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 4444 CALI IA FOREWORD Thank you for having selected a Engine for your use This manual describes the procedures for properhandling and maintenance of botha 10 Horsepower Marine Propulsion Engineb 3 KW Marine Generator Set To obtain best operating condition and longestlife it is important to use it sensibly and carryout operatiorl and maintenance according to thismanual If you have questions about your equipment orin the event of a failure please contact yournearest distributor or dealer We look forward to your continued patronage 1 TABLE OF CONTENTS PAGEGENERAL SPECIFICATIONS 3CAUTIONS IN HANDLING ENGINE 41 B REA KIN GIN 0 52 PREPARATIONS 63 STARTING PROCEDURES 74 STOPPING PROCEDURES I05 CAUTIONS ON STARTING AND OPERATION 0 co 0 106 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 187 RECOMfRIENDED MAINTENANCE SERVICE 198 TRANSMISSIONS 229 0 2310 SERVICE DATA 2411 TABLE OF TIGHTENING TORQUES 2412 INSTRUCTIONS 3KW GENERATOR SET2514 STOPPING PROCEDUPeo 2815 WIRING DIAGRAM 2917 EXPLODED VIEW GENERA I 0R PORTION 30 f 118 GENERAL INFORMATION ELECTRICAL 3119 MAl NlfENANCE II 3220 INTERNAL WIRING DIAGRAM 3321 LIMITED WARRANTY 34 2 GENERAL SPECIFICATIONS ENGINEType Vertical 4 cycle water cooledNo of cylinders TwoBore stroke inches 256 X 268Cubic inch displacement ratio 251Firing order 12Dry weight engine only 128 pump Bosch typeInjectors Throttle typeCombustion chamber Swirl typeFuel 2 dieselGovernor Centrifugal weight system Pressure by trochoid pumpOil filter Paper type engine mountedEngine oil capacity 2 quartsCooling system Forced circulation through heat starter 12 volt 1 35 ampere 12 voltGlow plugs Sheathed quick heat typeBattery capacity Recommend 60 amp hour type 4 pole revolving armature inherently regulated self limiting rectifier excited AC slip rings single bearing Class F 3INSTALLATION 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 manufacturer 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 ShackSAFETY PRECAUTIONS Never operate engine with inadequate ventilation 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 4BREAKING IN YOUR NEW ENGINE While your engine has had individual test operations sufficient todemonstrate accurate assembly and correct operation of all systems itstill requires break in time Service life of your engine is dependent on how your engine isoperated and serviced during the initial twenty hours of operation Your new engine needs twenty hours of conditioning operation forbreaking in each moving part thus maximizing performance and life ofeng 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 acceleration 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 ringsto the cylinder walls This is not accomplished by long per iods ofrunnIng idle nor by early running under full load nor by varyingloads with intervals of fast acceleration andor excessive speedIdle running may glaze the cylinder walls causing oil consumption andsmoky operation Excessive speeds and loads may score cylinder wallswith similar resultsAs indicated above use a short warm up at idle and put engine undermoderate load and speed for the first five hours of operationo Forthe next fifteen hours use approximately 70 load rhis kind ofcareful operation will result in best results from your engine steps as shown below in starting your engine for the first timeor after a prolonged shutdown1 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 Specifications page However it is best always to be guided by dipstick measure ment as angle of installation has some effect2 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 annually3 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 6STARTING panel description and use of Note 1 When engine is stopped after use the water temperature and oil pressure gauges may stay at their running readingsNote 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 systemNote 3 The engine is now prepared for starting 7STARTING PROCEDURES1 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 forward2 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 minute3 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 connection 84 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 throttleShould the engine not start even when the starter switch is left ats position for 10 seconds take your hand off the starter switch for30 seconds and then attempt to start the engine again by the glow plug The starter motor should never be allowedto run for more than 30 seconds at a time5 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 exhaustDuring engine operation do not turn the key to s position Thismay damage the starter motor6 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 9STOPPING PROCEDURE1 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 stop2 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 keyCAUTIONS ON STARTING AND OPERATION1 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 load2 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 deterioration Study page 12 10 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 83 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 11 REQUIREMENTS FOR PROPER SYSTEM1 Engine oil For engine lubrication use diesel engine oil Diesel engine oils are classified according to the API Specifications into grades CA CB CC and CD Anyone of them is usable but use of CC or higher grades prepared by wellknown makers is recommended2 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 suggested 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 speed4 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 125 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 leaksFUEL SYSTEM1 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 water2 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 133 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 selfbleeding 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 firmly4 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 season5 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 periodically Inspect water entrapment filter regularly 14If a water trap type filter see page 13 is not interposed between the fuel tank and engine lift pump any entrained water willtend to lay in bottom of lift pump Internal metal parts of thelift pump will rust Particles will pass on to filters and eventually to injection pump and injectors with damaging and many boat builders do supply a water trap filter there aresome who do not It is to prevent such omission that a trap filter as a desirable optionalextra at moderate cost It is supplied with fittings for eitherhose piping or metal tube pipingOrder it wi th the eng ine install it in an accessible placeinspect it daily and drain as needed 1510 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 effects2 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 concentration 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 16The total system is very reliable and requires only a daily checkof the water level in the system plus routine check of hose clampsand fittingsIt is likely that zinc electrodes will waste away from contactwith sea water It is also possible for the raw water pumpimpeller to fail due to lack of sea water or deter ioration Anearly sign of impeller failure is less water and more steam at theexhaust through hull fittingIt is recommended therefore that zinc electrodes 11885 waterpump belt 32942 alternator belt 13585 sea water pump assembly32617 and sea water impeller kit 32620 be carried onboard at alltimes These parts should be ordered from your nearest stockingdealer and used as inspection dictates 17Alternator 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 DIAGRAMYour engine is of 12V system and its electric circuit is as shown indiagram 24666 shipped loose with this manualFor installing electrical parts connect them correctly by referringto the diagram and at the same time check for damaged wire sheathingand confirm that grounding is provided properly Care must always betaken while working on the electrical systemNever shut the engine battery switch off while the engine is runningDamage to the battery charging alternator will result should this bedoneDOMESTIC HOT WATERThe smaller of two hoses at top left inthe photo is the FLOWCONTROLLER bypassWhen you connect your eng ine to supplydomestic hot water remove the bypasshose connect the spud on the to the lower connection on thewater heater coil Connect the on the water heater coil tothe spud on the manifold Study instructions and illustrations on next page 18Model WlOtwo comes complete with FLOWCONTROLLER which when to a heater tank produces domestic hot water from wasteengine heatprinciple There are two 78 hose connections at front of the enginewhich provide a parallel flow of engine cooling water to and from theheater These connections are part of the FLOWCONTROLLER whichassures a flow of hot water through the heater at all times and yetprecludes excessive restriction of engine cooling water flow caused bythe heater all simply and Remove the hose connecting the 78 spuds on front ofengine as shipped from the factory see illustration preceding pageConnect these spuds to the heater with 78 ID wire inserted hoseThe spud on thermostat housing is the flow FROM the engine and shouldconnect to lower fitting on heater The spud on manifold is the flowRETURNING to the engine and should connect to the upper connection onheaterHoses should rise continuously from their low point at the heater tothe engine so that trapped air will rise naturally from the heater tothe engine If trapped air can rise to the heater then an air bleedpetcock must be installed at the higher fitting on the heater forbleeding air while filling the system Avoid loops in hose runs whichwill trap airIf any portion of the engine cooling water circuit to or from theheater rises above the engines own pressure cap then the expansion tank must be installed in the circuit to become thehighest point The tank kit Part Number is 24177 Install the tank in a convenient location such as a sail locker for easeof checking fresh water coolant levelThe cap on the engine mounted expansion tankmanifold should not beopened once the remote system is installed and filledThe hose connection from the heater to the remote expansion tankshould be routed and supported so as to rise continuously from theheater to the tank enabling any air in the system to below are of FLOWCONTROLLER adapted to our two passmanifolds While on Model WlOtwo the appearance is different theprinciple is the same IIetlter BelowEgine fieZlter AbJveEngiJ1tZ 19 RECOMMENDED MAINTENANCE SERVICECheck and service your engine at specified intervals to maintain it inits best conditions and permit it to perform as it should As forthose asterisked items it is suggested that you have them performedby an authorized distributor or dealer1 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 vibration2 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 idle3 Servicing at every 100 hours of operation A Renewal of engine oil B Replacement of oil filter C Cleaning of fuel filter 20 D Adjustment of engine idle4 Servicing at every 200 hours of operation A Replacement of engine mounted fuel filter elements B Replacement of fuel filter cartridge type5 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 suggested6 Servicing at every 800 hours of operation A Checkup of nozzles Set the injection starting 142 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 21 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 BW3and 21 RG or optional HBW50 either 21 or 271 RG also optionalHBW150 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 slowlyThe transmissions their dipsticks and markings are illustrated in thesketches below For dipsticks that are threaded in the case measureoil by dropping dipstick on the case Do not screw in Hm 150 V 22 ENGINE DOES NOT STARTa Starting switch is defective Correct connections and contactsb Deficient drive torque of The battery is exhausted trouble the starter motor with the starter motor or dirty or loose wiringc Improper viscosity of engine Check the viscosity and renew oil oil if necessaryd Engine too cold Use glowplug starting aide Seizure of moving parts Rectifyf Air present in fuel system Purge thoroughly with electric fuel pumpg No fuel in fuel tank Refillh Fuel filter clogged Clean or renew2 ENGINE STALLS WHILE IN OPERATIONa Fuel tank is empty Refillb Fuel filter clogged Clean or renewc Air present in fuel system Retighten fuel line connections to allow electric fuel pump to run long enough to purge air thoroughly3 IMPROPER OIL PRESSUREa Oil shortage Refillb Oil leak through connections Repairc Oil pressure switch Replace defective4 ENGINE OVERHEATINGa Cooling water shortage Refillb Water leaks Repairc Belt loose or smeared with Clean or renew oild Raw water pump defective Repair or renew5 BATTERY IS UNDERCHARGEDa Belt tension improper Rectifyb Faulty wiring circuit Rectifyc Alternator not functioning Replace observe voltmeterd Battery faulty Replacee Faulty voltage regulator Repair or renew 23SERVICE DATA1 Valve clearance engine cold 025 mm 0010 in both intake and exhaust2 Compression pressure WlOtwo and 3 KW 32 kgcm 2 at 320 RPM 455 lbssq in3 Engine oil capacity 212 quarts approximately including oil filter Go by dipstick4 Firing order 1 25 Injection timing BTDC of compression stroke when started at smoke set positione Marine Engine 25 before top dead center Generator 25 before top dead center6 Injection starting pressure 142 1707 0 psi7 Cooling water capacity in 3 quarts approximately engine body TORQUES1 Cylinder head bolt M8 3 5 40 kgm 253 289 lbft2 Rocker cover nut U18 0 5 07 kgm 36 51 Ibft3 Connecting rod cap nut 302 3 5 kgm 231 253 Ibft4 Flywheel bolt MIO 65 70 kgm 47 0 506 Ibft5 Crankshaft pulley nut M24 15 20 kgm 108 5 144 7 Ibft6 Oil drain plug 5 0 60 kgm 362 434 Ibft7 Oil filter 101 13 kgm 7 96 940 Ibft8 Nozzle holder 50 60 kgm 362 434 Ibft9 Nozzle holder retaining nut 60 800 kgm 434 579 Ibft 24 INSTRUCTIONS FOR 3 KW GENERATOR SET Instructions for the engine portion are generally the same as forthe propulsion unit WlOtwo The differences will be described in thefollowing pagesBREAKING IN Service life of your generator is dependent upon how the engine isoperated and serviced during the initial 10 hours of operation Your new engine needs at least 10 hours of conditioning operationfor breaking each moving part in and maximizing performance and lifeof engine Perform this conditioning carefully bearing the in mind1 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 load2 Do not ever attempt to BREAK IN your generator set by running at NO LOAD3 Immediately on starting the set add approximately 25 load to cause a fast warm up4 For the first 10 hours of operation run between 20 and 60 percent load5 After 10 hours you may load as needed except that6 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 ringsto the cylinder walls This is not accomplished by long per iods ofrunning idle nor by early running under full loadIdle running may glaze the cylinder walls causing oil consumption andsmoky operation Excessive loads may score cylinder walls with similar resultsAs indicated above use a short warm up period under moderate load forthe first ten hours of operation For the next forty hours 70 load This kind of careful operation will result inbest results from your engine 25STARTING panel description and use ofNote 1 When generator is stopped after use the water temperature and oil pressure gauges may stay at their running readingsNote 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 systemNote 3 The generator is now prepared for starting See next page for specific instructions 26STARTING PROCEDURES1 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 minute2 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 connection3 The start wiring is designed so that the preheat switch must be depressed before the start switch will function 274 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 switchShould the engine not start when start switch is depressed for 10 to12 seconds wait 30 seconds and repeat 3 with adequate preheat timeNever run the starter motor for more than 30 seconds at a time5 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 motor6 Warmup operation Operate at reduced load until water temperature rises to the 140 to 150 degree rangeSTOPPING PROCEDURE PREHEAT START1 Stop To stop the generator depress the stop switch until engine stops completely and then release STOP J 28WIRING DIAGRAM FOR 3 KW GENERATOR SETYour engine is of 12V system and its electric circuit is as shown onwiring diagram 24700 as shipped loose with this manualFor installing electrical parts connect them correctly by referringto the diagram and at the same time check for damaged wire sheathingand confirm that grounding is provided properly Care must always betaken while working on the electrical systemNever shut the engine battery switch off while the engine is runningDamage to the battery charging alternator will result should this COMPONENT OF GENERATOR SETAll generators for the inherently regulated series are identical indesign and alike except for length of the various sizesWearing and replaceable parts are similar throughout Brushes 39bearings 8 rectifier 42 capacitor 45 all bear a high degree ofcommonali ty See next pageIt is necessary only to give correct model and serial number to obtaincorrect parts from your local Dealer or when a generator set is started there will be no voltagebuildup When this occurs the fields must be flashed to magnetism The fields may be flashed wi th a 6 or 12 vol tbattery as followsStop the engine remove thegener a tor end cover Youwill notice the positive lead from the field coil isconnected to the terminalof the rectifier Part 42opposite page the negativelead from the field coil isconnected to the opposite ACnegative unmarked terminal Fieldof the rectifier Using Excitation clips connect field coil posi ti ve to battery positive and field coil to battery negativefor approximately ten seconds The set will thenbuild voltage and outputBe careful not to connecton the AC terminals as thiswill destroy the rectifier 2930GENERAL INFORMATION AND CARE OF GENERATORS1 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 circumstances 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 splitphase 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 motor2 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 31 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 meter3 Maintenance See the engine instruction book for engine maintenanceo 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 replaced 32 11SV f 11SV 115 V AC END IC EXCITATION FIELD M MBEARING 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 hub 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 is 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 recirculation 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 FANEASY TO ASSEMBLE COAJER DETAil NOTE FM ASSEMBLY IS REQUIRED ON CERTAIN MODELS BA TTEAY CONNECTIONS INTAKE FOR SEA WATER WATER INJECTED RUBBER EXHAUST HOSE TO WATER LIFT TYPE MUFFlER FLEX DUCT FOR COMBUSTION AIR WARNINGAir in generator compartment should notexceed 100 degrees F If higher temperatures are expected an exhaust blowershould be installed 34 WESTERBEKE LIMITED WARRANTY1 Warnmty ObBgdon and Duradon Wcsterbeke warrants to the original consumer purchaser that all standard Westerbeke marine engines andgenerator sets manufactured or supplied by us will be free from dtfects in material and workmanship for a period ofone year from date of commission or date of purchase on repower OR fifteen hundred 1500 hours on only whichever occurs first2 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 Alternatively we mayreimburse 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 COD3 Notification If you encounter a problem with your Westerbeke engine or generator set within the warranty period as statedabove contact your nearest authorized Westerbeke Master Distributor directly by telephone or letterBe 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 diagnosis4 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 specifications h fuel systems cooling systems exhaust systems electrical systems and cable control systems beyond he connection points on the product5 of Warrnnty WARRANTY IS IN LIEU OF ALL OTHER EXPRESS VARRANTIES ANY BY LAW INCLUDING VARRANTIES OF OR FITNESS IS IN EFFECTONLY THE DURATION OF THE EXPRESS WARRANTY SET FORTH IN THE FIRST PARAGRAPHABOVE NO REPRESENTATIVE OR PERSON IS AUTHORIZED TO GIVE ANY OTHER WARRANTY ORTO ASSUME FOR WESTERBEKE ANY OTHER LIABILITY IN CONNECTION WITH THE SALE OF ITSPRODUCfS WESTERBEKE WILL NOT BE LIABLE FOR ANY CONSEQUENTIAL FROM THE USE OR INSTALLATION OF ITS PRODUCrSSOl1E STATES DO NOT ALLOW LIMITATIONS ON HOW LONG AN IMPLIED WARRANTY LASTS ORTHE EXCLUSIONS OR LIMITATION OF INCIDENTAL OR CONSEQUENTIAL DAMAGES SO THEABOVE LIMITATIONS AND EXCLUSION MAY NOT APPLY TO YOU THIS WARRANTY GIVES YOUSPECIFIC LEGAL RIGHTS AND YOU MAY ALSO HAVE OTHER RIGHTS WHICH VARY FROMSTATE TO STATEPIN 21479 6183 35

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