Westerbeke 10TWO User manual

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:

4444

~------

C.ALI

FOREWORD

Thank

you

for

having

selected

Westerbeke

Diesel

Engine

for

your

use.

This

manual

describes

the

procedures

for

proper

handling

and

maintenance

both:

(a)

Horsepower

Marine

Propulsion

Engine

(b)

Marine

Generator

Set

obtain

best

operating

condition

and

longest

life,

important

use

sensibly

and

carry

out

operatiorl

and

maintenance

according

this

manual

•.

you

have

questions

about

your

equipment

the

event

failure,

please

contact

your

nearest

distributor

dealer.

look

forward

your

continued

patronage.

TABLE

CONTENTS PAGE

GENERAL

SPECIFICATIONS

••••••••••.••••

CAUTIONS

HANDLING ENGINE

••••••••••

1 • B

REA

KIN

GIN

• • • • • • •

•

• • • 0

• • • •

••

PREPARATIONS

.....................

STARTING PROCEDURES

•.••...•.••••

STOPPING PROCEDURES

.••••.••.••••

CAUTIONS

STARTING

AND

OPERATION

•••

••

.........

REQUIREMENTS FOR PROPER

OPERATION

6-1

Lubrication

System

•.•..•••.

6-2

Fuel

System

•.•••••••.••••••

6-3

Cool

System

..•••.•••••••

6-4

Wiring

iagram~~

•••••.••..•

6- 5

Bel

t 'r

ens

ion.

• " e _ •

• • •

• •

6-6

Domestic

Hot

Water

.••••.•.•

RECOMfRIENDED

MAINTENANCE SERVICE

.19

8.. TRANSMISSIONS..

• •

...

...,

..............

TROUBLESHOOTING

.....

•••••••

SERVICE

DATA

..................

......

TABLE

TIGHTENING TORQUES"

..•

12.

INSTRUCTIONS:

3KW

GENERATOR

SET.25

14.

STOPPING

PROCEDUP~.e~o

••••••••••

15..

WIRING

DIAGRAM

............

...................

EXPLODED VIEW

GENERA

fI1

PORTION

GENERAL

INFORMATION ELECTRICAL

••

19..

MAl

NlfENANCE

............

" ........

........

,,32

20.

INTERNAL WIRING

DIAGRAM

..........

21.

LIMITED

WARRANTY

•••••••••.•.•.••

GENERAL

SPECIFICATIONS

ENGINE

Type

Vertical

cycle,

water

cooled

No.

cylinders

Two

Bore

stroke

(inches)

2.56

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

diesel

Governor

Centrifugal

weight

type

Lubrication

system

Pressure

trochoid

pump

Oil

filter

Paper

type,

engine

mounted

Engine

oil

capacity

quarts

Cooling

system

Forced

circulation

through

heat

exchanger

Electric

starter

volt,

horsepower

Alternator

ampere,

volt

Glow

plugs

Sheathed

quick

heat

type

Battery

capacity

Recommend

amp

hour

Generator

type

Insulation

GENERATOR

pole,

revolving

regulated,

self

excited,

slip

design

Class

armature,

inherently

limiting,

rectifier

rings,

single

bearing

INSTALLATION

AND

SUPPLY CAUTIONS

Check

important

aspects

installation

before

operating

engine

(1)

Alignment

(Error

than

one

thousandth

inch

per

inch

coupling

diameter)

(2)

Provide

sufficient

ventilation

(3)

Provide

around

clauses)

adequate

service

room

engine

(See

warranty

003

FEELER

GAGE

CHECKING

COUPLING

ALIGNMENT

Fill

fuel

tank

with

CLEAN

diesel

from

reputable

manufacturer.

Fill

lubricating

oil

full

mark

dipstick

(Select

readily

available

lubricating

oil

grade

CD).

Fill

water

with

suitable

mixture

water

and

antifreeze

suit

your

temperature

zone.

See

page

16.

Plug-in

Panel

Harness

Connection.

After

assembly,

joint

should

taped

prevent

corrosion

or,

preferably,

assembled

using

sili-

con

grease

which

can

obtained

electronic

store

such

Radio

Shack.

SAFETY PRECAUTIONS

Never

operate

engine

with

inadequate

ventilation.

not

touch

moving

parts

during

operation.

not

touch

hot

parts

such

exhaust

pipe,

and

not

place

com-

bustible

materials

near.

Inspect

and

adjust

parts

the

engine

only

after

stopped.

Check

and

refill

engine

oil,

cooling

water

and

fuel

after

the

engine

brought

stop.

checking

the

water

level

for

refilling,

remove

the

pressure

cap

only

after

the

water

temperature

has

fallen

enough

prevent

steam

burn.

Always

use

tools

that

fit

cor

rectly

and

use

caution

dur

ing

ser-

vicing.

* Be

sure

that

current

carrying

wires

are

protected

from

abrasion

and

that

all

connections

are

tight.

BREAKING IN

YOUR

NEW

ENGINE

While

your

engine

has

had

individual

test

operations

sufficient

demonstrate

accurate

assembly

and

correct

operation

all

systems,

still

requires

break

time~

Service

life

your

engine

dependent

how

your

engine

operated

and

serviced

during

the

initial

twenty

hours

operation.

Your

new

engine

needs

twenty

hours

conditioning

operation

for

breaking

each

moving

part,

thus

maximizing

performance

and

life

eng

Ine.

Perform

this

condi

tioning

carefully,

keeping

the

following

points

mind.

Start

engine,

run

idle

while

checking

that

all

systems

are

functioning

sea

water

pump,

oil

pressure,

battery

charge.

Warm

eng

ine,

preferably

running

propeller

fast

idle

while

tied

down,

until

water

temperature

gauge

moves

into

the

130

140

degree

range.

Then

use

engine

moderate

load

(60%

±)

for

first

five

hours.

Avoid

rapid

acceleration.

Use

caution

not

overload

engine.

Grey

black

smoke

sign

overload.

fifteen

hours

may

run

75%

load.

Explanation:

"Breaking

in"

a new

en~ine

basically

seating

the

piston

rings

the

cylinder

walls.

This

not

accomplished

long

per

iods

runnIng

idle,

nor

early

running

under

full

load,

nor

varying

loads

with

intervals

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.

indicated

above,

use

short

warm

idle

and

put

engine

under

moderate

load

and

speed

for

the

first

five

hours

operationo

For

the

fifteen

hours,

use

approximately

70%

load.

'rhis

kind

careful

operation

will

result

best

results

from

your

engine&

PREPARATIONS

Take

steps

shown

below

starting

your

engine

for

the

first

time

after

prolonged

shut-down.

Fill

your

engine

with

oil

near

the

upper

limit

the

dipstick.

Use

good

grade

oil

with

API

specification

better.

For

quantity

oil,

you

may

refer

the

General

Specifications

page.

However,

best

always

guided

dipstick

measure-

ment

angle

installation

has

some

effect.

Your

engine

supplied

with

coolant

recovery

system

which

the

following

instruc-

tions

apply:

Fill

engine

completely

the

neck

the

manifold

cap.

Then

fill

the

recovery

tank

the

bottom

level

line.

Need

for

adding

coolant

indicated

when

cold

engine

has

coolant

level

below

the

bottom

level

line.

winter

add

antifreeze

described

page

16.

Anti-

freeze

may

used

year

round

changed

annually.

Fill

the

fuel

tank

with

Diesel

fuel.

The

interior

the

fuel

tank

must

maintained

clean.

careful

not

allow

intro-

duction

dirt

when

filling

fuel

4 •

Engine

oil,

coolant

transmission

levels

should

checked

least

once

prior

engine

use.

and

day

011

filler

port

STARTING

PROCEDURES

Instrument

panel,

description

and

use

of:

......

"'"

Note

When

engine

stopped

after

use,

the

water

temperature

and

oil

pressure

gauges

may

stay

their

running

readings.

Note

When

eng

ine

used,

turn

start

swi

tch

"ON".

The

temperature

and

pressure

gauges

will

"ZERO"

and

the

volt-

meter

will

battery

voltage.

The

electric

fuel

pump,

mounted

the

engine,

will

also

begin

operate,

purging

any

air

accumulated

the

system.

Note

The

engine

now

prepared

for

starting.

STARTING

PROCEDURES

Turn

the

starter

switch

the

liON"

posi

tiona

making

ini

tial

start

after

lay-up,

fuel

filter

servicing

repairs,

allow

fuel

pump

work

lS-2S

seconds

purge

the

system

any

air.

Check

that

clutch

neutral

and

that

throttle

full

forward.

Glow

plug

preheating

with

key

1I0N

position,

push

about

1/4

inch

enough

that

voltmeter

indicates

dis-

charge.

Hold

key

depressed

posi

tion

until

glow

plugs

are

sufficiently

hot.

Table

below

for

preheating

time.

Quick-heat

type

(Yl14T)

Atmospheric

temperature

+S-C

(+41-F)

higher

+S-C

(+41-F)

-S-C

(+23-F)

-S·C

(+23-F)

lower

Limit

continuous

use

Proper

glow

plug

function

indicated

vol

tmeter

drop

when

key

depressed

This

drop

will

slight

but

dis-

cernible_

voltage

drop

noted,

may

indicate

defecti

glow

plugs

faulty

preheat

circuit

(check

for

loose

connection).

Preheating

Approx.

minute

time

sec.

sec

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