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: 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
fI1
0R PORTION .. 30
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 type
Insulation
GENERATOR
4 pole, revolving
regulated, self
excited, AC slip
design
Class F
3
armature, inherently
limiting, rectifier
rings, single bearing

INSTALLATION AND SUPPLY CAUTIONS
* Check important aspects of installation before operating engine .
(1) Alignment (Error to be no more
than one thousandth of an inch
per inch of 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 #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
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
transmission levels should
checked at least once a
prior to engine use.
and
be
day
6
011 filler port

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
+S-C (+41-F)
or
higher
+S-C
(+41-F)
to -S-C (+23-F)
-S·C (+23-F) or lower
Limit of continuous use
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
Preheating
Approx.
10
Approx.
20
Approx.
30
1 minute
time
sec.
sec.
sec ..

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.
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
This

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
battery is fully charged.
Check that the
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.
20·C (6S·F) or higher
SAE 30 or 1~W-30
SAE 20 or 10W-30
S·C (41·F) 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:
Note B:
After market filters are not recommended since the
material standard or diameters of important items might
be entirely different from genuine parts.
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
2.
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.
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-
tings for either hose or metal
tubing~ Mount in an accessible
place, inspect often and drain
off water accumulation fre~
quently ..
13
WATER LEVEI,
INDICATOR-
--~" .. ,,,,,~-,,-,,,,,,,,,-,,,-,,,-,,-
RING

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
5«C (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