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OPERATORS MANUAL
D-NET DIESEL GENERATORS
22.0 KW EDE • 60Hz
17.0 KW EDE· 60Hz
17 .0 KW EDE· 50Hz
13.5 KW EDE· 50Hz
SINGLE & THREE PHASE
DIIRI
1~A'TlnN
NO. 053852
SECOND EDITION
JULY 2008
WESTERBEKE CORPORATION' t50JOHN HANCOCK ROAD
MYLES STANDISH INDUSTRIAL PARK' TAUNTON MA 02780
W£BSITf£: www.W£8Tf£RBEK£.COM
§i1',d;t'"
Member
National MIlI'iM. ManufaclilrersAslociauqp
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Table of Contents
Troubleshooting
Related Manuals for Westerbeke 22.0 KW EDE-60Hz
Summary of Contents for Westerbeke 22.0 KW EDE-60Hz
- Page 1 OPERATORS MANUAL D-NET DIESEL GENERATORS 22.0 KW EDE • 60Hz 17.0 KW EDE· 60Hz 17 .0 KW EDE· 50Hz 13.5 KW EDE· 50Hz SINGLE & THREE PHASE NO. 053852 1~A'TlnN DIIRI SECOND EDITION JULY 2008 WESTERBEKE CORPORATION' t50JOHN HANCOCK ROAD MYLES STANDISH INDUSTRIAL PARK' TAUNTON MA 02780 W£BSITf£: www.W£8Tf£RBEK£.COM...
- Page 2 SBek medical anention. Shut down the unit and do not restart until it has been inspected and repaired. A WARNING DECAL is provided by WESTERBEKE and should be fixed to a bulkhead near your engine or generator. WESTERBEKE also recommends installing CARBON MONOXIDE DETECTORS in the living/sleeping quarters of your vessel.
- Page 3 SAFETY INSTRUCTIONS INTRODUCTION PREVENT BURNS - FIRE Read this safety manual carefully. Most accidents are caused by failure to follow fundamental rules and WARNING: Fire can cause InJury or death! precautions. Know when dangerous conditions exist and take the necessary precautions to protect yourself, your •...
- Page 4 SAFETY INSTRUCTIONS ACCIDENTAL STARTING TOXIC EXHAUST GASES WARNING: Accidental starting can cause Injury WARNING: Carbon monoxide (CO) is deadly gas! or death! • Ensure that the exhaust system is adequate to expel gases • Disconnect the battery cables before servicing the engine/ discharged from the engine.
- Page 5 SAFETY INSTRUCTIONS ABYC, NFPA AND USCG PUBLICATIONS FOR • Do not wear loose clothing or jewelry when servicing equipment; tie back long hair and avoid wearing loose INSTALLING DIESEL ENGINES jackets, shirts, sleeves, rings, necklaces or bracelets that Read the following ABYC, NFPA and USCG publications could be caught in moving parts.
- Page 6 INSTALLATION When installing WESTERBEKE engines and generators it is important that strict attention be paid to the following information: CODES AND REGULATIONS Strict federal regulations, ABYC guidelines, and safety codes must be complied with when installing engines and generators in a marine environment.
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Page 7: Table Of Contents
TABLE OF CONTENTS Parts Identification ............ Introduction ..............Coolant......5 Fuel, Engine Oil, and Engine Preparations for Initial Start-Up ........ 6 Panel ..........Digital Control Panel ..........Remote Start/Stop Generator Break-In Procedure ......... Daily Routine ............Maintenance Schedule (Chart) ......... Fuel System .............. -
Page 8: Parts Identification
PARTS IDENTIFICATION ECU CONNECTIONS REMOTE PANEL CONNECTION INTAKE ~-Llr~I;ANODE ELBOW THER,MOSTAT ASSEMBLY DRIP TRAY OIL DRAIN LEFT SIDE FRONT OIL FILL COOLANT PRESSURE PUMP HEAT FILTER CONTROL BOX AIR INTAKE SILENCER DIPSTICK DIGITAL SPIN-ON PANEl. FUEL FILTER DC BREAKER RIGHT SIDE REAR ISOLATED MOUNTS... -
Page 9: Introduction
INTRODUCTION This WESTERBEKE Diesel Generator is a product of PRODUCT SOFTWARE WESTERBEKB's long years of experience and advanced Product software, (tech data, parts lists, manuals, technology. We take great pride ill the superior durability and brochures and catalogs), provided from sources other than dependable p"errormance of our engines and generators. - Page 10 NOTE: A carbon monoxide warning decal has been provided SERIAL NUMBER LOCATION by WESTERBEKE. Affix this decal in a visible position in the The engine's model number and serial number are located on engine room. a nameplate mounted on the side of the engine's manifold.
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Page 11: Fuel, Engine Oil And Engine Coolant
FUEL, ENGINE OIL AND ENGINE COOLANT FUEL ENGINE COOLANT Engine coolant is a 50150 mixture of antifreeze and distilled water. This coolant allows the engine to run at its proper CAUTION: Use number 2 diesel fuel with celane temperature by transferring heat from the engine to the rating of 45 or higher. -
Page 12: Preparations For Initial Start-Up
PREPARATIONS FOR INITIAL START-UP PRESTART INSPECTION • Be sure that in power systems with a neutral line that Before starting your generator for the first time or after a pro- the neutral is properly grounded (or ungrounded) as the longed layoff, check the following items: system requires, and that the generator neutral is properly •... -
Page 13: Digital Control Panel
ENERGIZES THE FUEL PUMP START BUTTON LIGHT DESCRIPTION Battery Voltage Oil Pressure WESTERBEKE'S Digital Control panel provides the . 13.5 operator with an display that continuously monitors all the operations of the generator in easy to understand text messages. SCROLL... - Page 14 DIGITAL CONTROL PANEL· Examples: STOP SEQUENCE Failure Light is red. To stop the generator, press the STOP button. The display Coolant Temperature Light is orange. will cycle the following text messages and shutdown. thru High Engine Temp. Waiting for operator Shutting Press start to Down...
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Page 15: Remote Start/Stop Panel
The connecting harnesses come in three different lengths and two of these can combined for a maximum run at 75' (22.17M). NOTE: For additioMl information, contact your local WESTERBEKE dealer. 3·1/4» IO"-:.;,:aIYIIYII CONNECTING EXTENSION CABLES 15' (4.75M) -
Page 16: Generator Break-In Procedure
When the engine is warm - almost Smokeless. WESTERLlNK systel1L When the engine is overloaded - some Black Smoke. NOTE: Keep in mind that the Westerbeke generator maybe the DC power supply for the vessel's NMEA-2000 network. Engines & Generators... -
Page 17: Maintenance Schedule (Chart)
Check that all connections are tight. Engine Hoses 0 10 Hose should be hard & tight. Replace if soft or spongy. Check and tighten all hose clamps. *WESTERBEKE recommends this service be performed by an authorized mechanic. (continued) Engines & Generators... - Page 18 (see ENGINE ADJUSTMENTS). *Heat Exchanger have professionally cleaned and pressure tested. *WESTERBEKE recommends this service be performed by an authorized mechanic. CAUTION (WESTERlINK NMEA-2000): The electronic components in the Digital Diesels draw a very small amount of amperage (milli-amps) from the generator's starting battery when the unit is in a static state.
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Page 19: Fuel System
This process is accomplished by installing and maintaining a proper fuel filter/water separator between the fuel and the generator/engine. Westerbeke recommends tank: a 10 micron filter be used. FUEL LIFT PUMP... - Page 20 FUEL SYSTEM FUEL INJECTION PUMP BLEED SCREW The fuel injection pump is the most important component The bleed screw on the injection pump should be left in the of the diesel engine, requiring the utmost caution in handling. open position. This will then allow for ease in priming the The fuel injection pump has been thoroughly bench-tested engine's fuel system and during engine operation allow for and the owner/operator is cautioned not to attempt to service...
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Page 21: Cooling System
DESCRIPTION The heat exchanger is a copper tube which encloses a Westerbeke marine diesel engines are designed and equipped number of small copper tubes. Raw water is pumped through for fresh water cooling. Heat produced in the engine by com-... - Page 22 COOLING SYSTEM' THERMOSTAT A thermostat, located near the manifold at the front of the engine, controls the coolant temperature as the coolant continuously flows through the closed cooling circuit. When the engine is first started, the closed thermostat pre- vents coolant from flowing (some coolant is by-passed through hole in the thermostat to prevent the exhaust manifold from overheating).
- Page 23 COOLING SYSTEM FRESH WATER CODLING CIRCUIT CHANGING COOLANT The engine's coolant must be changed according to the NOTE: Refer to the ENGINE COOlANT section for the MAINTENANCE SCHEDULE. If the coolant is allowed to recommended antifreeze water mixture to be used as the become contaminated, it can lead to overheating problems.
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Page 24: Raw Water Cooling Circuit
COOLING SYSTEM RAW WATER COOLING CIRCUIT . wat~r ll1e raw flow is created by a positive displacement RAW WATER PUMP impeller pump. This pump draws water directly from the ocean, lake, or river from a thru-hull opening through a hose to the water strainer. -
Page 25: Engine Lubricating Oil
ENGINE LUBRICATING OIL GASKET ENGINE OIL CHANGE APPLY GLEAN OIL TO SEALING GASKET 1. Draining the Oil Sump. Discharge the used oil through the sump drain hose (attached to the front of the engine) while the engine is warm. Drain the used oil completely, replace the hose in bracket, and replace the end cap securely. -
Page 26: Testing Oil Pressure
OIL PRESSURE DESCRIPTION The lubricating system is a pressure feeding system using an oil pump. The engine oil is drawn from the oil sump by the oil pump, which drives the oil, under pressure, through TESTING OIL PRESSURE the oil filter, oil cooler and various lubricating points in the NOTE: To test oil pressure, install a mechanical pressure... -
Page 27: Remote Oil Filter (Optional)
REMOTE OIL FILTER (OPTIONAL) INSTALLATION NOTE: Westerbeke is not responsible for engine failure due incorrect installation of the Remote Oil Filter. This popular accessory is used to relocate the engine's oil fil- ter from the engine to a more convenient location such as an engine room bulkhead. - Page 28 • I _ _ _ _ _ _ ..J I""'WESTERBEKE Engines & Generators...
- Page 29 WIRING DIAGRAM #53829(24 VOLT) &F'OS~a..«:f( '::' ; - ' gt§ Nllg) EX~~·.I.., Ng,. --:----n..-c==> >1;) l , - ;..~; CONTROL BOX (AC SIDEI ROTOR ~JSnl'" :ljl ::.,"".:."""" . . '." M CONTROL BOX ~~bSE[} (DC SIDE) ...,.""'" ~4IXlIIAMA>:' AWJWIIIU: CI.IW:NT. L _ _ _ _ _ ~S1AI!IT/$1'QI'Mllrttl lmlillONlIDIIJIt"n,CelUfltln...
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Page 30: Engine Troubleshooting (Chart)
Engine starts, runs and shuts down. Check oil pressure switch. Faulty oil pressure switch. 2. Water temperature switch. 2. Check water temperature switch. Engine starts, runs at idle 1. flectronic governor system faulty Check governor system components. , """",WESTERBEKE ( continuedj Engines & Generators... - Page 31 ENGINE TROUBLESHOOTING Probable Cause Problem Verification/Remedy Exhaust'smoking problems Blue smoke. Incorrect grade of engine oil. Crankcase is overfilled with engine oil (oil is blowing out through the exhaust). 2. White smoke. 2. Engine is running cold. inj~ctor im:or.r~.ct 2a. Faulty injector til]ing: Black smoke.
- Page 32 A working alternator runs hot. A failed The following information applies to the standard alternators alternator can become very hot. Do not touch the that supplied with WESTERBEKE'S Engines and Generators. alternator until if has cooled. ELECTRICAL CHARGING CIRCUIT LOW BATTERY /FAULTY CIRCUIT...
- Page 33 ALTERNATORS TESTING/TROUBLESHOOTING MEASURING BAnERY VOLTAGE TESTING THE ALTERNATOR (IGNITION ON ENGINE OFF) CAUTION: Before starting the engine make certain that everyone is clear of moving Keep parts! away from sheaves and belts during test procedures. 1. Start the Engine. 2. After the engine has run for a few minutes, measure the starting battery voltage at the battery terminals using a multimeter set on DC volts.
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Page 34: Battery Care
If tests indicate a failed alternator, it will need to disas- sembled and repaired. Any good alternator service shop can do the job. NOTE: WESTERBEKE'S Service Manual has detailed instructions for the disassembly and repair of their standard alternators. BATTERY CARE The minimum recommended capacity of the battery used in 3. -
Page 35: Engine Adjustments
ENGINE ADJUSTMENTS NOTE: WESTERBEKE recommends tfull the following engine adjust- ments be peifonned by a competent engine mecfulnic. The information to assist the below provided mecfulnic. CHECKING VALlfE CLEARANCE Valve clearance must be checked and adjusted when engine cold. 1. Remove the head cover. -
Page 36: Glow Plugs
ENGINE ADJUSTMENTS DRIVE BELT ADJUSTMENT Proper inspection, service and maintenance of the drive belts is important for the efficient operation of your engine (see GLOW PLUG under Drive Belts MAINTENANCE SCHEDULE). CONNECTION STRAP Drive belts must be properly tensioned. Loose drive belts will not provide proper alternator charging and will eventually damage the alternator. -
Page 37: Fuel Injectors
FUEL INJECTORS Inspecting Spray Pattern REMOVING THE INJECTORS 1. Operate the hand lever of the nozzle tester a1 intervals of NOTE: Injector must be serviced ina "clean erwir01unent. room" one stroke per second to check if the fuel is injected COT- 1. -
Page 38: Starter Motor
STARTER MOTOR TROUBLESHOOTING Prior to testing, make certain the ships batteries are at full charge and that the starting system wiring connections (terminals) are clean and tight. Pay particular attention to the ground wire connections on the engine block. To check the wiring, cranking the starter for a few seconds, never more than seconds at a time, then run your... -
Page 39: Emergency Start
When you reach a repair facility, the starter will need to be repaired. SERVICE WESTERBEKE uses a standard starter motor which can REFER TO THR WIRING serviced or rebuilt at any starter motor automotive service... - Page 40 SPECIFICATIONS 22.0/17.0 EDE COOLING SYSTEM ENGINE SPECIFICATIONS Diesel, four-cycle, four-cylinder, fresh General Fresh water-cooled engine block, Engine Type thermostatically-controlled with heat water-cooled, vertical in-line overhead valve mechanism. exchanger. Operating Temperature Aspiration Naturally aspirated 160 -180 F (71 - 82° C) Compression Ratio 22.6:1 Fresh Water Pump...
- Page 41 SPECIFICATIONS 17.0/13.5 EDE ENGINE SPECIFICATIONS LUBRICATION SYSTEM Engine Type Diesel, four-cycle, three-cylinder, fresh Operating Oil Pressure 28 - 57 psi (2.0 - 4.0 kg/em') water-cooled, vertical in-line overhead valve (engine hot) mechanism. API Specification CF, CG-4, CF-4 or CH·4 Oil Grade Aspiration Naturally aspirated SAE 10W-30, 15W-40...
- Page 42 GENERATOR SPECIFICATION 3 PHASE 17.0/13.5 22.0/17.0 AC GENERATOR (3 Phase) AC GENERATOR (3 Phase) Three Phase Three Phase Brushless. six- pole, revolving field. Sealed Brushless, six- pole. revolving field. Sealed 17.0 Kw - 60 Hertz lubricated. single-bearing design. 12 Lead 22.0 Kw - 60 Hertz lubricated, single-bearing design.
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Page 43: Generator Information
(split-phase) are not CARBON MONOXIDE DETECTOR made in larger sizes. WESTERBEKE recommends mounting a carbon monoxide Because the heavy surge of current needed for starting detector in the living quarters. Carbon Monoxide, even in motors is required for only an instant. -
Page 44: Electronic Regulation
ELECTRONIC REGULATION 5R7·2G AVR 5AMP FUSE ADJUSTABLE THRESHO OVERLOAD PROTECTIO · D . INTERVENTION . DO ' ; :; ' " H Amp I ..@ffi ADJUSTABLE THRESHOLD @I:i:i z---..; ----, OF UNDERSPEED ®e CONNECT FOR 60Hz PROTECTION INTERVENTION Stab '.--l Do::: REMOVE FOR 50Hz... -
Page 45: Internal Wiring Diagram
ELECTRONIC REGULATION SR7·2G AVR TERMINAL SLOCK commONS SHOWN hRE CONF IG'JR!O lO-Wr~ 110/108 VAC TER!II'IAL iUCK Hertz: With this potentiometer, which is normally TO AC SENSE pre-calibrated then sealed by the manufacturer, it is possible CONNECTIONS to adjust the low frequency protection intervention. To recalibrate this protection, you must take the generator normal zero load condition, tum the potentiometer clockwise until the limit position is reached, then decrease... -
Page 46: Generator Wiring Schematics
GENERATOR WIRING SCHEMATICS , - - - ---1 EXCITER STATOR : CONOENSER [-----,- G--- STATOR : EXCITER ROTOR FIELD ...---~~ ROTOR ,..-.-----:--1 -r>t- ___ -:---; [)lODES _THREE PAIRS SUP~~E~O~ _____ ..J At TERMINAL BlOCI( Amp· Hertz- Stab- VQI!-- tI.. GREEN ~;-l SINGLE PHASE l_tf;... - Page 47 INTERNAL WIRING SCHEMATIC EXCITER ROTOR/ROTATING FIELD TRANSIENT CONDENSER r------------ EXCITER ROTOR WINDINGS -1::* FIELD =-----i • DIODE ~II-- ____ ...,.- t _____ _ _ _ _ _ _ _ _ _ _ ________ ...1 +" GREEN GREEN EXCITER ROTOR WINDINGS ISOLATION DIODE PLATES Engines &...
- Page 48 TWELVE LEAD WINDING/TERMINAL BOARD CONNECTIONS AND (NOMINAL) VOLTAGES PARALLEL Y SERIES Y SERIES SERIES PARALLEL DELTA STAR STAR 9--8-N-7-~ 8~Z5 7"'-. L 1(;1 10-12 10":11 1-12 50 Hz L-L 230 volts 50 Hz L-L 200 volts Hz L-L400 volts Hz L-N volts Hz L-N volts...
- Page 49 CHANGING HERTZ AND VOLTAGE CAUTION: precaution against an start, unintentional shut OFF the 20 Amp DC breaker on the control panel. CONNECT FOR 60Hz 1. Refer to the previous page that illustrates the various AC REMOVE FOR 50Hz voltage output configurations for both the 60 Hertz and 50 Hertz applications.
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Page 50: Be Troubleshooting (Chart)
BE TROUBLESHOOTING NOTE: AC GENERATOR TROUBLESHOOTING MUST BE PERFORMED WITH THE ENGINE OPERATlN AT 60 HZ. FAULT PROBABLE CAUSE NO AC VOLTAGE OUTPUT AT NO LOAD. 1. Short or open in the 4. Open in exciter stator winding. main stator winding. 2. -
Page 51: Exciter Rotor Troubleshooting
EXCITER ROTOR TROUBLESHOOTING LOW VOLTAGE· EXCITER ROTOR TESTING THE EXCITER ROTOR WINDINGS AND ROTATING FIELD These windings are tested in pairs: A to B, B to to A as shown on the drawing. Position the exciter rotor/rotating field so the transient suppressor is visible at the 12 O'Clock position. -
Page 52: Generator Servicing
GENERATOR· SERVICING TESTING THE MAGNETIC PICK UP COIL MAGNETIC PICK-UP [MPU] INSTALLATION Test the speed sensor connector for voltage and resistance The MPU is installed in the threaded opening on the side values. of the flywheel bellhousing. This positions the MPU over the teeth of the flywheel ring gear. -
Page 53: Generator/Maintenance Parts Breakdown
MECC ALTE GENERATOR MAINTENANCE/PARTS BREAKDOWN INSPECTION/CLEANING Periodically inspect the rotor carrier bearing. Replace this Remove all dirt, oil, grease and dust build up from the bearing at 10,000 hours of nonnal operation or sooner if external surface of the generator. Build-up reduces heat wear is evident. - Page 54 MECC ALTE GENERATOR ASSEMBLY OF THE GENERATOR TO THE ENGINE 4. Rotate the generator hand two full revolutions to 1. Position the rotor assembly onto the flywheel aligning the ensu.re the generator rotates freely. Reinstall the rear holes in the drive discs with the holes in the flywheel. vent-cover.
- Page 55 AC connections are correct. SHIP'S GROUND NOTE: Ship to shore switches are available at your SHORE GROUND WESTERBEKE dealer. SHORE POWER .Generator L1 L2 "\ 120 Volt/60 Hertz Three Wire Configuration Note the repositioning of the white ground lead on the telmi- nal block to the generator case.
- Page 56 LAY-UP & RECOMMISSIONING GENERAL Fuel System [Gasoline] Many owners rely on their boatyards to prepare their craft, Top off your fuel tanks with unleaded gasoline of 89 octane including engines and generators, for lay-up during the or higher. A fuel conditioner such as STABIL gasoline off-season or for long periods of inactivity.
- Page 57 Lay-up time provides a good opportunity to inspect your Lubrication and cleaning of the starter drive pinion is advisable, Westerbeke engine to see if external items such as drive belts if access to the starter permits its easy removal. Make sure the or coolant hoses need replacement.
- Page 58 STANDARD AND METRIC CONVERSION DATA LENGTH-DISTANCE Inches (in) x 25.4 = Millimeters (mm) x .0394 Inches Feet (ft) x .305 = Meters (m) x 3.281 :; Feet 1.609 = Kilometers (km) Miles .0621 Miles DISTANCE EQUIVALENTS Degree of latitude 60 Nm 111.120 km 1 Minute of latitude = 1 Nm 1.852 km...
- Page 59 DECIMAL TO METRIC EQUIVALENT CHART Fractions of Fractions of Decimal (in.) Metric (mm) Decimal (in.) Metric (mm) an inch an inch 0.015625 0.39688 33/64 0.515625 13.09687 1/64 0.53125 13.49375 1/32 0.03125 0.79375 17/32 0.546875 13.89062 3/64 0.046875 1.19062 35/64 14.28750 0.0625 1.58750 0.5625...
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Page 60: Thermostat
SUGGESTED SPARE PARTS WESTERBEKE MARINE GENERATORS CONTACT YOUR 'WESTERBEKE DEALER FOR SUGGESTIONS AND ADDITIONAL INFORMATION ~~~/~/ D·RING AND GASKET SET THERMOSTAT KIT HARDwARE KIT IN·L1NE FUEL FILTERS (OWNER INSTALLED) ~~~8AFUSE (ON FRONT MOLDED OF THE CONTROL PANEL). HOSE KIT WESTERBEKE RECOMMENDS HAVING ENOUGH SPARE INA CANVAS ENGINE OIL (YOUR BRAND) FOR AN OIL CHANGE (5 DTS.) - Page 61 Engines & Generators WM4-0BDWI121...