Westerbeke 5.5KW EDC User manual

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OPERATORS MANUAL
5.SKW EDC 60HZ
5.0KW EDC 50HZ
MARINE DIES GENERATORS
SECOND EDITION
DECEMBER2007
WESTERBEKE CORPORATION -150 JOHN HANCOCK ROAD
MYLES STANDISH INDUSTRIAL PARK' TAUNTON MA 02780
WEBSITE: WWW.WESTERBEKE.COM
---
§;JIH Mmtber National Marine Manufacturers Association

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 IMMEOIATELY. If symptoms persist,
seek medical attention. Shut down the unit and dQ not restart
until it has been inspected and repaired.
WAR'NING
Gene!ators Produce CARBON MONOXIDE
Regular Maintenance Required
IE[~!:
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 near the engine room. They
are inexpensive and easily obtainable at your local
hardware store.
Engines &Generators

SAFETY INSTRUCTIONS
INTRODUCTION
Read this safety manual carefuUy. Most accidents are
caused by failure to follow fundamental rules and
precautions. Know when dangerous conditions exist and
take the necessary precautions to protectyourself, your
personne4 andyour machinery.
The following safety instructions are in compliance with
the American 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-shore 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 terminals
together.
PREVENT BURNS - HOT ENGINE
A WARNING: Do not touch hot engine parts Of
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 ofan engine overheat, allow the engine to cool
before touching the engine or checking the coolant.
PREVENT BURNS - FIRE
A WARNING: Fire can cause injury Of 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 orpermit flames or sparks to occur near
the fuel system. Keep the compartment and the
engine/generator clean and free of debris to minimize the
chances of fire. Wipe up all spilled fuel and engine oil.
• Be aware -diesel fuel will burn.
PREVENT BURNS - EXPLOSION
A WARNING: Explosions from fuel vapors can cause
injury Of 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 ofchildren.
• 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
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.
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 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 ofexplosive 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
burns 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.
BATTERY ACIO
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
offat
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 of exhaust. 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 ofcarbon 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. Ifa
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.
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: Do 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 of the American Boat and Yacht
Council's (ABYC) standards. These standards are a
combination of
sources including the USCG and the NFPA.
Sections of the ABYC standards ofparticular 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
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 asiphon-break when
the exhaust manifold injection port is at or below the load waterline will result in
raw water damage to the engine and possible 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 designed 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 provided
with each unit.
Engines & Generators
iv
AVAILABLE FROM
YOUR WESTERBEKE
DEALER

TABLE OF CONTENTS
Parts Identification ............................................. 2
Engine Adjustments (cont.)
Introduction ......................................................... 3 Torquing the Cylinder
Head Bolts ..............23
Fuel, Engine Oil and Engine Coolant.. ................ 5 Generator Frequency Adjustment................24
Preparations for Initial Start·Up ......................... 6 Electronic Governor ....................................24
Digital Control PaneL ......................................... 7 Valve Clearance Adjustment .......................25
Generator Break-In Procedure .... ........................ 9 Engine Compression....................................25
Daily Routine ....................................................... 9 Spill Timing.................................................
26
Maintenance Schedule (Chart) ......................... 10 Testing Glow Plugs .....................................27
Fuel System ....................................................... 12 Testing Oil Pressure.....................................27
Cooling System ............ ...................................... 13
Fuel Injectors...............................................28
Fresh Water Cooling
CircuiL ......................14
Engine Troubleshooting (Chart) ........................ 29
Changing the Coolant..................................14
Alternator Testing ............................................. 31
Air Intake.....................................................14 Battery Care.................................................
33
Thermostat................................................... 15
Shore Power Connections .. .............................. .34
Raw Water Intake Strainer..........................15
Generator Information ...................................... .35
Raw Water Cooling Circuit.........................16 Generator Single Phase ...............................
36
Heat Exchanger ...........................................16 Circuit Breaker .................................
;..........36
Raw
Water Pump.........................................16 Internal Wiring Diagram .............................36
Engine Lubricating OiL ..................................... 17
No Load Voltage Adjustment......................37
Engine Oil Change ......................................17 Dual Exciter Model .....................................38
Remote Oil Filter (optional)........................
18
Bridge Rectifier ...........................................39
Starter Motor ..................................................... 19
Lay-up and RecommiSSioning .......................... .40
Troubleshooting...........................................20
Power Take·Off .................................................. 42
Generator Specifications .................................. 21
Metric Conversion Data (Chart) ....................... .43
Wiring Diagram #'52441 .....................................22
Sugges,ed Spares ............................................. .45
Engine Adjustments ..... ..................................... .23
Drive Belt Adjustment.................................23
Engines & Generators
1

AIR
REAR
COOLANT PRESSURE
5.5KW GENERATOR
PARTS IDENTIFICATION
CIRCUIT --\-~~~~-r1r
BREAKER
LIFT
PUMP
INTAKE SILENCER
-OIL DRAIN HOSE
FUEL FILTER
POWER TAKE-OFF
CONNECTION
FLEXIBLE'/SOLATED RIGHT SIDE
MOUNTS
ECU CONNECTION
.,.
INJECTION
THE"MOSTAT"- __ ~~~~~§I
ASSEMBLY
DRIVE BELT-----M~'
COVER
OIL PRESSURE Ol:lloun-
FRONT
HEAT
EXCHANGER
Engines & Generators
2
ALTERNATOR
REMOTE PANEL
CONNECTION
~'--- CONNECTION FOR
SUMP
SIPHON BREAK
LEFT
SIDE

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. A parts catalog is also
provided and a technical manual is available from your
WESTERBEKE dealer. If you are planning to install this
equipment contact your WESTERBEKE dealer for
WESTERBEKE'S installation manual.
WARRANTY PROCEDURES
Your WESTERBEKE Warranty is included in a separate
folder. If, after 60 days of submitting the Warranty Registry
form 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 commission date.
Customer Identification Card
,.""",."WESTERBEKE
, Engines & Generators
Customer Identification
MR. GENERATOR OWNER
MAIN STREET
HOMETOWN, USA
Model : Ser. #
Expires
PRODUCT SOFTWARE
Product software, (tech 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, T1MEUNESS OR
COMPLETENESS THEREOF AND WIU IN NO EVENT
BEUABLE FOR ANY TYPE OF DAMAGE OR INJURY
INCURRED IN CONNECTION WITH OR ARISING OUT
OF THE FURNISHING OR USE OF SUCH SOFTWARE.
WESTERBEKE customers should also keep in mind the
time span between printings of WESTERBEKE product
software and the unavoidable existence ofearlier
WESTERBEKE manuals. In summation, product software
provided with WESTERBEKE products, whether from
WESTERBEKE or other 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
WESTERBEKE or the supplier in question be consulted
to determine the accuracy and currentness of the
product software being consulted by the customer.
NOTES, CAUnONS 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: Pmcedures. which If not strictly
observed, can result In thll damagll Of datructlDn Df
your flngllHl.
A WARNING: Pmclldures, which if not pmpllf/y fo/~
towlld, can fllSult In personal InJury or loss of 1/111.
Engines & Generators
3

INTRODUCTION
SERIAL NUMBER LOCATION
The engine's model number and serial number areiocated on
a nameplate mounted on the side of the engiae's manifold.
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
information andlor ordering repair parts.
An identification plate on the engine manifold 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 insmall amounts,
is deadly.
The presence of
carbon monoxide indicated 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 type of valves, 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
contamination (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 in this manual. For Engine and
Generator Accessories, see the ACCESSORIES brochure.
INSTAllATION MANUAL
Publication #43400 provides detailed information for
installing generators.
Engines & Generators
4