Wednesday, April26, 2017 L-36.com

Westerbeke Diesel 108c Six Parts Manual




NOTE: DO NOT HIT REFRESH!!! These files are big and can take a long time to load. This file is 2.51 MB. Give it time.
If there is text in the file, you can scroll it while the image loads. Enjoy

View PDF

Image Preview



Ad by Google

PDF to Text

OPERATORS MANUAL
WESTERBEKE 12B TWO
MARINE DIESEL
ENGINE
Publication 37185
Edition One
January WESJERBEKE
WESTERBEKE CORPORATION
AVON INDUSTRIAL PARK AVON MA 02322 TEL 617 5887700
SAFETY following symbols appear in this manual to call attention Use Extreme Care When Handling Engine Fuel
to and emphasize conditions potentially dangerous to the A constant danger of explosion or fire
Do not fill fuel tanks while the engine is running
IWARNING Do not smoke or use an open flame near the engine or the
fuel tank
The above symbol is used in the manual to warn of personal injury or loss of life
Do Not Alter or Modify the Fllel System
Be sure all fuel supplies have a positive shutoff valve
CAUTION
Be certain fuel line fittings are adequately tightened and
The above symbol is used in the manual to caution personnel free of leaks
of possible damage to equipment
Make sure a 1ire extinguisher is installed nearby and is
Read the manual carefully and thoroughly before attempting properly maintained Be familiar with its proper use Ex
to operate the equipment Know when dangerous conditions tinguishers rated ABC by the NFPA are appropriate for all
can exist and take necessary precautions to protect personnel applications encountered in this exhaust gases batteries electrical
equipment and
moving and hot parts are potential hazards that could result in Use Extreme Care When Servicing personal injury or death Follow recommended
proce
dures carefully Wear rubber gloves a rubber apron and eye protection
when servicing operate bHge blowers for at least five minutes engine ensure no gasoline fumes are Lead acid batteries emit hydrogen a 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
Prevent 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 Ayoid Moving Ea1l
ment
Do 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 or bracelets that might be caught in
Do not connect utility shore power to vessels AC circuits moving parts
except through a shipAoshore doublethrow transfer
switch Damage to vessels AC generator may result if this Make sure all attaching hardware is properly tightened
is not done Keep protective shields and guards in their respective
place at all times
Be extremely careful when working on electrical com
ponents High voltage can cause injury or death Do not check fluid levels or the drivebelts tension while
the unit is operating
Do not work on the equipment when mentally or physical
Exhaust Gases Are Toxic ly incapacitated by fatigue
Ensure that the exhaust system is adequate to expel gases
discharged from the engine Check exhaust system
regularly for leaks and make sure the exhaust manifolds
are securely attached and no warping exists
Be sure the unit and its surroundings are IMPORTANT
PRODUCT SOFTWARE software of all kinds such as brochures drawings technical data operators and workshop lists and parts price lists and other
related information instructions and provided from
sources other than Westerbeke is no within Westerbekes control and accordingly is provided to Wester
beke customers only as a courtesy and service WESTERBEKE CANNOT BE RESPONSIBLE FOR THE CON
TENT OF SUCH SOFTWARE MAKES NO WARRANTIES OR WITH INCLUDING THE ACCURACY TIMELINESS OR COMPLETENESS THEREOF AND WILL IN NO
EVENT BE LIABLE FOR ANY TYPE OF DAMAGES OR INJURY INCURRED IN CONNECTION WITH OR
ARISING OUT OF THE FURNISHING OR USE OF SUCH example components and subassemblies incorporated into Westerbekes products and supplied by
others such as engine blocks fuel systems and components electrical components pumps
and other products are generally supported by their manufacturers with their own software and depend on such software for the design 01 Westerbekes
own product software Such may be outdated and no longer accurate Routine changes made by Westerbekes suppliers of
which Westerbeke rarely has notice in advance are frequently not reflected in the suppliers software until
after such changes take customers should also keep in mind the lime span between printings of Westerbeke and the unavoidable existence of earlier
noncurrent Westerbeke software editions in the field most Westerbeke products include special features that frequently do not in
clude complete summation product software provided with Westerbeke products whether from Westerbeke or other sup
pliers must not and cannot be relied upon exclusively as the definitive authority on the respective product
It not only makes good sense but is imperative that appropriate of Westerbeke or the sup
plier in question be consulted to determine the accuracy and currency of the product software being con
sulted by the 1 Weslerbeke Diesel Engines
you for selecting a Westerbeke marine product for your use We at Westerbeke are pleased to have
you as a this manual carefully and observe all safety precautions included throughout Operating preventive maintenance procedures installation
checks system descriptions and minor adjust
ment procedures are included herein so you can operate your equipment safely and properly maintain the
equipment at a high level of efficiency and expect dependable performance and long service life in your unit require special attention contact your
Westerbeke dealer for assistance The Organization is trained to provide the support necessary to ensure longterm dependable within 60 days of
submitting the Warranty Registration Form for your unit you have not received a Cus
tomer Card see below registering your warranty please contact the factory in writing with
Model information including the engines serial number and commission date
from WESlER8EKE CORPORA liON
AVON INDUSTRIAL PARK
AVON A 02322
fiITI WESTERBEKE
CUSTOMER Adall Smith
85 Maple Street
Mail To Alden 1M 12234
Model N 12 TWO Set 1234706
EJCpiree 7788
Inspection of engine is shipped from the factory mounted securely and properly crated Accessory equipment is
shipped in a separate small box usually packed within the engines accepting shipment of the engine from the company the crate should be opened and
the contents inspected for concealed damage If either visible or concealed damage is noted you that the delivery agent sign Received in damaged
condition on the proper delivery receipt Also
check the contents of the shipment against the packing list and make sure that the proper notation is made
if any discrepancies exist These noted discrepancies are your protection against loss or damage loss or damage must be made to the carrier not to the
Westerbeke Diesel Engines 2
TABLE OF 12B TWO MARINE DIESEL 7
W 12B TWO SYSTEM CHECKS FOR STARTING OF INSTRUMENT PANELS 23
STARTING PROCEDURE 26
STOPPING PROCEDURE 28
FUEL SYSTEM SySTEM 33
DC WIRING DIAGRAM 36467 SHOWING
THE CAPTAINS PANEL WIRING 34 35
DC WIRING DIAGRAM 36844 SHOWING
THE ADMIRALS PANEL WIRING 36 37
COOLING SySTEM 39
LUBRICATION SYSTEM 47
HBW 50 TRANSMISSION 50
BW 3 TRANSMISSION 54
ENGINE 57
MAINTENANCE ADJUSTMENTS 60
LAYUP 67
TABLE OF STANDARD HARDWARE
TIGHTENING TORQUES 71
TORQUE 72
SPARE PARTS 73
INDEX 74
3 Westerbeke Diesel Engines
manual contains the equipment operating procedures as well as additional information needed to help
the operator keep the equipment in proper working order Study and follow the instructions carefully A
planned maintenance program is included in this manual adhering to the program will result in better equip
ment performance and longer equipment life Proper diagnosis of a problem is the most important step repair therefore a table is the Diesel Engine
The diesel engine closely resembles the gasoline engine since the mechanism is essentially the same The
cylinders are arranged above a closed crankcase the crankshaft is of the same general type as that of a
gasoline engine and the diesel engine has the same type of valves camshaft pistons connecting rods to a great extent a diesel engine requires the
same preventive maintenance as a gasoline engine
The most impOltant factors are proper ventilation and proper maintenance of the luel lubricating and cool
ing systems Replacement of fuel and iubricating filter elements at the time periods specified is a must and
frequent checking for contamination that is water sediment or allege in the luel system is also important factor is the use of the same brand of high
detelgent diesel lubricating oil designed lor diesel engines Be careful not to put gasoline in the diesel fuel tanks Gasoline does not have the
same lubricating qualities as diesel fuel consequently gasoline in the fuel lines will damage components in
the fuel lift pump assembly fuel injection pump and diesel engine does differ from the gasoline engine however in its handling and firing of fuel The
buretor and ignition systems are done away with and in their place are two components the fuel and the fuel Paris
When contacting your Westerbeke dealer parts distributor or the factory concerning your Westerbeke unit
always provide the engines model and serial number and transmission number as they appear on the black
and silver Westerbeke plate which is mounted on the engines exhaust manrrold When ordering parts for
your Westerbeke engine be sure to insist upon Westerbeke factory packaged parts because will fit or
generic parts are frequently not made to the same as original that component locations in the rnanual are referenced from the front of the engine
which is the belt end The end is the rear end Left and right sides are determined by
the engine imagine straddling the engine and facing in the same direction as the front of the engine the left
side is at your left the right side is your engines and generator sets are thoroughly checked and given a final run under various before leaving the
factory Test running the engine ensure dependable operation long service
and a satisfied owner
Care at the factory during assembly and thorough testing have resulted in a Westerbeke diesel of many thousands of hours of dependable service
However the manufacturer cannot control the
treatment the unit receives in the field That part is up to the Diesel Engines 4
W 12B TWO Marine Diesel Engine
Exhaust Manifold Fresh Water Fill Cap Fuel Injection Pump
Fresh Water
gOO Exhaust Exchanger
Lever
Zinc Anode
Shutoff
Lever
Gear Shift
Lever Oil Pressure
Sender
Fuel Lift Pump
Oil Pressure Swi Lube Oil Drain Hose
Lube Oil Dipstick
5 Weserbeke Diesel Engines
W 12B TWO Marine Diesel Water Fill Cap Lube Oil Fill Amp DC Circuit Breaker
Pretlet Water
Air Bleed 0
gOO Exhaust Elbow
eat Exchanger
Sea Water
Pump
Gear Dipstick
Oil Filler
DC Charging
BW Marine Gear
Lube Oil Drain with Sol DC Battery Ground Connection Adjustable Engine
Isolator
Westerbeke Diesel Engines 6
W 1213 TWO MARINE DIESEL ENGINE
GENERAL Type Diesel lourcycle twocylinder fresh water cooled
vertical inline 12 hp at 3600 rpm Mechanical centrifugal weight type
Valve Mechanism Chamber Swirl chamber type
Bore Stroke 256 x 268 inches 65 x 68 mm
Piston Displacement 2752 cubic inches 045 Order of Rotation Clockwise when
viewed from the Torque at 2700 rpm 19 Ibft 283 Ratio 251
Compression Pressure 455 psi 32 kgcm at 320 rpm
Valve Seat Angle Intake 450
Exhaust 450
Valve Clearance Intake 00098 inches 025 mm
engine cold Exhaust 00098 inches 025 Height 1957 inches 49707 mm
Width 1775 inches 45085 mm
Length 2490 inches 63246 Continuous 140
Temporary 25 0 not to exceed 30 min
Dry Weight 205 Ibs 929 kgs
Fuel Consumption 03 US gph 114 Iph running at
2500 rpm 7 Westerbeke Diesel Engines
W 12B TWO SYSTEM SYSTEM Open flow totally Fuel No2 diesel oil cetana
rating of 45 or higher
I njection Pump Nippondenso Bosch M type
I njection Timing 25 OS BTDC Static
Nozzle Throttle type
I njection Starting Pressure 22752 psi 160 kgcm
Lift Pump 12Volt DC lift capacity 6 ft 18 m
Fuel Filter on engine Canister type with replaceable element
Air Cleaner Metal screen type cleanable
Air Flow engine combustion 270cfm SYSTEM
General Fresh water cooled block
with sea water exchanger system
Operating Temperature 170 190 F 77 88 C
Fresh Water Pump Centrifugal type metal impeller beltdriven
Sea Water Pump Positive displacement rubber impeller beltdriven
Sea Water Flow at 3600 rpm gpm Ipm approximate
measured before discharging
into exhaust elbow
System Capacity fresh water 40 qts 378 SYSTEM
General Forced lubrication by gear pump
Oil Filter Paper element spinon type
Sump Capacity includes filter 327 US qls 31 Diesel Engines 8
W 128 TWO SYSTEM Operating Oil Pressure 35 55 psi 246 386 kglcm2
Oil Grade API specification CC or SYSTEM
Starting Battery 12Volt 35 AH negative ground
recommended 45 AH cold areas
Battery Capacity 90 125 Starting Aid 12Volt sheathed type glow plug
Starter Motor 12Volt 12KW solenoid actuated shift
DC NoLoad Current 60 Amps at 115 Volts 6500 rpm min
Cold Cranking Current 209 Amps at 12 Volts
Alternator 12Volt DC 35 Amps
Regulator Internal regulator built into alternator
144 Volts DC 3 HBW50
Standard Gear Ratio 21
Optional Gear Ratio 251
Direction of Rotation Right handed standard Lubrication Fluid Automatic Transmission Fluid ATF
Type A or Dexron II
Sump Capacity 032 US qts 03 liters approximate
Standard Gear Ratio 2471
Direction of Rotation Right handed standard Lubricating Oil Grade API specification of CC or CD
SAE Grade SAE 20 or SAE 30 exclusively
Sump Capacity 037 US qts 035 liters 9 Westerbeke Diesel
Engines
INSTALLATION the crafts in which Westerbeke engines are installed vary in design installation procedures will to your crafts specific design It is
not the intent of this section to advise boatyards or installers
on procedures and However it is important that the there are details of the installation which require periodic checks to ensure the best operating
condi
tions for the equipment and safe operating conditions for the personnel on board Proper location and of the diesel engine in the vessel are of prime
in the installation that must be considered are ventilation to aid in cooling and to provide air for en
gine combustion exhaust system to property discharge raw cooling water quiet the exhaust and expel ex
haust gas cooling water supply fuel supply and electrical CAUTION
For safety reasons the engine and transmission are NOT filled with lubricating oil for ship
ment Before leaving the factory however each engine with transmission is thoroughly tested
with oil in it This testing among other things provides all internal parts with a coating of oil
This oil acts as a preservative providing reliable protection against corrosion for at least one
year if the engine and transmission are property location should be such that it is dry and away from being splashed by bilge water or water from
above
The engine should be properly ventilated and accessible for minor servicing and repairs access for major
repairs should be given consideration as well The location must be property ventilated to provide fresh air
for engine combustion The engines lubrication oil sump dipstick the fresh water and oil fills and dipstick and transmission or oil fill port must be
riLL CAP
COOLANT
RECOVERY COCKPIT
TANK
MOUN11NC
STIlAI
CABIN
INSTALLATION ANGLE
MUST HOT EXCEED 14
Please note that the engines installation angle cannot exceed 14 from the horizontal Diesel Engines 10
Rigging lind lilting
The engine is fitted wh lifting eyes Rope or chain slings capable of supporting the engines weight should
be attached to the eyes and the engine lifted by means of tackle attached to these slings The lifting eyes
have been designed to carry the full weight of the engine therefore auxiliary slings are not required or desired
CAUTION
Slings must not be so short as to place signijicant sheer stress on the engines lifting eyes
Strain placed on the engines lifting eyes by the lifting sling must not be in excess of 10 from
the vertical plain
SLING LIFTING
HCLE MUST NOT
EXCEEO 10
LIFTING
ENGINE
The general rule in moving engines is to see that all of the equipment used is amply strong and firmly fixed
in place Move the engine a little at a time and see that IT is firmly supported Eliminate the possibility of ac
cidents by avoiding haste Do nollift the engine by its 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
lain situations exist by which the engine must be lowered endwise through a small hatchway which cannot
be made larger Under these conditions if the opening of the hatchway is extremely narrow tt is possible
to reduce to some extent the outside dimensions of the engine by removing external components such as
the alternator the cooling systems piping the heat exchanger certain filters the mounting lugs and equipment This accessory equipment should be
removed by a competent mechanic and spe
cial care should be taken to avoid damaging any exposed parts In addition be careful not to allow dirt from
entering any opening created by the removal of equipment Parts removed should be returned to their respec
tive position as soon as the engine has cleared the hatchway
In case it becomes necessary to hoist the engine either frontend upwards or upwards of slings must be done carefully to avoid the possibility of
damaging the parts on which the weight
may bear Special rigging work is best done by someone experienced and competent in handling 11
Westerbeke Diesel Bolts
Bronze or stainless steel hanger bolts of appropriate size are recommended for use through the mounts Less preferred are lag screws because their
hold on the wood is weakened every time they
are moved whereas the hanger bolts stay in position If the nut on top of the hanger bolt is removed to allow
the engine to be lifted from its resting place the hanger bolt itself remains in place as a stud the bond between the hanger bolt and the wood is not
weakened by the removal of the nut or the for the Engine
A good engine bed contributes much toward the satisfactory operation of the engine The engines bed
must be rigidly constructed and neither deflect nor twist when it is subjected to the engines weight or to the
pressures that the boat may experience while operating in rough seas The bed must keep the within one or two thousandths of an inch of this position
at all times The bed has to withstand
the forward push of the propeller shaft which pushes against the thrust washer bearing which finally the engines bolts and bed
In fiberglass hulls we recommend that similar wooden stringers as in wooden hulls be formed fitted and
then glassed securely to the hull This allows the hanger bolts to be installed firmly in the wood noise and transmitted engine support stringers
must be as wide or wider than the engine mounting isolator Isolator rounded stringer surfaces are detrimental to the isolators ability to retain
fiberglass engine beds when used should be of sufficient thickness to properly support the en
gine and should be wellglassed to the hull temptation to install the engine on a pair of
fiberglass angle irons must be resisted will allow engine vibration to pass GOOD
through to the hull Flexible mounts require a against which they must act if they are
to perform their function When possible follow
bed design A and avoid bed design B refer to
the A
Supports between the bed stringers and extend
ing from the stringers to the hull may be required
for proper support and to aid in the absorption BAD
Note Avoid excessive height use
solid stringer construction Al
Westerbeke Diesel Engines 12
Propeller Coupling
The propeller shaft coupling fitted to the output flange must transmit not only the power of the
engine to turn the propeller shaft and propeller but must also transmit the thrust of the ahead or astern
The coupling bore should be carefully machined for a slight forced fit onto the shaft and an accurate for the coupling to the output flange of the
all engine models a propeller bored to shaft size for the specific order is supplied The
coupling either has a keyway with set screws or is of the clamping type
The fOlWard end of the propeller shaft has a long straight keyway Any burrs should be removed from the
shafts end The coupling should be a light drive fit on the shaft and the shaft should not have to be scraped
down or filed in order to get a fit It is important that the key be properly fitted both to the shaft and to the
coupling The key should fit the side of the keyway closely but should not touch the top of the keyway in
the hub of the coupling
If driving the coupling over the shaft is difficult the coupling can be expanded by heating it in a pail of boil
ing water The face of the propeller coupling must be exactly perpendicular to the centerline or axis of the
propeller type and size of propeller varies with the gear ratio and must be selected to fit the application based
upon boat tests To utilize the full power of the engine and to achieve ideal loading conditions use a will permit the engine to reach its full rated
RPM at full throttle while under a normal load and while it
is moving the boat fOlWard through the water See pages 53 and of the Engine
The engine must be exactly aligned with the propeller shaft in the proper fashion No matter what material
is used to build a boat the material will be found to be flexible to some extent hence the boats hull will
change its shape to a greater extent than is usually realized when the boat is launched and operated in the
water Therefore it becomes extremely important to check the engines alignment at frequent intervals and
to correct any errors when they between the engine and the propeller shaft often creates serious problems which are often
blamed on other areas suspected of causing the trouble Misalignment will cause excessive bearing wear
rapid shaft wear and will in many cases reduce the life of the boats hull by loosening the hulls fastenings
A bent propeller shaft will have the exact effect as those just stated therefore a pertectly straight is absolutely necessary One particularly
annoying result of misalignment may be leakage of oil through the rear oil seal If oil is leaking from this seal check and make sure that alignment
is within the limits prescribed on page 14
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 pertorm the propeller is with the fuel and water tanks about half full and all the usual
equipment on board and after the
main mast has been stepped and the final rigging has been 13 Westerbeke
Diesel Engines
Take plenty of time in making this alignment and do
not be satisfied with anything less than perfect results
The alignment is correct when the shaft can be easily 333 FEELER GAGE
slipped backward and forward into the when a feeler gauge indicates thaI the flanges
come together at all points The alignment between PROPELLER SHAFT
the propeller shaft coupling and the engines coupling
can contain an error no greater than one thousandth
of an inch per inch of the coupling diameter For ex
ample if your propeller shaft coupling is three inches
in diameter the maximum error thaI can be allowed in
the alignment is three thousandths of an inch making the final check for alignment the
engines half coupling should be held in one
position and the alignment with the tested with the propeller coupling in
each offour positions A while rotaled 90 be0
tween each position This test will also propellers halfcoupling is in on its shaft Then keeping the
propeller coupling in one position the align
ment should be checked by rotating the
engines halfcoupling in 90 0 dimension A while in each 90 until the halfcoupling has been rotated lull
circle
The engines alignment should be the boat has been in service lor one 10
three weeks and If necessary perform the
alignment again Usually it will be found that
the engine is no longer in alignment This does
not mean Ihat the work has been done im
properly at first rather it means Iha the boat
has taken some time to take its final shape and
that the engines bed and stringers have
probably absorbed some moisture It may
even be necessary to realign the coupling hal
ves again at a later Diesel Engines 14
Exhaust System
The exhaust system provides an outlet line to vent engine exhaust gases out of and away from the vessel
The system also discharges sea water which has passed through the engines sea water circuit by mixing it
with hot exhalJst 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 circuits thruhull discharge port If not prevented sea water entering through the dis
charge port can lill the exhaust system muffler and enter the engines 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 antiSiphon break should be installed when needed at the top of
this loop The top of the loop should be placed high enough above the vessels water line so as to remain
above the water line when the vessel is underway no matter what the angle of heel or roll may be
12 mEn
ENCINE INSTALLATIONS WITH EXHAUST MINIMUM OF 6
INCHES ABOVE VESSELWATER LINE
2 10
ID m
ENGINE INSTALLATIONS WITH EXHAUST MANI
FOLDWATER INJECTED ELBOW AT OR BELOW
VESSEL WATER LINE
The sea water supply thruhull sea cock fittings must be of the flushhull type Highspeed scoop type of fit
tings 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 thruhull discharge This routing will prevent sea water entry if the thruhull discharge fitting becomes
submerged when the vessel heels or rolls while under way or is subjected to following sea conditions Refer
to the figures shown above lor recommended exhaust system 15 Weslerbeke
Diesel exhaust discharge hose must be of adequate size and
minimal run to prevent excessive exhaust backpressure should be checked before a gener
ator is put into service Refer to the will affect the engines measure for 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 backpressure at the exhaust elbow when the en

gine is running at 3600 rpm as measured by n Exhaust
a manometer a pressure gauge or water column should not
be over the following Mercury
Manometer
NOTE Other pressure gauges may be available to test
for exhaust Check with a competent
to the pressure below
A water column can be made by taking a clear plastic tube
and taping one end of the tube along a yardstick and fitting
the other end of the tube with a 14 inch NPT National Pipe
Tap pipe backpressure at the exhaust elbow when the en
gine is running at 3600 A cannot exceed 39 inches of water
Back pressure as measured by a gauge instrument should
not exceed the following 3 inches of mercury 0104 kgcm 2
39 inches of water in a water column
099 kgcm2 at 40 C
22 ounces psi
1 12 psi
Excessive backpressure can be caused by a small diameter exhaust hose a small muffler sharp bends in
the exhaust hose improper fittings water pockets and a high volume of water in the exhaust system due
to the length of the exhaust discharge hose The use of elbows and fittings in the exhaust discharge hoses
routing should be limited since these will create flow restrictions and contribute to exhaust The generators exhaust system must be separate from any
other engines exhaust system Dry portions of
the exhaust system between the engines exhaust manifold and the water injected exhaust elbow must be
insulated to hold in the heat
Westerbeke Diesel Engines 16
Exhaust System the engines sea water is fed into an exhaust system so that the full stream of this water strikes a sur
face erosion takes place This erosion may cause premature failures The proper design of either a or water injected Wet exhaust system to prevent this
problem requires that the sea water inlet be
positioned so that the entering stream of sea water does not directly strike a surface In addition the velocity
of the entering sea water stream should be as low as possible which can be achieved by having inlet fittings
as big in diameter as best protection against exhaust system leaks is to routinely inspect the complete exhaust system Check
for leaks around manifolds gaskets and welds Make sure exhaust lines are not heating surrounding If excessive heat is present correct the situation
immediately If you notice a change in the
sound or appearance of the exhaust system inspect the exhaust system and correct the risers installed off the exhaust manifold should not exceed 8
Ibs in total weight when rigidly con
nected Excessive weight and vibration can result in a manifold failure andor the fracturing of the riser from
the manifold at Its 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 within 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 Carbon
monoxide is a dangerous gas that can cause and is potentially lethal Some
of the symptoms or signs of carbon monoxide inhalation or poisoning are as follows
o Dizziness o Vomiting
o I ntense Headache o Muscular Twitching
o Weakness and Sleepiness o Throbbing in Temples
If you experience any of the above symptoms get out into fresh air sure there are no unnecessary objects suspended from any portion of the exhaust
lines could cause deflection or distortion of the lines resulting in damage or leaks Inspect insulated por
tions of the exhaust system to ensure there is no deterioration of the Drain
An oil sump drain hose is installed on the engine with the discharge end secured by a bracket at the front of
the engine Oil may be drained from this hose by removing the cap and the discharge end of the hose from
the support bracket and lowering the hose into a container The hose cap fitting is 14 inch NPT Tap and can be extended or have a pump added for
easier removal of the old oil if desired
17 Westerbeke Diesel Pressure Sensing Devices 10 Oil pressure sensing devices such as senders and switches must not be
connected to an engines oil gal
lery with the use of extended nipples or tees The reason is simply that continued engine vibration of the fittings used to make such a connection If
these fittings fail the engine loses its oil pressure
and quickly seizes
When additional sensing devices such as switches or sensors need to be installed that function on these devices must be and connected to the oil
gallery using an of lubricatirig 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 System
The engine is fresh water cooled by an heat exchanger Sea water is used as the cooling medium Sea water is pumped into the exchanger by a sea water
pump where it cools
the fresh water that circulates through the engine block and is then injected into the exhaust discharge car
rying with it the heat removed from the engines fresh water cooling system
Sea water should be supplied to the sea water pump through a flushtype hull fitting using a between the thruhull fitting and the sea water pump The
sea water should be directed through a
visualtype sea water strainer which will trap debris before it reaches the sea water pump and the heat ex
changer and then be delivered to the pump Hoses routed from the thruhull fitting to the strainer and to
the sea water pump should be to prevent the hose from collapsing while the engine is run
ning suction from the pump may collapse a hose The sea water strainer should be mounted
at or below the water line to make sure the sea water line remains primed
CAUTION
DO NOT use a scooptype thruhull fitting as a means of supplying sea water to the engine
Water pressure against this type of fitting while the vessel is under sail can push sea water
past the sea water pumps impeller into the engines exhaust system filling it and the engine
as well Flushtype clear thruhull fittings are recommended and should be located on the
hull so as to be below the waterline during all angles of boat operation
The use of commontype street elbows is not recommended for plumbing the sea water cir
cuit These generally have very restrictive inside diameters Machine fittings are Alarm System
High Water Temperature Alarm
A high water temperature alarm has been supplied with the instrument panel If the engines fresh water
coolant reaches 205 F 96 C a switch located at the engines thermostat housing area will close sound
ing this alarm which will emIT a continuous signal Refer to the DESCRIPTION OF INSTRUMENT of this manual for the location of the alarm in your engine
panel page 23
Westerbeke Diesel Engines 18
Low Oil Pressure Alarm
A low oil pressure alarm switch is located off the engines oil gallery This switch monitors the engines oil
pressure Should the engines oil pressure fall to 10 15 psi the switch will close sounding this same alarm
In this event the alarm will emit a pulsating signal Refer to the DESCRIPTION OF INSTRUMENT of this manual for the location of the alarm in your
engine panel page 23
Sea Water Intake System
Make sure the intake system sea water cooling system is in proper order Check that the hull inlet sea
cock and strainer are unobstructed Sea cocks and strainers should be at least one size greater than the
inlet thread of the sea water pump The strainer should be of the type that may be withdrawn for the vessel is at sea and should be mounted below the
water line to ensure selfpriming Inspect the
sea water lines to ensure there are no collapsed sections which would restrict water flow Make sure there
are no air leaks at any of the System
The fuel system should be installed in such a manner as to allow the fuel lift pump to main
tain a positive inlet pressure to the injection pump under all operating conditions The minimum size of the
fuel supply line and fuel return line is 14 inch inside diameter and there should be a primary fuel filter in
stalled between the fuel tank and the fuel lift pump Only one fuel filter is installed on the engine between
the mechanical fuel lift pump and the injection pump this filter has a replaceable filter element
The fuel tanks fuel pickup tube should be clear and unobstructed No screens or gauze strainers should in the fuel pickup tube
Make sure that the fuel supply and return lines are securely anchored to prevent chafing and that all fittings
are sufficiently tightened to prevent leaking Also make sure your fuel system has a positive shutoff valve
know its location and how it operates
NOTE DO NOT use springloaded check valves in the fuel supply line in lieu of mechanical
shutoff valves
The fuel return at the tank should extend down into the tank in the same manner as a pickup tube This prac
tice is particularly important in installations where fuel tanks are below the engines fuel that the fuel tank filler is properly sealed to prevent
water entry should it become awash The fuel
tanks vent should be routed so as to prevent water entry as well
Be sure there is a fire extinguisher installed near the unit and that it is properly maintained Be familiar with
its use An extinguisher with the NFPA rating of ABC is appropriate for all applications in this System
The electrical system should be checked to ensure that all wiring harnesses are tied down properly with
clamps or plastic ties spaced at intervals close enough to prevent chafing from vibration Check to ensure
that all the engines harness connections are tight and that they are made to the appropriate HI
Westerbeke Diesel Engines
IWARNINGI
Do not smoke or allow an open flame near batteries Lead acid batteries emit hydrogen a
gas Turn oft the emergency switch in the posive line of sure the posive battery connection is connected to the battery connection of the starting
solenoid
The negative battery connection should be connected to the system ground the engine block
IWARNINGI
When servicing the battery or checking the electrolyte level wear rubber gloves a rubber
apron and eye protection Battery acid may splash on the skin or into the eyes inadvertent
ly when removing electrolyte caps
Check level and specic gravtty 01 battery electrolyte to ensure maximum engine starting efficiency Make
sure terminals are clean and ventilation requirements of the engine include the following combustion air is required for the and ventilating air is
required to clear the bilges below the engine as well as the compartment in
which the engine is located of potentially toxic and flammable diesel fumes Refer to the of this manual for the W 12B engines airflow requirements
page 8
Westerbeke Diesel Engines 20
PREPARATION FOR section of the manual provides the operator with preparation initial starting breakin starting cold or
warm and stopping procedures Follow the procedures as presented for the conditions indicated and
your Westerbeke engine set will give you reliable performance and long service life
Fill your engine with oil up to or near the upper limit on
the dipstick the installation angle may have an effect on
the dipstick reading Select readily available lubricat
ing oil with an API specification of CC or CD and an SAE
number suitable for the temperature in your see page 47 For the quantity of oil needed in this UPPER LIMIT
engine refer to the SYSTEM section IEORMAL LEVEL
of this manual page 8 LOWER LIMIT
Fill the transmission to the FULL mark on the dipstick
with the correct lubricant Refer to the section of this manual page 9
Each unit is supplied with a coolant recovery kit
24977 as standard equipment to which the A Remove the pressure cap from the engines exhaust manifold and slowly fill the engines cooling sys
tem wtth a mixture of water and antifreeze suitable for your temperature zone See the COOLING SyS
TEM section of this manual page 39 Operate the engine and observe the coolant level in the manifold
Maintain this level 10 the base of the filler neck Once the engine reaches its operating temperature 170
1900 F ensure that there is coolant flow to the domestic water heaters when installed Top off the
cooling system and install the pressure cap
B Make sure the plastic recovery tank is property mounted near the untt with the bracket provided in a
location where it can be monitored and filled easily The recovery tank should be mounted at manifold
level or above In these installations that require it the plastic recovery tank can be mounted below the
exhaust manifolds level
C Add coolant to the plastic tank aiter the engine has been started and operating temperature has been
reached to ensure that all air is expelled from the manHold and the engines cooling system With the
manifold filled and the pressure cap installed fill the plastic recovery tank half full Monitor daily and
add coolant as needed
Fill the fuel tank with a good grade of NO2 diesel fuel and prime the fuel system up to the engine see page
31 When returning fuel is free of air the engines fuel system is bled and the engine is ready to start
NOTE When the PREHEAT swch is depressed the glow plugs in the cylinder head are ener
gized use the PREHEAT switch to prevent overheating the glow that the Installation Checks have been made in accordance with those specified in the
CHECKS section of this manual refer to page 10
21 Westerbeke Diesel of Starting diesel engines use electric starters assisted by glow plugs for both normal and cold The
figure below shows a view of one cylinder The glow plug is located in the com
bustion chamber so that its tip is in the injector nozzles spray path When the glow plug is energized by the
PREHEAT button the plug glows red at the tip and assists in igniting the fuel The result is a rapid start with
less wear on the system is common to Westerbeke Diesels The start circuitry is designed so that the PREHEAT button
must be depressed for the time specified in the Preheat chart shown on page 26 Then while keeping the
PREHEAT button engaged the START button is depressed to crank the engine
GLOW PLUG
Combustion Chamber
NOTE The START button will not energize unless the PREHEAT button is depressed When
depressing the preheat switch we are activating the glow plugs in the cylinder head so use
the preheat so as not to overheat the glow Diesel Engines 22
DESCRIPTION OF INSTRUMENT offers two types of control panels as optional equipment for the W 12B engine Read the follow
ing instructions that apply to the panel you purchased with your engine
Captains control panel is equipped with a key switch an RPM gauge a PREHEAT and START
button and an instrument test button along wtth a low oil pressurehigh water temperature alarm The RPM
gauge is illuminated when the key switch is turned ON and remains illuminated While the engine is in opera
tion The key switch and the three buttons serve the following functions
1 Key Switch The Key Switch provides power only to the instrument panel cluster Refer to the STOP
PING PROCEDURE section of this manual page 28
2 PREHEAT The PREHEAT button activates the alternators regulator the engines glow plugs and bypas
ses the engines oil pressure alarm switch In addition this button energizes the START button
3 START The START button when pressed energizes the starters solenoid which cranks the engine
This button will not operate electrically unless the PREHEAT button is pressed and held at the 81me
time
4 Test Button The Test Button located above the key switch tests the alternator the oil pressure and
the water temperature control circuits When this button is pressed the alternator the oil pssure and
the water temperature indicator lights illuminate in addition to sounding the alarm
23 Westerbeke Diesel Engines
56Iarm The alarm is located above the lest button and will sound if the engines oil pressure falls below
15 psi In this event the alarm will emil apulsating signal The alarm will also sound if the water tempera
ture in the fresh water cooling circuit rises to 210 F In this event the alarm will emit continuous sig
Admirals control panel is equipped with a key switch and an RPM gauge with an ELAPSED
TIME meter which measures the engines running time in HOURS and in 110 hours The panel also includes
a water temperature gauge which indicates water temperature in degrees Fahrenheit WATER F an oil
pressure gauge which measures the engines oil pressure in pounds per square inch OIL PSI and a DC
control circuit voltage gauge which measures the systems voltage VOLTS All gauges are illuminated when
the key switch is turned ON and remain illuminated while the engine is in operation The panel also contains
two rubberbooted push buttons one for PREHEAT and one for START
1 Key Switch The Key Switch provides power only to the instrument cluster Refer to the STOPPING
PROCEDURE section of this manual page 28
2 PREHEAT The PREHEAT button activates the alternators exciter the engines glow plugs and bypas
ses the engines protective oil pressure switch In addition this button is energizes the START button
3 SI8BI The START button when pressed energizes the starters solenoid which cranks the engine
This button will not operate electrically unless the PREHEAT button is pressed and held at the same
Diesel Engines 24
NOTE An alarm buzzer is supplied with every Admiral Panel The installer is responsible connecting the buzzer to the fourpin connection on the engines
electrical har
ness The installer is also responsible for installing the buzzer in a dry location so that it will
be audible to the operator should it sound while the engine is running The buzzer will sound
when the ignition key is turned ON and should silence when the engine has started and when
the engines oil pressure rises above 15 psi
25 Westerbeke Diesel Engines
STARTING 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 key switch to the ON position 2 oclock
3 Depress and hold the PREHEAT switch Preheat according to the following chart
Atmospheric Temperature Preheating Time
410 F 5 0 C or higher Approx 10 sec
410 F 50 C to 230 F 50 C Approx 20 sec
23 0 F 50 C or lower Approx 30 sec
Limit of continuous use 1 glow plug function is indicated by a voltmeter drop
when the PREHEAT switch is depressed This drop will be
slight but discernible If no voltage drop is noted it may in
dicate defective glow plugs or a faulty preheat circuit check
for loose holding the PREHEAT button depressed 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 Check your for
proper engine operation Ensure sea water discharge with
exhaust 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 Never run
the starter motor for more than 30 seconds at a time
CAUTION
Prolonged cranking intervals without the engine starting can result in filling the engine
mounted exhaust system with sea water coolant This may happen because the sea
water pump is pumping sea water through the sea water cooling system during crank
ing This sea water can enter the engines cylinders by way of the exhaust manifold
once the exhaust system fills Prevent this from happening by closing the sea water
supply thruhull shutoff drain the exhaust muffler and correct the cause for the exces
sive engine cranking needed to obtain a start Engine damage resulting from this type
of sea water entry is not a warrantable issue the should keep this in
Diesel Engines 26
Once the engine starts run it at idle for a few minutes to warm up the engine and check instruments for
proper oil pressure and battery charging voltage Never attempt to engage the starter while the engine is
running
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
27 Westerbeke Diesel Engines
STOPPING PROCEDURES
A manual pull type stop control tee handle or knob is provided by the installer in a location close to the
engines controls Know the location of this control before attempting to start the engine To stop the en
gine pull out on this tee handle or knob fully and hold it out until the engine comes to a complete stop Push
back on this control to return it to the engine run position otherwise the engine will not the engine stopped turn the key switch to the OFF position
12 oclock If the key switch is left ON
the battery will discharge The alarm buzzer will sound in the Admirals Panel but not in the Captains Panel
should the key switch be left ON The best method of preventing the battery from discharge is to remove
the key from the key switch after stopping the engine
CAUTION
DO NOT attempt to shutdown the engine by turning the key switch OFF The key switch only
provides power to the instrument panel the engine will continue running even if the key switch
is turned OFF
An optional key shutoff package is available however This option allows the operator to shutoff the en
gine by turning the key switch OFF which turns OFF an electrically run Fuel Run Solenoid This option is installed at the factory upon the specific
requestorder of the BreakIn your engine has experienced a minimum of one hour of test operations to ensure accurate as
sembly and proper operation of all systems breakin time is required The service life of your engine is de
pendent upon how the engine is operated and serviced during its initial hours of use
Your new engine requires approximately 50 hours of initial conditioning operation to break in each moving
part in order to maximize the performance and service life of the engine Perform this conditioning careful
ly keeping in mind the following
1 Start the engine according to the STARTING PROCEDURE section found on page 26 run the engine
at fast idle while checking that all systems sea water pump oil pressure battery charging are function
2 Allow the engine to warm up preferably by running at fast idle until the water temperature gauge moves
into the 1301400 F range
3 While using the vessel run the engine at varying engine speeds for the first 25 hours
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
6 During the neX1 25 hours the engine may be operated at varying engine speeds with short runs at full
rated speed Avoid idling the engine for prolonged periods of Diesel Engines a new engine basically involves seating the
piston rings to the cylinder walls This cannot be by long periods of running at Idle nor by early running at full speed
Idle running may glaze the cylinder walls resulting in excessive oil consumption and smoky operation Ex
cessive speed or heavy overloading especially with a cold engine may cause scoring of the cylinder similar results
As indicated above operate the engine in moderation during the 50hour breakin period On one hand
dont baby the engine but on the other hand however dont abuse Under Normal the procedure below for normal starting of the engine
1 Check the engine and transmission lubricant levels and fill if necessary
2 Make sure there is sufficient fuel on board Keep fuel tanks as full as possible Check the fuel filters
and water separators for the presence of contaminants andor water Drain and clean them as needed
3 Check the coolant level in the plastic recovery tank Add coolant solution as needed
NOTE Excessive loss of coolant from the plastic recovery tank indicates a cooling system
leak Check the entire cooling system and 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 section of this manual page 21
4 Check for oil and fuel leaks particularly if signs of such leaks are found on the bottom of the engine or
below the the engine in accordance with the STARTING PROCEDURE instructions found on page 26 and allow
the engines operating temperature to reach 140 150 F before operating the engine Under Cold extremely cold temperatures the following conditions
can occur Follow the instructions listed below
when operating your engine in cold OIL TURNS VISCOUS Make certain that the lubricating oil used conforms with the ratings
for the prevailing atmospheric temperature Refer to the LUBRICATION SYSTEM section of this manual
page 47 for an viscosity specification ACROSS THE BATIERY TERMINALS DROPS Make certain that the battery is fully charged to
minimize voltage drop across the battery TEMPERATURE OF THE INTAKE AIR IS LOW AND THE COMPRESSION TEMPERATURE DOES NOT
RISE ENOUGH Allow the glow plugs to operate sufficiently to aid in starting during the preheat period when
ever the temperature of the intake air is low and when the compression temperature does not rise enough
Refer to the preheat chart found in the STARTING PROCEDURE section page 26
29 Westerbeke Diesel Engines
FUEL Fuel
Use No2 diesel fuel with a cetane rating of 45 Never use kerosene or home heating oil
In cold weather particularly water vapor is produced by condensation when air is present in the fuel tank
Keep fuel tanks full and completely free of dirt and water
Fuel Filters
A primary fuel filter of the type must be installed be
tween the fuel tank and the engine
INSTALLATION a filter shown here is available 1 aotT SECURl TO
HOSE FITTING
A ACCESSIBLE SIRUtlURE SO your local Westerbeke repre 111M R RECHTICLE TU cueH DAIMAH
tAM BE PUUD UWOR IT
sentative or your boatbuilder This fil
ter adapted for boatbuilder use 2 IF FUEL IS TO BE PIPED VITH COPPER
O BUMn IURlM USE NUIS MD complete with fittings for PROVUED BE URE TH TUBING PROJECts
14 ntH THROUGH UE FEAQULE BHORE
either hose or metal tubing Mount it TIHTEMIMG THE MUT
in an accessible place inspect it often
and drain off water accumulation fre
Irrjm 3 IF FUEL 15 TO BE PIPEO nlW HOS USE
THE TWO UAGS BIIRBEO fIlTIH5 AND WASHERS
BUPPtIU BE CERUU IHAI THE HOSE SELECHD
quently HAS UONAL BRUO INSERTED ITO ClIliS 011 U
8ARB TlIU IT 15 NEOPRENE LIMED lIND THIIT
IT IS n PPRDUED
If a water trap type filter is not installed
If VAIn IS PIIESENT 1M IH FUEL IT ULt
between the fuel lank and the engine COLLECT SlBWLY U THE BOTTOI Of THE
mounted fuel system any water in the 5EnINEMIER WilE THE REI FLOAT RIMG
REACMES THE RAtM LIME OM 111 PLum
fuel system will tend to lay in the bot Bon LOOStN THE BOllOM CRAIN PLUS
ALL WAIU RUMS DUI
NTlL
tom of the electric lift pump Internal
5 TIGHTEN DRUN PLUS ECUUtv SO MO AIR cw
metal parts of the lift pump will rust NTH THE will pass on to filters and
6 EMERG12E THE run PUIIP TO UrILl to the injection pump and BOWL
injectors with damaging results and
the possibility of expensive water damage to the fuel
system is not covered under warranty
In addition any gasoline in the fuel system will damage the engines fuel lift pump assembly as gasoline
does not have the same lubricating qualities as diesel fuel as well as have a damaging effect on the injec
tion pump and the most boatbuilders supply a water trapfilter some do not Westerbeke offers a as an optional extra at moderate cost The filter is
supplied with fittings for etther hose or metal
tubing fuel Diesel Engines 30
Priming the Fuel System
The Westerbeke selfbleeding fuel system is semiautomatic in operation The selfbleeding feature of the fuel
system allows for easy servicing of the fuel filters Simply remove the and replace the filter elements take
care in catching any fuel that may drain out of the fuel filtering assemblies as described in the Fuel Filter Elements section below Energize the
PREHEAT switch and allow the electric fuel pump to
operate for 20 to 30 seconds to prime and bleed air from the system No fittings should be opened Then
proceed to start the engine as you normally would II the engine does not start stop and wait a few mo
ments and then repeat the bleed procedure as indicated above When the PREHEAT switch is preheat elements the glow plugs are energized so take care
not to over heat them
CAUTION
Prolonged cranking intervals without the engine starting can result in filling the engine
mounted exhaust system with sea water coolant This may happen because the sea
water pump is pumping sea water through the sea water cooling system during crank
ing This sea water can enter the engines cylinders by way of the exhaust manifold
once the exhaust system fills Prevent this from happening by closing the sea water
supply thruhull shutoff drain the exhaust muffler and correct the cause for the exces
sive engine cranking needed to obtain a start Engine damage resulting from this type
of sea water entry is not a warrantable issue the should keep this in
the Fuel Filter it is unlikely that the operator will be forced to ser
vice the system at sea the possibility does exist There
fore it is recommended that banjo washers injector
seat washers electric lift pump filter and gasket fuel fil
ter and gasket be carried on board at all times Select
the parts for your engine from the Parts List and pur
chase spares from your local Westerbeke Dealer or For example hardware kit 33093 elements with gaskets items 9 11 26
27 28 If a leak should develop at a fuel banjo or seal
ing washer location that cannot be remedied by a of the filter cup retainer replace the filter
along with the Orings supplied with the new the first 50 hours of operation loosen ring 30 and
discard filter element 28 Clean bowl 29 and install
a new filter using new 27 and 28 gaskets Be careful in catching any fuel that may spill from within these
fuel filter assemblies This same service is required of the 9 filter element in the electric fuel lift install a new 9 filter element along with a
new 11 gasket The base of the electric fuel pump is
removed with the aid of an open end wrench Twist the base off the pumps locking tabs and reinstall the
base by twisting it back on the locking tabs Place the wrench on the hex nut cast into the base
NOTE DO NOT overtighten the filter cup retainer excessive tightening can strip the soft
aluminum threads on the fuel filter the first 50hour change the change period may be increased to 200 hours or once per season
31 Westerbeke Diesel Engines
Fuel Injection Pump
The illustration shown below is an exploded view of the W 128 TWOs fuel system The fuel injection pump
located at the lower righthand corner is one of the most important components of the diesel engine call s for the utmost caution in handling
Furthermore the fuel injection pump has been thorough
ly benchtested and should not be tampered with
Idle speed and timing adjustment are the only adjustments the servicing dealer can perform on the Other types of adjustments or repairs must be
performed by a qualified injection service shop
FUfl
SUPPLY
W 128 TWOs Fuel System
To obtain long and satisfactory service from the injection pump always use fuel which is free from maintain a good filtration and water separation
system between the fuel tank and generator engine Ser
vice this system regularly the injection pump it saves may be your own
Westerbeke Diesel Engines 32
ELECTRICAL 12Volt DC Control Circuit
The Westerbeke W 128 TWO propulsion engine has a 12Volt DC electrical control circuit as shown on the
wiring diagrams which follow on pages 34 to 37 Refer to these diagrams when or servic
ing electrical components on the engine
CAUTION
To avoid damage to the battery charging circuit never shut off the engine battery switch while
the engine is running
Shut off the engine battery switch however to avoid electrical shorts when working on the en
gine electrical minimum recommended capacity of the battery used in the engines 12Volt DC control circuit is 90
125 Amperehours minimum
CAUTION
When the battery with an external charger be sure to disconnect the battery
cables from the battery Leaving the charging circutt connected while will
damage the alternators CAUTION
When testing the alternator circuit charging cirCUIT do not use a highvoltage tester such as
a rnegger damaged diodes could result
During highspeed operation of the engine do not disconnect the positive terminal of the bat
tery from the B terminal of the alternator nor disconnect the negative terminal of the battery
from the ground
When cleaning the engine wtth a steam cleaner be careful to keep steam away from the aller
to pages 34 to 37 for the two electrical system wiring schematics one is used for the Captains panel
and the other for the Admirals Panel
33 Westerbeke Diesel Engines
DC Wiring Diagram 36467 Showing the Captains Panel Wiring
page 1 of 2
WRIV DItRAM bALTENn
0 c
GIOWPlUGS
Vi ATE
r
Tf p
50NOfR 1
0
OfJO
L W
A pEcJ
I
Il leur I
PEET
SCcUIIt
y BLU
RL 7 PRESSlJRE
ITCH
e 1
RL Vt j
TT1 uSD 50Ht OOE
I Il FUEL
I 1
LlIWoo OOLJ
BREAKE
CllICUoT 1 I
2l I I
JIL 1
PESSURE
SENDER
OPO
0000 C
TARTE
BLOC
bee NEUTRAL
SAFETY 5WTC
PUMP
I u
0 OC
a J lj
IE I
o I
il ii
fi 52 C I
CAPTAIN
PANEL
E I
I I
Diesel Engines 34
DC Wiring Diagram 36467 Showing the Captains Panel Wiring
page 2 012
r 2VOC SCHEMATIC DIAGRAM 0
CLOIJPUlGS II
1 j
STAT LTURN Ev TO ON POSITION THE ALARt WIn SOUND Olt PRESSURE AC
8ATTEIIf CHAGE INDICATORS WilL LlGH
2PUS PREHEAT SW11CH FOP 15 Tv GO SECONDS AS REOUIRD AlARN IL STot
VJHILE CONTiNUING TC PUSH PREKEAT SITCHPUSI THE START s ncl LSC
WHEN nlE ENGINE STARTS RELEASE THE START SIoIITC ONLY
wllI THE OIL PRESSURE INDICATO lAIoP GOES OUT RELEASE T E
PRrIAT NOTES
THIS PROOUC 15 PlIOTECTEO By A MANUAL SET CIRCUIT BREAKP lOChTt Nt
THE CURRl DAAIN WILL CAUSE BREhKE 10 TRoll AND T E
ENGINE WILL SHUT OOIoN flE MuseE SUIlE TT TNt INSTlUMET
AN ENGINE ARE IN5TAllEC it PRElENT COrTAC ETWEEII DElICES AND 2AN OOFf SWITCH SOUlD BE INSTALLED BET EEr THE
ElAnE AC 5TAE C
DISCONNECT THE SAnERV IrI All EERGENC ArlO HEN lEAlJlNG TI1E eOtT t S ITe
WIT A CONTiNUOUS ATNG OF 17 APS r
1210C WILL SERvE iHIS FUNCTtOr nns
5o1 1 TCH SHOULD NOT BE USEI TO MAKE 0R BREAI THE 35
Westerbeke Diesel Engines
DC Wiring Diagram 36844 Showing the Admirals Panel Wiring
page 1 of 2
ALTERNATOR
WIRING DIAGRAM
G 35 A 40 A 50 A
Eii 0
GLOW PLUGS
123 ORe SENDER SWITCH
I
DfPNDIN
NUMIlER OF
r gj
OuNERS
I 14LTBLUE I 1
PREHEAT
SOLENOID
Wi
I i
i ij p til
SWITCH I
I I I
2YRED 1 1
I
USED ON SOME MODELS 1 I Ii
I 111 j7i1
FUEL SOLENOID
I OIL
I i I
I PRESSURE I
i I I
SENDER i
STARTER
CCuT
I BREAKER
Ii II
ir I
i 1
NEUTRAL I I
p
GROUND TO
ENGINE BLOCK If SAFETY SWITCH
USED ON SOME
MODELS
BATIERY
12 VDC
1
z tol
I il
S21 C 01
Pl s Ii
P2C c
1 i I
ii i i i
Go J F
GH GV
c H
I e ADMIRAL
PANEL
k IC 1
THOMETER
START PREHEAT
KEy SWITCH ISWITCH SWITCH
VOLTMETER
Westerbeke Diesel Engines 36
DC Wiring Diagram 36844 Showing the Admirals Panel Wiring
page 2 of 2
SCHEMATIC DIAGRAM
12 VOLT DC
START
r SOL STARTER
t I t f II
PREEAT SOlI GLQWPLUGS
i
I 0ALT
i I
liCB iCB i
L10A
i lIFTPUMP
1 I I FU SOL
I I I L
OP DP SNDR
GSW 0
WT SNDR
I A
NOTE
1 THIS PRODUCT IS PROTECTED BY A MANUAL RESET CIRCUIT BREAKER LOCATED NEAR THE
STARTER EXCESSIVE CURRENT DRAIN WilL CAUSE THE BREAKER TO TRIP AND THE ENGINE
Will SHUT DOWN THE BUILDEROWNER MUST BE SURE THAT THE INSTRUMENT PANEL
WIRING AND ENGINE ARE INSTALLED TO PREVENT CONTACT BETWEEN ELECTRICAL
DEVICES AND SALTWATER
2 AN ONOFF SWITCH SHOULD BE INSTALLED BETWEEN THE BATTERY AND STARTER TO DIS
CONNECT THE BATTERY IN AN EMERGENCY AND WHEN LEAVING THE BOAT A SWITCH WITH
A CONTINUOUS RATING OF 175 AMPS AT 12 VOLTS DC WILL SERVE THIS FUNCTION THIS
SWITCH SHOULD NOT BE USED TO MAKE OR BREAK THE CIRCUIT
3 THE GRAY WIRE AT PLUG 2 IS UNUSED AND SHOULD BE 37 Westerbeke
Diesel Engines
The charging system consists of an alternator with an internal voltage regulator an a battery and connecting of the use of ICs integrated circuits
the electronic voltage regulator is very compact and is built
into the rear bracket of the Voltage Test
If you suspect that the alternator is not producing enough voltage to charge the engines battery perform
the following voltage test
ALTERNATOR
35 A 40 R 50 AJ
for Charging Voltage Test
1 Using a voltmeter connect the voltmeters red wire clip to the B output terminal on the alternator Refer
to the schematic shown above
2 Connect the other wire clip to a ground on the engine
3 Start the engine and increase the engines speed to 2000 rpm Now record the reading given by the
voltage reading for a properly operating alternator should be between 135 to 145 volts If your alter
nator is over or under charging have it replaced or rebuilt by a reliable service shop
Note Before removing the alternator for repair ensure that 12Volts excitation is present at
the R terminal should the above test show only battery voltage at the B output Westerbeke Diesel Engines 38
COOLING marine diesel engines are designed and equipped for fresh water cooling Heat produced in the
engine by combustion and friction is transferred to fresh water which circulates throughout the engine fresh water cools the engine block and its
internal moving parts The heat is transferred external
ly from the fresh water to sea water by means of a heat exchanger similar in function to an 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 itis 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 circuits are independent of each other
Using only fresh water within the engine allows the cooling water passages to stay clean and free from harm
ful deposits The two independent circuits and their components are discussed in the following 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 sys
Fresh water is pumped through the engine by a beltdriven Circulating pump absorbing heat from the en
gine The fresh water coolant circulates through the engines block absorbing heat then passes through 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 fresh water flow is prevented by the closed
thermostat although some fresh water flow is the thermostat to prevent exhaust manifold from overheating As the engine warms up the thermo
stat gradually opens allowing full flow of the engines fresh water coolant to flow unrestricted to the of the cooling system
A Fresh Water Coolant Antifreeze Mixture
It is recommended that a freshwater and antifreeze mixture be used yearround Water when it freezes ex
pands sufficiently to split the heat exchanger and crack the engine block A mixture of will prevent freezing see page 40 for an mixture chart
Use soft water with few impurities such as tap water potable water or rainwater Never use hard or foul
water Use of hard water or water containing impurities will lead to the collection of scale in the engine and
heat exchanger which will reduce the cooling systems 01 poor quality or without rust inhibitors will cause corrosion within the cooling system Always
use antifreeze which is compatible with aluminum cooling system components and is made by a Never mix different brands 01 sure that the cooling
system of the engine is well cleaned before adding antifreeze Recommended an
tifreeze for year round use is ZEREX or PRESTONE with rust order to control the concentration of the mixture mix the antifreeze and freshwater
thoroughly before ad
ding it to the cooling system
39 Weslerbeke Diesel Engines
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 It is advisable that an antifreeze concentration be selected on the basis of a tempera
ture which Is about 10 F 5 C lower than the actual atmospheric temperature expected
B Filling the Fresh Water System
A coolant recovery tank kit is supplied with each Westerbeke diesel engine The purpose of this recovery
tank is to allow for engine coolant expansion and contraction during engine operation Without the loss of
coolant and without introducing air into the cooling system
This coolant recovery tank should be installed at or above engine manifold level in a location where it can
be easily monitored and where coolant can be easily added if needed see the figure below A mounting bracket is supplied with each ktt along with a
3Dinch length of clear plastic hose and clamps
to connect the hose between the engines manifold fitting to the hose spud on the base of the recovery tank
FUNCTION OF MANIFOLD PRESSURE CAP
From Coolant Tenk COOLANT to Coolant Tank COOLANT from the engine when heated during engine operation will
expand lifting the springloaded cap and enter the recovery tank by way of the hose connecting the recovery tank to the the engine is shut down and
cools a small check valve in the pressure cap is opened by the contrac
tion of the engine coolant allowing some of the coolant in the recovery tank to be drawn back into the
engines cooling system free of air and without Diesel Engines 40
COOLANT RECOVERY TANI
PIESSUAE CAP
UANIFOLD
Ji I
I
Coolant Recovery Tank Recommended the fresh water system as follows
1 Remove the pressure cap from the manifold
2 Pour a clean antifreeze mixture into the manifold and allow enough time for the coolant to fill the fresh
water cooling system
3 Start the engine and allow it to come up to its operating temperature Monitor the coolant in the manifold
and add antifreeze coolant as air is expelled Once all air is expelled from the system fill the manifold to
the filler neck and install the pressure cap
4 Remove the plastic cap from the plastic coolant recovery tank and fill the tank with coolant halfway be
tween the ADD mark and the MAX mark Replace the plastic cap
5 Run the engine and observe the coolants expansion flow into the plastic recovery tank
6 Check for leaks between the pressure capfiller neck and then plastic recovery tank Stop the engine and
allow it to cool Coolant should be drawn back into the cooling system as the engines temperature comes
down
7 Add coolant to the recovery tank as required to top off the fresh water coolant thermostats are of two types One is simply a choking device which
opens and closes as the
engines temperature rises and falls The second type has a bypass mechanism Usually this is a disc on
the bottom olthe thermostat which moves downward to close off an internal bypass passage within the head
Since 1980 each type of thermostat has a hole punched through it The hole is a bypass to prevent the ex
haust manifold from overheating during the engines warmup Replacement thermostats must have this
design 41 Westerbeke Diesel Engines
Sea Water Circuil
The sea water flow is created by a belt
driven positive displacement neoprene im
peller pump The pump draws sea from the ocean through the sea cock
and sea water strainer and passes the water
to the heat exchangers sea water inlet The
sea water passes through the tubes from which heat from the
fresh water system is absorbed and then the
sea water is discharged from the cooling sys
tem overboard through the exhaust system
CL EAN
NEW OR
AHODE REPLACE REPLACE REPLACE
Zinc Anode Conditions
A zinc anode or pencil is located in the sea water cooling circuit within the heat exchanger The purpose
of the zinc anode is to sacrifice itself to electrolysis action taking place in the sea water cooling circuit there
by 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 car
ried on board
Sea Water Pump
The sea water pump is a sellpriming beltdriven rotary pump with a nonferrous housing and a The impeller has flexible vanes which wipe against a
curved cam plate within the impeller the pumping action On no account should this pump be run dry There should always be a
spare impeller and impeller cover gasket aboard an impeller kit Sea water failures occur when water is not present Such failures are not warrantable
and the operators are cautioned to ensure that
sea water flow is present at and Water Pump Drive Belt Tension
IWARNINGI
Never attempt to adjust the drive belts tension while the engine is in operation
CAUTION
Excessive alternator and water pump drive belt tension can cause rapid wear of the belt and
reduce the service life of the fresh water pump and alternator shaft bearings Excessive slack
or the presence of oil on the belt can cause belt slipping resulting in high operating tempera
ture as well as insufficient alternator Diesel Engines 42
The alternator and water pump drive belts isare property adjusted if the belt can be deflected no less than
38 inch and no more than 12 inch 10 mm 12 mm as the belt is depressed with the thumb at the the two pulleys on the longest span of the belt See the
figure below A spare drive belt should
be carried on board
Alternator and Water Pump Belt Tension
43 Westerbeke Diesel below is a typical Westerbeke engines cooling system Both fresh water and sea water flow
through their independent cooling circuits Refer to your engines Parts List for part numbers and if you need to order cooling system parts for your
engine
NOTE When the remote expansion tank 24177 is used the plastic coolant recovery tank
should be removed and discarded and its connection point on the exhaust manifold plugged
with a 18 NPT fitting
WATER INJECTED
LBOW
EXHAUST
MANIFOLD
WATER
COOLANT
RECOVERY
TANK SEA VATER
HEAT OVERHEAT ALARM
IICOMII SEA VITEK
Typical Cooling Diesel Engines 44
Domestic Hot Water
The 12B TWO engine is equipped with
domestic hot water heater connections If
the wishes to connect a hot
water heater remove only the small hose
that connects with the thermostat housing
and the exhaust manifold and connect to
these hose connections the hoses that run
to the heater
General With the small hose removed
there remain two connecting points for REMOVE THIS ATTACH HOSE RUNNING
hoses to run to and from the water heater HOSE TO WATER HEATER
These connections when plumbed correct ATTACH HOSE
RUNNING FROM
ly should allow for a flow of heated engine WATER HEATER
cooling system water to and from the
domestic water heater without effecting the
operation of the engines cooling system
Installation The heater should be mounted conveniently either in a high or low position in relation to the en
gine so that the connecting hoses from the heater to the engine can run in a reasonably direct line without
any loops which might trap air The connection made to the thermostat housing should connect to the lower
of the two connections on the water heater while the upper connection on the heater returns to the connec
tion on the exhaust manifold Note Use a good grade of wire reinforced 1 inch 10 hose to plumb from the
engines connections to the hot water heater
THE PRESSURE CfH OM TilE REMOTE EXPANSION TlHIIC
MUST BE RATED LOWER IHAN THE PRESSURE CAP ON
THE IoiAMIFOLO
REMOTE EXPANSION TANK
TANI KIT 24177J
HEATER COILS ABOU PREGGURE en
INTO
ENGINE ENGINE
IIRHIFOU
PREIiIiURE CRP
FLOW INTO
FLOW I
HEATER
FLOW BACI
Hno FLOW OUT OF
HEATER COILS BELOW PRESSURE CRP ENGINE
tGIN
The illustrations shown above are Flow Control designs which have been adapted to operate with the single
pass manifolds installed on the 12B TWO diesel engine
45 Westerbeke Diesel should rise continuously from their low point at the heater to the engine so that trapped
air will from the heater to the engine If trapped air is able rise to the heater then an air bleed petcock
must be installed at the higher fitting on the heater for bleeding air while filling the system Avoid loops in
hose runs which will trap air
Note If any portion of the heating circuit rises above the engines own pressure cap then a
pressurized aluminum remote expansion tank must be installed in the circuit to become the
highest point The remote expansion tanks part number is 24177 Install the remote expan
sion tank in a convenient location such as in a sail locker so the fresh water coolant level can
easily be checked
The cap on the engine mounted expansion tank should not be opened once the remote system is installed
and filled
The hose connection from the heater to the remote expansion tank should be rou1ed and supported so as
to rise continuously from the heater to the tank enabling any air in the system to rise
Refer to the illustrations on the previous Diesel Engines 46
LUBRICATION Oil
For engine lubrication use lubricating oil designated for diesel service These oils are classified according
to the API Into service grades CA CB CC and CD The use of CC or higher CD grades made
by wellknown manufacturers is recommended The oil selected should be used Oil Viscosity SAE Number
Use an oil having a viscostty best sutted to the atmospheric temperature Use of an allseason oil SAE 10W
30 with minimum visCOSITY change under different temperatures is suggested
Atmospheric Temperature Viscostty
68 F 20 C or higher SAE 30 or 1OW3
41 F 5 C 68 F 20 C SAE 20 or 1OW3
41 F5 C or lower SAE 10W30
NOTE Do not use an engine lubricating oil wtth an SAE number greater than 30 in the engine
Oil Pressure
The engines 011 pressure during operation is indicated by the oil pressure gauge on the Admiral Panel see
page 24
During normal operation the oil pressure will range between 35 and 55 psi At Idle speed the oil pressure
will range between 20 and 35 psi Atthetime of cranking the oil pressure will rise with speed
NOTE A newly started cold engine can have an oil pressure reading upwards of 60 psi A
warmed engine can have an oil pressure reading as low as 35 psI These readings will vary
depending upon the speed at which the engine is running
47 Westerbeke Diesel Oil Change to include filter
1 Draining the Oil the old oil through the sump drain hose attached
111 IIII II I
I I
at the front of the engine while engine is still warm Drain the
old oil completely replace the hose in ITS bracket and replace i
the end cap observe the old oil as IT is removed A 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 andor a siphoning through the sea water cooling cir
cuit into the exhaust filling IT up into the engine refer to 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 and lower portion of the
old filter to drain the oil from IT into a container before remov
ing it This helps to lessen spillage A small style wrench should be helpful in removing the old oil filter
Place some paper towels and a plastic bag around the filter
when unscrewing it to catch any all left in the filter Oil or any
other fluid on the engine reduces the engines cooling keep your generators engine clean Inspect the old
oil filter as it is ret110ved to make sure that the rubber came off with the old oil filter If this rubber remains sealed against the engine block
gently
remove it The replaceable oil filter requires no
cleaning inside so it may be properly disposed of
When installing the new oil filter element wipe the 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 firmly by hand
NOTE Generic filters are not recommended as the material standards or diameters of im
portant items on generic parts might be entirely different from genuine parts Immediately
after an oil filter cnange and oil fill run the engine to ensure that the oil pressure Is normal and
that there are no oil leaks around the new oil 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 for the
location of the oil filler cap and lube oil dipstick After refilling the oil run the engine for a few moments the engines oil pressure 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 with the lube oil dipstick Fill to but not
over the high mark on the dipstick should the engine require additional oil
49 Westerbeke Diesel Engines
THE HBW 50 HBW 50 transmission is equipped with a helical gearing sys
tem The multipledisc clutch requires only a minimum effort to change drives This feature
makes the transmission suitable for a singlelever remote control with a rod linkage such as a Morse or Bow
den cable For safety reasons the transmission is NOT filled with transmission fluid for shipment the factory however each transmission is thoroughly
tested with fluid in the transmission This test
ing among other things provides all internal parts with a coating of transmission fluid This fluid acts as providing reliable protection against
corrosion for at least one year if the transmission is proper
ly stored
DIPSTICKFIll HBW 50 transmission is an type Fill the transmission up to or near the top of the
machined notch cut on the dipstick with approximately 032 US quarts 03 Ikers of automatic fluid the transmission fluid after the first 30 hours of
engine operation and thereafter every 250 hours or
once per year minimum The HBW 50 transmission has a drain plug for draining the old transmission fluid
To ensure that most of the old fluid is drained from the transmission run the engine in NEUTRAL for 10 to 15 minutes so the transmission fluid may
warm and flow better from the transmission fluid may also be removed by inserting a small tube through the dipstick opening where fluid is added and
attaching a pump onto the tube so the old fluid may be sucked out
Westerbeke Diesel Engines 50
The operating oil temperature must not exceed 266 F 130 C If this temperature is to be exceeded during
normal operation an optional transmission oil cooler should be installed Consult you local for details on this cooler
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 was removed making
sure that the base of the dipsticks threaded portion rests on the transmission housing Now
remove the dipstick and see where the fluid measures on the dipstick If the fluid level lies below the notch add enough transmission fluid to
raise the level back up to the
notch Do not overfill the DO NOT screw the dipstick into this hole to check the transmission fluid level Screw the
dipstick into this hole only after an accurate reading of the fluids level has been taken Make
sure that the dipstick is screwed in before and while the engine is operating Ensure that the
sealing washer is present
TO CHECK OIL LEVEL TRANSMISSION
IN OPERATION
LING
FLUID LEVEL
DRAIN PLUG
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 between the coupling and the propeller shafts coupling can create Ensure that the alignment procedures
outlined in the Propeller Coupling the Propeller and
the Alignment of the Engine sections of this manual are followed pages 13 and 14
51 Weslerbeke Diesel only controls required to operate the transmission is a single lever remote control cable The cable
should be attached 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 posttion without running out of cable Allow approximately 118 inches 1 316
of cable throw from the NEUTRAL position on the gear box lever to the each of the two NOTE If the throw distance or travel of the remote cable
is too short the gear box lever
cannot fully engage the transmission into FORWARD or REVERSE In this situation the
clutch plates will wear prematurely and the transmission will eventually fail
Minimum Travel Inner nole uSed
118 N 118
30mm 30mm
J Ij
G5 ii
7f J
t I
I I
I
Shllt Cable AttaChment Iram Rear 11
o o
Shltt Arm Securing Boll
020 tncnes
NOTE Excessive throw distance in the remote control lever is not detrimental to the transmis
sion Note that the position of the remote control lever should align with the NEUTRAL mark
ing on its bracket when the transmission is really in shift the transmission from NEUTRAL into FORWARD exert a heavy push to the remote control lever
gentle throw may not carry enough force to actually shift the internal gears A gentle throw
is signalled by the transmission not engaging into the desired drive Make sure the remote control lever is
lubricated at lease once each operating season Shift the transmission while the engine is running at 1200
rpm or below The clutch pack within the transmission makes an audiable clunk when engaging into Diesel Engines 52
CAUTION
NEVER remove or loosen the fourbolt gear box lever cover from transmission The position
of this plate and the actuating lever inside of the transmission has been finely adjusted at the
factory to ensure equal throw distance of internal mechanisms Loosening of this covers
capscrews voids the HBW 50 transmission can be left in its NEUTRAL position while sailing Leaving the transmission in
NEUTRAL while sailing alleviates unnecessary drag on the vessel because the propeller is able to However should the operator wish to stop the
rotation of the propeller shaft while under sail this can
be done by placing the transmission into REVERSE to lock the propeller any seal on the transmission shows signs of leaking have the transmission
looked at by a qualified Wester
beke Dealer This problem especially concerning the rear seal is often contributed to an improper align
ment of the coupling and the propeller shafts coupling Refer to the Alignment olthe of this manual page Propeller Size
Propeller 12 0 x 6 P blade or 11 0 x 6 P 3 blade
using HBW 50 transmission Propeller should allow the engine to reach
2 1 reduction its full rated RPM 3600 000 100 at full open
throttle while underway
Propeller 120 x 8 P tlade or 12 0 x 6 P 3 blade
using optional HBW 50 Propeller should allow the engine to reach
transmission with 251 reduction its full rated RPM 3600 000 100 at full open
throttle while 53 Westerbeke Diesel Engines
THE BW 3 BW 3 transmission rotates opposite to the engine when the transmission is in FORWARD gear When
the transmission is engaged in FORWARD the input power is transmitted to the output shaft by helical spur
gears When the transmission is engaged in REVERSE the input power is transmitted to the output shaft by
a roller chain This feature makes the transmission suitable for a singlelever remote con
trol with a rod linkage such as a Morse or Bowden cable For safety reasons the transmission is NOT filled
with lubricating oil for shipment Before leaving the factory however each transmission is thoroughly tested
with lubricating oil in the transmission This testing among other things provides all internal parts with a
coating of lubricating oil This fluid acts as a preservative providing reliable protection against corrosion
for at least one year if the transmission is properly BW 3 transmission is an type Fill the transmission up to or near the top of the
machined notch cut on the dipstick with approximately 037 US quarts 032 liters of etther SAE 20Wj20
or W30 engine oil Do not mix SAE grades Do not use multigrade oils Use an oil having an API of CC CD SC or SE
DIPSTICKFIll the transmission oil after the first 30 hours of engine operation and thereafter every 250 hours or
once per year minimum The BW 3 transmission has a drain plug for draining the old transmission fluid
To ensure that most of the old oil is drained from the transmission run the engine in NEUTRAL for 10 to 15 minutes so the transmission oil may warm
and flow better from the transmission This
Westerbeke Diesel Engines oil may also be removed by inserting a small tube through the dipstick opening where the oil is
added and attaching a pump onto the tube so the old oil may be sucked out
The operating oil temperature must not exceed 266 F 130 C If this temperature is to be normal operation an optional transmission fluid cooler should
be installed Consult you Dealer for details on this cooler
NOTE To check the transmission fluid level remove the dipstick and wipe off all transmission
oil on the dipstick and place the dipstick back in the hole where it was removed making sure
that the dipsticks rubber head is properly inserted into the oil port Now remove the dipstick
and see where the oil measures on the dipstick If the oil level lies below the
notch add enough transmission oil to raise the level back up to the notch Do not overfill the
DO NOT force the dipstick into the oil port to check the transmission oil level Excessive pres
sure can ruin the dipstick Make sure that the dipstick is properly inserted into the oil port
before and while the engine is between the coupling and the propeller shafts coupling can create Ensure that the alignment procedures outlined in
the Propeller Coupling the Propeller and
the Alignment of the Engine sections of this manual are followed pages 13 and only controls required to operate the transmission is a single lever
remote control cable The cable
should be attached 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 The shift cable when properly adjusted should allow for an equal throw of the transmission shift
lever into FORWARD or REVERSE from the NEUTRAL position without running out of cable Allow 1 12 inches of cable throw from the NEUTRAL position on
the gear box lever to
the each of the two drive Minimum Travel mner hole usedj
1 12 1 12
Shit Cable AttaChment tram Rear
55 Westerbeke Diesel Engines
NOTE If the throw distance or travel of the remote cable is too short the gear box lever
cannot fully engage the transmission into FORWARD or REVERSE In this situation the
internal gears will wear prematurely and the transmission may over heat
NOTE Excessive throw distance in the remote control lever is not detrimental to the transmis
sion Note that the position of the remote control lever should align with the NEUTRAL mark
ing on its bracket when the transmission is really in shift the transmission from NEUTRAL into FORWARD exert a heavy push to the remote control lever
gentle throw may not carry enough force to actually shift the internal gears A gentle throw
is signalled by the transmission not engaging into the desired drive Make sure the remote control lever is
lubricated at lease once each operating season Shift the transmission while the engine is running at 1200
rpm or below
CAUTION
NEVER remove or loosen the twobolt gear box shift lever cover from transmission The posi
tion of this plate and the actuating lever inside of the transmission has been finely adjusted at
the factory to ensure equal throw distance of internal mechanisms Loosening of this covers
capscrews voids the BW 3 transmission should be left in its NEUTRAL position while sailing Leaving the transmission in
NEUTRAL while sailing alleviates unnecessary drag on the vessel because the propeller is able to However if the transmission is left in its FORWARD
gear while sailing the transmission will not be
damaged Leaving the transmission in NEUTRAL is just good sailing any seal on the transmission shows signs of leaking have the transmission looked at
by a qualified Wester
beke Dealer This problem especially concerning the rear seal is often contributed to an improper align
ment olthe coupling and the propeller shafts coupling Refer to the Alignment 01 the of this manual page 13
NOTE Never loosen the four gear box lever cover screws except in the course of qualified
servicing this upsets critical adjustments Disassembly of the transmission in the field is not
recommended If an overhaul or repair is needed the work should be done by Westerbeke
or an authorized Westerbeke service Propeller Size
Propeller 12 D x 6 P blade or 11 D x 6 P 3 blade
using BW 3 transmission Propeller should allow the engine to reach
21 reduction its full rated RPM 3600 000 100 at full open
throttle while Westerbeke Diesel Engines 56
ENGINE tables which follow indicate procedures based upon certain problem indicators the
probable causes of the problems and the to overcome these that the engines control system electrical system is protected by a 20Ampere manual reset
located on the rear lifting Probable Cause switch ON 1 Battery OFF
1 Turn Battery ON
but no panel or
test function
2 20 Amp circuit 2 Reset the breaker
breaker is tripped by pushing in the button
3 Loose battery 3 Check the connection
cable connection to the starter and the
connection to the ground
stud on the bell switch is de 1 Faulty solenoid 1 Connection for 12 volts at
pressed no preheat connections or switch S terminal of the solenoid is
solenoid activation faulty
no electric fuel pump or
alternator excitation 1 Check the preheat switch
2 Faulty connection or 2 Check for 12 volts at the
tripped 10 Amp breaker 10 Amp breaker Check
on the I terminal on the for 12 volts at fuel lift pump
preheat solenoid and at the R terminal on the
alternator when the preheat
button is pushed
57 Weserbeke Diesel Engines
ENGINE Probable Calise ART switch is de 1 Connection to 1 Check connection S at the
pressed no starter solenoid faulty starter solenoid for 12 with the
switch depressed
2 Faulty 8TART switch 2 Check SWitch with an
ohmmeter
3 Faulty solenoid 3 Twelve volts is present
at the S terminal of the
starter solenoid
4 Loose battery 4 Check battery connections
connection at both the and ground
5 Low batteries 5 Check battery charge state
Low voltrage at the solenoids
S terminal with no cranks 1 Shutoff valve at 1 Return shutoff valve to
but does not start fuel tank its ON position Now bleed
the fuel system
2 Faulty fueling system 2 Check for fuel
to engine
3 Air is in the fuel 3 Bleed the fuel system
system Locate the leak and correct
4 Fuel pump is not 4 Check pump operation
operating
5 Fuel filters are clogged 5 Cleanreplace to stop 1 Mechanical Run 1 Stop engine by man
linkage disconnected ually moving the
RUN linkage to STOP
That failing
shut off fuel and Diesel Engines 58
Problem Probable Cause Stops 1 Fuel starvation 1 Check to see that the
Fuel shu1off is turned shu1off valve at the
OFF fuel tank is ON
2 Fuel pump is 2 Inspect the fuel pump for
inoperative 12 volt and to see if it is
pumping
3 Water is in the 3 Pump water ou1 of the
fuel bottom of the fuel tanks and
change the fuel filters and
bleed the fuel system
4 Exhaust system is 4 Check exhaust system for
restricted some type of blockage
such as carbon buildup at
the exhaust elbow Check
for a fault in the muffler
Check for a collapsed
exhaust runs down 1 Alternator ou1pu1 1 Check drive belt tension
is low Make an Ou1pu1 check
wtth a voltmeter at the B
terminal on the alternator
2 Faulty alternator 2 Voltage leak through
the alternator when not
operating
3 Bad battery 3 Connections are corroded
connections or loose at the battery orland
at the engine
59 Westerbeke Diesel Engines
MAINTENANCE AND section contains a scheduled preventive maintenance program and several adjustment procedures can perform without the benefit of
sophisticated and expensive tools and the preventive maintenance in accordance with the schedules listed in the following to these schedules will
ensure the equipment is maintained in the best possible condition and
that it will perform to expectations Those items marked by an asterisk are recommended to be per
formed by an authorized dealer or before each use
1 Check the oil sump level Maintain the oil level at or near upper level mark on dipstick
2 Check the coolant level in the plastic recovery tank Maintain this level at or above the level marked
3 Check the lubricant level and add additional lubricant as needed
4 Visually inspect the unit check for loose bells chafed or broken wires loose brackets and fittings
damaged hoses loose clamps and other equipment not properly secured This check should include
the propeller shaft coupling to the output flange
5 Check the fuel supply Fill tanks with a good grade of No 2 dieselluel if required
6 Check the primary filterwater separator Drain and service as required A primary iilterjwater separator
is optional but strongly 7 Check the engines gauges or lights for proper oil pressure operating temperature and starting bat
tery charging voltage once the engine is operating
8 Check the alternators output gauge if installed for proper DC the condition of the zinc anode in the heat exchangers sea water circuit Clean or
replace the anode
as required Keep the area inside the heat exchanger clean 01 zinc anode After Initial 50 Hours 01 Operation
1 Change the engines lubrication oil and oil filter
2 Replace the fuel filter element in the electric fuel lift pump and in the optional separator
if a separator has been Westerbeke Diesel Engines 60
3 Torque the cylinder head boits
4 Adjust valve clearances
5 Adjust the alternator and water pump drive belt tension IT required
6 Lubricate the throttle the RUN linkage cable and the remote control cable
7 Change the transmission fluid IT your engine is equipped with a HBW 50 transmission or
change the transmission oil IT your engine is equipped with a BW 3 After Every 100 Hours of Operation
1 Change the engines lubrication oil and oil filter
2 Adjust the alternator and water pump drive belt tension IT required
3 Check the transmission fluid or oil After Every 250 Hours of Operation
1 Replace the fuellilter elements in Ihe electric fuel lift pump and in the optional separator
2 Change the transmission fluid IT your engine is equipped with a HBW 50 transmission or
change the transmission oil if your engine is equipped with a BW 3 After Every 500 Hours 01 Operation
1 Torque the cylinder head bolts
2 Adjust the valve clearances
3 Drain flush and relill the fresh water cooling system The illustration on page 5 shows the heat ex
changer and the zinc anode location The drain plug for the fresh water system is next to the zinc anode
4 Check the condition 01 the starler motor drive pinion lubricate the pinion
5 Check the resiste11ce of the glow plugs 4 to 6 ohms
NOTE Items highlighted by an asterisk should be performed by a competent 61
Westerbeke Diesel After Every 800 Hours 01 Operation
1 Remove and check fuel injectors
I njector spray pressure
1991 psi 140 psi
2 2
140 kglcm 10 kglcm
undesirable injection conditions dripping
2 Check the engines compression pressure jJ
Remove each glow plug and check each
cylinders compression pressure The engines GOOD
cranking speed is at 280 rpm
Standard Minimum
455 psi 3697 psi
32 kgcm 2 26 kglcm 2 Maximum difference between cylinders 355 psi 25 kgcm
3 Check the alternator for proper operation
4 Check the tightness of bolts nuts and After Every 1000 Hours of Operation
1 Remove clean and pressure test the primary heat exchanger A local automotive radiator shop should
be able to clean and test the heat exchanger
NOTE Operating in silty andor tropical waters may require that a heat exchanger cleaning
be performed more often than every 1000 hours
2 Check the injection pumps timing
Westerbeke Diesel Engines 62
Torquing Cylinder Head the cylinder head bolts according to the sequence shown in the illustration shown to the right Make
sure the engine is cold when this is done Loosen one head bold onehalf turn and then tighten it between
56 to 59 Ibft 78 to 82 kgm Then proceed to the next head bolt in the sequence numbering Clearance Adjustment
NOTE Retorque the cylinder head bolts before adjusting the engines valves
1 Remove the rocker arm cover
2 Position the No1 piston at Top Dead Center TDC of its compression stroke To do this align the timing
mark on the gear case with that on the crankshaft pulley refer to the photograph shown below Nowad
just the NO1 pistons intake and exhaust valves
25 BlOC INJECTION PUMP
TIMING MARK
MARK
ON GEAR
CASE TOP DEAD CENTER
ALIGNMENT MARK
63 Westerbeke Diesel Engines
3 Facing the front of the engine rotate the crankshaft 170 clockwise to position the No2 piston at TOC of
its compression stroke Now adjust the No2 pistons intake and exhaust valves
NOTE Adjust all valves to 00098 inches 025 mm with the engine cold
ADJUST VALVES TO 88898 INCHES
825 MJ
Adjusting a valves clearance with a feeler gauge
Westerbeke Diesel Engines 64
Injection Pump Timing Adjustment Spill Timing
If your engines fuel injection timing is not properly adjusted the engine will not operate properly and will be
difficult to start Have the injection pump delivery rate checked by a well established fuel injection shop Ad
just the injection timing as follows
NOTE The fuel lever throttle must be in the RUN position while making the adjustment or
no fuel will flow to the fuel injection pump
Refer to the illustration below when servicing the fuel injection pump First remove the highpressure fuel
line from between the No1 injector and the No1 fuel delivery valve holder Remove the No1 fuel holder and remove the delivery valve spring beneath the
holder Reinstall only the delivery valve holder
and reattach the hight pressure fuel line to the delivery holder Attach it so that the end that would connect
to the fuel injector is pointing away from the engine Fuel will flow from this line during the timing check
DELIVERY VALVE HOLDE
DELIVERY VALVE SPRING
DElIlERY
VALVE
BLEEDIIIG
SCREW
BAII II EL PlDNHR RAU
CONTROL
PUlIOM
TAPPET
PlUNGER SPIII1I6
Cutaway View of the W 12B TWOs Fuel Injection Pump
Move the throttle lever to mits full open position and
the electric lift pump Rotate the crankshaft as viewed from the front catching the fuel
MIIRK ON
from the No1 fuel line until the instant the fuel com stops flowing no drips At this instant the
25 BTDC timing mark on the crankshaft pulley
MIIRK
should be directly aligned with the timing indicator on ON GEIIR
the front of the gear case see the illustration to the CIISE 65
Westerbeke Diesel Engines
If the specified injection timing 25 BTDG cannot be attained adjust the timing by increasing or decreas
ing the thickness of the injection pump mounting shim Changing the shim thickness by 0004 inch 001 mm
changes the injection timing by approximately one degree To advance the timing decrease the shim thick
ness as required To retard the timing increase the shim thickness as required Refer to your List for shim part numbers
DELIVERY
VALVE
HOLDER
INJECTION
PUMP
ADJUSTING
SHIM
Fuel Injection Pump wtth an Adjusting Shim
Westerbeke Diesel Engines 66
LAYUP AND owners rely on their boatyards to prepare their craft including engines and generators for layup
during the offseason or for long periods of inactivity Others prefer to accomplish layup preparation procedures which follow will allow you to
perform your own layup and or to use as
a check list if others do the procedures should afford your engine protection during a layup and also help familiarize you with
the maintenance needs of your engine
If you have any questions regarding layup procedures call your local servicing dealer he will be more than
willing to provide Coupling
The transmission and propeller half couplings should always be opened up and the bolts removed when
ever the boat is hauled out of the water or moved from land to water and during storage in a cradle 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 In 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 period of time
Fresh Water Cooling System
A 5050 solution of antifreeze and fresh water is recommended for use in the fresh water cooling system at
all times This solution may require a higher concentration 01 antifreeze depending on the areas Check the solution to ensure that the antifreeze
protection is more antifreeze be needed drain an appropriate amount from the engine block and add a more mixture Operate the engine to ensure a
complete circulation and mixture of the antifreeze throughout the cooling system Now recheck the antifreeze solutions System
With the engine warm drain all the lubricating oil from the oil sump Remove and replace the oil filter Place
some paper towels and a plastic bag around the filter to catch the oil during its installing the new oil filter be sure to apply a small amount of
oil on the rubber sealing gasket at the
base of the lilter Fill the sump with the correct amount of oil for your engine Refer to section of this manual page 8 Use an oil with an API
specification of CC or CD Run
the engine and check for proper oil pressure and ensure that there are no leaks
67 Westerbeke Diesel Engines
CAUTION
Do not leave the engines old lubricating oil in the sump over the layup period Lubricating
oil and combustion deposITs combine to produce harmful chemicals which can reduce the
life of your engines internal parts
Fuel System
Top off your fuel tanks WITh No2 diesel fuel Fuel additives should be added at this time to control algae
and condition the fuel Care should be taken that the additives used are compatible with the primary separator used in the system Change the element
in your primary fuel filterwater separator if the
fuel system contains one and clean the separator sediment bowl
Change the fuel filter elements on the engine and bleed the fuel system as needed Start the engine and
allow it to run for 5 10 minutes to ensure that no air is left in the fuel system Check for any leaks that may
have been created in the fuel system during this servicing correcting them as needed
Sea Water the thruhull sea cock Remove the sea water intake hose from the sea cock Place the end of this
hose into a 5gallon bucket of clean fresh water Before starting the engine check the zinc anode found in
the primary heat exchanger on the engine and clean or replace IT as required Clean the sea strainer if one
is installed in the inside of the hull
Start the engine and allow the sea water pump to draw fresh water through the system When the bucket
is empty stop the engine and refill the bucket with an antifreeze solution slightly stronger than needed for
winter freeze protection In your area
Start the engine and allow all of this mixture to be drawn through the sea water system Once the bucket
is empty stop the engine This antifreeze mixture should protect the sea water circuit from freezing during
the winter layup as well as providing corrosion the impeller from your sea water pump some antifreeze mixture will accompany it so catch it in a
bucket Examine the impeller Acquire a replacement if needed and a cover gasket Do not replace the
impeller into the pump until but replace the cover and Manifold and ThroughHull a clean cloth lightly soaked in lubricating oil in the opening of
the intake manifold to block the open
ing Do not shove the cloth out of sight If it is not visible at and an attempt is made to
start the engine you may need the assistance of a servicing dealer Make a note to remove the cloth prior
to startup The throughhull exhaust part can be blocked in the same 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 68
Cylinder is not necessary to remove the fuel injectors from the cylinder head to squirt light lubricating oil into the
cylinders for the few months of normal layup However if you anticipate a longer layup period 12 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 Ensure that you have replacements for the injector and
return line sealing time provides a good opportunity to inspect your Westerbeke engine to see if external items such
as drive belts or coolant hoses need replacement Check your basic spares kit and order items not on hand
or replace those items used during the layup such as filters and zinc batteries are to be left on board during the layup period ensure that they are
fully charged and will remain
that way to prevent them from freezing If there exists any doubt that the batteries will not remain or that they will be subjected to severe
environmental conditions remove the batteries and store
them in a warmer more compatible of your Westerbeke engine after a seasonal layup generally follows the same proce
dures as those presented in the PREPARATIONS FOR STARTING section page 21 regarding starting and normal starts However some of the layup procedures
will need to be counteracted the engine
1 Remove the oilsoaked cloths from the intake manifold and from the throughhull exhaust port
2 Remove the sea water pump cover and gasket and discard the old gasket Install the sea water pump
impeller removed during layup or a replacement if required Install the sea water pump cover with a
new cover gasket
IWARNING
Wear rubber gloves a rubber apron and eye protection when servicing batteries
Lead acid batteries emit hydrogen a gas which can be ignited by electrical
arcing or a lighted cigarette cigar or pipe Do not smoke or allow an open flame near the
battery being serviced Shut off all electrical equipment in the Vicinity to prevent electrical ar
cing during Reinstall the batteries that were removed during the layup and reconnect the battery cables making sure
the terminals are clean and that the connections are tight Check to ensure that the batteries are fully
charged
69 Westerbeke Diesel Engines
4 Check the condITion of the zinc anode in the sea water circuit and clean or replace the anode as needed
Note that IT is not necessary to flush the water solution from the sea water coolant sys
tem When the engine is put Into operation the system will selfflush in a short period of time with no ad
verse affects
5 Start the engine in accordance with procedures in the PREPARATIONS FOR STARTING section of this
manual page 21
Westerbeke Diesel Engines 70
TABLE OF STANDARD HARDWARE TIGHTENING stated otherwise for a specific assembly use the following torque values when tightening stand
ard hardware
Pitch Iblt kgm
Grade 4T
6mm bolt headnut 29 51 0407
8mm bolt headnut 125 72 116 10 16
10mm bolt headnut 125 137 224 19 31
10mm bolt headnut 15 130 217 18 30
12mm bolt headnut 125 ISO 253 398 35 55
12mm bolt headnut 15 253 398 35 55
12mm bolt headnut 175 217 362 30 50
13mm bolt headnut 15 325 506 45 70
14mm bolt headnut 15 362 579 50 80
14mm bolt headnut 2 340 557 47 77
16mm bolt headnut 15 542 796 75110
16mm bolt headnut 2 514 767 71 106
Grade 6T
6mm bolt headnut 43 65 06 09
8mm bolt headnut 125 108 159 15 22
10mm bolt headnut 125 217 325 30 45
10mm bolt headnut 15 195 304 27 42
12mm bolt headnut 125 ISO 362 579 50 80
12mm bolt headnut 15 362 506 50 70
12mm bolt headnut 175 347 492 48 68
Grade 7T 8T and 88
6mm bolt headnut 58 87 08 12
8mm bolt headnut 125 145217 20 30
10mm bolt headnut 125 289 398 40 55
10mm bolt headnut 15 268 376 37 52
12mm bolt headnut 125 ISO 542 759 75105
12mm bolt headnut 15 506 651 70 90
12mm bolt headnut 175 434 615 60 85
13mm bolt headnut 15 579 868 80 120
14mm bolt headnut 15 723 1085 100 150
14mm bolt headnut 2 687 1013 95 140
16mm bolt headnut 15 1085 1664 150 230
16mm bolt headnut 2 1013 1591 140 220
Grade 5 capscrew
14 UNC 9 11 12 15
14 UNF 11 13 15 18
516 UNC 18 20 25 28
516 UNF 21 23 29 32
38 UNC 28 33 3746
38 UNF 30 35 41 48
716 UNC 44 49 61 68
716 UNF 50 55 69 76
12 UNC 68 73 94101
12 UNF 73 80 71
Westerbeke Diesel EnginE
TORQUE head bolt Ma 253 289 35 40
See the Tightening Cylinder Head Bolts section of this manual on page 63
Rocker cover nut Ma 36 51 05 rod cap nut 231 253
32 35
Flywheel bolt 470 506 65 pulley nut M24 1085 1447
15 20
Oil drain plug 362 434 50 60
Oil filter 79 94 11 13
or tighten firmly by hand
Nozzle holder 362 434 50 60
Nozzle holder and retaining nut 434 579 60 BO
Glow plug 108 145 15 20
Starter B terminal nut on copper stud 72 87 10 12
NOTE MB indicates Metric 8 mm thread Diesel Engines 72
SPARE PARTS
Since a possibility exists in which the engine may need to be serviced at sea or while in a port other than
your home port certain spare parts should be kept on board to help minimize delays in your voyage Please
refer to your engines Parts List for part numbers when ordering spare below are those spare parts that should be carried on board at all times
1 An I mpeller Kit
2 A Fuel System hardware Kit
3 An Electric Fuel Lift Pump Filter and a Secondary Fuel Filter
4 An Water Pump Belt
5 Hose Clamps
6 A Spare Oil Filter with a Spare Quart of Diesel Service Engine Oil along with a Quart of Transmission
Lubricant and a Gallon of Premixed parts whose life expectancy cannot be accurately should be carried on board in ad
dition to those listed above especially if the vessel is to be taken on long ocean voyages These parts are
listed below
1 Fuel Injectors
2 Glow Plugs
3 Cooling System Hoses
4 An Alternator
5 A Starter
6 A 20 Amp DC Circuit Breaker
7 An Electric Fuel Lift Pump
8 A Sea Water Pump
9 Battery Terminal spare parts listed directly above are those we recommend be carried on board during long You may wish to ask other boat owners
who have similar crafts and who have completed long
ocean voyages as to what spare parts they carried on board and what parts were needed at specific times
of the voyage From the list provided directly above and from these inquiries you can determine what spare
parts may be needed In addition you are planning a long ocean voyage consult your local for a listing of the Westerbeke dealers located on your
route
73 Westerbeke Diesel Engines
iNDEX
Injection Pump Timing MAINTENANCE AND
Valve Clearance Panel
24
ADMIRALS PANEL DC WIRING DIAGRAM 36 and 37
Alignment BW 3 Transmission HBW 50 Transmission and Water Pump Drive Belt of the Engine Installation Checks
CONCENTRATION DATA 40
Automatic Alarm System Installation Checks 18
Exhaust Installation Checks 16
Batteries Layup and Specification 33
Belt Tension Alternator and Water Pump Engine Installation Checks 12
Bolts Torquing Cylinder Head 63
Breakin Procedures Engine 3 TRANSMiSSiON c
Captains Panel 23
CAPTAINS PANEL DC WIRING DIAGRAM 38467 34 and 35
Change Engine Oil to include filter 48
Charging Voltage Test INSTALLATION 1 0
CirCUIT Fresh Water Sea Water 42
Circutt Sea Water Layup and Adjustment Valve Conditions Starting Under DATA ANTIFREEZE Starting Under Cold
Starting Under Pressure Sensing Devices to Oil Galleries Installation BW 3 Transmission 55
Controls HBW 50 52
Cooling System Installation Checks 18
COOLING SYSTEM System Fresh Water Layup and Circuit Engine 12Volt Propeller Installation Checks Propeller Layup and 67
Cylinder Head Bolts Torquing Westerbeke Diesel Engines 74
Cylinder Lubrication Layup and 69
CAUTIONS
ENGINE NOT SHIPPED WITH OIL 10
LIFTING SLINGS 11
SCOOPTYPE HULL FITTINGS 18
PROLONGED CRANKING INTERVALS 26
ENGINE SHUTDOWN 28
PROLONGED CRANKING INTERVALS 31
DAMAGE TO BATTERY CiRCUiT 33
BATTERY 33
ALTERNATOR TESTING 33
EXCESSIVE BELT TENSION 42
TRANSMISSION GEAR COVER 53
TRANSMISSION GEAR COVER 56
DC Control CirCUIT Engine 12Volt 33
DC WIRING DIAGRAM 36844 ADMIRALS PANEL 36 and 37
DC WIRING DIAGRAM 36467 CAPTAINS PANEL 34 and OF INSTRUMENT PANELS of Starting System 22
Devices to oil Galleries Connecting Pressure Sensing Installation Checks 18
Diesel Engine Understanding the 4
Diesel Fuel PRODUCT SOFTWARE 1
Domestic Hot Water 45
Drain Oil Installation Checks 17
Electrical System Installation Checks 19
ELECTRICAL SySTEM 33
Elements Replacing the Fuel Filter 31
Engine 12Volt DC Control Circuit 33
Engine Alignment of the Installation Checks 13
Engine Breakin Procedures 28
Engine Bolts Installation Checks 12
Engine Diesel Understanding the 4
Engine Foundation forthe Installation Checks 12
Engine Oil 47
Engine Oil Change to include filter 48
ENGINE 57
Equipment Inspection of 2
Exhaust BackPressure Installation Checks 16
Exhaust Intake Manifold and ThroughHull Layup and 68
Exhaust System Installation Checks 15
Exhaust System Failures Installation Checks 17
75 Westerbeke Diesel Engines
Failures Exhaust System Installation Checks 17
Filters Fuel for the Engine Water Circuit Water Cooling System Layup and Diesel Filters Filter Elements Replacing the Injection Pump System
Installation Checks System Layup and SYSTEM System Priming the G
Galleries Connecting Pressure Sensing Devices to Oil Installation Checks 18
GENERAL H
HARDWARE TIGHTENING TORQUES TABLE OF STANDARD 50 TRANSMISSION Bolts Torquing Cylinder Water Domestic Pump Fuel Pump Timing Adjustment nspection
of Equipment CHECKS PANELS DESCRIPTION OF Manifold and ThroughHull Exhaust Layup and 68
Intake System Sea Water Installation Checks 19
LAYUP AND Lifting Rigging and Installation Checks 11
Location Installation Checks Lubrication BW 3 Transmission Lubrication Cylinder Layup and Lubrication HBW 50 Transmission Lubrication System
Layup and Westerbeke Diesel Engines SYSTEM 47
AND ADJUSTMENTS 60
Manifold Intake and ThroughHull Exhaust Layup and 68
Motor Starter Layup and 68
Normal Conditions Starting Under 29
Oil Change Engine to include filter 48
Oil Drain Installation Checks 17
Oil Engine 47
Oil Galleries Connecting Pressure Sensing Devices to Installation Checks 18
Oil Pressure 47
Operation Sailing BW 3 Transmission 56
Operation Sailing HBW 50 53
Ordering Parts 4
Panel Admirals 24
Panel Captains 23
PANELS DESCRIPTION OF INSTRUMENT 23
Parts Ordering 4
Parts Spare FOR STARTING 21
Pressure Oil 47
Pressure Sensing Devices to Oil Galleries Connecting Installation Checks 18
Priming the Fuel System 31
PROCEDURE STARTING 26
PROCEDURE STOPPING Engine Breakin 28
PRODUCT SOFTWARE DISCLAIMER 1
Propeller Installation Checks 13
Propeller Coupling Installation Checks 13
Propeller Coupling Layup and 67
Propeller Size Recommended BW 3 56
Propeller Size Recommended HBW 50 Transmission 53
Pump Fuel Injection 32
Pump Injection Timing Adjustment 65
Pump Sea Water 42
77 Westerbeke Diesel Engines
Propeller Size BW 3 Transmission Propeller Size HBW 50 Transmission Layup and 69
Replacing the Fuel Filter Elements and Lifting Installation Checks 11
Sailing Operation BW 3 Transmission Operation HBW 50 Transmission Water Circuit Water Circuit Layup and Water Intake System Installation Checks
Sea Water Pump Devices to Oil Galleries Connecting Pressure Installation Checks 18
Service BW 3 Transmission HBW 50 Transmission BW 3 Transmission HBW 50 Transmission DISCLAIMER PRODUCT Parts Layup and Battery GENERAL
Motor Layup and HARDWARE TIGHTENING TORQUES PREPARATION FOR PROCEDURE System Description of Under Cold Conditions Under Normal Conditions
PROCEDURE Automatic Alarm Installation Checks Cooling Installation Checks COOLING Electrical Installation Checks
ELECTRiCAL Exhaust Installation Checks 15
Exhaust Failures Installation Checks 17
Fuel Installation Checks 19
Fuel Layup and Intake Sea Water Installation Checks 19
Lubrication Layup and LUBRICATION Priming the Fuel Westerbeke Diesel Engines
78
TABLE OF STANDARD HARDWARE TIGHTENING TORQUES 71
Tension Alternator and Water Pump Drive Belt 42
Test Charging Voltage 38
THE BW 3 54
THE HBW 50 TRANSMISSION 50
Thermostat Exhaust Intake Manifold Layup and
68
Timing Adjustment Injection Pump 65
Torquing Cylinder Head Bolts 57
Under Cold Conditions Starting 29
Under Normal Conditions Starting the Diesel Engine 4
Valve Clearance Adjustment Installation Checks 20
Voltage Test Charging 38
Water Circuit Fresh 39
Water Circuit Sea 42
Water Circuit Sea Layup and 68
Water Cooling System Fresh Layup and 67
Water Domestic Hot 45
Water Pump Sea 42
WIRING DIAGRAM 36844 DC ADMIRALS PANEL 36 and 37
WIRING DIAGRAM 36467 DC CAPTAINS PANEL 34 and 35
IWARNINGS
DIESEL EXHAUST GASES 17
FLAMES NEAR DIESEL FUEL 20
SERVICING BATTERIES 20
ADJUSTING DRIVE BELT TENSION 42
SERVICING BATTERIES 69
79 Weslerbeke Diesel Engines
YOUR NOTES

Ad by Google

Disclaimer:
The information on this web site has not been checked for accuracy. It is for entertainment purposes only and should be independently verified before using for any other reason. There are five sources. 1) Documents and manuals from a variety of sources. These have not been checked for accuracy and in many cases have not even been read by anyone associated with L-36.com. I have no idea of they are useful or accurate, I leave that to the reader. 2) Articles others have written and submitted. If you have questions on these, please contact the author. 3) Articles that represent my personal opinions. These are intended to promote thought and for entertainment. These are not intended to be fact, they are my opinions. 4) Small programs that generate result presented on a web page. Like any computer program, these may and in some cases do have errors. Almost all of these also make simplifying assumptions so they are not totally accurate even if there are no errors. Please verify all results. 5) Weather information is from numerious of sources and is presented automatically. It is not checked for accuracy either by anyone at L-36.com or by the source which is typically the US Government. See the NOAA web site for their disclaimer. Finally, tide and current data on this site is from 2007 and 2008 data bases, which may contain even older data. Changes in harbors due to building or dredging change tides and currents and for that reason many of the locations presented are no longer supported by newer data bases. For example, there is very little tidal current data in newer data bases so current data is likely wrong to some extent. This data is NOT FOR NAVIGATION. See the XTide disclaimer for details. In addition, tide and current are influenced by storms, river flow, and other factors beyond the ability of any predictive program.