Westerbeke 25.5KW EDE User manual

'OPERATORS MANUAL
D·NET DIESEL GENERATORS
--
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

· CALIFORNIA
PROPOSITION 65 WARNING
Marine diesel and gasoline engine
exhaust and some of its constituents
are known to the State of California
to cause cancer, birth defects,
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
- Weakness and Sleepiness
- Throbbing in Temples
- Muscular Twitching
- Vomiting
-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.
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. They are inexpensive and easily
obtainable at your local marine store.
Engines & Generators

SAFETY INSTRUCTIONS
INTRODUCTION
Readthis safety manual carefully. Most accidents are
causedbyfailure tofollow fumkzmental rules
and
precautions. Know when dangerous conditions exist and
take the necessary precautions to protectyourself, your
personnel, andyour machinery.
Thefollowing safety instructions are in compliance with
theAmerican Boat
and Yacht Council (ABYC) standards.
PREVENT ELECTRIC SHOCK
A WARNING: Do not touch AC electrical connections
while engine is running, or when connected to shore
power. Lethal voltage is present at these connections!
• Do not operate this machinery without electrical
enclosures and covers in place.
• Shut offelectrical power before accessing electrical
equipment.
• Use insulated mats whenever working on electrical
equipment.
• Make sure your clothing and skin are dry, not damp
(particularly shoes) when handling electrical equipment.
• Remove wristwatch and all jewelry when working on
electrical equipment.
• Do not connect utility shore power to vessels AC
circuits, except through a ship-to-shon'O double throw
transfer switch. Damage to vessels AC generator may
result if this procedure is not followed.
• Electrical shock results from handling a charged
capacitor. Discharge capacitor by shorting tenninals
together.
PREVENT BURNS - HOT ENGINE
A WARNING: Do not touch hot engine parts or
exhaust system components. A running engine gets
very hot!
• Always check the engine coolant level at the coolant
recovery
tank.
A WARNING: Steam can cause injury or death!
• In case of an engine overheat, allow the engine to cool
before touching
the engine or checking the coolant.
PREVENT BURNS - FIRE
A WARNING: Fire can cause injury or death!
• Prevent flash fires. Do not smoke or permit flames or
sparks to occur near the carburetor, fuel line, filter, fuel
pump, or other potential sources of spilled fuel or fuel
vapors. Use a suitable container to catch all fuel when
removing the fuel line, carburetor, or fuel filters.
• Do not operate without a Coast Guard Approved flame
arrester. Backfire can cause severe injury or death.
• Do not operate with the air cleaner/silencer removed.
Backfire can cause severe injury or death.
• Do not smoke or pennit flames or sparks to occur near
the fuel system. Keep the compartment and the
engine/generator clean and free ofdebris to minimize the
chances of fire. Wipe up all spilled fuel and engine oil.
• Be aware -diesel fuel will bum.
PREVENT BURNS - EXPLOSION
A WARNING: Explosions from fuel vapors can cause
injury or death!
• Follow re-fueling safety instructions. Keep the vessels
hatches closed when fueling.
Open and ventilate cabin
after fueling. Check below for fumes/vapor before
running
the blower. Run the blower for 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 of the reach of children.
• Do not fill the fuel tank(s) while the engine 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.
• Do not alter or modify the fuel system.
• Be sure all fuel supplies have a positive shutoff valve.
• Be certain fuel line fittings are adequately 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

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.
BATTERY 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
during servicing.
• Never connect the negative (-) battery cable to the
positive (+) connection tenninal 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 comparttnent 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 tenninals with tools, etc., to prevent
bums or sparks that could cause
an explosion. Remove
wristwatch,
rings, and any other jewelry before handling
the battery.
• Always tum the battery charger off before disconnecting
the battery connections. Remove the negative lead first
and reconnect it last when disconnecting the battery.
BATTERY ACID
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
protection. 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/water-injected
elbow is securely attached.
• Be sure the unit and its surroundings are well ventilated.
Run blowers when running the generator set or engine.
• Do not run the generator set or engine unless the boat is
equipped with a functioning marine carbon monoxide
detector that complies with ABYCA-24. Consult your
boat builder or dealer for installation of approved
detectors.
• For additional information refer to ABYC T-22
(educational 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
systems. Exhaust sulfur causes rapid deterioration of
copper 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
symptoms or signs of carbon monoxide inhalation or
poisoning are:
Vomiting Inability to think coherently
Dizziness
Headache
Nausea
Throbbing in temples
Muscular twitching
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
situation arises
in which it is absolutely necessary to
make operating adjustments, use extreme care to avoid
touching moving parts and hot exhaust system
components.
-..y' WESTERBEKE
Engines & Generators
ii

SAFETY INSTRUCTIONS
• Do not wear loose clothing orjewelry when servicing
equipment; tie back
long hair and avoid wearing loose
jackets, shirts, sleeves,
rings, necklaces or bracelets that
could be caught
in moving parts.
• Make sure all attaching hardware is properly tightened.
Keep protective shields and guards in their respective
places at
all times.
• Do not check fluid levels or the drive belts tension while
the engine is operating.
• Stay clear of the drive shaft and the transmission coupling
when the engine is running; hair and clothing can easily
be caught in these rotating parts.
HAZARDOUS NOISE
A WARNING: High noise levels can cause hearing
loss!
• Never operate an engine without its muffler installed.
• Do not run an engine with the air intake (silencer)
removed.
• Do not run engines for long periods with their enclosures
open.
A WARNING: 00 not work on machinery when you are
mentally or physically incapaCitated by fatigue!
OPERATORS MANUAL
Many of the preceding safety tips and warnings are repeated
in your Operators Manual along with other cautions and
notes to highlight critical information. Read your manual
carefully, maintain your equipment, and follow all safety
procedures.
GASOLINE ENGINE AND GENERATOR INSTALLATIONS
Preparations to install an engine should begin with a
thorough examination ofthe American Boat
and Yacht
Council's (ABYC) standards. These standards are a
combination ofsources including
the USCG and the NFPA.
Sections ofthe 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).
ABYC, NFPA AND USCG PUBLICATIONS FOR
INSTALLING DIESEL ENGINES
Read the following ABYC, NFPA and USCG publications
for safety codes and standards. Follow their
recommendations when installing your
engine.
ABYC (American Boat and Yacht Council)
"Safety Standards for Small Craft"
Order from:
ABYC
3069 Solomon's Island Rd.
Edgewater, MD 21037
NFPA (National Fire Protection Association)
"Fire Protection Standard for Motor Craft"
Order from:
NFPA
11 Tracy Drive
Avon Industrial Park
Avon, MA 02322
USCG (United States Coast Guard)
"USCG 33CFR183"
Order from:
U.S. Government Printing Office
Washington,
D.C. 20404
~ WESTERBEKE
Engines & Generators
iii

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.
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 20" above
the vessel's waterline. Failure to use a siphon-break when
the exhaust manifold injection port
is at or below the wad waterline will resull in
raw water damage to the engine and possihl£ flooding of the boat.
If you have any doubt about the position of the water-injected exhaust elbow relative
to the vessel's waterline under the vessel's various operating conditions, install a
siphon-break.
NOTE: A siphon-break requires periodic inspection and cleaning to ensure proper
operation. Failure to properly maintain a siphon-break can result in catastrophic
engine damage. Consult the siphon-break manufacturerfor proper maintenance.
EXHAUST SYSTEM
The exhaust hose must be certified for marine use. The system must be desigued to
prevent water from entering the exhaust under any sea conditions and at any angle
of the vessels hull.
A detailed 40 page Marine Installation Manual covering gasoline and
diesel, engines and generators, is available from your WESTERBEKE
dealer.
Engines & Generators
iv
AVAILABLE FROM
YOUR WESTERBEKE
DEALER

TABLE OF CONTENTS
Parts Identification ................................................... 2
Introduction ................................................................ 3
Fuel, Engine Oil and Engine Coolant ......................... 5
Preparations for Initial Start ...................................... 6
Oigital Control Panel .................................................. 7
Remote Stop/Start Panel ......................................... 8A
Generator Break·ln Procedure ................................... 9
Daily Routine .............................................................. 9
Maintenance Schedule (Chart) ................................ 10
Fuel System ............................................................. . 12
Cooling System ........................................................ . 13
Raw Water Intake Strainer................................. 15
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 011 .............................................. 17
Engine Oil Change............................................. 17
Remote Oil Filter (Optional) .............................. .18
Starter Motor (Troubleshooting) ............................... 19
Wiring Diagram #52413 .............. .............................. 21
Engine Troubleshooting (Chart) ................................ 22
Alternator Testing ..................................................... 24
Battery Care .......................................................24
Glow Plugs ................................................................ 27
Wiring Diagrams ....................................................... 20
Engine Troubleshooting (Chart) ................................ 22
Alternator Testing ..................................................... 24
Battery Care .......................................................26
Glow Plugs ................................................................ 27
Engine Adjustments .................................................. 28
Oil Pressure ........................................................28
Engine Compression ..........................................28
Valve Adjustment ...............................................28
Drive Belt Adjustment .......................................29
Fuel Injectors......................................................29
Magnetic Plck·Up .......................................................... .30
Generator Specifications .............................................. 31
Generator Information .................................................. .33
Twelve Lead Wiring Connections ................................ 34
Generator Voltage Adjustment ................................... .35
Electronic Regulation ................................................... .36
Internal Wiring Diagram ................................................ 37
Exciter Rotor/Rotating Field ........................................ .38
Shore Power Transfer Switch ................................... 39
Lay·Up and Recommissioning ................................. .40
Metric Conversion Data (Chart) .............................. .42
Suggested Spares .................................................... .4 3
Water Heater Connections (Optional) ..................... .44
Engines & Generators
1

PARTS IDENTIFICATION
CONNECTION FOR
SIPHON BREAK
DIGITAL CDNTROL
PANEL
Fl 8A FUSE
REAR
FUEL LIFT
AIR INTAKE .,LtN.'tH_"
AIR BLEED PETCOC:Ki.:~
DRIVE
COVER
. DC ALTEIINAnIR-----
FRDNT
FLEXIBLE ISOLATED
MOUNTS
COOLANT
RIGHT SIDE
CONTROL
LEFT
SIDE
Engines & Generators
2
OIL FILL
THERMOSTAT
f--~INJIECTION PUMP
1lc::::LI.L---11AW WATER PUMP
[J..e--- DIL DRAIN HOSE
HEAT
BREAKER
HIGH
EXHAUST
TEMPERATUR£
SWITCH
SYPHON BREAK
CONNECTION
'"n." •• MOTOR

INTRODUCTION
This WESlERBEKE Diesel Generator is a product of
WESlERBEKE's long years ofexperience and advanced
technology.
We take great pride in the superior durability and
dependable performance ofour engines and generators.
Thank
you forselecting WES1ERBEKE.
In order to get the full use and benefit from your generator,
it
is importan~ 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 engine require servicing, contact
your nearest WES1ERBEKE dealer
for assistance.
This
is your operators manual. A parts catalog is also
provided
and a technical manual is available from your
WES1ERBEKE
dealer. If you are planning to install this
equipment, contact your WES1ERBEKE dealer for
WES1ERBEKE'S installation manual.
WARRANTY PROCEDURES
Your WESTERBEKE Warranty is included in a separate
folder. If, after 60 days of SUbmitting the Warranty Registry
fonn you have not received a customer identification card
registering your warranty, please contact the factory in
writing with model information, including the unit's
serial number and cOnun1ssion date.
Customer Identification Card
''''''''WESTERBEKE
I
Customer Identification
MR. GENERATOR OWNER
MAINS1REET
HOMETOWN, USA
Model
Expires
Ser. #
NOTES, CAUTIONS AND WARNINGS
As this manual takes you through the operating procedures,
maintenance schedules, and troubleshooting of your marine
engine, critical information will be highlighted by NOTES,
CAUTIONS, and WARNINGS. An explanation follows:
NOTE: An operating procedure essential to note.
A CAUTION: Procedures which, If not strictly
ohsorved, can result In the damage or destruction of
your engine.
A WARNING: Procedures which, If not properly
followed, can result In pelSonal injury or loss of life.
PRODUCT SOFTWARE
Product software, (technical data, parts lists, manuals,
brochures and catalogs), provided from sources other than
WESTERBEKE are not within WESTERBEKE's control.
WESTERBEKE CANNOT BE RESPONSIBLE FOR THE
CONTENT OF SUCH SOFTWARE, MAKES NO WAR-
RANTIES OR REPRESENTATIONS WITH RESPECT
THERETO, INCLUDING ACCURACY, TIMELINESS OR
COMPLETENESS THEREOF AND WILL IN NO EVENT
BE LIABLE
FOR ANYTYPE OF DAMAGE OR INJURY
INCURRED IN CONNECTION WITH OR ARISING OUT
OF
THE FURNISHING OR USE OF SUCH SOFTWARE.
WES1ERBEKE customers should keep in mind the time
span between printings ofWES1ERBEKE product software
and the unavoidable existence ofearlier WES1ERBEKE
product software. The product software provided with
WES1ERBEKE products, whether from WES1ERBEKE or
other suppliers, must not and cannot be relied upon exclu-
sively as the definitive authority on the respective prodtict.Jt
not
only makes good sense but is imperative that appropriate
representatives ofWES1ERBEKE or the supplier in question
be consulted to determine the accuracy and currentness of the
product software being consulted by the customer.
PROTECTING YOUR INVESTMENT
Care at the factory during assembly and thorough testing
have resulted
in a WES1ERBEKE generator capable of
many thousands ofhours
of dependable service. However the
manufacturer cannot control how or where the generator is
installed in the vessel or the manner in which the unit is
operated and serviced in the field. This is up to the
buyer/owner-operator.
NOTE: Six imponant steps to ensure long generator life:
• Proper engine andgenerator installation andalignment.
• An efficient weU·designed exhaustsystem that includes
an anti-siphon break toprevent waterfrom entering the
engine.
• Changing the engine oil andoilfilters according to the
maintenance schedule.
• Proper maintenance of all engine and generator compo·
nents according to the maintenance scheduk in this
manual
• Use clean, filtered unleadedfueL
• Winterize yourengine according to the "Lay-up and
Recommissioning" section in this manual.
~ WESTERBEKE
Engines & Generators
3

INTRODUCTION
SERIAL NUMBER LOCATION
The engine's model number and serial number are located on
a nameplate mounted on the side
of the engine.
The engine's serial number can also
be found stamped into
the engine block
on the flat surface of the block just above
and inboard
of the injection pump. Take the time to enter this
information
on the illustration of the nameplate shown below,
as this will provide a quick reference when seeking technical
informatio~ and/or ordering repair parts. p
An identification plate on the top of the engine air intake 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 aclosed crankcase; the crankshaft is of
the same general type as that of a gasoline engine; and the
diesel engine has the same types of valves, camshaft, pistons,
connecting rods and lubricating system.
Therefore, to a great extent, a diesel engine requires the
same preventive maintenance as agasoline engine. The
most important factors are proper ventilation and proper
maintenance of the fuel, lubricating and cooling systems.
Replacement
of fuel and lubricating filter elements at the
time periods specified is a must, and frequent checking for
contamination (that is, water, sediment, etc.) in the fuel
system is also essential. Another important factor is the use
of the same brand of high detergent diesel lubrication oil
designed specifically for diesel engines.
The diesel engine does differ from the gasoline engine,
however, in its method
of handling 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
of both.
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 narae plate located on the generator end. You must
provide us with this infonnation 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 willfit or generic
parts are frequently not made
to the sarae 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 in this manual. For Engine and
Generator Accessories, see theACCESSORIES brochure.
INSTALLATION MANUAL
Publication #43400 provides detailed information for
installing generators.
Engines & Generators
4