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Century 170 T6 Operator's Manual




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OPERATORS OT4 120N6170T6
MARINE 01 L ENGINES
PUBLICATION NO 045139
FIRST EDITION
JULY 2000
WESTERBEKE CORPORATION
MYLES STANDISH INDUSTRIAL PARK
150 JOHN HANCOCK ROAD TAUNTON MA 027807319
NMMA Member National Marine Manufacturers Association
A gasses contain Carbon Monoxide an odorless and
colorless gas Carbon Monoxide is poisonous and can and death Symptoms of Carbon can include
Dizziness Throbbing in Muscular Vomiting
Weakness and Sleepiness Inability to Think YOU OR ANYONE ELSE EXPERIENCE ANY OF THESE SYMPTOMS
GET OUT INTO THE FRESH AIR IMMEDIATELY If symptoms persist
seek medical attention Shut down the unit and do not restart
until it has been inspected and repaired
A WARNING DECAL is provided by
WESTERBEKE and should be fixed to a
bulkhead near your engine or generator
WESTERBEKE also recommends installing
CARBON MONOXIDE DETECTORS in the
quarters of your vessel
They are inexpensive and easily
obtainable at your local marine store
CALIFORNIA
PROPOSITION 65 WARNING
Diesel engine exhaust and some
of its constituents are known to
the State of California to cause
cancer birth defects and other
reproductive harm
SAFETY PREVENT BURNS FIRE
Read this safety manual carefully Most accidents are caused
by failure to follow fundamental rules and when dangerous conditions exist and talre the A 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 the sparks to occur near the carburetor fuel line filter fuel
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
arrester removed Backfire can cause severe injury or
A WARNING Do not touch AC electrical connections death
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
ator 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 bum
Use insulated mats whenever working on electrical
equipment PREVENT BURNS EXPLOSION
Make sure your clothing and skin are dry not damp
particularly shoes when handling electrical equipment
Remove wristwatch and all jewelry when working on
A 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 before start
Electrical shock results from handling a charged capacitor ing 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
reach of children
A WARNING Do not touch hot engine parts or Do not fill the fuel tanks while the engine is running
exhaust system components A running engine gets
Shut off the fuel service valve at the engine when servicing
very hot 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 servicing
recovery tank Ensure proper ventilation exists when servicing the fuel
system
A 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 Engines Generators
SAFETY STARTING TOXIC EXHAUST GASES
A WARNING Accidental starting can cause injury A 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 manifolds
it last are securely attached and no warping exists Pay close
attention to the manifold water injection elbow and
Make certain all personnel are clear of the engine before
exhaust pipe nipple
starting
Be sure the unit and its surroundings are weIl ventilated
Make certain all covers guards and hatches are re
instaIled before starting the engine In addition to routine inspection of the exhaust system
instaIl a carbon monoxide detector Consult your boat
BATTERY EXPLOSION builder or dealer for instaIlation of approved detectors
For additional information refer to ABYC T22 educa
A WARNING Battery explosion can cause injury tional information on Carbon Monoxide
or death
A WARNING Carbon monoxide CO is an invisible
Do not smoke or aIlow an open flame near the battery odorless gas Inhalation produces flulike symptoms
being serviced Lead acid batteries emit hydrogen a nausea or death
highly explosive gas which can be ignited by electrical
arcing or by lit tobacco products Shut off all electrical Do not use copper tubing in diesel exhaust systems Diesel
equipment in the vicinity to prevent electrical arcing during fumes can rapidly destroy copper tubing in exhaust sys
servicing tems Exhaust sulfur causes rapid deterioration of copper
Never connect the negative battery cable to the positive tubing resulting in exhaustwater leakage
connection terminal of the starter solenoid Do not test Do not instaIl exhaust outlet where exhaust can be drawn
the battery condition by shorting the terminals together through portholes vents or air conditioners If the engine
Sparks could ignite battery gases or fuel vapors Ventilate exhaust discharge outlet is near the waterline water could
any compartment containing batteries to prevent accumu enter the exhaust discharge outlet and close or restrict the
lation of explosive gases To avoid sparks do not disturb flow of exhaust Avoid overloading the craft
the battery charger connections while the battery is being
charged Although diesel engine exhaust gases are not as toxic as
exhaust fumes from gasoline engines carbon monoxide
Avoid contacting the terminals with tools etc to prevent gas is present in diesel exhaust fumes Some of the symp
burns or sparks that could cause an explosion Remove toms or signs of carbon monoxide inhalation or poisoning
wristwatch rings and any other jewelry before handling are
the battery
Vomiting
Always turn the battery charger off before the battery connections Remove the negative lead first Dizziness
and reconnect it last when servicing the battery Throbbing in temples
Muscular ACID
Intense headache
A WARNING Sulphuric acid in batteries can cause
Weakness and sleepiness
severe injury or death AVOID MOVING PARTS
When servicing the battery or checking the electrolyte
level wear rubber gloves a rubber apron and eye protec A WARNING Rotating parts can cause injury
tion Batteries contain sulfuric acid which is destructive If or death
it comes in contact with your skin wash it off at once
with water Acid may splash on the skin or into the eyes Do not service the while it is running If a
inadvertently when removing electrolyte caps situation arises in which it is absolutely necessary to make
Engines Generators
SAFETY 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 GASOLINE AND DIESEL ENGINES AND
moving parts GENERATORS
Make sure all attaching hardware is properly tightened Read the following ABYC NFPA and USCG publications
Keep protective shields and guards in their respective for safety codes and standards Follow their recommenda
places at all times tions when installing your WESTERBEKE Do not check fluid levels or the drive belts
tension while ABYC American Boat and Yacht Council
the is operating Safety Standards for Small Craft
Stay clear of the drive shaft and the transmission coupling Order From
when the engine is running hair and clothing can easily ABYC
be caught in these rotating parts 3069 Solomons Island Rd
Edgewater MD NOISE NFPA National Fire Protection Association
Fire Protection Standard for Motor Craft
A WARNING High noise levels can cause hearing Order From
loss NFPA
1 Batterymarch Park
Never operate a generator without its muffler installed PO Box 9101
Quincy MA 022699101
Do not run an engine with the air intake silencer
removed USCG United States Coast Guard
USCG 33CFR183
Do not run engines or generators for long periods with
their enclosures open Order From
US Government Printing Office
Washington DC 20404
A WARNING 00 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 to install a gasoline engine or generator
should
begin with a thorough examination of the American Boat and
Yacht Councils ABYC standards These standards are from
a combination of sources including the USCG and the of the ABYC standards of particular interest are
H2 Gasoline fuel systems
Pl Exhaust systems
P4 Inboard engines
E9 DC Electrical systems
All installations must comply with the Federal Code FCR
Engines Generators
installing WESTERBEKE engines and generators it is important that be paid to the following AND regulations ABYC guidelines and safety codes must be
complied with 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 instaU 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
of the vessels hull
A detailed 40 page Marine Installation Manual covering gasoline and
diesel engines and generators is available from your WESTERBEKE
dealer
Engines Generators
TABLE OF 0
WIFing lagrams Engine 29
Warranty Procedures 3 Tachometer Serial Number Location 4 Engine Adjustments Control Panel 5
Drive Belt Adjustment 32
Fuel Engine Oil and Coolant Fuel Injectors 32
Oil Pressure 6 Testing Engine Compression for Initial StartUp Testing Oil Pressure 33
Valve Clearance Adjustment Procedure 8
Injection Timing 34
Warning Lights Alarms and Circuit Breaker 9 Hurth Transmissions BreakIn Procedure 10 Changing
Fluid 37
The Daily Routine 11 Maintenance 37
Starting the Engine 11 Cable Connections Schedule 12 Shaft Couplings 38
Cooling System 14 Borg Warner Transmission 39
Thermostat 15 Changing Fluid 40
Raw Water Pump 16 Maintenance 41
Heat Exchanger 17 Transmission 42
Air Intake Filter 18 Layup and 44
Fuel System 19 Metric Conversions 46
Fuel Lift Pump 19 80N4 48
Fuel Filters 19
Fuel PumplFuel Bleeding 20
11 49
Engine Lubricating Oil 21 120N6 Oil Change 21 170T6 51
Remote Oil Filter 22 Suggested Spares Heater Electrical System Alternator 24
Battery 25
Glow Plugs 26
Engines Generators
PARTS DC ALTERNATOR
ID NAME PLATE
EXHAUST ELBOW
MODEL 110T4
ILLUSTRATED
MANIFOLD
HEAT
COVER FRONT
TRANSMISSION
FLUID DIPSTICK
RAW WATER
STARTER MOTOR
OIL DRAIN HOSE
LEFT SIDE
THERMOSTAT
OIL FILL ASSEMBLY
MANIFOLD PRESSURE CAP
COOLANT BREAK FUEL FILTER
TURBOCHARGER
INJECTION
PUMP
FUEL PRIMING PUMP
AIR INTAKE
FILTER
TRANSMISSION
OIL COOLER
MOUNT
OIL DIPSTICK
REAR
RIGHT SIDE
OIL GALLERY OIL FILTER
Engines Generators
high perfonnance marine engines are products of PRODUCT long years of experience and advanced Product software
technical data parts lists We take great pride in the superior durability and brochures and catalogs provided from sources other perfonnance
of our engines and generators WESTERBEKE are not within WESTERBEKEs you for selecting WESTERBEKE
WESTERBEKE CANNOT BE RESPONSIBLE FOR THE
In order to get the full use and benefit from your generator CONTENT OF SUCH SOFTWARE MAKES NO WAR
it is important that you operate and maintain it correctly RANTIES OR WITH RESPECT
This manual is designed to help you do this Please read this THERETO INCLUDING ACCURACY TIMELINESS OR
manual carefully and observe all the safety precautions COMPLETENESS THEREOF AND WILL IN NO Should your engine require servicing contact
BE LIABLE FOR ANY TYPE OF DAMAGE OR INJURY
your nearest WESTERBEKE dealer for assistance INCURRED IN CONNECTION WITH OR ARISING OUT
This is your operators manual A parts catalog is also OF THE FURNISHING OR USE OF SUCH and a technical manual is available from your
WESTERBEKE customers should keep in mind the dealer If you are planning to install this span between printings of WESTERBEKE
product contact your WESTERBEKE dealer for and the unavoidable existence of earlier installation manual
product software The product software provided with
WESTERBEKE products whether from WESTERBEKE or
WARRANTY PROCEDURES other suppliers must not and cannot be relied upon exclu
Your WESTERBEKE Warranty is included in a separate sively as the definitive authority on the respective product It
folder If after 60 days of submitting the Warranty Registry not only makes good sense but is imperative that you have not received a customer
card of WESTERBEKE or the supplier in your warranty please contact the factory in be consulted to detennine the accuracy and
currentness of the
writing with model infonnation including the units product software being consulted by the number and commission date
NOTES CAUTIONS AND Card As this manual takes you through the operating procedures
maintenance schedules and of your marine
engine critical infonnation will be highlighted by NOTES
CAUTIONS and WARNINGS An explanation follows
I NOTE An operating procedure essential to note
Customer MR WESTERBEKE OWNER
MAIN STREET A CAUTION Procedures which if not strictly
HOMETOWN USA observed can result in the damage or destruction of
Model80N4 Ser UOOOOE702 your engine
Expires 2151200 I
A WARNING Procedures which if not properly
followed can result in personal injury or loss of life
The WESTERBEKE serial number is an that can assist in detennining the date of your WESTERBEKE engine or generator The date code is placed at the
end of the engine serial
number and consists of a character followed by three num
bers The character indicates the decade A1960s D1990s E2000s the first number represents the
year in the decade and the second and third numbers repre
sent the month of Engines Generators
NUMBER LOCATION ORDERING PARTS
The engines model number and serial number are located on Whenever replacement parts are needed always provide the
a nameplate mounted on the side of the engines manifold engine model number and serial number as they appear on
The engines serial number is stamped into the engine block the silver and black nameplate located on the manifold You
left side behind the alternator below the manifold Take the must provide us with this information so we may properly
time to enter this information on the illustration of the name identify your engine In addition include a complete part
plate shown below as this will provide a quick reference when description and part number for each part needed see the
seeking technical information andor ordering repair parts separately furnished Parts List Insist upon
packaged parts because will fit or generic parts are
not made to the same as original equipment
SPARES AND MODEL
0 SPEC AVO MA USA SERNO
Certain spares will be needed to support and maintain your
WESTERBEKE engine Your local WESTERBEKE dealer
will assist you in preparing an inventory of spare parts See
the SPARE PARTS page in this manual For engine acces
sories see WESTERBEKEs ACCESSORIES THE DIESEL ENGINE
The diesel engine closely resembles the gasoline engine
since the mechanism is essentially the same The cylinders
are arranged above a closed crankcase The crankshaft is the
same general type as a gasoline engine and the diesel engine
has the same type of valves camshaft pistons and lubricating to a great extent a diesel engine requires the maintenance as a gasoline engine The
factors are proper ventilation and proper mamte
nance of the fuel lubricating and cooling systems Fuel filter elements must be replaced at the time peri
ods specified and frequent checking for contaminants etc in the fuel system is also essential factor is the consistent use of the same brand of
high detergent diesel lubrication oil designed specifically for
diesel engines
The diesel engine does differ from the gasoline in its method of handling and firing of fuel and ignition systems are replaced by a the fuel
injection pump which performs the
function of both
Engines Generators
ADMIRAL CONTROL PANEL
DESCRIPTION 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 electrical
KEY 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 III 0 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 gauge
Fahrenheit 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 engines
switch 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 will
pushbuttons one for PREHEAT and on 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
OIL PRESSURE GAUGE THIS GAUGE IS GRADUATED
WATER TEMPERATURE GAUGE THIS GAUGE IS IN POUNDS PER SQUARE INCH PSI AND IS
GRADUATED IN DEGREES FAHRENHEIT AND IS ILLUMINATED WHILE THE KEY SWITCH IS TURNED
ILLUMINATED WHILE THE KEY SWITCH IS ON THE ENGINES NORMAL OPERATING OIL
TURNED ON THE ENGINES NORMAL OPERATING PRESSURE RANGES BETWEEN 40 85 pSi
TEMPERATURE IS 170 190 Fn SSC
RPM GAUGE REGIS
TERS MINUTE OF THE
ENGINE AND CAN FOR
ACCURACY FROM THE
REAR OF THE SWITCH
ELAPSED POWER ONLY TO THE
TIME AND SHOULD BE INSTRUMENT PANEL
USED AS A GUIDE FOR CLUSTER
THE
DC VOLTMETER
INDICATES THE AMOUNT THE
BATTERY IS BEING PRESSED ENERGIZES THE SHOULb
SHOW 13V TO EXCITER THE FUEL LIFT PUMP THE AUTOMATIC ALARM SYSTEM
FUEL SOLENOID ON THE INJECTION PUMP AND THE
ENGINES GLOW PLUGS IT BYPASSES THE ENGINES
OIL PRESSURE ALARM SWITCH IN ADDITION THIS I SUPPLIED WITH THE INSTRUMENT PANEL IF THE ENGINES ENERGIZES THE START
BUTTON REACHES 210 F 99C THIS SWITCH WILL CLOSE SOUNDING THE
ALARM WHICH WILL EMIT A CONTINUOUS SIGNAL
START BUTTON WHEN PRESSED ENERGIZES THE
STARTERS SOLENOID WHICH CRANKS THE ENGINE OIL PRESSURE ALARM AN OIL PRESSURE ALARM SWITCH IS
THIS BUTTON WILL NOT OPERATE ELECTRICALLY LOCATED OFF THE ENGINES OIL GALLERY THIS SWITCH THE PREHEAT
BUTTON IS PRESSED AND HELD THE ENGINES OIL PRESSURE SHOULD THE ENGINES OIL PRESSURE
AT THE SAME TIME FALL TO 5 10 psi 04 07 kgem THE SWITCH WILL CLOSE SOUND
ING THE ALARM IN THIS EVENT THE ALARM WILL EMIT A PULSATING
SIGNAL
Engines Generators
DIESEL FUEL ENGINE OIL AND ENGINE FUEL OIL PRESSURE
Use fuel that meets the requirements or specification of Class The engines oil pressure during operation is indicated
2D ASTM and has a cetane rating of 45 or better by the oil pressure gauge on the instrument panel During
normal operation the oil pressure will range between 25 and
Care Of The Fuel Supply 85 psi
Use only clean diesel fuel The clearance of the components NOTE A newly staned cold engine can have an oil pressure
in your fuel injection pump is very critical invisible dirt
reading up to 85 psi A warmed engine can have an oil which might pass through the filter can damage sure reading as low
as 25 psi These readings will vary
these finely finished parts It is important to buy clean fuel depending upon the temperature of the engine the load
and keep it clean The best fuel can be rendered unsatisfac placed on the engine and the RPMs
tory by careless handling or improper storage facilities To
assure that the fuel going into the tank for your engines daily ENGINE COOLANT
use is clean and pure the following practice is advisable
WESTERBEKE recommends a mixture of 50 a wellknown brand of fuel and 50 distilled water Distilled
water is free from the
Install and regularly service a good visualtype fuel chemicals that can corrode internal engine separator between the
fuel tank and the engine The antifreeze performs double duty It allows the engine to
The Raycor 445 or larger is a good example of such a filter run at proper temperatures by transferring heat away from the
engine to the coolant and lubricates and protects the OIL circuit from rust
and corrosion Look for a good quality
antifreeze that contains Supplemental Cooling API Grade CF or CG4 SCAs that keep the antifreeze
chemically balanced API Grade CG4 to long term the heavy duty engine oils as specified
above Change The distilled water and antifreeze should be premixed before
the engine oil after an initial 50 hour breakin period and being poured into the cooling 100 hours of operation thereafter
NOTE Look for the new long oil viscosity largely affects engine startability perfor antifreeze that is now oil consumption speed
of wearing and occurrence of
seizure etc Using lubricants whose viscosity is selected Antifreeze mixtures will protect against an unexpected to the
atmospheric temperature is important and they are beneficial to the engines cooling system They
retard rust and add to the life of the circulating pump seal
ENGINE OIL VISCOSITY CHART
ENGINE OIL VISCOSITY GRADE AMBIENT TEMPERATURE
ANTIFREEZE PROTECTION
I SAE 2020W SA 40501
Antifreeze Concentration 23 30 35 50
I I
SAE lOW
1 SAE 30
I Freezing Temperature 14F 8F
10C 13C
COOLANT RECOVERY TANK
A coolant recovery tank kit is supplied with each
WESTERBEKE diesel engine The purpose of this recovery
tank is to allow for engine coolant expansion and contraction
during engine operation without the loss of coolant and
A CAUTION Do not allow two or more brands of without introducing air into the cooling system This kit is
engine oil to mix Each brand contains its own additives provided and must be installed before operating the engine
additives of different brands could react in the mixture NOTE This tank with its short run of plastic hose must be
to produce properties harmful to your engine located above the level of the engines

Engines Generators
PREPARATIONS FOR INITIAL starting your engine for the first time or after a pro
longed layoff check the following items
D Check the engine oil level Add oil to maintain the level
at the high mark on the dipstick DIPSTICK
PUSH IN TIGHT
D Turn on the fuel supply then check the fuel supply and
examine the fuel filterwater separator bowl for contami
nants
D Check the transmission fluid leveL
NOTE Refer to the previous page for fuel oil and
transmission fluid
D Check the DC electrical system Inspect wire connections
and battery cable connections Make certain the positive
battery cable is connected to the starter solenoid and
the negative cable is connected to the engine ground
stud this location is tagged
D Check the coolant level in both the plastic recovery tank
and at the manifold
NOTE If the engine has not yet been filled with coolant
refer to the COOLING SYSTEM section of this manual
D Visually examine the engine Look for loose or missing
parts disconnected wires and unattached hoses Check
the threaded connections and engine Make certain there is proper ventilation around the
engine An ample supply is necessary for proper engine
Make sure the mounting installation is secure
D Ensure the propeller shaft is securely attached to the
transmission
D Open the throughhull and make certain raw water is
primed to the raw water strainer
1 1 I
1 I
ll i
j CcCr COOLANT PRESSURE CAP
MANIFOLD
Engines Generators
PROCEDURE
THE STARTING SYSTEM 5 Should the engine not start when the START button is
depressed for 10 to 20 seconds release both buttons and
These marine diesel engine have l2V DC electric starters The
wait 30 seconds repeat the procedure above and preheat
start circuitry is designed so that the PREHEAT button must
longer Never run the starter for more than 30 seconds
be depressed for the time specified in the preheat chart Then
while keeping the PREHEAT button engaged the START
button is depressed to crank the engine A CAUTION Prolonged cranking Intervals Procedure
the engine starting can result in the engine exhaust
1 Place the transmission in neutral and advance the throttle system filling wfth raw water This may happen because
control to slightly open the pump Is pumping raw water through the raw water
cooling system during cranking This raw water can
enter the engines cylinders by way of the exhaust
A CAUTION Make certain the transmission is manifold once the exhaust system fills Prevent this
in neutral Starting in gear could result in serious
from happening by closing the raw water supply
damage to your transmission your boat and
throughhull shutoff draining the exhaust muffler and
vessels nearby
correcting the cause of the excessive engine cranking
2 Turn the KEY SWITCH to the ON position 2 oclock Engine damage resulting from raw water entry is not a
warrantable issue the should keep this
3 Depress the PREHEAT switch The voltmeter panel
lights gauges meters and fuel solenoid will be activated in mind
The PREHEAT switch should be depressed in accordance
with the following chart 6 Once the engine starts check the instruments for proper
oil pressure and battery charging voltage
NOTE Never attempt to engage the starter while the
Atmospheric Temperature Preheating TIme engine is running
41F5C or higher Approx 5 seconds
41F5C to 23F 5C Approx 10 seconds Starting Under Cold Conditions
23F5C or lower Approx 15 seconds Make sure the lubricating oil is appropriate for the prevailing
temperature Use oil with an API Specification of CF or CG4
NOTE The START button will not energize unless the PRE SAE 30 lOW30 or 15W40 or 20W40
HEAT button is depressed Depressing the PREHEAT button The battery should be fully charged to minimize voltage the glow plugs in
the cylinder head so use the PRE Use a sufficient amount of preheat to aid in starting See the
HEAT to avoid overheating the glow plugs chart elsewhere in this section
4 While still depressing the PREHEAT switch depress the
START switch This will engage the starter solenoid
Stopping Procedure
Upon engine starting release the START switch and To stop the engine bring the throttle to an idle position and
release the PREHEAT switch place the transmission in neutral Allow the engine to idle for
a few moments to stabilize temperatures Turn the engine off
using the stop control cable
NOTE Make certain this key switch is in the OFF position
12 oclock If the key switch is left ON the battery will
12 I 14 discharge An engine alarm buzzer is provided to warn the
NOTE When starting 6 operator of this condition key switch ON The best method
of preventing the battery from discharging is to remove the
A voltage drop will occur
when the preheat button
key from the key switch after stopping the engine
is depressed LJ i VOLTS ALTERNATOR WARNINGS
The Admiral Control Panel uses a voltmeter to monitor the
performance of the alternator
COOLANT TEMPERATURE SWITCH
A coolant temperature switch is located on the thermostat
housing This switch will activate a continuous alarm if the
coolants operating temperature reaches approximately 210F
Engines Generators
WARNING LIGHTS ALARMS CIRCUIT WARNINGS LOW OIL PRESSURE ALARM SWITCH
The Admiral Control Panel uses a voltmeter to monitor the A low oil pressure alarm switch is located off the of the alternator
oil gallery This switchs sensor monitors the engines oil
pressure Should the engines oil pressure fall to 5 IO psi
COOLANT TEMPERATURE SWITCH 04 07 kgcm2 this switch will activate a pulsating alarm
A coolant temperature switch is located on the This switch will activate a continuous alarm if the ENGINE CIRCUIT operating temperature reaches
approximately 2IOOF The DC harness on the engine is protected by an mounted manual reset
circuit breaker 20 amps DC
AIR BLEED
Excessive current draw or electrical overload anywhere in the
PETCOCK instrument panel wiring or engine wiring will cause the
COOLANT TEMPERATURE breaker to trip In this event most engines will shut down
SENDOR because the opened breaker disconnects the fuel supply If
this should occur check and repair the source of the problem
After repairing the fault reset the breaker and restart the
engine
OIL PRESSURE SWITCH
NORMALLY OPEN
THERMOSTAT
HOUSING
OIL PRESSURE
SEND OR
FROM ENGINE
BLOCK
Engines Generators
ENGINE BREAKIN 3 While using the vessel run the engine at various engine
speeds for the first 25 hours Avoid prolonged periods of
Although your engine has experienced a minimum of one
idling
hour of test operations at the factory to make sure procedures were followed and that the engine oper 4 Avoid rapid acceleration especially
with a cold engine
ated properly a breakin time is required The service life of 5 Use caution not to overload the engine The presence of a
your engine is dependent upon how the engine is operated grey or black exhaust and the inability of the engine to
and serviced during its initial 50 hours of use reach its full rated speed are signs of an a new engine basically involves
seating the pis 6 During the next 25 hours the engine may be operated at
ton rings to the cylinder walls Excessive oil consumption varying engine speeds with short runs at full rated rpm
and smoky operation indicate that the cylinder walls are Avoid prolonged idling during this breakin which is caused by overloading the
engine during the
breakin period CHECK LIST
Your new engine requires approximately 50 hours of initial o Monitor the control panel operation to break in each moving part in order
o Check for leaks of fuel and engine oil
to maximize the performance and service life of the engine o Check for abnormal noise such as knocking this conditioning carefully keeping
in mind the fol vibration and blowback o Confirm exhaust smoke
1 Start the engine according to the STARTING PROCE When the engine is cold white smoke
DURE section Run the engine at fast idle while checking When the engine is warm almost smokeless
that all systems raw water pump oil pressure battery When the engine is overloaded some black smoke and soot
charging are functioning
NOTE See the TRANSMISSION section of this manualfor
2 Allow the engine to warm up preferably by running at
breakin information on your fast idle until the water temperature gauge moves into
the 130 140F 55 60C range
Engines Generators
THE DAILY ROUTINE
CHECK LIST STARTING THE ENGINE
Each day before starting your engine take a few moments to NOTE See PROCEDURE in this
run this check list manual for more detailed Visually inspect the engine for fuel oil or water
leaks
1 Put the transmission in neutral throttle advanced
o Check the oil level
o Check the transmission fluid level NOTE Hydraulically operated transmissions have a
neutral safety switch through which the starter solenoid
o Check for loose wires at the alternator energizing circuit passes This switch is open when the
o Check the starting batteries weekly transmission is in gear so the starter solenoid will not
o Check drive belts for wear and proper tension weekly energize
o Log your engine running time These hours relate to 2 Tum the KEY to the ON position 2 oclock
scheduled maintenance 3 Depress PREHEAT 5 seconds
o Check fuel supply always keep fuel tanks as full as 4 While pressing PREHEAT push START As the engine
possible fires release START and PREHEAT
o Look for clean fuel in the fueVwater separator bowl
NOTE Some unstable running may occur in a cold
o Check the coolant level in the plastic recovery tank engine This condition should abate as normal Excessive loss of coolant
indicates a cooling system temperature is reached and loads are Check the entire system If necessary use a cooling sys NOTE
Should the engine fail to start wait 30 seconds
tem pressure tester to pressurize the cooling system to locate then repeat the above procedure and PREHEAT longer
the area of leakage III cases of excessive coolant loss refill
5 Allow a few minutes for the engine to warm at a com
the svstem as outlined in the ENGINE COOLANT CIRCUIT
fortable rpm 1200 rpm then reduce the
sectin of this manual
rpm and get underway
A CAUTION When shifting the transmission always
reduce the engine rpm to idle then shift the transmis
sion firmly from one direction to another A slight pauSe
in neutral will allow the propeller to slow Shifting at
high rpm will damage the plate
Engines Generators
MAINTENANCE SCHEDULE
In order to use this Maintenance Schedule it will be neces
sary to log your engine hours Use your engine hounneter or A WARNING Never attempt to perform any your engine hours by running time
while the engine is running Wear the proper safety
NOTE Many maintenance procedures are equipment such as goggles and gloves and use the
simple but others are more difficult and may require the correct tools for each job Disconnect the knowledge 0 a service
mechanic terminals when servicing any of the engines DC
electrical equipment
SCHEDULED CHECK HOURS OF OPERATION MAINTENANCE DESCRIPTION
MAINTENANCE EACH
DAY 50 100 250 500 750 1000 1250
Fuel Supply 0 Diesel No2 rating of 45 cetane or higher
FuelWater Separator 0 Check for water and dirt in fuel filter
if necessary
Engine Oil Level 0 Oil level should indicate between MAX and LOW on
dipstick
Coolant Level 0 Check at recovery tank if empty check at manifold
Add coolant if needed
Transmission Fluid Level 0 Fluid level should indicate between MAX and LOW
on dipstick
Drive Belts 0 Inspect for proper tension 38 to 12 deflection
weekly and adjust if needed Check belt edges for wear
Visual Inspection of Engine 0 NOTE Keep engine surface clean Dirt and Check for fuel oil and water leaks Inspect wiring
oil will inhibit the engines ability to remain and electrical connections Keep bolts nuts tight
cool Check for loose belt tension
Fuel Filter 0 0 0 0 0 0 Change at 50 hours then every 250 hours
Starting Batteries 0 Check electrolyte levels every 50 operating hours
and House Batteries weekly and make sure connections are very tight Clean off
excessive corrosion
Engine Oil and Filter 0 0 0 0 0 0 0 Initial engine oil filter change at 50 hours then
change both every 100 hours
Heat Exchanger Zinc Anode 0 0 0 0 0 0 0 Inspect zinc anode replace if needed Clear the heat
exchanger end of zinc anode debris
FuelWater Separator 0 0 0 0 0 0 Change filter every 200 hours
Exhaust System 0 0 0 0 Initial check at 50 hours then every 250 hours
Inspect for leaks Check antisiphon valve opera
tion Check the exhaust elbow for carbon andor
corrosion buildup on inside passages clean and
replace as necessary Check that all connections are
tight Check casting integrity
Engine Hoses 0 0 0 0 0 0 Hose should be hard tight Replace if soft or
spongy Check and tighten all hose clamps
Throttle and Transmission 0 0 0 0 Check for loose fittings cotter pins etc
Control Cable Lubricate with WD40 or equivalent
Raw Water Pump 0 0 0 Remove the pump cover and inspect the impeller
gasket cam and cover for wear Check the bearings
and seals the shaft can turn but not wobble
Lubricate when
continued
Engines Generators
MAINTENANCE SCHEDULE
NOTE Use the engine hourmeter gauge to log your engine hours or record your
engine hours by running time
SCHEDULED CHECK HOURS OF OPERATION
MAINTENANCE EACH MAINTENANCE DESCRIPTION
DAY 50 100 250 500 750 1000 1250
Coolant System 0 0 Drain flush and refill cooling system with
appropriate antifreeze mix
DC Alternator 0 0 0 Check DC charge from alternator Check mounting
bracket tighten electrical connections
Transmission Oil Cooler 0 Remove have cleaned and pressure
tested
Engine Transmission 0 Chattering at idle and low rpms is an indication
Damper Plate of damper plate wear Remove and replace
0 Check and adjust injection opening pressure and
spray condition Refer to your service manual
Starter Motor 0 0 Check solenoid and motor for corrosion Remove
and lubricate Clean and lubricate the starter motor
pinion drive
Preheat Circuit 0 0 Check operation of preheat solenoid Remove and
clean glow plugs Reinstall with antiseize
compound on threads
Engine Cylinder 0 0 Check compression pressure and timing
Compression see ENGINE Adjust the Valve Clearances 0
0 0 Adjust Valve Clearances see ENGINE
Heat Exchanger 0 Remove have cleaned and pressure
tested
Lubricate Panel Key Switch 0 0 0 0 0 0 At first 100 hours then each year at winterizing
with Lockeze
Transmission 0 0 0 0 0 0 Initial fluid change at 25 hours then every
Fluid and Filter 300 hours or at winterizing Replace the filter at each
fluid change
Feed Pump Strainer 0 0 0 0 0 Clean every 250 operating hours
Turbocharger 0 0 Initial 50 hour check inspect all connections for oil
and exhaust leaks Check mounting bolts for
tightness Check for air leakage Inspect the radial
and axil play of the rotor shaft Lubricate the shaft
recommends this service be performed by an authorized Engines Generators
COOLING NOTE Periodically check the condition of the manifold marine diesel engines are
designed and equipped sure cap Ensure that the upper and lower rubber seals are ill
for fresh water cooling Heat produced in the engine by good condition and check that the vacuum valve opens and friction is transferred to
fresh water coolant closes tightly Carry a spare cap
which circulates throughout the engine This circulating fresh
water coolant cools the engine block its internal moving
parts and the engine oil The heat is transferred the fresh water coolant to raw water by means of a similar in function to an automotive radiator
water flows through the tubes of the heat exchanger while
fresh water coolant flows around the tubes engine to the fresh water coolant is conducted through
the tube walls to the raw water which is then pumped into the
exhaust system where finally it is discharged overboard In CHANGING COOLANT
other words the engine is cooled by fresh water coolant this The engines coolant must be changed according to the
coolant is cooled by raw water and the raw water carries the MAINTENANCE SCHEDULE If the coolant is allowed heat overboard through the exhaust
system The become contaminated it can lead to overheating water coolant and raw water circuits are independent of
each other Using only fresh water coolant within the the cooling water passages to stay clean and free from A CAUTION Proper cooling system
maintenance is
harmful deposits critical a substantial number of engine faiures can be
traced back to cooling system WATER COOLING CIRCUIT
NOTE Refer to the ENGINE COOLANT section for the rec Drain the engine coolant by loosening the drain plug on the
ommended antifreeze and water mixture to be used as the engine block and opening the manifold pressure cap Flush
fresh water coolant the system with fresh water then start the refill water coolant is pumped
through the engine by a
circulating pump absorbing heat from the engine The
coolant then passes through the thermostat into the manifold
A WARNING Beware of the hot engine coolant
to the heat exchanger where it is cooled and returned to the Wear protective block via the suction side of the circulating pump
When the engine is started cold external coolant flow is
prevented by the closed thermostat although some coolant
flow is bypassed around the thermostat to prevent the from overheating As the engine warms up gradually opens allowing full flow of the to flow
unrestricted to the external portion of the
cooling Recovery Tank
A coolant recovery tank allows for engine coolant expansion
and contraction during engine operation without loss of coolant and without introducing air into
the cooling system This tank should be located at or above
the engine manifold level and should be easily
TO COOLANT RECOVERY DRAIN PLUG
TANK
DRAIN PETCOCK
COOLANT
COOLANT EXPANSION I
SOME ENGINE MODELS ARE EQUIPPED
WITH A PETCOCK THAT ALLOWS FOR
Engines Generators A HOSE TO BE ATTACHED
COOLING the Coolant Replacing the closing the engine block drain pour clean premixed
Remove the cap screws and disassemble the thermostat hous
coolant into the manifold and when the coolant is visible in ing as shown When installing the new thermostat and gasket
the manifold start the engine and run it at slow idle Open apply a thin coat of sealant on both sides of the gasket before
the air bleed petcocks on the manifold and the thermostat pressing it into place Do not overtighten the cap
Run the engine and check for normal temperatures and that
Monitor the coolant in the manifold and add as needed Fill there are no leaks at the thermostat housing
the manifold to the filler neck and when the coolant flowing
from the petcock is free of air bubbles close the petcock and
install the pressure cap
Remove the cap on the coolant recovery tank and fill with
coolant mix to halfway between LOW and MAX and replace
the cap Run the engine and observe the coolant into the recovery tank When the petcock on housing is free of air bubbles close that checking for
leaks stop the engine and allow it to cool
Coolant should draw back into the cooling system as the
engine cools down Add coolant to the recovery tank if
needed Clean up any spilled coolant
AIR BLEED TEMPERATURE
PETCOCK y Q
0r1 j
THE GASKET IS GROOVED
FITS AROUND THE OUTER
EDGE OF THE I
A thennostat located near the manifold at the front of the
engine controls the coolant temperature as the flows through the closed cooling circuit
When the engine is first started the closed thermostat pre
vents coolant from flowing some coolant is a hole in the thermostat to prevent the from overheating As the engine warms up gradually opens The
thermostat is can be checked cleaned or replaced easily Carry a CHANGING THE thermostat and gasket
Engines Generators
COOLING SYSTEM
RAW WATER COOLING CIRCUIT Changing the Raw Water Pump Impeller
The raw water flow is created by a positive displacement Close the raw water intake valve Remove the pump pump This pump draws water
directly from the raw and with the aid of an impeller puller carefully pry the
water source ocean lake or river through a hose to the impeller out of the pump Install the new impeller and gasket
water strainer The raw water passes from the strainer Move the blades to conform to the curved cam plate and
through the raw water pump to the heat exchanger through push the impeller into the pumps housing When assem
the heat exchanger tubes where it cools the engine circulat bling apply a thin coating of lubricant to the impeller and
ing fresh water coolant The raw water is then discharged gasket Open the raw water intake valve
into the exhaust elbow mixing with and cool To be certain the pump is operating properly run the engine
ing the exhaust gasses This mixture of exhaust gas and raw and check the is discharged overboard by the engines exhaust gas
discharge pressure
o Inspect the raw water pump for leaks
o After warm up monitor the temperature gauge It should
Raw Water Pump indicate a normal engine raw water pump is a selfpriming rotary pump with
a o Check aft There should be a steady flow of water housing and a neoprene impeller The impeller the stem tube
has flexible vanes which wipe against a curved cam plate
within the impeller housing producing the pumping action
On no account should this pump be run dry as water acts as a A CAUTION If any of the vanes have broken off the
lubricant for the impeller There should always be a spare impeller they must be found to prevent blockage in the
impeller and impeller cover gasket an impeller kit aboard cooling circuit They onen can be found in the heat
Raw water pump impeller failures occur when lubricant raw is not present during engine operation Such failures
are not warrantable and operators are cautioned to make sure
raw water flow is present at startup Impeller Puller
NOTE Should a failure occur with the pumps internal parts WESTERBEKE recommends using an impeller puller to
seals and bearings it may be more cost efficient to pur remove the impeller this will prevent damage to the blades
chase a new pump and rebuild the original pump as a spare and to the edges of the pump housing
IMPELLER
INSPECTION CHECK AT THE BASE OF
EACH BLAOE BY BENDING VIGOROUSLY
REPLACE THE IMPELLER IF THERE
ARE ANY CRACKS WATER LEAKING HERE WOULD
WHEN INSTALLING TAKE CARE TO ALIGN INDICATE THE PUMP SEAL HAS
THE IMPELLER KEYWAY WITH THE SHAFT FAILED AND THE PUMP NEEDS
KEY FOLD THE IMPELLER BLADES IN IMMEDIATE SERVICE
EITHER DIRECTION THEY WILL TURN IN
THE CORRECT POSITION WHEN THE
PUMP STARTS
GREASE THE BLADES AND THE PUMP
CHAMBER WITH PETROLEUM JELLY
TO PROVIDE LUBRICATION FOR THE
FEW SECONDS THE PUMP HAS TO RUN DRY
THE GREASE IMPROVES THE SEAL
OF THE BLADES AND MAKES INSTALLATION
EASIER THE ORING GASKET
RAW WATER PUMP
ONLY NEEDS TO BE
REPLACED IF IT SHOWS
SIGNS OF WEAR
Engines Generators
COOLING SYSTEM
HEAT EXCHANGER
The heat exchanger is a copper cylinder which encloses a
large number of small copper tubes Raw water is the small copper tubes and the fresh water coolant ZINC ANODES
from the engine is circulated around the copper tubes The
raw water removes heat from the fresh water Exchanger Service
After approximately 1000 hours of operation remove clean
and pressure test the engines heat exchanger A local auto
motive radiator shop should be able to clean and test the NEW REPLACE
CLEAN REUSE
NOTE Operating in silty andor tropical waters may require If the zinc anodes need replacement hold the hex boss into
that a heat exchanger cleaning be perfonned more often than which the zinc anode is threaded with a wrench while loos
every 1000 hours ening the anode with another wrench This prevents the hex
boss from possibly tearing off the exchanger shell After
Zinc Anode removing the zinc note the condition of it If the zinc is in
A zinc anode or pencil is located in the raw water cooling poor condition there are probably a lot of zinc flakes within the heat exchanger
The purpose of having the exchanger Remove the end of the heat exchanger and
zinc anodes is to sacrifice them to electrolysis action taking clean the inside of all zinc debris Always have a spare heat
place in the raw water cooling circuit thereby reducing the exchanger end gasket in case the present one becomes dam
effects of electrolysis on other components of the system aged when removing the end cover Replace the gasket refer
The condition of the zinc anode should be checked monthly to your engine models heat exchanger end gasket part num
and the anode cleaned or replaced as required Spare anodes ber Oring and cover and install a new zinc anode
should be carried on board NOTE The threads of the zinc anodes are pipe threads and
NOTE Electrolysis action is the result of each particular do not require sealant Sealant should not be used as it and vessel location not
that of the engine insulate the zinc from the metal of the heat exchanger hou
ing preventing electrolysis action on the zinc
CLEAN OUT ACCUMULATED DEBRIS
CLEAN OUT
BOTH ENDS
ZINC ANODE
ALSO SERVES AS A DRAIN
FOR THE RAW WATER SYSTEM
HEAT EXCHANGER
GASKET
TO REMOVE HEAT 17
COOLING SYSTEM
Raw Water Intake Strainer NOTE Also follow the above procedure after having run hard
Always install the strainer at or below the waterline so
the strainer will always be selfpriming If the engine temperature gauge ever shows a higher than
normal reading the cause may be that silt leaves or grass
A clean raw water intake strainer is a vital component of the may have been caught up in the strainer slowing the flow of
engines cooling system Include a visual inspection of this raw water through the cooling when making your periodic engine check The water
in the glass should be the following maintenance after every 100 hours Close the raw water seacock
2 Remove and clean the strainer filter
WASHER
3 Clean the glass
4 Replace the washer if necessary
5 Reassemble and install the strainer
6 Open the seacock
7 Run the engine and check for leaks
STRAINER
FILTER
TYPICAL RAW WATER INTAKE STRAINER
tOwner Installed
AIR INTAKE FILTER
TO ARM COVER
A marine diesel engine will typically consume as much as
6000 cubic feet of air per hour Not only must the engine
room be well ventilated the air flow into the engine must The air intake should be 100 operating hours Cleanreplace when needed
AIR INTAKE FILTER
Engines Generators
FUEL SYSTEM
DIESEL FUEL FUEL FILTERS
Use No2 diesel fuel with a cetane rating of 45 or higher Do not The fuel injection pump and the fuel injectors are precisely
use kerosene or home heating fuel manufactured and they must receive clean diesel fuel free
from water and dirt To ensure this flow of clean fuel the fuel
FUEL WATER SEPARATOR must pass through at least two fuel filters a fuelwater sepa
A primary fuel filter of the water separating type must be rator and the engines spinon fuel filter Visually between the fuel tank
and the engine to remove clean and change these filters according to the and other contaminants from the fuel before they can
schedule in this manual
be carried to the fuel system on the engine
Most installers include a type of filterwater separator with
the installation package as they are aware of the problems A WARNING Shut off the fuel valve at the tank
that contaminants in the fuel can cause when servicing the fuel system Take care in catching
any fuel that may spill DO NOT allow any smoking
A typical fuel filterwater separator is iIIustrated below This open flames or other sources of fire near the fuel
is the Raycor Model 445 Keep in mind that if a water system when servicing Ensure proper ventilation exists
separator type filter is not installed between the fuel supply when servicing the fuel system
tank and fuel system any water in the fuel
will affect the fuel pump engine filter and injection
equipment The is responsible for making
certain the fuel reaching the engines injection equipment is
free of impurities This process is accomplished by installing
and maintaining a proper system
FUEL FILTER
WATER Installed
LIGHTLY WIPE
WITH CLEAN FUEL
TO LlFTPUMP
AND INCOMING
FUEL
TO INJECTION
PUMP
Changing the Fuel Filter
1 Shut the fuel supply off
2 Loosen the fuel filter turning with a
FUEL INJECTION PUMP filter wrench Place the used filter in a container for proper
disposal
The fuel injection pump is a very important component of the
diesel engine requiring the utmost care in handling The fuel 3 Using a rag wipe clean the sealing face on the housing
injection pump has been thoroughly benchtested and the bracket so the new filter can be seated properly
is cautioned not to attempt to service it If it 4 Lightly oil the sealing Oring on the new filter To rein
requires servicing remove it and take it to an authorized fuel stall turn the filter assembly carefully
injection pump service facility Do not attempt to disassemble until the Oring contacts the sealing surface of the housing
and repair it bracket Turn 23 further with the filter wrench
The only adjustment the servicing mechanic should make to the NOTE The cartridge contains fuel Take care not to spill it
fuel injection pump is the adjustment for engine idle speed during FUEL LIFT PUMP
The fuel lift pump is an integral part of the fuel injection pump
Engines Generators
FUEL SYSTEM
FUEL FEED PUMP STRAINER BLEEDING PRIMING THE FUEL SYSTEM
An additional fuel screen is located in the feed pump This 1 Loosen the bleeding screw on the fuel injection pump
screen strainer is removed for cleaning by releasing the 2 Tum the feed pump knob until the pump
banjo bolt at the bottom This screen should be cleaned every knob is forced up by the spring
250 operating hours Use compressed air andor clean 3 Depressing the pump knob will cause it
to drain out the air
mixed fuel from the loosened bleeding screws
TO FUEL FILTER 4 Repeat the pumping action until no bubbles are visible in
the flowing fuel
5 Tighten the bleed screw and the feed pump knob
FUEL ADDITIVES
If fungus or bacteria is causing fuel problems you should have
INJECTION PUMP
BLEED SCREW an authorized dealer correct these problems Then use a diesel
fuel biocide to sterilize the fuel follow the instructions
SPARE PARTS
FEED PUMP While the likelihood of having to service the system at sea is
slim the possibility does exist Therefore we recommend that
banjo washers injector seat washers and a fuel filter be carried on
board at all times Purchase needed spare parts from your local
FUEL FEED PUMP WESTERBEKE dealer or distributor If a leak should develop at
a banjo washer that cannot be corrected by a simple tightening of
the fitting replace the sealing washer with a replacement found in
the hardware kit for your model
14 BANJO
BOLT
After changing the fuel filter and cleaning the fuel feed WESTERBEKE recommends the following proce
dure for ensuring there is no air trapped in the fuel system
Engines Generators
ENGINE LUBRICATING lubricating system is a pressure feeding system using an NOTE Generic filters are not recommended as the mater
oil pump The engine oil is drawn from the oil sump by the ial standards or diameters of important items on generic
oil pump which drives the oil under pressure through the parts might be entirely different from genuine parts
oil filter oil cooler and various lubricating points in the Immediately after an oil filter change and oil fill run the
engine The oil then returns to the oil sump to repeat the engine to make sure the oil pressure is normal and cycle When the oil pressure
exceeds the there are no oil leaks around the new pressure the oil pushes open the relief valve in the 3 Filling the Oil
Sump Add new oil through the oil filler
oil pump and returns to the oil sump keeping the oil pressure cap on the top of the engine After refilling run the
within its specified range engine for a few moments while checking the oil
pressure Make sure there is no leakage around the new
Oil Pressure oil filter or from the oil drain system and stop the engine
The engines oil pressure during operation is indicated Then check the quantity of oil with the lube oil dipstick
by the oil pressure gauge on the instrument panel During Fill to but not over the high mark on the dipstick should
normal operation the oil pressure will range between 25 and the engine require additional oil
85 psi
ENGINE OIL CHANGE
1 Draining the Oil Sump Discharge the used oil through
the sump drain hose attached to the front of the engine
while the engine is wann Drain the used oil completely
replace the hose in its bracket and replace the end cap
SPIN ON
1 OIL FILTER
urely
FOR EXTENSION TURN HAND TIGHT AGAINST
14 NPT ORING THEN TIGHTEN
23 OF A TURN
SUMP
DRAIN ORING
HOSE APPLY CLEAN
600 ENGINE OIL
WHEN INSTALLING
Always observe the used oil as it is removed A
yellowgray emulsion indicates the presence of water in
the oil Although this condition is rare it does require
prompt attention to prevent serious damage Call a
qualified mechanic should water be present in the oil
Raw water present in the oil can be the result of a fault in
the exhaust system attached to the engine andor a
siphoning of raw water through the raw water cooling
circuit into the exhaust filling the engine This problem is
often caused by the absence of an antisiphon valve its CUSTOMER OPTION
poor location or lack of maintenance THIS WIRE CAN BE
USED TO ATTACH A
2 Draining the Oil Filter Back off the drain plug until oil GAUGE OR ALARM
flows from the drain into an appropriate container After OEVICE TO MONITOR
draining remove the filter and wipe off any excess oil THE CONDITION OF
Tighten the drain plug THE OIL FILTER THE
WIRE IS CURRENTLY
When installing the new oil filter element wipe the BUNDLED INTO THE
filters Oring gaskets sealing surface free of oil and WIRING HARNESS
apply a thin coat of clean engine oil to the rubber Oring
on the new oil filter Screw the filter onto the threaded oil
filter nipple on the oil filter bracket and then tighten the CHANGING THE ENGINE OIL
filter firmly by hand
Engines Generators
REMOTE OIL FILTER To install simply remove the engine oil filter and thread on
WESTERBEKEs remote oil filter kit as shown Always
This popular accessory is used to relocate the engines oil fil install this kit with the oil filter facing down as from the engine to a more
convenient location such as an
engine room bulkhead Contact your WESTERBEKE dealer for more Refer to ENGINE OIL CHANGE in this
manualfor NOTE Westerbeke is not responsible for engine failure due on removing the oil filter
incorrect installation of the Remote Oil Filter
A CAUTION It Is Ifltal to Install the oillnes
correctly If the 011 flows In themvelSB dlmctlon the
bypass valve In the filter assembly will prevent the 011
FASTEN SECURelY TO A BULKHEAD
from reaching the engine causing an Intemal engine SCREWS ARE OWNER SUPPLIED
failure If there Is no 011 pmssuTB reading shutdown
immediately and check the hose NOTE THE IN AND OUT MARKINGS
ON THE ADAPTER WHEN THE HOSES ARE
REMOVED FOR INSTALLATION SO THEY
WILL BE RECONNECTED I
APPLY A THIN COAT OF CLEAN OIL TO THE FIL
TER GASKET WHEN INSTALLING AFTER THE
APPLY A COAT OF CLEAN OIL TO THE ORING WHEN FILTER CONTACTS THE BASE TIGHTEN IT AN
INSTALLING THIS KIT THREAD THE KIT ON THEN HAND ADDITIONAL 34 TURN
TIGHTEN AN ADDITIONAL 34 TURN AFTER THE ORING
CONTACTS THE BASE
Engines Generators
WATER HEATER CONNECTION OPTIONAL
As an accessory WESTERBEKE wiJI provide a connector The water heater shouKl be mounted in a convenient location
that directs the engines hot water coolant flow to heat the either in a high or low position in relation to the engine so
fresh water in the ships hot water tank that the connecting hoses from the heater to the engine can
run in a reasonably direct line without any loops which
might trap air
Hoses should rise continuously from their low point at the
ROCKER
COVER
heater to the engine so that air will rise naturally from the
heater to the engine If trapped air is able to rise to the heater
then an air bleed petcock must be installed at the higher
fitting on the heater for bleeding air while filling the system
NOTE If any portion of the heating circuit rises above the
engines closed cooling system pressure cap then a pressur
ized aluminum remote expansion tank Kit 024177 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
ENGINE the other back to the engines return Install the remote
FRONT expansion tank in a convenient location so the fresh water
coolant level can easily be checked The remote expansion
tank will now serve as a check and system fill point The
plastic coolant recovery tank is not used when the remote
HOSES expansion tank kit is installed since this tank serves the
CONNECT TO same function
THE HOT WATER
TANK EITHER
CONNECTION
CUT THE DISCARDED
MOLDED HOSE TO
PROVIDE THE TWO HOSE
CONNECTIONS THAT REMOTE EXPANSION
ARE NEEDED TO ATTACH TANK
THE CONNECTOR TO
THE ENGINE
WATER WATER
HEATER HEATER
Engines Generators
DC ELECTRICAL SYSTEM
ALTERNATOR 1 Start the engine
The charging system consists of a DC belt driven alternator 2 After the engine has run for a few minutes measure the
with a voltage regulator an engine DC wiring harness a starting battery voltage at the battery terminals using a
mounted DC circuit breaker and a battery with connecting multimeter set on DC volts
cables Because of the use of integrated circuits lCs the a If the voltage is increasing toward 14 volts the alterna
electronic voltage regulator is very compact and is mounted tor is working omit Steps 3 through 8 and go directly
internally or on the back of the alternator to Checking the Service Battery on the next page
hIf the voltage remains around 12 volts a problem
exists with either the alternator or the charging circuit
14 continue with Steps 3 through 8
CIDJ
14 PINK BLUE
914 BROWN MULTIMETER
10 REO
SEE WIRING DIAGRAM
ENGINE FOR WIRE CONNECTIONS
GROUND 1 TO OPTIONAL ALTERNATOR TESTING THE STARTING
ENGINE RUNNING
A WARNING A failed alternator can become very
hot 00 not touch until the alternator has cooled down GROUND
Use this section to determine if a problem 3 Turn off the engine Inspect all wiring and connections
exists with the charging circuit or with the alternator If it is Ensure that the battery terminals and the engine ground
determined that the alternator or voltage regulator is faulty connections are tight and clean
have a qualified technician check it
The alternator charging circuit charges the starting battery A CAUTION To avoid damage to the battery
and the service battery An isolator with a diode a solenoid charging circuit never shut off the engine battery
or a battery selector switch is usually mounted in the circuit switch when the engine is running
to isolate the batteries so the starting battery is not discharged
along with the service battery If the alternator is charging the 4 If a battery selector switch is in the charging circuit
starting battery but not the service battery the problem is in ensure that it is on the correct setting
the service batterys charging circuit and not with the alterna
S Turn on the ignition switch but do not start the engine
6 Check the battery voltage If the battery is in good condi
Testing the Alternator tion the reading should be 12 to 13 volts
Cl2ID
A CAUTION Before starting the engine make certain
that everyone is clear of moving parts Keep away from
sheaves and belts during test procedures
A WARNING When testing with a multimeter
DC and AC circuits are often mixed together in marine
applications Always disconnect a shore power cord
isoate DC and AC converters and shut down the engine
TESTING THE
before performing DC testing No AC tests should be ALTERNATOR VOLTAGE
made without a proper knowedge of AC circuits IGNITION ON ENGINE OFF
Engines Generators GROUND
DC ELECTRICAL SYSTEM
7 Now check the voltage between the alternator output ter Checking the Service Battery
minal B and ground If the circuit is good the voltage at
Check the voltage of the service battery This battery should
the alternator will be the same as the battery or if an isola
have a voltage between 13 and 14 volts when the engine is
tor is in the circuit the alternator voltage will be zero If
running If not there is a problem in the service battery
neither of the above is true a problem exists in the circuit
charging circuit Troubleshoot the service battery charging
between the alternator and the battery Check all the
circuit by checking the wiring and connections the solenoid
connections look for an opening in the charging circuit
isolator battery switch and the battery itself
MULTIMETER CI2ID
WITCH
MumMETER i
a I
TESTING THE STARTING
ENGINE RUNNING I
8 Start the engine again Check the voltage between the
ENGIN E
GROUND
alternator output and ground SERVICE BATTERY
The voltage reading for a properly operating alternator
should be between 135 and 145 volts If your alternator GROUND TESTING THE SERVICE
is over or have it repaired at a reliable
BATTERY ENGINE RUNNING
service facility
NOTE Before removing the alternator for repair use a
voltmeter to ensure that 12 volts DC excitation is present
at the EXC terminal if the previous test showed only bat A CAUTION To avoid damaging the alternator diodes
tery voltage at the B output terminal do not use a high voltage tester ie a megger when
performing tests on the alternator charging circuit
If 12 volts is not present at the EXC terminal trace the
wiring and look for breaks and poor VOLT DC CONTROL CIRCUIT Battery Care
The engine has a 12 volt DC electrical control circuit that is Review the and then
shown on the wiring diagrams that follow Refer to these establish a systematic maintenance schedule for your
diagrams when or when servicing the DC engines starting batteries and house system
o Monitor your voltmeter for proper charging during
engine operation
A CAUTION To avoid damage to the battery charging o Check the electrolyte level and specific gravity with a
hydrometer
circuit never shut off the engine battery switch while
the engine is running Shut off the engine battery SWitch o Use only distilled water to bring electrolytes to a proper
level
however to avoid electrical shorts when working on the
engines electrical circuit
o Make certain that battery cable connections are clean and
tight to the battery posts and to your o Keep your batteries clean and free
of minimum recommended capacity of the battery used in
the engines 12 volt DC control circuit is 600 900 Cold
Cranking Amps CCA
A WARNING Sulfuric acid in lead batteries can
cause severe bums on skin and damage clothing Wear
protective gear
Engines Generators
GLOW PLUGS
DESCRIPTION Reinstall the plugs in the engine and test them again The
plugs should get very hot at the terminal end within 7 to 15
The glow plugs are wired through the preheat solenoid
seconds If the plugs dont heat up quickly check for a short
When PREHEAT is pressed at the control panel this solenoid
circuit When reinstalling the glow plugs use antiseize com
should click on and the glow plug should begin to get hot
pound on the threads
INSPECTION
To inspect the plug remove the electrical terminal connec A WARNING Do not keep a glow plug on for more
tions then unscrew or unclamp each plug from the cylinder than 30 seconds
head Thoroughly clean each plugs tip and threads with a
soft brush and cleaning solution to remove all the carbon and Glow Plug Tightening Torque 195 HIb 27 mkg
oil deposits While cleaning examine the tip for wear and
burn erosion if it has eroded too much replace the plug
TERMINAL
TESTING
An accurate way to test glow plugs is with an ohmmeter
Touch one prod to the glow plugs wire connection and the
other to the body of the glow plug as shown A good glow TESTING A GLOW PLUG
plug will have a 04 06 ohm resistance This method can be WITH AN OHMMETER
used with the plug in or out of the engine You can also use an ammeter to test the power drain 5 6 amps per plug
A WARNING These glow plugs will become very hot TIP
to the touch Be careful not to burn your fingers when
testing the plugs
TESTING A GLOW PLUG
GLOW PLUGS USING A TEST LIGHT
FROM
Engines Generators
WIRING SCHEMATIC
MARINE ENGINES 44781
START
SOl STARTER
IZV 24V
20A lOA
CB CB
OPTIONAL ALTERNATORS
e
c
PRESlOLllE 12 AMP ALl
TACHOMETER
KEY
90 AMP ALl
PREHEAT
SWITCH
DISCONNECT JUMPER fOR
USE WITH TWO LESTEK 135 160 190 AMP ALT
l ZUlli
Engines Generators
WIRING DIAGRAM
MARINE ENGINES 44781
ALTERNATOR 21Y 12A
USED
aNEUTRAL
DELSI
BATTERY
1221 VDC
NOTES
NIS IOOUCI IS onenD IT 1iI IiIUAL tun ClIltUIl RUln LOCATED IIUI TME
ITAnn attallV CUIIUT Will UUS Ttll ltUllII TO nIP AIID THE IIIII Will
SMUT DOIIiI HE MUST Sf SUII THU THE IISTIUIiIUT pln WIIIIG toIO
IIGI AlE STALUD TO IIVUT COIICT enEU lECTlICAL OUlets AIID sUlun
2 II allorr SWITCH ItOULD IE IUTALUI IUElI THE IHUr I STAUn TO
DISCOIIT THE aTTU UI MUGUel liD II LlAWl1IG TME 10AT SWnCM
WITH A COITIIIUGUS IUIG or 115 Allrs AT 12 DC WILL IlV THIS rUIICTlOI IMIS
1 TeM MOULD lOT IE uUD TO MAil 01 IAI THE C leUIT
J THE 11 11It AT LUG Z IS Iusn D SHOULD IE USULATED CAPUI un OIlU
II ADMIRAL
TME III AT UG 1 IS uusn 0 SMOULD liE IIilSULun ADlIIIAL u n Gell
5 co lcr rill CIICUIl IIURU 0 USIUOt I ro l rUIIL rOt 12 WOlf
nSTUS OIU FOt Z4 VOLT nSTtMs IMOVI rill Clleulr IIUIII 10 coler rill
IUISTOI lIl ro rill 4 LT ILU WillS ID rill GlOUID rll rUM l PANEL
L
110 REO
Engines Generators
ENGINE following table describes certain problems NOTE The engines electrical system is protected by a 20
relating to engine service the probable causes of these prob ampere manual reset circuit breaker located on a bracket at
lems and the to overcome these problems the back of the engine The preheat solenoid is mounted on
the same bracket
Problem Probable Cause No panel indications fuel solenoid 1 Battery switch
not on 1 Check switch andor battery connections
or fuel pump is not working key switch
is on and PREHEAT button is depressed 2 20amp circuit breaker tripped 2 Reset breaker if breaker trips again check preheat solenoid
circuit and check circuit for shorts to ground
3 10amp breaker tripped on 3 Check the voltage both at and after the breaker on the
preheat solenoid preheat solenoid wait for it to cool then rest
4 Loose battery connections 4 Check connection to starter solenoid and connection to
engine ground stud Check battery cable connections
5 Preheat solenoid not operating 5 Check solenoid S terminal for voltage
START button is depressed no starter 1 Connection to solenoid faulty 1 Check connection
engagement
2 Gear shift not in neutral 2 Gear shift must be in neutral see NEUTRAL SWITCH under
HURTH 3 Faulty switch 3 Check switch with ohmmeter
4 Faulty solenoid 4 Check that 12 volts are present at the solenoid connection
5 Loose battery connections 5 Check battery connections
6 Low battery 6 Check battery charge state
Engine cranks but does not 1 Faulty fueling system 1 Check that fuel valves are open
start
1a Check for air in fuel system Bleed air from fuel system
1b Fuel filters clogged Replace filters and bleed air from
fuel system
2 Preheat solenoid faulty 2 Check solenoid
3 Low battery power 3 Switch to combine house and start batteries
3a Replace batteries
Engine cant be stopped 1 Disconnect fuel shutoff cable 1 Check connection at shutoff lever Pull lever back to close
off the fuel
Battery runs down 1 Oil pressure switch 1 Observe if gauges and panel lights are activated when engine
is not running Test the oil pressure switch
2 High resistance leak to ground 2 Check wiring Insert sensitive 0 25 amp meter in battery
lines Do not start engine Remove connections and replace
after short is located
3 Low resistance leak 3 Check all wires for temperature rise to locate the fault
4 Poor battery connections 4 Check cable connections at battery for loose connections
corrosion
5 DC alternator not charging 5 Check connections check belt tension test alternator See
tachometer not operating DC ELECTRICAL Battery not charging 1 Alternator drive 1
Check drive belt tension alternator should turn freely Check
for loose connections Check output with voltmeter Ensure 12
volts are present at the Exc terminal
Engine slows and stops 1 Fuel starvation 1 Check fuel supply fuel valves fuel lift pump
2 20 Amp circuit breaker tripping 2 Check for high DC amperage draw during operation
Ensure breaker is not overly sensitive to heat which would
cause tripping Push button to reset
3 Exhaust system is restricted 3 Check for blockage collapsed hose carbon buildup at
exhaust elbow
4 Water in fuel 4 Pump water from fuel tanks change filters and
bleed fuel system
5 Air intake obstruction 5 Check air intake filter cartridge
Engines Generators
ENGINE Problem Probable Cause Engine overheats 1 Raw
water not circulating 1 Raw water pump failure Check impeller replace
2 Coolant not circulating 2 Obstruction at raw water intake or raw water filter
2a Thermostat remove and test in hot water
Replace thermostat
2b Loss of coolant check hoses hose clamps drain plug etc
lor leaks
2c Broken or loose belts 2d Air leak in system run engine and open
the pressure cap to
bleed air Add coolant as needed
Engine alarm sound pulsates 1 Loss of oil 1 Check dipstick look for oil leaks at oil filter and at
oil drain hose connection
2 Oil pressure switch 2 Replace oil pressure switch
Engine alarm sounds continuously 1 Engine coolant 1 Check engine coolant level
2 High temperature switch opens at 2 Check for satisfactory operation with switch bypassed
too Iowa temperature check with ohmmeter replace if faulty
Exhaust smoke problems 1 Blue smoke 1 Incorrect grade of engine oil
1a Crankcase is overfilled with engine oil oil is blowing out
through the exhaust
2 White smoke 2 Engine is running cold
2a Faulty injector or incorrect injector timing
3 Black smoke 3 Improper grade of fuel
3a Fuel burn incomplete due to high backpressure in exhaust or
insufficient air for proper combustion check for restrictions in
exhaust system check air intake
3b Improperly timed injectors or valves or poor compression
3c Lack of air check air intake and air filter Check for proper
ventilation
3d COOLANT TEMPERATURE AND OIL PRESSURE GAUGES
If the gauge reading is other than what is nonnally indicated If both of the above gauge tests are positive the gauge is
by the gauge when the instrument panel is energized the first undoubtedly OK and the problem lies either with the
step is to check for 12 volts DC between the ignition B conductor from the sender to the gauge or with the sender
and the Negative B tenninals of the gauge If either of the above gauge tests are negative the gauge is
Assuming that there is 12 volts as required leave the probably defective and should be panel energized and perfonn the following
steps Assuming the gauge is OK check the conductor from the
1 Disconnect the sender wire at the gauge and see if the sender to the sender tenninal at the gauge for continuity
gauge reads zero which is the nonnal reading for this Check that the engine block is connected to the ground
situation Some starters have isolated ground tenninals and if the
2 Remove the wire attached to the sender tenninal at the battery is connected to the starter both plus and minus
sender and connect it to ground See if the gauge reads tenninals the ground side will not necessarily be connected
full scale which is the nonnal reading for this situation to the block
Engines Generators
METER NOTE Current model tachometers use a coarse meter used in propulsion engine instru
dial to set the tachometer to the crankshaft pulley rpms The
ment panels contains two separate electrical circuits with a calibrating screw is then used for fine ground One circuit operates the hour
meter and the
other the tachometer The hour meter circuit operates on 12
volts alternator charging voltage supplied to the terminal
on the back of the tachometer circuit operates on AC voltage 68 volts fed
from one of the diodes in the alternator and supplied to input terminal while the engine is running and
the alternator producing battery charging voltage 130148 DC
The following are procedures to follow when COARSE
a fault in either of the two circuits in a
TACH INP
Hour meter Inoperative AC VOLTAGE
Check for the proper DC voltage between and TACHOMETER CHECK New Voltage present meter
is defective repair or replace NOTE In a new installation having new instrument panels
the tachometer may not always be correctly calibrated to the
2 Voltage not present trace and electrical con
engines rpm This calibration should be checked in all new
nections for fault Jump 12 volts DC to meter
terminal to verify the operation
1 Warm up the engine to normal operating Inoperative Remove any specks on the crankshaft pulley
with a clean
Check for the proper AC voltage between tachometer input cloth and place a piece of suitable reflecting tape on the
terminal and terminal with the engine running pulley to facilitate use of a photoelectric type Voltage present attempt
adjusting meter through calibra 2 Start and idle the engine
tion access hole No results repair or replace meter 3 Aim the light of the tachometer onto the reflecting tape to
2 AC voltage not present check for proper alternator DC confirm the engine speed Check the instrument panel
output voltage tachometer reading Adjust the tachometer in the panel by
3 Check for AC voltage at tach terminal on alternator to using the instrument coarse adjustment to calibrate the
ground instrument reading to the closest RPM that the photo tach
is showing Then use the fine calibration adjustment to
4 Check electrical connections from tachometer input ter bring the instrument to the exact reading as the photo tach
minal to alternator Sticking
1 Check for proper AC voltage between tach inp
terminal and terminal
2 Check for good ground connection between meter
terminal and Check that alternator is well grounded to engine block at
alternator pivot Inaccurate
a With a handheld tach on the front of the crankshaft
pulley retaining nut or with a strobetype tach read the
front crankshaft pulley rpm at idle
b Adjust the tachometer with a small Phillips type screw
driver through the calibration access hole in the rear of
the tachometer Zero the tach and bring it to the rpm
indicated by the strobe or hand tach Verify the rpm at
idle and at high speed and adjust the tach as needed
Engines Generators
ENGINE BELT inspection service and maintenance of the drive belts
is important for the efficient operation of your engine see
Drive Belts under MAINTENANCE SCHEDULE FUEL belts must be properly tensioned Loose drive belts win
not provide proper alternator charging and will the alternator Drive belts that are too tight will pun
HOLOOWN NUTS
the alternator out of alignment andor cause the alternator to
wear out prematurely Excessive drive belt tension can also
cause rapid wear of the belt and reduce the service life of the
coolant pumps bearing A slack belt or the presence of oil on
the belt can cause belt slipping resulting in high and tachometer variations FUEL INJECTORS
The drive belt is properly adjusted if the belt can be deflected In case of severe vibrations and detonation noise have the
no less than 38 inch lOmm and no more than 112 inch injectors checked and overhauled by an authorized fuel
12mm as the belt is depressed with the thumb at the mid injection service center Poor fuel quality contaminants and
point between the two pulleys on the longest span of the belt loss of positive fuel pressure to the injection pump can result
A spare belt or belts should always be carried on board in injector faults Since fuel injectors must be serviced in a
clean room environment it is best to carry at least one extra
A WARNING Never attempt to check Dr adjust the injector as a spare should a problem occur
drive belts tension while the engine is in operation Before removing the old injector clean the area around the
base of the injector to help prevent any rust or debris from
falling down into the injector hole If the injector will not Belt Tension out easily and is held in by
carbon buildup or the like work
1 Loosen the alternator adjusting strap bolt and the base the injector sidetoside with the aid of the socket wrench to
mounting bolt free it and then lift it out
2 With the belt loose inspect for wear cracks and frayed The injector seats in the cylinder head on a copper sealing
edges washer This washer should be removed with the injector and
3 Pivot the alternator on the base mounting bolt to the left replaced with a new washer when the new injector is installed
or right as required to loosen or tighten The fuel injectors should be pressure tested after 750 operating
4 Tighten the base mounting bolt and the adjusting strap hours
bolt INJECTION STARTING PRESSURE 2630 psi 181 Mpa 185 Kgem
5 Run the engine for about 5 minutes then shut down and INJECTION HOLDDOWN NUTS TORQUE 137 15 ItIb 19 02 Kgm
recheck the belt AND ALTERNATOR SERVICE
The starter and the alternator should be serviced every commentator slip ring brushes and the brush contact check
Refer to your WESTERBEKE SERVICE MANUAL
Engines Generators
ENGINE ADJUSTMENTS
NOTE WESTERBEKE recommends that the following engine adjust
ments be performed by a competent engine mechanic The information
below is provided to assist the ENGINE COMPRESSION OIL PRESSURE
Make certain the oil level dipstick is at the correct level The engines oil pressure during operation is indicated
and the air intake filter is clean The battery and starter motor by the oil pressure gauge on the instrument panel During
must also be in good condition normal operation the oil pressure will range between 40 and
1 Warm the engine to normal operating 85 psi
2 Move the control lever to a position for shutting off the NOTE A newly started cold engine can have an oil pressure
fuel Disconnect the wires if a fuel shutdown solenoid reading up to 85 psi A warmed engine can have an oil
is used pressure reading as low as 40 psi These readings will vary
3 Remove all the glow plugs from the engine and install depending upon the temperature of the engine the load
the compression gaugeadapter combination to the placed on the engine and the RPMs
cylinder on which the compression is to be measured
Low Oil Pressure
The specified safe minimum oil pressure is 5 10 psi A
gradual loss of oil pressure usually indicates worn bearings
For additional information on low oil pressure readings see
the ENGINE chart
MEASURING
Testing Oil Pressure
COMPRESSION To test the oil pressure remove the oil pressure sender then
DIAL GAUGE
install a mechanical oil pressure gauge in its place After
warming up the engine set the engine speed at idle and read
the oil pressure gauge
OIL PRESSURE 15 20 psi at idle speed
SENDER AND SWITCH TORQUE 9 13 nIb 12 18 m Kg
PREHEAT SOLENOID
4 Close the raw water seacock Crank the engine and allow the gauge to reach a
maximum reading then record that reading
6 Repeat this process for each cylinder 20A BREAKER
COMPRESSION PRESSURE 441 psi 310 Kgem at 200 rpm
ALLOWABLE LIMIT 370psi 260 Kgem
MAXIMUM PERMISSIBLE DIFFERENCE BETWEEN CYLINDERS
2844 psi 20 Kgem
NOTE Jfthe readings are below the limit the engine needs an
overhaul
7 Reinstall the glow plugs and reset the fuel shutoff to the
run position
S Open the raw water seacock low compression is found determine the cause by
applying a small amount of oil in the cylinder thru the glow
plug hole Allow the oil to the pressure gauge and repeat the above test If reading rises dramatically the fault is with the
rings If the compression valve does not rise the problem is OIL PRESSURE
with the valves SWITCH
A slight rise in compression would indicate a problem with
both the rings and the valves
Engines Generators
ENGINE ADJUSTMENTS
NOTE WESTERBEKE recommends that the following engine adjust
ments be performed by a competent engine mechanic The information
below is provided to assist the CLEARANCE ADJUSTMENT 3 After adjusting the valves with
piston No I at IDC
The valve clearance must be adjusted every 200 operating rotate the crankshaft 3600 again aligning the TDC mark
hours or whenever the valve rocker is abnormally noisy and the pulley mark This brings piston No6 or No4 to
Valve adjustment should only be done when engine is cold TDC then adjust the remaining valves
Cold engine valve clearance is 00157 in 040 mm
INJECTION TIMING Improper injection timing can cause engine
failure In normal
J DD1571N
servicing this check and adjustment in unnecessary however
it might be necessary in conjunction with other related work
D4DMMI such as an engine overhaul
TIMING MARKS
EARANCE MARK
NOTE The head bolts have been tightened with the
Angular Tightening Method Therefore it is not necessary
to retighten the cylinder head bolts before adjusting the valve PULLEY
PROCEDURE CRANKSHAFT PUllEY
Chart shows six cylinder model
Cylinder No 1 2 3 4 5 6
Valve arrangement I E I E I E I E I E I E
When No1 cylinder
is at TOC in the com O0 0 0 0 0 CHECK PROCEDURE
pression stroke
Bring No 1 piston to the top dead center on the compression
When No6 cylinder is
at TOC in the com stroke Turn the crankshaft pulley c1ockwie viewed at
pression stroke engine front and align the mark on the crankshaft pulley
with the IDC mark
1 In order to bring No I or No6 piston six cyl No4 Remove the access cover at the front of the injection pump
piston four cyl to the top dead center in the compression and check the alignment between the pointer A on the
stroke align the TDC mark and the crank shaft pulley injection pump gear lock plate and the projected pointer B on
mark the timing gear case If A and B are in alignment the timing
2 Do the adjustment on the circle marked valves in the is set correctly
above table where No I piston is in the IDC in the If they are in alignment No 1 cylinder is at the TDC on
compression stroke After these steps do the adjustment the compression stroke If it is in misalignment recheck by
on the double circle marked valves where the No6 piston turning the crankshaft pulley one more tum to repeat the
six cyl No4 piston four cylis on IDC in the procedure to make sure that it is in alignment
compression stroke
Chart shows four cylinder model INJECTION
PUMP
Cylinder No 1 2 3 4 MARKS
Valve arrangement I E I E I E I E
I When No1 is at TDC in the com
pression stroke
O0 0 0
When No4 cylinder is
at TOC in the com
pression stroke
Engines Generators
ENGINE ADJUSTMENTS
NOTE WESTERBEKE recommends that the following engine adjust
ments be peiformed by a competent engine mechanic The information
below is provided to assist the the crankshaft position for the start of fuel injection 5 Notice which injection timing mark is aligned with
1 Turn the crankshaft pulley viewed from pulley mark The timing mark in alignment with the
the engine front about 30 pulley mark indicates the degrees before IDC the start
of fuel injection
2 Remove No I high pressure injection line
The degrees before TDC differs depending on the engine
11DELIVERY HOLDER
VALVE
model Refer to the on the injection timing
for the respective model engine If the timing is incorrect
do the following adjustment
ADJUSTMENT PROCEDURES
1 Align the pulley mark and the specified timing mark
Refer to the injection timing 2 Loosen the four injection pump attachment nuts
3 To advance the timing pivot the injection pump at the
DELIVERY pump drive shaft away from the engine
VALVE
To retard the timing pivot the injection pump at the
pump drive shaft toward the engine
NOTE The 1mm misalignment between the timing marks
on the crankshaft pulley correspond to about r in crank
angle
3 Remove the injection pump No I delivery valve holder 4 Recheck the timing following procedures I through 5
delivery valve and spring and reinstall the delivery valve 5 Tighten the four injection pump attachment nuts
holder back into the pump
6 Again remove No I delivery valve holder and reinstall
DELIVERY VALVE HOLDER TIGHTENING TORQUE
39 44 Nm 4 45 Kgm289 325 ftIb the delivery valve spring and the valve holder
DELIVERY VALVE HOLDER TIGHTENING TORQUE
4 Slowly turn the crankshaft pulley clockwise and at the 39 44 Nm 4 45 Kgm289 325 ftIb
same time feed fuel to the injuection pump by slowly 7 Reinstall the No I high pressure injection line
pumping the feed pump When the fuel stops to flow out
from No I delivery valve holder stop tutning the crank
shaft pulley and pumping This is th beginning of fuel
injection LOOSEN FOUR NUTS
80TH SIDES
PULLEY MARK
TIMING GEAR
CASE
Engines Generators
HURTH INITIAL OPERATION
For safety reasons the transmission is not filled with trans Set the shifting lever to neutral position N Start the fluid during
shipment and the selector lever is tem and let it run long enough in idle to fill the cooler and attached to the actuating shaft
with transmission fluid Shift into gear forward and leaving the WESTERBEKE plant each transmission
shifting should be smooth and positive Direct changes a test run with Dextron III ATF transmission fluid forward to reverse are
permissible since the mUltiple disc
The residual fluid remaining in the transmission after drain clutch permits changing at high rpm including sudden revers
ing acts as a preservative and provides protection against cor ing at high speeds in the event of for at least one year if properly
stored After initial operation make a visual inspection of the output
coupling oil cooler and hoses and the cable connections to
the DIPSTICK
VENT
LOCKING THE PROPELLER
Locking of the propeller shaft by an additional brake is not
required use the gear shift lever position opposite your direc
tion of travel for this purpose Never put the gear shift in the
position corresponding to the direction of travel of the boat
FLUID
FIlTER
lIe3IN
WHEN UNDER SAIL OR BEING TOWED
Rotation of the propeller without a load such as when the
boat is being sailed being towed or anchored in a river as
OUTPUT well as operation of the engine with the propeller stopped
COUPLING for charging the battery will have no detrimental effects on
MODEL 630 the COOLER NOTE When the boat is being sailed engine
stopped the
gear shift must be in the neutral position The propeller is at
The oil cooler mounted above the transmission provides
idle and can cooling for the transmission fluid Raw water
passes through the tubes of the cooler and discharges over DAILY The transmission fluid is cooled as it flows around the
tubes and back into the transmission o Check the transmission fluid
o Visually check the gear shift linkage and WESTERBEKE RECOMMENDS CARRYING RAW WATER
CONNECTION
o Start the engine in neutral allowing a few minutes at idle
ASPARE OIL COOLER ABOARD to warm the fluid
o Shift into gear
NOTE Too Iowan idle speed will produce a chattering noise
from the transmission gear and damper plate In such cases
the idle speed should be increased
RAW WATER
CONNECTION TRANSMISSION OIL COOLER
Operating Temperature
The operating temperature of the transmission should FLUID exceed 176F 80C under normal
continous running A
Fill the transmission with Dextron ll ATF The fluid level connection for a temperature probe is provided At be up to the mark on
the dipstick After checking the output of the engine the fluid may reach 220F press the dipstick into the case and turn it to the
first 25 operating hours inspect the bell shaft and transmission cooler for leakage The fluid A CAUTION If the transmission fluid
temperature is
should be changed after the first 25 hours and every 300 too high stop the engine immediately and check the
hours thereafter transmission SWITCH
These transmissions are equipped with a neutral This is to prevent the engine frJrn starting in gear
Unless the transmission selector lever is perfectly aligned in
neutral the engine starter will not Engines Generators
HURTH CHANGING THE TRANSMISSION FLUID Replacing the Fluid
Pour in new Dextron 1Il ATF fluid and check the quantity
with the dipstick
Transmission fluid quantities will vary with the use of cool
ers length of hoses and the angle of the Approximate
Quantities
HURTH 45 212 quarts 20 Liters
HURTH 63 32 quarts 30 Liters
Reinsert the filter assembly into the housing Press it in place
and tighten the Allen screw
ACTUATING
LEVER NOTE Some transmissions use a T handle in place of a
screw on their filter assemblies
16mm 8 SCREW
After running the engine shut down and recheck the fluid level
A WARNING Neller pull out the dipstick while the
engine Is ronnlng Hot nuld will splash from the dipstick
hole This could cause sellere bums
ORINGS MAINTENANCE
MODEL 450 Transmission maintenance is minimal Keep the exterior
housing clean check the fluid level as part of your regular
routine and change the fluid every 300 operating hours
Periodically inspect the transmission and the cooler for leaks
FILTER ELEMENT and corrosion Make certain the air vent is clear and when
checking the fluid level look for signs of water fluid will appear as
strawberry cream
Element Storage requires special care Follow these Hurth transmission has a filter element
located opposite D Drain water from the transmission oil cooler and replace
the dipstick This filter must be replaced whenever the fluid is with a proper mixture of antifreeze
NOTE This operation will normally occur when the
Remove the filter by loosening the screw on the cover using a engine raw water cooling system is properly Allen wrench
D Clean up the transmission and touch up unpainted areas
Twist and pull out the filter and remove the element Place use heat resistant paint
the new filter onto the cover and lock it into place by turning
it clockwise Check the Orings for damage and replace if
D Fill the transmission with Dextron 1Il ATF fluid to pre
vent internal corrosion extended storage only Replacement filters can be obtained from your
months or more
local WESTERBEKE dealer or ZF Hurth dealer
D Loosen attaching hardware from the transmission the Fluid flange and propeller shaft
coupling flange before remov
Push a suction pump hose down through the pipe hole under ing the boat from the water Separate the flanges and
the filter to the bottom of the housing and suck out the fluid spray with the oil return line from the cooler and allow the oil
D Inspect the gear shift cable linkage and drain into a container then reconnect the oil return line Look for corrosion of the end
fittings cracks or cuts in
the conduit and bending of the actuator rods down the transmission and properly dispose of the used all moving
NOTE If the transmission is to be stored for a 10llg time
twelve months or more it should be topped off with
fluid to prevent internal corrosion Reduce the fluid level
before putting the engine back into service
Engines Generators
HURTH CABLE CONNECTIONS SHAn COUPLINGS
The transmission is suitable for a single lever gear shift WESTERBEKE recommends a flexible connection between
Upon loosening the retaining screw the actuating lever see the transmission and the propeller shaft if the engine is flexi
illustration can be moved to any position required for the bly mounted in order to compensate for angular deflections
control elements cable or rod linkage Make certain that the The installation of a special propeller thrust bearing is not
actuating lever does not contact the lever hub the minimum required since the propeller thrust will be absorbed by the
distance between the lever and hub should be transmission bearing provided the value specified under
The control cable or rod should be arranged at a right angle is not exceeded However the output
to the actuating lever when in the neutral position The neu shaft should be protected from additional loads Special care
tral position of the gear shift lever on the control console should be taken to prevent torsional vibration When using a
should coincide with the neutral position of the lever on the universal joint shaft make certain to observe the manufac
transmission turers Shifting Positions
Even with the engine solidly mountedthe use of a flexible
A Propeller rotation opposite of engine rotation coupling or DRIVESAVER will reduce stress in the gearbox
N Neutral position bearings caused by hull distortions especially in wooden
B Propeller rotation same as engine rotation boats or where the distance between the transmission output
coupling and stern gland is less than about 800mm
NOTE When shifting to A or B positions make sure the
shift lever travel is sufficient for the actuating lever to contact NOTE When installing the transmission make certain that
its stop CABLE N shifting is not impeded by restricted movability of the cable
BRACKET or rod linkage by unsuitably positioned guide sheaves too
small a bending radius or other restrictions In order to
mount a support for shift control cable connections use the
two threaded holes located on the cable bracket mounted 011
the gear housing Refer to the WESTERBEKE parts list
GEAR SHIFT LEVER
ACTUATING
LEVER
LEVER HUB
ACTUATING
1 0021n
r05mm
LEVER TYPICAL STEERING STATION
A greater amount of actuating lever travel is in no way
detrimental and is recommended However if the lever travel
is shorter proper clutch engagement might be impeded For additional information contact
which in turn would mean premature wear excessive heat HURTH MARINE GEAR
generation and clutch plate failure This would be indicated ZF Industries
by slow clutch engagement or no engagement at all see Marine US Headquarters
CONTROL CABLES under TRANSMISSION 3131 SW 42nd Street
Fort Lauderdale FL 33312
Tel 954 5814040
NOTE Check for proper actuating lever travel at least each
Fax 954 5814077
season
A CAUTION The position of the mechanism behind
the actuating lever Is to ensure equal
shift lever travel from neutral position to A and B If
this mechanism Is In any way tampered with the
transmlsslDn wananty will be vDld
Engines Generators
BORG WARNER VELVET DRIVE TRANSMISSION
SHIFT LEVER POSITION
OIL COOLER
The gear shift control mechanism and linkage must position
the actuating lever on the transmission exactly in Forward
F Neutral N and Reverse R shifting positions A detent
ball located behind the transmission lever must work freely
to center the lever in each position The gear shift positions at
the helm must be coordinated with those of the Velvet Drive
actuating lever through shift mechanism adjustments An
improperly adjusted shift mechanism can cause damage to
the transmission The shifting mechanism and transmission
actuating lever should be free of dirt and well lubricated to
ensure proper operation
Shifting Into Gear
Place the gear shift in Neutral before starting the engine
Shifting from one selector position to another selector posi
tion may be made at any time below 1000 rpm and in any
order Shifts should be made at the lowest practical engine
speed Start the engine and set the throttle at idle speed
allow the transmission fluid to warm up for a few safety reasons the transmission is not filled with trans fluid during shipment and the
selector lever is tem Move the gear shift lever to the middle position You attached to the actuating shaft
feel the detent This centers the actuating lever on the trans
Before leaving the WESTERBEKE plant each transmission mission With the control in this position hydraulic power is
undergoes a test run with Dextron III ATF transmission fluid completely interrupted and the output shaft of the transmis
The residual fluid remaining in the transmission after drain sion does not tum
ing acts as a preservative and provides protection against
NOTE Some transmissions are equipped with a neutral for at least one year if properly stored switch Unless the transmission
actuating lever is FLUID aligned in neutral the engine starter will not the transmission fluid
level on the dipstick If has not been filled fill with Dextron III and to use this fluid During the first 25 hours of opera Move
the gear shift lever to the forward position You should
tion keep a lookout for any leakage at the bell housing out feel the detent The actuating lever on the transmission is in
put shaft and transmission cooler This fluid should be the forward position The output shaft and the propeller shaft
changed after the first 25 hours and approximately every 300 move the boat in a forward hours thereafter andor at winter layup
Reverse
Move the gear shift lever to the reverse position You should
A CAUTION Be ceffaln the transmission Is filled feel the detent The actuating lever on the transmission is in
the reverse position The output shaft and the propeller
and the correct slzs cooler Is properly Installed before
should move the boat in a reverse direction astern
staffing the engine
NOTE Moving the transmission actuating lever from Neutral
Position to Forward is always toward the engine Reverse is
always away from the engine If boat moves backwards with
the gear shift control in the forward position shut off the
engine This problem may be a result of incorrect movement
of the actuating lever by the gear shift lever
Engines Generators
BORG WARNER VELVET DRIVE TRANSMISSION
o Clean off the transmission and properly dispose of the
used fluid
o Refill the transmission with DEXTRON II ATF The
quantity will vary depending on the transmission model
and the installation angle Fill through the dipstick hole
D Check the dipstick for the proper fluid level
D Replace the oil filler cap and dipstick Press the dipstick
into place and tum clockwise until D Run the engine shutdown and recheck
the fluid NEUTRAL
TRANSMISSION AC11JATING LEVER POSITIONS
REVERSE
A WARNING Never pull out the dipstick while the
engine Is running Hot nuld will splash from the OPERATION hole This could cause severs bums
o Check the transmission fluid
o Visually check the gear shift linkage and transmission Oil Capacity
o Start the engine in neutral Allow a few minutes at idle Approximately 25 quarts 236 liters will fill most transmis
for the fluid to warm sions to the oil level fill mark on the dipstick Many variables
NOTE Too Iowan idle speed will produce a chattering have a direct relationship to the oil capacity Additional oil
noise from the transmission gear and damper plate In will be required to fill the oil cooler and the cooler lines The
such cases the idle speed should be increased angle of installation will make a difference in the quantity of
oil required to fill the transmission
o Shift into gear
A CAUTION Shifting gears above 1000 rpm can Make certain the rubber
seal Is screwed tight
to the handle
cause damage to the engine damper plate Pulling the
throttle back to Idle when shifting gears will save wear
on the transmission and the damper plate
INSPECTION
o Visually check for oil leaks at the hydraulic connections
Check for wear on the hydraulic lines and replace if
worn
o Lubricate the detent ball and shift cable Inspect the shift linkage
o Inspect the transmission bolts retorque if necessary
A CAUTION Clutch fallurs will occur If the transmis OILDIPsnCK
sion shift lellSr does not fully engage the detent ball Oil Temperature
plISltlons A maximum oil temperature of 1900 P 88C is recom
mended Discontinue operation anytime sump oil tempera
CHANGING THE TRANSMISSION FLUID ture exceeds 230 0 P 1lO D C
After the initial 50 hour change the transmission fluid should PRESSURE GAUGE
be changed at every 300 operating hours thereafter or at win
ter haulout However the fluid must be changed whenever it An optional mechanical pressure gauge can be installed at
becomes contaminated changes color or smells rancid the control panel to constantly monitor the pressure of the
transmission fluid A normal reading at 2000 rpm in forward
o Remove the oil filler cap and dipstick gear should indicate 95 120 Ibin2 67 84 kgcm 2 and be
o Remove the oil cooler return line and allow the oil to constant
drain into a container
o Reconnect the oil cooler return line
D Use a suction pump to remove the transmission oil
through the filler capdipstick hole
EngInes Generators
BORG WARNER VELVET DRIVE WARRANTY maintenance is minimal Keep the exterior
Service manuals are available from your BORG clean check the fluid level as part of your regular and change the fluid every 300
operating hours For assistance inspect the transmission and the cooler for leaks BORG WARNER
and corrosion Make certain the air vent is clear and when 200 Theodory Rice the fluid level look for signs of water contamination
New Bedford MA 02745
fluid will appear as strawberry cream Tel 508 BORG WARNER
is aware of the shock loads that can be
placed on its gears as the result of mechanical propeller oper
Storage requires special care Follow these procedures
ation or fully reversing of the propeller blades while shiftIng
o Drain the water from the transmission oil cooler and Therefore torque loads and directional changes should be
replace it with a proper mixture of antifreeze coolant made at low engine speeds If it is found that a failure was
NOTE This operation will usually occur when the engine caused by a shock load any warranty claim wiJI be denied
raw water cooling system is properly winterized
o Clean up the transmission and touchup unpainted areas A CAUTION noises or vibrations can
use heat resistant paint occur at low engine speeds which can cause gear rattle
o Fill the transmission with Dextron III ATF fluid to pre resulting In damage to the engine andor vent internal corrosion
BORG WARNER Is not responsible for total system
o Loosen attaching hardware from the transmission related torsional vibration of this type
output flange and propeller shaft coupling flange before
removing the boat from the water Separate the flanges If any problems occur with the transmission see
and spray with lubricant TRANSMISSION in this manual
o Inspect the gear shift cable linkage and attachments
Look for corrosion of the end fittings cracks or cuts in
the conduit and bending of the actuator rods Lubricate
all moving parts
NOTE If the transmission is to be stored for a long time
twelve months or more it should be topped off with
fluid to prevent internal corrosion Reduce the fluid level
before putting the engine back into service
Engines Generators
TRANSMISSION CABLES OIL COOLERS
The majority of transmission difficulties arise as a result of The continued flow of raw water through the cooler will in
improper clutch adjustments manual or prob time erode the inside of the cooler causing cross leaks to
lems with control cables hydraulic rather than occur These internal cooler leaks will cause one of the fol
from problems with the transmission itself lowing two clutches in particular are very sensitive to improper
1 Transmission fluid will leak into the flow of raw water
cable adjustments and be discharged overboard through the engine exhaust
If you experience operating problems with the transmission A loss of transmission fluid will cause the transmission to
shut the engine down First check the level fail
then have a helper move the cockpit shift lever through the 2 The raw water will leak into the transmission fluid caus
full range from neutral to full forward back to neutral ing an increase in transmission fluid This full reverse and back
to neutral while you observe fluid will appear as strawberry cream The actuating lever on the transmission If the remote
is stiff will eventually fail
to operate break the cable loose at the transmission and try Either case requires an immediate If it is still stiff check the
cable for kinks or exces
sively tight bends and check any linkage for binding A new 1 Install a new oil cooler
cable and perhaps a new linkage mechanism may be needed 2 Refill the transmission with DEXTRON III ATF
While the cable is loose shift the transmission in and out of If water has contaminated the fluid the transmission fluid
gear using the lever on the side of the transmission to make needs to be cleaned out and replaced with fresh fluid It will
sure theres no binding inside the case take several fluid changes to get rid of the the transmission
passes these tests crank the engine and Check your dipstick each time until it appears as pure trans
have a helper put it in forward and reverse while you observe mission fluid Change the transmission filter and clean out
the propeller shaft if the shaft isnt turning the transmission the fluid lines that connect to the cooler
needs professional attention If it does tum but theres no If the transmission fails to shift properly it will most check
to see you still have a propeller on the end of need the attention of a qualified transmission service facility
the shaft or if you have a folding or feathering propeller that A transmission cooler may last ten years or more but in
it isnt stuck in the no pitch position some depending on operating hours tropical
waters maintenance etc it might only last half that time
WESTERBEKE recommends having a spare cooler aboard
Problem Probable Cause Transmission gears cannot be shifted 1 Shifting
lever is loose 1 TIghten damping bolt on shifting lever
2 Shifting cable is broken bent or 2 Check the cable reattach or replace
unattached
3 Loss of transmission fluid 3 Check for leaks at transmission seal and output shaft
Tighten gear case bolts Check all oil hoses for leaks
Oil cooler leak see OIL COOLER
4 Water in transmission fluid 4 Replace oil cooler see OIL COOLER High water in engine
compartment remedy cause Shifting pressure too low see
item 2
Shifting pressure too low 1 Improper fluid 1 Replace with DEXTRON 11 ATF
2 Filter is dirty if applicable 2 Replace filter
3 Water in transmission fluid 3 Replace oil cooler see OIL COOLER
4 Transmission fluid too low 4 Add fluid
5 Air vent is clogged 5 Remove painVdirt from vent
Transmission noise becomes louder 1 Fluid level too low 1 Top up with fluid to marking on dipstick
so that pump sucks in air
2 Damage starting on flexible coupling due 2 Replace flexible coupling Check alignment between engine
to wear or fatigue possibly due to misalign and ment between engine and
3 Beginning damage of bearings in trans 3 Transmission needs professional attention
mission due to torsional vibrations running
without fluid overload wrong alignment of
transmiSSion or excessive engine output
Engines Generators
TRANSMISSION Problem Probable Cause Chattering transmission noise
1 The engine or propeller generates torsional 1 Mount a flexible coupling with another stiffness factor
mainly at low engine speed vibrations in the drive unit which produces between the engine and transmission a coupling with
a chattering noise in the transmission a higher stiffness factor might be sufficient
Transmission shifts into gear but 1 Output coupling Is not tuming 1 Transmission needs professional attention
fails to propel the boat
2 Propeller shaft is not turning 2 The coupling bolts are sheared or the coupling is slipping
Output coupling is tuming on the propeller shaft Tighten or replace set screws keys
pins and coupling bolts as necessary
3 Output coupling and 3 Inspect the propeller it may be missing or damaged
propeller shaft are turning A folding propeller may be jammed
Variable pitch propeller may be in no pitch If you suspect a major problem in your contact your WESTERBEKE dealer or an
authorized marine transmission Engines Generators
LAYUP Fuel System owners rely on their boatyards to prepare their craft
Top off your fuel tanks with unleaded gasoline of 89 engines and generators for layup during the off of higher A fuel conditioner such as
STABIL or for long periods of inactivity Others prefer to stabilizer should be added Change the element in layup preparation themselves
separator and clean the metal bowl
The procedures which follow will allow you to perform your Reinstall and make certain there are no leaks Clean
own layup and or you may use them as a up any spilled fuel
check list if others do the procedures Fuel System procedures should afford your engine protection
Top off your fuel tanks with No2 diesel fuel Fuel a layup and also help familiarize you with the such as BlOB OR and STABIL should be
added at this time needs of your engine control algae and condition the fuel Care should be taken
If you have any questions regarding layup procedures call that the additives used are compatible with the primary fuel
your local servicing dealer he will be more than willing to filterwater separator used in the system Change the assistance
in your primary fuel filterwater separator if the fuel system
has one and clean the separator sediment Shaft Coupling Propulsion Engine
Change the fuel filter elements on the engine and bleed the
The transmission and propeller half couplings should always
fuel system as needed Start the engine and allow it to run
be opened up and the bolts removed when the boat is hauled
for 5 10 minutes to make sure no air is left in the fuel
out of the water or moved from land to water and during
system Check for any leaks that may have been created in
storage in the cradle The flexibility of the boat often puts a
the fuel system during this servicing correcting them as
severe strain on the propeller shaft or coupling or both while
needed Operating the engine for 5 10 minutes will help
the boat is taken out or put in the water In some cases the
allow movement of the treated fuel through the has actually been bent by these strains This does not
equipment on the engine
apply to small boats that are hauled out of the water when
not in use unless they have been dry for a considerable Raw Water Cooling of time
Close the throughhull seacock Remove the raw water intake
Fresh Water Cooling Circuit hose from the seacock Place the end of this hose into a five
gallon bucket of clean fresh water Before starting the engine
A 5050 solution of antifreeze and distilled water is
check the zinc anode found in the primary heat exchanger for use in the coolant system at all times
the engine and clean or replace it as required and also clean
This solution may require a higher concentration of
any zinc debris from inside the heat exchanger where depending on the areas winter climate Check the
zinc anode is located Clean the raw water to make sure the antifreeze protection is adequate
Start the engine and allow the raw water pump to draw the
Should more antifreeze be needed drain an appropriate
fresh water through the system When the bucket is empty
amount from the engine block and add a more concentrated
stop the engine and refill the bucket with an Operate the engine to ensure a complete circulation
solution slightly stronger than needed for winter freeze
and mixture of the antifreeze concentration throughout the
protection in your area
cooling system Now recheck the antifreeze solutions strength
Start the engine and allow all of this mixture to be System through the raw water system Once the
bucket is empty stop
With the engine warm drain all the engine oil from the oil the engine This antifreeze mixture should protect the raw
sump Remove and replace the oil filter and fill the sump water circuit from freezing during the winter layup as well
with new oil Use the correct grade of oil Refer to the as providing corrosion LUBRICATING OIL pages in this manual for the
Remove the impeller from your raw water pump some
oil changing procedure Run the engine and check for proper antifreeze mixture will accompany it so catch it in a bucket
oil pressure and make sure there are no leaks Examine the impeller Acquire a replacement if needed and
a cover gasket Do not replace the impeller into the pump
until but replace the cover and gasket
A CAUTION Do not leave the engines old engine Cylinder Lubrication Gasoline
oil in the sump over the layup period Engine oil and
combustion deposits combine to produce harmful With the engine running remove the flame arrester and spray
fogging oil into the open air intake The fogging oil will stall
chemicals which can reduce the life of your engines
out the engine as it coats the valves cylinders and spark
internal parts plugs for winter Engines
Generators
LAYUP Motor SPARE and cleaning of the starter drive pinion is advis Layup time
provides a good opportunity to inspect your
able if access to the starter permits its easy removal Make WESTERBEKE engine to see if external items such as drive
sure the battery connections are shut off before attempting to belts or coolant hoses need replacement Check your basic
remove the starter Take care in properly replacing any elec spares kit and order items not on hand or replace those items
trical connections removed from the starter used during the layup such as filters and zinc anodes Refer
to the SPARE PARTS section of this Lubrication Diesel
If you anticipate a long layup period 12 months or more recommends removing the glow plugs or The of your
WESTERBEKE engine after a
fuel injectors for access to the cylinders Squirt light seasonal layup generally follows the same procedures oil into the cylinders to
prevent the piston rings those described in the PREPARATIONS FOR STARTING
from sticking to the cylinder walls Rotate the engine by hand section regarding preparation for starting and normal starts
two revolutions then replace the glow plugs or injectors However some of the layup procedures will need to be
Make sure you have a replacement if removing the injector counteracted before starting the washer for the injector and fuel line return
1 Remove any rags that were placed in the exhaust intake
manifold or flame If engine storage is going to be a lengthy one 12
months or beyond it is wise to rotate the engine by hand two 2 Remove the raw water pump cover and gasket and turns every additional 4
months to allow the injec the old gasket Install the raw water pump impeller
tion pump components to move This will help prevent their removed during layup or a replacement if during extended storage periods
Install the raw water pump cover with a new cover gasket
3 Reinstall the batteries that were removed during the lay
Intake Manifold and ThruHull up and reconnect the battery cables making sure the
Place a clean cloth lightly soaked in lubricating oil in the terminals are clean and that the connections are of the intake manifold to
block the opening Do not Check to make sure that the batteries are fully the cloth out of sight If it is not visible at
4 Remove the spark plugs wipe clean regap and and an attempt is made to start the engine to proper tightness may need the assistance
of a servicing dealer Make a 5 Check the condition of the zinc anode in the raw water
note to remove the cloth prior to startup The throughhull circuit and clean or replace the anode as needed Note
exhaust port can be blocked in the same manner that it is not necessary to flush the water
Intake Manifold Gasoline solution from the raw water coolant system When the
engine is put into operation the system will selfflush in
Clean the filter screen in the flame arrester and place a clean
a short period of time with no adverse affects Also open
cloth lightly soaked in lube oil around the flame arrester to
up the heat exchanger ends and clear out any accumu
block any opening Also place an oilsoaked cloth in the
lated exhaust port Make a note to remove cloths prior
to startup 6 Check the transmission fluid if it had been topped off
during the layup lower the level of the fluid to Propulsion Engine Propulsion Engine
Check or change fluid in the transmission as required If the 7 Make certain all electrical connections and switches are
engine is to be layed up 12 months or more fill the transmis in the correct position and there are noloads on the
sion to the very top to prevent corrosion Lower the fluid to generator at start up nonnaI at Wipe off grime and grease 8
Start the engine in accordance with the touch up unpainted areas Protect coupling and output described in the PREPARATIONS FOR with
an anticorrosion coating Refer to the section of this SECTION in this manual for batteries are to be left on board during
the layup period
make sure they are fully charged and will remain that way
to prevent them from freezing If there exists any doubt that
the batteries will not remain fully charged or that they will
be subjected to severe environmental conditions remove
the batteries and store them in a warmer more Engines Generators
METRIC CONVERSIONS
INCHES TO MILLIMETERS MILLIMETERS TO INCHES
Inches mm Inches mm mm Inches mm Inches
1 2540 15 38100 1 00394 15 05906
2 5080 20 50800 2 00787 20 07874
3 7620 25 63500 3 01181 25 09843
4 10160 30 76200 4 01575 30 11811
5 12700 35 88900 5 01969 35 13780
10 25400 40 101600 10 03937 40 15748
10 MILLIMETERS 1 CENTIMETER 100 CENTIMETERS 1 METER 3937 INCHES 33 FEET
INCHES TO METERS METERS TO INCHES
Inches Meters Inches Meters Meters Inches Meters Inches
1 00254 7 01778 01 3937 07 27559
2 00508 8 02032 02 7874 08 31496
3 00762 9 02286 03 11811 09 35433
4 01016 10 02540 04 15748 10 39370
5 01270 11 02794 05 19685 11 43307
6 01524 12 03048 06 23622 12 47244
TO CONVERT METERS TO CENTIMETERS MOVE DECIMAL POINT TWO PLACES TO THE RIGHT
YARDS TO METERS METERS TO YARDS
Yards Meters Yards Meters Meters Yards Meters Yards
1 091440 6 548640 1 109361 6 656168
2 182880 7 640080 2 218723 7 765529
3 274320 8 731520 3 328084 8 874891
4 365760 9 822960 4 437445 9 984252
5 457200 10 914400 5 546807 10 1093614
MOVE DECIMAL POINT FOR HIGHER VALUES eg 6000 METERS 656168 YARDS
POUNDS TO KILOGRAMS KILOGRAMS TO POUNDS
Ib kg Ib kg kg Ib kg Ib
1 0454 6 2722 1 2205 6 13228
2 0907 7 3175 2 4409 7 15432
3 1361 8 3629 3 6614 8 17637
4 1814 9 4082 4 8818 9 19842
5 2268 10 4536 5 11023 10 22046
GALLONS TO LITERS LITERS TO Liters Gallons Liters Liters Gallons Liters
Gallons
1 379 10 3786 1 026 60 1566
2 757 20 7571 2 053 90 2377
3 1136 30 11357 5 132 120 3132
4 1514 40 15142 10 264 150 3962
5 1893 50 18928 20 528 180 4754
PINTS TO LITERS LITERS TO PINTS
Pints Liters Pints Liters Liters Pints Liters Pints
1 047 6 284 1 211 6 1268
2 095 7 331 2 423 7 1479
3 142 8 379 3 634 8 1691
4 189 9 426 4 845 9 1902
5 237 10 473 5 1057 10 2113
TEMPERATURE
32 40 50 60 70 75 85 95 105 140 175 212 OF
I I I I I I I I I I I I
I I I I I I I I I I I I
0 5 10 15 20 25 30 35 40 60 80 100 C
Engines Generators
STANDARD AND METRIC CONVERSION Inches in x 254 Millimeters mm x 0394 Inches
Feet ft x 305 Meters m x 3281 Feet
Miles x 1609 Kilometers km x 0621 Cubic Inches inJ x 16387 Cubic Centimeters x 061 in 3
Imperial Pints IMP pt x 568 Liters L x 176 IMP pt
Imperial Quarts IMP qt x 1137 Liters L x88 IMP qt
Imperial Gallons IMP gal x 4546 Liters L x 22 IMP gal
Imperial Quarts IMP qt x 1201 US Quarts US qt x 833 IMP qt
Imperial Gallons IMP gal x 1201 US Gallons US gal x 833 IMP gal
Fluid Ounces x 29573 Milliliters x 034 Ounces
US Pints US pt x 473 LitersL x 2113 Pints
US Quarts US qt x 946 Liters L x 1057 Quarts
US Gallons US gal x 3785 Liters L x 264 Ounces oz x 2835 Grams g x 035 Ounces
Pounds Ib x 454 Kilograms kg x 2205 Pounds Per Sq In psi x 6895 Kilopascals kPa x 145 psi
Inches of Mercury Hg x 4912 psi x 2036 Hg
Inches of Mercury Hg x 3377 Kilopascals kPa x 2961 Hg
Inches of Water H20 x 07355 Inches of Mercury x 13783 H20
Inches of Water H20 x 03613 psi x 27684 H20
Inches of Water H20 x 248 Kilopascals kPa x 4026 H20
TORQUE
PoundsForce Inches inIb x 113 Newton Meters Nm x 885 inIb
PoundsForce Feet ftIb x 1356 Newton Meters Nm x 738 Miles Per Hour MPH x 1609 Kilometers Per Hour KPH x 621 MPH
POWER
Horsepower Hp x 745 Kilowatts Kw x 134 MPH
FUEL CONSUMPTION
Miles Per Hour IMP MPG x 354 Kilometers Per Liter KmL
Kilometers Per Liter KmL x 2352 IMP MPG
Miles Per Gallons US MPG x 425 Kilometers Per Liter KmL
Kilometers Per Liter KmL x 2352 US Degree Fahrenheit OF OC X 18 32
Degree Celsius OC OF 32 x 56
Engines Generators
80N4 GENERAL FUEL SYSTEM
Engine Type Diesel four cylinder fourcycle marine engine General Closed system with bleed points
Vertical inline overhead valve water cooled
direct injection 80 hp 2500 rpm Fuel No2 diesel oil cetane rating of 45 or higher
Naturally aspirated Fuel Injection Pump BOSCH Model A type Integral with
injection pump Fuel Injection Timing
Nozzle Stroke 402 x 465 inches 1020 x 1180 mm
Fuel Filter Full flow Displacement 262 cubic inches 43 liter
on Order 1342
Air cleaner Replaceable paper of Rotation Clockwise when viewed from the front
AirFlow 150 efm
Engine Torque 210 ftIb 1500 rpm engine Ratio 171
Fuel Consumption 47 US gph 178 inches mm Height 320 inches 813 mm
wout transmission Width 252 inches 645mm ELECTRICAL SYSTEM
Length 472 inches 1168 mm
Starting Battery 12 Volt negative dry 971 Ibs 4408 kgs
Battery Capacity 750 900 Cold Cranking Amps CCA
TUNEUP DC Charging A1temator 51 Amp rated beltdriven
Starting Aid Glow Pressure 441 psi 31 kgcm at 200 rpm
Limit of difference Not to exceed 2844 psi 200 kgcm Starter 12 Volt 3 KW
Injector Pressure 2133 psi 150 kfcm DC Noload Current 2 of rated amps
Valve Seat Angle Intake 45 DC Cranking Current 400 CCA
Exhaust 45
Valve Clearance Intake and exhaust LUBRICATION cold 0Q16
inches 040 mm
General Gear typepressure Speed Idle 600 900 rpm
Cruise 1800 2200 rpm Oil Filter Full flow paper element spinon type
Max 2400 2500 rpm Sump Capacity 145 US QIs 138 liters
not including filter
COOLING SYSTEM Operating Oil Pressu re 2585 psi
General Fresh watercooled block engine hot
controlled with heat exchanger Oil Grade API Specification CF or Temperature 170 190 F 77 88 C
SAE 30 10W30 Water Pump Centrifugal type metal impeller beltdriven
Water Pump Positive displacement rubber impeller
General HURTH Standard Transmission
helical gears hydraulically operated multiple disc
Coolant Fresh Water Capacity 17 US Qts 161
liters
Gear Ratio Standard 2001 Hurth 45A or Hurth 63A
EXHAUST SYSTEM Propeller Shaft Right Elbow 45 elbow
Propeller 22x16 P2 blade or 22x14 P3 blade
using standard propeller should allow the engine to reach its full
Exhaust Hose Size 4 ID 1016 mm hose transmission rated rpm 2500 000 100 at full open throttle
while underway in forward gear
ENGINE AIR REQUIREMENTS Lubricating Fluid Dextron III
Combustion Air 150 cfm Transmission Sump
Note The pressure differential between the outside of the engine compart Capacity Hurth 45 213 US qts 20 liters approximate
ment versus the inside of the engine compartment should not exceed 2
inches of water 51 mm at full open throttle measure with a Engines
Generators
110T4 GENERAL FUEL SYSTEM
Engine Type Diesel four cylinder fourcycle turbocharged General Closed system with bleed pOints
marine engine Vertical inline overhead valve
water cooled direct injection 110 hp 2400 Fuel No2 diesel oil cetane rating of 45 or higher
rpm Fuel Injection Pump BOSCH Model A type Turbo charged
Fuel Injection liming 12 BTDC
Govemor Integral with injection pump Nozzle Stroke 402 x 465 inches
1020 x 1180 mm Fuel Filter Full flow Displacement 202 cubic inches 43 liter on
Order 1 3 4 2 Air cleaner Replaceable paper of Rotation Clockwise
when viewed from the front Air Flow 230 cfm
engine Torque max 280 ftIb 1500 rpm
Fuel Consumption 61 US gph 231 Ratio inches mm Height 320 inches 813 mm
ELECTRICAL SYSTEM
wout transmission Width 283 inches 719 mm
Length 472 inches 1168 mm Starting Battery 12 Volt negative dry 987 Ibs 4480 kgs
Battery Capacity 750 900 Cold Cranking Amps CCA
DC Charging Altemator 51 Amp rated beltdriven
TUNEUP Starting Aid Glow Pressure 441 psi 31 kgcm at 200 rpm
Starter 12 Volt 3 KW
Limit of difference Not to exceed 2844 psi 200 kgcm
DC Noload Current 2 of rated amps
Injector Pressure 2133 psi 150 kfcm
DC Cranking Current 400 CCA
Valve Seat Angle Intake 45
Exhaust 45
LUBRICATION SYSTEM
Valve Clearance Intake and cold 0016 inches 040 mm General Gear
typepressure Speed Idle 600 900 rpm Oil Filter Full flow paper element spinon
type
Cruise 1800 2200 rpm Sump Capacity 145 US Qts 138 liters
Max 2300 2400 rpm not including filter
Operating Oil Pressure 2585 psi
COOLING SYSTEM engine hot
General Fresh watercooled block Oil Grade API Specification CF or CG4
controlled with heat exchanger SAE 30 10W30 Temperature 180 190 F77 88 C
Fresh Water Pump Centrifugal type metal impeller Water Pump Positive displacement rubber impeller
TRANSMISSION
General HURTH Standard Transmission Fresh Water
helical gears hydraulically operated multiple disc
System Capacity 17 US Qts 161 liters clutch
Gear Ratio Standard 2001 Hurth 45A or Hurth 63A
EXHAUST SYSTEM Propeller Shaft Right Elbow 45 elbow
Propeller 24x18 P2 blade or 24x16 P3 blade
Exhaust Hose Size 4 10 1016 mm hose using standard propeller should allow the engine to reach its
full
transmission rated rpm 2400 000 100 at full open throttle
while underway in forward gear
Lubricating Fluid Dextron III
Transmission Sump
Capacity Hurth 45A 213 US Qts 20 liters Air 230 cfm
Note The pressure differential between the outside of the engine compart
ment versus the inside of the engine compartment should not exceed 2
inches of water 51 mm at full open throttle measure with a Engines
Generators
120N6 GENERAL FUEL SYSTEM
Engine Type Diesel six cylinder fourcycle Vertical inline General Closed system with bleed pOints
overhead valve fresh water cooled direct
injection marine engine 120 hp 2500 rpm Fuel No2 diesel oil cetane rating of 45 or Naturally
aspirated Fuel Injection Pump BOSCH Model A type Inline
Integral with injection pump Fuel Injection TIming 413 x 492 inches 1050 x 1250 mm
Nozzle Stroke
Piston Displacement 296 cubic inches 65 liter Fuel Filter Full flow replaceable
on Order 153624
Air cleaner Replaceable paper of Rotation Clockwise when viewed from the front
Air Flow 240 cfm
Engine Torque 298 ftIb 1500 rpm engine Ratio 171
Fuel Consumption 65 US gph inches mm Height 325 inches 823mm
wout transmission Width 252 inches 645mm ELECTRICAL SYSTEM
Length 564 inches 1410 mm
Starting Battery 12 Volt negative 1175 Ibs 5341 kgs
Battery Capacity 750 900 Cold Cranking Amps CCA
TUNEUP DC Charging Alternator 51 Amp rated beltdriven
Starting Aid Glow Pressure 441 psi 31 kgcm at 200 rpm
Limit of difference Not to exceed 2844 psi 200 kgcm Starter 12 Volt 3 IN actuated Pressure
2631 psi 180 kfcm DC Noload Current 2 of rated amps
Valve Seat Angle Intake 45 DC Cranking Current 400 CCA
Exhaust 45
Valve Clearance Intake and exhaust LUBRICATION cold 0016
inches 040 mm
General Gear typepressure Speed Idle 600 900 rpm
Cruise 1800 2200 rpm Oil Filter Full flow paper element spinon type
Max 2400 2500 rpm Sump Capacity 22 US qts 208 liters
not including filter
COOLING SYSTEM Operating Oil Pressure 25 85 psi 35 42 Fresh watercooled
block engine hot
controlled with heat exchanger Oil Grade API Specification CF or Temperature 180 1900 F 77 880 C
SAE 30 1OW3 15W40
Fresh Water Pump Centrifugal type metal impeller beltdriven
Water Pump Positive displacement rubber impeller
General HURTH Standard Transmission
helical gears hydraulically operated multiple disc
Coolant Fresh Water Capacity 25 US qts 237
liters
Gear Ratio Standard 2001 Hurth 45A or Hurth 63A
EXHAUST SYSTEM Propeller Shaft Right Elbow 45 elbow
Propeller 22x16 P2 blade or 22x14 P3 blade
using standard propeller should allow the engine to reach its
Exhaust Hose Size 4 ID 1016 mm hose transmission full rated rpm 2500 000 100 at full open
throttle while underway in forward gear
ENGINE AIR REQUIREMENTS Lubricating Fluid Dextran Air 240cfm
Transmission Sump
Capacity Hurth 45 213 US qts 20 liters The pressure differential between the outside of the engine compart
Hurth 63 42 US qts 40 liters versus the inside of the engine compartment should not exceed 2
inches of water 51 mm at full open throttle measure with a Engines
Generators
170T6 GENERAL FUEL SYSTEM
Engine Type Diesel six cylinder fourcycle turbocharged General Closed system with bleed points
marine engine Vertical inline overhead valve
fresh water cooled direct injection 170 hp Fuel No2 diesel oil cetane rating of 45 or higher
2500 rpm Fuel Injection Pump BOSCH Model A type Turbocharged
Fuel Injection TIming 12 BTDC
Govemor Integral with injection pump Nozzle Stroke 413 x 492 inches
1050 x 1250 mm Fuel Filter Full flow Displacement 423 cubic inches 65 liter on
Order 153624 Air cleaner Replaceable paper of Rotation Clockwise when
viewed from the front Air Flow 365 cfm
engine Torque max 423 ftIb 1800 rpm
Fuel Consumption 93 US gph 352 Ratio inches mm Height 335 inches 823 mm
ELECTRICAL SYSTEM
wout transmission Width 280 inches 711 mm
Length 575 inches 1410mm Starting Battery 12 Volt negative dry 12451bs 56523 kgs
Battery Capacity 750 900 Cold Cranking Amps CCA
DC Charging Alternator 51 Amp rated beltdriven
TUNEUP Starting Aid Glow Pressure 441 psi 31 kgcm at 200 rpm
Starter 12 Volt 3 Im
Limit of difference Not to exceed 2844 psi 200 kgcm
DC Noload Current 2 of rated amps
Injector Pressure 2631 psi 185 kfcm
DC Cranking Current 400 CCA
Valve Seat Angle Intake 45
Exhaust 45
LUBRICATION SYSTEM
Valve Clearance Intake and cold 0016 inches 040 mm General Gear
typepressure Speed Idle 600 900 rpm Oil Filter Full flow paper element spinon
type
Cruise 1800 2200 rpm Sump Capacity 22 US qts 208 liters
Max 2400 2500 rpm not including filter
Operating Oil Pressure 2585 psi
COOLING SYSTEM engine hot
General Fresh watercooled block Oil Grade API Specification CF or CG4
controlled with heat exchanger SAE 30 10W30 Temperature 180 190 F 77 88 C
Fresh Water Pump Centrifugal type metal impeller beltdriven Water Pump Positive
displacement rubber impeller General HURTH Standard Transmission Casehard
ened helical gears hydraulically operated multiple
disc Fresh Water
System Capacity 25 US qts 237 liters Gear Ratio Standard 2001 Hurth 45A or Hurth 63A
Propeller Shaft Right EXHAUST SYSTEM Propeller 24x18 P2 blade or
24x16 P3 blade
Exhaust Elbow 45 elbow using standard propeller should allow the engine to reach
transmission full rated rpm 2500 000 100 at full open
Exhaust Hose Size 4 10 1016 mm hose throttle while underway in forward gear
Lubricating Fluid Dextran III
Transmission Sump
Capacity Hurth 63 42 US qts 40 liters Air 365 cfm
Note The pressure differential between the outside of the engine compart
ment versus the inside of the engine compartment should not exceed 2
inches of water 51 mm at full open throttle measure with a Engines
Generators
SUGGESTED SPARE PARTS
WESTERBEKE MARINE DIESEL ENGINES
CONTACT YOUR WESTERBEKE DEALER FOR ADDITIONAL SUGGESTIONS AND TRANSMISSION
i FILTER
FUEL FILTERS OIL FILTERS
I FUEL
STRAINER
HARDWARE KIT
THERMOSTATS
JP AND GASKETS
SPARE PARTS KITS
WESTERBEKE offers Spare Parts Kits in two versions each packaged in a canvas duffel bag
Kit A has the basic spares Kit B is for more complete for offshore cruising
Kit A KitB
Impeller Impeller
Heat Exchanger Gasket Heat Exchanger Gasket
Fuel Filter Fuel Filter
Oil Filter Oil Filter
Drive Belts Drive Belts
Zincs Zincs
Thermostat Thermostat
The red and black duffel bag is Complete Gasket Kit
18 long with a full zipper dual Injector
handles and a carrying strap
Air Filter separate
Engines Generators Transmission Filter
Engines

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Disclaimer:
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 L-36.com. 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 L-36.com 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.