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Westerbeke Diesel W 40na Operator's Manual




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OPERATORS MANUAL
WESTERBEKE 46
Marine Diesel Engine
Publication 34468
Edition Two
May 1986
AVON INDUSTRIAL PARK AVON MA 02322 TEL 617 5887700
TELEX 924444 FAX 617 5599323 CABLE WESTCORP
FOREWORD
Thank you for having selected a Engine for your use
This manual describes the procedures for and routine maintenance of
Marine Diesel Propulsion Engines
To obtain best operating condition and life it is important to use it sensibly
and carry out operation and maintenance according
to this manual
If you have questions about your equipment or
in the event of a failure please contact your
nearest distributor or dealer
If within 60 days of submitting your card you have not received a Card see below registering please contact the factory in writing
We look forward to your continued from JH Weslerbeke Corp
Avon Industrial Park
Avon MA 02322
r1 J H WESTERBEKE COR
AVON ovrA p AVON AU oun
CUSTOMER W46 1234C408 Pleasure Craft
expi res 91585
Mail To
Adam Smith
85 Maple Street
Alden IN 12234
TABLE OF CONTENTS
PAGE
GENERAL PREPARATION AND SUPPLY
CAUTIONS 5
1 BREAKING 7
2 STARTING 8
3 INSTRUMENT PANEL USE 9
4 STARTING PROCEDURES IO
5 STOPPING PROCEDURES ll
6 CAUTIONS ON STARTING
AND OPERATION 11
7 REQUIREMENTS FOR PROPER
OPERATION
71 Lubrication System 13
72 Fuel System 14
73 Wiring Diagram Centerfold
73 Cooling System lS
74 Belt Tension 20
76 Domestic Hot Water 20
77 Cylinder Head Valves 24
S RECOMMENDED MAINTENANCE TRANSMISSIONS 28
10 40
11 TABLE OF TIGHTENING TORQUES 41
12 COMMON PARTS BY NUMBER 43
13 LIMITED WARRANTy 44
GENERAL Westerbeke 46
Type 4cycle fresh water cooled diesel engine
with raw water exchanger system
Arrangement of Cylinders 4 line
Bore Stroke 84 X 90mm 330 X 370 in
Dry Weight 535 Ibs Piston Displacement 2084cc 127 cu Ratio 21 1
Firing Order 1 3 4 2
Rotational Direction Clockwise as viewed from front of engine
Fuel 2 fuel oil cetane rating 45 or Oil Mineral oil heavy duty API CC or CD
Oil Pressure Idle 20 30 PSI 175 246 kgcm 2
Under power 30 60 PSI
246 421 kgcm 2 Power 475 horsepower at 3000 Rating 46 horsepower at 3000 Power 43 horsepower at 3000 RPM
Idle Speed 700850 RPM
Cruise RPM 20002500 Forced lubrication
Oil Pump Trochoid pump
Oil Filter Fullflow type with paper element
Oil Sump Capacity 7 quarts System Forced circulation by centrifugal pump
with controled temperature
Operating Temperature 170 190 F
Fuel System
Fuel Injection Pump NIHONCAV distributor type
Fuel Injection Nozzle Bosch type DNOSD
Governor Flyweight type built in pump
Fuel Filter with paper System Electric starter with glow plugs in head
starter 12V 16KW pinion shift 12V 50 12V 100 ampere hour
Raw Water Flow Rate 95100 at 3000 RPM
measured at discharge into exhaust lSD x 10P2 blade or lSD x SP 3 blade
using HBW150 18S1 propeller should allow engine to its rated RPM 3000 100 at full
throttle underway
PREPARATION AND SUPPLY CAUTIONS
Check important aspects of installation before operating engine
003 EELER GAGE
1 Alignment Error to be no more
than one thousandth of an inch
per inch of coupling diameter
2 Provide sufficient ventilation
3 Provide adequate service room STRAIGHT EDGE
around engine See warranty
clauses CHECKING COUPLING ALIGNMENT
Fill fuel tank with CLEAN 2 diesel from a reputable Fill engine sump with lubricating oil to full mar k on dipstick
Select readily available lubricating oil of grade CC or CD
Sump capacity 7 quarts
Fill freshwater cooling system with suitable mixture of water and
antifreeze to suit your temperature zone Thoroughly mix
antifreeze and freshwater BEFORE adding to cooling system
Plugin Panel Harness Connection After assembly joint should be
taped to prevent corrosion or preferably assembled using a sili
con grease which can be obtained at an electronic store such as
Radio Never operate engine with inadequate ventilation Confirm that
there are no exhaust leaks inside engine Do not touch moving parts during operation
Do not touch hot parts such as exhaust pipe and do not place com
bustible materialS near the engine
Inspect and adjust parts of the engine only after it is stopped
Check and refill engine oil cooling water and transmission lubri
cant only after the engine is brought to a stop
A coolant recovery bottle was supplied with the engine together
with instructions for installation Be sure that it is in place
Attempting to operate with only the manifold as an expansion tank
exposes the operator to a severe steam burn if the manifold pres
sure cap is removed while the engine is hot Follow instructions
on page 6
Always use tools
vicing
that fit correctly and use caution during ser
Be sure that current carrying wires are protected from abrasion
and that all connections are tight
steps as shown below in starting your engine for the first time
or after a prolonged a F ill your eng ine wi th oil
oil filler port
up to or near the upper limi t
on the dipstick Use a good
grade of oil with API specifi
cation of CC or better For
quantity of oil you may refer
to the General page
b Fill the transmission
with the proper lubricant
NOTE Some VDrives are filled
Your engine is supplied with a coolant recovery system to and ftller port
which the following instruc
tions apply
lowerlmt 7 oil
a Fill engine completely to
the neck of the manifold cap
b Then fill the recovery
tank to the bottom add line
Need for adding coolant is COOLANT RECOVERY TANK
indicated when a cold engine
has coolant level below the
bottom add line
c In winter add antifreeze
as described on page 18 A
mixture of antifreeze should be
used year round and changed as
needed
3 Fill the fuel tank with 2
Diesel fuel with 45 Cetane
rating or better The interior
of the fuel tank must be main
tained clean Be careful not
to allow introduction of dir t
when filling fuel
4 Engine oil coolant and
transmission levels should be
checked at least once a day
prior to engine use
BREAKING IN YOUR NEW ENGINE
While your engine has had at least one hour of test operations accurate assembly and correct operation of all systems it
still requires break in time
Service life of your engine is dependent on how your engine is
operated and serviced during initial breakin hours of operation
Your new engine needs approximately fifty hours of initial operation for breaking in each moving part thus performance and service life of engine
Perform this carefully keeping the following points in mind
1 Start engine run at idle while checking that all systems are
functioning sea water pump oil pressure battery charge
2 Warm engine prefer ably by running propeller at fast idle
while tied down until water temperature gauge moves into the
130 140 degree range
3 Then use engine at moderate load RPM until normal engine
operating temperature of 170 190F 77 BSC is reached
4 Avoid rapid acceleration especially with a cold engine
5 Use caution not to overload engine Grey or black smoke is a
sign of overload Select the correct propeller for the
engine and transmission reduction
6 Operate the engine in moderation varying the running RPM
under load during the break in in a new engine is basically a seating of the piston rings
to the cylinder walls This is not accomplished by long periods of
running idle nor by early running under full load
Idle running may glaze the cylinder walls causing oil consumption and
smoky operation Excessive speeds and loads may score cylinder walls
with similar results especially with the engine cold
As indicated above operate the engine in moderation during the ini
tial 50 hours of break in Dont baby it yet do not abuse it
OF STARTING SYSTEM
Model W46 uses an electr ic
starter assisted by glow plugs
for both normal and cold weather Glow The figure is a cross
section through one cylinder
The glow plug enters the com
bustion chamber so that the end
is in the spray path of the nozzle When the glow
plugs are energized by the pre
heat button they glow red at the
tips and assist rapid ignition of
the fuel The result is rapid
starts with less wear on This system is common to
Westerbeke Diesels The star t
circuitry is designed so that
first the preheat button must be
depressed for the time specified
in the glow plug use char t which and while keeping the preheat button engaged the start
button is depressed to crank the engine
Glow Plug Use Data
Atmospheric temperature Preheating time
SC 41F or higher Approx 10 sec
SC 4lF to SC 23F Approx 20 sec
SoC 23F or lower Approx 30 sec
Limit of continuous use 1 minute
For complete starting and stopping procedures see pages 10 and 11
INSTRUMENT PANEL Description and use of
Note 1 When engine is stopped after use the water temperature and
oil pressure gauges may stay at their running 2 When engine is next to be used turn keyswitch ON The
temperature and pressure gauges will ZERO and the voltmeter
will register battery voltage The elecric fuel pump
mounted on the engine will also begin to operate purging
any air accumulated in the system
Note 3 The engine is now prepared for 4 For INITIAL STARTS
The selfpriming feature of the W46 is different from other
models in that it requires longer time Two circuits are
required to bleed both fuel filter and injecion pump
Therefore when priming the W46 for the first time or when
the system has been wor ked on or has been run out of fuel
allow the electr lc fuel pump to oper te for 2 to 3 minutes
before the first cranking effort simply turn the ignition
key ON to activte the electric fuel pump
STARTING Advance throttle to full press Preheat button and hold for the
number of seconds indicated on Page 8 in Glow Plug Use Data
2 While still engaging Preheat button press Start button
Note Failure to engage the Preheat button will not allow the
Starter button to energize the starter
3 The starter will crank the engine which should start in 10 seconds
or less
4 As soon as the engine starts release buttons and throttle back to
a moderate idle warm up of 80 1000 RPM
5 Should the eng ine NOT star t even though cr anking for 10 seconds
release the buttons for 30 seconds and repeat the sequence by pre
heating the glow plugs sufficiently The starter motor should
never be run more than 30 seconds at a time
6 Proper glow plug function is
indicated by voltmeter drop
when the Preheat button 1S
depressed This drop will be
slight but discernible If no
vol tage drop is noted it may
indicate defective glow plugs
or a faulty preheat circuit
Check for loose As soon as the engine has started release both Start and Preheat
buttons Check that with engine running oil pressure and battery
charge voltage are registering and that raw water is discharging
with the exhaust
Note An alarm buzzer is supplied with every unit It is the
of the installer to electrically connect the alarm
buzzer to the two marked terminal connections on the engine
electr ical harness and install the buzzer in a dry location so
that it will be audible to the operator should it sound during
engine operation This buzzer will sound when the ignition key is
turned on and should silence when the engine is started and oil
pressure rises above 15 Ibs
8 To warm up engine run a few minutes at idle to make checks in 7
above Then operate under reduced RPM until water temperature
rises into the 140 range Then operate under moderate power
until normal operating temperature is reached
STOPPING PROCEDURES
1 Model W46 early models were supplied with a manual shutoff A
T handle or knob is pulled to shut off fuel stopping the
engine
Later Models June 1985 C506 on were supplied with an electric
shutoff operated by the key switch and having the manual shutoff
as an installers option
2 With the engine stopped it is necessary to turn off the key
switch If you fail to do this the panel remains energized and
the electric fuel pump continues to run This oversight results
in a dead battery with the alarm buzzer installed and
functioning it will sound when the engine is shut down manually
and the keyswitch left ON signaling to turn the key ON STARTING AND OPERATION
1 Normal starting
Follow the procedures below for routine starting of your engine
1 Check the engine and transmission oil levels and refill i f
necessary
2 Insure that you have sufficient fuel Keep tank as full as
possible
3 Check cooling water level and refill if necessary
Note Check for leaks of water or oil particularly when
signs of such leak are found on the bottom of the engine or
in the drip tray when provided
4 Start the engine in accordance with the procedures given on
the preceding pages
5 Allow the engine to warm up to 140150 F before placing the
engine under heavy load
2 Starting under cold conditions
The following three adverse conditions concur as the atmospheric
temperature drops exceedingly and the engine must under such
conditions be started by taking steps described below
LUBRICATING OIL TURNS VISCOUS Make certain that viscosity
is proper for the prevailing atmospheric temperature Check
the oil also for Study page 13
VOLTAGE ACROSS BATTERY TERMINALS DROPS Check that the
battery is fully charged
THE TEMPERATURE OF INTAKE AIR IS LOW AND COMPRESSION
TEMPERATURE DOES NOT RISE ENOUGH Allow the glow plug to
operate sufficiently to aid starting See table on page 8
3 Cautions during operation
Confirm that the oil pressure is normal during operation
Confirm that exhaust gas is as follows
While engine is cold White smoke
When the engine grows warm Almost smokeless
When the engine is overloaded Some black smoke
Check for abnormal noise such as knocking friction or leaking
sounds and vibration and blowback sounds
Check for leaks of fuel and engine oil
A knocking sound is normal while the engine is cold during quick
acceleration and at idle Confirm that no knocking sound is heard
in other cases
Photo above is right hand side of the W46 with Hurth 21 reverse
and reduction gear
REQUIREMENTS FOR PROPER SYSTEM
1 Engine oil
For engine lubrication use diesel engine oil Diesel engine oils
are classified according to the API into grades CA
CB CC and CD Anyone of them is usable but use of CC or higher
grades prepared by wellknown makers is recommended The oil
selected should be used Engine oil viscosity
Use oil having viscosity best suited to the atmospheric tem
perature Use of an allseason oil SAE10W30 with minimum visco
sity change under different temperatures is suggested
Atmospheric temperature Viscosity
20C 6SF or higher SAE 30 or 10W30
SC 41F 20C 6SF SAE 20 or 10W30
SC 41F or lower SAE 10W30
3 Oil pressure
The oil pressure during operation of the engine is indicated by
the oil pressure gauge
During normal operation Oil pressure will range between
Under Power 30 and 60 PSI
210 421 kgcm 2
At idle speed e 20 30 PSI
17S 210 kgcm 2
At the time of cranking Pressure will rise proportion
ately with speed
4 Replacement of oil filter
Being a replaceable car tr idge
type the oil filter requires
no cleaning inside
In installing the oil filter
element apply engine oil
thinly on to the Oring and
then tighten it by hand firmly
When removing the used filter
cover over wi th a plastic bag OIL DRAIN SYSTEM
This will allow both filter
element and spilled oil to be
collected cleanly without
spilling oil in the bilge
Note A Aftermarket filters are not recommended since the
material standard or diameters of important items might
be entirely different from genuine parts
Note B Immediately after filter change and oil filler run
engine to ensure that oil pressure is normal and that
there are no oil leaks
5 Engine oil change Initially at 50 hours then every 100 hours of
including filter operation
To renew engine oil discharge old oil through the sump drain hose
attached at front of engine while engine is still warm
Drain old oil completely replace the hose plug the end securely
and add fresh oil through the oil fill cap on the valve cover
After refilling oil idle the engine for several minutes and stop
Then check the quantity of oil by the oil level gauge Fill to
but not over the high mark on the dipstick Always observe old
oil as it is removed A yellowgrey emulsion indicates presence
of water in the oil While this condition is rare it does
require prompt attention to prevent serious damage Call a com
petent SYSTEM
1 Diesel fuel
USE 2 DIESEL FUEL NEVER USE KEROSENE OR HEAVY OIL
In cold weather particularly water vapor is produced by conden
sation when air is present in the fuel tank The tank therefore
should be kept full as much as possible
The fuel tank furthermore needs to be kept completely free of
dirt and water
2 It is required that a primary TRAP 2974
fuel filter of the water entrapment type be installed HOSE FITTING
8 9 Bolt
SGLlrly
tl1eurf
aCPcslole
positioned tht B
between the fuel tank and the rceptc to 0Lcll cnage
r lcl LJdr
engine Such a filter shown 2 If up I
cq 01
is to be piel with
hundy utdng use
here is available under Par t nut anj tcrules jlrovllel
SLlre th
lUbing Ioects 14
32974 from your local inch thLlg the rle bfo
tiqhteninq tno nut
Westerbeke or It
11D5
ud 5 to b pipd with
hp two Ir05 narleo
your boat builder This f U itLlrg
dm hprs suppiied
certHn lhat the hose
ter adapted for boat builder TUBE PIPING
oeiectell
In td
diagonal
clln on
braid
bar that j js neoprene
use comes complete wi th f i t lined and that it USCG
tings for either hose or metal 4 It pr s pesnt 1 ihc
tubing Mount in an accessible fuel
i t will collect dowly in
bottom of the hen tlw red float r1ng rKhes
place inspect often and drain th dri line on the plastic
bowl loown the bottom drain
off water accumulation fre plug unU all water runs out
5 lightEn dai plug ocurely 50
quently o a1t eiln enter 8ySlm
Ii Energiz uel pump to refill
HISTR 3309 bow
If a water trap type filter is not interposed between the fuel
tank and engine lift pump any entrained water will tend to lay in
the bottom of the electric lift pump Internal metal parts of the
lift pump will rust Particles will pass on to filters to injection pump and injectors with damaging and
expensive results IT IS WELL TO REMEMBER THAT WATER DAMAGE TO
THE FUEL SYSTEM IS NOT COVERED BY many boat builders do supply a water trap filter there are
some who do not It is to prevent such omission that a trap filter as a desirable at moderate cost It is supplied with fittings for either
hose piping or metal tube and self bleeding All engines covered by this manual
have a fuel filter with hand priming pump in the head casting for
emergency use The main priming source is the electric lift pump
mounted on the cylinder head front
The Westerbeke selfbleeding fuel system on Model W46 is If you run out of fuel perform a filter change or of the fuel system the system will then
contain air
which may prevent the engine from starting In such event turn
the keyswitch on allow electric pump to run for two minutes
and crank engine for approximately seven seconds If the engine
has not started wait for approximately thirty seconds more of
electric pump action and crank engine again These time periods
may vary from engine to The self bleeding feature on the W46 relates to the
enginess fuel system only
INJECTORS LIFT PUMP
FUEL FILTER
THROTTLE INCOMING FUel
INJECTOR PUMP
BUFFER SCREW
3 Notes on fuel system
See on prior page a typical exploded view of a fuel system for
this engine It is also illustrative of the selfbleeding and
priming system used by Westerbeke
The Westerbeke selfbleeding fuel system is in
operation While it is unlikely that the operator will be forced
to service the system at sea the possibility does exist
Therefore it is recommended that banjo washers injector seat
washers lift pump filter and gasket fuel filter and gasket be
carried on board at all timnes Select the parts for your engine
on page 43 and purchase spares from your local Westerbeke Dealer
or Distributor For example hardware kit 34441 will supply fuel
system washers for the Model 46
If a leak should develop at a banjo or washer that cannot be
remedied by a simple tightening of the screw renew the washers
The engine can be started by taking steps described on pages 9
and 10 In cases where the engine cannot be started easily loosen
two injection nuts on the nozzle side turn the speed control
lever to full open position turn the starter motor and then
tighten the nuts firmly
4 Replacing filter elements
After the first 50 hours of operation unscrew and discard fuel
filter element Install a new filter
This same treatment is required of the filter element in the fuel
lift pump Similarly replace with a new filter element using a
new gasket
After the first 50 hours change the change period may be
increased at 200 hours or once per season
5 Fuel injection pump
The fuel injection pump is one of the most important components of
the diesel engine and thus i t calls for the utmost caution in
handling Furthermore the fuel injection pump has been
thoroughly shopadjusted and should never be readjusted
carelessly
Such adjustments whenever necessary should be performed at an
authorized service station as a precision pump tester skill are
required
To obtain long and satisfactory use of your injection pump
Always use fuel which is free from impurities
Clean and renew the fuel filters Inspect water entrapment filter 16
On the forward control housing of the injection pump is a buffer
screw This buffer screw has all the visual of a
bleed screw but it is not The adjustment of this screw should
not be tampered with or the adjustment of this buffer screw can shut off the
delivery of fuel from the injection pump to the injectors and pre
vent the engine from starting
DO NOT TAMPER WITH THIS BUFFER SCREW INJECTOR PUMP
BUFFER SCREW
COOLING SYSTEM
1 Cooling water
As cooling water use soft water with least impurity content such
as tap water potable water or rainwater and never use hard
water or foul water Use of hard water or water containing much
impurity will lead to collection of scale in the engine and heat
exchanger with resultant decline in cooling effects
2 Antifreeze
In cold districts care should be taken to prevent cooling water
from freezing Cooling water when frozen expands to break the
heat exchanger and the cylinder block and it is essential that
antifreeze be added to cooling water in a quantity proportional to
the lowest temperature of the district It is recommended that
the antifreeze mixture be used throughout the year
Antifreeze of poor quality or without rust inhibitor
will cause corrosion of the cooling system Always use
antifreeze prepared by a reliable maker
Make sure that the cooling system of the engine is cleaned
well before adding antifreeze
Recommended antifreeze for year round use is ZEREX or
PRESTONE with rust inhibitor
Thoroughly mix the antifreeze and water before adding to the
cooling system
ANTIFREEZE ADDITION DATA
Antifreeze
Concentration 13 23 30 35 45 50 60
Freezing C 5 10 15 20 30 40 50
temperature F 23 14 5 4 22 40 58
Note It is advisable that antifreeze concentration be
selected on the basis of a temperature which is about
5C lOF lower than the actual atmospheric tem
perature expected
3 Fresh water cooling system
The system consists of a sea water pump which pumps raw sea water
through a heat exchanger to remove heat from the coolant The raw
water is discharged overboard through the exhaust line
The engine coolant fresh water with or without antifreeze is
circulated by the fresh water pump in continuous circuit pumped
through the cylinder block cylinder head heat exchanger and back
to the fresh water pump
The total system is very reliable and requires only a daily check
of the water level in the system plus routine checks of hose
clamps and fittings
It is likely that zinc electrodes will waste away from elecroly
sis action in the sea water circuit They should be It is also possible for the raw water pump impeller to
fail due to lack of sea water or An early sign of
impeller failure is less water and more stearn at the hull fitting and higher engine operating is recommended therefore that zinc electrodes water
pump
belt alternator belt sea water pump assembly and sea kit be carried onboard at all times These parts should
be ordered from your nearest stocking dealer and used as The part numbers for these mnay be taken from the parts
list on page 43
ELBOW
FRESH WATER
DRAIN
TO HOT WATER TANK
INCOMING RAW WATER
BELT TENSION
The belts are properly ten
sioned when they deflect 10 to
12 mm 039 to 047 in as they
are depressed with a finger
between the alternator pulley
and fresh water pump pulley
Excessive tension can cause
quick wear of the belt and
bearings of the water pump and
the alternator Excessive
slackness or presence of oil on
the belt on the other hand
can lead to engine overheating
insufficient charging due to a
slipping alternator belt and
rapid wear of the belt
CAUTION
Never attempt to adjust tension of any drive belt while the
engine is in DIAGRAM
Your engine has a 12 volt DC startrun circuit A pictoral schematic
of this is illustrated on Page 22 Study it and learn to the system installing electrical parts connect them correctly by referring
to the diagram and at the same time check for damaged wire sheathing
and confirm that grounding is provided properly Care must always be
taken while working on the electrical SHUT THE ENGINE BATTERY SWITCH OFF WHILE THE ENGINE IS TO THE BATTERY CHARGING ALTERNATOR WILL RESULT SHOULD
THIS BE
DONE
REMOVE ReTURN BEND HOT WATER
Sketch at right shows Model W46
complete wi th Flow Control mecha
nism and its bypass connection for
normal use If it is desired to
connect a hot water heater remove
the bypass hose altogether and con
nect the heater as instructed on
the following page Study 20
Model W 46 comes complete wi th a Flow Control which when proper ly
connected to a heater tank produces domestic hot water from waste
engine With the bypass hose 130962 removed there remain 2 con
necting points A and B for hose to and from the water heater assure a flow of hot water through the heater at all times
and yet preclude excessive restriction of engine cooling water flow
caused by the heater all simply and The heater should be mounted conveniently either in
high or low position so that connecting hoses from heater to engine
can run in reasonably direct line without loops which might entrap
air Connection Point A on the Flow Control housing should connect to
the lower of the two connections on the water heater while the on the heater returns to B nearest the heat should rise continuously from their low
point at the heater to
the engine so that trapped air will rise naturally from the heater to
the engine If trapped air can 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 Avoid loops in hose runs which
will trap air
If any portion of the engine cooling water circuit to or from the
heater rises above the engines own pressure cap then the expansion tank must be installed in the circuit to become the
highest point The tank kit part number is 24177 Install the tank in a convenient location such as a sail locker for ease
of checking fresh water coolant level
The cap on the engine mounted expansion tankmanifold should not be
opened once the remote system is installed and filled
The hose connection from the heater to the remote expansion tank
should be routed and supported so as to rise continuously from the
heater to the tank enabling any air in the system to below are of Flow Control adapted to our single
PRESSURE CAP IS RATED LOWER REMOTE EXPANSION TANK
THAN MANIFOLD CAP
HEATER COILS ABOVE PRESSURE CAP
HEATER COILS BELOW PRESSURE CAP
REMOVE RETURN BEND FROM
HEATER BELOW ENGINE HEATER ABOVE ENGINE
WI PI NG DIAGRAM
SEE NOTE B
W srNDER
0L PRESSURE
SWI CH I
I ALTERNATOR
o jACH
I SI AMP
ACARM
O R
J rt
o GRN
I I A 21
FUEL SOL 118 Nj2 70lV100 BUI
SPLlTT R
OPTIONA
oce un Cce
ro wl3 N2127 W 3
CCQoecco EVICE
CPT10A
AMMER
PREHEAT SOL
PuR 2
SEE NOTEB
PEIEATER
OP SENDER
24 WT
PR Z
2 NOEG
EL 4
BI 0
OR
i
EoPN SEE NOTE
NOT USEO
2 VDC
RED 10 V
1ATTERY
WT JEUTRAL
STARTER 0 SAFETY
SWITCH
B I
T
otJ F B i
la10 3K4i
IS ee
y NHT
SERlE 15 ALTERNATOR
2voi 9MP
SCHEMATIC DIAGRAM
r2VDC BATTERY BATTERY RETURN
NOTES 01 AlTERNATOR
o i
I 120AMP
OHER rygTES
PANEl PREHEA1 SOL
I i
WARNING ENCR
CONTACT WlrH 8 MAY DAMAGE SENPER
RwHEAT
START SOl ARe THRQUGH ENGINE 8LOC
FOR WIRING OF AUXLAIY AlTENATOeS Sec THE FOLLOWING DIAGRAHS
MOTOROtA 85 AMP fl232
START SWI MOTOROLA 20 AMP fl23 I
LtIECJY IS35
ECe L 14
rUEL
lfT PUMP
ALARM OP W APPLY SILASIe OR TiGHT WOUND ELECTRICAL
CD A APE AROUND CONNECTORS
CAuTION
THIS PRODUCT S PROTECTED BY A VfAJfAL RESET
WTSW ClRCUft BREAKER OCATED HIAR THE STARTER AND AS CLOSE
TO THE SOIRCE oFCUPRENT AS POSSIElL
EXCESSIVe CURRENT PIAIN ANYWHeRE fN rHe INSTRUMENT PANeL
0 olf 0 P S E NO R WIRfNG OR EIYUif WI Al HE 8EAKE TO TRfP IN THIS EllEN
4QF ENGfE MOjLS WILt SIfJlTPOWA 8ECAIIS TJE gpeNED
BREAKER DISCONNECTS THEIR THEREFORE 77te
oil WT SENOER 5UIIPEg aWNEE MUST BE SURE THAI me INSTRUMeNT PArjEI
WIfifNG AND EN61E ARe INSTALLeD TO PREVENT CONTACT
6Grwttv LCTRICAL DEVicE AND SALT WATEg
ITEM
CYLINDER HEAD AND VALVES
1 Tighten cylinder head bolts in the sequence shown The engine
should be cold Loosen each bolt oneeighth to onequarter turn
when tightening in the sequence shown Note that bolt 14 and 5
are located under the intake manifold where it is attached to the
head
0 16 14 12 10 11 15 1 Head Bolt Tightening Torque
0 0 0 0 0 0 0 Q
0 Exhaust Side
8 J 0
1
120 kgm 86 Ibft
Intake side
0 105 kgm 76 Ibft
6 2 7
2 Tighten rocker shaft bracket bolts to 15 kgm 11 Ibft
3 Adjust valve clearance with the engine cold following retorquing
of cylinder head bolts according to the following procedure The
valve clearance is 02 03 mm 0009 0012 inch
A Rotate the crankshaft slowly in the normal direction of
rotation to bring the piston of the number 1 cylinder front
of engine to TDC of its compression stroke Observe
when this is done that the valves of the number 4 cylinder
are in a position of valve overlap ie the period between
the opening of the inlet valve and the closing of the exhaust
valve
B In this position adjust the valve clearance in the
conventional manner of the intake and exhaust valve of the
number 1 cylinder the intake valve of the number 2
cylinder and the exhaust valve of the number 3 cylinder
C Rotate the crankshaft in the normal direction of rotation one
full turn 360 and stop
D In this position adjust the valve clearance of the intake
and exhaust valve of the number 4 cylinder the exhaust valve
of the number 2 cylinder and the intake valve of the number 3
cylinder
Exhaust valves
l f l 1
I I
Inlet valves
RECOMMENDED MAINTENANCE and service your engine at specified intervals to maintain it in
its best conditions and permit it to perform as it should As for
those asterisked items it is suggested that you have them performed
by an authorized distributor or dealer
1 Daily inspection before use
A Check up of engine oil lever and refilling
No refill is required if the level is near the upper limit
line of the gauge
B Checkup of cooling water and refilling
Refill up to the ADD line on coolant recovery tank
C Check your fuel supply
D Checkup of gauges and meters
After starting your engine check oil pressure water tem
perature and voltage readings
E Check for loose parts fan belt or bolt etc damage and
leaks
F Check for abnormality with exhaust gas noise and Servicing following initial 50 hours of operation
A 1 Renewal of engine lube oil and filter
2 Renewal of transmission lubricant
HBW units 25 hours
B Replacement of fuel filters
1 Secondary spinon
2 Electric fuel pump filter
C Tightening of bolts and nuts
D Adjustment of valve clearance Intake Exhaust 02 03mm
009 012 inches
E Check security of all electrical F Adjust belt tensions
G Check secur i ty of propeller shaft coupling both to
transmission flange and shaft to couplings
H Adjust engine idle speed if needed
I Check condition of zinc anode in heat exchanger
Should material be flaking off the zinc it should be scraped
clean or be replaced by a good solid zinc pencil
If it appears that a lot of material has been flaking off the
zinc then it is advised that the end cap of the exchanger be
removed and the flaked material be cleaned from that area of
the exchanger A new end cap gasket should be on hand in case
it is needed when replacing the end cap
ZINC 11885 REPLACE J Check for proper movement and security of throttle and shift
linkage
3 Servicing at every 100 hours of operation
A Renewal of engine oil
B Replacement of oil filter
4 Servicing at every 200 hours of operation
A Replacement of engine mounted fuel filter elements
B Relacement of fuel filter cartridge type
5 Servicing at every 500 hours of operation
A Adjustment of engine idle if necessary
B Tightening of bolts and nuts
C Adjustment of valve 26
D Checkup of glow plugs
Check glow plugs for blowout Do resistance check
E Removal of cooling water and flushing is suggested
F Lubricate fresh water pump
Grease fitting refill capacity 12 cu in
6 Servicing at ever 800 hours of operation
A Checkup of nozzles
set the injection starting
pressure to 1706 0 psi
and eliminate undesirable
injection conditions in
cluding after dripping
GOOD
B Check Compression pressure
Remove each glow plug and
check cylinders one by
one using a compression
pressure gauge If the
pressure differs by more
than 30kgcm 2 427 psi
between cylinders or if
the cylinder pressure is
less than 30kgcm 2
4270 psi at TOO RPM
correct it
C Fuel injection adjustment
In case of severe vibration during idling have it repaired
at an authorized distributor or dealer which is equipped with
a pump tester
D Check tightness of nuts and bolts
E Check up of starter motor and 27
HBW All HBW models turn right hand propellers
All HBW models have their own oil sumps and dipsticks
All HBW models use ATF lubricant
All HBW models should be shifted into gear in one swift
motion not allowed to slip in of gearbox
1 The gear box is su i table for o
single lever remote control o A B
using 33C cable I
2 The cable should attach at right
angles to the actuating lever
using the cable bracket
supplied
3 Both gear box lever and remote lever must be in o o
neutral position when cable is attached so that
travel of gearbox lever will be equal forward or
reverse
4 Check that actuating lever hub does not touch
cover plate hub Maintain at least 05 mm
0002 Over travel of the actuating lever does no harm OSmm
However if the travel is too short to give full
engagement premature wear excessive heat
generation and gear failure may result
6 The position of the cover plate
underneath the actuating lever
is factory adjusted to ensure TRANSMISSION
TO CHECK OIL LEVEL
equal lever travel from neutral IN OPERATION
to A and B DO NOT LOOSEN THE f
CAPSCREWS HOLDING THIS ASSEMBLY
Doing this voids transmission if
warranty I 1
I III rr
7 Fill gearbox with automatic l1 i
transmission fluid to the l e v e l r t
indicated by the dipstick mark 1
Study illustrations adjacent Ii
8 Note that to check oil level
the dipstick drops on the I DI t1 FLUID LEVEL
housing It does not screw in I
I I Iii I I
DRAIN PLUG
WARNER HYDRAULIC FROM COOLER
2101 ONLY
SHIFT LEVER DIPSTICK ASSEMBLY
SHIFT LEVER
FROM 10131014
COOLER FROM COOLER 10171018
EXCEPT 2101
1 CONTROL LEVER POSITION
The position of the control lever on transmission when in be shifted to the point where it covers the letter F on the
case casting and is located in its proper position by the poppet
ball The Warranty is cancelled if the shift lever poppet spring
andor ball is permanently removed or i f the the control lever is
changed in any manner or repositioned or if linkage between and transmission shift lever does not have sufficient travel
in both directions This does not apply to transmissions equipped
with Warner Gear electrical shift control
2 properties of the oil used in the transmission are to the proper function of the hydraulic system Therefore
it is extremely important that the recommended oil fluid ATF Type A or Dexron II be used
NOTE Be sure the cooler is properly installed and the oil before cranking or starting the engine
3 FILLING AND CHECKING THE HYDRAULIC SYSTEM
The oil level should be maintained at the full mark on the oil level prior to starting engine Check daily before The hydraulic circuit includes
the transmission oil lines and any gauge lines connected to the circuit The
complete hydraulic circuit must be filled when filling and this requires purging the system of air before the
oil level check can be made The air will be purged from the system
if the oil level is maintained above the pump suction opening while
the engine is running at approximately 1500 RPM The presence of air
bubbles on the dipstick indicates that the system has not been purged
of air
New applications or a problem installation should be checked to insure
that the oil does not drain back into the transmission from the cooler
and cooler lines Check the oil level for this drain back check after the engine has been shut off and again after the
engine has been stopped for more than one hour overnight A noticeable increase in the oil level after this waiting
per iod indicates that the oil is draining from the cooler and cooler
lines The external plumbing should be changed to prevent any STARTING ENGINE
Move the shift lever to the center position where the enters the chamfered hole in the side of the shift lever and pro
perly locates lever in neutral position before starting engine
5 from any selector position to any other selector position may
be made at any time and in any order if the engine speed is below 1000
RPM however it is recommended that all shifts be made at the engine speed Move the shift lever to the extreme where the spring loaded ball enters
the chamfered hole in the
side of the shift lever and properly locates lever in transmission shift lever to the extreme rearward position where
the springloaded ball enters the chamfered hole in the side of the
shift lever and properly locates it in the reverse sail with the propeller turning or at trolling speeds with one
of two engines shut down the design of the gear maintains and 30
7 COOLING passages inside of the cooler will sometimes become clogged and
this will reduce cooling capacity and cause Back
flushing of the cooler will sometimes help to flush the foreign
mater ial from the cooler passages The cooler and hose should be
thoroughly flushed or replaced in the event a failure has particles from the failure tend to collect in the case of the
cooler and gradually flow back into the lube system Replace oil
cooler to prevent contamination of the new hoses may collapse and reduce or completely shut off all flow to
the cooler Collapsed hoses are usually caused by aging of the hoses
or improper hose installation Hose installation should be made with
no sharp bends Hoses should be routed so there is no possibility for
engine shifting to cause hoses to pull loose or become pinched A
visual inspection of hoses while under way will sometimes allow detec
tion of faulty or complete loss of water flow can be caused by a faulty
water pump A rubber water pump impeller will sometimes fail and
after such a failure the cooler passages may be restricted by the par
ticles of rubber from the failed impeller Water pump cavitation may
be caused by improper or faulty plumbing or an air leak on the inlet
side of the pump The water pump may not prime itself or may lose its
prime when inlet plumbing is not properly is possible for cross leaks to occur inside the cooler to flow into the water or water flow into the oil
ROUTINE CHECKS AND CHECKS
1 PROPELLER AND OUTPUT SHAFT ALIGNMENT This check should also be
made any time the propeller strikes a heavy object and after any acci
dent where the boat is stopped suddenly Shaft alignment should also
be checked after the boat has been lifted by a hoist or moved on a
tr ailer
2 SHIFT LEVER POSITIONING The selector controls must position the
shift lever exactly in F Nand R selection positions with the ball
poppet centered in the shift lever hole for each position
3 BOLT TORQUE Check all bolts for COOLER CONNECTIONS Check water lines oil lines and leakage Make sure lines are securely fastened to
CHANGING OIL A seasonal oil change is recommended in Work boats require more frequent changes Change oil any time
the oil becomes contaminated changes color or becomes Automatic transmission fluids ATF Type A is use
DAILY CHECKS
1 Check transmission oil level
2 Check for any signs of oil leakage in the bellhousing at gasket
sealing surfaces or at the output shaft oil seal
3 A quick visual check of the general condition of the equipment may
cause faulty equipment to be detected
4 Listen for any unusual noises and investigate to determine the
cause of any such STORAGE
1 Drain water from transmission oil cooler This will prevent
freezing in cooler climates and prevent harmful deposits from
CHECKS
1 Check coupling alignment each time a tr ansmiss ion is replaced in
the boat
2 Check shift linkage adjustment to insure that the 32
shift lever is positioned so that the spring loaded ball enters
the chamfered hole in the side of the shift lever
3 Connect an oil cooler into the cooler circuit before cranking or
starting the engine various cooler circuits have been used and
the correct cooler connections should be found from service
literature prior to makeing the cooler Use a cooler or sufficient size to insure proper cooling
5 Check engine rotation and transmission pump setting and the pro
peller rotation prior to assembling the transmission to engine
6 Check oil pressue and temperature when transmission function
indicates that a problem exist
7 Use the recommended fluid for filling the Fill the transmission prior to starting the engine
9 Check oil level immediately after the engine has been shut off
10 Use a clean container for handling ransmission fluid
11 Replace cooler line after a transmission failure prior to
installing a new or rebuilt Check fluid level at operating 33
WALTER ALIGNMENT DIRECT COUPLED MODELS
Install the propeller shaft flange on
to the propeller shaft and tighten the two
clamping bolts on the spli t hub none on A selflocking set screw is pro I rSET
SCREW
vided for the propeller shaft flange GEAK SHAFT y
FLANGE
spot drill the propeller shaft and then
securely tighten the set screw Many are ruined by improper shaft
flange alignment Accurate alignment will
ensure a smooth operating drive train and
eliminate many problems that arise due Final alignment should not
be attempted until the boat has been
FEELE
GAGE o
7 tt
0 II
allowed to settle in the water After L HECK i
the engine has been installed adjust the PROP SHAFT I
FLANGE
CLAMPING
mounts per instructions BOLTS
until the pilot diameters of the gear FLANGE flange and the propeller shaft
flange engage freely Butt the flange
faces together without rotating either flange check with a feeler
gauge in at least four places as shown in the illustration If the
maximum feeler gauge that can slip between the flange faces at any
point is 003 the unit is properly aligned If a thicker gauge can
be inserted at any point the engine must be readjusted until is obtained Turn the propeller shaft flange 14 of a turn
without moving the gear shaft change Try inserting the 003 feeler
gauge as described above The gap will not change if the is straight If i t increases the shaft or flange is bent and
must be removed and straightened Rotate the propeller shaft flange
in two more 14 turn increments and repeat the procedure The must be rechecked to ensure that they still engage the two flanges
together with the heat treated bolts and spe
cial high collared lockwashers ALIGNMENT INDEPENDENT MODELS
The engine must be adjusted so that the alignment of the is within 3 An accurate steel rule should be used for this
purpose as shown in the illustration On short installations using a
flexible joint assembly the faces of the flexible joint must be
parallel within 18 Measure this in at least four places around the
diameter without rotating the assembly With long installations using
the 36 tubular drive shaft also on all RV10Ds the distance from
the 133A spool adapter to the bores in the universal joint which is
welded to the tubular shaft must be measured on both sides of the
joint Rotate the shaft exactly 14 of a turn and measure to the same
joint The four distances must be equal within 18 Do not measure
to the joint end that is
on the spool adapter
This distance will not
vry with misalignment lERK nTTN
Since the joint is
bolted and cannot move
Put the i3lA alignment
gauge on the machined
diameter of the 24
cover and slide it com 5tpIT INW Al1l
pletely around It will lN
SCREW 10 on
AN NCLFlAT indicate how the engine
must be moved to center
the spline shaft in the
oil seal Remeasure
the joints to see if
they are still parallel within 18 It is
important that both alignments be checked lClQ It is possible for the spline shaft
to be perfectly centered and the flexible joint
to be out more than 3 Premature failure of the
26 selfaligning bearing and seals may occur due
to misalignment The zerk fitting located on
the cross of the universal joint should be
greased with a light alemite lubricant The
above procedure should be repeated after the boat
has been placed in operation It is possible for
the engine to slightly shift and settle espe
cially if it has rubber ALIGNMENT INDEPENDENT MODELS
Install the propeller shaft flange on to the
propeller shaft and tighten the two clamping bolts
on the split hub none on RVlO A screw is provided for the propeller shaft
flange Spot drill the propeller shaft and secure
ly tighten the set screws
All Vdrives are supplied with 3way brackets 2way on the RVlO and RV20 as
standard equipment The brackets must face down
ward as shown in the illustration to propeller thrust The mounting plates can
be removed and reversed to fit wider engine bed
RVIQ Before installing the Vdrive loosen all
the nuts on the mounting brackets and check to see
that the studs are in the center of the slots Re
tighten the nuts place the Vdrive on the engine bed lining it up
by eye to the propeller shaft flange as closely as possible Firmly
bolt it down through the holes provided in the mounting the locking nuts on the adjusting screws Slightly loosen the
nuts on the mounting br ackets just enough to be able to move the V
drive
Many good installations are ruined by improper propeller shaft
flange alignment Accurate alignment will ensure a smooth operating
drive train and eliminate many problems that arise due to Final alignment should not be attempted until the boat has been
allowed to settle in the water Adjust the Vdrive until the of the gear shaft flange and the propeller shaft flange
engage freely Butt the flange faces together Wi thout flange check with a feeler gauge in at least four places as
shown in the illustration If the maximum feeler gauge that can slip
between the flange faces at any point is 003 the unit is If a thicker gauge can be inserted at any point the Vdrive
must be readjusted until proper alignment is obtained Turn the pro
peller shaft flange 14 of a turn without moving the gear shaft
flange Try inserting the 003 feeler gauge as described above The
gap will not change if the propeller shaft is straight If it
increases the shaft or flange is bent and must be removed Rotate the propeller shaft flange in two more 14 and repeat the procedure The pilot
diameters must be
rechecked to ensure that they still engage freely Tighten the nuts
on the mounting brackets and the locking nuts on the adjusting the set screws from the brackets none on RVIO or RV20 spot
drill and securely tighten Recheck the flange alignment to make sure
the Vdrive did not move out of alignment Secure the two with the heat treated bolts and special high collared lock
washers supplied
SET SCREw
GEAR SHAFT
FLANGE
FEELER
GAGE
CLAMPING cSET SCREW
BOLTS
MOUNTING PLATE
FLANGE ALiGNMEN T
RV30 RV40 AND SWITCH CONNECTIONS
Hook up the water lines to the two pipe connections on the and exhaust lines are Generally one line
from the seacock to the Vdr i ve and another from the Vdr i ve to the
intake of the engine water circulating pump are utilized In some
cases scuppers through the hull are connected to and from the Vdrive
to provide independent watercooling and are actuated by the movement
of the water wi th closed cooling systems the Vdr i ve should into the system between the cooler and the suction side
of the water pump Proper operating temperatures are from 140 to
IBOF although safe operating temperatures may be as high as 210F
On the models equipped with an oil circulating pump the 49 oil
pressure drop switch and the 12 volt 49A warning light should be
hooked up per the wir ing diagr am The swi tch may be grounded to any
part of the Vdrive or engine either terminal may be used for the
ground
OIL FILL
Pullout the 21 oil level the 12 breather cap and fill the
Vdrive with SAE 30 motor oil through the
12A breather elbow On the RVlO only
the oil may be added by removing the plug
in the 6D top cover See table below oil capacities The amount
varies with the angle oE oil level should be checked wi th the
oil level gauge Eully inserted in the
unit The proper level is between the H
and L marks on the gauge Add a 2 ounce
tube oE Molykote molybdenum is supplied with each Vdrive Eor VATER LINE
extra lubrication and breakin It provi
des protection against scoring or galling
oE gears bearings and other moving Molykote aEter breakin is not required Reinstall the
breather cap The oil level should be rechecked aEter the unit has
been run and allowed to stt Eor about a minute Add oil iE necessary
RVlO RV20 RV30 RV40 RV4B
Oil capacity 1 pint 2 pints 3 pints 4 pints 4
DEALER PREPARATION
The propeller shaEt and engine alignment must be checked if necessary beEore the boat is delivered Final align
ment should not be attempted until the boat is allowed to settle in
the water The oil level must be checked and oil added iE the boat is being run the water connections should be checked
Eor leaks The oil pressure drop switch and warning light iE the
V drive is equipped with an oil circulating pump should be checked
Eor proper operation Do not transport the boat with the coupling connected Damage to the shaEt shaEt log and Vdrive
can result
A pressure drop warning light is
mounted on the instrument panel on
Vdrives equipped with an oil cir
culating pump The warning light will
stay on until the boat gets under way
and the engine speed increases to suf
ficient RPM for the pump to This normally occurs 1200 RPM but the actual
speed may vary by as much as 400 RPM
Extended cruising at low RPM such as
when trolling is not harmful to the
Vdrive even though the warning light
may stay lit Normal operation is
between 6 to 12 PSI The light will
go on when the oil pressure drops
below 2 PSI Loss of oil andor 1149 QESSURE J
CROP oil level are the major
causes of pressure drop The oil
level should immediately be restored
and while running the boat the unit should be checked for leaks If
the oil level is normal and the light stays lit when the boat cruising speed the wiring should be checked for loose connections If the wiring is
correct and the light remains
lit the 49 pressure drop switch which is mounted on the side of the
Vdrive see should be checked for proper switch can easily be removed and an accurate oil pressure in its place If the pressure is normal the
switch should
be replaced If the pressure is below normal the oil lines should be
checked for blockage The pump should be inspected and replaced i f
necessary The pump is standard on the RV48 and an optional feature
on other models not available on the RVlO
The oil level should be checked several times during the on Vdrives whitout pumps see OIL FILL
A clatter or rattle in the Vdrive at low RPM is due to the over
riding of the propeller during the compression stroke of the annoying it is not harmful It may be reduced by adjusting
the idle speed andor tuning up the engine for smoother OIL CHANGE AND JOINT LUBE
After the first 100 hours of operation and every season andor
500 hours thereafter the oil should be changed Run the boat to warm
up the Vdrive to operating temperature Turn off the engine Remove
the plug in the 6B bottom cover that is opposite the 43S oil
strainer Reinstall after draining Disconnect the oil hose leading
from the 43S strainer leave the elbow on the strainer Unscrew the
strainer and clean the outside surface Reinstall the strainer and
reconnect the oil hose Unscrew the two 22 magnetic plugs that are
located on diagonally opposite corners of the lC main housing
The plugs can be checked to see if
they are magnetic only after the inside face with a such as a screwdriver Clean
them and reinstall Usually there
are four plugs in the bottom part of
the main housing Only two of these
are magnetic The other two need not
be removed see Refill
wi th SAE 30 motor oi I to the proper
level see INSTALLATION OIL FILL
The Zerk fitting on the external uni
versal joint should be greased with a
light alemite lubricant see ENGINE
AL I GNMENT
2 WATER DRAIN
For protection from freezing during winter layup remove the
small pipe plugs located diagonally opposite on the front and back
of the housing marked Water Drain see illutration On the RVIO
only one of the water lines going into the 6 watercooled bottom
cover must be disconnected to drain the water
3 FLANGE AND ENGINE REALIGNMENT
When the boat is launched after being in drydock the lineup of
the Vdrive to the propeller shaft flange and the engine to the V
drive should be rechecked and corrected i f necessary Some engines
with rubber mounts may sag and must be raised with adjustments or
shims for proper alignment see Flange Alignment and
ENGINE PROBLEM REMEDY
1 ENGINE DOES NOT START
a Starting switch is defective Correct connections and contacts
b Deficient drive torque of The battery is exhausted trouble
the starter motor with the starter motor or dirty or
loose wiring
c Improper viscosity of engine Check the viscosity and renew oil
oil if necessary
d Engine too cold Use glowplug starting aid
e Seizure of moving parts Rectify
f Air present in fuel system Purge thoroughly wi th electr ic fuel
pump
g No fuel in fuel tank Refill
h Fuel filter clogged Clean or renew
i 20 Amp circuit breaker Manually reset
tripped
2 ENGINE STALLS WHILE IN OPERATION
a Fuel tank is empty Refill
b Fuel filter clogged Clean or renew
c Air present in fuel system Retighten fuel line connections and
allow electric fuel pump to run long
enough to purge air IMPROPER OIL PRESSURE
a Oil shortage Refill
b Oil leak through connections Repair
c Oil pressure sender Replace
defective
d oil filter clogged Replace
4 ENGINE Cooling water shortage Refill
b Water leaks Repair
c Belt loose or smeared with Clean or renew
d Raw water pump defective Repair or renew
e Thermostat defective Replace
5 BATTERY IS Belt tension improper Rectify
b Faulty wiring circuit Rectify
c Alternator not functioning Replace
observe voltmeter
d Battery faulty Replace
e Faulty voltage regulator Repair or renew
TORQUE Kgm head bolts
Exhaust side 1l5 125 832 905
Intake side 100 110 724 796
Main bearing cap 80 90 579 rod bearing caps 50 60 362 434
Rocker shaft bracket 10 20 72 145
Front plate bolts 7 15 51 108
Timing gear cover 7 15 51 thrust plate 15 23 108 166
Idle thrust plate 30 40 21 7 pulley 395 405 2857 to block
30 35 21 7 253
Rear oil seal 04 29
Flywheel bolts 80 90 579 652
Oil pan bolts 07 51
Banjo bolt oil drain hose 95 105 687 retaining nut 45 55 325 pump delivery
valve holder 25 35 181 253
UNLESS OTHERWISE INDICATED
pitch kgm Ibft
Grade 4T
6mm boltnut 1 04 07 29 51
8mm boltnut 1 25 10 16 72 11 6
10mm boltnut 1 25 19 31 137 224
10mm boltnut 15 18 30 130 21 7
12mm boltnut 1 25 ISO 35 55 253 398
12mm boltnut 15 35 55 253 398
12mm boltnut 1 75 30 50 21 7 362
13mm boltnut 15 45 71 325 506
14mm boltnut 15 50 80 362 579
14mm boltnut 2 47 77 340 557
16mm boltnut 15 75 11 2 542 796
16mm boltnut 2 71 106 51 4 767
Grade 6T
6mm boltnut 1 06 09 43 65
8mm boltnut 1 25 15 22 108 159
10mm boltnut 1 25 30 45 21 7 325
10mm boltnut 15 27 42 195 304
12mm boltnut 1 25 ISO 50 80 362 579
12mm boltnut 15 50 70 362 506
12mm boltnut 1 75 48 68 347 492
Grade 7T 8T and 88
6mm boltnut 1 08 12 58 87
8mm boltnut 1 25 20 30 145 21 7
10mm boltnut 1 25 40 55 289 398
10mm boltnut 15 37 52 268 376
12mm boltnut 1 25 ISO 75 105 542 759
12mm boltnut 15 70 90 506 651
12mm boltnut 1 75 60 85 434 61 5
13mm boltnut 15 80 120 579 868
14mm boltnut 15 100 150 723 1085
14mm boltnut 2 95 140 687 101 3
16mm boltnut 15 150 230 085 1664
16mm boltnut 2 140 220 01 3 1591
Grade 5 capscrew
14 UNC 12 15 9 11
14 UNF 15 18 11 13
516 UNC 25 28 18 20
516 UNF 29 32 21 23
38 UNC 37 46 28 33
38 UNF 41 48 30 35
716 UNC 61 68 44 49
716 UNF 69 76 50 55
12 UNC 94 101 68 73
12 UNF 101 111 73 80
COMMON PARTS BY NUMBER
NUMBER REQUIRED
DESCRIPTION PART NUMBER PER ENGINE
Fuel Hardware Kit including banjo
washers injector seat washers 34441 1
Lift Pump Filter Gasket 30548 1
Fuel Filter 24363 1
Lube Oil Filter 35828 1
Glow Plugs 34380 4
Sea Water Pump 16423 1
Sea Water Pump Mounting Gasket 11143 1
Sea Water Pump Repair Kit 18172 1
Sea Water Pump Impeller Gasket Kit 33104 1
Alternator Belt 30475 1
Thermostat 24688 1
Thermostat Housing Gasket 33966 2
Oil Pressure Alarm Switch 34761 1
Injector 34376 4
Zinc Plugs 11885 1
Spare parts Kit A 34444 1
Spare parts Kit B extended cruising 34445 1
WESTERBEKE LIMITED WARRANTY
1 Warranty Obligation and Duration
Westerbeke warrants to the original conumtr purchaser that all standard Westerbeke marine engines and
generator sets manufactured or supplied by us wii be free from defects in material and workmanship for a period of
one year from date of commission or Jate of purchase on rcpower OR fifteen hundred 1500 hours on only whichever occurs first
2 Remedy
Westerbeke will elect to repair or replace free of charge to you any product or part returned to our costs prepaid which we adjudge defective in
materials or workmanship we may
reimburse at our discretion a portion of labor costs incurred to repair defective parts or products on site If you of replacement parts to you prior
to our determination of cause of failure such shipment will be sent COD
3 Notification
If you encounter a problem with your Westerbeke engine or generator set within the warranty period as stated
above contact your nearest authorized Westerbeke Master Distributor directly by telephone or letter
Be prepared to furnish the following information
a number of hours on unit
b date of commission date of purchase
c owners office and home telephone
d model number serial number
e name of vessel
f present location of vessel or product
g name and address of builder
h boat model name
I who performed prior servicing installation
j description of current problem
k any service outlet consulted and their diagnosis
4 Exclusions
This warranty shall not apply to
a failures due to wear and tear misuse accident or negligence including but not limited to improper storage
or installation inadequate maintenance overloading and insufficient lubrication
b consequential harm caused by overheating of engine cooling water or loss of engine lubricating pressure
these conditions should be constantly monitored by engine instruments andor alarms
c consequential harm caused by improper installation or failure of accessories attached to our product such
as water heaters and refrigeration d products altered or modified in a manner not authoriLed in writing by Westerbeke
e products damaged in transit
t replacement of engine tluids filter elements or vee belts engine tuncup valve adjustment oil and water
leaks or any other normal service items
g specially manufactured products provided to customer h fuel systems cooling systems exhaust systems electrical systems and cable control
systems beyond the
connection points on the product
S Application of Warranty
THIS WARRANTY IS IN LIEU OF ALL OTHER EXPRESS WARRANTIES ANY BY LAW INCLUDING WARRANTIES OF OR FITNESS IS IN EFFECT
ONLY FOR THE DURATION OF THE EXPRESS WARRANTY SET FORTH IN THE FIRST NO OR PERSON IS AUTHORIZED TO GIVE ANY OTHER WARRANTY OR
TO ASSUME FOR WESTERBEKE ANY OTHER LIABILITY IN CONNECTION WITH THE SALE OF ITS
PRODUCTS WESTERBEKE WILL NOT BE LIABLE FOR ANY CONSEQUENTIAL FROM THE USE OR INSTALLATION OF ITS STATES DO NOT ALLOW LIMITATIONS ON HOW LONG AN
IMPLIED WARRANTY LASTS OR
THE EXCLUSIONS OR LIMITATION OF INCIDENTAL OR CONSEQUENTIAL DAMAGES SO THE
ABOVE LIMITATIONS AND EXCLUSION MAY NOT APPLY TO YOU THIS WARRANTY GIVES YOU
SPECIFIC LEGAL RIGHTS AND YOU MAY ALSO HAVE OTHER RIGHTS WHICH VARY FROM
STATE TO STATE
PIN 21479 6183
I H WESTERBEKE CORP
AvON mOuSTjAL PARK AVON MASS 02322 1571 568 7700
CABlf WfSrCOflP AVON THfIC 92 4 4

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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.