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

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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 ..