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Westerbeke Diesel Rd 80 Technical Manual




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OPERATORS
MANUAL
1 TWO
MARINE ENGINE
SlCtIII
GENERATOR SET
Publication Number 33105
Printed in USA
J H WESTERBEKE CORP
AVON INDUSTRIAL PARK AVON MASS 02322 6f7 588 7700
CABLE WESTCORP AVON TELEX 92 CALI IA
FOREWORD
Thank you for having selected a Engine for your use
This manual describes the procedures for and maintenance of both
a 10 Horsepower Marine Propulsion Engine
b 3 KW Marine Generator Set
To obtain best operating condition and longest
life it is important to use it sensibly and carry
out operatiorl and maintenance according to this
manual
If you have questions about your equipment or
in the event of a failure please contact your
nearest distributor or dealer
We look forward to your continued 1
TABLE OF CONTENTS
PAGE
GENERAL 3
CAUTIONS IN HANDLING ENGINE 4
1 B REA KIN GIN 0 5
2 PREPARATIONS 6
3 STARTING PROCEDURES 7
4 STOPPING PROCEDURES I0
5 CAUTIONS ON STARTING
AND OPERATION 0 co 0 10
6 REQUIREMENTS FOR PROPER
OPERATION
61 Lubrication System 12
62 Fuel System 13
63 Cool System 16
64 Wiring iagram 18
6 5 Bel t r ens ion e 18
66 Domestic Hot Water 18
7 RECOMfRIENDED MAINTENANCE SERVICE 19
8 22
9 0 23
10 SERVICE DATA 24
11 TABLE OF TIGHTENING TORQUES 24
12 INSTRUCTIONS 3KW GENERATOR SET25
14 STOPPING PROCEDUPeo 28
15 WIRING DIAGRAM 29
17 EXPLODED VIEW GENERA I 0R PORTION 30
18 GENERAL INFORMATION ELECTRICAL 31
19 MAl NlfENANCE II 32
20 INTERNAL WIRING DIAGRAM 33
21 LIMITED WARRANTY 34
GENERAL ENGINE
Type Vertical 4 cycle water cooled
No of cylinders Two
Bore stroke inches 256 X 268
Cubic inch displacement ratio 251
Firing order 12
Dry weight engine only 128 pump Bosch Throttle chamber Swirl type
Fuel 2 Centrifugal weight system Pressure by trochoid pump
Oil filter Paper type engine oil capacity 2 system Forced circulation through heat starter 12 volt 1
35 ampere 12 volt
Glow plugs Sheathed quick heat type
Battery capacity Recommend 60 amp hour
type 4 pole revolving armature inherently
regulated self limiting rectifier
excited AC slip rings single bearing
Class F
AND SUPPLY CAUTIONS
Check important aspects of installation before operating engine
1 Alignment Error to be no more 003 FEELER GAGE
than one thousandth of an inch
per inch of coupling diameter
2 Provide sufficient ventilation
3 Provide adequate service room
around engine See warranty
clauses CHECKING COUPLING ALIGNMENT
Fill fuel tank with CLEAN 2 diesel from a reputable Fill lubricating oil to full mark on dipstick Select readily
available lubricating oil of grade CC or CD
Fill water with suitable mixture of water and antifreeze to suit
your temperature zone See page 16
Plugin Panel Harness Connection After assembly joint should be
taped to prevent corrosion or preferably assembled using a sili
con grease which can be obtained at an electronic store such as
Radio Never operate engine with inadequate Do not touch moving parts during operation
Do not touch hot parts such as exhaust pipe and do not place com
bustible materials near
Inspect and adjust parts of the engine only after it is stopped
Check and refill engine oil cooling water and fuel after the
engine is brought to a stop
In checking the water level for refilling remove the pressure cap
only after the water temperature has fallen enough to prevent a
steam burn
Always use tools that fit cor rectly and use caution dur ing ser
vicing
Be sure that current carrying wires are protected from abrasion
and that all connections are tight
BREAKING IN YOUR NEW ENGINE
While your engine has had individual test operations sufficient accurate assembly and correct operation of all systems it
still requires break in time
Service life of your engine is dependent on how your engine is
operated and serviced during the initial twenty hours of operation
Your new engine needs twenty hours of conditioning operation for
breaking in each moving part thus maximizing performance and life of
eng Ine Perform this condi tioning carefully keeping the in mind
1 Start engine run idle while checking that all systems are
functioning sea water pump oil pressure battery charge
2 Warm eng ine preferably by running propeller at fast idle
while tied down until water temperature gauge moves into the
130 140 degree range
3 Then use engine at moderate load 60 for first five
hours
4 Avoid rapid 5 Use caution not to overload engine Grey or black smoke is a
sign of overload
6 Next fifteen hours may be run at 70 75 in a new enine is basically a seating of the piston rings
to the cylinder walls This is not accomplished by long per iods of
runnIng idle nor by early running under full load nor by varying
loads with intervals of fast acceleration andor excessive speed
Idle running may glaze the cylinder walls causing oil consumption and
smoky operation Excessive speeds and loads may score cylinder walls
with similar results
As indicated above use a short warm up at idle and put engine load and speed for the first five hours of operationo For
the next fifteen hours use approximately 70 load rhis kind of
careful operation will result in best results from your engine
steps as shown below in starting your engine for the first time
or after a prolonged Fill your engine with oil up to 011 fillerport
or near the upper limit on the
dipstick Use a good grade of
oil with API specification of
CC or better For quantity of
oil you may refer to the
General page
However it is best always to
be guided by dipstick measure
ment as angle of installation
has some effect
2 Your engine is supplied with a
coolant recovery system to
which the following instruc
tions apply
a Fill engine completely to
the neck of the manifold cap
b Then fill the recovery
tank to the bottom level line
Need for adding coolant is
indicated when a cold engine
has coolant level below the
bottom level line
c In winter add antifreeze
as described on page 16 Anti
freeze may be used year round
if changed annually
3 Fill the fuel tank with Diesel
fuel The interior of the fuel
tank must be maintained clean
Be careful not to allow intro
duction of dirt when filling
fuel
4 Engine oil coolant and
transmission levels should be
checked at least once a day
prior to engine use
STARTING panel description and use of
1 When engine is stopped after use the water temperature and
oil pressure gauges may stay at their running 2 When eng ine is next to be used turn start swi tch to ON
The temperature and pressure gauges will ZERO and the volt
meter will register battery voltage The electric fuel pump
mounted on the engine will also begin to operate purging
any air accumulated in the system
Note 3 The engine is now prepared for 7
STARTING Turn the starter switch to the
liON posi tiona If making an
ini tial start after layup
fuel filter servicing or
repairs allow fuel pump to
work lS2S seconds to purge the
system of any air Check that
clutch is in neutral and that
throttle is in full forward
2 Glow plug preheating
with key in 1I0N II position push
in about 14 inch or enough so
that voltmeter indicates dis
charge Hold key in depressed
posi tion until glow plugs are
sufficiently hot Follow Table
below for preheating time
Quickheat type Yl14T
Atmospheric temperature Preheating time
SC 41F or higher Approx 10 sec
SC 41F to SC 23F Approx 20 sec
SC 23F or lower Approx 30 sec
Limit of continuous use 1 minute
3 Proper glow plug function is
indicated by vol tmeter drop
when key is depressed This
drop will be slight but dis
cernible If no voltage drop
is noted it may indicate
defecti ve glow plugs or a
faulty preheat circuit check
for loose 8
4 Starting
Continuing to hold the key
depressed turn to the START
position The starter motor
will run thereby cranking the
engine Hold throttle open
until engine runs and then
reduce the engine not start even when the starter switch is left at
s position for 10 seconds take your hand off the starter switch for
30 seconds and then attempt to start the engine again by the glow plug The starter motor should never be allowed
to run for more than 30 seconds at a time
5 Operation
As soon as the engine has
star ted release the key The
key will automatically return
to the ON posi tiona Leave
the key at ON dur ing oper a
tion Check that wi th eng ine
running oil pressure and bat
tery charge voltage are
registering and that raw water
is discharging with the
engine operation do not turn the key to s position This
may damage the starter motor
6 Warmup operation
Run a few minutes at IDLE
position to assure that all
functions are operating Then
operate under reduced load
until water temperature rises
into the 140150 range
STOPPING PROCEDURE
1 Stop
To stop the engine move the
throttle control through the
idle position to stop As the
throttle is moved past idle
there will be increased resis
tance to movement because a
spring loading must be over
come Hold the throttle firmly
against the pressure until the
engine comes to a complete
stop
2 Starter switch off
Wi th the eng ine stopped turn
the starter key back to OFF
position The battery will be
discharged if the key is left
at ON position An engine
alarm buzzer is provided to
warn the operator of this
possibility Best precaution
is always to remove the ON STARTING AND OPERATION
1 Normal starting
Follow the procedures below for routine starting of your engine
I Check the engine and transmission oil levels and refill if
necessary
2 Insure that you have sufficient fuel Keep tank as full as
possible
3 Check cooling water level and refill if necessary
Note Check for leaks of water or oil particularly lhen
signs of such leak are found on the bottom of the egine or
in the drip tray
4 Start the engine in accordance with the procedures given on
the preceding pages
5 Allow the engine to warm up to 140150 F before placing the
engine under heavy load
2 Starting under cold conditions
The following three adverse conditions concur as the atmospheric
temperature drops exceedingly and the engine must under such
conditions be started by taking steps described below
LUBRICATING OIL TURNS VISCOUS Make certain that viscosity
is proper for the prevailing atmospheric temperature Check
the oil also for Study page 12
VOLTAGE ACROSS BATTERY TERMINALS DROPS Check that the
battery is fully charged
THE TEMPERATURE OF INTAKE AIR IS LOW AND COMPRESSION
TEMPERATURE DOES NOT RISE ENOUGH Allow the glow plug to
operate sufficiently to aid starting See table on page 8
3 Cautions during operation
Confirm that the oil pressure is normal during normal operation
Confirm that exhaust gas is as follows
While engine is cold White smoke
When the engine grows warm Almost smokeless
When the engine is overloaded Some black smoke
Check for abnormal noise such as knocking fr iction or leaking
sounds and vibration and blowback sounds
Check for leaks of fuel and engine oil
A knocking sound is heard while the engine is cold during quick
acceleration and at idle Confirm that no knocking sound is heard
in other cases
Photo above is right hand side of WlOtwo wi th 2 1 reverse and
reduction gear Note convenient cable attachment brackets for
clutch and throttle accessible filter location and lube oil drain
hose
REQUIREMENTS FOR PROPER SYSTEM
1 Engine oil
For engine lubrication use diesel engine oil Diesel engine oils
are classified according to the API into grades CA
CB CC and CD Anyone of them is usable but use of CC or higher
grades prepared by wellknown makers is Engine oil viscosity
Use oil having viscosity best suited to the atmospheric tem
perature Use of an allseason oil SAEIOW30 with minimum visco
sity change under different temperatures is 20C 6SF or higher SAE 30 or 1W30
SAE 20 or 10W30
SC 41F or lower SAE IOW30
3 Oil pressure
The oil pressure during operation of the engine is indicated by
the oil pressure gauge
During normal operation Oil pressure will range between
50 and 70 PSI
At the time of cranking Pressure will rise proportion
ately with speed
4 Engine oil change
To renew engine oil discharge old oil through the sump drain hose
attached at front of engine while engine is still warm
Drain old oil completely replace the hose plug the end securely
and add fresh oil through the oil inlet port on the valve cover
After refilling oil idle the engine for several minutes and stop
Then check the quantity of oil by the oil level gauge Fill to
but not over the high mark on the dipstick Always observe old
oil as it is removed A yellowgrey emulsion indicates presence
of water in the oil While this condition is rare it does
require prompt attention to prevent serious damage
5 Replacement of oil filter
Being a replaceable cartridge
type the oil fil ter requires
no cleaning inside
In installing the oil filter
apply eng ine oil th inly on to
the Oring and then tighten it
by hand firmly
When removing the used fil ter
cover over with a plastic bag
This will allow both filter
element and spilled oil to be
collected cleanly without
spilling oil in the bilge
Note A After market filters are not recommended since the
material standard or diameters of important items might
be entirely different from genuine parts
Note B Immediately after filter change and oil fill run engine
to ensure that oil pressure is normal and that there are
no oil leaks
FUEL SYSTEM
1 Diesel fuel
USE 2 DIESEL FUEL NEVER USE KEROSENE OR HEAVY OIL
In cold weather particularly water vapor is produced by conden
sation when air is present in the fuel tank The tank therefore
should be kept full as much as possible
The fuel tank furthermore needs to be kept completely free of
dirt and water
2 It is required that a primary
fuel filter of the water
entrapment type be installed
betvleen the fuel tank and the
eng ine Such a fil ter shovln
her e is avail able under Par t
32974 from your local
Wester beke representati ve or
your boat builder rrhis fil
ter adapted for boat builder
use comes complete wi th fi t WATER LEVEI
tings for either hose or metal INDICATOR
tubing
Mount in an accessible RING
place inspect often and drain
off water accumulation fre
quently
3 Notes on fuel system
See on facing page a typical explode view of a fuel system for a
two cylinder engine It is also illustrative of the system used on the Westerbeke 3 KW marine generator set
The Westerbeke selfbleeding fuel system is automatic in opera
tion While it is unlikely that the operator will be forced to
service the system at sea the possibility does exist Therefore
it is recommended that the following parts be carried onboard
Banjo washers s 11 30 31 33 34 45
Injector seat washers 42
Lift pump filter and gaskets s 6 7 8
Fuel filter element and gaskets s 13 14 15
I f a leak should develop at a banjo or washer that cannot be
remedied by a simple tightening of the screw renew the washers
The engine can be started by taking the steps described on pages 8
and 9 In cases where the engine cannot be started easily loosen
two injection nuts on the nozzle side turn the speed control
lever to full open position turn the starter motor and then
tighten the nuts firmly
4 Cleaning fuel filter and replacing filter element
After the first 50 hours of operation loosen the retainer ring
16 and discard filter element 15 Clean bowl 17 and reinstall
new filter using new gasket 13 and 14
This same treatment is required of the filter element 6 in the
fuel lift pump Similarly replace new filter element 6 using
new gasket 7 and 8
After the first 50 hour change the change period may be increased
to 200 hours or once per season
5 Fuel injection pump
The fuel injection pump is one of the most important components of
the diesel engine and thus it calls for the utmost caution in
handling Furthermore the fuel injection pump has been
thoroughly shopadjusted and should never be readjusted care
lessly
Such adj ustment whenever necessary should be per formed at an
authorized service station as a precision pump tester and skills
are required
To obtain long and satisfactory use of your injection pump
Always use fuel which is free from impurities
Clean and renew the fuel filter Inspect water entrapment filter 14
If a water trap type filter see page 13 is not interposed bet
ween the fuel tank and engine lift pump any entrained water will
tend to lay in bottom of lift pump Internal metal parts of the
lift pump will rust Particles will pass on to filters and even
tually to injection pump and injectors with damaging and many boat builders do supply a water trap filter there are
some who do not It is to prevent such omission that a trap filter as a desirable at moderate cost It is supplied with fittings for either
hose piping or metal tube it wi th the eng ine install it in an accessible it daily and drain as needed
10 Cooling water
As cooling water use soft water with least impurity content such
as tap water potable water or rainwater and never use hard
water or foul water Use of hard water or water containing much
impurity will lead to collection of scale in the engine and heat
exchanger with resultant decline in cooling effects
2 Antifreeze
In cold districts care should be taken to prevent cooling water
from freezing Cooling water itlhen frozen expands to break the
heat exchanger and the cylinder block f and it is essential that
antifreeze be added to cooling water in a quantity proportional to
the lUvlest temperature of the district It is recommended that
the antifreeze mixture be used throughout the yearo
Antifreeze of poor quality or without rust inhibitor
will cause corrosion of the cooling system Always use
antifreeze prepared by a reliable maker and never use
it mixed with antifreeze of a different brand
Make sure that the cooling system of the engine is cleaned
well before adding antifreeze
Recommended antifreeze for year round use is ZEREX or
PRESTONE vIi th rust inhibi tor
ANTIFREEZE ADDITION DATA
Antifreeze
Concentration 13 23
30 35 45 50 60
Freezing c 5 10 15 20 30 40 50
t eEEa t r E C F 23 14 5 4 22 40 58
Note It is advisable that antifreeze be
selected on the basis of a temperature which is about
5C 106F lower than the actual atmospheric tem
perature expected
3 Fresh water cooling system
The system consists of a sea water pump which pumps raw sea water
through a heat exchanger to remove heat from the coolant The raw
water is discharged overboard through the exhaust line
The engine coolant fresh water with or without antifreeze is
circulated by the fresh water pump in continuous circuit pumped
through the cylinder block cylinder head heat exchanger and back
to the fresh water pump
The total system is very reliable and requires only a daily check
of the water level in the system plus routine check of hose clamps
and fittings
It is likely that zinc electrodes will waste away from contact
with sea water It is also possible for the raw water pump
impeller to fail due to lack of sea water or deter ioration An
early sign of impeller failure is less water and more steam at the
exhaust through hull fitting
It is recommended therefore that zinc electrodes 11885 water
pump belt 32942 alternator belt 13585 sea water pump and sea water impeller kit 32620 be carried onboard at all
times These parts should be ordered from your nearest and used as inspection dictates
belt and water pump tension
The belts are properly tense if
they deflect 10 to 12 mm 039
to 047 in as they are de
pressed wi th a finger between
the pulley and pulley of the
long distance side Excessi ve
tension can cause quick wear of
the belt and bearings of the
water pump and the al ternator
Excessive slackness or presence
of oil on the belt on the
other hand can lead to engine
overheating and insufficient
charging due to a slipping
belt
CAUTION
Never attempt to adjust tension of the fan belt while the
engine is in DIAGRAM
Your engine is of 12V system and its electric circuit is as shown in
diagram 24666 shipped loose with this manual
For installing electrical parts connect them correctly by referring
to the diagram and at the same time check for damaged wire sheathing
and confirm that grounding is provided properly Care must always be
taken while working on the electrical shut the engine battery switch off while the engine is to the battery charging alternator will result should
this HOT WATER
The smaller of two hoses at top left in
the photo is the bypass
When you connect your eng ine to hot water remove the bypass
hose connect the spud on the to the lower connection on the
water heater coil Connect the on the water heater coil to
the spud on the manifold Study and illustrations on next page
Model WlOtwo comes complete with which when to a heater tank produces domestic hot water from waste
engine There are two 78 hose connections at front of the engine
which provide a parallel flow of engine cooling water to and from the
heater These connections are part of the which
assures a flow of hot water through the heater at all times and yet
precludes excessive restriction of engine cooling water flow caused by
the heater all simply and Remove the hose connecting the 78 spuds on front of
engine as shipped from the factory see illustration preceding these spuds to the heater with 78 ID wire inserted hose
The spud on thermostat housing is the flow FROM the engine and to lower fitting on heater The spud on manifold is the to the engine and should
connect to the upper connection should rise continuously from their low point at the heater to
the engine so that trapped air will rise naturally from the heater to
the engine If trapped air can rise to the heater then an air bleed
petcock must be installed at the higher fitting on the heater for
bleeding air while filling the system Avoid loops in hose runs which
will trap air
If any portion of the engine cooling water circuit to or from the
heater rises above the engines own pressure cap then the expansion tank must be installed in the circuit to become the
highest point The tank kit Part Number is 24177 Install the tank in a convenient location such as a sail locker for ease
of checking fresh water coolant level
The cap on the engine mounted expansion tankmanifold should not be
opened once the remote system is installed and filled
The hose connection from the heater to the remote expansion tank
should be routed and supported so as to rise continuously from the
heater to the tank enabling any air in the system to below are of adapted to our two While on Model WlOtwo the appearance is different the
principle is the same
IIetlter fieZlter 19
RECOMMENDED MAINTENANCE and service your engine at specified intervals to maintain it in
its best conditions and permit it to perform as it should As for
those asterisked items it is suggested that you have them performed
by an authorized distributor or dealer
1 Daily inspection before use
A Checkup of engine oil level and refilling
No ref ill is required if the level is near the upper limi t
line of the gauge
B Checkup of cooling water and refilling
Refill up to the filler cap neck
C Check your fuel supply
D Checkup of gauges and meters
After starting your engine check oil pressure water tem
perature and voltage reading
E Checkup for loose parts fan belt or bolt etc damage and
leaks
F Checkup for abnormality with exhaust gas noise and Servicing following initial 50 hours of operation
A Renewal of engine oil
B Replacement of oil filter
C Renewal of cooling water
D Adjustment of valve clearance See SERVICE DATA
E Tightening of bolts and nuts
F Adjustment of engine idle
3 Servicing at every 100 hours of operation
A Renewal of engine oil
B Replacement of oil filter
C Cleaning of fuel filter
D Adjustment of engine idle
4 Servicing at every 200 hours of operation
A Replacement of engine mounted fuel filter elements
B Replacement of fuel filter cartridge type
5 Servicing at every 400 hours of operation
A Cleaning of fuel tank
B Adjustment of valve clearance
C Checkup of starter motor alternator and regulator
Check the brush and surface of commutator for the degree of
wear Replace the brush if it is rvorn beyond the limi ts of
wear
D Checkup of glow plugs
Check the glow plugs for blowout
E Removal of cooling water and flushing is Servicing at every 800 hours of operation
A Checkup of nozzles
Set the injection starting
pressure to 1707 0 psi
and eliminate undesirable
injection conditions in
cluding after dripping
GOOD
B Checkup of compression pressure
Remove each glow plug and check cylinders one by one using
a compresslom pressure gauge If the pressuce differs by
more than 25 kgcm 2 35 6 psi between cylinders or if the
cylinder pressure is less than 32 kgcm 2 4550 psi at
320 RPM correct it
Co Fuel injection adjustment
In case of severe vibration during idling have it repaired
at an authorized distributor or dealer which is equipped with
a pump tester
D Checkup of alternator and regulator
Regulate the voltage and current by use of a circuit tester
E Checkup of starter motor pinion and flywheel ring gear
Rectify the chamfered area that has been severely damaged by
use of an oil stone or some pencil grinder and replace the
part if it is damaged allover
F Tightening of bolts and Model 10two may be supplied with standard transmission BW3
and 21 RG or optional HBW50 either 21 or 271 RG also Vdrive 18 21 or 31 RG
All models turn right hand propellers
All models have their own oil sumps and dipsticks
All HBW models use ATF lubricant
BW units may use either ATF or 30 weight engine oil
All models should be dumped into gear in one swift motion
not allowed to slip in slowly
The their dipsticks and markings are illustrated in the
sketches below For dipsticks that are threaded in the case measure
oil by dropping dipstick on the case Do not screw in
Hm 150 V
ENGINE DOES NOT START
a Starting switch is defective Correct connections and contacts
b Deficient drive torque of The battery is exhausted trouble
the starter motor with the starter motor or dirty or
loose wiring
c Improper viscosity of engine Check the viscosity and renew oil
oil if necessary
d Engine too cold Use glowplug starting aid
e Seizure of moving parts Rectify
f Air present in fuel system Purge thoroughly with electric fuel
pump
g No fuel in fuel tank Refill
h Fuel filter clogged Clean or renew
2 ENGINE STALLS WHILE IN OPERATION
a Fuel tank is empty Refill
b Fuel filter clogged Clean or renew
c Air present in fuel system Retighten fuel line connections to
allow electric fuel pump to run long
enough to purge air IMPROPER OIL PRESSURE
a Oil shortage Refill
b Oil leak through connections Repair
c Oil pressure switch Replace
defective
4 ENGINE Cooling water shortage Refill
b Water leaks Repair
c Belt loose or smeared with Clean or renew
d Raw water pump defective Repair or renew
5 BATTERY IS Belt tension improper Rectify
b Faulty wiring circuit Rectify
c Alternator not functioning Replace
observe voltmeter
d Battery faulty Replace
e Faulty voltage regulator Repair or renew
SERVICE DATA
1 Valve clearance engine cold 025 mm 0010 in
both intake and exhaust
2 Compression pressure
WlOtwo and 3 KW 32 kgcm 2 at 320 RPM 455 lbssq in
3 Engine oil capacity 212 quarts including oil filter Go by Firing order 1
5 Injection timing BTDC of compression stroke when started at
smoke set positione
Marine Engine 25 before top dead center
Generator 25 before top dead center
6 Injection starting pressure 142
1707 0 psi
7 Cooling water capacity in 3 quarts engine body TORQUES
1 Cylinder head bolt M8 3 5 40 kgm 253 289 lbft
2 Rocker cover nut U18 0 5 07 kgm 36 51 Ibft
3 Connecting rod cap nut 302 3 5 kgm 231 253 Ibft
4 Flywheel bolt MIO 65 70 kgm 47 0 506 Ibft
5 Crankshaft pulley nut M24 15 20 kgm 108 5 144 7 Ibft
6 Oil drain plug 5 0 60 kgm 362 434 Ibft
7 Oil filter 101 13 kgm 7 96 940 Ibft
8 Nozzle holder 50 60 kgm 362 434 Ibft
9 Nozzle holder retaining nut 60 800 kgm 434 579 Ibft
INSTRUCTIONS FOR 3 KW GENERATOR SET
Instructions for the engine portion are generally the same as for
the propulsion unit WlOtwo The differences will be described in the
following IN
Service life of your generator is dependent upon how the engine is
operated and serviced during the initial 10 hours of operation
Your new engine needs at least 10 hours of conditioning operation
for breaking each moving part in and maximizing performance and life
of engine Perform this conditioning carefully bearing the in mind
1 Since generator sets operate at 1800 RPM to obtain 60 cycle
current your control of the breaking in process is limi ted to
control of load
2 Do not ever attempt to BREAK IN your generator set by running at
NO LOAD
3 Immediately on starting the set add approximately 25 load to
cause a fast warm up
4 For the first 10 hours of operation run between 20 and 60 percent
load
5 After 10 hours you may load as needed except that
6 You must avoid overload at all times Overload is signalled by
smoky exhaust andor a reduction in speed and in a new engine is basically a seating of the piston rings
to the cylinder walls This is not accomplished by long per iods of
running idle nor by early running under full load
Idle running may glaze the cylinder walls causing oil consumption and
smoky operation Excessive loads may score cylinder walls with simi
lar results
As indicated above use a short warm up period under moderate load for
the first ten hours of operation For the next forty hours 70 load This kind of careful operation will result in
best results from your engine
STARTING panel description and use of
Note 1 When generator is stopped after use the water temperature
and oil pressure gauges may stay at their running 2 When generator is next to be used depress preheat switch
The temperature and pressure gauges will ZERO and the volt
meter will register battery voltage The electric fuel pump
mounted on the engine will also begin to operate purging
any air accumulated in the system
Note 3 The generator is now prepared for starting See next page
for specific 26
STARTING If making an initial start
after layup fuel filter ser
vicing or repairs depress the
preheat switch for 15 to 25 se
conds This will energ ize the
fuel pump allowing it to purge
the system of any accumulated
air This will preheat the
glow plugs at the same time
See table below for preheating
time
Quickheat type Yll4T
Atmospheric temperature Preheating time
SC 4lF or higher Approx 10 sec
SC 4lF to SC 23F Approx 20 sec
SC 23F or lower Approx 30 sec
Limit of continuous use 1 minute
2 Proper glow plug function is
indicated by voltmeter drop
when key is depressed This
drop will be slight but dis
cernible If no voltage drop
is noted it may indicate
defective glow plugs or a
faulty preheat circuit check
for loose The start wiring is designed so
that the preheat switch must be
depressed before the start
switch will 27
4 Starting
While still holding preheat
switch depressed depress the
start switch The starter PREHEAT START
motor will run thereby cranking
the eng ine As soon as the
eng ine runs release the start
switch which will return to its
normally open posi tion Con STOP
tinue holding the preheat
switch depressed for 2 or 3
seconds This defeats the low
oil pressure shutdown until the
engine oil pressure rises to
normal running pressure Now
release the preheat the engine not start when start switch is depressed for 10 to
12 seconds wait 30 seconds and repeat 3 with adequate preheat time
Never run the starter motor for more than 30 seconds at a time
5 Operation
With the engine running check that oil pressure and battery
charge voltage are registering and that raw water is discharging
with the exhaust During engine operation do not depress start
switch as this will damage starter motor
6 Warmup operation
Operate at reduced load until water temperature rises to the 140
to 150 degree PROCEDURE
PREHEAT START
1 Stop
To stop the generator depress
the stop switch until engine
stops completely and then
release STOP
WIRING DIAGRAM FOR 3 KW GENERATOR SET
Your engine is of 12V system and its electric circuit is as shown on
wiring diagram 24700 as shipped loose with this manual
For installing electrical parts connect them correctly by referring
to the diagram and at the same time check for damaged wire sheathing
and confirm that grounding is provided properly Care must always be
taken while working on the electrical shut the engine battery switch off while the engine is to the battery charging alternator will result should
this COMPONENT OF GENERATOR SET
All generators for the inherently regulated series are identical in
design and alike except for length of the various and replaceable parts are similar throughout Brushes 8 rectifier 42 capacitor 45 all bear a
high degree of
commonali ty See next page
It is necessary only to give correct model and serial number to parts from your local Dealer or when a generator set is started there will be no
When this occurs the fields must be flashed to magnetism The fields may be flashed wi th a 6 or 12 vol t
battery as the engine remove the
gener a tor end cover You
will notice the positive
lead from the field coil is
connected to the terminal
of the rectifier Part 42
opposite page the negative
lead from the field coil is
connected to the opposite AC
negative unmarked terminal Field
of the rectifier Using Excitation
clips connect
field coil posi ti ve to bat
tery positive and field coil to battery negative
for approximately ten sec
onds The set will then
build voltage and output
Be careful not to connect
on the AC terminals as this
will destroy the INFORMATION AND CARE OF Use of Electric Motors
The power required to start an electr ic motor is considerably
more than is required for keeping it running after it 1S once
started Some motors require much more current to start them than
others Split phase AC motors require more current to start
them under similar than other types They are
commonly used on easy starting loads such as washing machines or
where loads are applied after the motor is started such as small
power tools Since they require 5 to 7 times as much current to
start as to run their use should be avoided whenever possible if
the electric motor is to be driven by a small generator
Capacitor and motors require from 2 to 4 times
as much current to start them as to run them The current
required to start any motor varies with the load connected to it
An electr ic motor connected to an air compressor for example
will require more than a motor to which no load is connected
In general the current required to start 115 volt motors con
nected to medium starting loads will be approximately as follows
MOTOR AMPS FOR AMPS FOR
SIZE RUNNING STARTING
16 32 64 to 224
14 46 92 to 322
13 52 104 to 728
12 72 144 to 292
34 102 204 to 408
1 13 26 to 52
Note that in the above table the maximum amps for starting is
more for some small motors than for larger ones This is because
the hardest starting types are not made in larger
sizes
Because the heavy surge of current required for starting motors is
required for only an instant the generator will not be damaged if
it can bring the motor up to speed in a few seconds of time If
difficulty is experienced in starting motors turn off all other
electrical loads and if possible reduce the load on the electric
motor
2 Required Operating Speed
Although individual units and models may vary slightly the normal
voltage and frequency of typical 60 cycle enginedriven generators
described in this book are approximately as follows when run first
vii th no load applied then at half the generator capaci ty and
finally when loaded to its full capacity as rated on the
nameplate
Generator Voltage
Load Speed l15v 230v
AEElied 4 Eole Freguency Plants Plants
None 1830 61 129 258
Half 1800 60 120 240
Full 1755 58 115 230
The output voltage should be checked periodically to insure proper
operation of the generating plant and appliances If the genera
tor is not equipped wi th a vol tmeter it can be checked wi th a
portable meter
3 Maintenance
See the engine instruction book for engine BRUSHES Check the brushes for ylear after about 1000 hours of
operation and every few hundred hours of operation thereafter
They should be replaced when worn down to one half inch Whenever
replacing brushes or removing them to do other service work
remove one brush at a time and put the screws back into the brush
holder to hold the wire terminals on place so there will be no
difficulty replacing the wires correctly
COlviMUTATOR A commutator in good condi tion has a glossy finish
and is brownish in color If it gets greasy rough or dirty it
may be cleaned with very fine sandpaper Do not use emery
cloth
BEARINGS All ball bearings used in these generators are packed
with grease before assembly no further greasing is required If
they become rough or worn they should be 32
11SV f 11SV 115 V
AC END IC
EXCITATION FIELD M
BEARING RECTIFIER RECTIFIER
IRTURE
AC AC
IITERNAL
3 4 3 IRE
120240
SOUND GUARD INSTRUCTIONS
INSTRUCTIONS SOUND GUARD AIR FLOW DIAGRAM
1 Plywood b3se generator set bolls and skirt are in place as re
ceived
2 Hoist the generator set enough so that two men can lift the
plywood base and enter the bolts into corresponding holes il
generator set rails Spin nuts finger tight Assembly may then b
lowered into position and bolting completed
3 The generator set and base may then be bolted to the subbas
through holes in corner of the plywood
4 To assemble frame follow the drawing Be sure that open holes
are opposite guide pins and that riveted screw receptacles are
opposite screws
5 On units which require a fan foUow this procedure
A Remove 4 short screws which hold fresh water pump pulley
8 Reassemble hub with fan fan spacer and 4 cap screws fur
nished Tighten securely
6 Holes for fuel lines battery cables remote panel cable and power
lines are to be cut in the lower skirt by the installer These holes
9 The engine must receive combustion air from outside the
should be Gut to minimum usable size in order to minimize the
SOUND GUARD Be sure that flex duct for combustion air
escape of sound
Make a final check to be sure fan has clearance in its opening that
10 set up tl18
the fresh air duct from intake plenum to engine air intake is
Do not use excessive
clamped in place and that there is a tight fit of air plenum against
the end of the generator to prevent of air
8 If you plan to order SOUND GUARD order the generator set with
remole panel and cable extension
CAUTION With the air discharge end panel removed the fan is
exposed and unprotected
00 NOT remove air discharge end panel without firs stopping engine
SIMPLE QUICK ACTION LOCK AND
DISCHARGE FAN
EASY TO ASSEMBLE COAJER DETAil NOTE FM ASSEMBLY IS
REQUIRED
ON CERTAIN MODELS
BA TTEAY INTAKE FOR SEA WATER
WATER INJECTED RUBBER EXHAUST
HOSE TO WATER LIFT TYPE MUFFlER
FLEX DUCT FOR COMBUSTION AIR
WARNING
Air in generator compartment should not
exceed 100 degrees F If higher are expected an exhaust blower
should be 34
WESTERBEKE LIMITED WARRANTY
1 Warnmty ObBgdon and Duradon
Wcsterbeke warrants to the original consumer purchaser that all standard Westerbeke marine engines and
generator sets manufactured or supplied by us will be free from dtfects in material and workmanship for a period of
one year from date of commission or date of purchase on repower OR fifteen hundred 1500 hours on only whichever occurs first
2 Remedy
Westerbeke will elect to repair or replace free of charge to you any product or part returned to our costs prepaid which we adjudge defective in
materials or workmanship we may
reimburse at our discretion a portion of labor costs incurred to repair defective parts or products on site I f you of replacement parts to you prior
to our determination of cause of failure suh shipment will be sent COD
3 Notification
If you encounter a problem with your Westerbeke engine or generator set within the warranty period as stated
above contact your nearest authorized Westerbeke Master Distributor directly by telephone or letter
Be prepared to furnish thefollowing information
a number of hours on unit
b date of commission date of purchase
c owners office and home telephone
d model number serial number
e name of vessel
f present location of vessel or product
g name and address of builder
h boat model name
i who performed prior servicing installation
j description of current problem
k any service outlet consulted and their diagnosis
4 Exclusions
This warranty shall not apply to
a failures due to wear and tear misuse accident or negligence including but not limited to improper storage
or installation inadequate maintenance oyerloading and insufficient lubrication
b consequential harm caused by overheating of engine cooling water or loss of engine lubricating pressure
these conditions should be constantly monitored by engine instruments andor alarms
c consequential harm caused by improper installation or failure of accessories iiuached to our product such
as water heaters and refrigeration compressors
d products altered or modified in a manner not authorized in writing by Vesterbeke
e products damaged in transit
t replacement of engine fluids filter elements or vee belts engine tuneup valve adjustment oil and water A
leaks or any other normal service items
g specially manufactured products provided to customer h fuel systems cooling systems exhaust systems electrical systems and cable control
systems beyond he
connection points on the product
5 of Warrnnty
WARRANTY IS IN LIEU OF ALL OTHER EXPRESS VARRANTIES ANY BY LAW INCLUDING VARRANTIES OF OR FITNESS IS IN EFFECT
ONLY THE DURATION OF THE EXPRESS WARRANTY SET FORTH IN THE FIRST NO OR PERSON IS AUTHORIZED TO GIVE ANY OTHER WARRANTY OR
TO ASSUME FOR WESTERBEKE ANY OTHER LIABILITY IN CONNECTION WITH THE SALE OF ITS
PRODUCfS WESTERBEKE WILL NOT BE LIABLE FOR ANY CONSEQUENTIAL FROM THE USE OR INSTALLATION OF ITS STATES DO NOT ALLOW LIMITATIONS ON HOW LONG AN
IMPLIED WARRANTY LASTS OR
THE EXCLUSIONS OR LIMITATION OF INCIDENTAL OR CONSEQUENTIAL DAMAGES SO THE
ABOVE LIMITATIONS AND EXCLUSION MAY NOT APPLY TO YOU THIS WARRANTY GIVES YOU
SPECIFIC LEGAL RIGHTS AND YOU MAY ALSO HAVE OTHER RIGHTS WHICH VARY FROM
STATE TO STATE
PIN 21479 6183

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