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'OPERATORS MANUAL
D·NET DIESEL GENERATORS
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33KW EDE • 60Hz
28.5KW EDE • 60Hz
26KW EDE • 50Hz
23.5KW EDE • 50Hz
25.5KW EDE • 60Hz
. 21.0KW EDE·· 50Hz
WESTERBEKE CORPORATION -150 JOHN HANCOCK ROAD
MYLES STANDISH INDUSTRIAL PARK - TAUNTON MA 02780
WEB SITE: WWW.WESTERBEKECOM
.F..I"
Member Nallonal Marine Manufacturers Assocrotlon
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Table of Contents
Troubleshooting
Related Manuals for Westerbeke 33KW EDE-60Hz
Summary of Contents for Westerbeke 33KW EDE-60Hz
- Page 1 28.5KW EDE • 60Hz 26KW EDE • 50Hz 23.5KW EDE • 50Hz 25.5KW EDE • 60Hz . 21.0KW EDE·· 50Hz WESTERBEKE CORPORATION -150 JOHN HANCOCK ROAD MYLES STANDISH INDUSTRIAL PARK - TAUNTON MA 02780 WEB SITE: WWW.WESTERBEKECOM .F..I" Member Nallonal Marine Manufacturers Assocrotlon...
- Page 2 WARNING Generators Produce CARBON MONOXIDE Regular Maintenance Required ri?i![~E!::!!!~~ 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 WARNING: caused by failure to follow fumkzmental rules and Fire can cause injury or death! precautions. Know when dangerous conditions exist and take the necessary precautions to protect yourself, your •...
- Page 4 Acid may splash on the skin or situation arises in which it is absolutely necessary to into the eyes inadvertently when removing electrolyte make operating adjustments, use extreme care to avoid touching moving parts and hot exhaust system caps. components. WESTERBEKE -..y' Engines & Generators...
- Page 5 USCG and the NFPA. Sections of the ABYC standards of particular interest are: H-2 Ventilation P-l Exhaust Systems P-4 Inboard Engines E-9 DC Electrical Systems All installations must comply with the Federal Code of Regulations (FCR). WESTERBEKE Engines Generators &...
- 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 ........... 2 Introduction ..............Fuel, Engine Oil and Engine Coolant ......Preparations for Initial Start ........6 Oigital Control Panel ..........Remote Stop/Start Panel ......... Generator Break·ln Procedure ........Daily Routine .............. Maintenance Schedule (Chart) ........ 10 Fuel System .............. -
Page 8: Parts Identification
PARTS IDENTIFICATION OIL FILL COOLANT CONNECTION FOR THERMOSTAT SIPHON BREAK DIGITAL CDNTROL PANEL f--~INJIECTION PUMP 1lc::::LI.L---11AW WATER PUMP Fl 8A FUSE DIL DRAIN HOSE [J..e--- REAR RIGHT SIDE FUEL LIFT CONTROL HEAT .,LtN.'tH_" AIR INTAKE BREAKER HIGH EXHAUST AIR BLEED PETCOC:Ki.:~ TEMPERATUR£... -
Page 9: Introduction
WES1ERBEKE products, whether from WES1ERBEKE or WARRANTY PROCEDURES other suppliers, must not and cannot be relied upon exclu- Your WESTERBEKE Warranty is included in a separate sively as the definitive authority on the respective prodtict.Jt folder. If, after 60 days of SUbmitting the Warranty Registry... - Page 10 A carbon monoxide warning decal has been provided The engine's model number and serial number are located on by WESTERBEKE. Affix this decal in a visible position in the a nameplate mounted on the side of the engine. engine room.
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Page 11: Fuel, Engine Oil And Engine Coolant
ENGINE COOLANT Use fuel that meets the requirements or specification of Class WESTERBEKE recommends a mixture of SO% antifreeze 2-D (ASTM), and has a cetane rating of #4S or better. and SO% distilled water. Distilled water is free from the chemicals that can corrode internal engine surfaces. -
Page 12: Preparations For Initial Start
PREPARATIONS FOR INITIAL START-UP PRESTART INSPECTION CAUTION: When starting the generator, it is Before starting your generator for the fIrst time or after a prolonged layoff, check the following items: recommended that aI/ loads, espeCially large motors, be switched OFF until the engine has come •... - Page 13 - _ .• TOne ~.T"DT BUTTON DESCRIPTION Battery Voltage Oil Pressure WESTERBEKE'S' Digital Control Panel provides the 13.5 operator with an LCD 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 S1DP button. The d,isplay 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 Stop/Start Panel
The connecting harnesses come in three different lengths and two of these can be combined for a maximum run at 75' (22.17M). NOTE: For additional information, contact your local WESTERBEKE dealer. 3·1/4" (82.!55MIII) CONNECTING EXTENSION 6" (152.4MM) CABLES 15' (4.75M) -
Page 16: Generator Break·ln Procedure
• Check for abnormal noise such as knocking, vibrating and blow-back sounds. • Confirm exhaust smoke: When the engine is cold - White Smoke. When the engine is warm - almost Smokeless. When the engine is overloaded - some Black Smoke. WESTERBEKE -.,.y- Engines & Generators... -
Page 17: Maintenance Schedule (Chart)
MAINTENANCE SCHEDULE WARNING: Never attempt to perform any service while the engine is running. Wear the proper safety equipment such goggles and gloves, and use the co"ect tools for each job. Disconnect the battery terminals when servicing any of the engine's DC electrical equipment. NOTE: Many of the following maintenance jobs are simple but others are more difficult and may require the expert knowledge of a service mechanic. - Page 18 NMEA-2000 system o(shl# off the DC breaker on the generators control box for a WESTERLlNK system. NOTE: Keep ill mind that the Westerbeke generator maybe the DC power slIpplyfor the vessels NMEA-2000 network. CAUTION: When serviCing/changing DC components.
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Page 19: Fuel System
FUEL SYSTEM DIESEL FUEL ENGINE FUEL FILTER Use No.2 diesel fuel with a Celane rating of 45 or higher. In Periodically check the fuel connections and the filter bowl for conjunction with Ultra Low Sulphur Diesel. Use an additive leakage. Change the filter element after the first 50 houTS. See such as "Diesel Kleen"... -
Page 20: Cooling System
COOLING SYSTEM DESCRIPTION WASHER-:!~~Sl1 Westerbeke marine diesel engines are designed and equipped for fresh water cooling. Heat produced in the engine by com- bustion and friction is transferred to fresh water coolant which circulates throughout the engine. This circulating fresh water coolanteools the engine block .. -
Page 21: Fresh Water Cooling Circuit
COOLING SYSTEM CHANGING COOLANT FRESH WATER COOLING CIRCUIT The engine's coolant must be changed according to the NOTE: Refer to the ENGINE COOLANT section for the rec- MAINTENANCE SCHEDULE. If the coolant is allowed to ommended antifreeze and water mixture to be used as the become contaminated, can lead to overheating problems fresh water coolant... -
Page 22: Thermostat
COOLING SYSTEM THERMOSTAT REPLACING THE THERMOSTAT A thermostat, located near the manifold at the front of the 1. Drain ofT some coolant: Release the coolant pressure cap engine. controls the coolant temperature as the coolant and drain the coolant to the approximate level off the continuously flows through the closed cooling circuit. -
Page 23: Raw Water Cooling Circuit
COOLING SYSTEM HEAT EXCHANGER RAW WATER COOLING CIRCUIT The raw water flow is created by a positive displacement impeller pump. This pump draws water directly from the ocean, lake, or river through a hose to the water strainer. The raw water passes from the strainer through the heat exchanger (through the heat exchanger tubes) where it cools the engine Circulating fresh water coolant. -
Page 24: Engine Lubricating 011
Screw the filter onto the threaded oil filter nipple on the oil filter bracket, and tighten the filter firmly by hand. NOTE: The engine oil is cooled by engine coolant flowing through passages in the oil filter bracket hOl/sing assembly WESTERBEKE Engines & Generators... -
Page 25: Remote Oil Filter (Optional)
REMOTE OIL FILTER (OPTIONAL) NOTE: INSTALLATION Westerbeke is not responsible for engine failure due to incorrect installation of the Remote Oil Filter. Irhls popular accessory is used relocate the engine's oil fil- from the engine a more convenient location such as an engine room bulkhead. -
Page 26: Starter Motor (Troubleshooting)
Using a muitimeter, test the voltage between the positive temlinal stud on the start solenoid and the engine block (ground). fly when jumping terminals. Be certain-the engine space is free of potentially explosive fumes, especially you read 12 volts, the starter is faulty. gasoline_ WESTERBEKE Engines & Generators... - Page 27 STARTER MOTOR SERVICE Westerbeke uses a standard marine starter motor which can be (+) POSITIVE serviced or rebuilt at any starter motor automotive service center. ____ ----)TERMINAl If replacing the starter motor, make certain the new motor is certified for marine use. Automotive starters do not meet USCG standards.
- Page 28 - " - " - " , " - " - : 1, 1 i i i f§! '---~-' " ===~_:;=- " " L_ .. _ .. _. __ I __ _ - - - - - - - ,,,",,~WESTERBEKE , Eng/ires Generators &...
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Page 29: Engine Troubleshooting (Chart)
Engine starts, runs and shuts down 1. Oil pressure switch. 1. Check oil pressure switch. Water temperature switch. Check water temperature switch. Engine starts, runs at idle 1. Electronic governor system faulty 1. Check governor system components. I~/WESTERBEKE (continued) Engines & Generators... - Page 30 ENGINE TROUBLESHOOTING Problem Probable Cause Verllicatlon/Remedy Exhaust smoking problems Blue smoke. Incorrect grade of engine oil. 1a. Crankcase is overfilled with engine oil (oil is blowing out through the exhaust). 2. White smoke. 2. Engine is running cold. 2a. Faulty injector or incorrect injector timing. 3.
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Page 31: Alternator Testing
ALTERNATORS TESTING/TROUBLESHOOTING '10 ORANGE B TO STARTER SOLENOID 60 AMP ALTERNATOR VOLTAGE REGULATOR The integral voltage regulator is an electronic switching device which senses the system voltage level and switches Ibe voltage applied to Ibe field in order to maintain a proper EXCITER system voltage. - Page 32 ALTERNATORS TESTING/TROUBLESHOOTING MEASURING BATTERY VOLTAGE TESTING THE ALTERNATOR (IGNITION ON ENGINE CAUTION: Before starting the engine make certain that everyone is clear of moving parts! Keep 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 termin'lls using a multimeter set on DC volts.
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Page 33: Battery Care
If tests indicate a failed alternator, it will need to be 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 a/their standard altemators. BATTERY CARE The minimum recommended capacity of the battery used in 3. -
Page 34: Glow Plugs
GLOW PLUGS DESCRIPTION Re-install the plugs in the engine and test them again. The plugs should get very hot (at the terminal end) within 7 to 15 The glow plugs are wired through the preheat solenoid. seconds. If the plugs don't heat up quickly, check for a short When PREHEAT is pressed at the control panel this solenoid circuit. -
Page 35: Engine Troubleshooting (Chart)
ENGINE ADJUSTMENTS NOTE: WESTERBEKE recommends that the following engine adjust- ments be peiformed by a competent engine mechanic. The information below is provided to assist the mechanic. ENGINE COMPRESSION Check the compression pressure. To do this wann the engine, PLUG remove all fuel injectors, or glow plugs, disconnect the fuel "~Shut_Off... -
Page 36: Drive Belt Adjustment
Clean the area around the base of the injector prior to lifting it out of the cylinder head to help prevent For your safety, WESTERBEKE generator models come any rust or debris from falling down into the injector equipped with belt guards that cover over the belt(s) on the hole. -
Page 37: Magnetic Plck·up
ENGINE ADJUSTMENTS MAGNETIC PICK·UP [MPUjINSTALLATION TESTING THE MAGNETIC PICK UP COIL 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 38 NOTE: Increase cooling air flow 15% for slower tuming 50hz units. DC Charging Aliemator 60 Amp rated, belt-doven Generator Compartment 122° F (50° C) maximum Starter 2.5Kw, 12VDC direct dove Ambient Temperature Starting Aid Glow plugs, sheathed type Cran~ng Current 400 - 600 (includes glow plugs) WESTERBEKE Engines & Generators...
- Page 39 122'F (50'C) maximum Recommendations NOTE: Forced ventilation should be provided Generator Compartment to maintain generator compattment Ambient Temperature NOTE: Forced ventilation should be provided temperatures below 104'F (40'C). Recommendations to maintain generator compattment temperatures below 104'F (40'C). WESTERBEKE Engines & Generators...
- Page 40 Generator Compartment 122'F (50'C) maximum Recommendations Forced ventilation should be provided to maintain generator compartment Ambient Temperature lemperatures below 104'F (40'C). Recommendations NOTE: Forced ventilation should be provided to maintain generator compartment temperatures below 104'F (40'C). ""'" WESTERBEKE Engines & Generators...
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Page 41: Generator Information
Run the generator first with no load applied, then at half the Carbon Monoxide Detector generator's capacity, and finally loaded to its full capacity as WESTERBEKE recommends mounting a carbon indicted on the generator's data plate. The output voltage monoxide detector in the vesssel's living quarters. Carbon... - Page 42 TWELVE LEAD WINDING/TERMINAL BOARD CONNECTIONS AND (NOMINAL) VOLTAGES . (SERIES WYE) (pARALLEL WYE) SERIES SERIES PARAllEL STAR DElTA STAR 2 1 3 10-11 10-12 10-'11 4-8-12 1~12 L-L 230 volts L-L 400 volts 50 Hz L-L 200 volts L-N 115 volts L-N 230 volts L-N 115 volts L-L 277 volts...
- Page 43 [3·WIRE SPLIT SINGLE PHASEI r2·WIRE SINGLE PHASE] ffil [TI] IZO·2>lOV/60 Hl 240V/60 Hl r IO·220V/50 Hz 220V/50 flz 25.5·33.0 EDE I-PHASE / 3·PHASE NOTE: TIe off rhe L3 sensillg connection wizen 110t ill lise ..v- WESTERBEKE Engines & Generators...
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Page 44: Electronic Regulation
ELECTRONIC REGULATION SR7-2G AVR 5 AMP FUSE ADJUSTABLE THRESH OVERLOAD PROTECTIO ~~Oo INTERVENTION ' " fa Iy AOJUSTABLETHRESHOLD ~i§ /Hert OFUNDERSPEEO CONNECT FOR 60Hz ,.----i Stab PROTECTION INTERVENTION 1·-; - - l ..., REMOVE FOR 50Hz volt ------; ...-I EXCITER FIELD f=I:TI 0 DESCRIPTION The voltage regulator (AVR) ensures optimum AC generator... -
Page 45: Internal Wiring Diagram
1 1 . 1 DIODE L , - L---r-----------' ----------- lmOo~ ",",. I!\lWlWiJJjIJI ,.,,". :;:J ~!:.'- on", ~------------~A"..-~---+J =~====~======~~=---~===f----~ ,; if '" ./oI.::::::' . ..::::J I I ] 0 i= 1Il---, , <Tno AtuE YElLOW ''¥t7,WESTERBEKE , Engines & Generators... -
Page 46: Exciter Rotor/Rotating Field
INTERNAL WIRING SCHEMATIC EXCITER ROTOR/ROTATING FIELD TRANSIENT ,------- ----- - - - i EXCITER ROTOR WINDINGS -I>f- FIELO ""'----l • f---.O---~-,-- DlOOE = - - 1 -----------------------~ GREEN EXCITER ROTOR WINDINGS , ISOLATION DIODE PLATES Engines & Generators... -
Page 47: Shore Power Transfer Switch
,-_ ..==-+-----/11· GROUND ,S2S1N, • NOTE: SHIP TO SHORE SWITCHES ARE AVAILABLE AT YOUR WESTERBEKE DEALER . SHORE POWER NOTE: Diagram slwws connections for a two-wire, 120 volt system. For a· three-Wire system, use the dotted lines for the other Iwt leg. - Page 48 & 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 Sta-Bil gasoline off-season or for long periods of inactivity.
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Page 49: Lay·up And Recommissioning
Lay-up time provides a good opportunity to inspect your if access to the starter pennits its easy removal. Make sure the Westerbeke engine to see if external items such as drive belts battery connections are shut off before attempting to remove or coolant hoses need replacement. -
Page 50: Metric Conversion Data (Chart)
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 Miles x 1.609 = Kilometers (km) x .0621 = Miles DISTANCE EQUIVALENTS 1 Degree of Latitude = 60 Nm = 111.120 km 1 Minute of Latitude = 1 Nm = 1.862 km VOLUME... -
Page 51: Suggested Spares 4
SUGGESTED SPARE PARTS WESTERBEKE MARINE DIESEL GENERATORS CONTACT YOUR WESTERBEKE DEALER FOR ADDITIONAL SUGGESTIONS AND INFORMATION FUEUWATER "" ' FILTERS FUEL INJECTOR HEAT EXCHANGER END ZINC ANODE GASKET AND O-RING MATCHING DRIVE BELTS FUEL SYSTEM HARDWARE~KlIT~~~,,~, THERMOSTAT AND GASKET INLET... -
Page 52: Water Heater Connections (Optional)
Open this petcock when filling the engine's coolant system to allow air in the exchanger to escape. Close tightly after all the air is removed. -OWNERS HOT WATER HOSE HOT WATER TANK. WATER HEATER CONNECTIONS ,... WESTERBEKE Engines & Generators... -
Page 53: Engines & Generators
Engines Generators &...