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Westerbeke Diesel Rd 80 Technical Manual



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 OPERATOR'S
  MANUAL

                   for

tIIIEStERBEICE 1() TWO
     )\


    MARINE ENGINE
                  AND


tIIIES.,.ERBEICE SlCtIII
    GENERATOR SET
          Publication Number 33105
               Printed in U.S.A.




      J. H. WESTERBEKE CORP.
          AVON INDUSTRIAL PARK, AVON, MASS. 02322 {6f7} 588 7700
                     CABLE: WESTCORP, AVON TELEX:   92 4444
~------
  C.ALI   IA
                     FOREWORD


    Thank you for having      selected   a   Westerbeke
Diesel Engine for your use.

    This manual describes the procedures for proper
handling 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 patronage.




                         1
                  TABLE OF CONTENTS
                                                                                        PAGE

GENERAL SPECIFICATIONS . 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
        6-1 Lubrication System .... 12
        6-2 Fuel System .. 13
        6-3 Cool         System ... 16
        6-4 Wiring       iagram~~ ... 18
        6 - 5 Bel t 'r ens ion. ..  " e _  ..    ..   .. 18
        6-6 Domestic Hot Water ... 18

7       RECOMfRIENDED MAINTENANCE SERVICE .19

8..     TRANSMISSIONS.. ..   .. . ...               ..., .............. 22

9.      TROUBLESHOOTING . . . . .                ~       0                            23

10 ..   SERVICE DATA .................. " ..                        _ ...... 24

11 ..   TABLE OF TIGHTENING TORQUES" . .  24

12.     INSTRUCTIONS: 3KW GENERATOR SET.25



14.     STOPPING       PROCEDUP~.e~o                   28

15..    WIRING DIAGRAM ............ " ................... 29



17 ..   EXPLODED VIEW GENERA I 0R PORTION .. 30
                                           f 1




18 .    GENERAL INFORMATION ELECTRICAL  31

19..    MAl NlfENANCE .. " ............ " ........            II    ........            ,,32

20.     INTERNAL WIRING DIAGRAM .......... 33

21.     LIMITED WARRANTY ... 34


                                 2
                      GENERAL SPECIFICATIONS

                             ENGINE


Type                       Vertical 4 cycle, water cooled

No. of cylinders            Two

Bore & stroke (inches)      2.56 X 2.68

Cubic inch displacement     27.52

Compression ratio           25:1

Firing order                1-2

Dry weight, engine only     128 pounds

Injection pump              Bosch type

Injectors                  Throttle type

Combustion chamber          Swirl type

Fuel                        #2 diesel

Governor                   Centrifugal weight type

Lubrication system         Pressure by trochoid pump

Oil filter                 Paper type, engine mounted

Engine oil capacity         2 quarts

Cooling system             Forced circulation through heat exchanger

Electric starter            12 volt, 1 horsepower

Alternator                  35 ampere, 12 volt

Glow plugs                 Sheathed quick heat type

Battery capacity            Recommend 60 amp hour



                            GENERATOR

Generator type             4 pole, revolving armature, inherently
                           regulated,  self   limiting,  rectifier
                           excited, AC slip rings, single bearing
                           design

Insulation                 Class F



                                    3
INSTALLATION 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.

*   Plug-in 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 Shack.


SAFETY 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.




                                    4
BREAKING IN YOUR NEW ENGINE


    While your engine has had individual test operations sufficient to
demonstrate 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 following
points 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% load.




Explanation:

"Breaking in" a new en~ine 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 and/or 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 under
moderate 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&




                                      5
PREPARATIONS


Take steps as shown below in starting your engine for        the first time
or after a prolonged shut-down.


1.   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 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.




                                    6
STARTING PROCEDURES

Instrument 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 readings.

Note 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 starting.




                                   7
STARTING PROCEDURES


1.   Turn the starter switch to the
     liON" posi tiona   If making an
     ini tial   start  after   lay-up,
     fuel     filter   servicing    or
     repairs,    allow fuel pump to
     work lS-2S 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 1/4 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.



                         Quick-heat type (Yl14T)


            Atmospheric temperature         Preheating time


          +S-C (+41-F) or higher            Approx. 10 sec.

          +S-C (+41-F) to -S-C (+23-F)      Approx. 20 sec.

          -SC (+23-F) 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 connection).




                                      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 throttle.



Should 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 sufficiently
preheating 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
     exhaust.


During engine operation, do not turn the key to "s" position.    This
may damage the starter motor.




6.   Warm-up 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 140-150 range.




                                     9
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 key.


CAUTIONS 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 e~gine 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 140-150 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 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 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 blow-back 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 OPERATION


LUBRICATION SYSTEM

1.   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 well-known makers is recommended.

2.   Engine oil viscosity

     Use oil having viscosity best suited to the atmospheric tem-
     perature.  Use of an all-season oil SAEIOW-30 with minimum visco-
     sity change under different temperatures is suggested.




          20C (6SF) or higher                     SAE 30 or    1~W-30


                                                    SAE 20 or 10W-30

          SC (41F) or lower                       SAE IOW-30



 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 yellow/grey emulsion indicates presence
     of water in the oil.      While this condition is rare, it does
     require prompt attention to prevent serious damage.




                                    12
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 O-ring, 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 ..



                                        13
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 self-bleeding
     system used on the Westerbeke 3 KW marine generator set.

     The Westerbeke self-bleeding 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 re-install
     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 shop-adjusted 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.




                                   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 expensive
results.

While many boat builders do supply a water trap filter, there are
some who do not.   It is to prevent such omission that Westerbeke
offers a sedimenter/water trap filter as a desirable optional
extra at moderate cost.   It is supplied with fittings for either
hose piping or metal tube piping.

Order it wi th the eng ine, install it   in   an   accessible   place,
inspect it daily and drain as needed.




                              15
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 dist.rict..    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 engi.ne is cleaned
                 well before adding antifreeze~

                *Recommended antifreeze for. year                                     round     use   is        ZEREX        or
                 PRE;STONE 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   e.~.E.~E_a t ~ r. E:   C' F)          (23)           (14)          ( 5.)   (-4)     (-22)   (-40)        (-58)


      Note:                 It   is   advisa.ble that antifreeze concen"tration be
                            selected on the basis of a temperature which is about
                            5C   (106F)   lower than the actual atmospheric tem-
                            pera.ture 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.



                                                                      16
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 assembly
#32617 and sea water impeller kit #32620 be carried onboard at all
times..  These parts should be ordered from your nearest stocking
dealer and used as inspection dictates ..




                              17
Alternator belt and water pump tension

    The belts are properly tense if
    they deflect 10 to 12 mm (0.39
    to 0.47 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 operation.


WIRING 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 system.

Never shut the engine battery switch off while the engine is running.
Damage to the battery charging alternator will result should this be
done.

DOMESTIC HOT WATER

The smaller of two hoses at top left in
the photo is the FLOWCONTROLLER bypass.
When you connect your eng ine to supply
domestic hot water, remove the bypass
hose, connect the spud on the thermostat
housing to the lower connection on the
water heater coil.    Connect the higher
connection on the water heater coil to
the spud on the manifold.  Study instruc-
tions and illustrations on next page.




                                   18
Model WlOtwo comes complete with FLOWCONTROLLER which, when properly
connected to a heater tank, produces domestic hot water from waste
engine heat.

principle: There are two 7/8" 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 FLOWCONTROLLER 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 automatically.

Installation:  Remove the hose connecting the 7/8" spuds on front of
engine as shipped from the factory (see illustration preceding page).
Connect these spuds to the heater with 7/8" ID wire inserted hose.
The spud on thermostat housing is the flow FROM the engine and should
connect to lower fitting on heater.  The spud on manifold is the flow
RETURNING to the engine and should connect to the upper connection on
heater.

Hoses 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 engine's own pressure cap, then the pressurized
remote expansion tank must be installed in the circuit to become the
highest point. The tank kit Part Number is 24177.   Install the remote
expansion 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 tank/manifold 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 rise.

Illustrations below are of FLOWCONTROLLER adapted to our two pass
manifolds.   While on Model WlOtwo the appearance is different, the
principle is the same.

        IIetlter BelowEgine:




                                              fieZlter Ab::JveEngiJ1tZ:


                                  19
                     RECOMMENDED MAINTENANCE SERVICE


Check 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 vibration


2.    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



                                       20
      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 r.vorn beyond the limi ts of
           wear.

     *D.   Checkup of glow plugs

           Check the glow plugs for blow-out.

      E.   Removal of cooling water and flushing is       suggested~



6.    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 pressu:ce differs by
           more than 2.5 kg/cm 2 (35 .. 6 psi) between cylinders or if the
           cylinder pressure is less than 32 kg/cm 2 (455.0 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 nuts


TRANSMISSIONS

Westerbeke Model 10two may be supplied with standard transmission BW-3
and 2:1 RG or optional HBW-50 either 2:1 or 2.7:1 RG, also optional
HBW-150 V-drive 1.8, 2.1, or 3:1 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 transmissions, 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




                                           22
                               TROUBLESHOOTING




1.   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 thoroughly

3.   IMPROPER OIL PRESSURE

a.   Oil shortage                     Refill
b.   Oil leak through connections     Repair
c.   Oil pressure switch              Replace
     defective

4.   ENGINE OVERHEATING

a.   Cooling water shortage           Refill
b.   Water leaks                      Repair
c.   Belt loose or smeared with       Clean or renew
     oil
d.   Raw water pump defective         Repair or renew

5.   BATTERY IS UNDERCHARGED

a.   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




                                      23
SERVICE DATA

1.     Valve clearance (engine cold) 0.25 mm (0.010 in.)
       (both intake and exhaust)

2.     Compression pressure

       WlOtwo and 3 KW                       32 kg/cm 2 at 320 RPM (455 lbs/sq in)

3.     Engine oil capacity                   2-1/2 quarts approximately
       (including oil filter)                (Go by dipstick.)

4.     Firing order                          1 - 2

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 approximately
       engine body alone)


TIGHTENING TORQUES

1 ..   Cylinder head bolt (M8)               3 .. 5       -    4.0 kg-m         (25.3          -    28.9 lb-ft)

2 ..   Rocker cover nut U18 )                0 .. 5       -    0/7 kg-m         (3.6       -       5.1 Ib-ft)

3.     Connecting rod cap nut                302          -    3 .. 5 kg-m      (23.1          -    25.3 Ib-ft)

4.     Flywheel bolt (MIO)                   6.5          - 7.0 kg-m            (47 .. 0       -    50/6 Ib-ft)

5.     Crankshaft pulley nut (M24 )          15       -       20 kg-m        (108 .. 5     -       144 .. 7 Ib-ft)

6,.    Oil drain plug                        5 .. 0 - 6.0 kg-m                  (36.2          -    43.4 Ib-ft)

7 ..   Oil filter                            101          -   1.3 kg-m          (7  96        -    9.40 Ib-ft)

8.     Nozzle holder                         5.0          -   6.0 kg-m          (36.2          -    43.4 Ib-ft)

9 ..   Nozzle holder    &   retaini.ng nut 6,,0           -   800 kg-m          (43.4          -    57.9 Ib-ft)




                                             24
                  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 pages.


BREAKING 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 following
points 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 and/or a reduction in speed and voltage.


Explanation:

"Breaking 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, use
approximately 70% load. This kind of careful operation will result in
best results from your engine.




                                     25
STARTING PROCEDURES


Instrument 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 readings.

Note 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 instructions.




                                   26
STARTING PROCEDURES


1.   If making    an  initial   start
     after lay-up, 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. )



                         Quick-heat type (Yll4T)


            Atmospheric temperature         Preheating time


          +SC (+4l-F) or higher            Approx. 10 sec_

          +SC (+4l-F) to -SC (+23-F)      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 connection).




3.   The start wiring is designed so
     that the preheat switch must be
     depressed   before   the  start
     switch will function.




                                      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 switch.

Should 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.   Warm-up operation

     Operate at reduced load until water temperature rises to the 140
     to 150 degree range.


STOPPING PROCEDURE

                                              PREHEAT           START
1.   Stop

     To stop the generator, depress
     the stop switch until engine
     stops    completely and   then
     release.                                           STOP


                                                        ~                J



                                   28
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 system.

Never shut the engine battery switch off while the engine is running.
Damage to the battery charging alternator will result should this be
done.


GENERATOR COMPONENT OF GENERATOR SET

All generators for the inherently regulated series are      identical in
design and alike except for length of the various sizes.

Wearing and replaceable parts are similar throughout.    Brushes (39),
bearings (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 obtain
correct parts from your local Dealer or Distributor.

Occasionally when a generator set is started, there will be no voltage
build-up.   When this occurs, the fields must be flashed to restore
residual magnetism.   The fields may be flashed wi th a 6 or 12 vol t
battery as follows:

Stop 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
                                                                Rectifier
alligator     clips,  connect                       +
field coil posi ti ve to bat-
tery positive and field coil             Annature
negative 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 rectifier.)




                                    29
30
GENERAL INFORMATION AND CARE OF GENERATORS


1.   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 (A.C.) 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 repulsion-induction 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

                1/6                  3.2          6.4   to   22.4*
                1/4                  4.6          9.2   to   32.2*
                1/3                  5.2         10.4   to   72.8*
                1/2                  7.2         14.4   to   29.2
                3/4                 10.2         20.4   to   40.8
                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 (split-phase), 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 engine-driven 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 meter.


3.   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                ,!'I.C
                                                     EXCITATION                               FIELD         M
                                                                                                            M

BEARING                                           RECTIFIER                                     RECTIFIER
                                    

           I~R~TURE
                                        AC                                      AC




                  I~ITERNAL
                  3 ~,4   3 \~IRE
                  120/240
                                        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 sub-bas'
     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 re-circulation 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   COA~JER   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




                      WARNING
Air in generator compartment should not
exceed 100 degrees F. If higher tempera-
tures are expected, an exhaust blower
should be installed.



                                                                             34
                      WESTERBEKE LIMITED WARRANTY
1.  Warnmty ObBg_don 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 dt:fects 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 Commercial
Generators, 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 factory
transportation costs prepaid which we adjudge defective in materials or workmanship. Alternatively. we may
reimburse at our discretion a portion of labor costs incurred to repair defective parts or products on site. I f you request
shipment of replacement parts to you prior to our determination of cause of failure, su~h shipment will be sent C.O.D.

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.   owner's 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 and/or 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 tune-up, 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 product.

5.          of Warrnnty
        WARRANTY IS IN LIEU OF ALL OTHER EXPRESS \VARRANTIES. ANY \VARRANTY
IMPLIED BY LAW, INCLUDING \VARRANTIES OF fv1ERCHANTABILITY OR FITNESS, IS IN EFFECT
ONLY     THE DURATION OF THE EXPRESS WARRANTY SET FORTH IN THE FIRST PARAGRAPH
ABOVE. NO REPRESENTATIVE 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 DAMAGES
RESULTING FROM THE USE OR INSTALLATION OF ITS PRODUCrS.
SOl\1E 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                                                                                                           6/1/8-3
                                                         35


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