identification of common spare parts like filters, impellers, and anodes.

Spare Parts Kits

Description of available spare parts kits for basic and extensive use.

Westerbeke 20.0 BEDA Specifications

General IconGeneral
Model20.0 BEDA
Power Output20 kW
Fuel TypeDiesel
Frequency60 Hz
Engine Speed1800 RPM
Starting SystemElectric
Voltage120/240V

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