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Westerbeke Diesel W 40 Technical Manual




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OPERATORS MANUAL
WESTERBEKE 40NA
MARINE DIESEL
ENGINE
Publication 37169
Edition One
February 1988
WESTERBEKE
WESTERBEKE CORPORATION
AVON INDUSTRIAL PARK AVON MA 02322 TEL 617 5887700
SAFETY following symbols appear in this manual to call attention Use Extreme Care When Handling Engine Fuel
to and emphasize conditions potentially dangerous to the
operator A constant danger of explOSion or fire exists
00 not fill fuel tanks while the engine is running
IIWARNINGI Do not smoke or use an open flame near the engine or the
fuel tank
The above symbol is used in the manual to warn of personal injury or loss of life
Do Not Alter or Modify the Fuel System
Be sure all fuel supplies have a positive shutoff valve
CAUTION
Be certain fuel line fittings are adequately tightened and
The above symbol is used in the manual to caution personnel free of leaks
of possible damage to equipment
Make sure a fire extinguisher is installed nearby and is
Read the manual carefully and thoroughly before attempting properly maintained Be familiar with its proper use ex
to operate the equipment Know when dangerous conditions tinguishers rated ABC by the NFPA are appropriate for all
can exist and take necessary precautions to protect personnel applications encountered in this exhaust gases batteries electrical equipment
moving and hot parts are potential hazards that could result in Use Extreme Care When Servicing personal injury or death Follow recommended
proce
dures carefully Wear rubber gloves a rubber apron and eye protection
when servicing operate bilge blowers for at least five minutes a engine ensure no gasoline fumes are Lead acid batteries emit hydrogen a
present before starting which can be ignited by electrical arcing or by a lighted
cigarette cigar or pipe Do not smoke or allow an open
flame near the battery being serviced Shut off all electri
Preyent Electric Shock cal equipment in the vicinity to prevent electrical arcing
during servicing
Shut off electric power before accessing electrical equip
ment
Use insulated mats whenever working on electrical equip Avoid Moving parts
ment
00 not service the unit while the unit is running if a situa
Make sure your clothing is dry not damp particularly tion arises in which it is absolutely necessary to make
shoes and keep your skin surfaces dry when handling operating adjustments use extreme care to avoid moving
electrical equipment parts and hot exhaust system components
Remove wristwatch and jewelry when working on electri Do not wear loose clothing or jewelry when servicing
cal equipment equipment avoid wearing loose jackets shirts or sleeves
rings necklaces O bracelets that might be caught in
Do not connect utility shore power to vessels AC circuits moving parts
except through a shiptoshore doublethrow transfer
switch Damage to vessels AC generator may result if this Make sure aU attaching hardware is properly tightened
is not done Keep protective shields and guards in their respective
place at all times
Be extremely careful when working on electrical com
ponents High voltage can cause injury or death Do not check fluid levels or the drivebelts tension while
the unit is operating
Do not work on the equipment when mentally or physical
Exhaust Gases Are Toxic ly incapacitated by fatigue
Ensure that the exhaust system Is adequate to expel gases
discharged from the engine Check exhaust system
regularly for leaks and make sure the exhaust manifolds
are securely attached and no warping exists
Be sure the unit and its surroundings are IMPORTANT
PRODUCT SOFTWARE software of all kinds such as brochures drawings technical data operators and workshop lists and parts price lists and other
related information instructions and provided from
sources other than Westerbeke is not within Westerbekes control and accordingly is provided to Wester
beke customers only asa courtesy and service WESTERBEKE CANNOT BE RESPONSIBLE FOR THE CON
TENT OF SUCH SOFTWARE MAKES NO WARRANTIES OR WITH INCLUDING THE ACCURACY TIMELINESS OR COMPLETENESS THEREOF AND WILL IN NO
EVENT BE LIABLE FOR ANY TYPE OF DAMAGES OR INJURY INCURRED IN CONNECTION WITH OR
ARISING OUT OF THE FURNISHING OR USE OF SUCH example components and SUbassemblies incorporated into Westerbekes products and supplied by
others such as engine blocks fuel systems and components electrical components pumps
and other products are generally supported by their manufacturers with their own software and depend on such software for the design of Westerbekes
own product software Such may be outdated and no longer accurate Routine changes made by Westerbekes suppliers of
which Westerbeke rarely has notice in advance are frequently not reflected in the suppliers sofivare until
after such changes take place
Westerbeke customers should also keep in mind the time span between printings of Westerbeke and the unavoidable existence of earlier noncurrent
Westerbeke software editions In the field most Westerbeke products include special features that frequently do not In
clude complete summation product software provided with Westerbeke products whether from Westerbeke or other sup
pliers must not and cannot be relied upon exclusively as the definitive authority on the respective product
It not only makes good sense but is imperative that appropriate of Westerbeke or the sup
plier in question be consulted to determine the accuracy and currency of the product software being con
sulted by the 1 Westerbeke Diesel Engines
INSTALLATION the crafts In which Westerbeke engines are installed vary in design installation procedures will to your crafts specific design It is
not the intent of this section to advise boatyards or installers
on procedures and However it is important that the there are details of the installation which require periodic checks to ensure the best operating
condi
tions for the equipment and safe operating conditions for the personnel on board Proper location and of the diesel engine in the vessel are of prime
in the installation that must be considered are ventilation to aid in cooling and to provide air for en
gine combustion exhaust system to properly discharge raw cooling water quiet the exhaust and expel ex
haust gas cooling water supply fuel supply and electrical CAUTION
For safety reasons the engine and transmission are NOT filled with lubricating oil for ship
ment Before leaving the factory however each engine with transmission is thoroughly tested
with oil in it This testing among other things provides all internal parts with a coating of 011
This oil acts as a preservative providing reliable protection against corrosion for at least one
year if the engine and transmission are properly location should be such that it is dry and in an area where bilge water or water from above cannot
splash
on the engine The engine should be properly ventilated and accessible for minor servicing and repairs ac
cess for major repairs should be given consideration as well The location must be properly ventilated to
provide fresh air for engine combustion The engines lubrication oil sump dipstick the fresh water and oil
fills and the dipstick and transmission or oil fill port must be FILL CAoP
COOLANT
RECOVERY COCKPIT
TANK
MOUN11NO
STRAP
CABIN
INSTALLATION ANGLE
MUST HOT EXCEED l
Please note that the engines installation angle cannot exceed 17 from the horizontal Diesel Engines 10
Rigging and Lifting
The engine is fitted with lifting eyes Rope or chain slings capable of supporting the engines weight should
be attached to the eyes and the engine lifted by means of tackle attached to these slings The lifting eyes
have been designed to carry the full weight of the engine therefore auxiliary slings are not required or desired
CAUTION
Slings must not be so short as to place signaicant sheer stress on the engines lifting eyes
Strain placed on the engines lifting eyes by the lifting sling must not be in excess of 10 from
the vertical plain
SLXNG LIFTJNG
ANGLE IoiUST NOT
EXCEED 10
LIFTING
ENGINE
The general rule in moving engines is to see that all of the equipment used is amply strong and firmly fixed
in place Move the engine a little at a time and see that tt is firmly supported Eliminate the possibility of ac
cidents by avoiding haste Do not lift the engine by tts propeller coupling or pry against this coupling with
a crowbar because excessive pressure of this type may distort the coupling
In certain situations it may be necessary to lift the engine in positions other than the horizontal position Cer
tain situations exist by which the engine must be lowered endwise through a small hatchway which cannot
be made larger Under these conditions if the opening of the hatchway is extremely narrow tt is possible
to reduce to some extent the outside dimensions of the engine by removing external components such as
the alternator the cooling systems piping the heat exchanger certain filters the mounting lugs and equipment This accessory equipment should be
removed by a competent mechanic and spe
cial care should be taken to avoid damaging any exposed parts In addition be careful not to allow dirt from
entering any opening created by the removal of equipment Parts removed should be returned to their respec
tive position as soon as the engine has cleared the hatchway
In case it becomes necessary to hoist the engine either frontend upwards or upwards of slings must be done carefully to avoid the possibility of
damaging the parts on which the weight
may bear Special rigging work is best done by someone experienced and competent in handling
11 Westerbeke Diesel Bolts
Bronze or stainless steel hanger bolts of appropriate size are recommended for use through the mounts Less preferred are lag screws because their
hold on the Wood is weakened every time they
are moved whereas the hanger bolts stay in position If the nut on top of the hanger bolt is removed to allow
the engine to be lifted from s resting place the hanger bolt self remains in place as a stud the bond between the hanger bolt and the wood is not
weakened by the removal of the nut or the for the Engine
A good engine bed contributes much toward the satisfactory operation of the engine The engines bed
must be rigidly constructed and neither deflect nor twist when it is subjected to the engines weight or to the
pressures that the boat may experience while operating in rough seas The bed must keep the within one or two thousandths of an inch of this position
at all times The bed has to withstand
the forward push of the propeller shaft which pushes against the thrust washer bearing which finally the engines bolts and bed
In fiberglass hulls we recommend that similar wooden stringers as in wooden hulls be formed fitted and
then glassed securely to the hull This allows the hanger bolts to be installed firmly in the wood noise and transmitted engine support stringers
must be as wide or wider than the engine mounting isolator Isolator rounded stringer surfaces are detrimental to the isolators ability to retain
fiberglass engine beds when used should be of sufficient thickness to properly support the en
gine and should be wellglassed to the hull temptation to Install the engine on a pair of
fiberglass angle Irons must be resisted will allow engine vibration to pass
through to the hull Flexible mounts require a against which they must act ifthey are
to perform their function When possible follow
bed design A and avoid bed design B refer to
the A
Supports between the bed stringers and extend
ing from the stringers to the hull may be required
for proper support and to aid in the absorption BAD
Note Avoid excessive height use
solid stringer construction A
Westerbeke Diesel Engines 12
Propeller Shaft Coupling
The propeller shaft coupling fitted to the output flange must transmit not only the power of the
engine to turn the propeller shaft and propeller but must also transmit the thrust of the ahead or astern
The coupling bore should be carefully machined for a slight forced fit onto the shaft and an accurate for the coupling to the output flange of the W
40NA engine is equipped with a Federal Flexible Coupling The Federal Flexible Coupling consists of
a metal hub and a flange The hub Is accurately bored to accept the rubber bushings and the face of the
flange Is machined to match the engines coupling The neoprene rubber bushings have a bonded inner
brass sleeve and the entire bushing is pressed into the flange using the correct compression pressure Alloy
steel spider pins screw through the bushings into the hub which are locked into posttion The rubber bush
ings are ample to absorb vibration from the propeller and to allow a slight angular misalignment The is not designed to do the work of a universal
joint The engine must be properly aligned before the
Flexible Coupling is installed Afterthe coupling has been installed the coupling will compensate for misalign
ments caused by hull distortion and from engine movement The Federal Flexible Coupling will absorb both
thrust and torsional loads The pins and rubber bushings are replaceable in case of damage
When ordering replacement parts refer to the Parts List at the back of this type and size of propeller varies with the gear ratio and must be
selected to Itt the application based
upon boattests To utilize the full power olthe engine and to achieve ideal loading conditions use a will permit the engine to reach tts full rated
RPM at full throttle while under a normal load and while it
is moving the boat forward through the of the Engine
The engine must be exactly aligned with the propeller shaft using a solid coupling before installing the No matter what material is used to build a
boat the material will be found to be flexible to some ex
tent hence the boats hull will change its shape to a greater extent than is usually realized when the boat is
launched and operated in the water Therefore it becomes extremely important to check the engines align
ment at frequent intervals and to correct any errors when they between the engine and the propeller shaft often creates serious problems which are
often
blamed on other areas suspected of causing the trouble Misalignment will cause excessive bearing wear
rapid shaft wear and will in many cases reduce the life of the boats hull by loosening the hulls fastenings
A bent propeller shaft will have the exact effect as those just stated therefore a perfectly straight is absolutely necessary One particularly
annoying result of misalignment may be leakage of oil through the rear oil seal
Never attempt a final alignment with the boat on land The boat should be in the water and have had an op
portunity to assume its final water form The best time to perform the propeller is with the fuel and water tanks about half full and all the usual
equipment on board and after the
main mast has been stepped and the final rigging has been 13 Westerbeke
Diesel Engines
Take plenty of time in making this alignment and do
not be satisfied wtth anything less than perfect results
The alignment is correct when the shaft can be easily 093 FEELER GAGE
slipped backward and forward into the when a feeler gauge indicates that the flanges
come together at all points The alignment between PROPELLER SHAFT
the propeller shaft coupling and the engines coupling
can contain an error no greater than one thousandth
of an inch per Inch of the coupling diameter For ex
ample if your propeller shaft coupling is three inches
in diameter the maximum error that can be allowed in
the alignment is three thousandths of an inch making the final check for alignment the
engines half coupling should be held in one
position and the alignment with the tested wtth the propeller coupling in
each offour positions A while rotated 90 be
tween each position This test will also check
whether the propellers halfcoupling is in on its shaft Then keeping the
propeller coupling in one position the align
ment should be checked by rotating the
engines halfcoupling in 90 increments
checking dimension A while in each 90 posi
tion until the halfcoupling has been rotated full
circle
The engines alignment should be the boat has been in service for one to
three weeks and if necessary perform the
alignment again Usually tt will be found that
the engine is no longer in alignment This does
not mean that the work has been done im
properly at first rather tt means that the boat
has taken some time to take its final shape and
that the engines bed and stringers have
probably absorbed some moisture It may
even be necessary to realign the coupling hal
ves again at a later time
Westerbeke Diesel Engines 14
Exhaust System
The exhaust system provides an outlet line to vent engine exhaust gases out of and away from the vessel
The system also discharges sea water which has passed through the engines sea water circuit by mixing it
with hot exhaust gases This mixing helps cool the exhaust gases and exhaust elbow and plumbing The ex
haust system and the sea water supply to the exhaust must be configured to prevent the siphoning of sea
water into the exhaust through the sea water cooling circuit and to prevent the entry of sea water into the ex
haust through the circutts throughhull discharge port If not prevented sea water entering through the dis
charge port can fill the exhaust system muffler and enter the engines cylinders This will prevent and possibly cause damage to internal engine sea
water supply hose to the exhaust system water injection elbow should be routed looped at least
12 inches above the vessel water line An antisiphon break should be installed when needed at the top of
this loop The top of the loop should be placed high enough above the vessels water line so as to remain
above the water line when the vessel is underway no matter what the angle of heel or roll may be
74 or 1 It LD hose
NOTE The engines heat exchanger
outlet will determme the Ik or 1
dimenSion lor the vented loop
48 max
Installation with exhaust
elbow
at a minimum of 6 above
vessel water line
Insulate
48 mal
CAUTION Vented loop must be
in a location where it will remain
above the water line during all
aHitudes of the vessels operation
installation with exhaust HydroHush
elbow
at or below vessel water line
The sea water supply throughhull sea cock fittings must be of the flushhull type Highspeed scoop type
of fittings should not be used as they tend to encourage exhaust discharge from the water lift muffler should be routed well above the water line
then downward
to the throughhull discharge This routing will prevent sea water entry if the throughhull discharge submerged when the vessel heels or rolls while
under way or is subjected to following sea condi
tions Refer to the figures shown above for recommended exhaust system 15
Westerbeke Diesel exhaust discharge hose must be of adequate size and
minimal run to prevent excessive exhaust backpressure should be checked before the engine
is put into service Refer to the Excessive will affect the engines measure for use a mercury manometer a
pressure gauge or a water column A boatyard or marine
should have a manometer or a pressure gauge
backpressure at the exhaust elbow when the en
gine is running at 3000 rpm as measured by
Exhaust
a manometer a pressure gauge or water column should not
be over the following
Mercury
Manometer
NOTE Other pressure gauges may be available to test
for exhaust Check with a competent
to the pressure below
A water column can be made by taking a clear plastic tube
and taping one end of the tube along a yardstick and fitting
the other end of the tube with a 14 inch NPT National Pipe
Tap pipe backpressure at the exhaust elbow when the en
gine is running at 3600 A cannot exceed 39 inches of water
Back pressure as measured by a gauge instrument should
not exceed the following 3 inches of mercury 0104 kgcm 2
39 inches of water in a water column
099 kgcm2 at 4 C
22 ounces psi
1 12 backpressure can be caused by a small diameter exhaust hose a small muffler sharp bends in
the exhaust hose improper fittings water pockets and a high volume of water in the exhaust system due
to the length of the exhaust discharge hose The use of elbows and fittings in the exhaust discharge should be limited since these will create flow
restrictions and contribute to exhaust engines exhaust system must be separate from any other engines exhaust system Dry portions of the
exhaust system between the engines exhaust manifold and the water injected exhaust elbow must be insu
lated to hold in the Diesel Engines 16
Exhaust System the engines sea water is fed into an exhaust system so that the full stream of this water strikes a sur
face erosion takes place This erosion may cause premature failures The proper design of either a or water injected wet exhaust system to prevent this
problem requires that the sea water inlet be
positioned so that the entering stream of sea water does not directly strike a surface In addition the velocity
of the entering sea water stream should be as low as possible which can be achieved by having inlet fittings
as big in diameter as best protection against exhaust system leaks is to routinely inspect the complete exhaust system Check
for leaks around manifolds gaskets and welds Make sure exhaust lines are not heating surrounding If excessive heat is present correct the situation
immediately If you notice a change in the
sound or appearance of the exhaust system inspect the exhaust system and correct the risers installed off the exhaust mannold should not exceed 8 Ibs
in total weight wen rigidly con
nected Excessive weight and vibration can result in a manifold failure andor the fracturing of the riser from
the manifold at tts attachment Dry portions of the exhaust connected to the manifold which lay before the
water Injected exhaust system MUST be properly insulated to retain the exhaust heat wtthin the
iWARNINGI
Although diesel engine exhaust gases are not as toxic as exhaust fumes from gasoline en
gines carbon monoxide is present in diesel exhaust fumes in less Carbon
monoxide is a dangerous gas that can cause and is potentially lethal Some
of the symptoms or signs of carbon monoxide inhalation or pOisoning are as follows
a Dizziness a Vomiting
a Intense Headache a Muscular Twitching
a Weakness and Sleepiness a Throbbing in Temples
If you experience any of the above symptoms get out into fresh air sure there are no unnecessary objects suspended from any portion of the exhaust
lines could cause deflection or distortion of the lines resulting in damage or leaks Inspect insulated por
tions of the exhaust system to ensure there is no deterioration of the Drain Hose
An oil sump drain hose is located at the lower front of the engine Oil may be drained from this hose by
removing the cap and the discharge end of the hose from the support bracket and lowering the hose into a
container The hose cap fitting is 14 inch NPT National Pipe Tap and can be extended or have a pump
added for easier removal of the old oil if desired
17 Westerbeke Diesel Pressure Sensing Devices to Oil pressure sensing devices such as senders and switches must not be
connected to an engines oil gal
lery with the use of extended nipples or tees The reason is simply that continued engine vibration of the fittings used to make such a connection If
these fittings fail the engine loses its oil pressure
and quickly seizes
When additional sensing devices such as switches or sensors need to be installed that function on engine
oil pressure these devices must be and connected to the oil gallery using an of lubricating oil hose Any fittings used to connect the hose to the
gallery must be of steel or malle
able iron composition Brass must not be used for this Alarm System
High Water Temperature Alarm
A high water temperature alarm buzzer has been supplied with the instrument panel If the engines fresh
water coolant reaches 2100 F 988 C a water temperature switch on the engine closes causing the alarm
to emit a continuous signal Refer to the DESCRIPTION OF INSTRUMENT PANEL section of this manual
for the location of the alarm in your engine panel page 24
Low Oil Pressure Alarm
A low oil pressure alarm switch is located off the engines oil gallery This switch monitors the engines oil
pressure Should the engines oil pressure fall to 10 15 psi the switch will close sounding this same alarm
In this event the alarm will emit a pulsating signal Refer to the DESCRIPTION OF INSTRUMENT of this manual for the location of the alarm in your
engine panel page 24
Cooling System
The engine is fresh water cooled by an heat exchanger Sea water is used as the cooling medium Sea water is pumped into the exchanger by a sea water
pump where it cools
the fresh water that circulates through the engine block and is then injected into the exhaust elbow carry
ing with it the heat removed from the engines fresh water cooling system
Sea water should be supplied to the sea water pump through a flushtype hull fitting using a between the throughhull fitting and the sea water pump
The sea water should be directed through a
visualtype sea water strainer which will trap debris before it reaches the sea water pump and the heat ex
changer and then be delivered to the pump Hoses routed from the throughhull fitting to the strainer and
to the sea water pump should be to prevent the hose from collapsing while the engine is run
ning suction from the pump may collapse a hose The sea water strainer should be mounted
at or below the water line to make sure the sea water line remains Diesel Engines 18
CAUTION
DO NOT use a scooptype throughhull fitting as a means of supplying sea water to the en
gine Water pressure against this type of fitting while the vessel is under sail can push sea
water past the sea water pumps impeller into the engines exhaust system filling it and the
engine as well Flushtype clear throughhull fittings are recommended and should be lo
cated on the hull so as to be below the waterline during all angles of boat operation
The use of commontype street elbows is not recommended for plumbing the sea water cir
cuit These generally have very restrictive inside diameters Machine fittings are To Fresh Water Circulating
Pump Inlel on Engine Block
rJ r Fresh Water Pressure Fill Cap
Y W Coolant Recovery Tank
FRESH
WATER
Thermostat f
Incoming Sea Water I
Exhaust Manifold J
Sea Water Impeller Pump
To Transmission Oil Cooler
111ustrated above is the cooling system for the W 40NA engine
19 Westerbeke Diesel Engines
Sea Water Intake System
Make sure the intake system sea water cooling system is in proper order Check that the throughhull inlet
sea cock and strainer are unobstructed Sea cocks and strainers should be at least one size greater than
the inlet thread of the sea water pump The strainer should be of the type that may be withdrawn for clean
ing while the vessel is at sea and should be mounted below the water line to ensure selfpriming Inspect
the sea water lines to ensure there are no collapsed sections which would restrict water flow Make sure
there are no air leaks at any of the connections Placing double clamps at the sea water plumbing connec
tion located below the water line is strongly System
The fuel system should be installed in such a manner as to allow the mechanical fuel lift
pump to maintain a positive inlet pressure to the fuel injection pump under all operating conditions The
minimum size of the fuel supply line and fuel return line is 14 inch inside diameter and there should be a
primary fuel filter installed between the fuel tank and the fuel lift pump Only one fuel filter is installed on the
engine between the mechanical fuel lift pump and the injection pump this filter has a replaceable filter fuel tanks fuel pickup tube should be clear
and unobstructed No screen or gauze strainers should in the fuel pickup tube
Make sure that the fuel supply and return lines are securely anchored to prevent chafing and that all fillings
are sufficiently tightened to prevent leaking Also make sure your fuel system has a positive shutoff valve
know its location and how it operates
NOTE DO NOT use springloaded check valves in the fuel supply line in lieu of mechanical
shutoff valves This type of valve can create fuel starvation problems for the engines fuel sys
Fuel tanks that are located below the engines fuel system level must have its fuel return at the tank extend
ing down into the tank in the same manner as a pickup tube otherwise fuel siphoning out of the engines
fuel system through the return will take that the fuel tank filler is properly sealed to prevent water entry should tt become awash The fuel
tanks vent should be routed so as to prevent water entry as well
Be sure there is a fire extinguisher Installed near the unit and that it is properly maintained Be familiar with
its use An extinguisher with the NFPA rating of ABC is appropriate for all applications in this Westerbeke Diesel Engines
System
The electrical system should be checked to ensure that all wiring harnesses are tied down properly with
clamps or plastic ties spaced at intervals close enough to prevent chafing from vibration Check to ensure
that all the engines harness connections are tight and that they are connected to the appropriate terminals
WARNINGI
Do not smoke or allow an open flame near batteries Lead acid batteries emit hydrogen a
gas Turn off the emergency switch in the positive line of sure the positive battery connection is connected to the battery connection of the
starting solenoid
The negative battery connection should be connected to the system ground the engine block
IWARNINGI
When servicing the battery or checking the electrolyte level wear rubber gloves a rUbber
apron and eye protection Battery acid may splash on the skin or into the eyes inadvertent
ly when removing electrolyte caps
Check level and specific gravity of battery electrolyte to ensure maximum engine starting efficiency Make
sure terminals are clean and ventilation requirements of the engine include the following combustion air is required for the and ventilating air is
required to clear the bilges below the engine as well as the compartment in
which the engine is located of engine heat and potentially toxic and flammable diesel fumes Refer to section of this manual for airflow requirements
page 8
21 Westerbeke Diesel Engines
PREPARATION FOR section of the manual provides the operator with preparation initial starting breakin starting cold or
warm and stopping procedures Follow the procedures as presented for the conditions indicated and
your Westerbeke engine set will give you reliable performance and long service life
Fill the engine with 011 by pouring engine oil through the
oil filler cap Fill the engine up to or near the upper limij
on the dipstick the installation angle may have an effect
on the dipstick reading Select readily available Oil Filler oil with an API specification of CC or CD and
an SAE number suitable for the temperature in your Rocker area see page 47 For the quantity of oil
needed in this engine refer to the SYSTEM section of this manual page 8
Fill the transmission to the FULL mark on the dipstick Oil Dipstick
with the correct lubricant Refer to the section of this manual page 9
Upper Limit
Each unit is supplied with a coolant recovery kit Normal as standard equipment to which the follow
ing applies Lower Limit Oil
A Remove the pressure cap from the engines ex Crankcase
haust manifold and slowly fill the engines cooling
system with a mixture of water and antifreeze
suitable for your temperature zone See the
COOLING SYSTEM section of this manual page 42 Operate the engine and observe the coolant
level in the manifold Maintain this level to the base of the filler neck Once the engine reaches its operat
ing temperature 170 190 F ensure that there is coolant flow to the domestic water heaters when in
stalled Top off the cooling system and install the pressure cap
B Make sure the plastic recovery tank is properly mounted near the unit with the bracket provided in a
location where it can be monitored and filled easily The recovery tank should be mounted at manifold
level or above In these installations that require ij the plastic recovery tank can be mounted below the
exhaust manifolds level
C Add coolant to the plastiC tank after the engine has been started and operating temperature has been
reached to ensure that all air is expelled from the manifold and the engines cooling system With the
manifold filled and the pressure cap Installed fill the plastic recovery tank half full Monitor daily and
add coolant as needed
Fill the fuel tank with a good grade of No2 diesel fuel and prime the fuel system up to the engine see page
32 When returning fuel is free of air the engines fuel system is bled and the engine is ready to that the Installation Checks have been made in
accordance with those specified in the CHECKS section of this manual refer to page Diesel Engines 22
Starting System
The W 40NA diesel engine uses an electric starter for both normal and cold weather starting A cold start aid
system is furnished on the W 40NA engine as standard equipment part 36258 Both the thermostart device
and the cold start aid are located on the air intake manifold side of the engine The PREHEAT button ener
gizes the thermostart device assists in vaporizing the fuel at the intake manifold inlet The vaporized diesel
fuel is drawn into the cylinder during cranking and allows for easy combustion during compression This
process allows the engine to start rapidly and reduces wear on the starter
Air I ntake Screen
Stand Pipe
Cold Start Aid
The W 40NA engines electrical system is designed so that the PREHEAT button must be depressed for the
time specified in the Preheat chart shown on page 26 While keeping the PREHEAT button depressed the
START button must be pressed to crank the engine
NOTE The START button will not crank the engine unless the PREHEAT button is depressed
atthe same time When the PREHEAT button is depressed the thermostart device is activated
USE THE PREHEAT BUnON ONLY AS NECESSARY Overuse of the PREHEAT button will
overheat the thermostart to the STARTING PROCEDURE section of this manual for starting instructions page 26
23 Westerbeke Diesel Engines
STOPPING the cockpit of the boat there Is a tee handle or a knobtype shutof control When this control is the control will STOP the engine The other
end of the shutoff control is attached to a lever on
the top of the fuel Injection pump Pushing the shutoff control fully inward will place the engine in the RES
TART RUN the engine is stopped turn the Circuit Breaker located in the vessel to the OFF position If the is left ON the battery will discharge
CAUTION
DO NOT attempt to shutdown the engine by turning the Circu Breaker OFF The Circuit
Breaker only provides power to the instrument panel and to the DC alternator the engine will
continue running even if the Circuit Breaker is turned OFF Stop the engine by pulling the
shutoff control fully BreakIn your engine has experienced a minimum of one hour of test operations to ensure accurate as
sembly and proper operation of all systems breakin time is required The service life of your engine is de
pendent upon how the engine is operated and serviced during s initial hours of use
Your new engine requires approximately 50 hours of Inial conditioning operation to break In each moving
part in order to maximize the performance and service life of the engine Perform this conditioning careful
ly keeping in mind the following
1 Start the engine according to the STARTING PROCEDURE section found on page 26 run the engine
at fast idle while checking that all systems sea water pump oil pressure battery charging are function
2 Allow the engine to warm up preferably by running at fast idle until the gauge moves
into the t 30140 F range
3 While using the vessel under power vary the engines rpm cruise settings during the engines initial 25
hours of operation
4 Avoid rapid acceleration especially with a cold engine
5 Use caution not to overload the engine The presence of a gray or black exhaust and the inability of
the engine to reach its full rated speed are signs of an overload that is a propeller that is too large
6 During the next 25 hours the engine may be operated at varying engine speeds with short runs at full
rated rpm Avoid idling the engine for prolonged periods of a new engine basically involves seating the piston rings to the cylinder walls This cannot
be by long periods of running at Idle nor by early running at full speed
Idle running may glaze the cylinder walls resulting in excessive oil consumption and smoky operation Ex
cessive speed or heavy overloading especially with a cold engine may cause scoring of the cylinder similar Diesel Engines
28
As indicated above operate the engine in moderation during the 50hour breakin period On one hand
dont baby the engine but on the other hand however dont abuse Under Normal the procedure below for normal starting of the engine
1 Check the engine and transmission lubricant levels and fill if necessary
2 Make sure there is sufficient fuel on board Keep fuel tanks as full as possible Check the fuel filters
and water separators for the presence of contaminants andor water Drain and clean them as needed
3 Check the coolant level in the plastic recovery tank Add coolant solu1ion as needed
NOTE Excessive loss of coolant from the plastic recovery tank indicates a cooling system
leak Check the entire cooling system and the recovery tank and s connections at the ex
haust manifold and pressurize the system to locate the leak In cases of excessive coolant
loss the system must be refilled as outlined under the PREPARATION FOR STARTING sec
tion of this manual page 22
4 Check for oil and fuel leaks particularly if signs of such leaks are found on the bottom of the engine or
below the engine
5 When checking your engines coolant and oil levels check the engine for any noticeable such as loose or missing bolts loose brackets and mounts
loose hose clamps chafed wires or any
other components that exhibit wear or are loose
Start the engine in accordance with the STARTING PROCEDURE instructions found on page 26 and allow
the engines operating temperature to reach 140 150 F before operating the engine 29
Westerbeke Diesel Under Cold extremely cold temperatures the following conditions can occur Follow the instructions listed below
when operating your engine in cold OIL TURNS VISCOUS Make certain that the lubricating oil used conforms with the ratings
for the prevailing atmospheric temperature Refer to the LUBRICATION SYSTEM section of this manual
page 47 for an viscosity specification ACROSS THE BATTERY TERMINALS DROPS Make certain that the battery is fully charged to
minimize voltage drop across the battery TEMPERATURE OF THE INTAKE AIR IS LOW AND THE COMPRESSION TEMPERATURE DOES NOT
RISE ENOUGH Allow the thermostart device to operate sufficiently to aid In starting during the whenever the temperature of the intake air is low and
when the compression temperature within the
cylinders will not rise quickly during cranking Refer to the Preheat chart found in the STARTING PROCE
DURE section of this manual page Diesel Engines 30
FUEL Fuel
Use No2 diesel fuel with a cetane rating of 45 or higher Never use kerosene or home heating oil since these
fuels do not have the same lubricating properties as No2 diesel fuel
In cold weather particular1y water vapor is produced by condensation when air is present in the fuel tank
Keep fuel tanks full and completely free of dirt and water
Fuel Filters
A primary fuel filter of the type must be installed be
tween the fuel tank and the engine A XN5TALLATXON fuel filter shown here is avail HOSE FITTING
1 aau TIIM SCUREL TO
All MCESI1L snucrul SII from your local Westerbeke rep IHAr IfCETIClE II tille HlUAU
UI IE nKO 111101 or your boatbuilder This
2 If FOn IS rl IE 111 1111 emu
filter adapted for boatbuilder use II tullO lllIlH 11K IUtl IU FUIIILEI
PlBUIK II SUI fIE 1111111 complete with fittings for either 1 UCII 111108111 TIE FUllUl BFOIIE
hose or metal tubing Mount it in an mllrtllllC 111 place inspect it often and
3 IF TIn XI fa I 10 nH IIU utI
drain off water accumulation fre TIlE n 111118 SHIU rIm AID SNEll
IUPPUtl IE cuun INU m HlIIt MU IUllaDl 18111 IIIUIlED lTD CUIII DI
111E
IAaI TIlIT IT IB MEOUIIE LUEt AlII Hill
IT II UKI IPOUED
If a water trap type filter is not installed
4 If IlitEi 11 IEUII III HIE FUEl 11 tILL
between the fuel tank and the engine COLLECT SlOlU II Til IDTUII OF Til
SOUUIER llIEl THE lEI flOAT III
mounted fuel system any water in the IUCIlES THE DIAU LUI 01 TilE Lum
BOWL LOast TIlE SOTTOII IUU lua UMnL
fuel system will tend to lay in the bot ALL ITEI RUd OUT
tom of the electric lift pump Internal S 118111 DUll LUI IEtUIElf II 110 u UII
metal parts of the lift pump will rust NUl THE will pass on to filters and
EMElGIl TIlE FaEl PUIIP TD HILL Til
to the injection pump and
injectors with damaging results and
the possibility of expensive water damage to the fuel
system is not covered under warranty
In addition any gasoline In the fuel system will damage the engines fuel injection pump assembly and injec
tors as gasoline does not have the same lubricating qualities as diesel most boatbuilders supply a water trapfilter some do not Westerbeke offers a
as an optional extra at moderate cost The filter is supplied with fittings for either hose or metal
tubing fuel lines
31 Weslerbeke Diesel and Bleeding the Fuel System
The W 40NA engine has only one replaceable fuel filter located on the fuel system This
fuel filter is located just after the discharge side of the mechanical fuel lift pump Gust below the fuel filter
The design of the fuel system allows the fuel filter to be easily serviced To replace the fuel
filter remove and replace filter elements as described in the Replacing Filter Elements section of this
manual page 35 Be careful to catch any fuel that may spill from within this fuel filter assembly
NOTE Any primary fuel filterWater separator installed between the fuel tank and the engines
fuel lift pump that is a Raycor Dahl or other similar filters should be manually filled before
an attempt to bleed the fuel system between the fuel tank and the engine is made
To bleed remaining air from that portion of the fuel system which runs between the fuel tank and the engine
once the primary fuel filter has been manually filled move the mechanical fuel lift pumps priming lever up
and down using steady even strokes one stroke per second for a period of one minute For this no fittings should be open Refer to the illustration of
the fuel system when following the proce
dure described above page 33
Fuel Supply IN
Manual Priming Lever
Mechanical Fuel Lift to the illustration on the next page when following the procedures described below
1 After all air has been bled from between the fuel tank and the engine proceed to either one of the two
bleed points 1 located on top of the fuel filter see the next page Choose the one that is easily asses
sable Loosen the banjo bolt on top of the filter or the plug on the side of the filter housing one to two
turns DO NOT remove the bolt or the plug
2 Move the priming lever up and down as described on the previous page to purge the air out of the secon
dary fuel filter through the open banjo bolt or Diesel Engines 32
NOTE As a safety precaution place a small plastic trash bag containing a few cloth rags
around and under the secondary filterto catch any fuel that may spill from within the filter when
it is removed
Also note that when working the manual priming lever on the fuel lift pump move the lever up
and down using long even strokes DO NOT operate the lever using rapid jerks
In some rare instances the fuel lift pump may be at or near its internal maximum pump stroke
In this situation no pumping action will be accomplished using the external manual priming
lever In this case turn the engine over one or two turns do not attempt to start the engine
to reposition the pumps internal pumping lever Now attempt to bleed the fuel system using
the manual priming lever
Once the fuel system is bled which is indicated by a flow of bUbblefree fuel from bleed point 1 the banjo bolt or the plug and proceed to point 2
3 Using either a 516 box wrench or a 14 drive 516 socket wrench open the 516 2 bleed screw lo
cated on the side of the fuel injection pump onehalf to one turn only DO NOT remove this special bleed
screw Once again move the manual priming lever up and down to purge all of the air from this area of
the fuel Injection pump When the fuel flows bubblefree from the 2 bleed screw retighten the bleed
screw and proceed to point 3 Refer to the illustration below
Return Fuel ToFuel Ta
81eedscrew 1
Bleedscrew 1t1
Fuel Supply IN
Mechanical Lift Pump
High pressure Injectors
Fuel Line IN
Sleedscrew 3
81eedscrew 2
Fuel Injection Pump
Fuel System
33 Westerbeke Diesel Engines
4 Using the 516 box wrench or the 14 drive 516 socket wrench open the 3 bleed screw and bleed this
portion of the fuel Injection pump in the same manner as described in step 3 Proceed to step 5
NOTE Make sure that the throttle Is fully open and the engines shutoff lever is in its RUN
poslon before proceeding to step 5
5 Using a 58 open end wrench loosen all four high pressure injector line nuts 4 located at the base of
each injector one to two turns Using the starter motor crank the engine over to bleed any air in the high
pressure lines between the fuel Injection pump and the injectors Crank the engine until fuel spurts from
between the injector nut and the high pressure injector line
NOTE Only spurts of fuel should come from this bleed point not a steady flow of fuel
DO NOT crank the engine for long periods of time Excessive cranking will cause the starter
to overheat and will flood the exhaust system with sea ali four high pressure injector line nuts with the 58 open end wrench
NOTE Excessive torque is not required to properly tighten the injector line nuts to the base
of the high pressure The engine is now primed and ready to start Leaving the throttle in the FULL OPEN posion make sure
that the engines STOP lever is in the RUN posion and that the transmission is in NEUTRAL At this point
proceed to start the engine Use the PREHEAT button as required and crank the engine using the starter
Once the engine fires return then throttle to its IDLE position Check to make sure that the engines In
struments indicate the proper oil pressure reading and that sea water is discharged with the exhaust Allow
the engine to idle between 1000 to 1200 rpm for five minutes to make sure that all air in the fuel system
has been bled
If the engine fails to start reprime the fuel system and try to start the engine once again
CAUTION
Prolonged cranking intervals without the engine starting can result in filling the engine
mounted exhaust system with sea water coolant This may happen because the sea
water pump is pumping sea water through the sea water cooling system during crank
ing This sea water can enter the engines cylinders by way of the exhaust manifold
once the exhaust system fills Prevent this from happening by closing the sea water
supply throughhull shutoff drain the exhaust muffler and correct the cause for the
excessive engine cranking needed to obtain a start Engine damage resulting from this
type of sea water entry is not a warrantable issue the should keep this
in mind
NOTE When the secondary onengine fuel filter has been serviced the 1 and 2 bleed
points should only be bleed to make sure that ali air has been removed from the fuel system
No other bleed points need to be opened at this time
may find daubing white paint on each of the bleed points helpful If an un
expected problem occurs in which the fuel system needs bleeding these points will be clear
Diesel Engines 34
While the likelihood of having to service the fuel system at sea is small the possibility does exist Therefore
we recommend that a replacement fuel filter be carried on board at all times Each fuel filter comes with two
Oring gaskets Select the part numbers for this fuel filter from your Parts List and purchase spares from your
local Westerbeke Dealer or a leak should develop at a banjo or sealing washer that cannot be corrected by a simple tightening of the
fitting replace the leaking washer A Fuel Hardware Kit is available for this engine which contains all the seal
ing washers used in the fuel system except those noted in the fuel filter replacement cartridge below
Replacing the Fuel Filter the first 50 hours of operation remove filter cup 9 by unscrewing bolt 3 and drawing down on the
6 element Be careful to catch any fuel that may spill from within this fuel filter cup Discard the old 6
filter element and the old 5 7 and 8 Orings Clean the 9 filter cup and install the new 6 filter ele
ment along with new 5 7 and 8 Orings
8 NOTE Replacement element
part number 14776 contains
items 5 6 7 and 8
Fuel the first 50hour change the change period may be increased to 200 hours or once per season
35 Westerbeke Diesel Engines
Fuel Injection Pump
The fuel injection pump is one of the most important components of the diesel engine and therefore calls
for the utmost caution in handling Furthermore the fuel injection pump has been thoroughly should not be tampered with
Idle speed and timing adjustment are the only adjustments the servicing dealer can perform on the Other types of adjustments or repairs must be
performed by a qualified injection service shop
To obtain long and satisfactory service from the injection pump always use fuel which is free from maintain a good filtration and water separation
system between the fuel tank and the engine Service
this system regularly the Injection pump it saves may be your own
Belt Drive System
The illustration below shows the complete belt drive system for the W 40NA engine A compressor bracket
and mounting bracket are provided for the installation of a Grunnert refrigeration alternators are mounted on the W 40NA engine The second alternator
charges the ships service bat
terys Two oil pressure cutout switches for the fields on the alternators are mounted on a bracket at the
rear of the engine These switches will prevent any load on the engine upon the engines Inttlal Westerbeke Diesel Engines
ELECTRICAL 12Volt DC Control Circuit
The Westerbeke 40NA propulsion engine has a 12Volt DC electrical control circuit as shown on the which follow on pages 40 and 41 Refer to these
diagrams when or components on the engine
CAUTION
To avoid damage to the battery charging circuit never shut off the engine battery switch while
the engine is running
When the engine Is not running shut OFF the engines battery switch to avoid when working on the engine electrical circuit
Prereat that the engines electrical System is
protected by a 20Ampere
DC Circuit reset circuit breaker lo
cated on the rear lifting minimum recommended capacity of the battery used in the engines 12Volt DC control circuit is 125
150 Amperehours minimum
CAUTION
When the battery with an external charger be sure to disconnect the battery
cables from the battery Leaving the charging circuit connected while will
damage the alternators diodes
37 Westerbeke Diesel CAUTION
When testing the alternator circuit charging circuit do not use a highvoltage tester such as
a megger damaged diodes could result
During highspeed operation of the engine do not disconnect the positive terminal of the bat
tery from the B terminal of the alternator nor disconnect the negative terminal of the battery
from the ground Damage to the alternators diodes will result
When cleaning the engine with a steam cleaner be careful to keep steam away from the al
ternator
Always connect the batterys cables to the correct terminals Reversing the connections will
damage the DC charging alternator To connect the battery connect the Positive lead
Hot first and then connect the Negative lead Ground last To disconnect the battery
disconnect the Negative lead Ground first and then disconnect the Positive lead
Hot last
Refer to pages 40 and 41 for the electrical system wiring schematic for the W Diesel Engines 38
The charging system consists of two alternators with external voltage regulators an a battery and connecting of the use of ICs integrated circuits
the electronic voltage regulator is very compact and is
mounted on the rear bracket of the Voltage Test
If you suspect that the alternator is not producing enough voltage to charge the engines battery perform
the following voltage test
14 L T BLUE
10 RED 14 GREEN
ALTERNATOR 51 A
for Charging Voltage Test
1 Using a voltOhms meter make sure that 12 Volts are at the EXC connection while the engine is running
and the oil pressure EXC switches are closed
2 Using a voltmeter connect the voltmeters red wire clip to the B output terminal on the alternator Refer
to the schematic shown above
3 Connect the other wire clip to a ground on the engine
4 Start the engine and increase the engines speed to 2000 rpm Now record the reading given by the
voltage reading for a properly operating alternator should be between 135 to 145 volts If your alter
nator is over or under charging have tt replaced or rebuilt by a reliable service shop
NOTE Disconnect all battery power to the engine before attempting to disconnect or remove
the alternators for repair
39 Westerbeke Diesel Engines
W 40NA DC Control Circuit Wiring Diagram 37248
page 1 of 2
WIPING DIAGPAM
s
y rt
b I
I w
lO
os Diesel Engines 40
W 40NA DC Control Circuit Wiring Diagram 37248
page 2 of A
0 L j
40110 IRING ODIFICATIOS ANDPARTS SUPPLIED BY
HANSEN MARINE EIIGINEERING 01945
41 Westerbeke Diesel Engines
COOLING marine diesel engines are designed and equipped for fresh water cooling Heat produced in
the engine by combustion and friction is transferred to fresh water which circulates throughout the engine
This circulating fresh water cools the engine block and s internal moving parts The heat is transferred ex
ternally from the fresh water to sea water by means of a heat exchanger similar in function to an automo
tive radiator Sea water flows through the tubes of the heat exchanger while fresh water flows around the
tubes engine heat transferred to the fresh water is conducted through the tube walls to the sea water which
is then pumped into the exhaust system where finally is discharged overboard In other words the engine
is cooled by fresh water the fresh water is cooled by sea water and the sea water carries the over the side through the exhaust system The fresh
water and sea water circus are independent of
each other Using only fresh water whin the engine allows the cooling water passages to stay clean and
free from harmful deposs The two independent circuits and their components are discussed in the follow
ing Water Circuit
NOTE Refer to paragraphs A and B in this section for the recommended antifreeze and water
mixture to be used as the fresh water coolant and for information on filling the fresh water
below is a typical Westerbeke engines cooling system Both fresh water and sea water flow
through their independent COOling circus
To Fresh Water Circulating
Pump Inlet on Engine Block
Incoming Sea Water
Sea Water Impeller Pump
To Transmission Oil Diesel Engines System
The electrical system should be checked to ensure that all wiring harnesses are tied down properly with
clamps or plastic ties spaced at intervals close enough to prevent chafing from vibration Check to ensure
that all the engines harness connections are tight and that they are connected to the appropriate terminals
IWARNINGI
Do not smoke or allow an open flame near batteries Lead acid batteries emit hydrogen a
gas Turn off the emergency switch in the positive line of sure the positive battery connection is connected to the battery connection of the
starting solenoid
The negative battery connection should be connected to the system ground the engine block
WARNINGI
When servicing the battery or checking the electrolyte level wear rUbber gloves a rubber
apron and eye protection Battery acid may splash on the skin or into the eyes inadvertent
ly when removing electrolyte caps
Check level and specific gravity of battery electrolyte to ensure maximum engine starting efficiency Make
sure terminals are clean and ventilation requirements of the engine include the following combustion air Is required for the and ventilating air is
required to clear the bilges below the engine as well as the compartment in
which the engine is located of engine heat and potentially toxic and flammable diesel fumes Refer to section of this manual for airflow requirements
page 8
21 Westerbeke Diesel Engines
PREPARATION FOR section of the manual provides the operator with preparation initial starting breakin starting cold or
warm and stopping procedures Follow the procedures as presented for the conditions indicated and
your Westerbeke engine set will give you reliable performance and long service life
Fill the engine with oil by pouring engine oil through the
oil filler cap Fill the engine up to or near the upper limit
on the dipstick the installation angle may have an effect
on the dipstick reading Select readily available Oil Filler oil with an API specification of CC or CD and
an SAE number suitable for the temperature in area see page 47 For the quantity of oil
needed in this engine refer to the SYSTEM section of this manual page 8
Fill the transmission to the FULL mark on the dipstick Oil Dipstick
with the correct lubricant Refer to the section of this manual page 9
Upper Limit
Each unit is supplied with a coolant recovery kit Normal as standard equipment to which the follow
Oil
ing applies Lower Limit
A Remove the pressure cap from the engines ex Crankcase
haust manifold and slowly fill the engines cooling
system with a mixture of water and antifreeze
suitable for your temperature zone See the
COOLING SYSTEM section of this manual page 42 Operate the engine and observe the coolant
level in the manifold Maintain this level to the base of the filler neck Once the engine reaches its operat
ing temperature 170 190 F ensure that there is coolant flow to the domestic water heaters when in
stalled Top off the cooling system and install the pressure cap
B Make sure the plastic recovery tank is property mounted near the unit with the bracket provided in a
location where it can be monitored and filled easily The recovery tank should be mounted at manifold
level or above In these installations that require it the plastic recovery tank can be mounted below the
exhaust manifolds level
C Add coolant to the plastic tank after the engine has been started and operating temperature has been
reached to ensure that all air is expelled from the manifold and the engines cooling system With the
manifold filled and the pressure cap installed fill the plastic recovery tank half full Monitor daily and
add coolant as needed
Fill the fuel tank with a good grade of No2 diesel fuel and prime the fuel system up to the engine see page
32 When returning fuel is free of air the engines fuel system is bled and the engine is ready to that the Installation Checks have been made in
accordance with those specified in the CHECKS section of this manual refer to page Diesel Engines 22
Starting System
The W 40NA diesel engine uses an electric starter for both normal and cold weather starting A cold start aid
system is furnished on the W 40NA engine as standard equipment part 36258 Both the thermostart device
and the cold start aid are located on the air intake manifold side of the engine The PREHEAT button ener
gizes the thermostart device assists in vaporizing the fuel at the intake manifold Inlet The vaporized diesel
fuel is drawn into the cylinder during cranking and allows for easy combustion during compression This
process allows the engine to start rapidly and reduces wear on the starter
Air Intake Screen
Stand Pipe
Cold Start Aid
The W 40NA engines electrical system is designed so that the PREHEAT button must be depressed for the
time specified in the Preheat chart shown on page 26 While keeping the PREHEAT button depressed the
START button must be pressed to crank the engine
NOTE The START button will not crank the engine unless the PREHEAT button is depressed
at the same time When the PREHEAT button is depressed the thermostart device is activated
USE THE PREHEAT BUTTON ONLY AS NECESSARY Overuse of the PREHEAT button will
overheat the thermostart device
Refer to the STARTING PROCEDURE section of this manual for starting instructions page 26
23 Westerbeke Diesel Engines
DESCRIPTION OF INSTRUMENT 40NA engines are supplied with instrument panels Read the following instruction operating the engine
RPM Gauge Water Temperature Gauge Oil Pressure Gauge
Ammeter
Voage panel is equipped with an RPM gauge with an ELAPSED TIME meter which measures
the engines running time in HOURS and in 110 hours The panel also includes a water temperature gauge
which indicates in degrees Fahrenheit WATER 0 F an oil pressure gauge which measures
the engines oil pressure in pounds per square inch OIL PSI a DC control circuit voltage gauge the systems DC voltage VOLTS and a DC Ammeter which
allows the operator to in the DC charging circuit All gauges are illuminated when the circuit breaker is turned ON and
remain illuminated while the engine is in operation The panel also contains two rubberbooted push but
tons one for PREHEAT and one for START
1 Circuit Breaker Not Shown The Circuit Breaker positioned somewhere in the vessel so it may be
easily reached provides power only to the instrument cluster Refer to the STOPPING PROCEDURE
section of this manual page 28
2 PREHEAT The PREHEAT button energizes the alternators EXC terminal and the intake manifolds
thermostart device This button also energizes the START button
3 SIABI The START button when pressed energizes the starters solenoid which cranks the engine
This button will not operate electrically unless the PREHEAT button is pressed and held at the same
Diesel Engines 24
4 Ammeter Gauge An Ammeter gauge is provided by the Dealer and is located in the lower right hand
corner of the instrument panel The Ammeter is not shown in the photograph on the preceding page
NOTE An alarm buzzer is supplied with every panel The installer is responsible for electrical
ly connecting the buzzer to the fourpin connection on the engines electrical harness The in
staller is also responsible for installing the buzzer in a dry location so that will be audible to
the operator should sound while the engine is running The buzzer will sound when the eir
cui Breaker is turned ON and should silence when the engine has started and when the
engines oil pressure rises above 15 psi
5 Water Temperature Gauge This gauge is graduated in degrees Fahrenhe and is illuminated while the
main engine circuit breaker is turned ON The engines normal operating temperature is 170 190 F
77 88C
6 Oil Pressure Gauge This gauge is graduated in pounds per square inch PSI and Is illuminated while
the main engine circuit breaker is turned ON The engines normal operating oil pressure ranges be
tween 30 60 PSI
NOTE When the engine is manually shut down and the engines circuit breaker Is turned OFF
the water temperature gauge will continue to register the last temperature reading indicated
by the gauge before electrical power was turned OFF The temperature gauge will once again
register the engines true temperature once electrical power is restored to the gauge
25 Westerbeke Diesel Engines
STARTING PROCEDURE
1 Place the transmission in the NEUTRAL position and advance the throttle to its full open position for a cold
engine and partially open for a warm engine
2 Turn the Circuit Breaker to the ON position Make sure the pushpull stop lever has been returned to the
RUN position
3 Depress and hold the PREHEAT switch Preheat according to the following chart
Atmospheric Temperature Preheating Time
41 F 5 C or higher Approx 10 sec
41F 5Cto 23F5C Approx 20 sec
23 F 5 C or lower Approx 30 sec
Limit of continuous use 1 minute
The Instrument panel includes a DC control gauge A properly operating is indicated when the voltmeter registers a volt Drop
age drop when the PREHEAT button is voltage drop will be slight but noticeable If the
voltmeter indicates no voltage drop at the time the
PREHEAT button is depressed then the could be defective or the preheat circuit is faul
ty check for any loose holding the PREHEAT button depressed 13 15
depress the START button The starter motor will run
thereby cranking the engine As soon as the engine
runs release the START button and PREHEAT the engine not start when the START button is
depressed for 10 to 12 seconds release both buttons
and wait 30 seconds repeat the previous procedure DC Control Circuit Voltage Gauge
Never run the starter motor for more than 30 seconds
at a time
CAUTION
Prolonged cranking intervals without the engine starting can result In filling the engine
mounted exhaust system with sea water coolant This may happen because the sea
water pump is pumping sea water through the sea water cooling system during crank
ing This sea water can enter the engines cylinders by way of the exhaust manifold
once the exhaust system fills Prevent this from happening by closing the sea water
supply throughhull shutoff drain the exhaust muffler and correct the cause for the
excessive engine cranking needed to obtain a start Engine damage resulting from this
type of sea water entry is not a warrantable issue the should keep this
in Diesel Engines 26
Once the engine starts move the throttle into a fast idle position 1000 1200 rpm Check your for proper engine operation Make sure that sea water
discharges along with the exhaust discharge
NOTE Some unstable running may occur in a cold engine but this condition should smooth
out as the operating temperature of 170 190 F 77 88 C is Shifting
To shift the transmission use the remote control shifting lever located in the cockptt This remote lever rotates the shifting lever on the side of
the standard transmission Rotating the shifting lever in
a direction places the transmission In FORWARD gear To shift the transmission in
REVERSE gear rotate the shifting lever in a clockwise direction through NEUTRAL into FORWARD GEAR Rotate the lever REVERSE
GEAR Rotate the lever CLOCKWISE through NEUTRAL into REVERSE
For a more detailed description of the HBW operation refer to the HBW of this manual page 50
Remote Control Shifting Cable
Neutral
o Reverse
A B
Soljl o
0 Or
Counter Clockwise Clockwise
Transmission Cover Plate 0 0
Shifting Lever
Transmission Shifting 27 Westerbeke Diesel Engines
STOPPING the cockpit of the boat there is a tee handle or a knobtype shutof control When this control is the control will STOP the engine The other
end of the shutoff control is attached to a lever on
the top of the fuel Injection pump Pushing the shutoff control fully inward will place the engine in the RES
TART RUN the engine is stopped turn the Circuit Breaker located in the vessel to the OFF position If the is left ON the battery will discharge
CAUTION
DO NOT attempt to shutdown the engine by turning the Circutt Breaker OFF The Circutt
Breaker only provides power to the instrument panel and to the DC alternator the engine will
continue running even H the Circuit Breaker is turned OFF Stop the engine by pulling the
shutoff control fully BreakIn your engine has experienced a minimum of one hour of test operations to ensure accurate as
sembly and proper operation of all systems breakin time is required The service life of your engine is de
pendent upon how the engine is operated and serviced during its initial hours of use
Your new engine requires approximately 50 hours of initial conditioning operation to break In each moving
part in order to maximize the performance and service life of the engine Perform this conditioning careful
ly keeping in mind the following
1 Start the engine according to the STARTING PROCEDURE section found on page 26 run the engine
at fast idle while checking that all systems sea water pump oil pressure battery charging are function
2 Allow the engine to warm up preferably by running at fast idle until the water temperature gauge moves
into the 130140 F range
3 While using the vessel under power vary the engines rpm cruise settings during the engines initial 25
hours of operation
4 Avoid rapid acceleration especially with a cold engine
5 Use caution not to overload the engine The presence of a gray or black exhaust and the inability of
the engine to reach its full rated speed are signs of an overload that is a propeller that is too large
6 During the next 25 hours the engine may be operated at varying engine speeds with short runs at full
rated rpm Avoid idling the engine for prolonged periods of a new engine basically involves seating the piston rings to the cylinder walls This cannot
be by long periods of running at Idle nor by early running at full speed
Idle running may glaze the cylinder walls resulting in excessive oil consumption and smoky operation Ex
cessive speed or heavy overloading especially with a cold engine may cause scoring of the cylinder similar Diesel Engines
28
As indicated above operate the engine in moderation during the 50hour breakin period On one hand
dont baby the engine but on the other hand however dont abuse Under Normal the procedure below for normal starting of the engine
1 Check the engine and transmission lubricant levels and fill if necessary
2 Make sure there is sufficient fuel on board Keep fuel tanks as full as possible Check the fuel filters
and water separators for the presence of contaminants andor water Drain and clean them as needed
3 Check the coolant level in the plastic recovery tank Add coolant solution as needed
NOTE Excessive loss of coolant from the plastic recovery tank indicates a cooling system
leak Check the entire cooling system and the recovery tank and its connections at the ex
haust manifold and pressurize the system to locate the leak In cases of excessive coolant
loss the system must be refilled as outlined under the PREPARATION FOR STARTING sec
tion of this manual page 22
4 Check for all and fuel leaks particularly if signs of such leaks are found on the bottom of the engine or
below the engine
5 When checking your engines coolant and all levels check the engine for any noticeable such as loose or missing bolts loose brackets and mounts
loose hose clamps chafed wires or any
other components that exhibit wear or are loose
Start the engine in accordance with the STARTING PROCEDURE instructions found on page 26 and allow
the engines operating temperature to reach 140 150 F before operating the engine 29
Westerbeke Diesel Under Cold extremely cold temperatures the following conditions can occur Follow the instructions listed below
when operating your engine in cold OIL TURNS VISCOUS Make certain that the lubricating oil used conforms with the ratings
for the prevailing atmospheric temperature Refer to the LUBRICATION SYSTEM section of this manual
page 47 for an viscosity specification ACROSS THE BATIERY TERMINALS DROPS Make certain that the battery is fully charged to
minimize voltage drop across the battery TEMPERATURE OF THE INTAKE AIR IS LOW AND THE COMPRESSION TEMPERATURE DOES NOT
RISE ENOUGH Allow the thermostart device to operate sufficiently to aid in starting during the whenever the temperature of the intake air is low and
when the compression temperature within the
cylinders will not rise quickly during cranking Refer to the Preheat chart found in the STARTING PROCE
DURE section of this manual page 26
Westerbeke Diesel Engines 30
Fresh water is pumped through the engine by a beltdriven fresh water circulating pump absorbing heat from
the engine The fresh water coolant circulates through the engines block absorbing heat then the thermostat into the exhaust manifold to the heat
exchanger where it is cooled and then is
returned to the engine block through the suction side of the fresh water circulating pump When the engine
is started cold external fresh water flow is prevented by the closed thermostat although some fresh water
flow Is bypassed around the thermostat to prevent the exhaust manifold from overheating As the engine
warms up the thermostat gradually opens allowing full flow of the engines fresh water coolant to flow to the external portion of the cooling system
A Fresh Water Coolant Antifreeze Mixture
A freshwater and antifreeze mixture should be used yearround in the fresh water cooling system Water
when it freezes expands sufficiently to split the heat eXChanger and crack the engine block A mixture of proper concentration will prevent freezing
see below for an mixture chart
Use soft water with few Impurities such as tap water potable water or rainwater Never use hard or foul
water Use of hard water or water containing Impurities will lead to the collection of scale in the engine and
heat exchanger which will reduce the cooling systems of poor quality or without rust inhibitors will cause corrosion within the COOling system Jways
use antifreeze which is compatible with aluminum cooling system components and is made by a Never mix different brands of sure that the cooling
system of the engine is well cleaned before adding antifreeze Recommended an
tifreeze for year round use is ZEREX or PRESTONE with rust order to control the concentration of the mixture mix the antifreeze and freshwater
thoroughly before ad
ding it to the cooling system
ANTIFREEZE CONCENTRATION DATA
Antifreeze
Concentration 13 23 30 35 45 50 60
Freezing F 23 14 5 4 22 40 58
Temperature C 5 10 15 20 30 40 50
NOTE An antifreeze concentration should be selected on the basis of a temperature which
is about 10 F 5 C lower than the actual atmospheric temperature expected
B Filling the Fresh Water System
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 without introducing air into the cooling system
This coolant recovery tank should be installed at or above engine manifold level in a location where it can
be easily monitored and where coolant can be easily added if needed see the figure below A mounting bracket is supplied with each kit along with a
3Dinch length of clear plastic hose and clamps
to connect the hose between the engines manifold fitting to the hose spud on the base of the recovery tank
43 Westerbeke Diesel Engines
COOANT RECOVERY TANK
PIISSURE CAP
Coolant Recovery Tank Recommended from the engine when heated during engine operation will expand lifting the springloaded cap and enter the coolant
recovery tank by way of the hose connecting the recovery tank to the
exhaust the engine is shut down and cools a small check valve in the pressure cap is opened by the contrac
tion of the engine coolant allowing some of the coolant in the recovery tank to be drawn back Into the
engines cooling system free of air and without loss
FUNCTION OF MANIFOLD PRESSURE CAP
COOLANT to Coolant Tlnk COOLANT Diesel Engines thermostats are of two types One is simply a
choking device which opens and closes as the
engines temperature rises and falls The second type has a bypass mechanism Usually this is a disc on
the bottom olthe thermostat which moves downward to close off an internal bypass passage within the head
Since 1980 each type of thermostat has a hole punched through it The hole is a bypass to prevent the ex
haust manifold from overheating during the engines warmup Replacement thermostats must have this
design Water Circuit
The sea water flow is created by a geardriven positive displacement neoprene impeller pump The pump
draws sea water directly from the ocean through the sea cock and sea water strainer and passes the water
to the heat exchangers sea water inlet The sea water passes through the heat exchangers tubes from
which heat from the fresh water system is absorbed and then the sea water is discharged from the overboard through the wet exhaust system
A zinc anode or pencil is located in the sea
water cooling circuit within the heat ex
changer The purpose of the zinc anode is
to sacrifice itself to electrolysis action
taking place in the sea water cooling circuit
thereby reducing the effects of other components of the system The
condition of the zinc anode should be
checked monthly and the anode cleaned
or replaced as required Spare anodes
should be carried on board Be sure to
clean zinc debris from the area inside of the
CLEAN
NEW OR
heat exchanger where the zinc anode is AHODE REPLACE REPLACE REPLACE
positioned
Zinc Anode Water Pump
The sea water pump is a selfpriming geardriven rotary pump with a nonferrous housing and a The impeller has flexible vanes Which wipe against a
curved cam plate within the impeller the pumping action On no account should this pump be run dry There should always be a and impeller cover gasket
aboard an impeller kit Sea water failures occur when lubricant sea
water Is not present Such failures are not warrantable and the operators are cautioned to ensure that sea
water flow is present at 45 Westerbeke Diesel and Water Pump Drive 8elt
Tension
iWARNINGI
Never attempt to adjust the drive belts tension while the engine is in operation
CAUTION
Excessive alternator and water pump drive belt tension can cause rapid wear of the belt and
reduce the service life of the fresh water pump and alternator shaft bearings Excessive slack
or the presence of oil on the belt can cause belt slipping resulting in high operating tempera
ture as well as insufficient alternator output
The alternator and water pump drive belts isare properly adjusted if the belt can be deflected no less than
38 inch and no more than 12 Inch 10 mm 12 mm as the belt is depressed with the thumb at the the two pulleys on the longest span of the belt See the
figure below A spare drive belts should
be carried on board
Alternator and Water Pump Belt Diesel Engines 46
LUBRICATION Oil
For engine lubrication use lubricating oil designated for diesel service These oils are classified according
to the AFI Into service grades CA CB CC and CD The use of CC or higher CD grades made
by wellknown manufacturers is recommended The oil selected should be used Oil Viscosity SAE Number
Use an oil having a viscosity best suited to the atmospheric temperature Use of an allseason oil SAE 10W
30 with minimum viscosity change under different temperatures is suggested
Atmospheric Temperature Viscosity
68 F 20 C or higher SAE 30 or 1OW3
41 F 5 C 68 F 20 C SAE 20 or 1OW3
41 F5 C or lower SAE 10W30
NOTE Do not usean engine lubricating oil with an SAE number greater than 30 in the engine
Oil Pressure
The engines oil pressure during operation is indicated by the oil pressure gauge on the instrument panel
see page 24
During normal operation the oil pressure will range between 30 and 60 psi At idle speed the oil pressure
will range between 20 and 35 psi At the time of cranking the oil pressure will rise with speed
NOTE A newly started cold engine can have an oil pressure reading upwards of 60 psi A
warmed engine can have an oil pressure reading as low as 35 psi These readings will vary
depending upon the speed at which the engine is running
47 Westerbeke Diesel Oil Change to include filter
1 Draining the Oil Sump
111 1
11 I
ilill IP
1
Remove the oil drain hose from s attachment bracket
and lower the end of the hose into a container to allow
the oil to drain or attach a pump to the drain hose and
pump the oil out Make sure the oil drain hose is
properly secured in its holder after all of the old oil has
been observe the old oil as it is removed A yel
lowgray emulsion indicates the presence of water in
the oil Although this condition is rare it does attention to prevent serious damage Call a
competent mechanic should water be present in the oil
Sea water present In the oil can be the result of a fault
in the exhaust system attached to the engine andor a
siphoning through the sea water cooling circuit into the
exhaust filling it up into the engine refer to the illustrations on page 15
2 Replacement of the Oil Filter
When removing the used oil filter you may find it
helpful and cleaner to punch a hole in the upper Oil Filter Part Number 16655
and lower portion of the old filter to drain the oil
from It Into a container before removing it This
helps to lessen spillage A small style wrench should be helpful in removing the old
oil filter Place some paper towels and a plastic
bag around the filter when unscrewing it to catch
any oil left In the filter Oil or any other fluid on
the engine reduces the engines cooling keep your engine clean Inspect the old
oil filter as it is removed to make sure that the rub
ber sealing gasket came off with the old oil filter Oil Filter Bracket
If this rubber sealing gasket remains the engine block gently remove it oil filter requires no
cleaning inside so it may be properly disposed of Oil Filter
When Installing the new oil filter element wipe the
filter gaskets sealing surface on the engine block free of oil and apply a thin coat of clean engine oil to the
rubber gasket on the oil filter Screw the filter onto the threaded oil filter stub and then tighten the filter firm
ly by hand See the TORQUE section of this manual for the proper oil filter page Diesel Engines 48
3 Filling the Oil Sump
Add fresh oil through the oil filler cap on the valve
cover refer to the photographs on pages 5 and 6
Oil Filler Cap
for the location of the oil filler cap and lube After refilling the oil run the engine for a
few moments while checking the engines oil pres
sure Ensure there is no leakage around the new
oil filter or from the oil drain system and then stop
the engine Then check the quantity of oil wtth the
lube oil dipstick Fill to but not over the high mark
Oil Dipstick
on the dipstick should the engine require r Oil
NOTE Immediately after an oil filter change Lower Limit 0
and oil fill run the engine to ensure that the
oil pressure is normal and that there are no Crankcase
oil leaks around the new oil filter Check the
oil pressure by observing the oil pressure
gauge in your instrument panel
STARBOARD
To Fresh Water Circulating
Pump Inlet on Engine Block
From Heat Exchanger
Exhaust Manifold
PORT
Oil Cooler Assembly
49 Westerbeke Diesel Engines
THE HBW 150 HBW 150 transmission Is equipped with a helical gearing sys
tem The multlpledisc clutch requires only a minimum effort to change drives This feature
makes the transmission suitable for a singlelever remote control with a rod linkage such as a Morse or Bow
den cable For safety reasons the transmission is NOT filled with transmission fluid for shipment the factory however each transmission is thoroughly
tested with fluid in the transmission This test
ing among other things provides all internal parts with a coating of transmission fluid This fluid acts as providing reliable protection against
corrosion for at least one year if the transmission is proper
1y stored
DIPSTICK
AND FIll
HBW 150 transmission is an type Fill the transmission up to or near the top of
the machined notch cut on the dipstick with approximately 060 US quarts 056 liters of automatic fluid ATF The HBW 150 has its own dipstick and oil
sump
Change the transmission fluid after the first 30 hours of engine operation and thereafter every 250 hours or
once per year minimum The HBW 150 transmission has a drain plug for draining the old transmission fluid
To ensure that most of the old fluid is drained from the transmission run the engine in NEUTRAL for 10 to 15 minutes so the transmission fluid may
warm and flow better from the transmission fluid may also be removed by inserting a small tube through the dipstick opening where fluid is added and
attaching a pump onto the tube so the old fluid may be sucked out
NOTE When removing the dipstick or drain plug make sure the thin aluminum sealing washer
located under the plug is not lost Leakage will result if the sealing washer is not Diesel Engines 50
NOTE To check the transmission fluid level remove the dipstick and wipe off all transmission
fluid on the dipstick and place the dipstick back in the hole where it was removed making
sure that the base of the dipsticks threaded portion rests on the transmission housing Now
remove the dipstick and see where the fluid measures on the dipstick If the fluid level lies below the notch add enough transmission fluid to
raise the level back up to the
notch Do not overtill the DO NOT screw the dipstick into this hole to check the transmission fluid level Screw the
dipstick into this hole only after an accurate reading of the fluids level has been taken Make
sure that the dipstick is screwed in before and while the engine is operating Ensure that the
sealing washer is present and that the dipstick Is not or TO CHECK OIL LEVEL TRANSMISSION
IN
FLUID LEVEL
Transmission drain plug is located directly below the dipstick and is the same size hex head as the
dipstick This drain plug also has a sealing washer
Maximum tightening torque for the Drain Plug and Dipstick 25 Ibft 345 between the coupling and the propeller shafts coupling can create Ensure that
the alignment procedures outlined in the Propeller Coupling the Propeller and
the Alignment of the Engine sections of this manual are followed pages 13 and 14
51 Westerbeke Diesel only controls required to operate the transmission is a single lever remote control cable using a 33C
cable The cable should be attached at right angles to the gear box lever using the cable bracket supplied
with the unit Both the gear box lever and the remote control lever must be in the NEUTRAL position when
the cable is attached to the gear box lever This allows the remote cable an equal throw distance to shift the
gear box into FORWARD or into REVERSE from the NEUTRAL position without running out of cable 118 inches 1 316 minimum of cable throw from the NEUTRAL
position on the box lever to the each of the two drive positions
NOTE If the throw distance Remote Control Shifting Cable
or travel of the remote cable
is too short the gear box lever Cable Bracket
Neutral
cannot fully engage the trans Forward 0 Reverse
mission Into FORWARD A or
REVERSE 8 In this situa C f d
tion the clutch
plates will wear prematurely
0X Or
and the transmission will Counter Clockwise I Clockwise
eventually fail
Transmission Cover Plate
NOTE Excessive throw dis
tance in the remote control
lever is not detrimental to the Cover Plate Hub
Shifting Lever HUb
transmission Note that the
position of the remote control
lever should align with the
NEUTRAL marking on its
bracket when the transmis 05 mm Clearance
sion is really in NEUTRAL
Transmission Shifting shift the transmission from NEUTRAL into FORWARD exert a heavy push to the remote control lever A
gentle throw may not carry enough force to actually shift the internal gears A gentle throw
is signalled by the transmission not engaging into the desired drive Make sure the remote control lever is
lubricated at lease once each operating season Shift the transmission while the engine is running at 1200
rpm or below The clutch pack within the transmission makes an audible clunk when engaging into gear
CAUTION
NEVER remove or loosen the fourbolt gear box lever COVElr from the transmission The posi
tion of this plate and the actuating lever inside of the transmission has been finely adjusted at
the factory to ensure equal throw distance of internal mechanisms Loosening of this covers
capscrews voids the Diesel Engines any seal on the transmission shows signs of leaking have the transmission looked at
by a qualified Dealer This problem especially concerning the rear seal is often contributed to an improper align
ment of the coupling and the propeller shafts coupling Refer to the Alignment of the En
gine section of this manual page 13
NOTE A leaking rear seal can also be the result of a blocked vent hole in the head of the
dipstick Propeller Size
Propeller 18 D x 10 P 2 blade or 18 D x 8 P 3 blade
using HBW 150 transmission Propeller should allow the engine to reach
1881 reduction its full rated RPM 3000 000 100 at full open
throttle while 53 Westerbeke Diesel Engines
ENGINE tables which follow Indicate procedures based upon certain problem indicators the
probable causes of the problems and the to overcome these that the engines control system electrical system is protected by a 20Ampere manual reset
located on the rear lifting probable Cause button is de Battery switch or
Check the swttch Breaker and
pressed no panel in Circuit Breaker or the battery is not ON
20Amp circutt Reset breaker Hthe breaker
breaker has tripped trips again check the preheat
solenoid circutt and circuit for
button is de Must PREHEAT first PREHEAT button must be
pressed no starter depressed to activate
START button
Connection to the Check the connection
solenoid is faulty
FaUlty START switch Check the switch with an
ohmmeter
Faulty solenoid Check that 12 Volts is present
at the solenoid connection on
the Diesel Engines 54
Problem Probable Cause switch Is de Loose battery Check no starter connection Low
battery Check voltage present at
voltage the solenoid S terminal when
the START button is ignition engine Shutoff lever Return shutoff lever to
cranks but does not the RUN Faulty fueling system 1 Check for fuel to the
engine
2 Check for air in the fuel
system Bleed the fuel
system
3 Fuel lift pump is faulty
4 Filters are clogged
Replace filters and bleed
the fuel to stop Shutoff linkage is Stop engine by manually
disconnected moving the RUN linkage
to STOP That failing
shut off fuel and air Loosen high
pressure lines to the stops Fuel starvation RPM fluctuation before
stopping Check for fuel
blockage clogged filters
or air in the fuel system
Fuel Suddenly stops Fuel
contamination damaging
the fuel injection pump
Clean the filter and bleed
the fuel system Check
fuel delivery to the 55 Westerbeke Diesel Probable Cause stops
Transmission failure Check the fluid level in transmission Transmission
seizure will stop the engine
Engine will not turn over
by engaging the is not Alternator drive Check drive belt Be sure the alternator turns
freely Check for loose
connections Check output
with a voltmeter Ensure that
12 Volts are present at the
EXC connection Check the
alternator as described on
page runs down Circuit Breaker Observe if the gauges and
panel lights are activated
when the engine is not running
Test the Circuit Breaker
High resistance leak Check wiring Insert a
to the ground sensitive 025 Amp Amp
meter in the battery lines
Do not start the engine
Remove connections and
replace after the short Is
located
Low resistance leak Check all wires for
to ground temperature rise to locate
the fault
Alternator Disconnect the alternator
at the output after a good
battery charging If the
leakage stops remove the
alternator and bench test
Repair or replace the unn
Preheat solenoid Test the preheat solenoid
with a voltmeter on the lead
to the thermostart Diesel Engines 56
MAINTENANCE AND section contains a scheduled preventive maintenance program and several adjustment procedures can periorm without the benefit of
sophisticated and expensive tools and the preventive maintenance in accordance with the schedules listed in the following to these schedules will
ensure the equipment Is maintained in the best possible condition and
that tt will periorm to expectations Those ttems marked by an asterisk are recommended to be periormed
by an authorized dealer or before each use
1 Check the 011 sump level Maintain the 011 level at or near upper level mark on dipstick
2 Check the coolant level in the plastic recovery tank Maintain this level at or above the level marked
3 Check the lubricant level and add additional lubricant as needed
4 Visually inspect the engine check for loose belts chafed or broken wires loose brackets and fmings
damaged hoses loose clamps and other equipment not properly secured This check should Include
the propeller shaft coupling to the output flange
5 Visually Inspect the sea water strainer
6 Check the fuel supply Fill tanks with a good grade of No2 diesel fuel if required Fuel additives are
recommended to prevent algae growth
7 Check the primary filterWater separator Drain and service as required A primary fllterWater separator
is optional but strongly 8 Check the engines gauges or lights for proper 011 pressure operating temperature and starting battery
charging voltage once the engine is operating
9 Check each alternators output gauge if installed for proper DC the condttion of the zinc anode in the heat exchangers sea water circuit Clean or
replace the anode
as required Keep the area inside the heat exchanger clean of zinc anode debris The rapid deterioration of
the zinc anode may be an indication of electrolysis action caused by an electrical fault adjacent to the ves
sel or from an electrical fault on the vessel
57 Westerbeke Diesel After Initial 50 Hours of Operation
1 Change the engines lubrication oil and oil filter
2 Replace the fuel filter element as described on page 35 Clean and replace the filter element and bowl
of the primary fuel filterWater separator if one has been installed
3 Torque the cylinder head nuts
4 Adjust valve clearances
5 Adjust the alternator water pump and compressor drive belt tension if required
6 Lubricate the throttle the RUN linkage cable and the remote control cable
7 Clean the air intake screen
8 Adjust the engines idle as needed
9 Change the transmission After Every 100 Hours of Operation
1 Change the engines lubrication oil and oil fnter
2 Adjust the alternator and water pump drive belt tension if required
3 Check the transmission fluid or oil After Every 250 Hours of Operation
1 Replace the onengine fuel filter element and service the primary fuel filterwater separator as needed
Check the sea water pumps impeller
2 Change the transmission After Every 500 Hours of Operation
1 Torque the cylinder head nuts
2 Adjust the valve clearances
3 Drain flush and refill the fresh water cooling system
4 Check the condition of the starter motor drive pinion lubricate the pinion
5 Check the sea water pump for any internal wear Check the pumps cover cam and impeller Replace
those parts that are excessively Diesel Engines 58
6 Check the condition of all hoses and drive belts Replace those that are badly worn
NOTE Items highlighted by an asterisk should be performed by a competent After Every 800 Hours of Operation
1 Remove and check fuel injectors
Injector spray setting pressure
2200 psi 155 kglcm 2
Minimum working pressure
POOR
2000 psi 140 kglcm 2
Eliminate undesirable injection conditions Refer to the illustration to the right fef em
GOOD
2 Check the engines compression pressure
Remove each glow plug and check each
cylinders compression pressure The engines
cranking speed is between 250 and 300 rpm
Standard Minimum
450 psi 350 psi
316 kglcm 2 246 kglcm 2 Maximum difference between cylinders 25 psi 17 kglcm 2
3 Check the alternator for proper operation
4 Check the tightness of bolts nuts and After Every 1000 Hours of Operation
1 Remove clean and pressure test the primary heat exchanger A local automotive radiator shop should
be able to clean and test the heat exchanger
NOTE Operating in silty andor tropical waters may require that a heat exchanger cleaning
be performed more often than every 1000 hours
2 Check the fuel Injection pumps timing
59 Westerbeke Diesel Engines
VALVE CLEARANCE ADJUSTMENT
CAUTION
The cylinder head nuts must be retightened after the first 50hours of breakin operation and
before adjusting the valves Make sure the engine is cold when retightening the cylinder head
nuts Refer to the TORQUE section of this manual for proper tightening
page 61
If the engine needs to be timed refer to the TIMING ADJUSTMENT section in the Technical Manual En
gine timing should be performed by a competent diesel the procedure described below when tightening cylinder head nuts and when adjusting valves
1 Loosen the hose clamp on the air breather pipe and remove the hose clamp and the air breather from the
rocker cover Remove the rocker cover bolts and remove the rocker cover
2 Tighten the cylinder head nuts according to the sequence shown in the illustration shown below Make
sure the engine is cold when this is done Loosen one head nut onehalf turn and then tighten it to either
60 Ibft 83 kgm or to 81 Nm Then proceed to the next head nut in the sequence numbering shown
3 Torque the rocker shaft bracket securing nuts evenly between 12 to 15 Ibft or 17 to 2 kgm
4 Adjust the valve clearances according to the procedures described in steps AD Adjust all valve clearan
ces to 0012 inches 030 mm while the engine is cold
A While facing the front of the engine turn the engines crankshaft clockwise so that the No 1 cylinders
valves are in their Valve overlap position that is the period between the opening of the inlet valve and
the closing of the exhaust valve
B In this pOSition adjust the clearances of the No4 cylinders valves Turn the crankshaft as described
in step A so that the valves of the No3 cylinder are in their overlap position and then adjust the NO2
cylinders valves
C Turn the crankshaft again so that the valves of the No4 cylinder are in their overlap position and ad
just the No1 cylinders valves
D Turn the crankshaft so that the valves of the NO2 cylinder are in their overlap position and adjust the
No3 cylinders Diesel Engines 60
TORQUE following torque tensions apply when the components are lightly oiled before assembly
Lbft Kgm Nm
Cylinder Head Nuts 60 83 Rod Cap Bolts 42
58 57
Main Bearing Cap Bolts 85 1175 115
Flywheel Bolts 60 83 81
Idle Gear Hub Bolts 36 50 Pulley Bolt 150
207 203
Injector Securing Nuts 12 17 16
Fuel High Pressure Pipe Nuts 15 21 Pulley Nut 30
41 Housing 10 138 I nsulating Adapter
10 138 13
The tab and shim washers may be discarded where they were once used on earlier models but the bolts
must be tightened to the torque specification threads used except those used to manufacture the basic engine are of the Unified Series and American
Pipe Series The crankshaft and the pulley retaining bolts are threaded 58 inch Unified National Fine UNF
18 threads per inch
61 Westerbeke Diesel Engines
GENERAL TORQUE TIGHTENING CHART
OTHERWISE 6T
6mm boltnut 07
10 5 7
8mm boltnut 16
23 12 17
10mm boltnut 32
47 23 24
12mm boltnut 56
82 41 59
14mm 8T and 88
77 105 56 76
6mm boltnut 8 12 6 9
8mm boltnut 18
27 13
10mm boltnut 37
55 27
12mm boltnut
14mm boltnut
64 95
104 140
46
75 101
Grade 5 capscrew
14 UNC 12 18
15 9
14 UNF 15 28 11 13
516 UNC 25 32 18 20
516 UNF 29 21 23
38 UNe 37 46 28 33
38 UNF 41 48 30 35
716 UNe 61 68 44 49
716 UNF 69 76 50 55
12 UNe 94 101 68 73
12 UNF 101 111 73 80
Westerbeke Diesel Engines 62
LAYUP AND owners rely on their boatyards to prepare their craft including engines and generators for layup during
the offseason or for long periods of inactivity Others prefer to accomplish layup preparation procedures which follOW will allow you to perform your
own layup and or to use as
a check list others do the procedures should afford your engine protection during a layup and also help familiarize you with needs of your engine
If you have any questions regarding layup procedures call your local servicing dealer he will be more than
willing to provide Coupling
The transmission and propeller half couplings should always be opened up and the bolts removed whenever
the boat Is hauled out of the water or moved from land to water and during storage in a cradle The the boat often puts a severe strain on the
propeller shaft or coupling or both while the boat Is taken out
or put in the water I n some cases the shaft has actually been bent by these strains This does not apply to
small boats that are hauled out of the water when not in use unless they have been dry for a of time
Fresh Water Cooling System
A 5050 solution of antifreeze and fresh water is recommended for use in the fresh water cooling system at
all times This solution may require a higher concentration of antifreeze depending on the areas Check the solution to ensure that the antifreeze
protection is more antifreeze be needed drain an appropriate amount from the engine block and add a more mixture Operate the engine to ensure a
complete circulation and mixture of the antifreeze throughout the cooling system Now recheck the antifreeze solutions System
With the engine warm drain all the lubricating oil from the oil sump Remove and replace the oil filter Place
some paper towels and a plastic bag around the filter to catch the oil during its installing the new oil filter be sure to apply a small amount of
oil on the rubber sealing gasket at the
base of the filter Fill the sump with the correct amount of oil for your engine Refer to section of this manual page 8 Use an oil with an API
specicatlon of CC or CD Run
the engine and check for proper oil pressure and ensure that there are no leaks
63 Westerbeke Diesel Engines
CAUTION
Do not leave the engines old lubricating oil in the sump over the layup period Lubricating
oil and combustion deposits combine to produce harmful chemicals which can reduce the
life of your engines internal parts
Fuel System
Top off your fuel tanks with No2 diesel fuel Fuel additives should be added at this time to control algae
and condition the fuel Care should be taken that the additives used are compatible with the primary separator used in the system Change the element
in your primary fuel filterWater separator if the
fuel system contains one and clean the separator sediment bowl
Change the fuel filter elements on the engine and bleed the fuel system as needed Start the engine and
allow it to run for 5 10 minutes to ensure that no air is left In the fuel system Check for any leaks that may
have been created in the fuel system during this servicing correcting them as needed
Sea Water the throughhull sea cock Remove the sea water intake hose from the sea cock Place the end of
this hose into a 5gallon bucket of clean fresh water Before starting the engine check the zinc anode found
in the primary heat exchanger on the engine and clean or replace it as required Clean the sea strainer
one is installed in the inside of the hull
Start the engine and allow the sea water pump to draw fresh water through the system When the bucket Is
empty stop the engine and refill the bucket with an antifreeze solution slightly stronger than needed for winter
freeze protection in your area
Start the engine and allow all of this mixture to be drawn through the sea water system Once the bucket Is
empty stop the engine This antifreeze mixture should protect the sea water circuit from freezing during the
winter layup as well as providing corrosion the Impeller from your sea water pump some antifreeze mixture will accompany it so catch it in a
bUCket Examine the impeller Acquire a replacement needed along with a cover gasket Do not replace
the impeller into the pump until but replace the cover and Manifold and ThroughHull a clean cloth lightly soaked In lubricating oil in the opening
of the intake manifold to block the open
ing Do not shove the cloth out of sight If it is not visible at and an attempt is made to
start the engine you may need the assistance of a servicing dealer Make a note to remove the cloth prior
to startup The throughhull exhaust part can be blocked in the same and cleaning of the starter drive pinion is advisable if access to the starter
permits its easy
removal Ensure that the battery connections are shut off before attempting to remove the starter Take care
in properly replacing any electrical connections removed from the Diesel Engines 64
Cylinder is not necessary to remove the fuel injectors from the cylinder head to squirt light lubricating oil into the
cylinders for the few months of normal layup However if you anticipate a longer layup period 12 we recommended that this procedure be performed The
light oil in the cylinders will prevent the
pistons rings from sticking to the cylinder walls Make sure you have replacements for the injector and return
line sealing time provides a good opportunity to inspect your Westerbeke engine to see if external ITems such as
drive belts or coolant hoses need replacement Check your basic spares kit and order items not on hand
or replace those items used during the layup such as filters and zinc batteries are to be left on board during the layup period make sure they are
fully charged and that they
will remain that way to prevent them from freezing If there exists any doubtthat 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 compatible of your Westerbeke engine after a seasonal layup generally follows the same proce
dures as those presented in the PREPARATIONS FOR STARTING section page 22 regarding starting and normal starts However some of the layup procedures
will need to be counteracted the engine
1 Remove the oilsoaked cloths from the intake manifold and from the throughhull exhaust port
2 Remove the sea water pump cover and gasket and discard the old gasket Install the sea water pump im
peller removed during layup or a replacement if required Install the sea water pump cover WITh a new
cover gasket
Wear rubber gloves a rubber apron and eye protection when servicing batteries
Lead acid batteries emit hydrogen a gas which can be ignited by electrical
arcing or a lighted cigarette cigar or pipe Do not smoke or allow an open flame near the bat
tery while someone is servicing it Shut off all electrical equipment in the vicinity to prevent
electrical arCing during Reinstall the batteries that were removed during the layup and reconnect the battery cables making sure
the terminals are clean and that the connections are tight Check to ensure that the batteries are fully
charged
65 Westerbeke Diesel Engines
4 Check the condition of the zinc anode in the sea water circuit and clean or replace the anode as needed
Note that it is not necessary to flush the water solution from the sea water coolant sys
tem When the engine is put into operation the system will selfflush in a short period of time with no ad
verse affects
5 Start the engine In accordance with procedures in the PREPARATIONS FOR STARTING section of this
manual page 22
Westerbeke Diesel Engines 66
INDEX
MAINTENANCE AND VALVE CLEARANCE 60
Alignment The HBW 150 Transmission 51
Alignment of the Engine Installation Checks 13
Alternator and Water Pump Drive Belt Tension 46
ANTIFREEZE CONCENTRATION DATA 43
Assembly Oil Cooler 49
Automatic Alarm System Installation Checks 18
Exhaust Installation Checks 15
Batteries Layup and 65
Battery Specification 37
Belt Drive System 36
Belt Tension Alternator and Water Pump Drive 46
Bleeding the Fuel System Priming and 32
Bolts Engine Installation Checks 12
BreakIn Procedures Engine 28
CAUTIONS
ENGINE SHIPPED WITHOUT OIL 10
LIFTING SLINGS 11
THROUGHHULL FITTINGS 19
PROLONGED CRANKING 26
SHUTTING OFF THE ENGINE WITHOUT THE CIRCUIT BREAKER 28
PROLONGED CRANKING 32
BATTERY CHARGING CiRCUiT 37
THE BATTERy 37
TESTING THE ALTERNATOR 38
EXCESSIVE BELT TENSION 46
GEAR BOX LEVER COVER 52
TIGHTENING CYLINDER HEAD NUTS 60
LEAVING OLD OIL IN THE SUMP 64
Change Engine Oil to include filter 48
Charging Voltage Test 39
CHART GENERAL TORQUE TIGHTENING 62
Circuit Fresh Water 42
Circuit Sea Water 45
Cold Conditions Starting Under 30
CONTENTS TABLE OF 3
Control Circutt Engine 12Volt DC 37
Control Circuit Wiring Diagram 37248 DC 40 and 41
67 Westerbeke Diesel The HBW 150 Transmission Pressure Sensing Devices to Oil Galleries Installation Checks 18
Cooler Oil Assembly System Installation Checks SYSTEM Propeller Layup and Propeller Shaft Installation Checks Lubrication Layup and D
DC Control Circuit Engine 12Volt Control Circuit Wiring Diagram 37248 40 and OF INSTRUMENT PANEL Engine Understanding the Fuel PRODUCT SOFTWARE
Hose Oil Installation Checks System Bell E
Electrical System Installation Checks SYSTEM 12Volt DC Control Alignment of the Installation Checks Bolts Installation Checks BreakIn Procedures
Diesel Understanding the Foundation for the Installation Checks 011 47
Engine 011 Change to Include filter Oil Viscosity SAE Number Inspection of BackPressure Installation Checks System Installation Checks System
Failures Installation Checks F
Failures Exhaust System Installation Checks Foundation for the Engine Installation Checks Fresh Water Circuit Fresh Water Cooling System Layup and
Fuel Diesel Fuel Filters Fuel Filter Elements Replacing the Westerbeke Diesel Engines 68
Fuel Injection Pump 36
Fuel System Installation Checks 20
FUEL SYSTEM 31
Fuel System Layup and 64
Fuel System Priming and Bleeding 32
GENERAL 4
GENERAL 7
GENERAL TORQUE TIGHTENING CHART 62
HBW 150 TRANSMISSION THE 50
Hose Oil Drain Installation Checks 17
INDEX 67
Injection Pump Fuel 36
Inspection of Equipment 10
INSTRUMENT PANEL DESCRIPTION OF 24
Intake Manifold and ThroughHull Exhaust Layup and 64
LAYUP AND 63
Lifting Rigging and Installation Checks 11
LIST PARTS Installation Checks The HBW 150 Transmission Cylinder Layup and SYSTEM System Layup and 63
AND ADJUSTMENTS 57
Motor Starter Layup and 64
Normal Conditions Starting Under 29
69 Westerbeke Diesel Engines
Oil Change Engine to Include filter Cooler Assembly Drain Hose Installation Checks Engine Engine Viscosity SAE Number Galleries Connecting
Pressure Sensing Devises to Installation Checks 18
Oil Pressure p
PANEL DESCRIPTION OF INSTRUMENT LIST Ordering and Bleeding the Fuel System SAFETY front FOR STARTING Oil Sensing Devices to Oil Galleries
Connecting Installation Checks Engine BreakIn STARTING STOPPING SOFTWARE DISCLAIMER Installation Checks Coupling Layup and Shaft Coupling
Installation Checks Size Recommended The HBW 150 Transmission 53
Pump Fuel Injection Sea Water Propeller Size The HBW 150 Transmission Layup and the Fuel Filter and Lifting Installation Checks
s
SAFETY PRECAUTIONS Inside front cover
Sea Water Circuit Water Circuit Layup and Water Intake System Installation Checks Water Pump The HBW 150 Transmission Coupling Propeller
Installation Checks The HBW 150 Transmission Westerbeke Diesel Engines 70
Shifting Transmission 27
SOFTWARE DISCLAIMER PRODUCT 1
Spares Layup and GENERAL 7
SYSTEM 8
Battery 37
TORQUE 61
STOPPING PROCEDURES 28
Starter Motor Layup and 64
STARTING PREPARATION FOR 22
STARTING PROCEDURE 26
Starting Under Cold Conditions 30
Starting Under Normal Conditions 29
SYSTEM
Exhaust Installation Checks 15
Failures Exhaust Installation Checks 17
Automatic Alarm Installation Checks 18
Cooling Installation Checks 18
Fuel Installation Checks 20
Electrical Installation Checks 21
Starting 23
FUEL 31
Belt Drive 36
ELECTRICAL 37
COOLING 42
TABLE OF CONTENTS 3
Tension Alternator and Water Pump Drive Belt Tension 46
Test Charging Voltage 39
THE HBW 150 TRANSMISSION 50
Thermostat Exhaust Intake Manifold and Layup and 64
TORQUE 61
TORQUE TIGHTENING CHART GENERAL Shifting THE HBW 150 ENGINE 54
Under Cold Conditions Starting 30
Under Normal Conditions Starting the Diesel Engine 4
71 Westerbeke Diesel Engines
VALVE CLEARANCE ADJUSTMENT Installation Checks Engine Oil SEA Number Test Charging W
iWARNINGsl
DIESEL FUMES 17
SMOKING NEAR BATTERIES 21
SERVICING BATTERIES 21
ADJUSTING DRIVE BELT TENSiON 48
BATTERY ACiD 85
Water Clrcu Fresh Clrcu Sea Intake System Sea Installation Checks Pump Sea
Wiring Diagram 37248 DC Control Circu 40 and 41
Westerbeke Diesel Engines 72
PARTS Block 100
Cylinder Head and Valves and Pistons 104
Timing System and Camshaft 106
Rocker Shaft and Cover 108
Intake Manifold 110
Lube Oil Sump and Oil Pump 112
Cooling System 114
Fresh Water Pump and Exhaust Elbow 118
Sea Water Pump 120
Fuel System 122
Back End Transmission
Mounting System 126
HBW Bracket 130
Standard Alternator
Oil manifold Harness Panel and System 138
99 Westerbeke Diesel Engines
15 14
ESTERBEKE 40A CYLINDER BLOCK
REF PN NAME REMARKS QUAN
1 1 030870 ENGINE BLOCK HEAD ASSEMBLY 1
12 011487 ENGINE ASSEMBLY 1
2 019990 LINER 4
4 012452 PLUG 1
5 012458 PLUG REAR CAMSHAFT CHAMBER 1
6 012334 HOUSING 1
7 012356 BOLT 2
8 031758 LOCKIASHER 516 2
9 012475 CAPSCREIJ 516NF X 138 FULLY THREADED 6
10 031758 LOCKIJASHER 516 6
11 012661 GASKET 1
12 011993 SEAL 2
13 013341 PLUG BLOCK DRAIN 1
14 012454 PLUG EXPANSION 5
15 019992 PLUG OIL GALLERY 2
16 012469 BOLT MAIN BEARING CAP 6
17 012623 SHIM 6
18 012380 DOIJEL 6
19 012456 PLUG EXPANSION FRONT REAR 2
20 031758 LOCKIJASHER 516 4
21 012473 CAPSCREIJ 516NF X 34 4
22 012656 PLATE TIMING COVER MOUNT 1
23 012406 GASKET 1
24 012371 CONNECTOR FRESH IJATER HOSE 1
25 012464 PLUG ALTERNATE DIPSTICK POSITION 1
26 012484 SHAFT TACHOMETER DRIVE 1
27 014686 BEARING TACHOMETER DRIVE 1
28 012485 SLEEVE TACHOMETER DRIVE 1
29 012363 SNAPRING TACHOMETER DRIVE 1
301 012620 CAP PLASTIC 1
302 019994 CAP METAL 1
31 012619 IJASHER TACHOMETER DRIVE 1
32 012666 GASKET SIDE COVER TO BLOCK 1
33 020029 COVER SIDE 1
34 012652 STIFFENER 10
35 031758 LOCKIJASHER 5116 10
36 012473 CAPSCREIJ 516NF X 34 2
37 031760 NUT 516NF 8
38 012498 STUD 8
40 020020 GASKET HEAD 1
41 019965 STUD 18
42 013341 PLUG BLOCK DRAIN 1
1 01
WESTERBEKE 40A CYLINDER HEAD AND VALVES
18 25
1 2
15 iil
jESTERBEKE 40A CYLINDER HEAD AND VALVES
REF PN NAME REMARKS QUAN
1 019939 HEAD ASSEMBLY 1
2 019979 PLUG TOP 3
3 023143 PLUG TOP 4
4 012452 PLUG SIDE 1
5 012454 PLUG REAR 1
6 012455 PLUG REAR 1
7 012629 GUIDE INTAKE VALVE 4
8 012628 GUIDE EXHAUST VALVE 4
9 012546 EYE REAR LIFTING 1
10 031764 LOCKWASHER 38 2
11 031628 CAPSCREW 38NF X 34 2
12 019999 SEAT INTAKE VALVE 4
13 019997 SEAT EXHAUST VALVE 4
14 012509 VALVE INTAKE 4
15 012635 DEFLECTOR INTAKE VALVE 8
16 01251 0 VALVE EXHAUST 4
18 019960 SPRING VALVE 8
19 012536 SEAT VALVE SPRINGLOWER 8
20 012360 SEAT VALVE SPRINGUPPER 8
21 012378 COTTER VALVEPAIR 8
22 012682 INSERT COMBUSTION CHAMBER 4
23 012542 WASHER WELSH 4
25 014445 NUT HEADSHORT 12
26 020005 NUT HEADLONG 6
27 014443 WASHER HEAD STUDS 18
28 031760 NUT 516NF 4
291 031758 LOCKWASHER 516 4
292 031759 WASHER FLAT 516 4
30 011653 GASKET HEAD TO EXHAUST MANIFOLD 2
31 014810 STUD EXHAUST MANIFOLD TO HEAD 4
WESTERBEKE 40A CR AND PISTONS
ANKSHAFT
WESTERBEKE 40A CRANKSHAFT AND PISTONS
REF PN NAME REMARKS QUAN
1 023105 CRANKSHAFT ASSEMBLY 1
21 012343 BEARING ROD STD 1
22 012414 BEARING ROD o 01 0 1
23 012423 BEARING ROD 0020 1
24 012519 BEARING ROD 0030 1
31 012342 BEARING SETMAIN STD 1
32 012349 BEARING SETMAIN 0010 1
33 012370 BEARING SETMAIN 0020 1
34 012373 BEARING SETMAIN 0030 1
41 014707 WASHER THRUST STD 2
42 019969 WASHER THRUST 0007 AR
51 012537 WASHER THRUST STD 1
52 019968 WASHER THRUST 0007 AR
6 014719 GEAR CRANKSHAFT 1
7 012383 SLINGER 1
8 012633 ADAPTER CRANKSHAFT PULLEY 1
9 011857 WASHER CRANKSHAFT PULLEY 1
10 012613 BOLT PULLEY RETAINING 1
1 1 1 012595 PULLEY CRANKSHAFT STD 1
112 023526 PULLEY OPTIONAL 6 IN 6 GR 1
113 016356 PULLEY OPTIONAL 5 IN 4 GR 4 IN 2 GR 1
114 012038 PULLEY OPTIONAL 7 IN 2 GR 1
115 036428 PULLEY OPTIONAL 6 IN 4 GR 1
116 012020 PULLEY ACCESSORY 5 IN 2 GR 1
11 7 012039 PULLEY ACCESSORY 6 IN 2 GR 1
12 031752 LOCKWASHER 14 4
13 CAPSCREW 14NF X 118 STD PULLEY 4
14 012408 KEY 2
15 019935 ROD CONNECTING ASSEMBLY 4
16 012348 BOLT CONNECTING ROD 8
17 012622 WASHER FLAT 8
18 019986 BUSHING CONNECTING ROD 4
19 019938 PISTON ASSEMBLY 4
20 019984 SNAPRING PISTON PIN 8
21 019937 RING SET STD 4
ESTERBEKE 40A TIMING SYSTEM AND CAMSHAFT
l 1
ab 7
9 10
20 17 16
30 31
WESTERBEKE 40A TIMING SYSTEM AND CAMSHAFT
REF PN NAME REMARKS QUAN
1 012605 CAMSHAFT 1
2 012460 PUSHROD FUEL LI FT PUMP 1
3 012654 PLATE CAMSHAFT THRUST 2
4 012440 DOWEL 1
5 012597 GEAR CAMSHAFT 1
6 012625 PLATE 1
7 031758 LOCKWASHER 516 3
8 012474 CAPSCREW 516NF X 78 3
9 012481 CAPSCREW IDLER GEAR 2
10 012541 TABWASHER 1
11 012551 PLATE IDLER GEAR 1
12 012689 GEAR IDLER WITH BUSHING 1
13 014685 BUSHING IDLER GEAR 1
14 012388 HUB IDLER GEAR 1
15 012658 GASKET TIMING COVER 1
16 012652 STIFFENER 8
17 031758 LOCKWASHER 516 10
18 012474 CAPSCREW 516NF X 78 9
19 012493 STUD 1
20 031760 NUT 516NF 1
21 012466 SEAL TIMING COVER 1
22 012678 COVER TIMING 1
23 031760 NUT 516NF 4
24 031758 LOCKWASHER 516 4
25 012471 CAPSCREW 14NF X 58 4
26 013536 STIFFENER 3
27 031752 LOCKWASHER 14 4
28 031754 NUT 14NF 4
29 012636 GASKET PLATE TO TIMING COVER 1
30 012500 STUD SEA WATER PUMP MOUNT 4
31 012626 PLATE SUPPORT SEA WATER PUMP 1
WESTERBEKE lOA ROCKER SHAFT AND COVER
REF PN NAME REMARKS QUAN
1 012681 COVER ROCKER
2 012404 GASKET ROCKER COVER 1
3 012429 NUT 2
4 012535 WASHER 2
5 012467 SEAL 2
6 012567 CAP OIL FILLER INCL GASKET 1
7 032184 GASKET OIL FILLER CAP 1
8 012607 PUSHROD 8
9 012606 TAPPET 8
10 012434 NUT LOCKING 8
11 031759 WASHER FLAT 516 8
12 012499 STUD SHORT 358 6
13 012494 STUD LONG 412 2
14 012336 SHAFT COMPLETE ASSEMBLY 1
15 012335 SHAFT ROCKER WITH PLUGS 1
16 012446 PLUG 2
17 012362 SNAPRING 2
18 012525 WASHER 4
19 012539 WASHER 2
20 012333 ROCKER WITH BUSHING 8
21 012488 SPRING 3
22 012358 BRACKET 4
23 012462 SCREW ROCKER ADJUSTING 8
24 012433 NUT 8
25 012372 CONNECTOR OIL FEED TO ROCKER SHAFT 1
26 012413 FERRULE 2
27 012419 NUT 2
28 012637 LINE HEAD TO ROCKER SHAFT 1
29 012331 BUSHING ROCKER 8
WESTERBEKE 40A INTAKE MANIFOLD
11 0
WESTERBEKE 40A INTAKE MANIFOLD
REF PN NAME REMARKS QUAN
1 012683 COVER AIR INTAKE 1
2 012556 FILTER AIR INTAKE 1
3 011411 CLAMP HOSE 32 1
4 020021 GASKET INTAKE MANIFOLD TO HEAD 1
51 022841 ADAPTER MANIFOLD TO 78UNF 1
52 024881 PLUG 78UNFWHEN HEATER NOT INSTALLED 1
53 013392 BUSHING 78UNF TO 18NPT 1
61 011 688 START AID ETHER TYPE 1
62 011615 PLUG 18NPT 1
7 031758 LOCKWASHER 516 7
81 031582 CAPSCREW 516NF X 112 4
82 031581 CAPSCREW 516NF X 114 2
91 012688 MANIFOLD AIR INTAKE 1
92 019382 MANIFOLD AIR LUBCEL 1
10 031588 CAPSCREW 516NF X 3 1
11 012639 ELBOW BREATHER HOSE 1
12 01 134 1 CLAMP HOSE 8 2
13 011530 HEATER MANIFOLD 12 VDC 1
11 1
ESTERBEKE 40A LUBE OIL SUMP AND OIL PUMP
27 26
a 18
WESTERBEKE 40A LUBE OIL SUMP AND OIL PUMP
REF PN NAME REMARKS QUAN
1 035304 SUMP OIL 1
2 035305 PLUG SUMP DRAIN 3416UNF 1
3 035306 WASHER SUMP DRAIN PLUG 1
4 012473 CAPSCREW 516NF X 34 8
5 031758 LOCKIJASHER 516 8
6 012652 STIFFENER SUMP SIDE 8
7 012547 STIFFENER 1
8 031758 LOCKIJASHER 516 8
9 012474 CAPSCREIJ 516NF X 78 8
10 012407 GASKET 2
11 012550 STIFFENER 1
12 012659 GASKET SET SUMPLEFT AND RIGHT 1
13 012549 STIFFENER 1
14 012548 STIFFENER 1
15 012612 DIPSTICK 1
16 014816 IJASHER 1
17 012686 STRAINER OIL PICKUP 1
18 012491 SPRING OIL PICKUP 1
19 012651 LINE OIL STRAINER TO PUMP 1
20 012473 CAPSCREIJ 516NF X 34 1
21 031758 LOCKIJASHER 516 1
22 031759 IJASHER FLAT 516 1
23 020006 NUT SUCTION LINE 1
24 019950 FERRULE SUCTION LINE 1
25 012692 PUMP LUBE OIL 1
26 020017 TABIJASHER OIL PUMP RETAINING CAPSCREIJ 1
27 CAPSCREIJ 516NF X 1116 1
28 019951 FERRULE LUBE OIL DELIVERY LINE 2
21 019952 NUT LUBE OIL DELIVERY LINE 2
30 012442 LINE LUBE OIL DELIVERY TO BLOCK 1
31 036088 IJASHER SUMP DRAIN HOSE TO SUMP 1
32 036392 HOSE SUMP DRAIN 1
33 036087 TABIJASHER SUMP DRAIN 1
34 036085 BOLT BANJOSUMP DRAIN 1
35 024922 BRACKET SUMP DRAIN HOSE 1
36 024905 CAP SUMP DRAIN HOSE 1
2 9j10
53
1
11
131O
S 55
50 54
r 14
15 cr 0 E
41
j n
34 a
49 z
nv21
28 47
J 7 48
2
WESTERBEKE 40A COOLING SYSTEM
REF PN NAME REMARKS QUAN
1 015564 MANIFOLD EXHAUST 1
2 019334 PLUG EXPANSION 1
3 024306 CAP PRESSURE 15 PSI 1
4 011653 GASKET MANIFOLD TO HEAD 2
5 019324 PLUG 1 5NPT 1
6 024907 ELBOW MANIFOLD TO COOLANT RECOVERY TANK HOSE 1
7 021878 CLAMP HOSE 20 2
8 011652 HOSE THERMOSTAT TO MANIFOLD 1
9 031923 CAPSCREW 38NF X 2 SOCKET HEAD 1
10 031764 LOCKWASHER 38 2
11 031922 CAPSCREW 38NF X 1 SOCKET HEAD 1
12 012009 HOUSING THERMOSTAT 1
13 012663 GASKET THERMOSTAT HOUSING 1
14 024688 THERMOSTAT 1
15 011 951 FILTER LUBE OIL 1
16 013610 NIPPLE OIL FILTER TO ADAPTER 1
17 036379 ADAPTER LUBE OIL FILTER WITHOUT OIL COOLER 1
18 012669 GASKET LUBE OIL FILTER ADAPTER TO BLOCK 1
19 011143 GASKET SEA WATER PUMP MOUNTING 1
20 016423 PUMP SEA WATER 1
21 036366 ELBOW 12NPT 45 DEGREE STREET 1
22 032230 NIPPLE 12NPT TO 78 HOSE 1
23 011386 CLAMP HOSE 12 2
24 030166 HOSE SEA WATER PUMP TO EXCHANGER 1
25 011885 ZINC 1
26 011471 PET COCK 2
27 036896 EXCHANGER HEAT 1
281 013619 CAPSCREW M 8 X 30 DIN 933 2
282 031786 LOCKWASHER M 8 DIN 127 2
283 031787 WASHER M 8 DIN 125 2
291 036838 NIPPLE 34NPT TO 78 HOSE 1
292 036622 NIPPLE 34NPT TO 1 HOSE 1
30 021878 CLAMP HOSE 20 2
31 024304 HOSE MANIFOLD TO EXCHANGER 1
321 031506 CAPSCREW 14NC X 114 2
322 031752 LOCKWASHER 14 2
323 031753 WASHER FLAT 14 2
33 021878 CLAMP HOSE 20 4
34 036325 HOSE 1
35 036456 TUBE WHEN OIL COOLER NOT USED 1
36 036324 HOSE 1
37 022851 GASKET EXCHANGER END 2
38 019321 ORING 2
39 022850 COVER EXCHANGER END 2
40 022852 CAPSCREW 38NC X 12 BRASS 2
91r 10
Jt11
13 10
tf5p
I 14
15 b
34 r
20 df11
45 33
1 36
47 48
WESTERBEKE 40A COOLING SYSTEM
REF PN NAME REMARKS QUAN
41 036260 KIT OIL COOLER EXCLUDING REF 153334 36
42 0344134 COOLER LUBE OIL 1
43 0351131 CLAMP OIL COOLER MOUNT 1
441 031506 CAPSCREU 14NC X 114 1
442 031752 LOCKUASHER 14 1
443 031753 UASHER FLAT 14 1
451 013334 CONNECTOR INCLUDING NUT AND FERRULE 4
452 013333 FERRULE AR
461 0316130 CAPSCREU 716NF X 1 1
462 031770 LOCKUASHER 716 1
47 0363132 LINE ADAPTER TO OIL COOLER 1
413 0363131 LINE OIL COOLER TO ADAPTER 1
49 0113972 ADAPTER LUBE OIL FILTER UITH OIL COOLER 1
50 024977 KIT COOLANT RECOVERY TANK 1
51 0247136 STRAP COOLANT RECOVERY TANK MOUNT 1
52 024704 TANK COOLANT RECOVERY 1
53 024858 CAP COOLANT RECOVERY TANK 1
54 024637 TUBING MANIFOLD TO RECOVERY TANKINCHES REQD 30
55 024906 CLAMP HOSE 2
56 0316131 CAPSCREU 716NF X 114 2
57 031770 LOCKUASHER 716 2
40A FRESH WATER PUMP AND WATER INJECTED EXHAUST ELBOW
WESTERBEKE 40A FRESH WATER PUMP AND WATER INJECTED EXHAUST ELBOW
REF PN NAME REMARKS QUAN
1 1 020035 PUMP FRESH WATER 1
12 019933 KIT WATER PUMP REPAIR 1
2 031758 LOCKWASHER 515 4
3 031584 CAPSCREW 515NF X 2 2
4 019987 PULLEY FRESH WATER PUMP 1
5 031750 NUT 516NF 1
5 031583 CAPSCREW 516NF X 134 1
7 035388 STUD 516NF X 218
8 012673 GASKET WATER PUMP TO PLATE 1
9 012655 PLATE FRESH WATER PUMP TO BLOCK 1
10 012674 GASKET PLATE TO BLOCK 1
11 036259 KIT WATER INJECTED EXHAUST ELBOW 1
12 020439 NIPPLE 1 5NPT CLOSE 1
13 034486 ELBOW WATER INJECTED EXHAUST 45 DEGREE 1
141 030183 ELBOW 12NPT TO 78 HOSE 1
142 035616 ELBOW 12NPT TO 1 HOSE 1
15 035747 PLUG 12NPT 1
1 19
IESTERBEKE 40A SEA lATER PUMP
WESTERBEKE 40A SEA WATER PUMP
REF PN NAME REMARKS QUAN
1 011143 GASKET SEA WATER PUMP MOUNTING 1
21 016423 PUMP SEA WATER 1
22 018169 HOUSING SEA WATER PUMP BODY 1
23 018172 KIT PUMP MAJOR REPAIR 1
3 018160 SCREW BRASSPUMP HOUSING TO CAM 1
4 018152 CAM 1
5 015153 GASKET IMPELLER COVER 1
G 018171 COVER IMPELLER 1
7 032183 LOCKWASHER 4
8 018151 SCREW COVER 4
9 033104 KIT IMPELLER AND COVER GASKET 1
10 018159 SEAL 1
11 018170 BEARING 2
12 018176 SHAFT 1
13 018148 KEY IMPELLER TO SHAFT 1
t1
4 Q 2
G
56 I
753
50 i
QP7
53 76
VkII
43 J
ru
38 32
WESTERBEKE lOA FUEL SYSTEM
REF PN NAME REMARKS QUAN
1 023909 HOSE FUEL SUPPLY 1
2 031062 VALVE CHECK 1
3 031061 WASHER SEALING 1
4 016245 GASKET LIFT PUMP MOUNT 1
51 016443 PUMP FUEL LIFT 1
52 035125 KIT FUEL LIFT PUMP REPAIR 1
6 034857 HOSE FUEL RETURN 1
7 032974 FILTER TRAPOPTIONAL 1
8 031756 NUT 516NC 4
9 019509 FILTER FUEL 1
10 ORING FUEL FILTERSEE REF 12 1
11 GASKET SET FUEL FILTERSEE REF 12 1
12 014776 ELEMENT FUEL FILTER INCL REF 1011 1
13 011936 BANJO FUEL RETURN 1
14 011944 WASHER BANJO 2
15 012351 BOLT BANJO 1
161 019505 PLUG UNUSED FILTER PORT 1
162 019507 WASHER FUEL FILTER PLUG 1
17 012522 WASHER BANJO 4
18 011941 BANJO FILTER TO INJECTION PUMP LINES e
19 012350 BOLT BANJO e
20 01951 1 LINE LIFT PUMP TO FILTER 1
21 014814 LINE INJECTION PUMP TO FILTER 1
22 014813 LINE FILTER TO INJECTION PUMP 1
23 014678 PUMP FUEL INJECTION 1
24 016034 LEVER THROTTLE 1
25 016033 BRACKET IDLE SCREW 1
26 016539 SCREW IDLE ADJUSTING 1
27 011934 FERRULE 2
28 019364 BALL JOINT THROTTLE CABLE 1
29 031760 NUT 516NF 2
30 031758 LOCKWASHER 516 3
31 031759 WASHER FLAT 516 3
32 012497 STUD e
33 012561 CAPSCREW 516NF X 114 SOCKET HEAD FULL THREAD 1
34 019261 WASHER 1
35 019204 SCREW BLEED ASSEMBLY 1
36 019370 PIVOT FUEL SHUTOFF LEVER 1
37 014744 SHAFT INJECTION PUMP DRIVE 1
38 012402 GASKET INJECTION PUMP MOUNT 1
39 031323 CIRCLIP HUB 1
401 031324 BEARING ASSEMBLY 1
402 031322 BUSHING HUB 1
41 020004 HUB DRIVE 1
42 019989 GEAR INJECTION PUMP DRIVE 1
431 012614 SHAFT SEA WATER PUMP DRIVE 1
432 023764 SHAFT SEA WATER PUMP DRIVE 0001 OS 1
44 019944 BRACKET STOP LEVER SPRING 1
45 014674 SPRING STOP LEVER 1
75 56
Iy 111
53
32 30
WESTERBEKE 40A FUEL SYSTEM
REF PN NAME REMARKS QUAN
46 012641 LINE INJECTOR 1 1
47 012645 LINE INJECTOR 2 1
48 012646 LINE INJECTOR 3 1
49 012647 LINE INJECTOR 4 1
50 035374 INJECTOR FUEL 4
51 012653 FLANGE INJECTOR MOUNTING 4
52 035375 NOZZLE INJECTOR 4
53 011945 WASHER 4
54 012495 STUD 4
55 012501 STUD INJECTORLONG 4
561 019500 FERRULE RUBBERFUEL LINE 2
562 013343 FERRULE 2
57 013517 LINE INJECTOR RETURN 1
58 011 935 BOLT BANJO 4
59 011943 WASHER BANJO M 8 8
60 019510 LINE INJECTOR RETURN TO FILTER 1
61 015197 LINE FILTER TO STANDPIPE 1
621 011014 STANDPIPE WHEN OPTIONAL HEATER INSTALLED 1
622 013755 BRACKET RAISES STANDPIPE WHEN ALTNR IN UP RT POS 1
631 023612 LINE STANDPIPE TO HEATER 1
632 037394 LINE ASSY STANDPIPE TO 013755 1
64 011530 HEATER MANIFOLD 12 VDC OPTIONAL 1
65 013345 ELBOW 18NPT MALE TO 316 COMPRESSION 1
661 031583 CAPSCREW 516NF X 134 2
662 031758 LOCKWASHER 516 2
671 013343 FERRULE COMPRESSION 316 2
672 013344 NUT COMPRESSION 316 2
68 013346 CONNECTOR 18NPT MALE TO 316 COMPRESSION 2
69 016676 NUT COMPRESSION 14 2
70 019501 FERRULE FUEL LINE 2
71 011 934 FERRULE FUEL LINE 2
72 031765 WASHER FLAT 38 2
73 031764 LOCKWASHER 38 2
74 031630 CAPSCREW 38NF X 1 2
75 013344 NUT COMPRESSION 316 2
761 023920 CLAMP FUEL LINE 4
762 SCREW 1032 X 78 RH 2
763 NUT 1032 LOCKING 2
77 031760 NUT 516NF 8
78 031578 CAPSCREW 516NF X 34 3
79 031758 LOCKWASHER 516 3
80 031759 WASHER FLAT 516 3
81 019442 WASHER 1
18 17 f
1 0
50 I 2 to
22
II I U I J I
23 1
25 A 1 J ji
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I I I I I r 35 l7 39
c A Z
t I
41 n 4 44
42 z
27 ts III 1i16 I Jlbll iYl1I11 c
32 PI
WESTERBEKE 40A BACK END TRANSMISSION MOUNTING SYSTEM
REF PN NAME REMARKS QUAN
1 034589 CAPSCREW M 10 X 30 DIN 933 2
2 019262 LOCKWASHER M1 0 DIN 127 2
3 031789 WASHER M1 0 DIN 125 2
4 030593 MOTOR STARTER 12 VDC 1
5 034589 CAPSCREU Ml0 X 30 DIN 933 4
6 019262 LOCKWASHER M10 DIN 127 4
7 011498 DOUEL BACKPLATE TO BLOCK 2
8 031764 LOCKUASHER 716 5
9 031630 CAPSCREW 716NF X 1 5
10 034833 CAPSCREW Ml0 X 60 DIN 912 FULLY THREADED 1
11 019262 LOCKUASHER Ml0 DIN 127 2
12 035332 PLATE BACK 1
131 034502 FLYUHEEL ASSEMBLY INCL RING GEARBALANCED 1
132 030230 GEAR RING 1
141 034544 COOLER HBU GEAR 78 HOSE 1
142 036648 COOLER HBU GEAR 1 HOSE 1
151 030183 ELBOU 12NPT TO 78 HOSE 1
152 036614 ELBOU 34NPT TO 1 HOSE 1
lEil 017196 CAPSCREU M 8 X 20 DIN 933 4
162 031786 LOCKUASHER M 8 DIN 127 4
17 031789 UASHER Ml0 DIN 125 1
18 015887 NUT Ml0 DIN 934 2
191 020650 CAPSCREU M 8 X 18 DIN 933 HBU150 6
192 013629 CAPSCREW Ml0 X 25 DIN 933 HBU VDRIVE 6
201 031786 LOCKUASHER M 8 DIN 127 HBU150 6
202 031790 LOCKUASHER Ml0 DIN 137B HBU VDRIVE 6
21 024778 CAPSCREU DAMPER TO FLYUHEEL 5
221 031267 ADAPTER HBU150 TO HOUSING 1
222 030063 ADAPTER HBU VDRIVE TO HOUSING 1
231 031248 HBU GEAR MODEL 150 16 TO 1 1
232 024631 HBU GEAR MODEL 150 19 TO 1 1
233 030049 HBU GEAR MODEL 150 26 TO 1 1
24 024950 NUT Ml0 X 125 DIN 934 4
25 019262 LOCKUASHER Ml0 DIN 127 4
26 031228 CAPSCREU Ml0 X 125 X 30 DIN 961 4
271 023679 COUPLING BORE 075 1
272 023680 COUPLING BORE 0875 1
273 023681 COUPLING BORE 10 1
274 023682 COUPLING BORE 1 125 1
275 023683 COUPLING BORE 125 1
276 023684 COUPLING BORE 1375 1
277 023685 COUPLING BORE 15 1
281 023450 SETSCREU COUPLING 716NC X 1 2
282 023651 SETSCREU COUPLING 38NC X 34 2
283 023652 SETSCREU COUPLING 38NC X 1 2
1 11
50 D
14 48
22 o
23 D
N
0 f
41
42 a
ESTERBEKE 40A BACK END TRANSMISSION MOUNTING SYSTEM
REF PN NAME REMARKS QUAN
29 013629 CAPSCRE Ml0 X 25 DIN 933 4
30 031790 LOCKIoIASHER Ml0 DIN 137B 4
311 023706 COUPLING VDRIVE BORE 075 1
312 023707 COUPLING VDRIVE BORE 0875 1
313 023708 COUPLING VDRIVE BORE 10 1
314 023709 COUPLING VDRIVE BORE 1125 1
315 023710 COUPLING VDRIVE BORE 125 1
316 023711 COUPLING VDRIVE BORE 1375 1
317 023712 COUPLING VDRIVE BORE 15 1
321 031249 HB GEAR VDRIVE 18 TO 1 1
322 030048 HB GEAR VDRIVE 21 TO 1 1
323 031250 HBIoI GEAR VDRIVE 3 TO 1 1
331 013629 CAPSCREIoI Ml0 X 25 DIN 933 HBIoI150 6
332 034589 CAPSCREIoI Ml0 X 30 DIN 933 HBIoI VDRIVE 6
34 019262 LOCKIoIASHER Ml0 DIN 127 6
35 019039 DOEL ADAPTER TO HOUSING 2
36 019398 DAMPER 1
37 031926 CAPSCRE Ml0 X 35 DIN 933 2
38 031789 ASHER Ml0 DIN 125 2
39 034682 HOUSING FLYHEEL 1
40 031928 CAPSCREIoI 716NF X 1 GRADE 8 5
41 034504 MOUNT Ldv1 REAR 2
421 036341 ISOLATOR INCLUDING LOCKING NUTS 4
422 036334 ISOLATOR INCLUDING LOCKING NUTS1oI40NA 4
43 036338 NUT M16 DIN 985 LOCKING 8
44 034589 CAPSCRE Ml0 X 30 DIN 933 6
45 019262 LOCKIoIASHER Ml0 DIN 127 6
46 031681 CAPSCREIoI 716NF X 114 4
47 031770 LOCKIoIASHER 716 4
481 013132 MOUNT FRONT LEFT 1
482 013133 MOUNT FRONT RIGHT 1
49 013919 DOIolEL HOUSING TO BACKPLATE 2
501 019059 HOSE 78 IDINCHES REQUIRED 24
502 011 779 HOSE lIDINCHES REQUIRED 24
511 011386 CLAMP HOSE 12 2
512 011405 CLAMP HOSE 16 2
40A HBW TRANSMISSION SHIFTING BRACKET
3 13
WESTERBEKE 40A HBW TRANSMISSION SHIFTING BRACKET
REF PN NAME REMARKS QUAN
1 030756 NUT PILLAR M 8 2
2 030181 BRACKET SHIFT CABLE TOP ENTRY 1
3 031786 LOCKWASHER M 8 DIN 127 2
4 013630 CAPSCREW M 8 X 25 DIN 933 2
5 031847 NUT 1032 2
6 031849 LOCKWASHER 10 2
7 013870 SHIM CABLE CLAMP 1
8 013325 CLAMP CABLE 1
9 031873 SCREW 1032 X 58 2
10 033482 BALL JOINT 1
11 031752 LOCKWASHER 14 1
12 031754 NUT 14NF 1
13 032161 BRACKET SHIFT CABLE REAR ENTRY 1
WESTERBEKE 40A STANDARD ALTERNATOR OIL MANIFOLD
WESTERBEKE 40A STANDARD ALTERNATOR OIL MANIFOLD
REF PN NAME REMARKS QUAN
1 031709 CAPSCREW 12NC X 2 1
2 031776 LOCKWASHER 12 1
3 024684 ALTERNATOR 51 AMP 12 VDC 1
41 031555 CAPSCREW 516NC X 1 1
42 031758 LOCKWASHER 516 1
43 033381 WASHER ADJUSTING STRAP 1
6 011969 MANIFOLD OILTO MOUNT SWITCHES 1
7 011615 PLUG 18NPT AR
8 036395 HOSE BLOCK TO OIL MANIFOLD 1
9 015122 ELBOW 45 DEGREE 1
10 013328 ELBOW 90 DEGREE 1
11 011492 NIPPLE 1
12 012060 BRACKET ALTERNATOR 1
13 035338 STRAP ADJUSTING 1
14 011548 PULLEY ALTERNATOR 1
15 035759 BELT ALTERNATOR AND FRESH WATER PUMP 1
16 012955 BRACKET THROTTLE AND STOP CABLES 1
17 013325 CLAMP THROTTLE CABLE 1
18 013870 SHIM THROTTLE CABLE CLAMP 1
19 013871 CLAMP STOP CABLE 1
20 024132 SENDER OIL PRESSURE 1
211 033935 SW ITCH OIL PIN HARNESS 1
212 034761 SWITCH OIL PIN HARNESS 1
221 031631 CAPSCREW 38NF X 114 2
222 031764 LOCKWASHER 38 2
23 024152 SPACER THROTTLE CABLE CLAMP 1
40A ELECTRICAL HARNESS
WESTERBEKE 40A ELECTRICAL HARNESS
REF PN NAME REMARKS QUAN
1 024639 SOLENOID PREHEAT 1
3 031678 CAPSCREW 716NF X 34 2
4 031770 LOCKWASHER 716 2
5 024683 BREAKER CIRCUIT 20 AMP 1
6 035772 BRACKET CIRCUIT BREAKER AND SOLENOID 1
7 020005 NUT PILLAR 2
81 036079 HARNESS 8 PIN 1
82 036602 HARNESS 12 PIN 1
9 030125 SW ITCH WATER 1
10 035109 SENDER WATER TEMPERATURE 1
11 032119 BUSHING REDUCER 12NPT TO 18NPT 2
12 013355 BUZZER ALARM 1
WESTERBEKE 40A INSTRUMENT PANEL
4 5
00
WESTERBEKE 40A INSTRUMENT PANEL
REF PN NAME REMARKS QUAN
1 033866 PANEL INSTRUMENT ASSEMBLY 1
2 030913 SCREW 1
3 030119 COVER PANEL REAR 1
4 035118 HOLDER LAMPIJEDGE BASE AR
5 035114 LAMP BASE AR
6 035108 METER IJATER TEMPERATURE 1
7 03511 0 METER OIL PRESSURE 1
8 033865 PANEL PLATE 1
9 033693 SWITCH KEY 1
10 030003 NUT NYLON LOCKING 632 1
11 033684 COVER FACEPLATE 1
12 030002 SPACER NYLON 1
13 024996 WINDOW KEYSIJ ITCH COVER 1
14 030001 SCREW NYLON 632 X 12 IJASHER HEAD 1
15 035111 VOLTMETER 12 VDC 1
16 033682 DECAL SWITCH 1
17 030148 CABLE PANEL TO ENGINE 1
181 033764 SIJITCH PUSH BUTTON STARTPREHEAT 2
182 019031 CAP SWITCH COVER REPLACEMENT AR
19 011917 METER 1
20 036630 DRAWING TEMPLATE TO INSTALL PANEL 1
W40NA ALTERNATORS AND COMPRESSOR MOUNTING SYSTEM
WESTERBEKE W40NA ALTERNATORS AND COMPRESSOR MOUNTING SYSTEM
REF PN NAME REMARKS QUAN
1 031719 CAPSCREW 12NC X 412 1
2 011548 PULLEY ALTERNATOR 2
3 036430 SPACER 1
4 024684 ALTERNATOR 51 AMP 12 VDC 2
5 036429 SPACER 1
6 031776 LOCKWASHER 12 2
7 031774 NUT 12NC 1
8 036427 BRACKET ALTERNATOR 1
9 031553 CAPSCREW 516NC X 34 2
10 031758 LOCKWASHER 516 2
11 033381 WASHER ADJUSTING STRAP 2
12 033064 STRAP ADJUSTING 2
13 031764 LOCKWASHER 38 2
14 031633 CAPSCREW 38NF X 134 1
15 031632 CAPSCREW 38NF X 112 1
16 036452 BRACKET COMPRESSOR 1
17 033537 CAPSCREw 38NC X 118 4
18 031765 WASHER FLAT 38 4
19 031764 LOCKWASHER 38 4
20 031762 NUT 38NC 4
21 036413 BRACKET COMPRESSOR 1
22 031553 CAPSCREW 516NC X 34 2
23 CAPSCREW 516NF 2
24 031758 LOCKWASHER 516 2
25 031274 CAPSCREW 38NC X 2 FULLY THREADED 1
26 033361 BELT ALTERNATOR AND FRESH WATER PUMP 2
27 036428 PULLEY 4 GROOVE 1
28 031752 LOCKWASHER 14 4
29 CAPS CREW 114NF X 1118 4
30 031559 CAPSCREW 516NC X 2 1
31 031758 LOCKWASHER 516 1
32 031759 WASHER FLAT 516 1
33 012225 PULLEY FRESH WATER PUMP 2 GROOVE 1
34 031758 LOCKWASHER 516 2
35 031756 NUT 516NC 2
36 036426 BRACKET ALTERNATOR 1
37 031554 CAPSCREW 516NC X 78 1
38 033713 SPACER 1
39 031713 CAPSCREW 12NC X3 1
40 031108 SPACER 1
41 036457 BELT BE MATCHED PAIR 2
42 037248 DIAGRAM WIRING 1
ESTERBEKE 40A PN NAME REMARKS QUAN
3 019934 GASKET SET UPPER 1
4 020719 GASKET SET LOIJER 1
5 020720 GASKET SET COMPLETE 1
6 032974 FILTER TRAP 1
7 013758 PAINT RED AEROSOL SPRAY CAN 1
8 015010 STRAINER SEA ATER 1
9 020654 SPLITTER ALTERNATOR OUTPUT 1
10 011988 KIT FUEL HARDIJARE 1
11 020502 MANUAL TECHNICAL 1
12 012169 LINE FLEXIBLE STEEL 12 LONG 1
131 034936 MUFFLER HYDROHUSH C UNIVERSAL MOUNT 1
132 033340 CONNECTOR HOSESTRAIGHT 178 AR
133 033341 CONNECTOR HOSE 45 DEGREE 178 AR
134 033342 CONNECTOR HOSE 90 DEGREE 178 AR
135 036680 ADAPTER 178 TO 2 HOSE AR
136 033943 KIT HOSE COUPLING AND CLAMPS 1
14 033327 VALVE ANTISIPHON 1

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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.