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Westerbeke Diesel W 40 Technical Manual



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OPERATOR'S MANUAL


                                                                ..~




     WESTERBEKE 40NA

         MARINE DIESEL
            ENGINE




           Publication # 37169

                Edition One

               February 1988




~    WESTERBEKE
    WESTERBEKE CORPORATION
    AVON INDUSTRIAL PARK, AVON, MA 02322. TEL: (617) 588-7700
                                            SAFETY PRECAUTIONS

The 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 tank(s) 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 possible
serious personal injury or loss of life.
                                                                   ·   Do Not Alter or Modify the Fuel System
                                                                       Be sure all fuel supplies have a positive shut-off 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 environment.
and equipment.

Fuels, exhaust gases, batteries, electrical equipment, and
moving and hot parts are potential hazards that could result in    ·   Use Extreme Care When Servicing Batteries
serious personal injury or death. Follow recommended proce-
dures carefully.                                                       Wear rubber gloves, a rubber apron, and eye protection
                                                                       when servicing batteries.
Always operate bilge blowers for at least five minutes before
starting a gasoline-fueled engine; ensure no gasoline fumes are        Lead acid batteries emit hydrogen, a highly-explosive gas,
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 vessel's AC circuits,       moving parts.
     except through a ship.to-shore double-throw transfer
     switch. Damage to vessel's 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 drive-belt's 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 well-ventilated.
                                                IMPORTANT

                                   PRODUCT SOFTWARE DISCLAIMER

Product software of all kinds, such as brochures, drawings, technical data, operator's and workshop manuals,
parts lists and parts price lists (and other related information), instructions and specifications provided from
sources other than Westerbeke, is not within Westerbeke's 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 REPRESENTATIONS WITH RESPECT
THERETO, 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 SOFTWARE.

For example, components and SUbassemblies incorporated into Westerbeke's products and supplied by
others (such as engine blocks, fuel systems and components, transmissions, electrical components, pumps
and other products) are generally supported by their manufacturers with their own software, and Westerbeke
must depend on such software for the design of Westerbeke's own product software. Such software,
however, may be outdated and no longer accurate. Routine changes made by Westerbeke's suppliers, of
which Westerbeke rarely has notice in advance, are frequently not reflected in the supplier's sofi',vare until
after such changes take place.                                                                     .

Westerbeke customers should also keep in mind the time span between printings of Westerbeke product
software, and the unavoidable existence of earlier, non-current Westerbeke software editions In the field. Ad-
ditionally, most Westerbeke products include customer-requested special features that frequently do not In-
clude complete documentation.

In 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 representatives 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 customer.




                                                        1                        Westerbeke Diesel Engines
                                               INSTALLATION CHECKS
General

Because the crafts In which Westerbeke engines are installed vary in design, installation procedures will vary
according to your craft's specific design. It is not the intent of this section to advise boatyards or installers
on procedures alreadywell-developed and well-understood. However, it is important that the owner/operator
realize 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 in-
stallation of the diesel engine in the vessel are of prime importance.

Factors 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 connections.

                                                    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 stored.


Location

The 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 engine's lubrication oil sump dipstick, the fresh water and oil
fills, and the transmission's dipstick and transmission or oil fill port must be accessible.




                                   FILL CAoP
                        COOLANT
                        RECOVERY --..               COCKPIT
                          TANK     ;,

                                 ALT'RN"T.~~~~~~~;;:==="
                                 MOUN11NO
                                  STRAP
                                 POSITIONS




                           CABIN




                                                                       INSTALLATION     ANGLE
                                                                       MUST   HOT   EXCEED   .l? ·




          Please note that the engine's installation angle cannot exceed 17' from the horizontal plain.



Westerbeke Diesel Engines                               10
Rigging and Lifting

The engine is fitted with lifting eyes. Rope or chain slings capable of supporting the engine's 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 engine's lifting eyes.
      Strain placed on the engine's lifting eyes by the lifting sling must not be in excess of 10' from
      the vertical plain.




                                                 10'

                                                                 SLXNG    L:IFTJ:NG
                                                                 ANGLE    IoiUST   NOT
                                                                 EXCEED    10·




                                                                   LIFTING
                                                                   EYE



                                                   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 system's piping, the heat exchanger, certain filters, the mounting lugs and other
obstructive 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 front-end upwards or transmission-end upwards, the
attachment 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 heavy
machinery.




                                                         11                              Westerbeke Diesel Engines
Engine Bolts

Bronze or stainless steel hanger bolts of appropriate size are recommended for use through the engine's
flexible 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. Consequent-
ly, the bond between the hanger bolt and the wood is not weakened by the removal of the nut or the engine.


Foundation for the Engine

A good engine bed contributes much toward the satisfactory operation of the engine. The engine's bed
must be rigidly constructed and neither deflect nor twist when it is subjected to the engine's weight or to the
pressures that the boat may experience while operating in rough seas. The bed must keep the engine's
alignment 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 pushes
against the engine's 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, thereby
reducing noise and transmitted vibration.

The engine support stringers must be as wide or wider than the engine mounting isolator. Isolator overhang
and/or rounded stringer surfaces are detrimental to the isolators' ability to retain vibration.

Preformed fiberglass engine beds, when used, should be of sufficient thickness to properly support the en-
gine and should be well-glassed to the hull when
installed.

The temptation to Install the engine on a pair of
fiberglass angle Irons must be resisted. Such
construction will allow engine vibration to pass
through to the hull. Flexible mounts require a firm
foundation 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 illustration).                                                                                 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 of
vibrations.
                                                                                   BAD




                                                                                                  B

                                                      Note:     Avoid excessive height, use
                                                                solid stringer construction (A).




 Westerbeke Diesel Engines                             12
Propeller Shaft Coupling

The propeller shaft coupling fitted to the transmission's 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 engine/transmission
either ahead or astern,

The coupling bore should be carefully machined for a slight forced fit onto the shaft and an accurate mating
surface for the coupling to the output flange of the transmission.

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 engine's 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 Flexible
Coupling 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 manual.


Propeller

The 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 propeller
which 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 water.


Alignment of the Engine

The engine must be exactly aligned with the propeller shaft using a solid coupling before installing the Federal
Flexible. No matter what material is used to build a boat the material will be found to be flexible to some ex-
tent; hence, the boat's 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 engine's align-
ment at frequent intervals and to correct any errors when they appear.

Misalignment 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 boat's hull by loosening the hull's fastenings.
A bent propeller shaft will have the exact effect as those just stated; therefore, a perfectly straight propeller
shaft is absolutely necessary. One particularly annoying result of misalignment may be leakage of transmis-
sion oil through the transmission's 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 shaft/transmission coupling
alignment 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 accomplished.




                                                       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 counterbore,
and when a feeler gauge indicates that the flanges
come together at all points. The alignment between                     PROPELLER SHAFT
the propeller shaft coupling and the engine's 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 (.003).




In making the final check for alignment, the
engine's half coupling should be held in one
position and the alignment with the propeller
coupling tested wtth the propeller coupling in
each offour positions (A), while rotated 90' be-
tween each position. This test will also check
whether the propeller's half-coupling is in exact
alignment on its shaft. Then, keeping the
propeller coupling in one position, the align-
ment should be checked by rotating the
engine's half-coupling in 90' increments,
 checking dimension A while in each 90' posi-
tion until the half-coupling has been rotated full
 circle.                                   .

The engine's alignment should be rechecked
after 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 engine's 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 engine's 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 circutt's through-hull discharge port. If not prevented, sea water entering through the dis-
charge port can fill the exhaust system muffler and enter the engine's cylinders. This will prevent proper
starting and possibly cause damage to internal engine components.

The 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 anti-siphon break should be installed, when needed, at the top of
this loop. The top of the loop should be placed high enough above the vessel's 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 engine's heat exchanger
                                                                  outlet will determme the Ik or 1 "
                                                                                            ff

                                                                  dimenSion lor the vented loop.




                                                                                           48" max.


          Installation with exhaust                                                              !




                                                                                        ~J
          manifold/water-injected elbow
          at a minimum of 6" above
          vessel water line.
                                                             HydrO-Hush




          Waterline!\.....
                   -~-~,
                      '-"-~.~~:-.~
                            Insulate -      -.



                                                                            48" mal(,




                                                                                        CAUTION: Vented loop must be
                                                                                        in a location where it will remain
                                                                                        above the water line during all
                                                                                        aHitudes of the vessel's operation.
           installation with exhaust                          Hydro-Hush
           manifoldiwater.injected elbow
           at or below vessel water line.

The sea water supply through-hull sea cock fittings must be of the flush-hull type. High-speed scoop type
of fittings should not be used as they tend to encourage siphoning.

The exhaust discharge from the water lift muffler should be routed well above the water line then downward
to the through-hull discharge. This routing will prevent sea water entry if the through-hull discharge fitting
becomes 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 installations.




                                                                           15                                Westerbeke Diesel Engines
Exhaust Back-Pressure

The exhaust discharge hose must be of adequate size and
minimal run to prevent excessive exhaust back-pressure.
Exhaust back-pressure should be checked before the engine
is put into service. (Refer to the illustration.) Excessive back-
pressure will affect the engine's performance.

To measure for back-pressure, use a mercury manometer, a
pressure gauge, or a water column. A boatyard or marine
                                                                                               Exhaust
mechanic should have a manometer or a pressure gauge.
                                                                       ..
                                                                       ..
                                                                                               Elbow

Measure back-pressure at the exhaust elbow when the en-                  "
gine is running at 3000 rpm. Back-pressure, as measured by               "
                                                                         "                     Exhaust
a manometer, a pressure gauge, or water column, should not           ."
be over the following specifications:                                . "
                                                                     I "
                                                                       ·
                                                                             Mercury
                                                                             Manometer
      NOTE: Other pressure gauges may be available to test
      for exhaust back-pressure. Check with a competent
      mechanic.

Refer to the pressure specifications 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 1/4 inch NPT (National Pipe
Tap) pipe fitting.

Measure back-pressure at the exhaust elbow when the en-
gine is running at 3600 rpm.

Dimension A cannot exceed 39 inches of water.

Back pressure, as measured by a gauge instrument, should
not exceed the following specifications:


    3 inches of mercury (0.104 kg/cm 2)
    39 inches of water in a water column
                    (.099 kg/cm2 at 4' C)
    22 ounces psi                                                                   \
    1 1/2 psi


Excessive back-pressure 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 hose's
routing should be limited since these will create flow restrictions and contribute to exhaust back-pressure.
The engine's exhaust system must be separate from any other engine's exhaust system. Dry portions of the
exhaust system between the engine's exhaust manifold and the water injected exhaust elbow must be insu-
lated to hold in the heat.




Westerbeke Diesel Engines                                16
Exhaust System Failures

When the engine's 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 water
jacketed 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 possible.

The 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 areas
excessively. 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 cause.

Exhaust risers installed off the exhaust mannold should not exceed 8 Ibs in total weight w~en rigidly con-
nected. Excessive weight and vibration can result in a manifold failure and/or 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 exhaust
pipe.



                                                  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 concentration. Carbon
      monoxide is a dangerous gas that can cause unconsciousness 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 immediately.

Make sure there are no unnecessary objects suspended from any portion of the exhaust lines. Excessive
weight 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 insulation.


Oil 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 1/4 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 Engines
Connecting Pressure Sensing Devices to Oil Galleries

Oil pressure sensing devices, such as senders and switches, must not be connected to an engine's oil gal-
lery with the use of extended nipples or tees. The reason is simply that continued engine vibration causes
fatigue 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 bulkhead-mounted and connected to the oil gallery using an appropriate
grade 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 application.


Automatic Alarm System


    High Water Temperature Alarm

A high water temperature alarm buzzer has been supplied with the instrument panel. If the engine's fresh
water coolant reaches 2100 F (98.8° 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 engine's oil gallery. This switch monitors the engine's oil
pressure. Should the engine's 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 PANEL"
section 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 engine-mounted heat exchanger. Sea water is used as the heat
exchanger's 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 engine's fresh water cooling system.

Sea water should be supplied to the sea water pump through a flush·type hull fitting using a wire-reinforced
hose between the through-hull fitting and the sea water pump. The sea water should be directed through a
visual-type 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 through-hull fitting to the strainer and
to the sea water pump should be wire-reinforced to prevent the hose from collapsing while the engine is run-
ning (suction from the pump may collapse a non-reinforced hose). The sea water strainer should be mounted
at or below the water line to make sure the sea water line remains primed.




Westerbeke Diesel Engines                              18
                                                                    CAUTION

 DO NOT use a scoop-type through-hull 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 pump's impeller into the engine's exhaust system, filling it and the
 engine as well. Flush-type, clear, through-hull 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 common-type street elbows is not recommended for plumbing the sea water cir-
 cuit. These generally have very restrictive inside diameters. Machine fittings are preferred.




    To Fresh Water Circulating
    Pump Inlel on Engine Block



                                                                            ~iI



   ~
     .:,~.: ',- '.': . :~ .r:J r-"\.                      Fresh Water Pressure Fill Cap
         "                   Y            '~,os   ~UEL




Westerbeke Diesel Engines                      40
                 W 40NA DC Control Circuit Wiring Diagram #37248
                                   page 2 of 2



SCHEMATIC OIAGRA\I1




             A
                 @
                       ~-.
                     ~ ~",.



             '§l.,,, ....

   0 L - - ! -_ _-j




                                        ®   "401'1.0. .... IRING ~ODIFICATIO"S AND-PARTS SUPPLIED BY
                                            HANSEN MARINE: EI'IGINEERING INC.,MAR8LEfoIEAO,MA 01945




                                       41                                      Westerbeke Diesel Engines
                                            COOLING SYSTEM
Description

Westerbeke 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 transferred
heat over the side through the exhaust system. The fresh water and sea water circu~s are independent of
each other. Using only fresh water w~hin the engine allows the cooling water passages to stay clean and
free from harmful depos~s. The two independent circuits and their components are discussed in the follow-
ing paragraphs.


Fresh 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
      system.

Illustrated below is a typical Westerbeke engine's cooling system. Both fresh water and sea water flow
through their independent COOling circu~s.



          To Fresh Water Circulating
          Pump Inlet on Engine Block

                                 b~""




                  Incoming Sea Water




                     /
       Sea Water Impeller Pump




                                                                         To Transmission Oil Cooler



Westerbeke Diesel Engines                            42
Electrical 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 engine's 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
      highly-explosive gas. Turn off the emergency switch in the positive line of battery.

Make 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 tight.


Ventilation

The ventilation requirements of the engine include the following: combustion air Is required for the engine's
cylinders 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 the
"SPECIFICATIONS" section of this manual for airflow requirements, page 8.




                                                       21                        Westerbeke Diesel Engines
                                        PREPARATION FOR STARTING

This section of the manual provides the operator with preparation, initial starting, break-in, 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 Cap
lubricating oil with an API specification of CC or CD and
an SAE number suitable for the temperature in your
operating area (see page 47). For the quantity of oil
needed in this engine, refer to the "SYSTEM SPECIFICA-
TION" 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 "SYSTEM
SPECIFICATIONS" section of this manual, page 9.)
                                                                    Upper Limit
Each unit is supplied with a coolant recovery kit                  (Normal   Level~h,\f:=,,=._;=_.=1
(#24977) as standard equipment, to which the follow-                            --;;-_.           Oil
ing applies:                                                           Lower Limit            ===---. . -
   A. Remove the pressure cap from the engine's ex-                             Crankcase
      haust manifold and slowly fill the engine's 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 manifold's 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 engine's 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 No.2 diesel fuel and prime the fuel system up to the engine (see page
32). When returning fuel is free of air, the engine's fuel system is bled and the engine is ready to start.

Ensure that the Installation Checks have been made in accordance with those specified in the "INSTALLA-
TION CHECKS" section of this manual (refer to page 10).




Westerbeke 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




                          Thermostart




                                               Cold Start Aid




The W 40NA engine's 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 PANEL

Westerbeke 40NA engines are supplied with instrument panels. Read the following instruction carefully
before operating the engine.


           RPM Gauge                       Water Temperature Gauge                   Oil Pressure Gauge




                                                                                     Ammeter




                                                                     .   Vo~age   Gauge


General

The manually-controlled panel is equipped with an RPM gauge with an ELAPSED TIME meter which measures
the engine's running time in HOURS and in 1/10 hours. The panel also includes a water temperature gauge
which indicates watertemperature in degrees Fahrenheit (WATER 0 F), an oil pressure gauge which measures
the engine's oil pressure in pounds per square inch (OIL PSI), a DC control circuit voltage gauge which
measures the system's DC voltage (VOLTS), and a DC Ammeter which allows the operator to monitor
amperage 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 rubber-booted 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 alternator's EXC terminal and the intake manifold's
      thermostart device. This button also energizes the START button.

   3.   SIABI.:  The START button, when pressed, energizes the starter's solenoid which cranks the engine.
        This button will not operate electrically unless the PREHEAT button is pressed and held at the same
        time.




Westerbeke 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 four-pin connection on the engine's 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
   engine's 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 engine's normal operating temperature is 170 - 190' F
  (77 - 88'C).

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 engine's normal operating oil pressure ranges be-
   tween 30 - 60 PSI.

   NOTE: When the engine is manually shut down, and the engine's 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 engine's 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 push/pull 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.
                           + 41'F(+ 5'C)to + 23'F(-5'C)               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 circuit
voltage gauge. A properly operating thermostart
device is indicated when the voltmeter registers a volt-                      ,...,_-Voltage Drop
age drop when the PREHEAT button is depressed.
This voltage drop will be slight but noticeable. If the
voltmeter indicates no voltage drop at the time the
PREHEAT button is depressed, then the thermostart
device could be defective or the preheat circuit is faul-
ty (check for any loose connections).

While 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 button.


Should 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 engine's cylinder's by way of the exhaust manifold
       once the exhaust system fills. Prevent this from happening by closing the sea water
       supply through-hull shut-off, 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 owner/operator should keep this
       in mind.




Westerbeke Diesel Engines                               26
Once the engine starts. move the throttle into a fast idle position (1000 - 1200 rpm). Check your instrumen-
tation 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 reached.


Transmission Shifting

To shift the transmission, use the remote control shifting lever located in the cockptt. This remote control
shifting lever rotates the shifting lever on the side of the standard transmission. Rotating the shifting lever in
a counterclockwise 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 REVERSE.

Remember:

             FORWARD GEAR: Rotate the lever COUNTERCLOCKWISE.

             REVERSE GEAR: Rotate the lever CLOCKWISE through NEUTRAL into REVERSE.

For a more detailed description of the HBW transmission's operation, refer to the "HBW TRANSMISSION"
section of this manual, page 50.




                                           Remote Control Shifting Cable

                                                                     Neutral
                                                                       o     Reverse
                                                               A                    B
                                                                \               /
                                                               ~r=~
                                                                                Shifting Lever




                                       Transmission Shifting Positions




                                                        27                              Westerbeke Diesel Engines
                                         STOPPING PROCEDURES

In the cockpit of the boat, there is a tee handle or a knob-type shut-of control. When this control is pulled
OUTWARD, the control will STOP the engine. The other end of the shut-off control is attached to a lever on
the top of the fuel Injection pump. (Pushing the shut-off control fully inward will place the engine in the RES-
TART - RUN posttion.

When the engine is stopped, turn the Circuit Breaker located in the vessel to the OFF position. If the Circuit
Breaker 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
      shut-off control fully OUTWARD.


Engine Break-In Procedures

Although your engine has experienced a minimum of one hour of test operations to ensure accurate as-
sembly and proper operation of all systems, break-in 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-
      ing.

   2. Allow the engine to warm up (preferably by running at fast idle) until the water temperature gauge moves
      into the 130-140' F range.

   3. While using the vessel under power, vary the engine's rpm cruise settings during the engine's 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 time.

Breaking-in a new engine basically involves seating the piston rings to the cylinder walls. This cannot be ac-
complished 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 walls,
producing similar results.




Westerbeke Diesel Engines                              28
As indicated above, operate the engine in moderation during the 50-hour break-in period. (On one hand
don't baby the engine, but on the other hand, however, don't abuse it.)


Starting Under Normal Conditions

Follow 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 tank(s) as full as possible. Check the fuel filters
     and water separators for the presence of contaminants and/or 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 engine's coolant and all levels, check the engine for any noticeable abnormalities
     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 engine's operating temperature to reach 140 - 150· F before operating the engine underway.




                                                      29                          Westerbeke Diesel Engines
Starting Under Cold Conditions

Under extremely cold temperatures, the following conditions can occur. Follow the instructions listed below
when operating your engine in cold weather.

LUBRICATING 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 atmospheric/oil viscosity specification table.

VOLTAGE ACROSS THE BATIERY TERMINALS DROPS - Make certain that the battery is fully charged to
minimize voltage drop across the battery terminals.

THE 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 preheat
period 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 belt-driven fresh water circulating pump, absorbing heat from
the engine. The fresh water coolant circulates through the engine's block absorbing heat, then passes
through 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 engine's fresh water coolant to flow un-
restricted to the external portion of the cooling system.


    A. Fresh Water Coolant (Antifreeze) Mixture.

A freshwater and antifreeze mixture should be used year-round in the fresh water cooling system. Water,
when it freezes, expands sufficiently to split the heat eXChanger and crack the engine block. A water/an-
tifreeze mixture of proper concentration will prevent freezing (see below for an antifreeze/water 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 system's efficiency.

Antifreeze 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 reliable
manufacturer. Never mix different brands of antifreeze.

Make 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 inhibitors.

In 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 stainless
steel mounting bracket is supplied with each kit along with a 3D-inch length of clear plastic hose and clamps
to connect the hose between the engine's manifold fitting to the hose spud on the base of the recovery tank.




                                                        43                          Westerbeke Diesel Engines
                       COO~ANT     RECOVERY TANK
                                                             ,.. P~IISS'URE CAP




                               Coolant Recovery Tank, Recommended Installation

Coolant from the engine, when heated during engine operation, will expand, lifting the spring-loaded mannold
pressure cap, and enter the coolant recovery tank by way of the hose connecting the recovery tank to the
exhaust mannold.

When 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
engine's cooling system, free of air and without loss.


                        FUNCTION OF MANIFOLD PRESSURE CAP

                                           COOLANT RETRACTION




             to Coolant Tlnk               COOLANT EXPANSION




Westerbeke Diesel Engines                            44
Thermostat

Generally, thermostats are of two types. One is simply a choking device which opens and closes as the
engine's 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 engine's warm-up. Replacement thermostats must have this
design characteristic.

Sea Water Circuit

The sea water flow is created by a gear-driven, 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 exchanger's sea water inlet. The sea water passes through the heat exchanger's tubes, from
which heat from the fresh water system is absorbed, and then the sea water is discharged from the cooling
system overboard through the water-injected 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 electrolysis
on 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 Conditions


Sea Water Pump

The sea water pump is a self-priming, gear-driven rotary pump with a non-ferrous housing and a neoprene
impeller. The impeller has flexible vanes Which wipe against a curved cam plate within the impeller housing,
producing the pumping action. On no account should this pump be run dry. There should always be a spare
impeller 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 operator's are cautioned to ensure that sea
water flow is present at start-up.




                                                             45                  Westerbeke Diesel Engines
Alternator and Water Pump Drive 8elt Tension



                                                iWARNINGI

      Never attempt to adjust the drive belt's 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 belt(s) is/are properly adjusted if the belt can be deflected no less than
3/8 inch and no more than 1/2 Inch (10 mm, 12 mm) as the belt is depressed with the thumb at the midpoint
between the two pulleys on the longest span of the belt. (See the figure below.) A spare drive belt(s) should
be carried on board.




                                  Alternator and Water Pump Belt Tension




Westerbeke Diesel Engines                             46
                                           LUBRICATION SYSTEM

Engine Oil

For engine lubrication, use lubricating oil designated for diesel service. These oils are classified according
to the AFI specifications Into service grades CA, CB, CC and CD. The use of CC or higher (CD) grades, made
by well-known manufacturers is recommended. The oil selected should be used thereafter.


Engine Oil Viscosity (SAE Number)

Use an oil having a viscosity best suited to the atmospheric temperature. Use of an all-season 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 1OW-3~
                          41° F (5° C) - 68° F (20° C)              SAE 20 or 1OW-3~
                          41° F(5° C) - or lower                         SAE 10W-30


      NOTE: Do not usean engine lubricating oil with an SAE number greater than 30 in the engine.


Oil Pressure

The engine's 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 proportionately 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 Engines
Engine Oil Change (to include filter)

1. Draining the Oil Sump
                                                                             I\IIIIIIIIII!
                                                                             I'
                                                                                           111\ 1
                                                                                    1.1",. I,
                                                                                                ilill': \;:I;P:!'
                                                                                       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 removed.

Always observe the old oil as it is removed. A yel-
low/gray emulsion indicates the presence of water in
the oil. Although this condition is rare, it does require
prompt attention to prevent serious damage. Call a
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 and/or a
siphoning through the sea water cooling circuit into the
exhaust, filling it up into the engine (refer to the instal-
lation 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 automotive
filter 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 engine's cooling ability.
Please 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 sealed
against the engine block, gently remove it. The
replaceable cartridge-type 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 gasket's 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 SPECIFICATIONS" section of this manual for the proper oil filter tightening
specification, page 61.




Westerbeke 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 oil
dipstick). After refilling the oil, run the engine for a
few moments while checking the engine's 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 additlon-
aloil.



                                                                               ----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 TRANSMISSION

General

The HBW 150 transmission Is equipped with a positively-driven. mechanically-operated helical gearing sys-
tem. The servo-operated multlple-disc clutch requires only a minimum effort to change drives. This feature
makes the transmission suitable for a single-lever 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. Before
leaving 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 a
preservative. providing reliable protection against corrosion for at least one year if the transmission is proper-
1y stored.

                                             DIPSTICK
                                             AND FIll
                                             PORT




Lubrication

The HBW 150 transmission is an immersion-lubricated type. Fill the transmission up to or near the top of
the machined notch cut on the dipstick with approximately 0.60 U.S. quarts (0.56 liters) of automatic trans-
mission 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 ap-
proximately 10 to 15 minutes so the transmission fluid may warm and flow better from the transmission. This
transmission fluid may also be removed by inserting a small tube through the dipstick opening (where the
transmission 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 present.




Westerbeke 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 dipstick's threaded portion rests on the transmission housing. Now
     remove the dipstick and see where the fluid measures on the dipstick. If the transmission's
     fluid level lies below the notch, add enough transmission fluid to raise the level back up to the
     notch. Do not overtill the transmission.

     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 fluid's 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 cross-threaded or overtightened.


                                             TO CHECK OIL LEVEL      TRANSMISSION
                                                                     IN OPERATION




                                   ,
                                   ,
                                   ,
                                   ,
                                   ,
                                  ,,
                                  ,.
                                  ,,
                                  : '
                                "'b!
                                                            FLUID LEVEL




                    DAAINPLUG


The 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 Ib-ft (3.45 kg-m)


Alignment

Misalignment between the transmission's coupling and the propeller shaft's coupling can create serious
problems. 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 Engines
Controls

The 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. Allow
approximately 1.18 inches (1 3/16) minimum of cable throw from the NEUTRAL position on the transmission's
gear 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 transmission's clutch
      plates will wear prematurely
                                                                             0;X : ~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-                                                    0.5 mm Clearance
      sion is really in NEUTRAL.
                                                            Transmission Shifting Positions




Shifting

To 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 transmission's 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 four-bolt 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 cover's
      capscrews voids the transmission's warranty.




Westerbeke Diesel Engines                             52
Service

If any seal on the transmission shows signs of leaking, have the transmission looked at by a qualified Hurth
Servicing Dealer. This problem, especially concerning the rear seal, is often contributed to an improper align-
ment of the transmission's coupling and the propeller shaft's 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 tube.




Recommended Propeller Size

    Propeller Recommendations                           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
    1.88:1 reduction)                                   its full rated RPM (3000 + 000 - 100) at full open
                                                        throttle while underway.




                                                       53                        Westerbeke Diesel Engines
                                     ENGINE TROUBLESHOOTING


Introduction

The tables which follow Indicate troubleshooting procedures based upon certain problem indicators, the
probable causes of the problems, and the recommendations to overcome these problems.

Note that the engine's control system (electrical system) is protected by a 20-Ampere manual reset circuit
breaker located on the rear lifting bracket.




problem                                  probable Cause                     Verification/Remedy

PREHEAT button is de-                    Battery switch or                  Check the swttch, Breaker and!
pressed: no panel in-                    Circuit Breaker                    or the battery connections.
dications.                               is not ON.

                                         20-Amp circutt                     Reset breaker; Hthe breaker
                                         breaker has tripped.               trips again, check the preheat
                                                                            solenoid circutt and circuit for
                                                                            shorts.




START button is de-                      Must PREHEAT first.                PREHEAT button must be
pressed: no starter                                                         depressed to activate the
engagement.                                                                 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 starter.




Westerbeke Diesel Engines                           54
Problem               Probable Cause           Verification/Remedy

START switch Is de-   Loose battery            Check battery
pressed: no starter   connection.              connections.
engagement.
(continued)           Low battery              Check voltage present at
                      voltage.                 the solenoid S terminal when
                                               the START button is depressed.




No ignition; engine   Shut-off lever.          Return shut-off lever to
cranks but does not                            the RUN position.
start.
                      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 system.)




Failure to stop.      Shut-off 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 injectors.




Engine stops.         Fuel starvation.         RPM fluctuation before
                                               stopping. Check for fuel
                                               blockage, clogged filters,
                                               or air in the fuel system.

                      Fuel contamination.      Suddenly stops. Fuel
                                               contamination damaging
                                               the fuel injection pump.
                                               Clean the filter and bleed
                                               the fuel system_ Check
                                               fuel delivery to the injectors.




                                  55            Westerbeke Diesel Engines
Problem                     Probable Cause          Verification/Remedy

Engine stops.               Transmission failure.   Check the fluid level in the
(continued)                                         transmission. Transmission
                                                    seizure will stop the engine.
                                                    Engine will not turn over
                                                    by engaging the starter.


Battery is not              Alternator drive        Check drive belt tension.
charging.                                           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 39.




Battery 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 (0-.25 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 device.




Westerbeke Diesel Engines                 56
                                  MAINTENANCE AND ADJUSTMENTS

Introduction

This section contains a scheduled preventive maintenance program and several adjustment procedures the
owner/operator can periorm without the benefit of sophisticated and expensive tools and instruments.


Preventive Maintenance

Periorm the preventive maintenance in accordance with the schedules listed in the following paragraphs.
Adherence 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 distributor.


Daily (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
     ADD.

  3. Check the transmission's 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 transmission's output flange.

  5. Visually Inspect the sea water strainer.

  6. Check the fuel supply. Fill tank(s) with a good grade of No.2 diesel fuel, if required. Fuel additives are
     recommended to prevent algae growth.

  7. Check the primary filter/Water separator. Drain and service as required. (A primary fllter/Water separator
     is optional, but strongly recommended.)

  8. Check the engine's gauges or lights for proper 011 pressure, operating temperature, and starting battery
     charging voltage once the engine is operating.

  9. Check each alternator's output gauge (if installed) for proper DC voltage.


Monthly

Check the condttion of the zinc anode in the heat exchanger's 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 Engines
Servicing After Initial 50 Hours of Operation

  1. Change the engine's 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 filter/Water 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 transmission's remote control cable.

  7. Clean the air intake screen.

  8. Adjust the engine's idle as needed.

  9. Change the transmission's transmission fluid.


Servicing After Every 100 Hours of Operation

  1. Change the engine's lubrication oil and oil fnter.

  2. Adjust the alternator and water pump drive belt tension, if required.

  3. Check the transmission fluid or oil level.


Servicing After Every 250 Hours of Operation

  1. Replace the on·engine fuel filter element and service the primary fuel filter/water separator as needed.
     Check the sea water pump's impeller.

  2. Change the transmission's transmission fluid.


Servicing 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 pump's cover, cam, and impeller. Replace
      those parts that are excessively worn.




Westerbeke 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 mechanic.


Servicing 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 including
after-dripping. Refer to the illustration to the right.        ~~~f~e-f:              --em
                                                                          lIiilii......
                                                                      ......
                                                                                                GOOD
 *2. Check the engine's compression pressure.
     Remove each glow plug and check each
     cylinder's compression pressure. The engine's
     cranking speed is between 250 and 300 rpm.

          Standard         Minimum

           450 psi           350 psi
         (31.6 kglcm 2)     (24.6 kglcm 2)     (Maximum difference between cylinders: 25 psi (1.7 kglcm 2)

 *3. Check the battery-charging alternator for proper operation.

 *4. Check the tightness of bolts, nuts, and clamps.


Servicing 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 and/or tropical waters may require that a heat exchanger cleaning
      be performed more often than every 1000 hours.

 *2. Check the fuel Injection pump's timing.




                                                       59                           Westerbeke Diesel Engines
                                   VALVE CLEARANCE ADJUSTMENT


                                                   CAUTION

      The cylinder head nuts must be retightened after the first 50-hours of break-in operation, and
      before adjusting the valves. Make sure the engine is cold when retightening the cylinder head
      nuts. Refer to the "TORQUE SPECIFICATION" section of this manual for proper tightening
      specifications, 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 mechanic.

Follow 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 one-half turn and then tighten it to either
   60 Ib-ft, 8.3 kg-m, or to 81 N-m. 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 Ib-ft or 1.7 to 2 kg-m.

4. Adjust the valve clearances according to the procedures described in steps A-D. Adjust all valve clearan-
ces to 0.012 inches (0.30 mm) while the engine is cold.

  A. While facing the front of the engine, turn the engine's crankshaft clockwise so that the No 1 cylinder's
     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 No.4 cylinder's valves. Turn the crankshaft as described
     in step A so that the valves of the No.3 cylinder are in their overlap position, and then adjust the NO.2
     cylinder's valves.

  C. Turn the crankshaft again so that the valves of the No.4 cylinder are in their overlap position, and ad-
    just the No.1 cylinder's valves.

   D. Turn the crankshaft so that the valves of the NO.2 cylinder are in their overlap position, and adjust the
      No.3 cylinder's valves.




Westerbeke Diesel Engines                              60
                                       TORQUE SPECIFICATIONS

The following torque tensions apply when the components are lightly oiled before assembly.

                                                     Lb-ft                    Kg-m                 N-m

Cylinder Head Nuts                                   60                        8.3                  81

Connecting Rod Cap Bolts                             42                        5.8                  57

· Main Bearing Cap Bolts                             85                       11.75                 115

Flywheel Bolts                                       60                         8.3                 81

Idle Gear Hub Bolts                                  36                        5.0                  49

Crankshaft Pulley Bolt                               150                       20.7                 203

Injector Securing Nuts                               12                         1.7                 16

Fuel High Pressure Pipe Nuts                          15                        2.1                 20

Alternator Pulley Nut                                30                         4.1                  41

Thermostat Housing                                    10                       1.38                  13

Thermostat I nsulating Adapter                        10                       1.38                  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 indicated.

All 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 5/8- inch Unified National Fine (U.N.F.
18 threads per inch).




                                                      61                        Westerbeke Diesel Engines
                              GENERAL TORQUE TIGHTENING CHART




                                                                     1b-ft.


UNLESS OTHERWISE INDICATED
Grade 6T
     6mm bolt/nut                                      0.7   -
                                                             1.0      5   -    7
     8mm bolt/nut                                      1.6   -
                                                             2.3     12   -   17
    10mm bolt/nut                                      3.2   -
                                                             4.7     23   -   24
    12mm bolt/nut                                      5.6   -
                                                             8.2     41   -   59
    14mm bolt/nut
Grade 8T and 8.8
                                                       7.7 -10.5     56   -   76
     6mm bolt/nut                                       .8 - 1.2      6   -9
     8mm bolt/nut                                      1.8   -
                                                             2.7     13   -
                                                                          20
    10mm bolt/nut                                      3.7   -
                                                             5.5     27   -
                                                                          40
    12mm bolt/nut
    14mm bolt/nut
                                                       6.4 - 9.5
                                                      10.4 -14.0
                                                                     46   -
                                                                          69
                                                                     75 -101
Grade 5 capscrew
    1/4 UNC                                            1.2   - 1.8
                                                               1.5    9   -
                                                                         11
    1/4 UNF                                            1.5   - 2.8   11- 13
    5/16 UNC                                           2.5   - 3.2   18   -   20
    5/16 UNF                                           2.9   -       21   -   23
    3/8 UNe                                            3.7   - 4.6   28   -   33
    3/8 UNF                                            4.1   - 4.8   30   -   35
    7/16 UNe                                           6.1   - 6.8   44   -   49
    7/16 UNF                                           6.9   - 7.6   50   -   55
    1/2 UNe                                            9.4   -10.1   68   -   73
    1/2 UNF                                           10.1   -11.1   73   -   80




  Westerbeke Diesel Engines                  62
                                    LAY-UP AND RECOMMISSIONING

General

Many owners rely on their boatyards to prepare their craft, including engines and generators, for lay-up during
the off-season or for long periods of inactivity. Others prefer to accomplish lay-up preparation themselves.

The procedures which follOW will allow you to perform your own lay-up and recommissioning, or to use as
a check list ~ others do the procedures.

These procedures should afford your engine protection during a lay-up and also help familiarize you with the
maintenance needs of your engine.

If you have any questions regarding lay-up procedures, call your local servicing dealer; he will be more than
willing to provide assistance.


Propeller 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 flexibility
of 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 considerable
period of time.


Fresh Water Cooling System

A 50-50 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 area's winter
climate. Check the solution to ensure that the antifreeze protection is adequate.

Should more antifreeze be needed, drain an appropriate amount from the engine block and add a more con-
centrated mixture. Operate the engine to ensure a complete circulation and mixture of the antifreeze con-
centration throughout the cooling system. Now recheck the antifreeze solution's strength.


Lubrication 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 removal.)

When 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 the"SYSTEM
SPECIFICATIONS" section of this manual, page 8.) Use an oil with an API spec~icatlon 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 engine's old lubricating oil in the sump over the lay-up period. Lubricating
      oil and combustion deposits combine to produce harmful chemicals which can reduce the
      life of your engine's internal parts.


Fuel System

Top off your fuel tanks with No.2 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 fil-
ter/water separator used in the system. Change the element in your primary fuel filter/Water 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 Circuit

Close the through-hull sea cock. Remove the sea water intake hose from the sea cock. Place the end of
this hose into a 5-gallon 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 lay-up, as well as providing corrosion protection.

Remove 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 recommissioning, but replace the cover and gasket.


Intake Manifold and Through-Hull Exhaust

Place 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 recommissioning, 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 start-up. The through-hull exhaust part can be blocked in the same manner.


Starter Motor

Lubrication 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 starter.




Westerbeke Diesel Engines                              64
Cylinder Lubrication

It 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 lay-up. However, if you anticipate a longer lay-up period (12 months
or.more), 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 washers.


Spares

Lay-up 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 lay-up, such as filters and zinc anodes.


Batteries

If batteries are to be left on board during the lay-up 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 environment.


Recommissioning

The recommissioning of your Westerbeke engine after a seasonal lay-up generally follows the same proce-
dures as those presented in the "PREPARATIONS FOR STARTING" section, page 22, regarding preparation
for starting and normal starts. However, some of the lay-up procedures will need to be counteracted before
starting the engine.

1. Remove the oil-soaked cloths from the intake manifold and from the through-hull 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 lay-up (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 highly-explosive 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 servicing.

3. Reinstall the batteries that were removed during the lay-up, 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 antifreeze/fresh water solution from the sea water coolant sys-
   tem. When the engine is put into operation. the system will self-flush 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
        A

ADJUSTMENTS, MAINTENANCE AND ..................................................................................................... 57
ADJUSTMENT, 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 (Illustration) .............................................................................................................. 49
Automatic Alarm System (Installation Checks) ........................ ,................................................................. 18


         B

Back-Pressure, Exhaust (Installation Checks) ........................................................................................... 15
Batteries (Lay-up and Recommissioning) .................................................................................................. 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
Break-In Procedures, Engine ...................................................................................................................... 28


         C

                                                                        CAUTIONS

         ENGINE SHIPPED WITHOUT OIL ......................................................................................... 10
         LIFTING SLINGS ................................................................................................................... 11
         THROUGH-HULL FITTINGS .................................................................................................. 19
         PROLONGED CRANKING ..................................................................................................... 26
         SHUTTING OFF THE ENGINE WITHOUT THE CIRCUIT BREAKER ...................................... 28
         PROLONGED CRANKING ..................................................................................................... 32
         BATTERY CHARGING CiRCUiT ............................................................................................ 37
         QUICK-CHARGING 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 12-Volt DC ............................................................................................................. 37
Control Circuit Wiring Diagram # 37248, DC ................................................................................ 40 and 41




                                                                               67                                    Westerbeke Diesel Engines
Controls (The HBW 150 Transmission) .......................................................................................................52
Connecting Pressure Sensing Devices to Oil Galleries (Installation Checks) ........................................... 18
Cooler, Oil, Assembly (Illustration) ..............................................................................................................49
Cooling System (Installation Checks) .........................................................................................................18
COOUNG SYSTEM .....................................................................................................................................42
Coupling, Propeller (Lay-up and Recommissioning) .................................................................................63
Coupling, Propeller Shaft (Installation Checks) ..........................................................................................13
Cylinder Lubrication (Lay-up and Recommissioning) ................................................................................65


         D

DC Control Circuit, Engine, 12-Volt.. ...........................................................................................................37
DC Control Circuit Wiring Diagram # 37248 ................................................................................. 40 and 41
DESCRIPTION OF INSTRUMENT PANEL ..................................................................................................24
Diesel Engine, Understanding the .................................................................................................................4
Diesel Fuel.. ..................................................................................................................................................31
DISCLAIMER, PRODUCT SOFTWARE .........................................................................................................1
Drain Hose, Oil (Installation Checks) ..........................................................................................................17
Drive System, Bell.. ......................................................................................................................................36


          E

Electrical System (Installation Checks) .......................................................................................................21
ELECTRICAL SYSTEM ................................................................................................................................37
Engine 12-Volt DC Control Circuit...............................................................................................................37
Engine, Alignment of the (Installation Checks) ...........................................................................................13
Engine Bolts (Installation Checks) ..............................................................................................................12
Engine Break-In Procedures .......................................................................................................................28
Engine, Diesel, Understanding the ................................................................................................................4
Engine, Foundation for the (Installation Checks) .......................................................................................12
Engine 011 ............................................................................................................................ ~ ...................... .47
Engine 011 Change (to Include filter) ...........................................................................................................48
Engine Oil Viscosity (SAE Number) ............................................................................................................47
ENGINE TROUBLESHOOTING ..................................................................................................................54
Equipment, Inspection of ..............................................................................................................................2
Exhaust Back-Pressure (Installation Checks) .............................................................................................16
Exhaust System (Installation Checks) ........................................................................................................15
Exhaust System Failures (Installation Checks) ..........................................................................................17


          F

 Failures, Exhaust System (Installation Checks) .........................................................................................17
 FORWARD......................................................................................................................................................2
 Foundation for the Engine (Installation Checks) ........................................................................................12
 Fresh Water Circuit ......................................................................................................................................42
 Fresh Water Cooling System (Lay-up and Recommissioning) ..................................................................63
 Fuel Diesel ....................................................................................................................................................31
 Fuel Filters ....................................................................................................................................................31
 Fuel Filter Elements, Replacing the .............................................................................................................35




 Westerbeke Diesel Engines                                                         68
Fuel Injection Pump .................................................................................................................................... 36
Fuel System (Installation Checks) .............................................................................................................. 20
FUEL SYSTEM ............................................................................................................................................ 31
Fuel System (Lay-up and Recommissioning) ............................................................................................ 64
Fuel System, Priming and Bleeding ........................................................................................................... 32


         G

GENERAL ...................................................................................................................................................... 4
GENERAL SPECIFICATIONS ....................................................................................................................... 7
GENERAL TORQUE TIGHTENING CHART ............................................................................................... 62


         H

HBW 150 TRANSMISSION, THE ................................................................................................................ 50
Hose, Oil Drain (Installation Checks) ......................................................................................................... 17




INDEX .......................................................................................................................................................... 67
Injection Pump, Fuel ................................................................................................................................... 36
Inspection of Equipment ............................................................................................................................... 2
INSTALLATION CHECKS............................................................................................................................ 10
INSTRUMENT PANEL, DESCRIPTION OF ................................................................................................ 24
Intake Manifold and Through-Hull Exhaust (Lay-up and Recommissioning) ........................................... 64


          L

LAY-UP AND RECOMMISSIONING ........................................................................................................... 63
Lifting, Rigging and (Installation Checks) .................................................................................................. 11
LIST, PARTS ................................................................................................................................................99
Location (Installation Checks) .................................................................................................................... 10
Lubrication (The HBW 150 Transmission) ................................................................................................. 50
Lubrication, Cylinder (Lay-up and Recommissioning) .............................................................................. 65
LUBRICATION SYSTEM ............................................................................................................................. 47
Lubrication System (Lay-up and Recommissioning) ................................................................................. 63


          M

MAINTENANCE AND ADJUSTMENTS ...................................................................................................... 57
Motor, Starter (Lay-up and Recommissioning) .......................................................................................... 64


          N

 Normal Conditions, Starting Under ............................................................................................................ 29




                                                                                  69                                      Westerbeke Diesel Engines
         a
Oil Change. Engine (to Include filter) ..........................................................................................................48
Oil Cooler Assembly (illustration) ................................................................................................................49
all Drain Hose (Installation Checks) ...........................................................................................................17
Oil. Engine ....................................................................................................................................................47
Oil. Engine. Viscosity (SAE Number) ..........................................................................................................47
Oil Galleries. Connecting Pressure Sensing Devises to (Installation Checks) .......................................... 18
Oil Pressure ..................................................................................................................................................47
Ordering Parts................................................................................................................................................4


          p

PANEL. DESCRIPTION OF INSTRUMENT .................................................................................................24
PARTS LIST ..................................................................................................................................................99
Parts. Ordering ...............................................................................................................................................4
Priming and Bleeding the Fuel System .......................................................................................................32
PRECAUTIONS. SAFETY ...................................................................................................Inside front cover
PREPARATION FOR STARTING .................................................................................................................22
Pressure. Oil .................................................................................................................................................47
Pressure Sensing Devices to Oil Galleries. Connecting (Installation Checks) .......................................... 18
Procedures. Engine Break-In ......................................................................................................................28
PROCEDURE. STARTING ...........................................................................................................................26
PROCEDURES. STOPPING ........................................................................................................................28
PRODUCT SOFTWARE DISCLAIMER ..........................................................................................................1
Propeller (Installation Checks) ....................................................................................................................13
Propeller Coupling (Lay-up and Recommissioning) ..................................................................................63
Propeller Shaft Coupling (Installation Checks) ...........................................................................................13
Propeller Size. Recommended (The HBW 150 Transmission) .................................................................. 53
Pump. Fuel Injection ....................................................................................................................................36
Pump. Sea Water .........................................................................................................................................45


          R

Recommended Propeller Size (The HBW 150 Transmission) ...................................................................53
Recommissioning (Lay-up and Recommissioning) ...................................................................................65
Replacing the Fuel Filter Elements..............................................................................................................35
Rigging and Lifting (Installation Checks) ....................................................................................................11


          s
SAFETY PRECAUTIONS .................................................................................................... Inside front cover
Sea Water Circuit .........................................................................................................................................45
Sea Water Circuit (Lay-up and Recommissioning) ....................................................................................64
Sea Water Intake System (Installation Checks) ..........................................................................................20
Sea Water Pump ..........................................................................................................................................45
Service (The HBW 150 Transmission) ........................................................................................................53
Shaft Coupling. Propeller (Installation Checks) ..........................................................................................13
Shifting (The HBW 150 Transmission) ........................................................................................................52




 Westerbeke Diesel Engines                                                        70
Shifting, Transmission ................................................................................................................................. 27
SOFTWARE DISCLAIMER, PRODUCT. ........................................................................................................ 1
Spares (Lay-up and Recommissioning) ..................................................................................................... 65
SPECIFICATION(S)
       GENERAL ............................................................................................................................................ 7
       SYSTEM .............................................................................................................................................. 8
       Battery ............................................................................................................................................... 37
       TORQUE ............................................................................................................................................ 61

STOPPING PROCEDURES ........................................................................................................................ 28
Starter Motor (Lay-up and Recommissioning) ........................................................................................... 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


          T

TABLE OF CONTENTS ................................................................................................................................. 3
Tension, Alternator and Water Pump Drive Belt Tension .......................................................................... 46
Test, Charging Voltage ............................................................................................................................... 39
THE HBW 150 TRANSMISSION ................................................................................................................. 50
Thermostat .................................................................................................................................................. 45
Through-Hull Exhaust, Intake Manifold and (Lay-up and Recommissioning) .......................................... 64
TORQUE SPECiFiCATIONS ....................................................................................................................... 61
TORQUE TIGHTENING CHART, GENERAL .............................................................................................. 62
Transmission Shifting .................................................................................................................................. 27
TRANSMISSION, THE HBW 150 ................................................................................................................ 50
TROUBLESHOOTING, ENGINE ................................................................................................................. 54


          u
Under Cold Conditions, Starting ................................................................................................................ 30
Under Normal Conditions, Starting ............................................................................................................ 29
Understanding the Diesel Engine ................................................................................................................. 4




                                                                                  71                                     Westerbeke Diesel Engines
         v
VALVE CLEARANCE ADJUSTMENT ..........................................................................................................60
Ventilation (Installation Checks) ..................................................................................................................21
Viscosity, Engine Oil (SEA Number) ...........................................................................................................47
Voltage Test, Charging ................................................................................................................................39


         W

                                                                     iWARNINGsl

         DIESEL FUMES .................................................................................................................... 17
         SMOKING NEAR BATTERIES ................................·...·...·..··....··..................·...................···... 21
         SERVICING BATTERIES ······..................................··.··.·.................·.............··....................·.. 21
         ADJUSTING DRIVE BELT TENSiON ....·.·.....·.·..·.·....···........................·.........··.................····. 48
         BATTERY ACiD ..................................................................................................................... 85


Water Clrcu~, Fresh .....................................................................................................................................42
Water Clrcu~, Sea ........................................................................................................................................45
Water Intake System, Sea (Installation Checks) .........................................................................................20
Water Pump, Sea
Wiring Diagram #37248, DC Control Circu~ ................................................................................. 40 and 41




 Westerbeke Diesel Engines                                                     72
                        PARTS LIST

Cylinder Block ................................................................ 100

Cylinder Head and Valves .............................................. 102

Crankshaft 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 Water
Injected Exhaust Elbow ................................................. 118

Sea Water Pump ............................................................ 120

Fuel System .................................................................... 122

Back End - Transmission -
Mounting System ........................................................... 126

HBW Transmission
Shifting Bracket .............................................................. 130

Standard Alternator -
Oil manifold .................................................................... 132

Electrical Harness .......................................................... 134

Instrument Panel ............................................................ 136

Alternators and Compressor
Mounting System ........................................................... 138




                                        99                                  Westerbeke Diesel Engines
 +---17
 4--16
          15   14




100
                         ~ESTERBEKE   40A - CYLINDER BLOCK
REF      PN       NAME           REMARKS                         QUAN
  1 -1   030870   ENGINE         BLOCK & HEAD ASSEMBLY            1
  1-2    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   LOCK\.IASHER   5/16                             2
  9      012475   CAPSCREIJ      5/16NF X 1-3/8 FULLY THREADED    6
 10      031758   LOCKIJASHER    5/16                             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    5/16                             4
21       012473   CAPSCREIJ      5/16NF X 3/4                     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
30-1     012620   CAP            PLASTIC                          1
30-2     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      5/16NF X 3/4                     2
37       031760   NUT            5/16NF                           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




                                         24
              ~~      21
         ~20

                   --18         25
                                         1    2




                                                      11
         ~r-19




15 ---'ii!l

                                    28
14




                              102
                 \.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   3/8                               2
11     031628    CAPSCREW     3/8NF X 3/4                       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 SPRING-LOWER                8
20     012360    SEAT         VALVE SPRING-UPPER                8
21     012378    COTTER       VALVE-PAIR                        8
22     012682    INSERT       COMBUSTION CHAMBER                4
23     012542    WASHER       WELSH                             4
25     014445    NUT          HEAD-SHORT                        12
26     020005    NUT          HEAD-LONG                         6
27     014443    WASHER       HEAD STUDS                        18
28     031760    NUT          5/16NF                            4
29-1   031758    LOCKWASHER   5/16                              4
29-2   031759    WASHER       FLAT 5/16                         4
30     011653    GASKET       HEAD TO EXHAUST MANIFOLD          2
31     014810    STUD         EXHAUST MANIFOLD TO HEAD          4




                                        103
~~~~~______
       WESTERBEKE 40A -   CR              AND PISTONS
                               ANKSHAFT



              21




                   20
                          19




                                                   1




                    8




                               104
                  WESTERBEKE 40A - CRANKSHAFT AND PISTONS

REF      PN       NAME         REMARKS                          QUAN
  1      023105   CRANKSHAFT   ASSEMBLY                          1
  2-1    012343   BEARING      SET-CONNECTING   ROD STD          1
  2-2    012414   BEARING      SET-CONNECTING   ROD o . 01 0     1
  2-3    012423   BEARING      SET-CONNECTING   ROD 0.020        1
  2-4    012519   BEARING      SET-CONNECTING   ROD 0.030        1
 3-1     012342   BEARING      SET-MAIN STD                      1
 3-2     012349   BEARING      SET-MAIN 0.010                    1
  3-3    012370   BEARING      SET-MAIN 0.020                    1
 3-4     012373   BEARING      SET-MAIN 0.030                    1
  4-1    014707   WASHER       THRUST STD                        2
  4-2    019969   WASHER       THRUST 0.007                      AR
 5-1     012537   WASHER       THRUST STD                        1
 5-2     019968   WASHER       THRUST 0.007                      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
11-2     023526   PULLEY       OPTIONAL 6 IN 6 GR                1
11-3     016356   PULLEY       OPTIONAL 5 IN 4 GR & 4 IN 2 GR    1
11-4     012038   PULLEY       OPTIONAL 7 IN 2 GR                1
11-5     036428   PULLEY       OPTIONAL 6 IN 4 GR                1
11-6     012020   PULLEY       ACCESSORY 5 IN 2 GR               1
11 -7    012039   PULLEY       ACCESSORY 6 IN 2 GR               1
12       031752   LOCKWASHER   1/4                               4
13                CAPSCREW     1/4NF X 1-1/8 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




                                         105
                      ~ESTERBEKE   40A - TIMING SYSTEM AND CAMSHAFT

                  3




             l~                           1




 8


ab,    7
                                              :!s---12




I      9     10




     20 17   16


                                     23




                                                                      30 31




                                       22


                                               106
                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   5/16                             3
  8    012474    CAPSCREW     5/16NF X 7/8                     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   5/16                             10
 18    012474    CAPSCREW     5/16NF X 7/8                     9
 19    012493    STUD                                          1
 20    031760    NUT          5/16NF                           1
 21    012466    SEAL         TIMING COVER                     1
 22    012678    COVER        TIMING                           1
 23    031760    NUT          5/16NF                           4
 24    031758    LOCKWASHER   5/16                             4
 25    012471    CAPSCREW     1/4NF X 5/8                      4
 26    013536    STIFFENER                                     3
 27    031752    LOCKWASHER   1/4                              4
 28    031754    NUT          1/4NF                            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




                                        107
a




         <0


    <0

    !
              21
                   <0
              I
              !
                        <2
                        I
                        ,


                             <0
               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 5/16                       8
 12   012499   STUD        SHORT 3-5/8                     6
 13   012494   STUD        LONG 4-1/2                      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




                                     109
         WESTERBEKE 40A - INTAKE MANIFOLD




    12

1




               10




                         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
  5-1   022841     ADAPTER      MANIFOLD TO 7/8UNF                  1
  5-2   024881     PLUG         7/8UNF-WHEN HEATER NOT INSTALLED    1
  5-3   013392     BUSHING      7/8UNF TO 1/8NPT                    1
  6-1   011 688    START AID    ETHER TYPE                          1
  6-2   011615     PLUG         1/8NPT                              1
  7     031758     LOCKWASHER   5/16                                7
  8-1   031582     CAPSCREW     5/16NF X 1-1/2                      4
  8-2   031581     CAPSCREW     5/16NF X 1-1/4                      2
  9-1   012688     MANIFOLD     AIR INTAKE                          1
  9-2   019382     MANIFOLD     AIR INTAKE-ACCEPTS LUB-CEL          1
 10     031588     CAPSCREW     5/16NF 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




                                19
                                       a---   18

                                                   17




                                                        1




                                 112
                WESTERBEKE 40A - LUBE OIL SUMP AND OIL PUMP
REF    PN         NAME         REMARKS                        QUAN
  1    035304    SUMP          OIL                             1
  2    035305    PLUG          SUMP DRAIN 3/4-16UNF            1
  3    035306    WASHER        SUMP DRAIN PLUG                 1
  4    012473    CAPSCREW      5/16NF X 3/4                    8
  5    031758    LOCKIJASHER   5/16                            8
  6    012652    STIFFENER     SUMP SIDE                       8
  7    012547    STIFFENER                                     1
  8    031758    LOCKIJASHER   5/16                            8
  9    012474    CAPSCREIJ     5/16NF X 7/8                    8
 10    012407    GASKET                                        2
 11    012550    STIFFENER                                     1
 12    012659    GASKET SET    SUMP-LEFT 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     5/16NF X 3/4                    1
21     031758    LOCKIJASHER   5/16                            1
22     031759    IJASHER       FLAT 5/16                       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     5/16NF X 1-1/16                 1
28     019951    FERRULE       LUBE OIL DELIVERY LINE          2
2':1   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          BANJO-SUMP DRAIN                1
35     024922    BRACKET       SUMP DRAIN HOSE                 1
36     024905    CAP           SUMP DRAIN HOSE                 1




                                         113
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                        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       3/8NF X 2 SOCKET HEAD                     1
 10    031764    LOCKWASHER     3/8                                       2
 11    031922    CAPSCREW       3/8NF 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         1/2NPT 45 DEGREE STREET                    1
22     032230    NIPPLE        1/2NPT TO 7/8 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
28-1   013619    CAPSCREW      M 8 X 30 DIN 933                           2
28-2   031786    LOCKWASHER    M 8 DIN 127                                2
28-3   031787    WASHER        M 8 DIN 125                                2
29-1   036838    NIPPLE        3/4NPT TO 7/8 HOSE                         1
29-2   036622    NIPPLE        3/4NPT TO 1 HOSE                           1
30     021878    CLAMP         HOSE 20                                    2
31     024304    HOSE          MANIFOLD TO EXCHANGER                      1
32-1   031506    CAPSCREW      1/4NC X 1-1/4                              2
32-2   031752    LOCKWASHER    1/4                                        2
32-3   031753    WASHER        FLAT 1/4                                   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    O-RING                                                   2
39     022850    COVER         EXCHANGER END                              2
40     022852    CAPSCREW      3/8NC X 1/2 BRASS                          2




                                          115
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                         WESTERBEKE 40A - COOLING SYSTEM
REF     PN        NAME           REMARKS                                  QUAN
 41     036260    KIT            OIL COOLER EXCLUDING REF 15,33,34 & 36
 42     0344134   COOLER         LUBE OIL                                  1
 43     0351131   CLAMP          OIL COOLER MOUNT                          1
 44-1   031506    CAPSCREU       1/4NC X 1-1/4                             1
 44-2   031752    LOCKUASHER     1/4                                       1
 44-3   031753    UASHER         FLAT 1/4                                  1
 45-1   013334    CONNECTOR      INCLUDING NUT AND FERRULE                 4
 45-2   013333    FERRULE                                                  AR
 46-1   0316130   CAPSCREU       7/16NF X 1                                1
 46-2   031770    LOCKUASHER     7/16                                      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 TANK-INCHES REQD     30
 55     024906    CLAMP          HOSE                                      2
 56     0316131   CAPSCREU       7/16NF X 1-1/4                            2
 57     031770    LOCKUASHER     7/16                                      2




                                           117
WESTERBEKE 40A - FRESH WATER PUMP AND WATER INJECTED EXHAUST ELBOW




                                 118
 WESTERBEKE 40A - FRESH WATER PUMP AND WATER INJECTED EXHAUST ELBOW

REF      PN       NAME         REMARKS                                QUAN
  1 -1   020035   PUMP         FRESH WATER                             1
  1-2    019933   KIT          WATER PUMP REPAIR                       1
  2      031758   LOCKWASHER   5/15                                    4
  3      031584   CAPSCREW     5/15NF X 2                              2
  4      019987   PULLEY       FRESH WATER PUMP                        1
  5      031750   NUT          5/16NF                                  1
  5      031583   CAPSCREW     5/16NF X 1-3/4                          1
  7      035388   STUD         5/16NF X 2-1/8
  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
 14-1    030183   ELBOW        1/2NPT TO 7/8 HOSE                      1
 14-2    035616   ELBOW        1/2NPT TO 1 HOSE                        1
 15      035747   PLUG         1/2NPT                                  1




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                             120
                        WESTERBEKE 40A - SEA WATER PUMP
REF     PN       NAME           REMARKS                     QUAN
  1     011143   GASKET         SEA WATER PUMP MOUNTING      1
  2-1   016423   PUMP           SEA WATER                    1
  2-2   018169   HOUSING        SEA WATER PUMP BODY          1
  2-3   018172   KIT            PUMP MAJOR REPAIR            1
  3     018160   SCREW          BRASS-PUMP 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          BRASS-IMPELLER 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




                                          121
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                         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
  5-1   016443    PUMP          FUEL LIFT                                 1
  5-2   035125    KIT           FUEL LIFT PUMP REPAIR                     1
  6     034857    HOSE          FUEL RETURN                               1
  7     032974    FILTER        SEDIMENTER/WATER TRAP-OPTIONAL            1
  8     031756    NUT           5/16NC                                    4
  9     019509    FILTER        FUEL                                      1
 10               O-RING        FUEL FILTER-SEE REF 12                    1
 11               GASKET SET    FUEL FILTER-SEE REF 12                    1
 12     014776    ELEMENT       FUEL FILTER INCL REF 10-11                1
 13     011936    BANJO         FUEL RETURN                               1
 14     011944    WASHER        BANJO                                     2
 15     012351    BOLT          BANJO                                     1
 16-1   019505    PLUG          UNUSED FILTER PORT                        1
 16-2   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           5/16NF                                    2
30      031758    LOCKWASHER    5/16                                      3
31      031759    WASHER        FLAT 5/16                                 3
32      012497    STUD                                                    e
33      012561    CAPSCREW      5/16NF X 1-1/4 SOCKET HEAD FULL THREAD    1
34      019261    WASHER                                                  1
35      019204    SCREW         BLEED ASSEMBLY                            1
36      019370    PIVOT         FUEL SHUT-OFF LEVER                       1
37      014744    SHAFT         INJECTION PUMP DRIVE                      1
38      012402    GASKET        INJECTION PUMP MOUNT                      1
39      031323    CIRCLIP       HUB                                       1
40-1    031324    BEARING       ASSEMBLY                                  1
40-2    031322    BUSHING       HUB                                       1
41      020004    HUB           DRIVE                                     1
42      019989    GEAR          INJECTION PUMP DRIVE                      1
43-1    012614    SHAFT         SEA WATER PUMP DRIVE                      1
43-2    023764    SHAFT         SEA WATER PUMP DRIVE 0.001 OS             1
44      019944    BRACKET       STOP LEVER SPRING                         1
45      014674    SPRING        STOP LEVER                                1




                                          123
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                         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         INJECTOR-SHORT                          4
 55     012501    STUD         INJECTOR-LONG                           4
 56-1   019500    FERRULE      RUBBER-FUEL LINE                        2
 56-2   013343    FERRULE      BRASS-COMPRESSION                       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
 62-1   011014    STANDPIPE    WHEN OPTIONAL HEATER INSTALLED           1
 62-2   013755    BRACKET      RAISES STANDPIPE WHEN ALTNR IN UP RT POS 1
 63-1   023612    LINE         STANDPIPE TO HEATER                      1
 63-2   037394    LINE ASSY    STANDPIPE TO HEATER-BRACKET 013755       1
 64     011530    HEATER       MANIFOLD 12 VDC - OPTIONAL               1
 65     013345    ELBOW        1/8NPT MALE TO 3/16 COMPRESSION          1
 66-1   031583    CAPSCREW     5/16NF X 1-3/4                           2
 66-2   031758    LOCKWASHER   5/16                                     2
 67-1   013343    FERRULE      COMPRESSION 3/16                         2
 67-2   013344    NUT          COMPRESSION 3/16                         2
 68     013346    CONNECTOR    1/8NPT MALE TO 3/16 COMPRESSION          2
 69     016676    NUT          COMPRESSION 1/4                          2
 70     019501    FERRULE      FUEL LINE                                2
 71     011 934   FERRULE      FUEL LINE                                2
 72     031765    WASHER       FLAT 3/8                                 2
 73     031764    LOCKWASHER   3/8                                      2
 74     031630    CAPSCREW     3/8NF X 1                                2
 75     013344    NUT          COMPRESSION 3/16                         2
 76-1   023920    CLAMP        FUEL LINE                                4
 76-2             SCREW        10-32 X 7/8 RH                           2
 76-3             NUT          10-32 LOCKING                            2
 77     031760    NUT          5/16NF                                   8
 78     031578    CAPSCREW     5/16NF X 3/4                             3
 79     031758    LOCKWASHER   5/16                                     3
 80     031759    WASHER       FLAT 5/16                                3
 81     019442    WASHER                                                1




                                         125
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         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   7/16                                  5
  9        031630   CAPSCREW     7/16NF 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
 13-1      034502   FLYUHEEL     ASSEMBLY INCL RING GEAR-BALANCED      1
 13-2      030230   GEAR         RING                                  1
 14-1      034544   COOLER       HBU GEAR 7/8 HOSE                     1
 14-2      036648   COOLER       HBU GEAR 1 HOSE                       1
 15-1      030183   ELBOU        1/2NPT TO 7/8 HOSE                    1
 15-2      036614   ELBOU        3/4NPT TO 1 HOSE                      1
 lEi-l     017196   CAPSCREU     M 8 X 20 DIN 933                      4
16-2       031786   LOCKUASHER   M 8 DIN 127                           4
17         031789   UASHER       Ml0 DIN 125                           1
18         015887   NUT          Ml0 DIN 934                           2
19-1       020650   CAPSCREU     M 8 X 18 DIN 933 HBU150               6
19-2       013629   CAPSCREW     Ml0 X 25 DIN 933 HBU V-DRIVE          6
20-1       031786   LOCKUASHER   M 8 DIN 127 HBU150                    6
20-2       031790   LOCKUASHER   Ml0 DIN 137B HBU V-DRIVE              6
21         024778   CAPSCREU     DAMPER TO FLYUHEEL                    5
22-1       031267   ADAPTER      HBU150 TO HOUSING                     1
22-2       030063   ADAPTER      HBU V-DRIVE TO .HOUSING               1
23-1       031248   HBU GEAR     MODEL 150 1.6 TO 1                    1
23-2       024631   HBU GEAR     MODEL 150 1.9 TO 1                    1
23-3       030049   HBU GEAR     MODEL 150 2.6 TO 1                    1
24         024950   NUT          Ml0 X 1.25 DIN 934                    4
25         019262   LOCKUASHER   Ml0 DIN 127                           4
26         031228   CAPSCREU     Ml0 X 1.25 X 30 DIN 961               4
27-1       023679   COUPLING     BORE 0.75                             1
27-2       023680   COUPLING     BORE 0.875                            1
27-3       023681   COUPLING     BORE 1.0                              1
27-4       023682   COUPLING     BORE 1. 125                           1
27-5       023683   COUPLING     BORE 1.25                             1
27-6       023684   COUPLING     BORE 1.375                            1
27-7       023685   COUPLING     BORE 1.5                              1
28-1       023450   SETSCREU     COUPLING 7/16NC X 1                   2
28-2       023651   SETSCREU     COUPLING 3/8NC X 3/4                  2
28-3       023652   SETSCREU     COUPLING 3/8NC X 1                    2




                                           127
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                         31
       ~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
31-1     023706     COUPLING       V-DRIVE BORE 0.75                    1
31-2     023707     COUPLING       V-DRIVE BORE 0.875                   1
31-3     023708     COUPLING       V-DRIVE BORE 1.0                     1
31-4     023709     COUPLING       V-DRIVE BORE 1.125                   1
31-5     023710     COUPLING       V-DRIVE BORE 1.25                    1
31-6     023711     COUPLING       V-DRIVE BORE 1.375                   1
31-7     023712     COUPLING       V-DRIVE BORE 1.5                     1
32-1     031249     HB~ GEAR       V-DRIVE 1.8 TO 1                     1
32-2     030048     HB~ GEAR       V-DRIVE 2.1 TO 1                     1
32-3     031250     HBIoI GEAR     V-DRIVE 3 TO 1                       1
33-1     013629     CAPSCREIoI     Ml0 X 25 DIN 933 HBIoI150            6
33-2     034589     CAPSCREIoI     Ml0 X 30 DIN 933 HBIoI V-DRIVE       6
34       019262     LOCKIoIASHER   Ml0 DIN 127                          6
35       019039     DO~EL          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        FLY~HEEL                             1
40       031928     CAPSCREIoI.   .7/16NF X 1 GRADE 8                   5
41       034504     MOUNT :!;L;dv1 REAR                                 2
42-1     036341     ISOLATOR        INCLUDING LOCKING NUTS              4
42-2     036334     ISOLATOR        INCLUDING LOCKING NUTS-1oI40NA      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     7/16NF X 1-1/4                       4
47       031770     LOCKIoIASHER 7/16                                   4
48-1     013132     MOUNT          FRONT LEFT                           1
48-2     013133     MOUNT          FRONT RIGHT                          1
49       013919     DOIolEL        HOUSING TO BACKPLATE                 2
50-1     019059     HOSE           7/8 ID-INCHES REQUIRED               24
50-2     011 779    HOSE            lID-INCHES REQUIRED                 24
51-1     011386     CLAMP          HOSE 12                              2
51-2     011405     CLAMP          HOSE 16                              2




                                             129
WESTERBEKE 40A - HBW TRANSMISSION SHIFTING BRACKET




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                          130
           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          10-32                              2
  6   031849     LOCKWASHER   10                                 2
  7   013870     SHIM         CABLE CLAMP                        1
  8   013325     CLAMP        CABLE                              1
  9   031873     SCREW        10-32 X 5/8                        2
 10   033482     BALL JOINT                                      1
 11   031752     LOCKWASHER   1/4                                1
 12   031754     NUT          1/4NF                              1
 13   032161     BRACKET      SHIFT CABLE - REAR ENTRY           1




                                        131
     WESTERBEKE 40A - STANDARD ALTERNATOR - OIL MANIFOLD




                                     12




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                                                       7




                                                           20




                         21




                                   132
             WESTERBEKE 40A - STANDARD ALTERNATOR - OIL MANIFOLD
REF     PN         NAME        REMARKS                             QUAN
  1     031709    CAPSCREW     1/2NC X 2                            1
  2     031776    LOCKWASHER   1/2                                  1
  3     024684    ALTERNATOR   51 AMP 12 VDC                        1
  4-1   031555    CAPSCREW     5/16NC X 1                           1
  4-2   031758    LOCKWASHER   5/16                                 1
  4-3   033381    WASHER       ADJUSTING STRAP                      1
  6     011969    MANIFOLD     OIL-TO MOUNT SWITCHES                1
  7     011615    PLUG         1/8NPT                               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
21-1    033935    SW ITCH      OIL PRESSURE-ALARM-12 PIN HARNESS    1
21-2    034761    SWITCH       OIL PRESSURE-ALARM-8 PIN HARNESS     1
22-1    031631    CAPSCREW     3/8NF X 1-1/4                        2
22-2    031764    LOCKWASHER   3/8                                  2
23      024152    SPACER       THROTTLE CABLE CLAMP                 1




                                         133
WESTERBEKE 40A - ELECTRICAL HARNESS




                                      6




                            7




                 134
                   WESTERBEKE 40A - ELECTRICAL HARNESS
REF     PN       NAME         REMARKS                        QUAN
  1     024639   SOLENOID     PREHEAT                         1
  3     031678   CAPSCREW     7/16NF X 3/4                    2
  4     031770   LOCKWASHER   7/16                            2
  5     024683   BREAKER      CIRCUIT 20 AMP                  1
  6     035772   BRACKET      CIRCUIT BREAKER AND SOLENOID    1
  7     020005   NUT          PILLAR                          2
  8-1   036079   HARNESS      8 PIN                           1
  8-2   036602   HARNESS      12 PIN                          1
  9     030125   SW ITCH      WATER TEMPERATURE-ALARM         1
 10     035109   SENDER       WATER TEMPERATURE               1
 11     032119   BUSHING      REDUCER 1/2NPT TO 1/8NPT        2
 12     013355   BUZZER       ALARM                           1




                                        135
    WESTERBEKE 40A -    INSTRUMENT PANEL




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                       136
                     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      LAMP-IJEDGE BASE                 AR
  5     035114    LAMP        INSTRUMENT-WEDGE 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 6-32               1
 11     033684    COVER       FACEPLATE                        1
 12     030002    SPACER      NYLON                            1
 13     024996    WINDOW      KEYSIJ ITCH COVER                1
 14     030001    SCREW       NYLON 6-32 X 1/2 IJASHER HEAD    1
 15     035111    VOLTMETER   12 VDC                           1
 16     033682    DECAL       SWITCH IDENTIFICATION            1
 17     030148    CABLE       PANEL TO ENGINE                  1
 18-1   033764    SIJITCH     PUSH BUTTON START-PREHEAT        2
 18-2   019031    CAP         SWITCH COVER REPLACEMENT         AR
 19     011917    METER       TACHOMETER-HOUR                  1
 20     036630    DRAWING     TEMPLATE TO INSTALL PANEL        1




                                        137
WESTERBEKE W40NA - ALTERNATORS AND COMPRESSOR MOUNTING SYSTEM




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                               138
      WESTERBEKE W40NA - ALTERNATORS AND COMPRESSOR MOUNTING SYSTEM
REF      PN       NAME         REMARKS                                QUAN
  1      031719   CAPSCREW     1/2NC X 4-1/2                           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   1/2                                     2
  7      031774   NUT          1/2NC                                   1
  8      036427   BRACKET      ALTERNATOR                              1
  9      031553   CAPSCREW     5/16NC    X 3/4                         2
 10      031758   LOCKWASHER   5/16                                    2
 11      033381   WASHER       ADJUSTING STRAP                         2
12       033064   STRAP        ADJUSTING                               2
13       031764   LOCKWASHER   3/8                                     2
14       031633   CAPSCREW     3/8NF X 1-3/4                           1
15       031632   CAPSCREW     3/8NF X 1-1/2                           1
16       036452   BRACKET      COMPRESSOR                              1
17       033537   CAPSCREw     3/8NC    X 1-1/8                        4
18       031765   WASHER       FLAT 3/8                                4
19       031764   LOCKWASHER   3/8                                     4
20       031762   NUT          3/8NC                                   4
21       036413   BRACKET      COMPRESSOR                              1
22       031553   CAPSCREW     5/16NC    X   3/4                       2
23                CAPSCREW     5/16NF                                  2
24       031758   LOCKWASHER   5/16                                    2
25       031274   CAPSCREW     3/8NC    X 2 FULLY THREADED             1
26       033361   BELT         ALTERNATOR AND FRESH WATER PUMP         2
27       036428   PULLEY       4 GROOVE                                1
28       031752   LOCKWASHER   1/4                                     4
29                CAPS CREW    114NF X 1-118                           4
30       031559   CAPSCREW     5/16NC X 2                              1
31       031758   LOCKWASHER   5/16                                    1
32       031759   WASHER       FLAT 5/16                               1
33       012225   PULLEY       FRESH WATER PUMP 2 GROOVE               1
34       031758   LOCKWASHER   5/16                                    2
35       031756   NUT          5/16NC                                  2
36       036426   BRACKET      ALTERNATOR                              1
37       031554   CAPSCREW     5/16NC    X   7/8                       1
38       033713   SPACER                                               1
39       031713   CAPSCREW     1/2NC    X3                             1
40       031108   SPACER                                               1
41       036457   BELT         COMPRESSOR-MUST BE MATCHED PAIR         2
42       037248   DIAGRAM      WIRING                                  1




                                         139
                    ~ESTERBEKE   40A - MISCELLANEOUS

REF     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       SEDIMENTER/IJATER 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 EXHAUST-STAINLESS STEEL 12 LONG 1
 13-1   034936   MUFFLER      HYDRO-HUSH C (UNIVERSAL MOUNT)           1
 13-2   033340   CONNECTOR    HOSE-STRAIGHT 1-7/8                      AR
 13-3   033341   CONNECTOR    HOSE 45 DEGREE 1-7/8                     AR
 13-4   033342   CONNECTOR    HOSE 90 DEGREE 1-7/8                     AR
 13-5   036680   ADAPTER      1-7/8 TO 2 HOSE                          AR
 13-6   033943   KIT          HOSE COUPLING AND CLAMPS                 1
 14     033327   VALVE        ANTI-SIPHON                              1




                                        140


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The information on this web site has not been checked for accuracy. It is for entertainment purposes only and should be independently verified before using for any other reason. There are five sources. 1) Documents and manuals from a variety of sources. These have not been checked for accuracy and in many cases have not even been read by anyone associated with 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.