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' Westerbeke Marine Engine Installation Manual'

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2nd Edition
May 2004
Diesel engine exhaust and some of
its constituents are known to the
State of California to cause cancer
birth defects and other
reproductive harm
n gasses contain Carbon Monoxide an odorless and
colorless gas Carbon Monoxide is poisonous and can and death Symptoms of Carbon Monoxide expo
sure can include
Dizziness Throbbing in Temples
Nausea Muscular Twitching
Headache Vomiting
Weakness and Sleepiness Inability to Think YOU OR ANYONE ELSE EXPERIENCE ANY OF THESE SYMPTOMS
seek medical attention Shut down the unit and do not restart until
it has been inspected and A WARNING DECAL is provided by
WESTERBEKE and should be fixed to a
bulkhead near your engine or generator
WESTERBEKE also recommends installing
quarters of your vessel
They are inexpensive and easily
obtainable at your local marine store
Read this safety manual carefully Most accidents are caused
by failure to follow fundamental rules and when dangerous conditions exist and take the
WARNING Fire can cause injury or precautions to protect yourself your your machinery Prevent
flash fires Do not smoke or permit flames or
The following safety instructions are in compliance with sparks to occur near the carburetor fuel line filter fuel
the American Boat and Yacht Council ABYC standards pump or other potential sources of spilled fuel or fuel
vapors Use a suitable container to catch all fuel when
PREVENT ELECTRIC SHOCK removing the fuel line carburetor or fuel filters
Do not operate with a Coast Guard Approved flame
WARNING Do not touch AC electrical connections arrester removed Backfire can cause severe injury or
while engine is running or when connected to shore
Do not operate with the air removed
power Lethal voltage is present at these connections Backfire can cause severe injury or death
Do not smoke or permit flames or sparks to occur near the
Do not operate this machinery without electrical fuel system Keep the compartment and the enclosures and covers in place
tor clean and free of debris to minimize the chances of
Shut off electrical power before accessing electrical fire Wipe up all spilled fuel and engine oil
equipment Be aware diesel fuel will burn
Use insulated mats whenever working on electrical
Make sure your clothing and skin are dry not damp
particularly shoes when handling electrical equipment
Remove wristwatch and all jewelry when working on
WARNING Explosions from fuel vapors can cause
injury or death
electrical equipment
Do not connect utility shore power to vessels AC
circuits except through a shiptoshore double throw Follow refueling safety instructions Keep the vessels
transfer switch Damage to vessels AC generator may hatches closed when fueling Open and ventilate cabin
result if this procedure is not followed after fueling Check below for fumesvapor before
running the blower Run the blower for four minutes
Electrical shock results from handling a charged capacitor before starting your engine
Discharge capacitor by shorting terminals together
All fuel vapors are highly explosive Use extreme care when
PREVENT BURNS HOT ENGINE handling and storing fuels Store fuel in a
area away from equipment and out of the
WARNING Do not touch hot engine parts or
reach of children
Do not fill the fuel tanks while the engine is running
exhaust system components A running engine gets very
Shut off the fuel service valve at the engine when servicing
the fuel system Take care in catching any fuel that might
spill DO NOT allow any smoking open flames or other
Always check the engine coolant level at the coolant sources of fire near the fuel system or engine when
recovery tank servicing Ensure proper ventilation exists when servicing
the fuel system
WARNING Steam can cause injury or death Do not alter or modify the fuel system
Be sure all fuel supplies have a positive shutoff valve
In case of an engine overheat allow the engine to cool Be certain fuel line fittings are adequately tightened and
before touching the engine or checking the coolant free of leaks
Make sure a fire extinguisher is installed nearby and is
properly maintained Be familiar with its proper use
Extinguishers rated ABC by the NFPA are appropriate
for all applications encountered in this i
WARNING Accidental starting can cause injury WARNING Carbon monoxide CO is a deadly gas
or death
Ensure that the exhaust system is adequate to expel gases
Disconnect the battery cables before servicing the engine discharged from the engine Check the exhaust system
generator Remove the negative lead first and reconnect regularly for leaks and make sure the exhaust
it last elbow is securely attached
Make certain all personnel are clear of the engine before Be sure the unit and its surroundings are well ventilated
starting Run blowers when running the generator set or engine
Make certain all covers guards and hatches are re Do not run the generator set or engine unless the boat is
installed before starting the engine equipped with a functioning marine carbon monoxide
detector that complies with ABYCA24 Consult your boat
BATTERY EXPLOSION builder or dealer for installation of approved
WARNING Battery explosion can cause injury For additional information refer to ABYC T22
or death educational information on Carbon Monoxide
Do not smoke or allow an open flame near the battery WARNING Carbon monoxide CO is an invisible
being serviced Lead acid batteries emit hydrogen a odorless gas Inhalation produces flulike symptoms
highly explosive gas which can be ignited by electrical nausea or death
arcing or by lit tobacco products Shut off all electrical
equipment in the vicinity to prevent electrical arcing Do not use copper tubing in diesel exhaust systems Diesel
during servicing fumes can rapidly destroy copper tubing in exhaust systems
Never connect the negative battery cable to the Exhaust sulfur causes rapid deterioration of copper tubing
positive connection terminal of the starter solenoid resulting in exhaustwater leakage
Do not test the battery condition by shorting the terminals Do not install exhaust outlet where exhaust can be drawn
together Sparks could ignite battery gases or fuel vapors through portholes vents or air conditioners If the engine
Ventilate any compartment containing batteries to prevent exhaust discharge outlet is near the waterline water could
accumulation of explosive gases To avoid sparks do not enter the exhaust discharge outlet and close or restrict the
disturb the battery charger connections while the battery flow of exhaust Avoid overloading the craft
is being charged
Although diesel engine exhaust gases are not as toxic as
Avoid contacting the terminals with tools etc to prevent
exhaust fumes from gasoline engines carbon monoxide
burns or sparks that could cause an explosion Remove gas is present in diesel exhaust fumes Some of the
wristwatch rings and any other jewelry before handling symptoms or signs of carbon monoxide inhalation or
the battery poisoning are
Always turn the battery charger off before disconnecting Vomiting Inability to think coherently
the battery connections Remove the negative lead first
and reconnect it last when servicing the battery Dizziness Throbbing in temples
Headache Muscular ACID Nausea Weakness and sleepiness
WARNING Sulphuric acid in batteries can cause AVOID MOVING PARTS
severe injury or death
When servicing the battery or checking the electrolyte
WARNING Rotating parts can cause injury
or death
level wear rubber gloves a rubber apron and eye protec
tion Batteries contain sulfuric acid which is destructive If Do not service the engine while it is running If a
it comes in contact with your skin wash it off at once with situation arises in which it is absolutely necessary to make
water Acid may splash on the skin or into the eyes inad operating adjustments use extreme care to avoid touching
vertently when removing electrolyte caps moving parts and hot exhaust system
Do not wear loose clothing or jewelry when servicing ABYC NFPA AND USCG PUBLICATIONS FOR
equipment avoid wearing loose jackets shirts sleeves
rings necklaces or bracelets that could be caught in INSTALLING DIESEL ENGINES
moving parts Read the following ABYC NFPA and USCG publications
for safety codes and standards Follow their
Make sure all attaching hardware is properly tightened
when installing your engine
Keep protective shields and guards in their respective
places at all times ABYC American Boat and Yacht Council
Safety Standards for Small Craft
Do not check fluid levels or the drive belts tension while
the is operating Order from
Stay clear of the drive shaft and the transmission coupling
when the engine is running hair and clothing can easily be 3069 Solomons Island Rd
caught in these rotating parts Edgewater MD 21037
NFPA National Fire Protection NOISE Fire Protection Standard for Motor Craft
Order from
WARNING High noise levels can cause hearing NFPA
loss 11 Tracy Drive
Avon Industrial Park
Never operate a generator without its muffler installed Avon MA 02322
Do not run an engine with the air intake silencer USCG United States Coast Guard
removed USCG 33CFR183
Do not run engines or generators for long periods with
Order from
their enclosures open US Government Printing Office
Washington DC 20404
WARNING Do not work on machinery when you
are mentally or physically incapacitated by MANUAL
Many of the preceding safety tips and warnings are repeated
in your Operators Manual along with other cautions and
notes to highlight critical information Read your maintain your equipment and follow all ENGINE AND GENERATOR to install an engine should begin
with a
thorough examination of the American Boat and ABYC standards These standards are a
combination of sources including the USCG and the of the ABYC standards of particular interest are
H2 Ventilation
P1 Exhaust Systems
P4 Inboard Engines
E9 DC Electrical Systems
All installations must comply with the Federal Code FCR
installing WESTERBEKE engines and generators it is important that be paid to the following AND federal regulations ABYC guidelines and safety codes
must be complied with
when installing engines and generators in a marine installations where the exhaust injected exhaust elbow is close to
or will be below the vessels waterline provisions must be made to install a siphon
break in the raw water supply hose to the exhaust elbow This hose must be looped a
minimum of 20 above the vessels waterline Failure to use a siphonbreak when
the exhaust manifold injection port is at or below the load waterline will result in
raw water damage to the engine and possible flooding of the boat
If you have any doubt about the position of the exhaust elbow relative
to the vessels waterline under the vessels various operating conditions install A siphonbreak requires periodic inspection and cleaning to ensure
Failure to properly maintain a siphonbreak can result in damage Consult the siphonbreak manufacturer for proper SYSTEM
The exhaust hose must be certified for marine use The system must be designed to
prevent water from entering the exhaust under any sea conditions and at any angle AVAILABLE FROM
of the vessels hull YOUR WESTERBEKE
A detailed 40 page Marine Installation Manual covering gasoline and
diesel engines and generators is available from your WESTERBEKE
TABLE OF Fuel System Installation Codes and Safety Fuel Tanks General Recommended Reading
Fuel Tanks Product Software Fuel Tanks Located Above The 25
Notes Cautions and Warnings Fuel Tanks Located Below The 25
Inspection of Shipment Gasoline Engine Fuel Location and Mounting Diesel Fuel System AntiSiphon
Devices Engine Location Dual Purpose Fuel Tank Engine Bed Fuel SSB Grounding
Rigid Fuel Lines Engine Flexible Fuel Lines
ShutOff Valves Location and Mounting
Fuel Filters Generator Generator Mounting
SOUND Cooling System Raw Water
Intake and Lifting Raw Water Outlet Shaft Alignment
Propeller Shaft Coupling Engines Coolant Recovery Flexible Couplings Coolant
Engine Oil Selection Oil System
Oil Drain Hose Recommended Guidelines Oil Dipstick Water Separator Exhaust
Pressure Sensing Dry Stack Exhaust Systems Relocating Engine Parts Exhaust Back Pressure Remote Oil
Filter Exhaust Installation Exhaust Elbow Precautions Ventilation System Water Heater
Installation DC Electrical Connections Control Panels for
Propulsion Engines Transmission Diesel Generator Instrument Transmission Optional
Instrument Panel Gasoline Optional Remote StartStop Panel
Fluid Diesel and Gasoline Generators Control Cables ZF Control Wiring Borg Warner Velvet
AC Wiring Installation Final Check Wire Sizing Chart Metric Conversion Chart Admiral Control Panel
Captain Control Panel 1
marine Installation Manual covers all WESTERBEKE Within the CFRs are the detailed requirements and Generator models both diesel and
gasoline The to boats with gasoline engines The majority of of this manual is to provide boatyards and installers pertinent to
recreational vessels are contained in 33 CFR
who are already familiar with installation procedures addi Part 183
tional detailed installation instructions to ensure the safest
and most efficient operating conditions These instructions Subpart IElectrical Systems vary due to the many WESTERBEKE Engines and
Subpart JFuel Systems available and the diversity of boat designs Subpart location and
installation of the engine or generator in Standards for marine carburetors and the requirements for the
the vessel are of prime importance Factors in the installation backfire flame arrester are contained in 46 CFR Subparts
that must be considered are 2535 and 5810 Also within Subpart 5810 are the exhaust
manifold and exhaust system requirements for both gasoline
1 Ventilation to provide air for engine combustion and and diesel engine Several publications that
to remove heat produced by the while address these federal mandates making compliance easier
operating include
2 Exhaust System to properly discharge cooling water The USCG Fuel System Electrical System and
quiet the exhaust and expel exhaust gas Install a Ventilation Compliance Guidelines
The USCG Safety Standards for Backyard Boat Builders
3 Cooling Water Supply to cool the engine with a
continuous flow of filtered raw water The National Fire Prevention Association NFPA302
Fire Protection Standard for Pleasure and Commercial
4 Fuel System to provide an unrestricted fuel supply and Motor Craft
properly filtered fuel to the fuel pump
The ABYC Standards and Recommended Practices for
5 Electrical Connections both AC and DC and proper Small Craft
The ABYC Standards Manual is the most comprehensive and
6 Transmission Propeller Connections Engines only widely used reference ABYC constantly revises and read this manual carefully and
observe the safety its projects as it calls each topic section The manual Should your engine or generator require easy
to read and quite detailed Adherence with contact your WESTERBEKE dealer For Serial standards will put the recreational boater in
compliance with
Number location Decal information or Parts Ordering federal mandates Anyone considering installing an refer to your WESTERBEKE
Operators or generator should start with a thorough review of these
Manual standards
of Boats Using CODES AND SAFETY STANDARDS Fuel publications concerning Safety Codes and
of Exhaust are listed in this safety section Following is a P4Marine Inboard of what these standards include Both the US
E9DC Electrical Systems Under 50 Volts
Code USC which are the laws passed by Congress and the USCG inspected vessels especially those carrying
Code of Federal Regulations CFR which are agency passengers for hire are required to meet even more rules contain pertinent
information standards than those discussed above A very 46 Chapter 43 of the USC applies specifically to review
of the applicable CFRs is necessary before the vessels It gives the Secretary of Guard arrives for their authority to set the standards for
boats that and operated in the United States It also spells Recommended Reading
out the penalties for violation of the standards For added information on installing Marine Engines and
According to Title 46 USC 4307 a person may not Generators WESTERBEKE recommends the construct assemble offer for sale introduce
into interstate commerce or import into the United States Elements of Yacht Design Skene
any recreational vessel that does not comply with the federal Marine Engines Any associated equipment or component used on
The Propeller Handbook Gerr
one of these vessels must also be in compliance Further a
person is prohibited from operating any vessel that does not
comply with the 2
SOFTWARE INSPECTION OF software tech data parts lists manuals brochures The is shipped
from the factory securely
and catalogs provided from sources other than mounted and properly crated Accessory equipment is
WESTERBEKE are not within WESTERBEKEs control shipped in a separate small box usually packed within the
CONTENT OF SUCH SOFTWARE MAKES NO Before accepting shipment of the engine from OR WITH RESPECT
company the crate should be opened and the
THERETO INCLUDING ACCURACY TIMELINESS OR contents inspected for damage If there is either visible THEREOF AND WILL IN NO
EVENT concealed damages you should require the delivery agent to
receipt Also compare the contents of the shipment against
OF THE FURNISHING OR USE OF SUCH SOFTWARE the packing list and make sure that any discrepancies are
properly noted This is your protection against loss or
WESTERBEKE customers should also keep in mind the damage Claims concerning loss or damage must be made to
time span between printings of WESTERBEKE product the carrier not to WESTERBEKE and the unavoidable existence of manuals In
summation product software NOTE For safety reasons the engine is NOT filled with
provided with WESTERBEKE products whether from lubricating oil for shipment Before leaving the or other suppliers must not and
cannot be however each is thoroughly tested with oil
relied upon exclusively as the definitive authority on the in its engine This testing among other things provides product It not only makes
good sense but is internal parts with a coating of oil This oil acts as a
imperative that appropriate of preservative providing reliable protection against or the supplier in question be consulted to
for at least one year if the is the accuracy and currentness of the product being consulted by the CAUTIONS AND
As this manual takes you through the installation your critical information will be high
lighted by NOTES CAUTIONS and WARNINGS An operating procedure essential to note
CAUTION Procedures which if not strictly
observed can result in the damage or destruction of
your engine
WARNING Procedures which if not properly fol
lowed can result in personal injury or loss of life
ENGINE LOCATION AND LOCATION Many boat manufacturers are now providing preformed
fiberglass mounting beds for their engine These
The overall layout of the engine room should be planned for beds when used should be of sufficient thickness for proper
easy inspection servicing and handling of the engine support and should be wellglassed to the hull when study all the equipment to be
installed and make
a paper plan to provide optimum engine room space Avoid the temptation to install the engine on a pair of the following
irons glassed in place Such a construction will allow
1 Ventilation Since an increase in engine room vibration to pass through to the hull Flexible engine
temperature causes a reduction in the intake air and thus a mounts require a firm foundation
drop in engine output ventilation inside the engine room
must be ample See your Operators Manual for the
ventilation requirements for your a Dimension and capacity with a ventilator installed
b Dimension and capacity with an intake duct
2 Engine Room Height For engines having a top oil fill
the distance from the oil cap at the top of the rocker cover
to the overhead must be enough that oil can easily be
3 Space to move the propeller shaft flange Allow
approximately 3 4 in 77 100 cm of space to move
the flange toward the stern for changing the etc
4 Exhaust System Make sure there is adequate space for
all exhaust system components including the exhaust
silencer See the BASIC EXHAUST SYSTEMS section in
this BED
A strong mounting bed contributes to the and operating of the engine The bed must be
rigidly constructed and neither deflect nor twist when it is
subjected to the engines weight or to the pressures that the
boat may experience while operating in rough seas The bed
must be strong enough to keep the engines alignment within
one or two thousands of an inch at all times The bed has to
withstand the forward push of the propeller shaft It is also
critical that the beds are parallel to one another and to the
line of the propeller shaft when viewed from above They
also must be offset an equal distance from the line of the
propeller shaft
In fiberglass hulls we recommend that solid wooden similar to those in wooden hulls be formed and
fitted then glassed securely to the hull This will allow the
hanger bolts to be installed firmly in the wood noise and transmitted vibration When preparing the engine load also plan
out and build an
engine drip pan To simplify cleaning up after oil changes
The stringers must be as wide or wider than the engine
consider a separate drip pan for use under the oil and fuel
mounting isolator Avoid excessive height Isolator overhang
rounded stringer surfaces are detrimental to the
flexible mounts ability to retain between the bed stringers and supports extending at SSB angles from the stringers to the hull may be
required for If your boat needs a ground plane for a radio and other
proper strength and to aid in the absorption of vibrations electronic gear this is the ideal time to bond a engine bed must be constructed
so that a wrench can be area of copper mesh into the base of the engine space while
set at the engine base to retighten the engine mounting bolts it is the mounting feet
ENGINE LOCATION AND MOUNTING The engines mounting angle cannot exceed 15L from the
horizontal plane Refer to the specification section in your
Bronze or stainless steel hanger bolts of appropriate size are
operating manual for the angle limit of your for use through the engines flexible mounts
Less preferred are lag screws because their hold on the wood NOTE There are various transmissions that provide down
is weakened every time they are moved whereas hanger angle output flanges to help in positioning the engine on a
bolts stay in position If the nut on top of the hanger bolt is more level to allow the engine to be lifted the hanger bolt
itself remains in place as a stud Consequently the bond
between the hanger bolt and the wood is not weakened by
the removal of the nut or the engine
To screw a hanger bolt onto a stringer thread two nuts onto
the hanger bolt jam them together then turn the hanger bolt
into the stringer using a wrench on the uppermost nut
A solid level mounting platform is very important for the Generator mounting rails have numerous predrilled bolt
proper operation of your generator Select a location that will holes to ensure that the generator is properly positioned and
allow adequate space on all sides for ventilation and secured to its mounting preferably on and parallel with the keel or vessel
center line Keep the generator away from living quarters
and away from bilge splash and vapors
Make sure there is room to access the following Negative and positive battery connections
Fuel inlet and outlet connections
Oil fill and oil drain hose
Raw water inlet and outlet
Location of the owner supplied fuelwater fuel filter
A generator will rock on its mounts in rough seas is necessary on all sides Larger generators require
up to a threeinch 76mm supporting the generator from bulkheads which can
create drumming effects and transmit noise and the location is preferable in the same room as the propulsion engine as this is usually a
well ventilated area insulated close to the fuel supply and
the center of the electrical load distribution However a
generator cannot be installed in the propulsion unless specific conditions are met
USCG regulation 33CFR183 pertains to gasoline fuel
systems and requires a generator operating in a gasoline to be ignition protected This means a
generator capable of operating in an explosive igniting that environment Properly installed and
operated a WESTERBEKE gasoline generator can operate
in an explosive WARNING Gasoline fire or explosion can result in
severe personal injury or death Do not install a
gasoline generator in the same room or compartment as
a diesel engine or generator The diesel unit may not be
ignition protected and may ignite gasoline fumes Be
sure a gasoline generator is installed in its own room or
compartment on a diesel powered boat
Do not install a diesel generator in the same room or
compartment as a gasoline engine
SOUND are custom designed sound enclosures for each model
of WESTERBEKE generators The Sound Guard is a easy to clean enclosure that reduces the to a pleasant hum The enclosure can be in close action
fittings allow for easy access for inspection or
routine maintenance of the generator If major repairs are
needed all the panels can be disassembled in a few minutes
No tools Guard is prepackaged with the skirt and to assure a safe arrival and easy provides the necessary fittings hoses for water exhaust fuel
and a quiet dependable sound enclosure contact dealer
The is fitted with lifting eyes Attach wire If it becomes necessary to hoist the or chain slings capable of supporting the engine
frontend pulleydrive belt end upwards or rearend weight to the eyes and lift the by end upwards the attachment of lifting
means of tackle attached to these slings The lifting eyes have slings must be done carefully to avoid damaging the parts on
been designed to carry the full weight auxiliary slings are which the weight of the slings may bear
not necessary
NOTE Rigging work is best done by someone experienced
and competent in handling heavy machinery
WARNING Sings must NOT be so short as to place
stress on the lifting eyes A sling must be long enough so
that its angle to the vertical plane does not exceed 10
The general rule in moving an is to ensure
that all equipment used is adequately strong and firmly fixed
in place Move the a little at a time and
make sure it is firmly supported Eliminate the possibility of
accidents by avoiding haste Do not lift by the WARNING Make certain all personnel stand clear
during lifting and lowering certain situations it may be necessary to lift in positions other than the Certain situations require it to be lowered
a small hatchway which cannot be made larger If
the opening of the hatchway is extremely small it is possible
to reduce the outside dimensions of the by
removing external components such as the cooling the heat exchanger certain filters the mounting rails
on generators and other obstructive components These
should be removed by a competent mechanic and special
care should be taken to avoid damage to any exposed parts
Be careful not to allow dirt to enter any openings created by
the removal of equipment Reinstall the components in positions after the engine is in its installation area
Replace gaskets as needed for the parts that were removed
A propeller shaft halfcoupling is available for all It is bored to shaft size for the specific order and has
either a keyway with set screws and two locking bolts or is
of the clamping type with a keyway
This coupling is carefully machined to allow a onto the shaft and to make an accurate between the coupling and the output flange of forward end of
the propeller shaft has a long Any burrs should be removed from the shafts end
The coupling should be a light drive fit onto the shaft and
the shaft should not have to be scraped down or filed in order
to get a fit It is important that the key be properly fitted to
both the shaft and to the coupling The key should fit the side
of the keyway closely but should not touch the top of the
keyway in the hub of the coupling
If driving the coupling over the shaft is difficult the coupling
can be expanded by heating it in a pail of boiling water The
face of the propeller coupling must be exactly the center line axis of the propeller shaft Have a
machine shop fit the coupling and face the coupling so that
the mating surface of the flange is at a perfect right angle to
the propeller shaft
After driving the coupling over the shaft remove the two
locking bolts from the coupling and countersink the shaft
below each locking bolt hole Insert and tighten the two
bolts then wire the two bolt heads together with This will secure the coupling to the shaft security a stainless hose clamp can be the coupling
shoulder and over the two bolt heads
These illustrations show typical propeller shaft with variations on stuffing
boxes and stern tubes The
propeller shaft on the boat with the spade rudder is supported
by the stern tube An external strut supports the shaft on the
A flexible coupling or a drive saver can be the WESTERBEKE shaft coupling and coupling to reduce vibration and absorb thrust
and torque This is an important consideration when engine mounts Follow the and
PROPELLER SHAFT engine must be exactly aligned with the propeller shaft
No matter what material is used to build a boat the material
will be flexible to some extent The boats hull will change
its shape to a greater extent than is usually realized when the
boat is launched and operated in the water Therefore it
becomes extremely important to check the at frequent intervals and to correct any errors
when they between the engine and the propeller shaft The alignment is correct when the propeller shaft can be
often creates serious problems which are often blamed on easily slipped backward and forward into the areas suspected of causing the
trouble Misalignment and when a feeler gauge indicates that the flanges come
will cause excessive bearing wear rapid shaft wear and will together at all points The alignment between the propeller
in many cases reduce the life of the boats hull by loosening shaft halfcoupling and the transmisson halfcoupling can
the hulls fastenings A bent propeller shaft will produce these contain an error no greater than 001in 25 mm per inch of
same effects therefore a perfectly straight propeller shaft is the coupling diameter For example if your propeller necessary One result of
misalignment may be halfcoupling is 3 76mm in diameter the maximum error
leakage of transmission oil through the rear oil that can be allowed in the alignment is 003 in If oil should leak from this seal check and
make sure
that the alignment is within the limits attempt a final alignment when the boat is on land
The boat should be in the water and have had an assume its final water form The propeller coupling alignment is best performed with the
fuel and water tanks about half full with all the on board and on sailboats after the mainmast
has been stepped and the final rigging has been sufficient time to make this alignment dont be
satisfied with less than perfect results
In making the final check for alignment the transmisson
halfcoupling should be held in one position and the align
ment with the propeller shaft halfcoupling tested with the
propeller shaft halfcoupling in each of four positions A
while rotated 90 between each position This test will also
check whether the propeller shaft halfcoupling is in exact
alignment on its shaft Then keeping the propeller shaft
halfcoupling in one position the alignment should be
checked by rotating the transmission halfcoupling in 90L
increments checking dimension A while in each 90L
position until it has been rotated fullcircle
The engines alignment should be rechecked after the boat
has been in service for one to three weeks and if necessary
the alignment performed again Usually it will be found that
the engine is no longer in alignment This does not mean that
the first alignment has been done improperly rather it means
that the boat has taken some time to take its final shape and
that the engines bed and stringers have probably absorbed
some moisture It may even be necessary to realign the
coupling halves again at a later time
The type and size of propeller varies with the gear ratio and
must be selected to fit the application based upon boat tests
To utilize the full power of the engine and to achieve ideal
loading conditions use a propeller which will permit the
engine to reach its full rated rpm at full throttle while under a
normal load and while the boat is moving forward through
the water
The following information is needed to calculate and match a
marine propeller to a boat
a The engine output in hp
b The maximum rpm of the engine
c The reduction of the d The maximum hull speed of the boat
e The type of boat and its f The waterline length LWL
Most propeller shops now have computer programs that will
analyze all this data and select the propeller choices in
number of blades diameter and pitch Inwater is always the final answer
For more information on propellers read The by Gerr published by International 11
EXHAUST SYSTEM GUIDELINES Sea Water Intrusion Through The Exhaust Outlet
These guidelines dated February 2004 supercede all The diagram above illustrates a below waterline guidelines published by
Westerbeke of an engine or genset The letters A through H are for all types of exhaust systems Water
important dimensions that are discussed in detail in the
intrusion is not covered by warranty because it is not following text
caused by a product defect Please study these before planning your exhaust system installation Lets start with A the difference between the
underside of the boat deck near the and these guidelines our use of the word engine is high point of the exhaust run from the water lift
muffler to
generic it refers equally to either a propulsion engine or to the the exhaust outlet A should be minimized There is every
engine driving a generator set sea water and raw water are the reason to attach the high point of the exhaust hose directly to
same the underside of the deck There is no reason to fail to take
Beyond conveying exhaust gases and cooling system sea full advantage of this maximum available height because it
water out of the boat the other purpose of the exhaust system forms the primary barrier to water intrusion
is to prevent sea water intrusion into the engine at the exhaust We need to define the water line for exhaust under all conceivable conditions of
boat trim boat purposes By water line we mean the highest point the sea conditions and heel angle while not exceeding level can
reach at the location of the exhaust through hull
the back pressure Seawater fitting from all conceivable causes other than is usually catastrophic to catalytic converters and
waves of a duration of not more than a second or two This
engines The enginegenset supplier is not in a position to worst case water level could be caused by any of the
judge what installation will prevent water following backing down aggressively turning in all conceivable That judgment is
coming up onto a plane decelerating off a plane extreme
the of the engine installer What we as the boat trim high seas wallowing in following seas can do is advise the best practice as we see
it etc Hereafter these instructions will refer exclusively to this
leaving final judgments to the installer worst case water level as the relevant water level to plan a
good 12
EXHAUST SYSTEM leads to B the amount by which the spill over point of G is the length of exhaust hose leading from the water lift
the exhaust outlet is above the worst case water level B muffler to the high point The shorter this length the lower
should be maximized and certainly always positive Then the back pressure and the greater will be the reserve capacity
the exhaust loop height C from the high point spill over inside a given water lift muffler The shorter the better but it
point to the through hull fitting spillover point becomes a is much more important to minimize A than to minimize G
back up to B for preventing water intrusion rather than being The water lift muffler should be sized to hold multiples of
the primary defense as becomes the case whenever the the volume of water that spills back from the exhaust high
exhaust outlet spillover point dips beneath the water level point when the shuts off The actual amount
of normal spill back at shut down is a function of length G
the exhaust hose inside diameter E and the sea water pump
flow rate The larger the muffler the better Remember
when all else fails and water comes pouring over the high
point only reserve capacity in the muffler can contain it and
prevent it from entering the H is the height of the engines water injected
exhaust elbow
outlet above the top of the water lift muffler This should be
maximized This length of hose is additional reserve capacity
to contain both intruding water and splashing inside the water
lift muffler
J is the total height engine exhaust gas pressure must move
water up hill from the bottom of the muffler to the spillover
point at the exhaust run high point J is driven by other
installation dimensions It results from a conservative
installation rather than being a driving factor In most
J would not exceed 4 12m this height should
produce adequate exhaust system back pressure level
But the height of C is also important The only momentary passing waves when they immerse the
exhaust outlet is the exhaust loop height C If A has C will probably be in excess of a couple of feet
The higher the better Maximize this height C because it is
your only defense against a passing wave rogue verticality D of the hose run from the high point to the
exhaust outlet is also important When a momentarily rising
water level immerses the exhaust outlet and is water velocity towards that through hull fitting it is easier
for the intruding water to rise along a sloping hose towards
the high point than to rise vertically towards that high D and keep this part of the exhaust hose as vertical
as it is desirable that angle N be a 90 degree angle
with the exhaust hose rising vertically This will water intrusion especially when backing or otherwise experiencing sea water the exhaust outlet
E is the inside diameter of the exhaust hose This should be
no less than F the outside diameter of the generators exhaust elbow E should only exceed F if back pressure requirements are not met
NOTE When the length of G is more than 20 ft increase the
hose diameter E by 12 in to relieve back pressure
WARNING Use extreme care during installation
to ensure a tight exhaust system Exhaust gases are
EXHAUST SYSTEM water Intrusion Through The Intake Seacock GeneratorNot in Operation Water means of water intrusion is though
the sea water Boat operators may be accustomed to seeing a seacock This can occur when any part of the sea engine exhaust
outlet dip beneath the water frequently when
water system or exhaust system are below the worst case underway and think this is acceptable for a generator exhaust
water level other than the seacock itself which is already outlet as well Not so When the boat is underway exhaust
below the water level of course What happens is that upon pressure keeps water out of the propulsion engine shutdown sea water siphons from
the intake seacock But when the generator is not running there is no exhaust
up through the sea water cooling circuit containing the sea pressure to keep water out of its exhaust outlet The exhaust
water pump heat exchanger and water injected exhaust outlet of engines which may not be operating when the
elbow into the water lift muffler This seawater will siphon vessel is underway sailboat engines and generators must
past the impeller of the sea water pump and fill the muffler be well above the worst case water level
and all hoses attached to the muffler until the outside water
level is reached If the engine exhaust manifold is below the Cumulative water level seawater will simply pour into the Water
intrusion between operations of the engine is a
cylinders destroying the engine cumulative process If just a little bit of water spills over the
high point but it happens many times it will fill the muffler
This form of water intrusion is avoided by the proper and endanger the engine This could easily be the case for of an anti siphon
valve in the sea water circuit power boat not using its generator or for a sailboat not using
between the sea water pump outlet and the water injected its engine If you suspect that water is intruding run the
exhaust elbow inlet Refer again to the generic drawing of a engine frequently until the suspected problem is water line installation
utilizing a and fixed
water lift muffler
NOTE Running the engine or Genset will normally preclude
water intrusion as the exhaust flow under pressure prevents
water from entering the exhaust outlet
Cranking the Starter Draining the Muffler
Prolonged cranking of the starter may cause excessive sea
water to build up between the engine and the high point
Each time cranking is interrupted additional water may spill
back into the muffler In time this cumulative spill back can
flood the engine Unusual cranking andor cranking
interruptions must be monitored and the muffler drained
before excessive water buildup occurs This may be made
more convenient by installing a suitable noncorrosive valve
at the muffler drain is the difference between the highest underside of the boat
deck near the and the anti siphon valve K
should be minimized There is every reason to attach valve directly to the underside of the deck There
is no reason to fail to take full advantage of this height because it forms the only barrier to by siphoning The anti siphon valve must be well
above the worst case water level under all conceivable condi
tions of boat trim boat operation sea conditions and heel
angle The antisiphon break and the exhaust hose point
should be located as near to the boats centerline as on sailboats due to large and steady healing The
siphon must be accessible for 14
EXHAUST SYSTEM Valves Dry Stack Exhaust types of check valves are available and suitable
for Commonly seen on commercial fishing boats dry stack
exhaust runs Examples are inline check valves offered by exhausts can also be used on trawler style pleasure boats A
some exhaust component manufacturers and flapper valves dry stack exhaust directs the exhaust gas straight from the
on exhaust outlets None of these may be considered as an generator or engine without obstructions A dry stack to a good installation They
can leak they can becomes very hot when the engine is operating and should
foul and they can open Think of them as an not be close to any combustible materials wood means to keep out that rogue wave or extreme
etc unless it is properly shielded or sea Never rely on them to stay closed for more
than a second or two Read again CUMULATIVE Make certain the exhaust and muffler are of on the previous page
diameter to clear the exhaust gasses and prevent excessive
back pressure Provisions must also be made for Separators Exhaust Systems the raw cooling water
Water separators are the latest innovation in exhaust systems After final assembly test run the generator and check all
The separator uses gravity and centrifugal force to separate connections and elbows for exhaust leaks A cooling water from the exhaust gas
and then discharges test should also be performed at this time Back pressure
then separately under the vessels hull This makes for a quiet should not exceed 15 psi 011 kgcm2
and efficient system that reduces back pressure and prevents Regulations require that the exhaust muffler be water intrusion by wave action
of aluminized steel or other corrosion resistant material and
be of welded or crimped construction An approved spark
arrestor must be installed with the muffler in gasoline
NOTE Liability for damage or injury and warranty expenses
becomes the of the person installing an exhaust
system Contact WESTERBEKE or your WESTERBEKE
dealer regarding any exhaust system separator must be securely mounted as high as A in the previous diagrams above the water lift
muffler and well above the vessels waterline in all attitudes
of discharge drain hose for the separated cooling water
must go directly and vertically down from the separator to a
thru hull fitting on the hull below the waterline This
provides a very quiet exhaust
The discharge drain hose for the exhaust gas must also go
directly and vertically down to a thru hull fitting under the
hull just above the waterline This gas discharge hose will
still contain some water to prevent this water from becoming Exhaust Back and impeding the flow of gases make certain the After
the installation is operational exhaust back pressure
hose leads down hill without any loops or dips must be measured at the outlet of the water injected exhaust
elbow Measure with an appropriate gauge or separators are manufactured by
Operate a propulsion engine underway at cruising RPM
Halyard Limited Centek Industries Inc Operate a generator at rated load As the Business Park 116 Plantation
Oak Drive operates it continuously pushes the exhaust gases and Road PO Box 3028
water thru the exhaust system up hill and overboard thru the
Whadden Salisbury SP53HF Thomasville GA Kingdom exhaust
outlet This causes significant back Excessive back pressure reduces engine power higher
temperatures and cab reduce the life of the engine
EXHAUST SYSTEM Back Pressure cont Exhaust Hose
Back pressure should not exceed 15 psi or 41 WC To ensure that vibration doesnt transmit to
Excessive back pressure can be reduced by increasing E the hull most installations use flexible rubber exhaust the size of the water
lift muffler reducing J and for the water cooled section of the exhaust line because of
reducing G However A C and B should not be compromised the ease of installation and flexibility This exhaust hose must
to relieve back pressure be marine certified Provide adequate support for the rubber
hose to prevent sagging bending and formation of water
Back pressure should not exceed the following
pockets Always use corrosion resistant carriers and 3 inches of mercury For dry or custom pipe
exhaust systems use a flexible
41 inches of water in the water column section preferably of stainless steel no less than 12 30 cm
15 psi 01 kgcm2 overall threaded at each end and installed as close to the
engine as possible This flexible section should be installed
with no bends and covered with insulating material The
exhaust line should be properly supported by brackets to
eliminate any strain on the manifold flange studs
WARNING Do not install rubber hose with sharp
bends as this will reduce efficiency Do not use rubber
hose on dry type exhaust applications Doing so may
cause hose failure and leakage of deadly exhaust gas
Make sure that the water discharge into the rubber hose
section is behind a riser elbow or sufficiently below the
exhaust flange so that water cannot possibly flow back into
the engine Also in custom systems make sure that entering
raw water cannot spray directly against the inside of the
exhaust piping Otherwise excessive erosion will occur
Dry components of the exhaust system between the exhaust
manifold and the water injected exhaust elbow must be
properly insulated to hold in the heat prior to the cooling
water being Trial
A sea trial must be conducted to confirm that no takes place either via the exhaust outlet or via the
sea water intake seacock Do not operate the engine during
the trial Disconnect the exhaust hose at the muffler outlet
and place it in an empty bucket bucket 1 Disconnect the
sea water hose entering the exhaust elbow and place it into a
second empty bucket bucket 2
Select the worst sea conditions available Operate the boat as possible putting it through as large a variety ScoopType Intake
of operating situations as you would ever encounter Operate Where generators are installed in very high speed vessels
the boat in this way for as long as possible 5060 knots it has been necessary to use a scooptype verify that no water enters
either bucket Any water intake to insure an adequate supply of cooling water to
water in bucket 1 is water intrusion via the exhaust outlet the generator Generally this is not recommended but if it
Any water in bucket 2 is water intrusion via the sea water needs to be done the generator must be mounted high
intake seacock Either instance of water intrusion shows that enough so that the exhaust piping has a installation is not adequate since you
will someday downward pitch from the muffler to the exhaust outlet in conditions worse than the sea trial hull
The pitch should be adequate so that the muffler will
continuously drain and no water can backup into the engine
see 16
EXHAUST ELBOW elbows are standard on generators optional on
For installation on your we offer
450 700 and 900 exhaust elbows
NOTE Fabricated exhaust elbows or risers attached to the
exhaust manifold shall not exceed 8 lbs when Coat only one side of the exhaust gasket with High Tack
manufactured by Permatex Company Brooklyn NY
adhesive sealant Place this coated surface against the
exhaust manifolds exhaust port flange the gasket should
stick to the flange without falling off
2 Place the clamp over the elbows flange Place your
exhaust elbow against the exhaust manifolds flange so
the exhaust manifolds flange rests snug against the
exhaust elbows flange with the gasket centered between
the two Now slip the exhaust clamp over both flanges
3 Tighten the clamp just enough so the exhaust elbow can
remain attached to the manifold and still be rotated The
exhaust elbow discharge must be directed downward so
the mixture of raw water and exhaust gases will flowfall
downward into the exhaust muffler which must be posi
tioned below the exhaust elbow There should be no loops
or rises in the exhaust hose connected between the
exhaust elbow and the muffler as these would trap water
and possibly allow water to flow back into the engine dur
ing starting or at shutdown
4 Adjust the elbow by rotating it until the desired alignment
with the exhaust piping is acquired
5 Carefully tighten the clamp between 8 to 10 lbft or 24 to
35 lbin or 027 to 041 kgm
CAUTION 10 lbft 14 kgm Torque Limit
approach the 10 lbft 14 kgm torque limit with
caution The clamps threads will break if more than
10 lbft 14 kgm is applied to the clamp
6 When the engine is started for the first time with the new
elbow check this exhaust connection for
leaks If a leak exists correct it 17
When the engines raw water is fed into an exhaust system so
Carbon Monoxide
that the full stream of this water strikes a surface erosion
The best protection against carbon monoxide poisoning is a takes place This erosion may cause premature failures The
daily inspection of the complete exhaust system Check for proper design of either a or around manifolds gaskets and welds Make sure
wet exhaust system to prevent this problem requires that
exhaust lines are not heating surrounding areas excessively the raw water inlet be positioned so that the entering stream
If excessive heat is present correct the situation immediately of raw water does not directly strike a surface In addition
If you notice a change in the sound or appearance of the the velocity of the entering raw water stream should be as
exhaust system shut down the unit immediately and have the low as possible which can be achieved by having inlet fit
system inspected and repaired at once by a qualified tings as big in diameter as
Excessive Weight
WARNING Carbon Monoxide Gas is Deadly Make sure there are no unnecessary objects suspended from
any portion of the exhaust lines Exhaust risers installed off
Carbon monoxide is a dangerous gas that can cause the exhaust manifold should not exceed 8 lbs in total weight
and is potentially lethal Some of the when rigidly constructed Excessive weight could cause
symptoms or signs of carbon monoxide inhalation or poi deflection or distortion of the manifold resulting in damage
andor internal leaks
soning are
Dizziness Throbbing in Temples Insulation
Nausea Muscular Twitching Inspect insulated portions of the exhaust system to ensure
Headache Vomiting there is no deterioration of the insulation
Weakness and Inability to Think
Sleepiness Coherently
If you experience any of the above symptoms get out Prolonged cranking intervals without the engine starting can
result in filling the exhaust system with raw
into fresh air immediately
water coolant This may happen because the raw water pump
is pumping raw water through the raw water cooling system
A carbon monoxide warning decal has been provided by during cranking This raw water can enter the engines Display this decal near
your engine or generator ders by the way of the exhaust manifold once the exhaust
on your cabin bulkhead or in some other nearby location system fills To prevent this from happening close the raw
water supply throughhull shutoff drain the exhaust It is extremely important that a carbon monoxide and correct the cause for the
excessive engine be installed in your boats living quarters Make needed to obtain a start Engine damage resulting form this
sure it is manufactured for the marine industry They are type of raw water entry is not a warrantable and easily available at your
marine 18
DC ELECTRICAL CONNECTIONS The panel can also be remote mounted by using optional
plugin extension harnesses which are available in 15 engines and generators are supplied 46 m increments A maximum of two
harnesses 30 ft
prewired and with plugin connectors Never make or break 92 m can be connected For longer distances hard while the engine is running
Carefully follow all can be used as shown in the Operators Manual An on the wiring diagram supplied especially those cover plate is
available to cover the face of the panel box
relating to fusecircuit breaker requirements Wiring diagrams when the instrument panel is remote mounted An optional
are included in your Operators Manual plate with preheat and start and stop switches is also
NOTE WESTERBEKE manufactures marine engines and available for mounting in place of the instrument panel using components that
meet very rigid safety operation at the If a component on the engine or generator is The 5776 BTD comes standard with an
instrument with one that is then the safety of for remote mounting see illustration and one 15 ft 46 m
the boat is jeopardized Make certain that any engine extension harness Preheat and start and stop switches are
component you replace is a genuine WESTERBEKE provided on the PANELS FOR PROPULSION ENGINES
Two optional control panels engines are available from are the ADMIRAL CONTROL PANEL and the
CAPTAIN CONTROL PANEl Both panels come with 15 ft
46 m of connecting harness The features of these two
panels are described in detail at the end of this GENERATOR INSTRUMENT PANELS
All WESTERBEKE diesel generators come with a instrument panel see With the exception
of the 5776 BTD they are mounted in a panel box attached
to the AC alternator The panel faces the service side of the Two instrument panels can be installed using the and can be rotated to suit
particular dual gauge sender kit This second panel must be hardwired
by the installer
An optional instrument panel is available supplied with an
engine oil pressure gauge water temperature gauge engine
mounted alternator voltage gauge engine operating
hourmeter and control switches This panel must be wired
into the terminal strip in the main control panel on the
and must be mounted in a remote location
where the instruments can be monitored and the switches
NOTE This panel must not be located in an engine or
generator compartment because it is not ignition protected
and has not been Coast Guard approved
An optional remote StartStop panel is available containing
three switches and a run indicator light green This panel
must be wired into the terminal strip in the main control
panel on the and must be mounted in a
remote location such as the vessels wheelhouse
NOTE This panel must not be located in an engine or gener
ator compartment because it is not ignition protected and
has not been Coast Guard 19
ELECTRICAL WIRING Starter batteries must be of a type which permits a high rate
of control wiring see the DC WIRE SIZING page in this
manual See your Operators Manual for cold cranking
ampere hours requirements Most marine batteries on the
NOTE All wiring should be tied down with clamps or plastic market today have large cranking capacities The battery
ties and spaced at intervals close enough to prevent chafing compartment must be well ventilated to prevent
from vibration Check to make sure all the harness connec accumulation of explosive battery gases
tions are tight and that they are made to the Mount the battery in an tray on a
above the floor It must be secured to prevent shifting If
CAUTION The electrical code will not allow DC
mounted in an engine compartment always install a
nonmetallic cover to prevent battery damage and arcing
wiring to be routed together with AC wiring from accidentally dropped tools Be sure the battery
connections are clean and tight then cover the battery
Refer to the wire size chart DC in this manual when terminals with a dielectric grease to retard the wire size to be used
between the engine control US Coast Guard regulations and Marine and remote startstop panel Use color codes to comply
Companies require that the ships batteries have a fixed cover
with ABYC Standards See your WESTERBEKE Operators or holdown straps to keep the batteries in place should a
Manual for the remote panel wiring schematic rollover occur
NOTE Generator AC load connections shore power Carefully follow the recommended wire sizes voltage adjustments and all the
necessary in WESTERBEKES wiring diagrams for the diagrams are included in your WESTERBEKE Manual
Various AC output voltages and frequencies are available for Cable Size 2 1 0 00 000 0000
your generator For these and for information Length ft 4 5 7 9 11 14
about AC wiring connections and adjustments refer to Manual Length m 12 15 21 27
34 43
The generators data plate gives the voltage current and fre
quency rating of the generator A diagram of the various AC
voltage connections is provided on the AC wiring decal that WARNING Do not connect the starting battery
is affixed to the inside of the louvered cover at the generator until installation is complete Accidental starting of the
end of the unit engine or generator could cause serious personal publications concerning
electrical and safety codes are listed in the section of this manual Make sure that all connections tests and adjustments are
by a qualified electrician Generators and propulsion engines must be grounded in
accordance with USCG regulation 33CFR183415 The
BATTERIES regulation requires that a common ground conductor be
connected between the generator and the vessels main
Starter batteries should be located as close to the engine or propulsion engines grounded cranking motor as possible to avoid voltage
drop through long
leads Install a battery disconnect switch in the B cable so The engine or generator must be bonded to the vessels
the battery can be disconnected when the is common bonding conductor with a bonding strap If a
serviced It is bad practice to use the starter batteries for other metallic fuel line is installed between the fuel tank and the
services unless they require low amperage or are intermittent shutoff valve it too must be bonded to the
In cases where there are substantial loads from lights same vessel common radios depth sounders etc it is essential to
This conductor prevents accidental passage of cranking
have a complete separate system and to provide charging current through the fuel systems and smaller for this by means of a second
alternator dual output conductors common to engines and generators This or alternator output splitter The output splitter is a
happen if a cranking motor ground circuit becomes marine accessory It comes with complete or opens from corrosion vibration
a bad cable on how it can be integrated with an 20
WARNING An improper ground can cause severe
personal injury or death from fire or explosion Be sure
to install a common ground conductor between all on
board cranking circuits
A common ground for negative DC is located at of the next to the starter in the
form of a threaded grounding stud This location is tagged It
is recommended that the battery ground be connected here
Failure to do so can cause arcing or resistance in the WARNING The ignition of gasoline fuel or fumes
can result in severe personal injury or death Connect
the battery ground lead only at the
location battery positive to the starter solenoid for this DC power source for the generator can be obtained from
the main engines starting battery A battery disconnect switch
should be installed in the B battery cable to the 21
ADMIRAL CONTROL When the engine is shut down with the key switch turned off
the water temperature gauge will continue to register the last
This control panel is equipped with a temperature reading indicated by the gauge before switch and RPM gauge with an ELAPSED TIME
power was turned off The oil pressure gauge will fall to zero
meter which measures the engines running time in hours and when the key switch is turned off The temperature gauge
in 110 hours The panel also includes a WATER TEMPER will once again register the engines true temperature when
ATURE gauge which indicates water temperature in degrees electrical power is restored to the an OIL PRESSURE gauge which measures the
engines oil pressure in pounds per square inch and a DC A separate alarm buzzer with harness is supplied with every
control circuit VOLTAGE gauge which measures the sys Admiral Panel The installer is responsible for electrically con
tems voltage All gauges are illuminated when the key necting the buzzer to the fourpin connection on the is turned on and remain
illuminated while the engine electrical harness The installer is also responsible for installing
is in operation The panel also contains two rubberbooted the buzzer in a location where it will be dry and where it one for PREHEAT and one
for START be audible to the operator should it sound while the engine is
running The buzzer will sound when the ignition key is turned
on and should silence when the engine has started and the
engines oil pressure rises above 15 psi 11 kgcm2
CAPTAIN CONTROL The panel also includes an alarm buzzer for low OIL
This control panel is equipped with a PRESSURE or high COOLANT TEMPERATURE The
KEY switch an RPM gauge PREHEAT and START but RPM gauge is illuminated when the KEY switch is turned on
tons an INSTRUMENT TEST button and three indicator and remains illuminated while the engine is in one for ALTERNATOR DISCHARGE one for low
OIL PRESSURE and one for high ENGINE 23
FUEL Mount the fuel tank and secure it into position The NFPA
recommends that the bottom tanks be installed on slatted
It is very important that the design construction and wooden platforms to help prevent moisture of all fuel system components meet
the highest Cylindrical tanks should be set in chocks or cradles and
possible standards Use only products specified for marine securely all wood or metal surfaces
the tank surface with a nonabrasive and tanks for diesel engines and generators may be made of aluminum or
stainless Fuel tanks for and generators may be made of only fiberglass or FUEL stainless is not appropriate for gasoline because
Tanks must be labeled with the name tank
improper welding can remove carbon leaving only steel material and capacity They also must be marked that they
which will rust and then leak have been pressure tested to the requirements of Title 33
If the tank is made of fiberglass be certain that the interior is CFR sub part J If either the fuelfill fitting or the tank is
gelcoated to prevent fibers from contaminating the fuel sys metallic it will need to be grounded A 10gauge or larger
tem Copper or galvanized fuel tanks should not be used The stranded copper wire must be fastened from the metal com
nominal thickness of a fuel tank depends on the material ponents to the boats ground
used Any fitting or opening must be at the top of the tank A Design the fuel tank vent line so that gasoline cannot spill
drain plug at the bottom of the tank is not acceptable onto the boat A loop in the vent line from the top of the tank
Avoid the use of fittings made of copperbased alloys such as to the underside of the deck and then to the throughhull fit
brass as they will deteriorate the aluminum fittings ting will prevent this The line should drain back to the for an aluminum
tank should be 300 series stain with no traps The vent line should be no less than 9160 ID
less steel The throughhull vent fittings must be equipped with a flame
It is not necessary to mount the tank above the engine level arrestor
as the fuel lift pump provided will raise the fuel from the Fuel Tanks Located Above the The amount of lift should be kept to a minimum
6 feet
being maximum If a tank is already installed above engine A carburetor float valve cannot be trusted to hold back fuel in
level it can be utilized in this position an installation having a fuel tank located at or above the
fuel system This type of system and care are especially important when the fuel some or all of the fuel supply line to the carburetor
tank is installed because any dirt left in the tank will cause below the level of the fuel tanks top requires a when the engine is started
for the first time valve to shut off the fuel supply to the engine or generator
when the engine isnt running
CAUTION Make sure the fuel tank filler is
properly sealed to prevent water reentry should it
become awash The fuel tanks vent should be routed
so as to prevent water entry as well
The fuel tanks fuel pickup tube should be clear and without screens or gauze strainers Make sure that
all fittings are sufficiently tightened to prevent leaking
Fuel tanks that are located below the engines fuel system
level must have their fuel return connection at the down into the tank in the same manner as the
pickup tube otherwise air will replace fuel siphoning out of
the engines fuel system through the return
The fuel tanks vent should be located so that its cannot allow water to enter through to the fuel must not be allowed to accumulate in the vents
This shutoff valve is necessary to guard against the possibil GASOLINE ENGINEFUEL TANKS
ity of gasoline siphoning through the supply line to the car
buretor and into the engine in case the carburetor float valve
doesnt close the carburetor needle valve doesnt or the fuel line ruptures between the engine and the
fuel tank at a point below the fuel level The shutoff valve
can be installed at the tank withdrawal fitting or at a the line from the fuel tank will no longer remain
above the fuel tank top level It can be electrically with manual override to open when the
engine starts and close when it shuts down A manually oper
ated valve can also be used operated either from panel area or from the vessels deck The should be of the fuel oil type and it is important that
all joints be free of pressure leaks
NOTE The use of mechanical springtype check of a solenoid shutoff valve is not recommended since
these may tax the fuel lift pumps ability to draw fuel through
a check valve A check valve can trap debris under its seat
which inhibits the valves ability to close In addition if a
check valves cracking pressure is too high it can contribute
to vapor lock Should a springloaded check
valve be used it should be an adjustable type such as a
Weatherhead 43 x 6 This adjustable type valve should be
adjusted to have a cracking pressure that will when the engine or generator is not operating but
not so excessive as to prevent the fuel lift pump from drawing
fuel through the valve
Fuel Tanks Located Below the installation having a fuel tank located below the engine fuel system with the fuel supply line to the car
buretor routed above the level of the fuel tanks top does not
require an antisiphon shutoff valve but does require service shutoff valves one located at
the fuel connection to the tank and another located at the
Fuel system antisiphon devices should not be used with a
diesel It is not necessary and in addition
introduces air into the fuel which may cause erratic operation
The fuel system should include one or more fuel shutoff
DUAL PURPOSE FUEL TANK Run fuel lines at the top level of the fuel tank to a point as
close to the engine or generator as possible to reduce the
If youre running both a generator and a propulsion engine danger of fuel siphoning out of the tank if the line should
and they use the same fuel you can use the same fuel tank before that decision is made the following factors
must be considered Fuel piping should always be routed and securely anchored
to prevent leaks from vibration and chafing Fuel piping is
4 There must be adequate fuel capacity for both usually secured by copper straps every 1214 in 3036 cm
engines refer to the section of Use as few connections as possible and install the lines so
your owners manual for fuel consumption figures they are accessible and protected Avoid lockedin torsional
4 In diesel installations the fuel returning to the tank is
warm To obtain maximum engine efficiency fuel RIGID FUEL LINES
delivered to the injectors must be cooled The fuel
tank volume must be adequate to cool the returned For installations with rigid fuel lines Westerbeke recom
fuel mends using copper tubing with suitable flated fittings both
for the supply line and the return line Use seamless annealed
If a fuel tank is shared a fuel line tee should not be used A double flared fuel lines that are approved for marine installa
tee can cause erratic genset operation due to fuel starvation tions Run the tubing in the longest pieces obtainable to
The gensets fuel pump does not have the capacity to avoid the use of unnecessary fittings and connectors The
overcome the draw of the propulsion engines fuel pump minimum size of the fuel supply line and fuel return line is
This is true also of the return lines Pressure from one engine 14 inch inside be higher than the other and force return fuel back into
When a copper fuel line is used electrically bond the fuel
the engine injector The return line should line to the vessels common bonding conductor with a
enter the tank as far as possible from the supply lines suitable strap or 10 gauge wire
If a rigid metallic fuel line is run into the compartment a length of
flexible hose must be installed to
absorb vibration from the Install a
nonorganic flexible hose without metal between the rigid fuel line and the
to absorb
the vibration This line must be long enough to prevent
binding or stretching because of movement
A flexible fuel line may also be installed between the fuel
yank and the for both the supply line and
the return line For the supply line flexible hose may be
FUEL LINES installed from the fuel tank outlet to the fuel proper installation of fuel
lines is very important All separator and from the fuel filterwater separator to the
fuel line materials must be approved for marine installations fuel pump inlet
and meet the requirements of both the USCG and the ABYC Use suitable end fittings and install all the hose in the
The fuel system should be installed in such a manner as to longest runs possible to avoid the use of unnecessary the fuel lift pump to
maintain a and connectors There must not be an electrical inlet pressure to the injection pump under all between
the hose end fittings as a bad ground in the conditions As the fuel lift pump has a capacity in circuit will cause a hose to become of
that required by the injection pump the overflow is and ignite the fuel during to the fuel tank and should be connected at the top of
the tank
Great care should be taken to ensure that the fuel system is WARNING Ignition of fuel can cause fire and
correctly installed so that airlocks are eliminated and severe personal injury or death Be sure any flexible taken against dirt and
water entering the fuel line used between the fuel tank and the engine
NOTE The fuel supply line to the should be generator meets ABYC and USCG its own pickup in the fuel tank and NOT teed off the
supply line to another the fuel lines as far as possible from the exhaust pipe
and hot engine areas this is to keep the fuel at a to reduce the chance of vapor lock in
Make sure your fuel system has positive shutoff valves To insure satisfactory operation an engine or generator must
know their locations and how they operate have a dependable supply of clean fuel
NOTE See the US Coast Guard publication Fuel System Diesel Fuel use No 2 oil with a cetane rating of 45 or
Compliance Guideline for basic fuel system layouts and valve locations Gasoline use
unleaded 89 octane or higher
A primary fuelwater separator should be installed in the fuel WARNING Gasoline leakage in or around the
supply line between the fuel tank and the to compartment is a potential for fire
help remove contaminants in the fuel before the fuel reaches andor explosions Repair leaks promptly and ensure that
the engine mounted fuel lift pump It should be mounted in the compartment is properly accessible location for ease in monitoring for
water and for servicing Such contaminants can
cause the failure of components and such failures are not Make sure there is a installed near A recommended type of fuelwater separator
is and that it is properly maintained Be from the list of accessories A secondary fuel filter iar with its use An extinguisher
with the NFPA rating of
is mounted on the and it has a replacement ABC is appropriate for all installation test the fuel system for tightness per Fuel filters
for gasoline installations must use metal
bowls to meet Coast Guard 27
RAW WATER INTAKE A throughhull fitting that is completely flush with the
surface of the boats hull and without an external strainer
Raw water should be supplied to the raw water pump may be necessary for the generator raw water intake on very
through a standardtype throughhull fitting located on the highspeed boats The protrusion of a standard type through
hull so as to be below the waterline during all angles of boat hull fitting and a strainer can cause a venturi effect on
intake of a high speed boat creating a suction which works
against the raw water pump causing an inadequate supply of
CAUTION Do not use a high speed scooptype cooling water to the engine
throughhull fitting for the raw water supply for
generators and auxiliary sailboat engines as it will tend
to encourage siphoning Water pressure against this type
CAUTION On some extremely highspeed boats
the use of a sea scoop type strainer may be necessary to
of fitting while the vessel is underway with the provide an adequate supply of cooling to the generator
generator off or when sailing can push water past the when the boat is underway If this is necessary the
raw water pump impeller and into the exhaust system exhaust piping from the generator must have a
filling it and the engine as well continuous downward pitch to the outlet at the transom
so that no water can be trapped and backup into the
The raw water should be directed from the through a seacock to a visualtype raw water strainer engine A solenoid operated shutoff valve can
also be
and then delivered to the pump The strainer should be of the installed in the raw water supply to the raw water pump
type that may be withdrawn for cleaning while the vessel is and wired to close when the generator is not in
underway and should be mounted below the waterline to selfpriming Seacocks and strainers should be at least
one size greater than the inlet thread of the raw water pump
Hoses routed from the throughhull fitting to the strainer and
to the raw water pump should be to prevent CAUTION Water intrusion into the engine through
the hose from collapsing during the the exhaust system is not covered by suction from the pump may collapse hose
If a generator set is located above the waterline of the boat it
is good practice to provide a loop or loops above the inlet of
the raw water pump in the raw water supply hose from the
raw water strainer The loops provide a head of water on
the raw water pump which on startup lubricates the pump
impeller until the pump starts drawing water from the intake
flexible hose should be used between the
raw water outlet on the heat exchanger and the exhaust
system This reduces vibration and permits the engine to be
moved slightly when its being realigned
Make sure this system is in proper order Check that the hull All pipe and fittings should be of bronze Use seacock and strainer are
unobstructed Inspect the raw compound or tape at all connections to prevent air leaks The
water lines to make sure there are no collapsed sections neoprene impeller in the raw water pump should never be
which would restrict water flow Make sure there are no air run dry All hose joints should be double clamped with
leaks at any of the connections use double clamps on hose 304306 hose clamps Tbolt clamps are below the waterline
better but must be 304306 stainless
Be sure that the raw water intake is clear of any by the propellers
CAUTION The use of common street elbows is
The raw water intake to the engine or generator should be not recommended in plumbing the raw water and not combined with any other
inlet for the main These generally have a very restrictive inside or air conditioners The use of sea chest intakes
is permissible but they must be engineered to provide an The use of machinetype fittings is supply of water for all equipment
connected to
A coolant recovery tank kit is supplied with The purpose of this
recovery tank is to allow for engine coolant expansion during engine operation without the loss of
coolant and without introducing air into the cooling system
This coolant recovery tank should be installed at or above
engine manifold level in a location where it can be A wire mounting bracket is supplied with each
kit along with a 30 in 76 cm length of clear plastic hose
and clamps to connect the hose between the fitting and the hose spud on the base of the
recovery recommends a mixture of 50 quality and compatible with aluminum 50 distilled water
OIL When additional sensing devices such as switches or sensors
need to be installed that function on engine oil pressure these
Refer to your Westerbeke Operators Manual for the oil devices must be and connected to the for your
sump using an appropriate grade of lubricating oil hose Any
fittings used to connect the hose to the gallery must be of
OIL DRAIN HOSE steel or malleable iron composition Brass must not be used
An oil sump drain hose is located at the front or side of the for this Oil may be drained from this hose by removing the
cap and the discharge end of the hose from its mounting RELOCATING ENGINE PARTS
bracket and lowering the hose into a container The hose cap Any reassembly or relocation of engine parts such as fuel
fitting is 14 NPT and it can be extended or have a pump filters dipstick senders and switches to accommodate a
added for easier removal of the old oil restricted engine space must be authorized by the
When installing the engine make certain that this drain hose WESTERBEKE Corporation and the work must be
is accessible and that the drain hose fitting at the bottom of performed by a WESTERBEKE approved mechanic or the
the engine oil pan is well clear of the boats oil pan engines warranty will be void The oil filter can be relocated
to a convenient bulkhead location by using a
If the engine is going to be mounted at an angle instead of
level its a good idea to add the proper amount of lube oil to
the engine and check the dipstick before installation with the
engine level After installation check the dipstick to see
where the oil now rests and mark the dipstick at this point
Oil pressure sensing devices such as senders and not be connected to an engines oil sump with the use
of extended nipples or tees The reason is simply engine vibration causes fatigue of the fittings used
to make such a connection If these fittings fail during lubricating oil will be lost and internal engine
damage will Oil filter assemblies vary with each engine etc are shown in detail in all
Operators Manuals
REMOTE OIL Always install this kit with the oil filter facing down as
popular accessory is used to relocate the engines oil
filter from the engine to a more convenient location such as Contact your WESTERBEKE dealer for more engine room bulkhead
NOTE WESTERBEKE is not responsible for engine failure
To install simply remove the engine oil filter and thread on due to incorrect installation of the Remote Oil Remote Oil Filter kit as shown
ventilation requirements of the engine or the following combustion air is required for the
engines cylinders and cooling air is required for the engine
and generator electrical end and also for removing the heat
produced during operation
WARNING Ventilating air is required to clear the
bilges as well as the compartment in which the engine
or generator is located of potentially toxic and
flammable vapors
Keep in mind that hot air rises so heated air should be
removed from the upper area of the engine or and cool fresh air should be directed to the
lower areas of the compartment Ventilation should with the aid of power ventilation the vessel is not ventilation incorporates a powered exhaust
blower to
draw air from the compartment and discharge to The exhaust blower must meet a rating based on compartment volume The graph
below is used to calculate the required capacity
NOTE See your Operators Manual for the ventilation
requirements of your generator Refer to the ABYC standards
and US Coast Guard regulations for ventilation require
ments on both engines and 32
Water heater hose connections vary from one engine to The pressure cap on the engines manifold should be
another Refer to your WESTERBEKE Operators Manual for installed after the engines cooling system is filled with
your engines water heater connections coolant Finish filling the cooling system from the remote
tank after the system is filled and is free of air and Water heater connections are not standard on marine
good coolant circulation During engine operation products
the engines coolant should be done at the remote tank marine engines are equipped with not at the engine manifold cap The
hose connection from for the plumbing of engine coolant to heat an heater to the remote expansion tank should be routed and
onboard water heater The water heater should be mounted supported so it rises continuously from the heater to the tank
in a convenient location either in a high or low position in enabling any air in the system to rise up to the tank and out
relation to the engine so that the connecting hoses from the of the to the engine can run in a reasonably direct line with
NOTE Air bleed petcocks are located on the engines heat
out any loops which might trap air
exchanger and on the thermostat housing Open these pet
Hoses should rise continuously from their low point at the cocks when filling the engines fresh water system to allow
heater to the engine so that air will rise naturally from the air in the coolant circuit to escape Close tightly after all the
heater to the engine If trapped air is able to rise to the air is then an air bleed petcock must be installed at the
higher fitting on the heater for bleeding air while filling
the system
NOTE If any portion of the heating circuit rises above the
engines closed cooling system pressure cap then a
pressurized aluminum remote expansion tank must be
installed in the circuit to become the highest point Tee the
remote expansion tank into the heater circuit choosing the
higher of the two connections for the return Tee at the
heater and plumb a single line up to the tanks location and
the other back to the engines return Install the tank in a convenient location so the fresh water
coolant level can easily be checked The remote will now serve as a check and system fill point The
plas ticc oo lantr ecov ery tank is not used when the
remote expa nsion ta n kk itisi nstalledsin cet his tank
serves the same function The remote expansion tank has
an overflow fitting that should be directed by a hose to an
area where any overflow will not cause damage
For safety reasons the transmission is not filled with NOTE When installing the transmission make certain fluid during shipment and
the selector lever is shifting is not impeded by restricted movability of attached to the actuating shaft
Bowden cable or rod linkage by unsuitably positioned guide
Before leaving the WESTERBEKE plant each transmission sheaves too small a bending radius etc In order to mount a
undergoes a test run with Dextron III ATF transmission fluid support for shift control cable connections use the two
The residual fluid remaining in the transmission after threaded holes located above the shift cover on top of the
draining acts as a preservative and provides protection gear housing Refer to the WESTERBEKE parts list
against corrosion for at least one year if properly stored CONTROL CABLES
The transmission is suitable for single lever remote control
Upon loosening the retaining screw the actuating lever can
be moved to any position required for the control elements
cable or rod linkage Make certain that the shift lever does
not contact the actuating lever cover plate the minimum
distance between lever and cover should be 05mm
The control cable or rod should be arranged at right angle to
the actuating shift lever when in the neutral position The
neutral position of the operating lever on the control console
should coincide with the neutral position of this lever
The shifting travel as measured at the pivot point of the
actuating lever between the neutral position and end
positions A and B should be at least 35mm for the outer and
30mm for the inner pivot FLUID A greater amount of shift lever travel is in no way
detrimental and is recommended However if the lever
Fill the transmission with Dextron III ATF The fluid level
travel is shorter proper clutch engagement might be be up to the mark on the dipstick After checking the
which in turn would mean premature wear excessive heat
level press the dipstick into the case and turn it to tighten
generation and clutch plate failure This would be the first 25 operating hours inspect the bell shaft and transmission cooler for leakage The fluid
by slow clutch engagement or no engagement at all
should be changed after the first 25 hours and every 300 NOTE Check for proper lever travel at least each season
hours SWITCH
These transmissions are equipped with a neutral This is to prevent the engine from starting in gear
Unless the transmission selector lever is perfectly aligned in
neutral the engine starter will not OF GEAR BOX WITH PROPELLER
Use a flexible connection between the transmission gearbox
and the propeller shaft if the engine is flexibly mounted in
order to compensate for angular deflections The a special propeller thrust bearing is not required since the
propeller thrust will be taken by the transmission the value specified under is not
exceeded However the output shaft should be additional loads Special care should be taken to vibration When using a universal joint shaft make
certain to observe the manufacturers instructions For additional information contact
Even with the engine solidly mounted the use of flexible ZF or DRIVESAVER will reduce stress in the
Marine US bearings caused by hull distortions especially in 3131 SW 42nd Street
wooden boats or where the distance between transmission Fort Lauderdale FL 33312
output flange and stern gland is less than about 800mm Tel 954 is a product of Globe Marine Rockland MA
Fax 954 5814077
Check the transmission fluid level on the dipstick If the Place the transmission selector control in Neutral has not been filled fill
with Dextron III and starting the engine Shifting from one selector position to
continue to use this fluid During the first 50 hours of another selector position may be made at any time keep a lookout for any
leakage at the bell housing 1000 rpm and in any order Shifts should be made at the
output shaft and transmission cooler This fluid should be lowest practical engine speed Start the engine and set the
changed after the first 50 hours and approximately every throttle at idle speed allow the transmission fluid to warm up
1000 operating hours or at winter layup for a few Some transmissions are equipped with a neutral
switch Unless the transmission shift lever is in neutral the engine starter will not activate Move the shift control handle to the
middle position You
should feel the detent Center the shift lever on the
Shift Lever Position transmission through the linkage to the selector lever With
The shift control handle and linkage must position the shift the control in this position hydraulic power is on the transmission exactly in
Forward F Neutral N interrupted and the output shaft of the transmission does not
and Reverse R shifting positions A detent ball located turn
behind the transmission shift lever must work freely to center Forward
the lever in each position The shift control positions at the
helms must be coordinated with those of the Velvet Drive Move the shift control handle to the forward position You
shift lever through shift mechanism adjustments An should feel the detent The shift lever on the transmission is
improperly adjusted shift mechanism can cause damage to in the forward position The output shaft and the propeller
the transmission The shifting mechanism and transmission shaft move the boat in a forward lever should be free of dirt to ensure proper
operation Reverse
NOTE Do not remove the detent ball Move the shift control handle to the reverse position You
NOTE If the boat moves backwards with the selector control should feel the detent The shift lever on the transmission is
in the forward position shut off the engine This problem in the reverse position The output shaft and the propeller
may be the result of incorrect movement of the shift lever by should move the boat in a reverse direction astern
the shift control NOTE Moving the transmission shift lever from Neutral
Position to Forward is always towards the engine Reverse is
always away from the engine
NOTE Be aware of any unusual noises or vibrations and
investigate to determine the cause
NOTE Low engine idle rpm can produce damper plate and
gear box This is the result of unstable rotation
through the damper plate and the gear box Increase the idle
rpm until this is eliminated
Refer to your transmission operators manual
for more detailed information on installation and operation
For additional information on throttle and shift controls
contact Edson New Bedford 35
NOTE Also refer to PREPARATIONS FOR INITIAL STARTUP in your Operators starting the engine or generator complete the follow With the engine or
generator running check the checklist
Make certain that water is flowing from the exhaust
Is there fuel in the tanks and are the fuel valves open
Check the instrument gauges for proper readings
Has lube oil been added to the engine
Inspect the engine for fuel water coolant and oil
Is there transmission fluid in the transmission leaks
Has the proper coolant mix been added Listen for unusual sounds and vibrations
Are the battery cables properly connected Will the engine shift in and out of gear
Is the exhaust system secure and all connections tight Can you throttle up to the recommended rpms Is the
Is the transmission linkage positioned correctly Is the throttle action smooth
gear in Neutral Apply a load to the generator check the output fre
Is the raw water petcock open Is the raw water pump quency
primed NOTE See your operators manual for the output
Are the AC and load connection wires securely adjustment
connected to the circuit breaker After shutdown check the engine or generator carefully
inspect all fluid levels check hose clamps fuel lines etc

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The information on this web site has not been checked for accuracy. It is for entertainment purposes only and should be independently verified before using for any other reason. There are five sources. 1) Documents and manuals from a variety of sources. These have not been checked for accuracy and in many cases have not even been read by anyone associated with I have no idea of they are useful or accurate, I leave that to the reader. 2) Articles others have written and submitted. If you have questions on these, please contact the author. 3) Articles that represent my personal opinions. These are intended to promote thought and for entertainment. These are not intended to be fact, they are my opinions. 4) Small programs that generate result presented on a web page. Like any computer program, these may and in some cases do have errors. Almost all of these also make simplifying assumptions so they are not totally accurate even if there are no errors. Please verify all results. 5) Weather information is from numerious of sources and is presented automatically. It is not checked for accuracy either by anyone at or by the source which is typically the US Government. See the NOAA web site for their disclaimer. Finally, tide and current data on this site is from 2007 and 2008 data bases, which may contain even older data. Changes in harbors due to building or dredging change tides and currents and for that reason many of the locations presented are no longer supported by newer data bases. For example, there is very little tidal current data in newer data bases so current data is likely wrong to some extent. This data is NOT FOR NAVIGATION. See the XTide disclaimer for details. In addition, tide and current are influenced by storms, river flow, and other factors beyond the ability of any predictive program.