Westerbeke 29.0 EGED 60Hz User manual

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OPERATORS MANUAL
.· MARINE DIESEL GENERATORS
29.0 EGED 60Hz 23.0 EGED 50 Hz
Single and Three Phase .
PUBLICATION NO. 056402
REVISIONO
MARCH 2017
member' WESTERBEKE CORPORATION • MYLES STANDISH INDUSTRIAL PARK
~--- 150 JOHN HANCOCK ROAD, TAUNTON, MA 02780·7319 U.S.A.
§.J!H TEL: (508)823·7677 • FAX: {508)884-9688 • WEBSITE: WWW. WESTERBEKE.COM

CALIFORNIA
PROPOSITION 65 WARNING
Diesel engine exhaust and some
of its constituents are known to
the State of California to cause
cancerJ birth defectsJ and other
reproductive harm.
A wARNING:
Exhaust gasses contain Carbon Monoxide, an odorless and
colorless gas. Carbon Monoxide is poisonous and can cause
unconsciousness and death. Symptoms of Carbon Monoxide
exposure can include:
• Dizziness
•Nausea
•Headache
• Throbbing in Temples
• Muscular Twitching
• Vomiting
• Weakness and Sleepiness
•Inability to Think Coherently
IF YOU OR ANYONE ELSE EXPERIENCE ANY OF THESE SYMPTOMS,
GET OUT INTO THE FRESH AIR IMMEDIATELY. If symptoms persist,
seek medical attention. Shut down the unit and do not restart
until it has been inspected and repaired.
This 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.
They are inexpensive and easily
obtainable at your local marine store.

SAFETY INSTRUCTIONS
IRTRODUCnON
Read this safety 11Ullluol carefully. Most accidents are
caused by failure to follow fundamental rules and
precautions. Know when dangerous conditions exist and
toke the necessary precautions to protect yourself, your
personne4 and your machinery.
The foUowing sofety instruciions are in compliance with
the American Boat and Yacht Council (ABYC) standards.
PREVENT ELEcTRIC SHOCK
A WARNING: liD IIIII tout:h AC electrical t:llllllet:tiDifS
while IIIJine/s runlling. Lethal raltage is ptt~Sent at
tllese t:D111181:ti1111SI
• Do not oPerate tbis machinery without electrical
enclosures and co:vers in place.
• Shut off electrical power before accessing electrical
equipment ·
•
Use insulated mats whenever working on electrical
equipment
• Make sure your clothing and skin are dty, not damp
(particularly shoes) when handling electrical'equipment.
•
Remove wristwatch and all jewelry when working on
electrical equipment
PREVENT BURRS- HOT ENGINE
A WARNING: Do 11111 fDIIDb bill tlllg/ne patls or
8Xhstlst"""" comptlllllllls. A IIIIJIIIng engine gets
,. '
• Monitor EingiQe -~ cooiant ievei at the plastic
coolant recovery·tank and periodiCaly at the filler atp
location on the waterjacketed exhau.<tt manifold, but only
when the engineis COLD.
j AwA1818: ___ ,.,.,_
• In case of an engine overheat, allow the engine to cool
before touching the engine or checking the coolant.
PREVENT BURNS- FIRE
IA WARIIIIIG: Flnl""" ...... illjmp ... _, ]
• Prevent flash fires. Do not smoke or permit flames or
sparlcs to occur near the fuel injector, fuel line, filter, fuel
pump, or other potential sources ofspilled fuel or fuel
vapors. Use a suitable container to catch all fuel when
removing the fuel lines or fuel filters.
• Do not operate with the air cleaner/silencer removed.
Backfire can cause severe injury or death.
• Do not smoke or permit flames or sparks to occur near
the fuel system. J(eep ~compartment and the
engine 'clean imd free of debris to minimize the
chances of fire. wq,e up all spilled fuel and engine oil.
• Be aware- diesel fuel will bum.
PREVENT BURNS- EXPLOSION
A WARNING: Exp/llsiiiiiS frllm fuel V11J1D1S can t:aiiSI1
Injury D1 dlllf#'l
• . Follow re--fueling safety instructions. Keep the vessel's
hatches closed when fueling. Open and ventilate the cabin
after fueling. Check below for fumes/vapor refore running
the blower. Run the blower per four minutes before starting
your engine.
• All fuel vapors are highly explosive. Use extreme care .
when handling and storing fuels. Store fuel in a
well-ventilated area away from spark-producing
equipment and out ofthe ~h of children.
• Do notfill the fuel tank(s) while the ,engine while it is running.
• Shut off the fuel service Valve at the engine when servicing
the fuel system. Take care in catching any fuel that might
spill. DO NOT allow any smoking, open flames, or other .
sources of fire near the fuel system or engine when
servicing. Ensure proper ventilation exists when servicing
the fuel system.
• Qo not alter or modify the fuel system.
·• ~~ sure all fuel supplies have a positive shutoff valve.
• Becertain fuel line fittings are ?dequately tightened and
free of leaks.
• Make sure a fire extinguisher is installed nearby and is
properly maintained. Be familiar with its proper use.
Extinguishers rated ABC by the NFPA are appropriate
for all applications encountered in this environment.
Engines & Generators
i

SAFETY INSTRUCTIONS
ACCIDENTAL STARTING
A WARNING: Accidental starting can cause injury
or death!
• Disconnect the battery cables before servicing the engine/
generator. Remove the negative lead first and reconnect
it
last.
• Make certain all personnel are clear of the engine before
starting.
• Make certain all covers, guards, and hatches are re-
installed before starting the engine.
BAmRY EXPLOSION
A WARNING: Battery explosion can cause injury
or death!
• Do not smoke or allow an open flame near the battery
being serviced. Lead acid batteries emit hydrogen, a
highly explosive gas, which can be ignited by electrical
arcing or by lit tobacco products. Shut off all electrical
equipment in the vicinity to prevent electrical arcing dur-
ing servicing.
• Never connect the negative(-) battery cable to the posi-
tive (+) connection terminal of the starter solenoid. Do
not test the battery condition by shorting the terminals
together. Sparks could ignite battery gases or fuel vapors.
Ventilate any compartment containing batteries to prevent
accumulation of explosive gases. To avoid sparks, do not
disturb the battery charger connections while the battery
is being charged.
• Avoid contacting the terminals with tools, etc., to prevent
bums or sparks that could cause an explosion. Remove
wristwatch, rings, and any otherjewelry before handling
the battery.
• Always tum the battery charger offbefore disconnecting _
the battery connections. Remove the negative lead first
and reconnect it last when disconnecting the battery.
BAnERYACID
A WARNING: Sulfuric acid in batteries can cause
severe injury or death!
• When servicing the battery or checking the electrolyte
level, wear rubber gloves, a rubber apron, and eye protec-
tion. Batteries contain sulfuric acid which is destructive.
If it comes in contact with your skin, wash it off at once
with water. Acid may splash on the skin or into the eyes
inadvertently when removing electrolyte caps.
TOXIC EXHAUST GASES
A WARNING: Carbon monoxide (CO} is a deadly gas!
• Ensure that the exhaust system is adequate to expel gases
discharged from the engine. Check the exhaust system
regularly for leaks and make sure the exhaust manifolds
are securely attached and no warping exists. Pay close
attention to the manifold, water injection elbow, and
exhaust pipe
nipple.
• Be sure the unit and its surroundings are well ventilated.
• In addition to routine inspection of the exhaust system,
install a carbon monoxide detector. Consult your boat
builder
or dealer for installation of approved detectors.
• For additional information refer to ABYC T-22 (educa-
tional information on Carbon Monoxide).
A WARNING: Carbon monoxide (CO) is an invisible
odorless gas. Inhalation produces flu-like symptoms,
nausea or death!
• Do not use copper tubing in diesel exhaust systems. Diesel
fumes can rapidly destroy copper tubing in exhaust sys-
tems. Exhaust sulfur causes rapid deterioration ofcopper
tubing resulting in exhaust/water leakage.
• Do not install exhaust outlet where exhaust can be drawn
through portholes, vents, or air conditioners. If the engine
exhaust discharge outlet
is near the waterline, water could
enter the exhaust discharge outlet and close or restrict the
flow ofexhaust. Avoid overloading the craft.
• Although diesel engine exhaust gases are not as toxic as
exhaust fumes from gasoline engines, carbon monoxide
gas is present in diesel exhaust fumes. Some of the symp-
toms or signs ofcarbon monoxide inhalation or poisoning
are:
Vomiting
Dizziness
Throbbing in temples
Muscular twitching
Intense headache
Weakness and sleepiness
AVOID MOVING PARTS
A WARNING: Rotating parts can cause injury
or death!
• Do not service the engine while it is running. If a situa-
tion arises in which it is absolutely necessary to m'ake
operating adjustments, use extreme care to avoid touch-
ing moving parts and hot exhaust system components.
Engines & Generators
ii

SAFETY INSTRUCTIONS
a Do not wear loose clothing or jewehy when servicing
equipment: avoid wearing loose jackets, shirts, sleeves,
rings, necklaces or bmcelets that could be caught in
. maving parts.
• Make sure all attaching hardware is properly tightened.
Keep protective shields and guards in their respective
places at all times. · ·
a Do not check fluid levels or the drive belt's tension while
.the engine is operating.
IIi Stay clear ofthe drive shaft and the transmission coupling
when the engine is running; h3ir and clothing can easily
be caught in these rotating parts.
HAZARDOUS NOISE
A WARNING: High llt1ise IBvetsl:atl t:BIISfl bearing
IIISSI
~ Never operate an engine withoutits -muffler installed.
• Donot nm an engine with the airintake (sUencer)
removed.
A WARNING: Dollllf Pllltk Dll macblnety PJbell,. are
. mBIItally D1 physlally /muipat;llatstJ by fatl!lllel
OPERATORS MANUAL
·Many of the preceding safety tips and warnings ate-repeated
in yOur opemtors Manual along with other cautions and
notes to highlight critical inforination. Read your manual
carefully, m•tain your equipment. and follow all safety
procedures. .
ENGINE AID GENERATOR INSTALLATIONS .
Preparations to install an engine should begin with a thor-
ough examiDation of the American Boat and Yacht Council's
(ABYQ standat:ds. These standards ate a combination of
soun:es including the USCG and the NPPA.
Sections of the ABYC standards ofparticular interest are:
H-32 Ventilation for boats using diesel fuel
H-33 Diesel Fuel Systems
P-1 Installatiion of Exhaust Systems for Propulsion
and Auxiliary Engines
P-4 Marine Jnbo$'d Engines and Transmissions
E-ll AC & DC Electrical Systems on Boats
TA Batteries and Battery Chargers
All installations must comply with the Federal Code of
Regulations (FCR.).
ABYC, NFPA AND USCG PUBUCAnONS FOR
.. INSTALLING MARINE ENGINES AND GENERATORS
Read the following ABYC, NFPA and USCG publications
for
safety codes and standards. Follow their recommenda-
tions when insialUng your UNIVERSAL engine
ABYC
(American Boat and Yacht Council)
"Safety Standaras for Small Craft'' .
Order From:
ABYC
613 Third Dtreet, Suite 10
Annapolis, MD 21403
[phone]
· www.abycinc.O!J
NFPA (National Fire Protection Association)
"Fue Protection Standard for Motor Craft"
Order From~
NFPA
1 Ba.tterymarch Park
P.O. Box 9101
Quincy, MA 02269--9101
USCG (United States Coast Guard)
"CFR 33 AND CFR46'•
Code.ofFedeml Regulations
Order From:
U.S. GovernmentPrinting Office
Washington, D.C. 20404
I""''V"IWESTERSEKB
(Engines & Generators
•••
Ill

.INSTALLATION
When installing WESTERBEKE engines and generators it isimportant that strict
attention be paid to the following information:
CODES AND REGULATIONS
Strict federal regulations, ABYC guidelines, and safety codes must becomplied with
when installing engines and generators in a marine environment.
SIPHON-BREAK
For installations where the exhaust manifold/water injected exhaust elbow is close to
or will be below the vessel's waterline, provisions must be made to install a siphon-
break in the raw water supply hose to the exhaust elbow. This hose must be looped a
minimum of 2ft' above the vessel's waterline. Failure to use a siphon-break' when
the exhaust manifold injection porl Ia at or below the loaJ1 waterline will result in
raw water damage to Ow engine and po~Bible Jlboding of the boat.
If you have any doubt abOut' the positii;>.n oft}w. water-injected exhaust elbow relative :
to· the vessel's watedirte.under the vessel's various operating cOnditions, install a
siphon-break. .. ,. .. . ......
AVAILABLE FROM
YOUR. WESTERBEKE
NOTE: A si.Phon~break requires periodic inspection ·and cleaning to ensure proper
operation. Failure to properly maintain a siphon-break can· result in catastrophic
en~ne damage. CoMllt the siphon-break manufacturer for proper maintenance.
. DEALER
EXHAUST SYSTEM
· Tlie exhauSt system's hose 'Mli~t:~ certified for marine use. Corrugated Marine
Exhaust Hose is recommen~~ The use ofthis type of hose; a,llows for extreme bends
and turns without the~ ofadditiinal fitting and clamps to accomplish these bends
and turns .In this regard, a single length of coxrugated 9xhaust hose can be used. 'The
system MUST be designed to prevent the entry ofwater·into the exhaust syste~ ·
under any sea conditions and at any angle of vessels heal.
A detailed Marine lnstaHation Manual covering gasoline and diesel
engines an~ generators is supplied wHb ~ unit sold. This manual
Js also available In pdf format on our website to download
We~lte: www.westerbeke.com
l"YYV'IWESTERBEKE
l Eng/,_ & Generators
iv
SIPHON-BREAK WfTH fifAINLES,
LOOP FOR 1" HOSE .
PART NO. 044010

TABLE OF CONTENTS
Parts Identification ............................................. 2 Glow Plugs ......................................................... 21
Introduction ......................................................... 3 Inspection and Testing.................................
21
Fuel, Engine Oil and Engine Coolant.. ................ 5
Alternators ......................................................... 22
Preparations for Initial Start·Up ......................... 6 Testing and Troubleshooting ....................... 22
Control Panel ....................................................... 7 Battery Care.................................................
24
Manual Engine Shut-Off...............................7
Starter Motor ..................................................... 25
Starting/Stopping Procedure ............................... 8
Remote Panels ...............................................8 .Testing withElectrical Jumper....................
25
Testing with Screwdriver............................. 26
Benerator Break-In Procedure ... : ........................ 9 Removing for Service.................................. 27
Daily Routine ....................................................... 9
Raw Water Pump (Exploded View) .................... 28
Maintenance Schedule ..................................... 1o
Fuel System ........................................... : ........... 12
Cooling System .................................................. t3',,
Raw Water Intake........................................ 13
Draining the Raw Water System ................. 13
Fresh Water Cooling Circuit......................... 14
Changing the Coolant.................................. 14
Thermostat................................................... 15
Raw Water Cooling Circuit ......................... 16
Heat Exchanger ........................................... 16
Raw Water Pump......................................... 16
Engine Lubricating Oil ....................................... 17
Engine Oil Change ...................................... 17
Water Heater Installation (Optional) ................. 29
Remote 011 Filter (Optional) .............................. 30
Block Heater (Optional) .................................... .30
Specifications .................................................... 31
Benerator Information ...................................... .33
Twelve Lead Winding Connections .................. .34
Electronic Regulation (AVR) ............................. 35
Internal Wiring Diagram .................................... 37
AC Outlet Configuration ..................................... 37
Shore Power Transfer Switch ........................... .38
Lay·Up and Recommissioning.' .......................... 39
Suggested Spares ............................................. .41
Engine Troubleshooting ..................................... 18
Wiring Diagrams and Schematics .................... .42
Engine AdJustments ........................................... 19
Drive BeltAdjustment................................. 19
Fuel Injectors............................................... 19
Troubleshooting Instrument Gauges ........... 19
Testing Oil Pressure.....................................20
Checking Valve Clearance........................... 20
Valve Adjustment.........................................20
r.viWE§I"ERBEKE
l Engines & Generators
1

PARTS IDENTIFICATION
CONNECTION FOR
SIPHON BREAK
REAR
FUEL LIFT
MANIFOLD PRESSURE CAP
COOLA~T FILL
DRIVE BELT
COVER
DC ALTERNATO
FRONT.
FLEXIBLE ISOLATED
MOUNTS
COOLANT FILL
RIGHT SIDE
CONTROl
LEFT.
SIDE
Engines & Generators
2
OIL FILL
I
PUMP
DC FIELD BREAKER
SYPHON BREAK
CONNECTION

INTRODUCTION
This WESTERBEKE Diesel Generator is a product of
WESTERBEKE's long years of experience and advanced .
technology. We take great pride in the superior durability and
dependable performance of our engines and generators.
Thank you for selecting WESTERBEKE.
In order to get the full use and benefit from your generator it
is important that you operate and maintain it correctly~ This
manual is designed to help you do this. Please, read this
manual carefully and observe all the safety precautions
throughout Should your generator require servicing, contact
your nearest WESTERBEKE dealer for assistance.
This is your operators manual. Along wi~ ~ manual, .there
is an Installation Manual and Parts Information. A Semce
Manual is available in pdf form on our website or can be
ordered in book form from a WESTERBEKFJUNIVERSAL
Dealer
WARRANTY PROCEDURES
Your WESTERBEKE Warranty Statement is included in the
product documentation package. There is a Warranty
Registration Card you can fill out and mail to Westerbeke ·
Corporation or go to our website:www. westerbeke.com and
register your products warranty on line. You should receive a
Customer Identification card in the mail within 60 days of
registering. If.you do not, please contact the factory and have
your product model number, serial number and in service ·
date available.
Customer Identification Card
I,.,IWESTERSEKE
I Engines & Generators
Customer Identification
MR. GENERATOR OWNER
MAIN STREET
HOMETOWN, USA
Model
Expires
Serihl #
NOTES, CAUTIONS AND WARNINGS
As this manual takes you through the operating procedures,
maintenance schedules, and troubleshooting ofyour marine
engine, critical information will be highlighted by NOTES,
CAUTIONS, and WARNINGS. An explanation follows:
NOTE: An operating procedure essential to note.
A CAUTION: Proceduress which if not strictly
observed, can result In the damage or destruction of
your engine.
A ·WARNING: Procedures, which If not properly
followed, can result in personal injuryor loss oflife.
PRODUCT SOFTWARE
Pioduct software, (tech dlUa. pans, lists, manuals,
brochures and catalogs), provided from sources other than
WESTERBEKE are not within WESTERBEKE's control.
WESTERBEKE CANNOT BERESPONSIBLE FOR THE
CONTENT OF SUCH SOFTWARE, MAKEs NO .
WARRANTIES OR REPRESENTATIONS WITH RESPECT
THERETO, INCLUDING ACCURACY; TIMELINESS OR
COMP'zErENESS THEREOFANDW1U IN NO EVENT ·
BE UABLE FOR ANYTYPE OF DAMAGE OR INJURY
iNCURRED INCONNECI10NWITH OR ARISING OUT
.. OF THE FURNISHING OR USE OF SUCH SOF1WARE.
WESTERBEKE customers should also keep in mind the
time span between printirigs ofWESTERBEKE product
software and the tinavoidable existence ofearlier ·
WESTERBEKE manuals. In summation, product software
provided with WESTERBEKE products, whether from
WESTERBEKE orother suppliers, must not and cannot
be relied upon· exclusively as the definitive authority on
the respective product It not only makes good sense
but is imperative that appropriate representatives of
WES'IERBEKE or the supplier in question be consnited
to detennine the accuracy and currentness ofthe
product software being consulted by the customer.
PROTECTING YOUR. INVESTMENT·
care at~ factory during assembly and tl)orough testing
have n$tdtedin a WESTERBEKE generat9r capable of
Ill8I).Y tbousands ofhours of dependable ~ce~ ·However the
manuflicturer cannot control how orwhere the generator is
install~ in the vessel orthe manner in which the unit is
operat6jl 'and serviced in the field. This is up to the
buyer/owner.:Operator. ·
;•
NOTE: SU: imp~rtant steps to ensure long generaJor life:
• Proper engine andgenerotor insttlllaiion and.alignment.
• An efficient weU-designed exhtiust system that irtt;,.ludes
an mzti:.siphon breafc to prevent water from entering the
engine.
. . . .
• Changingthe engine oilandoil filters' accordiit.g .. to tlie
maintenance scltedule.
•
.Proper niainte1tizliee of all engine a7ii1 generfdor compo- ·
ne1its accortli;ng to the maintenance schedule in this
mimuii! . .
·• Use clei:bi;:(ilierf!d #2 dieselfUel.
• Wznterize your engine ticcoriliitg to the ""Lay-up and
Reco;mmissioninlf'section in this manuaL
Engines & Generators
3

INTRODUCTION
SERIAL NUMBER LOCATION
The engine's model and serial number are lo,cate<i on
anameplate mounted on the side
of the waterjacketed
exhaust manifold.
The engine's serial number is also found stamped in
the engine block on a flat surfacejust above the
the side oil fill opening. Take time to enter this inform-
ation below on the illustrated nameplate.
50 HZ. 60HZ.
I
An identification plateon the top of the engine airintake also
displays the engine model and serial number.
CARBON MONOXIDE DETECTOR
WESTERBEKE recommends mounting a carbon monoxide
detector in the vessels living quarters.
Carbon monoxide,
even in small amounts, is deadly.
The presence of carbon monoxide indicates an exhaust leak
from the engine
or generator or from the exhaust
elbow/exhaust
hose, or the fumes from a nearby vessel are
entering your boat.
If carbon monoxide is present, ventilate the area with clean
air and correct the problem immediately!
NOTE: A carbon monoxide warning decal has been provided
by WESTERBEKE. Affix this decal in a visible position in the
engine
room.
UNDERSTANDING THE DIESEL ENGINE
The diesel engine closely resembles the gasoline engine,
since the mechanism is essentially the
same. The cylinders
are arranged above a closed crankcase; the crankshaft is of
the same general type as that of a gasoline engine; and the
diesel engine has the same types ofvalves, camshaft, pistons,
connecting rods and lubricating system.
Therefore,
to a great extent, a diesel engine requires the
same preventive maintenance
as a gasoline engine. The
most important factors
are proper ventilation and proper
maintenance ofthe
fuel, lubricating and cooling systems.
Replacement of fuel and lubricating filter elements at the
time periods specified is a must, and frequent checking
for
contaillination (that is, water, sediment, etc.) in the fuel
system is also essential. Another important factor is the use
of the same brand ofhigh detergent diesel lubrication oil
designed specifically for diesel engines.
The diesel engine
does differ from the gasoline engine,
however, in its method ofhandling and firing of fuel. The
carburetor and ignition systems are done away with
and in
their place is a single component -the
fuel injection pump -
which performs the function ofboth.
ORDERING PARTS
Whenever replacement/service parts are needed, always
provide the generator model
number, engine serial number,
and generator serial number as they appear on the silver and
black name plate located on the generator end. You must
provide
us with this information so we may properly identify
your generator
set. In addition, include a complete part
description and part number for each part needed
(see the
separately furnished Parts List). Also insist upon
WESTERBEKE packaged parts because will fit or generic
parts are frequently not made to the same specifications as
original equipment.
SPARES AND ACCESSORIES
Certain spares will be needed to support and maintain your
WESTERBEKE generator.
Your local WESTERBEKE
dealer
will assist you in preparing an inventory of spare parts.
See the SPARE PARTS page inthis manual. For Engine and
Generator Acces8ories, see the ACCESSORIESbrochure.
INSTALLATION MANUAL
The Westerbeke Installation Manual publication #043268 is
supplied with this unit.
Engines & Generators
4