Westerbeke 5.5 kw EDC 60 HZ Operator's Manual
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Westerbeke 5.5 kw EDC 60 HZ Operator's Manual

Westerbeke 5.5 kw EDC 60 HZ Operator's Manual

Marine diesel generators, single phase
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·OPERAT.ORS MANUAL··
·5.5KWEDC60HZ
:
; 5.0KW EDC 50HZ
Single . . Phase·
(MARINE DIE· GENERATORS
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REVISION 3
DECEMBER 2011 .
WESTERBEKE CORPORATION' 150 JOHN HANCOCK ROAD
MYLES STANDISH INDUSTRIAL PARK. TAUNTON MA 02780
WEBSITE: WWW.WESTERBEKE.COM
§..Gfi!4
Member National MarineManufllcturers Association
...,,.,,.
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'--~--"------"
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  • Page 1 _ _ _ _ _ • • ..• • REVISION 3 DECEMBER 2011 . WESTERBEKE CORPORATION' 150 JOHN HANCOCK ROAD MYLES STANDISH INDUSTRIAL PARK. TAUNTON MA 02780 WEBSITE: WWW.WESTERBEKE.COM §..Gfi!4 Member National MarineManufllcturers Association ...,,.,,. '--~--"------"...
  • Page 2 ·:WARNING GenelalolB Produce CARBON MONOXIDE Regular Maintenance Required ~~::'~;.,! A WARNING DECAL is provided by WESTERBEKE and should be fixed to bulkhead near your engine or generator. WESTERBEKE also recommends installing CARBON MONOXIDE DETECTORS near the engine room. They...
  • Page 3 Be familiar with its proper use. • In case of an engine overheat, allow the engine to cool Extinguishers rated ABC by the NFPA are appropriate before touching the engine or checking the coolant. for all applications encountered in thls environment. WESTERBEKE Engines & Generators...
  • Page 4 Acid may splash on the skin or sitnation arises in which is absolutely necessary to into the eyes inadvertently when removing electrolyte make operating adjustruents, use extreme care to avoid caps. touching moving parts and hot exhaust system 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 t)1at strict attention be paid to the following information: CODES AND REGULATIONS Strict federal regulations, ABYC guidelines, and safety codes mnst be complied with when installing engines and generators in a marine environment.

  • Page 7: Table Of Contents

    Lay-up and Recommissioning ......A( Power Take-Off ..........Troubleshooting ........... 20 Metric Conversion Data (Chart) ......44 . Generator Specifications ........#52414 ........Suggested Spares ..........Wiring Diagram ..46 Wiring Diagram #52793 ........Wiring Diagram #53477 ......... """ WESTERBEKE Engines & Generators...

  • Page 8: Parts Identification

    5~5KWGENERATOR PARTS IDENTIFICATION COOLANT PRESSURE ~..---IOP OIL FILL DIGITAL rn"'Dm PANEL. FILTER 'AIR OIL FILTER t--~?>-...t"""'C'" 20A DC CIRCUIT BREAKER WATER PUMP :---DO'" REAR CIRCUIT DRAIN HOSE FILTER FUEL FILTER LIFT ..'·OWI;R TAKE·OFF CONNECTION FLEXIBLE'ISOLATED' RIGHT SIDE "MOUNTS ECU, C( INNElmO~1 REMOTE PANEL , CONNECTION...

  • Page 9: Introduction

    INTRODUCTION This WESTERBEKE Engine is a product of WESTERBEKE customers should also keep in mind the time WESTERBEKE'S long years of experience and advanced span between printings of WESTERBEKE product technology. We take great pride in the superior durability and software and the unavoidable existence of earlier WESTERBEKE manuals.
  • Page 10 NOTE: A carbon monoxide waming decal ha.s been provided SERIAL NUMBER LOCATION by WESTERBEKE. Affix this decal in a visible position in the The units's model number and serial number are located on a engine room. nameplate that is mounted on the side of the engine's water jacketed exhaust manifold.

  • Page 11: Fuel, Engine Oil And Engine Coolant

    ENGINE OIL AND ENGINE COOLANT DIESEL FUEL ENGINE COOLANT WESTERBEKE recommends a mixture of 50% antifreeze USE A DIESEL FUEL WITH A CETANE RATING DF 1145 OR HIGHER. and 50% distilled water. Distilled water is free from the (No. 2-D (SAE J313) diesel fuel according to ASTM D975).

  • Page 12: Preparations For Initial Start-Up

    BEFORE REMOVING THE RADIATOR RECOVERY TANK TOP OIL FILL MANIFOlD PRESSURE ~~r.,,:;~~~~, -..,...",.,t )_m---C~~~S PRESS DOWN AND TURN ..TO LIFT OFF TO NIPPLE AT MANIFOLD PRESSURE CAP STOP BOLT ADJUSTMENT SPEED ADJUSTMENT FACTORY SET OIL DIPSTICK WESTERBEKE Engines & Generators...

  • Page 13: Digital Control Panel

    DIGITAL CONTROL PANEL DESCRIPTION LCD DISPLAY WESTERBEKE'E Digital Control Panel provides the Operating temperatures may cause th!, LCD display to vary operator with an LCD display that contunuously monitors in color. This is nonnal and a change in color will...
  • Page 14 The word LOCK will appear in the COfl)!lr. Use the up and down arrows find and observe other functions. To resume scrolling, press the SCROLL LOCK button again. Conlrol Box Components Frequency Adjustments. are on Ihe following pag •. WESTERBEKE "'loY' Engines & Generators...

  • Page 15: Digital Control Box

    NMEt\.200q ,Iystem or shllt off the DC breaker the generator's control box for a WESTERL/NK system. NOTE: Keep mind that the Westerbeke gellerator maybe the DC power supplyJor the vessel)' N1v1EA·2000 network. WESTERBEKE Generators Engines &...
  • Page 16 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" (B2.ij5Mn~1 CONNECTING EXTENSION CABLES' 6"...

  • Page 17: Generator Break-In Procedure

    : WESTERLINK system. When the engine is warm - almost Smokeless. 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 18: Maintenance Schedule (Chart)

    MAINTENANCE SCHEDULE WARNING: Never attempt perform any service while the engine is running. Wear the proper safety equipment such as goggles and gloves, and use the correct 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 19 (see ENGINE ADJUSTMENTS). • Adjust the Valve Clearances Adjust Valve Clearances (see ENGINE ADJUSTMENTS). 'Heat Exchanger Remove, have professionally cleaned and pressure tested. 'WESTERBEKE recommends this service be performed by an authorized mechanic. "'7-:_ " • ". c"', _ ser~icingJchanging CAUTION: When DC components, the DC power must be.

  • Page 20: Fuel System

    This process is accomplished by installing and maintaining a proper fuel filter/water separator between the fuel tank and generator/engine. Westerbeke recommends a 10 micron filter be used. FUEL INJECTION PUMP The fuel injection pump is the most important component of the diesel engine, requiring the utmost caution in handling.

  • Page 21: Cooling System

    DESCRIPTION fresh water coo hint flows around the tubes; engine heat trat]s- Westerbeke marine diesel engines are designed and equipped for fresh water cooling. Heat produced mille engine by com- ferred to the fresh water coolant is conducted through the...

  • Page 22: Fresh Water Cooling Circuil

    ···CootINGSYS-TEM FRESH WATER COOLING CIRCUIT CHANGING COOLANT The engine's coolant must be changed according to the NOTE: Refer to the ENGINE COOlANT section for the rec- MAINTENANCE SCHEDUlE. If Ihe coolant is allowed to ommended antifreeze and water mixture to be used as the become contaminated, it can lead to overheating problems.

  • Page 23: Thermostat

    I-~''!'-''=.~~:~ PETCDCK FOR PUSHING AIR FROM THE COOLING SYSTEM GASKET PN#036956 STI)A,INER _-"'"liS' USEHI-TACKSEAf.ANT ~I~TER INSPECTAND CLEAN EVERY 100 HOURS THERMOSTAT ASSEMBLY WATE;R~~; TYPICAL RAW (OWIIER INSTALLED) INCOMING I',! RAW WA1'tR-..SEACOCK ---'7>""_ WESTERBEKE EngInes Generators &...

  • Page 24: Raw Water Cooling Circuit

    COOLING SYSTEM RAW WATER CODLING CIRCUIT RAW WATER PUMP The raw water pump is a self-priming, rotary pump with a The raw water flow is created by a positive displacement non-ferrous housing and a Neoprene inlpeller_ The inlpeller impeller pump. TIns pump draws water directly from the ocean, lake, or river from a thru-hull opening through a hose has fle«ible blades which wipe against a curved caro plate within the inlpeller housing, producing the pumping action.

  • Page 25: Engine Lubricating Oil

    - - --- --------~---~~ ENGINE LUBRICATING OIL ENGINE OIL CHANGE When installlng the new oil filter element, wipe the filter gasket's sealing surface on the bracket free of oil and 1. Drainulg Oil Sump. Discharge the used oil through apply a thin coat of clean engine oil to the rubber gasket the sump drain hose (attached to the front of the engine) on the new oil filter.

  • Page 26: Remote Oil Filter (Optional)

    Contact your WESTERBEKE dealer for more information an engine roorri bulkhead. NOTE: Westerbeke is not responsible for engine failure due to NOTE: Refer to ENGINE OIL CHANGE in this manual for incorrect installation of the Remote Oil Filter.

  • Page 27: Starter Motor

    STARTER MOTOR DESCRIPTION The starter is a new type, small, light-weight and is called a high-speed internal-reduction starter. The pinion shaft is separate from motor shaft; the pinion slides only on the pinion shaft A reduction gear is installed between the motor shaft and a pinion shaft.

  • Page 28: Engines & Generators

    If the spin, the motor is probably fanlty. fails WESTERBEKE uses a standard starter motor which can be If no arching occurred, there is no juice reaching the serviced or rebuilt at any starter motor automotive service solenoid. center,...
  • Page 29 SPECIFICATIONS· 5.5 KW"EDC GENERATOR ENGINE SPECIFICATIONS ELECTRICAL SYSTEM Engine Type Diesel, four-cycle, three-cylinder, Iresh 12-Volt, (-) negative ground Starting Battery water-cooled, vertical in-line overhead valve 600 -1000 Cold CranWng Amps (CCA) Battery Capacity mechanism, (llhp@1600rpml9hp@1500rpm) DC Charging Altemator 50 Amp rated, belt driven Aspiration Naturally aspirated.

  • Page 30: Wiring Diagram #52414

    - D. cpJ; ' 1 1- • >=p cb-r • I • 116VID II! Rto IIiKE 110 RED P(l) ItODRG~j~6~ 110 DHD :"i6lK~ 1\66l! mrKTIGRK ; !! 1I1HIBL lUcK IlltiHlIULK ,---------------- ' r.,-,WESTERBEKE , .--: Engines & Generators...

  • Page 31: Wiring Diagram #52793

    WIRING DIAGRAM # 52793 NMEA 2000 ~lc'i' .", .,.'" l'.S. II I =f=lll:~ ~Ih' .= . I1I1' i = I If=: ... y' y' y ':· IL--I-+-l---I--+-l- ,li~ ~I'i ~ ~: 81~- f-' '- ;j ; I _ _ _ _ _ Engines &...

  • Page 32: Wiring Diagram #53477

    WIRING DIAGRAM #53477 24VDC t-l "" ~" - -----= · . . WWESTERBEkE Engines & Genera'tors...

  • Page 33: Engine Adjustments

    ENGINE ADJUSTMENTS NOTE: WESTERBEKE recommends that the following engine adjust- ments be peiformed by a competent engine mechanic. The information below provivedto assist the mechanic. TORQUING THE CYLINDER HEAD BOLTS DRIVE BELT ADJUSTMENT For your safety, WES1ERBEKE generator models come...

  • Page 34: Generator Frequency Adjustment

    ENGINE ADJUSTMENTS GENERATOR FREQUENCY ADJUSTMENT (HERTZ) ELECTRONIC GOVERNOR Once the diesel generator set has been placed in operation, The Electronic Governor regclates the engirie sPeed by there may be adjustments required for engine speed (Hertz) sensing the engine's RPM with a magnetic pick-up during the engine's break-in period (first 50 hours) or after flywheel.

  • Page 35: Valve Clearance Adjustment

    Each cylinder is adjusted following the engine's firing cylinder is still low, apply a small amount of 011 into the order (1-3-2 for WESTERBEKE three cylinder engines). cylinder to seal the rings and repeat the test. compression Valve adjustment beginning with cylinder #1.

  • Page 36: Spill Timing

    -----,====--=---=--=-=--,,----------- ENGINE ADJUSTMENTS NDTE: WESTERBEKE recommends that the following engine adjust- ments be performed by a competent engine mechanic. The information below is provided to assist ihe mechanic. Injection Pump Timing Adjustment (Spill Timing) INJECTION PUMP" DELiVERY VALVE HOLDER If your engine's fuel injection timing is not properly adjusted,...

  • Page 37: Testing Glow Plugs

    '~--------""'--- ENGINE ADJUSTMENTS NOTE: WESTERBEKE recommends that the following engine adjust- ments be performed by a competent engine mechanic. The information _ below is provided to assist the mechanic. -GLOW PLUGS OIL PRESSURE The engine's oil pressure, is constantly monitored by ,the...

  • Page 38: Fuel Injectors

    FUEL INJECTORS REMOVING THE INJECTORS Inspecting Spray Pattern 1. Operate the. hand lever of the nozzle tester at intervals of NOTE: Injector must be serviced in a "clean room" erwironment. one stroke per second to check if the fuel is injected cor- 1.

  • Page 39: Engine Troubleshooting (Chart)

    - - - - - - - - - ' ,--=----~--- ---~c_-~ ENGINE TROUBLESHOOTING LCD DISPLAY FAULTS '"' (continued) Note: The engines DC electrical system protected by a 20 amp _ rocker type reset circuit breaker mounted on the control panel, -Problem Probable Cause Verilicalion}Remedy...
  • Page 40 #4 and #5. 6. Check between pins P2-24 and P2-25. P2 ECU plug 6. Battery Voltage to ECU. unplugged from ECU. Power turned ON. If voltage is present, ECU is faulty. WESTERBEKE "'i'Y' qenerators Eng/ryes &...

  • Page 41: Alternator Testing

    ALTERNATORS TESTING/TROUBLESHOOTING 50 AMP MITSUBISHI VOLTAGE REGULATOR ALTERNATOR The integral voltage regulator is an electronic switching device which senSeS the system voltage level and switches the voltage applied to the field in order to 'maintain a proper system voltage. The regulator design utilizes all-silicon seini conductors and thick-fihn assembly techniques.
  • Page 42 ALTERNATORS TESTING/TROUBLESHOOTING MEASURING BATTERY VOLTAGE TESTING THE ALTERNATOR ENGINE OFF) CAUTION: Before starting the engine make certain that everyone is clear of moving parts! Keep away from sheaves and belts during test procedures. ~tart the Engine. 2. After the engine has run for a few minutes, measure the starting battery voltage at the battery tenninals using a multimeter set on DC volts.

  • Page 43: 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 Ml1JlUl11 has detailed instructionsfor the disassembly and repair of their standmd alternators. BATTERY CARE...

  • Page 44: Shore Power Transfer Switch

    NOTE: Ship to shore switches are available at your at the same time. This type of generator damage Is not WESTERBEKE dealel: covered under the warranty; it Is the installer's respons/· bility to make sure all AC connections are correct.

  • Page 45: Generator Information

    AC equipment of 120 volts only, it is recommended tim! the generator's AC tenninalblock be configured to pro- vide one 120 volt AC hot leg for the vessel's distribution panel. This will ensure good I1wtDr sta.ting response from the generator. WESTERBEKE ...-N" Engines Generators &...

  • Page 46: Generator Single Phase

    This mutual buildup of NOTE: This circuit breaker is available as a WESTERBEKE voltage in the four rotating poles and in the exciter windings add-on kit for earlier model generators; contact your quickly reaches the saturation point of the capacitor(s) and a WESTERBEKE dealer.

  • Page 47: No Load Voltage Adjustment

    3. Refer to the AC load connections diagram for the correct bered plug is connected, refer to the WESTERBEKE BC configuration then check the generator's no-load voltage Generator Troubleshooting Guide).
  • Page 48 5Jln "OJ .. > cc=ItI cre:::3=I ·'1 r" "'("1 c:c:::Jt::t .:AC SENSE CABu'.), c:c:JI=;Il ;fROM HARNESS' cc::::::b c:c:::::Ita (.AI ..'" oc:::>o oc:::::>o VOLTAGE SENSE RESISTOR BOARD #053762 LOAD LOAD CONNECTION CONNECT! ON WESTERBEKE· 'Engines Generator. &...

  • Page 49: Dual Exciter Model

    AC terminal block moved to the correct neutral terminal..REFER TO THE PREVIOUS PAGE FOR AC TERMINAL BLOCK CONNECTIONS WESTERBEKE -..v' Engines & Generators...
  • Page 50 ~------'-------~~~-----===-~~~------ 5.5/5.0KW EDe GENERATOR TROUBLESHOOTING The following troubleshooting chart is designed to give Before attempting any repairs, gel a clear an explanation of insight into problems which may be encountered with the the problem as possible, preferably from an individual single ahd dual capacitor Be brushless generators.
  • Page 51 , I'· 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 generalnrs, for lay-up during the or higher. A fuel conditioner such as Sta-Bil gasoline off-season or for long periods of inactivity.

  • Page 52: Lay-Up And Recommissioning

    Cylinder Lubrication [Diesel] Recommissioning you anticipate a long lay-up period (12 months or !Dare) The recomntissioning of your Westerbeke engine after a WESTERBEKE recommends removal of the glow plugs for seasonal lay-up generally follows the same procedures as access to the cylinders. Squirt some Marvel Mystery Oill into those described in the PREPARATIONS FOR STARTING the cylinder walls.

  • Page 53: Power Take-Off

    1800 rpm. This horsepower can be utIlized either for AC generator amperage output Or to operate the power take off. Not both simultaneously. Contact your Westerbeke Distributor for additional information. POWER TAKE OFF KITiI34786 STUDS AND HARDWARE...
  • Page 54 DECIMAL TO METRIC EQUIVALENT CHART Fractions of Fractions of Decimal (in.) Decimal (in.) Metric (mm) Metric (mm) an inch an inch 0.015625 13.09687 1/64 0.39688 0.515625 33/64 0.03125 13.49375 1/32 0.79375 17/32 0.53125 3/64 0.046875 13.89062 1.19062 35/64 0.546875 0.0625 1/16 1.58750 0.5625...

  • Page 55: Metric Conversion Data (Chart)

    Degree Celsius (OC) = (OF - 32) x .56 LIQUID WEIGHTS Diesel Oil = 1 US gallon = 7.131bs Fresh Water = 1 US gallon = 8.33 Ibs Gasoline = 1 US gallon 6.1 Ibs Salt Water:, 1 gallon = 8.56 Ibs . WESTERBEKE Engiitfl6,~_,~neratprs ~.~'...
  • Page 56 -------------~SUGG&SlE_D~AR&=PART_S-~==~~ CONTACT YOUR WESTERBEKE DEALER FOR SUGGESTIONS AND ADDITIONAL INFORMATION WESTERBEKE RECOMMENDS CARRYING ENOUGH ENGINE OIL (YOUR BRAND) FOR AN OIL CHANGE AND A GALLON OF PREMIXED COOLANT. THERMOSTAT DRIVE (lELTS FUEL SYSTEM HARDWARE KIT MOLDED IN·L1NE HOSE KIT FUEIJWATER...
  • Page 57 WESTERBEKE Engines Generators & 1165-11-2011...

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