Westerbeke 21.0 KW-50Hz, Operator'S Manual

Page 1: ...23 5KW 50Hz 21 0KW 50Hz EDE and EDEA MODELS SIN GLE and THRE HASE PUBLICATION N0 053042 REVISIONS NOVEMBER 2012 WESTERBEKE member WESTERBEKE CORPORATION MYLES STANDISH INDUSTRIAL PARK ddf 150 JOHN HAN...

Page 2: ...iness Throbbing in Temples Muscular Twitching Vomiting Inabilityto Think Coherently IF YOU OR ANYONEELSE EXPERIENCEANYOF THESE SYMPTOMS GET OUTINTO THE FRESHAIR IMMEDIATELY Ifsymptoms persist seekmedi...

Page 3: ...r 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 fil...

Page 4: ...skin or into the eyes inadvertently when removing electrolyte caps TOXIC EXHAUST GASES A WARNING Carbon monoxide CO is a deadlygas Ensure that the exhaust system is adequate to expel gases discharged...

Page 5: ...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 Prepara...

Page 6: ...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 b...

Page 7: ...18 aw Water Pump 18 Engine Lubrication Oil 19 Engine Oil Chru1ge 19 Remote Oil Filter Optional 20 Starter Motor 21 Wiring Diagrams 23 Specifications Engines 26 33 0Kw Generator 27 28 25 Kw Generator 2...

Page 8: ...DRIVE BELT COVER DCAL PARTS IDENTIFICATION CONNECTION FOR SIPHON BREAK REAR FRONT FLEXIBLE ISOLATED MOUNTS COOLANT RIGHT SIDE CONTROL LEFl SIDE Engines Generators 2 OIL ALL PUMP BREAKER...

Page 9: ...uct software technical data parts lists manuals brochures and catalogs provided from sources other than WES1ERBEKE are not within WES1ERBEKE s control WESTERBEKE CANNOT BE RESPONSIBLE FOR THE CONTENT...

Page 10: ...e 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...

Page 11: ...n of this manual and not be extended if synthetic oils are used NOTE The information above supersedes all previous statements regarding synthetic oil SAE OIL VISCOSITY GRADE For all temperature ranges...

Page 12: ...loads Visually examine the unit Look for loose or missing parts disconnected wires unattached hoses and check threaded connections Search for any fuel leaks OIL FILL SIDE OIL FILTER A SIDE OIL FILL I...

Page 13: ...located just below the fixed throttle lever on the side ofthe engine block below the fuel injection pump Move this lever to the left and hold it there until the engine comes to a stop Then release LCD...

Page 14: ...will BUNK 1 Turn the DC breaker on the control panel to the OFF position 2 Open the cover of the control box and view the ECU Electronic Control Unit 3 Locate the 1 dipswitch on the ECU and move it t...

Page 15: ...d down arrows to find and observe other functions To resume scrolling press the SCROLL LOCK button again STOP SEQUENCE To stop the generator press the STOP button The display will cycle thru the follo...

Page 16: ...6 152 4MM CONNECTING EXTENSION CABLES 15 4 75M 30 9 1M 60 18 2M PN 052959 PN 052789 PN 052960 PN 052560 Note These two dimensions are the measurement of the cut out opening LCD DISPLAY EXTENSION CABLE...

Page 17: ...rrent draw requiredfor starting motors This starting amperage draw can be 3 to 5 times normal running amperage See GENERATOR INFORMATION in this manual GENERATOR ADJUSTMENTS Once the generator has bee...

Page 18: ...and electrical connections Keep bolts nuts tight remain cool Check for loose belt tension Fuel Filter D D D D D D Initial change at 50 hrs then change every 250 hrs Inlet Fuel Filter D D D D D Replace...

Page 19: ...e ENGINEADJUSTMENtS Heat Exchanger 0 Remove have professionally cleaned and pressure testetl Water InJected Exhaust 0 0 Check casting integrity every500 hours of Elbow operation Replace as needed WEST...

Page 20: ...ms with the injection pump leave on engine BLEED SCREW The bleed screw on the injection pump should be left in the open position This will then allow for ease in priming the engine s fuel system and d...

Page 21: ...glass 4 Replace the washer if necessary 5 Reassemble and install the strainer 6 Open the seacock 7 Run the engine and check for leaks NOTE Alsofollow the above procedure after having run hard aground...

Page 22: ...ssible NOTE T7ti s tOJtk with its short run ofplastic lwse is best located at or above the level ofthe engine s manifold CHANGING COOLANT The engine s coolant must be changed according to the MAINTENA...

Page 23: ...ain offsome coolant Release the coolant pressure cap and drain the coolant to the approximate level off the thermostat housing This can be done using the heat exchanger drain plug 2 Rotate the thermos...

Page 24: ...low indicates the pump has not primed itself properly 1 NOTE Never allow the pump to run dry Even a short period ofdry running may destroy the impeller RAW WATER PUMP PN52650 INSPECTION CHECK THE BASE...

Page 25: ...when unscrewing it to catch any oil left in the filter Oil or any other fluid on the engine reduces the engine s cooling ability Keep your engine clean Inspect the old oil filter as it is removed to...

Page 26: ...he oil filter facing down as illustrated Contact your WES IERBEKE dealer for more infonnation APPLY ATHIN COAT OF CLEAN OIL TO THE 0 RING WHEN INSTALLING THIS KIT THREAD THE KIT ON THEN HAND TIGHTEN A...

Page 27: ...N THIS MANUAL TROUBLESHOOTING SOLENOID Prior to testing make certain the ships batteries are at full charge and that the starting system wiring connections terminals are clean and tight Pay particular...

Page 28: ...ll run the motor without engaging thejly vheel Turn the starter switch on to provide the power to the solenoid Hopefully it will create enough magneticfieldfor the arm to move even though the contacts...

Page 29: ...IUIIII ll h IIU Lllf l I l I NETWORK I CJI rttthUUD BLOCK ii Ill t i i I I J arrUollfiiSIIII r g _ oilI CJ gnl 000 ULLI ILLIIIIIICII Ifi 1 LAIPUU UICAIUOIPIN liDIOIR IIOI liiCUIQI lrHl l9 IOPIIQIIAU S...

Page 30: ...en CW iS c c Cl z a i li i 2 t 2 i u i I li 0 WIRING DIAGRAM 53901 24 VOLT 0 1011 I I M I W I II I Li t t r ttlj t 4 t J pl 24 I _j e i...

Page 31: ...CC SIDEI I I L l CIIU Cliii L EUI MWC rnm I IIIIIIIIU 1 I e I z r 1 om s N Mru rii 1 I I r 1111 I I iii iiiiii n c z r p uon I I I I j a l I _ _ _ _ t 1 1 i J I J li41WI sntCLIJllll l J I I I I I I I...

Page 32: ...ing Amps CCA 60A rated belt driven 2 5Kw 12VDC direct drive Glow plugs sheathed type 400 600 includes glow plugs General Operating Temperature Fresh Water Pump Raw Water Pump System Capacity fresh wat...

Page 33: ...Volts Voltage regulation 2 no load to full load 50 Hertz DELTA 230 Volts Frequency regulation 3 Hertz 5 no load to full load Amperage 3phase Low Voltage WYE 99 3 Amps Rating Volts AC 60 Hertz High Vo...

Page 34: ...lm 5 66 6 37 cmm NOTE Increase airsupply 15 for 50 Hertz operation 1500 rpm 122 F 50 C maximum SPECIFICATIONS 28 5 23 5KW EDE AC GENERATOR Single Phase AC GENERATOR 3 Phase Single Phase Brushless six...

Page 35: ...ust temperature switch 2 TesVreplace 3 Ground Connection 3 Check ground circuit 4 Faulty control module ECU 4 Check plug connections 5 Sea water pump 5 Inspect impeller replace 6 Faulty fire suppressi...

Page 36: ...the field in order to maintain a proper system voltage The regulator design utilizes all silicon semi conductors and thick film assembly techniques After the voltage has been adjusted to the proper r...

Page 37: ...should be 12 to 13 volts MEASURING BATTERY VOLTAGE IGNITION ON ENGINE OFF TESTING THE OUTPUT CIRCUIT 31 1 Connect the positive probe to the output terminal B and connect the negative probe to ground 2...

Page 38: ...nd 14 volts when the engine is running Ifnot there is a problem in the service battery charging circuit Troubleshoot the service battery charging circuit by checking the wiring and connections the sol...

Page 39: ...connection and the other to the body of the glow plug as shown A good glow plug will have a 1 0 1 5 ohm resistance This method can be used with the plug in or out of the engine You can also use an mul...

Page 40: ...e oil pressure sender then install a mechanical oil pressure gauge in it s place Mter warming up the engine set the engine speed at idle and read the oil pressure gauge OIL PRESSURE WILL RANGE BETWEEN...

Page 41: ...g a 17mm long socket remove the fuel return line in its entirety from the top of the injectors Take care not to lose the two sealing washers and banjo bolt that attaches the fuel return line to each i...

Page 42: ...otate the engine crankshaft so as to position the flat of one of the ring gear s teeth directly under the opening Thread the MPU into the opening until it gently contacts the flat of this tooth Thread...

Page 43: ...voltage and load check it with a portable meter and amp probe 37 Generator Frequency Adjustment Frequency is a direct result ofengine generator speed as indi cated by the following D When the generat...

Page 44: ...volts 60 Hz L L 240 volts 60Hz L N 138 volts SINGLE PHASE PARALLEL ZIG ZAG 7 10 5 L N 10 12 2 4 S 9 r 1 3 5 7 9 11 N 1 1 l2 50 Hz L L 230 volts SO Hz L N 115 volts 60Hz L L 277 volts 60Hz L N 138 vol...

Page 45: ...INTERNAL WIRING SCHEMATIC EXCITER ROTOR ROTATING FIELD EXCITER ROTOR WINDINGS TRANSIENT EXCITER ROTOR WINDINGS A 8 c GREEN RED GREEN RED ISOLATION DIODE PLATES Engines Generators 39...

Page 46: ...n the Hertz Frequency dip switch in the correct position for the Hertz Frequency desired 5 Verify all connections are correct and tum off any AC panel breakers 6 Stmt the generator and monitor the AC...

Page 47: ...The supply and sensing separate This is the case of a generator equipped with auxiliary winding for regulator supply Supply is always connected to terminals 3 and 5 of the regulator 0 I In both of the...

Page 48: ...the overload protection This protection system has an intervention delay which permits a temporary overload necessary when starting motors or similar applications To modify this protection you must o...

Page 49: ...C loads on the vesselbeing operated maycause damage to the excitercircuit components in thegenerator Shore Power Connections 60 Hertz GENERATOR I I I I L f D l r I __ I I I Ship to Shore SWitch 3 Pole...

Page 50: ...el conditioner such as Sta Bil gasoline stabilizer should be added Change the element in your gasoline water separator and clean the metal bowl Re install and make certain there are no leaks Clean up...

Page 51: ...required Wipe off grime and grease and touch up any unpainted areas Protect the coupling and the output flange with an anti corrosion coating Check that the transmission vent is open For additional in...

Page 52: ...85 Liters L x 264 Gallons MASS WEIGHT Ounces oz x 28 35 Grams g x 035 Ounces Pounds lb x 454 Kilograms kg x 2 205 Pounds PRESSURE Pounds Per Sq In psi x 6 895 Kilopascals kPa x 145 psi Inches of Mercu...

Page 53: ...her back to the engines return Install the remote expansion tank in a convenient location so the coolant level can easily be checked The remote expansion tank will now serve as a check and systemfill...

Page 54: ...ed in a rugged hinged toolbox Kit A includes the basic spares Kit B is for more extensive off shore cruising KIT A ZINC ANODES DRIVE BELTS OIL FILTER FUEL FILTER HEAT EXCHANGER GASKET IMPELLER KIT FUE...

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Page 56: ...Engines Generators 1179 rev 5 11 2012...