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Westerbeke Diesel 30c Three Technical Manual




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OPERATORS MANUAL
WESTER8EKE
358 THREE 388 FOUR 428 FOUR
MARINE DIESEL
ENGINES
Publication 37435
Edition One
March 1988
WESIERBEKE
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 Filel
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
IIWARNINGII 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 Filel System
Be sure all fuel supplies have a positive shutoff valve
CAUTION
Be certain fuel line fitting are adequately tightened and
The above symbol is used in the manual to caution personnel free of leaks
of possible damage to equipment
Make sure a fire extinguisher is installed nearby and is
Read the manual carefully and thoroughly before attempting properly maintained Be familiar with its proper use Ex
to operate the equipment Know when dangerous conditions tinguishers rated ABC by the NFPA are appropriate for aU
can exist and take necessary precautions to protect personnel applications encountered in this exhaust gases batteries electrical equipment
moving and hot parts are potential hazards that could result in Use Extreme Care When Servicing personal injury or death Follow recommended
proce
dures carefully Wear rubber gloves a rubber apron and eye protection
when servicing operate bilge blowers for at least five minutes a engine ensure no gasoline fumes are Lead acid batteries emit hydrogen a
present before starting which can be ignited by electrical arcing or by a lighted
cigarette cigar or pipe Do not smoke or allow an open
flame near the battery being serviced Shut off all electri
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 Avoid Moving Parts
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 shiptoshore 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
Ensure1hatthe 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 01 all kinds such as brochures drawings technical data operators and parts lists and parts price lists and other related
information instructions and from sources other than Westerbeke Is not within Westerbekes control and accordingly is
provided to Westerbeke customers only as a courtesy and service WESTERBEKE CANNOT BE RESPON
SIBLE FOR THE CONTENT OF SUEH SOFTWARE MAKES NO WARRANTIES OR RESPECT THERETO INCLUDING THE ACCURACY TIMELINESS OR COMPLETENESS THEREOF
AND WILL IN NO EVENT BE LIABLE FOR ANY TYPE OF DAMAGES OR INJURY INCURRED IN CONNEC
TION 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 Wester
beke must depend on such software for the design of Westerbekes own product software Such may be outdated and no longer accurate Routine changes made
by Westerbekes suppliers of
which Westerbeke rarely has notice in advance are frequently not reflected in the suppliers software until
after such changes take customers should also keep in mind the time span between printings of Westerbeke and the unavoidable existence of earlier
noncurrent Westerbeke software editions in the most Westerbeke products include special features that frequently do not
include complete summation product software provided WITh Westerbeke products whether from Westerbeke or other sup
pliers must not and cannot be relied upon exclusively as the definitive authority on the respective product
It not only makes good sense but is imperative that appropriate of Westerbeke or the sup
plier in question be consulted to determine the accuracy and currency of the product software being con
sulted by the 1 Westerbeke Diesel Engines
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 ali 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 WESTERBEKE CORPORATION
AVON INDUSTRIAL PARK
AVON MA 02322
Tit 5 0
CUSTOMER Adam Smith
85 Maple Street
Mail To Alden 1M 12234
Model W 358 THREE Ser It 1234C7G6
Expires 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 craie should be opened and
the contents inspected lor 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 rnade to the carrier not to
the Westerbeke Diesel Engines
TABLE OF 358 THREE MARINE DIESEL 12
W 35B THREE SYSTEM 13
W 38B FOUR MARINE DIESEL 15
W 38B FOUR SYSTEM 16
W 42B FOUR MARINE DIESEL 18
W 428 FOUR SYSTEM CHECKS FOR STARTING OF INSTRUMENT PANELS 35
STARTING PROCEDURE 39
STOPPING PROCEDURE 41
FUEL SYSTEM SYSTEM 46
CAPTAINS PANEL DC CONTROL DIAGRAM 36467 48 49
ADMIRALS PANEL DC CONTROL DIAGRAM 36844 50 51
COOLING SySTEM SYSTEM 60
JS TRANSMISSION 63
OPTIONAL TRANSMISSIONS 66
ENGINE ADJUSTMENTS 82
3 Westerbeke Diesel Engines
TABLE OF CONTENTS
LAYUP TABLE OF STANDARD HARDWARE
TIGHTENING TORQUES TORQUE SPARE PARTS INDEX Diesel Engines
4
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 important factors are proper ventilation and proper maintenance of the fuel lubricating and cool
ing systems Replacement of fuel and lubricating filter elements at the time periods specified is a must and
frequent checking for contamination that is water sediment or algae in the fuel system is also important factor is the use of the same brand of high
detergent diesel lubricating oil designed for 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 Parts
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 manHold 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 specHications as original that component locations in the manual 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 afe thoroughly checked and given a final run under various before leaving the
factory Test running the engine ensures 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 5
Westerbeke Diesel Engines
W 358 THREE Marine Diesel Engine
Fresh Water Fill
Fresh Water
Air Bleed Unit Data Plate
20 Amp DC
Circuit Breaker
90 Exhaust Elbow
Fresh Water
Circulating
Heat Exchanger
Pump
Transmission
Shift Lever
Sea Water Pump
Engine Isolator
DC Battery
Starter with Solenoid Ground Diesel Engines
W 35B THREE Marine Diesel Engine
Top Lube Oil Fill
20 Amp DC Circuit Breaker Fresh Water
Preheat Solenoid Air Bleed
DC Charging
Fuel Lift Plmp
Instrument
Connections
Side Lube
Secondary Oil Fill
Fuel Filter Zinc Anode Shutoff
Lever
Transmission
Dipstick
Throttle Lever
Lube Oil
JS Transmission Drain Hose
Fresh Water
Block Drain
Switch
Lube Oil Dipstick Oil Pressure
Sender
7 Westerbeke Diesel Engines
W 38B FOUR Marine Diesel Engine
Top Engine Oil Fill
Diesel Engines
W 388 FOUR Marine Diesel Engine
Top Engine Oil Fill
Air Intake SilElnCler
Fuel Lift Secondary
Fuel Filter
Zinc Anode
Throttle lever
lube Oil Dipstick Oil Pressure Oil Pressure
Sender Switch
lube Oil Filter
Westerbeke Diesel Engines
W 4213 FOUR Marine Diesel Engine
Top Engine Oil Fill
90 Exhaust Elbow
Lever
Diesel Eng ines 10
W 428 FOUR Marine Diesel Engine
Top Oil Fill
Fuel Lift pump
Fuel Filler
Zinc Anode
Throttle lever
Lube Oil Dipstick Oil Pressure Oil Pressure
Sender Switch
Lube Oil Filler
11 Westerbeke Diesel Engines
W 358 THREE MARINE DIESEL ENGINE
GENERAL Engine Type Diesel fourcycle fresh vertical inline 32 hp at
3600 rpm maximum
Governor Mechanical centrifugal weight type
Valve Mechanism Overhead
Combustion Chamber Swirl chamber type
Bore Stroke 307 x 307 inches 78 x 78 mm
Piston Displacement 6823 cubic inches 1118 liters
Firing Order 132
Direction of Rotation Clockwise when viewed from the front
Maximum Torque at 2300 rpm 41 Ibsft 567 kgsm
Compression Ratio 231
Compression Pressure 455 psi 32 kgcm2 at 320 rpm
Valve Seat Angle Intake 45
Exhaust 45
Valve Clearance Intake 0010 inches 025 mm
engine cold Exhaust 0010 inches 025 mm
Dimensions Height 2125 inches 53975 mm
Width 1837 inches 46660 mm Max
Length 3010 inches 76454 mm
Inclination Continuous 14
Temporary 25 not to exceed 30 min
Dry Weight 3681bs 1669 kgs
Fuel Consumption 042 US gph 159 Iph running at
2500 rpm Idle Speed 800 1000 rpm
Cruise RPM 2500 3000 Diesel Engines 12
W 35B THREE SYSTEM SYSTEM Open flow totally Fuel No2 diesel oil cetane
rating of 45 or higher
Injection Pump Nippondenso Bosch M type
Injection Timing 23 OS BTDC Static
Nozzle Throttle type
Injection Starting Pressure 2275 psi 160 kgcm2
Lift Pump with filter element 12Volt DC lift capacy 6 ft 18 m
Fuel Filter on engine Canistertype with replaceable element
Air Cleaner Metal screen type cleanable
Air Flow engine combustion 71 cfm 20 SYSTEM
General Fresh watercooled block
wh sea water exchanger system
Operating Temperature 170 190 F 77 88 C
Fresh Water Pump Centrifugal type metal impeller Sea Water Pump Positive displacement
rubber impeller Sea Water Flow at 3600 rpm gpm Ipm approximate
measured before discharging
into exhaust elbow
System Capacity fresh water 6 US qts SYSTEM
General Forced lubrication by gear pump
Oil Filter Paper element spinon type
Sump Capacity includes filter 422 US qts 41ers
13 Westerbeke Diesel Engines
W 358 THREE SYSTEM Operating Oil Pressure 35 55 psi 246 386 kgcm 2
Oil Grade API specijication CC or SYSTEM
Starting Battery 12Volt 35 AH negative ground
recommended 45 AH cold areas
Battery Capactty 90 125 Starting Aid 12Voit 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 190 Amps at 12 Volts
Alternator 12Volt DC 50 Amps
Regulator Internal regulator built into alternator
144 Volts DC 3 General Casehardened helical gears with an intermediate
JS Transmission reverse gear Reversing carried out by a servo
double disc system
Standard Gear Ratio 2471
Propeller Shaft
Direction of Rotation Right handed standard Propeller 16 D x 12 P 2 blade or 16 D x lOP 3 blade
using JS transmission Propeller should allow the engine to reach
2471 reduction tts full rated RPM 3600 000 100 at full open
throttle while underway
Lubricating Oil Grade API specification of CC CD SC SD or SE
SAE Grade SAE 20W20 or SAE 30 exclusively
DO NOT mix grades of oil
DO NOT use multigrade oils
Transmission Sump
Capacity 1 qt 1 Diesel Engines 14
W 38B FOUR MARINE DIESEL ENGINE
GENERAL Type Diesel fourcycle fresh vertical inline 37 hp at 3600 rpm
Mechanical centrifugal weight type
Valve Mechanism Chamber Swirl chamber type
Bore Stroke 287 x 307 inches 73 x 78 mm
Piston Displacement 7964 cubic inches 1305 Order of Rotation Clockwise when
viewed from the Torque at 2400 rpm 53 Ibsft 733 Ratio Pressure 455 psi 32 kgJcm 2 at 320
Valve Seat Angle Intake 45
Exhaust 45
Valve Clearance Intake 00098 inches 025 mm
engine cold Exhaust 00098 inches 025 Height 2370 inches 60198 mm
Width 1837 inches 46660 mm Max
Length 3377 inches 85776 Continuous 14
Temporary 25 not to exceed 30 min
Dry Weight 4191bs 190 kgs
Fuel Consumption 042 US gph 159 Iph running at
2500 rpm Speed 750 950 rpm
Cruise RPM 2500 3000 rpm
15 Westerbeke Diesel Engines
W 38B FOUR SYSTEM SYSTEM Open flow totally Fuel No2 diesel oil
cetane rating of 45 or higher
Injection Pump Nippondenso Bosch M type
Injection Timing 23 OS BTDC Static
Nozzle Throttle type
Injection Starting Pressure 2275 psi 160 kgcm2
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 829 cfm 234 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 geardriven
Sea Water Flow at 3600 rpm gpm Ipm approximate
measured before discharging
into exhaust elbow
System Capacity fresh water 7 US qts 66 SYSTEM
General Forced lubrication by gear pump
Oil Filter Paper element spinon type
Sump Capacity includes filter 475 US qts 45 Diesel Engines 16
W 38B FOUR SYSTEM Operating Oil Pressure 35 55 psi 246 386 kgcm 2
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 190 Amps at 12 Volts
Alternator 12Volt DC 50 Amps
Regulator Internal regulator built into alternator
144 Volts DC 3 General Casehardened helical gears with an intermediate
JS Transmission reverse gear Reversing carried out by a servo
double disc system
Standard Gear Ratio 2471
Propeller Shaft
Direction of Rotation Right handed standard Propeller 180 x 12 P 2 blade or 18 0 x 10 P 3 blade
using JS transmission Propeller should allow the engine to reach
2471 reduction its full rated RPM 3600 000 100 at full open
throttle while underway
Lubricating Oil Grade API specification of CC CD SC SO or SE
SAE Grade SAE 20W20 or SAE 30 exclusively
DO NOT mix grades of oil 1
DO NOT use multigrade oils
Transmission Sump
Capacity 1 qt 1 liter
17 Westerbeke Diesel Engines
W 42B FOUR MARINE DIESEL ENGINE
GENERAL Engine Type Diesel fourcycle fresh vertical inline 42 hp at
3600 rpm maximum
Governor Mechanical centrifugal weight type
Valve Mechanism Overhead
Combustion Chamber Swirl chamber type
Bore Stroke 307 x 307 inches 78 x 78 mm
Piston Displacement 9093 cubic inches 149 liters
Firing Order 1324
Direction of Rotation Clockwise when viewed from the front
Maximum Torque at 2500 rpm 561bft 774 kgm
Compression Ratio 231
Compression Pressure 455 psi 32 kgcm at 320 rpm
Valve Seat Angle Intake 45
Exhaust 45
Valve Clearance Intake 00098 inches 025 mm
engine cold Exhaust 00098 inches 025 mm
Dimensions Height 2370 inches 60198 mm
Width 1837 inches 46660 mm Max
Length 3377 inches 85776 mm
Inclination Continuous 14
Temporary 25 not to exceed 30 min
Dry Weight 4191bs 190 kgs
Fuel Consumption 042 US gph 159 Iph running at
2500 rpm Idle Speed 750 950 rpm
Cruise RPM 2500 3000 Diesel Engines 18
W 42B FOUR SYSTEM SYSTEM Open flow totally Fuel NO2 diesel oil
cetane rating 0145 or higher
Injection Pump Nippondenso Bosch M type
Injection Timing 23 05 BTDC Static
Nozzle Throttle type
Injection Starting Pressure 2275 psi 160 kgcm 2
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 940 clm 266 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 geardriven
Sea Water Flow at 3600 rpm gpm Ipm approximate
measured before discharging
into exhaust elbow
System Capacity fresh water 7 US qts 66 SYSTEM
General Forced lubrication by gear pump
Oil Filter Paper element spinon type
Sump Capacity includes filter 475 US qts 45 liters
19 Westerbeke Diesel Engines
W 42B FOUR SYSTEM Operating Oil Pressure 35 55 psi 246 386 kgcm2
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 190 Amps at 12 Volts
Alternator 12Volt DC 50 Amps
Regulator Internal regulator built into alternator
144 Volts DC 3 General Casehardened helical gears with an intermediate
JS Transmission reverse gear Reversing carried out by a servo
double disc system
Standard Gear Ratio 2471
Propeller Shaft
Direction of Rotation Right handed standard Propeller 18 D x 13 P 2 blade or 18 D x 11 P 3 blade
using JS transmission Propeller should allow the engine to reach
2471 reduction its full rated RPM 3600 000 100 at full open
throttle while underway
Lubricating Oil Grade API specification of CC CD SC SD or SE
SAE Grade SAE 20W20 or SAE 30 exclusively
DO NOT mix grades of oil
DO NOT use multigrade oils
Transmission Sump
Capacity 1 q 1 Diesel Engines 20
INSTALLATION the crafts in which Westerbeke engines are installed vary in design installation procedures will to your crafts specific design The
intent of this section is not to advise boatyards or installers
on procedures and However the must realize there
are details of the installation which require periodic checks to ensure the best operating conditions for the
equipment and safe operating conditions for the personnel on board Proper location and installation of the
diesel engine in the vessel are of prime in the installation that must be considered are ventilation to aid in cooling and to provide air for en
gine combustion exhaust system to properly discharge raw cooling water quiet the exhaust and expel ex
haust gas cooling water supply fuel supply and electrical CAUTION
For safety reasons the engine and transmission are NOT filled with lubricating oil for ship
ment Before leaving the factory however each engine with transmission is thoroughly tested
with oil in it This testing among other things provides all internal parts with a coating of oil
This oil acts as a preservative providing reliable protection against corrosion for at least one
year if the engine and transmission are properly location should be dry and in an area where bilge water or water from above cannot splash on the en
gine 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 properly ventilated to provide
fresh air for engine combustion The engines lubrication oil sump dipstick the fresh water and oil fills and
the dipstick and transmission or oil fill port must be FILL CM
COOLANT
COCKPIT
RECOVERV
TANK fr
MOUNTING
STRAP
CABIN
IHSTLATIOH RHGL
MUST NOT IOXCEED 14
Please note that the engines installation angle cannot exceed 14 from the horizontal plain
21 Westerbeke Diesel and lifting
The engine is fitted with lifting eyes Rope or chain slings capable of supporting the engines weight should
be attached to the eyes and the engine lifted by means of tackle attached to these slings The lifting eyes
have been designed to carry the full weight of the engine therefore auxiliary slings are not required
CAUTION
Slings must not be so short as to place significant sheer stress on the engines lifting eyes
Strain placed on the engines lifting eyes by the lifting sling must not be in excess of 100 from
the vertical plain
SLING LIFTING
ANGLE MUST NOT
EXCEED 10
LIFT ING
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 not lift 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 otherthan the horizontal position Cer
tain situations exist by which the engine must be lowered endwise through a small hatchway which cannot
be made larger Under these conditions if the opening of the hatchway is extremely narrow it 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 position as soon as the engine has cleared the 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 Diesel Engines 22
Engine Bolls
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 lor the Eng ine
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 when temptation to install the engine on a pair of
fiberglass angle irons must be resisted Such will allow engine vibration to pass through GOOD
to the hull Flexible mounts require a firm which they must act if they are to perform When possible follow bed design A and
avoid bed design B refer to the A
Supports between the bed stringers and the stringers to the hull may be required for
proper support and to aid in the absorption of BAD
Note Avoid excessive height use
solid stringer construction A
23 Westerbeke Diesel Shaft Coupling
The propeller shaft coupling fitted to the output flange must transmit not only the power of
the engine to turn the propeller shaft and propeller but must also transmit the thrust of the either 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 forward 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 forward through the 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 me of the boats hull by loosening the hulls fastenings
A bent propeller shaft will have the exact effect as those just stated therefore a perfectly straight is absolutely necessary One particularly
annoying result of misalignment may be leakage of oil through the rear oil seal If oil is leaking from this seal check and make sure that alignment
is within the limits prescribed on page 25
Never attempt a final alignment with the boa on land The boat should be in the water and have had an op
portunity to assume its final water form The best lime to perform the propeller coupling
alignment is with the fuel and water tanks about half full and all the usual equipment on board and after the
main mast has been stepped and the final rigging has been Westerbeke Diesel Engines 24
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 B93 FEELER GAGE
slipped backward and forward into the counterbore and
when a feeler gauge indicates that the flanges come
together at all points The alignment between the propeller PROPELLER SHAFT
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 example if your propeller is three inches in diameter the maximum error
that can be allowed in the alignment is three 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 of four positions A while rotated 90 be
tween each pOSition This test will also check
whether the propellers halfcoupling is in on its shaft Then keeping the
propeller coupling in one position the align
ment should be checked by rotating the
engines halfcoupling in 90 dimension A while in each 90 posi
tion until the halfcoupling has been rotated full
circle
The engines alignment should be the boat has been in service for one to
three weeks and if necessary perform the
alignment again Usually it will be found that
the engine is no longer in alignment This does
not mean that the work has been done im
properly at first rather it means that the boat
has taken some time to take its final shape and
that the engines bed and stringers have
probably absorbed some moisture It may
even be necessary to realign the coupling hal
ves again at a later time
25 Westerbeke Diesel System
The exhaust system provides an outlet line to vent engine exhaust gases out 01 and away from the vessel
The system also discharges sea water which has passed through the engines sea water circuit by mixing it
with hot exhaust gases This mixing helps cool the exhaust gases and exhaust elbow and plumbing The
exhaust 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
exhaust through the circuits throughhull discharge port If not prevented sea water entering through the
discharge port can fill the exhaust system muffler and enter the engines cylinders This will prevent and possibly cause damage to internal engine
sea water supply hose to the exhaust system water injection elbow should be routed looped at least
12 inches above the vessel water line An antisiphon break should be installed when needed at the lop 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
HGINEaboye Wgttr line
l LD
INSULAT E
1 LD
4B MAX
ELBOW NINIMU OF 6
INCHES ABOVE VESSELS WATER LINE
ENGINEbelow water line
HYDROHUSH
SrPItOH EAK
IART If 33327
CAIJIION Vented loop Must
be in a location where it
will remin bove the
water line during all
angles of vessel
ENGINE INSTALLATIONS WITH EXHAUST MANI operation
FOLDWATER INJECTED ELBOW AT OR BELOW
VESSELS WATER LINE
The sea water supply throughhull sea cock fittings must be of the flushhull type Highspeed scoop type
of fittings should nol be used as they tend to encourage exhaust discharge from the water lift muffler should be routed well above the water line
then downward
to the throughhull discharge This routing will prevent sea water entry if the throughhull discharge submerged when the vessel heels or rolls while
under way or is subjected to following sea con
ditions Refer to the ligures shown above for recommended exhaust system Diesel Engines 26
Exhaust exhaust discharge hose must be of adequate size and mini
mal run to prevent excessive exhaust should be checked before the engine is put into Refer to the Excessive
backpressure will
affect the engines measure for use a mercury manometer a pres
sure gauge or a water column A boatyard or marine mechanic
have a manometer or a pressure backpressure at the exhaust elbow when the engine is
Elbow
running at 3600 rpm as measured by a 2 a pressure gauge or water column should not be
over the listed below
Mercury
NOTE Other pressure gauges may be available to test for Manometer
exhaust Check with a competent
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 engine is
running at 3600 A cannot exceed 39 inches of as measured by a gauge instrument should not
exceed the following 3 inches 01 mercury 0104 kgcm 2
39 inches 01 water in a water column
099 kgcm2 at 4 C
22 ounces psi
1 12 backpressure can be caused by a small diameter exhaust hose a small muffler sharp bends in
the exhaust hose improper fittings water pockets and a high volume of water in the exhaust system due
to the length of the exhaust discharge hose The use of elbows and fittings in the exhaust discharge should be limited since these will create flow
restrictions and contribute to exhaust engines exhaust system must be separate from any other engines exhaust system Dry portions of the
exhaust system between the engines exhaust manifold and the water injected exhaust elbow must be insu
lated to hold in the heat
21 Westerbeke Diesel 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 surtace 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 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 Intense 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 make sure there is no deterioration of the Westerbeke Diesel Engines 28
Exhaust Elbow Westerbeke Corporation offers a 45and 900 exhaust
elbow as well as an exhaust riser you can install on engine Refer to the instructions below the exhaust elbow purchased for your engine
1 Coat only one side of the exhaust gasket with High
Tack adhesive sealant Place this coated surface
against the exhaust manifolds exhaust port flange the
gasket should stick to the flange without falling off
2 Place the clamp over the elbows flange Place your ex
haust elbow against the exhaust manifolds flange so
the exhaust manifolds flange rests snug against the ex
haust elbows flange with the gasket centered between
the two Now slip the exhaust clamp over both flanges CLAMP 45 ELBOW
3 A Tighten the clamp just enough so the exhaust elbow
can remain attached to the manifold and still be
rotated
B The exhaust elbow discharge must be directed
downward so the mixture of sea water and exhaust
gases will flowfall downward into the exhaust muf
fler which must be positioned below the exhaust
elbow There should be no loops or rises in the ex
haust hose connected between the exhaust elbow
and the muffler as these would trap water and pos
sibly allow water to flow back into the engine during
ClAMP
starting or at shut down
90 ELBOW
4 Adjust the elbow by rotating it until the desired align
ment with the exhaust piping is acquired
5 Carefully tighlen the clamp between 2 to 3 IbI or 24 to
35 Ibin or 02710 041 kgm
CAUTION
Approach the I Ibf torque limit with caution
The clamps threads will break if more than I Ib
tI is applied to lhe clamp
6 When the engine is started for the first time with the new
elbow check Ihis exhaust connection
for leaks II a leak exists correct it immediately
EXHAUST RISER
Manufactured by Permatex Company Brooklyn NY
CLAMP
29 Weslerbeke Diesel Engines
Oil Drain Hose
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 Pressure Sensing Devices to Oil pressure sensing devices such as senders and switches must not be connected to an
engines oil gal
lery with the use of extended nipples or tees The reason is simply that continued engine vibration of the fittings used to make such a connection If
these fittings fail the engine loses its oil pressure
and quickly seizes
When additional sensing devices such as switches or sensors need to be installed that function on engine
oil pressure these devices must be and connected to the oil gallery using an of lubricating oil hose Any fittings used to connect the hose to the
gallery must be of steel or malle
able iron composition Brass must not be used for this 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 throughhull fitting using a hose between the throughhull fitting and the sea
water pump The sea water should be a visualtype sea water strainer which will trap debris before reaches the sea water pump and the
heat exchanger and then be delivered to the pump Hoses routed from the throughhull fitting to the strainer
and to the sea water pump should be to prevent the hose from collapsing while the engine
is running 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 throughhull fitting as a means of supplying sea water to the en
gine Water pressure against this type of fitting while the vessel is under sail can push sea
water past the sea water pumps impeller into the engines exhaust system filling it and the
engine as well Flushtype clear throughhull fittings are recommended and should be lo
cated on the hull so as to be below the waterline during all angles of boat operation
The use of commontype street elbows is not recommended for plumbing the sea water cir
cuit These generally have very restrictive inside diameters Machine fittings are Diesel Engines 30
Automatic Alarm System
High Water Temperature Alarm
A high water temperature alarm buzzer has been supplied with the instrument panel If the engines fresh
water coolant reaches 205 F 96 C a water temperature switch on the engine closes causing the alarm
buzzer to emit a continuous signal Refer to the DESCRIPTION OF INSTRUMENT PANELS section of this
manual for the location of the alarm in your engine panel page 35
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 35
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 make sure 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 condftions 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 Iilter 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 This type valve can create fuel starvation problems for the engines fuel sys
Fuel tanks that are located below the engines fuel system level must have its fuel return at the tank extend
ing down into the tank in the same manner as the pickup tube otherwise fuel siphoning out of the engines
fuel system through the return will take place
31 Westerbeke Diesel Engines
Make sure 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 make sure all wiring harnesses are tied down properly with
clamps or plastic ties spaced at intervals close enough to prevent chafing from vibration Check to make
sure all the engines harness connections are tight and that they are made to the appropriate
IWARNINGI
Do not smoke or allow an open flame near batteries Lead acid batteries emit hydrogen a
gas Turn off the emergency switch in the positive line of sure the positive battery connection is connected to the battery connection of the
starting solenoid
The negative battery connection should be connected to the system ground the engine block
When servicing the battery or checking the electrolyte level wear rubber gloves a rubber
apron and eye protection Battery acid may inadvertently splash on skin or into eyes when
removing electrolyte caps
Check level and specHic gravity of battery electrolyte to ensure maximum engine starting efficiency Make
sure terminals are clean and ventilation requirements of the engine include the following combustion air is required for the and ventilating air is
required to clear the bilges below the engine as well as the compartment in
which the engine is located of heated air produced during engine operation and of potentially toxic and
flammable diesel fumes Refer to the SYSTEM section of this manual for engine page 13 for the W 35B page 16 for the W 38B and page 19 for the W
Diesel Engines 32
PREPARATION FOR section of the manual provides the operator wtth 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 limn on the
dipstick the installation angle may have an effect on the
dipstick reading Select readily available lubricating oil with
an API specification of CC or CD and an SAE number suitable
for the temperature in your operating area see page 60 For
the quantity 01 oil needed in your engine refer to the SYS
UPPER LIMIT
TEM section 01 this manual page 13 for the
HORMRL LEVEL
W 35B page 16 lorthe W 38B and page 19 for the W 42B
LOWER LIMIT
Fill the JS transmission to the FULL mark on the dipstick with
the correct lubricant The JS transmission takes 1 US qt or
1 liter of oil Refer 10 your engines SYSTEM section of this manual lor a listing of oil grades to be
used in this unit is supplied with a coolant recovery kit 24977 as standard equipment to which the following ap
plies
A Remove the pressure cap from the engines exhaust manifold and slowly fill the engines COOling sys
tem with a mixture of water and antifreeze suitable for your temperature zone See the COOLING SYS
TEM section 01 this manual page 53 Operate the engine and observe the coolant level in the manifold
Maintain this level to the base 01 the Iiller neck Once the engine reaches its operating temperature 170
190 F make sure there is coolant flow to the domestic water heaters when installed Top off the cool
ing system and Instalilha pressure cap
8 Make sure the plastic recovery tank is properly mounted near the unit with the bracket provided in a
location where it can be monitored and filled easily The recovery tank should be mounted at manifold
level or above In these installations that require it the plastic recovery tank can be mounted below the
exhaust manifolds level
c Add coolant to the plastic tank after the engine has been started and after the engines operating
temperature has been reached to make sure all air is expelled from the manifold and the engines cool
ing 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 lank with a good grade of NO2 diesel fuel and prime the fuel system up to the engine see page
44 When returning fuel is free 01 air the engines fuel system is bled and the engine is ready to start
NOTE When the PREHEAT switch is depressed the glow plugs in the cylinder head are ener
gized use the PREHEAT switch to prevent overheating the glow plugs
Make sure the Installation Checks have been made in accordance with those specified in the CHECKS section 01 this manual refer to page 21
33 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 39 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 34
DESCRIPTION OF INSTRUMENT offers two types of control panels as optional equipment for the W 35B the W 38B and the W
42B engines Read the following instructions that apply to the panel you purchased with your engine
Captains Captains Panel is equipped with a Key Switch an RPM gauge a PREHEAT and
START button and an instrument test button along with 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 operation 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 41
2 PREHEAT The PREHEAT button energizes the alternators regulator the engines glow plugs and
bypasses 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 same
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 pressure and
the water temperature indicator lights illuminate in addttion to sounding the alarm
35 Weslerbeke Diesel Engines
5 Alarm The alarm is located above the test button and will sound if the engines oil pressure falls below
15 psi In this event the alarm will emit a pulsating signal The alarm will also sound if the ture in the fresh water cooling circuit rises to
210 F In this event the alarm will emit continuous sig
6 Water Temperature Gauge This gauge is graduated in degrees Fahrenheit and is illuminated while the
Key Switch is turned ON The engines normal operating temperature is 170 190 F 77 88C
7 Oil Pressure Gauge This gauge is graduated in pounds per square inch PSI and is illuminated while
the Key Switch is turned ON The engines normal operating oil pressure ranges between 30 60 PSI
NOTE When the engine is manually shut down and the engines Key Switch is turned OFF
the water temperature gauge will continue to register the last temperature reading indicated
by the gauge before electrical power was turned OFF The temperature gauge will once again
register the engines true temperature once electrical power is restored to the gauge The oil
pressure gauge will fall to zero when the engine is manually shut Diesel Engines 36
Admirals Admirals 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 0 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 41
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 SIABI The START button when pressed energizes the starters solenoid which cranks the engine
This button will not operate electrically unless the PREHEAT button is pressed and held at the same
time
37 Westerbeke Diesel Engines
NOTE An alarm buzzer is supplied with every Admiral Panel The installer is responsible for
electrically 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
5 Water Temperature Gauge This gauge is graduated in degrees Fahrenheit and is illuminated while the
Key Switch is turned ON The engines normal operating temperature is 170 190 F 77 88C
6 Oil Pressure Gauge This gauge is graduated in pounds per square inch PSI and is illuminated while
the Key Switch is turned ON The engines normal operating oil pressure ranges between 30 60 PSI
NOTE When the engine is manually shut down and the engines Key Switch is turned OFF
the water temperature gauge will continue to register the last temperature reading indicated
by the gauge before electrical power was turned OFF The temperature gauge will once again
register the engines true temperature once electrical power is restored to the gauge The oil
pressure gauge will fall to zero when the engine is manually shut Diesel Engines 38
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 Make sure the pushpull stop lever has been returned
to the RUN position
3 Depress and hold the PREHEAT switch Preheat according to the following chart
Atmospheric Temperature Preheating Time
41 F 5 C or higher Approx 10 sec
41 F 5 C to 23 F 5 C Approx 20 sec
23 F 5 C or lower Approx 30 sec
Limit of continuous use 30 seconds
before 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 indi
cate 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 Make sure sea water discharges with the ex
haust 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 inlervals 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 01 the exhaust manifold
once the exhaust system fills Prevent Ihis from happening by closing the sea water
supply throughhull shutoil drain the exhaust muffler and correct the cause for the
excessive engine cranking needed 10 obtain a start Engine damage resulting from this
type of sea water entry is not a warrantable issue Ihe should keep this
in mind
39 Westerbeke Diesel Engines
Once the engine starts run tt 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 130 150 F 55 66 C is reached
0 0
Westerbeke Diesel Engines 40
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 specffic
requestorder of the BreakIn your engine has experienced a minimum of one hour of test operations to make sure accurate as
sembly procedures were followed and that the engine operated properly a breakin time is required The
service life of your engine is dependent 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 39 run the engine
at fast idle while checking that all systems sea water pump oil pressure battery charging are function
2 Allow the engine to warm up preferably by running at fast idle until the water temperature gauge moves
into the 130140 F range
3 While using the vessel 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 that is operating the engine with a
propeller that is too large
6 During the next 25 hours the engine may be operated at varying engine speeds with short runs at full
rated speed Avoid idling the engine for prolonged periods of time
41 Westerbeke Diesel 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 33
4 Check for oil and fuel leaks particularly Hsigns 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 39 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 60 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 OFTHE 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 Diesel Engines 42
FUEL Fuel
Use No2 diesel fuel with a cetane rating of 45 or higher Never use kerosene or home heating oil since
these fuels do not have the same lubricating properties as No2 diesel fuel
In cold weather 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 Fillers
A primary fuel filter of the water must be installed between the fuel
XNSTRLLRTION and the engine A primary fuel filter L BOLT TRAP SHURELl TO
HOSE FITTING RII ACCESSIBLE STRUCTUII SO here is available from your local TIIU 1
RECEITICL Tn CATCH DRAINAGE
CAM BE PUtED IIMOER or your This filter adapted for boatbuilder 2 IF FUEL IS TO BE IIIIED nTH COPPER
011 BUMD IUBUS USE NUTS AMD FUULES
use comes complete with fittings for either PRaUIDED BE SUlIE THE HIllING PROJECTS
114 IlCH THROUIIH THE FERRULE BEFIU
hose or metal tubing Mount tt in an acces TlSHTEMING TNE HUt
sible place inspect tt often and drain off
3 If FUEl IS Til BE PIPU mil HOSE USE
water accumulation frequently THE TMD BRASS BARBED FIITIIiSS AWO WASHERS
SUPPLIED SE CERIAU IHAI THE HOSE SElEtlED
HAS IIUGOMAL BRAID INSERTED no CLUG ON lHE
BARB TIIRT IT IS NDPREIIE LINED AMO THRT
If a water trap type filter is not installed be IT IS gl the fuel tank and the engine
4 IF ATR IS lRESEMT IN THE FUEL IT Ull
mounted fuel system any water in the fuel ClltlECT StDtV III THE BOTTCH or TH
system will tend to lay in the bottom of the SEllINEMTER 1I11EN TilE REO HOAT RIMS
UERCHU THE ORAIN LIIiE 011 THE lift pump Internal metal parts of the BOWL l005EK THE BonUM DIIAU PlUS UNTIL
ALL ArEA RUNS OUT
lift pump will rust Particles will pass on to
6 lUHlEN ORRIN PLUI SECURELY SO O An CAW
filters and eventually to the injection pump ENlER THE SUrE
and injectors wtth damaging results and 6 HUGI2E THE rUEL PUMP TO RErILL TilE
the possibility of expensive repairs water damage to the fuel sys
tem is not covered under the addttion any gasoline in the fuel system
will damage the engines fuel injection pump assembly and injectors as gasoline does not have the qualtties as diesel most boatbuilders supply a
water trapfilter some do not Westerbeke offers a as an optional extra at moderate cost The filter is supplied with fittings for either hose or metal
tubing fuel lines
43 Westerbeke Diesel the Fuel System
The Westerbeke selfbleeding fuel system is semiautomatic in operation The selfbleeding feature of the fuel
system allows for easy servicing 01 the fuel filters Simply remove the and replace the filter elements take
care in catching any fuel that may drain out 01 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 If 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 01 the exhaust manifold
once the exhaust system Iills Prevent this irom happening by closing the sea water
supply throughhull shutoff drain the exhaust muffler and correct the cause for the
excessive engine cranking needed to obtain II slart Engine damage resulting from this
type of sea water entry is nol II warrantable issue the should keep this
in the Fuel Filler it is unlikely that the operator will be forced to service the system at sea the possibility does it is recommended that banjo
washers injector seat washers electric lift pump filter and gasket
fuel filter and gasket be carried on board at all times Select the parts for your engine from the Parts List and
purchase spares from your local Westerbeke Dealer For example hardware kit 33093 in
cludes replacement elements with gaskets items 6
8 20 21 If a leak should develop at a fuel banjo or
sealing washer location that cannot be remedied by a
slight tightening of the filter cup retainer replace the fil
ter along with the Orings supplied with the new the first 50 hours of operation loosen retainer ring
23 and discard filter element 21 Clean bowl 22
and install a new filter using a new 20 gasket Be
careful to catch any fuel that may spill from within these I
fuel filter assemblies This same service is required of
the 6 filter element in the electric fuel lift install a new 6 filter element along with a
new 8 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
After the first 50hour change the change period may
be increased to 200 hours or once per Diesel Engines 44
Fuel Injection Pump
The illustration below shows the W 356 THREEs fuel system The W 386 FOUR and W 426 FOURs fuel
system differ in that they have an additional fuel Injector and injector pump plunger The fuel injection pump
located to the right is one of the most important components of the diesel engine and therefore calls for
the utmost caution in handling Furthermore the fuel injection pump has been thoroughly 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
FUEL ElECTRIC FUEL
LIFT PUMP
FUEL PUMP FILTER THROTTLE
INJECTION
PUMP
OIL PUMP
OIL FILTER
Fuel Injection 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 engine Service this
system regularly the injection pump it saves will be your own
45 Westerbeke Diesel Engines
ELECTRICAL 12Volt DC Control Circuit
The Westerbeke 35B 38B and 42B propulsion engines have a 12Volt DC electrical control circuit as shown
on the wiring diagrams which follow on pages 48 to 51 Refer to these diagrams when or
servicing 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
engine 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 circuit connected while will
damage the alternators CAUTION
When testing the alternator circuit charging circuit do not use a highvoltage tester such as
a megger damaged diodes could result
During highspeed operation of the engine do not disconnect the positive terminal of the bat
tery from the B terminal of the alternator nor disconnect the negative terminal of the battery
from the ground
When cleaning the engine with a steam cleaner be careful to keep steam away from the al
to pages 48 to 51 for the two electrical system wiring schematics one is used for the Captains panel
and the other for the Admirals Diesel Engines 46
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
Al TERNATOR
135 n 40 A 50 Al
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 make sure 12Volts excitation is present at the
R terminal should the above test show only battery voltage at the B output 47
Westerbeke Diesel Engines
Captains Panel DC Control Circuit Wiring Diagram 36467
page 1 of 2
DIAGRAM
GLOWLUGS
WATER
TEMP
ATER
TEMP
lO6 tI il
SENDER SWITCH
OfPD 01 1llP
loTIONAL
NU aEIOI T ST
iNDERS
PAtU
CIRCUIT
PflEHEh 1
SOLENOtO
Gj
Q 0 Q
i ilIJi
f lQ Q J1
I
tir 0
SO 8 OP
1
r 15
TEST SwiTCH
STIlRT
ILSe Ifli
Apl 14 I I I
PREHEAT
LAtPt
4sUr
TACHOMETER
I SITCH
18 Bl I
Gc I I
BBL I
I oSL
I
Diesel Engines 48
Captains Panel DC Control Circuit Wiring Diagram 36467
page 2 of 2
r 2VOC
hi
5TIIOIT
SWTCH n
ALARM
START ITURN KEY TO ON POSITION THE ALARt WILL SOUNDOIL PRESSURE NO
BATTERY CHARGE INQICATORS HILL LIGHT
2PUSH pqEHEAT SWITCH FOR 15 TO 50 SECONDS AS REQUIRED ALARM WILL STOP
3WHILE CONTINUING TO PUSH PREHEAT SWITCHPUSH THE START SWITCH ALSO
IrlEN THE ENGINE STAins gElEASE THE START SWITCH ONLY
lWHEN THE OIL PRESSURE INDICATOR LAMP GOEs our RELEASE THE
PREHEAT SWITCH
STOP TURN THE KEY TO THE OFF POSITION
I THIS PRODUCT IS PROTECTED a
A MANUAL RESET CIRCUIT BREAKER LOCATED EAR
THE CURRENT DRAIN WILL CAUSE THE BREAKER TO 7RIf AND THE
ENGINE WILL SHUT OOiN THE MUST 8E SURE THAT THE ICiSTHUMENT
PANElWIRING AND ENGINE IRE INSTALLED TO PREVENT CONTACT BETWEEJ ELECTRICAL
DEVICES AND SALTWATER
2AN ONOFF SWITCH SHOULD BE INSTALLEO BETIEEN THE BATTEA AND STARTER TO
DISCONNECT THE BATTER IN AN EMERGENCY AND WHEN LEAVING THE EOAT A SWITCH
WITH A CONTIlUOUS RATING OF 17AMPS AT 12VDC WILLSERVE THIS FUNCTION THIS
SWITCH SHOULD NOT 8E USED TO MAKE 0R BREAK TH CIRCUIT
PINK WIRE AT PLUG 2 IS UNUSEf AND SHOULD BE 49
Westerbeke Diesel Engines
Admirals Panel DC Control Circuil Wiring Diagram 36844
page 1012
JFs AR r C
EAKER I
BLUE
PREHEAT
SOLENOID
It r7j
n M1 14LTBLUe
I I I
RED lil I
Ic
1 IJ UDD
E2
STARTER
CIRCUIT
I BREAKER
J 20 A
1m II iRE I III
i r l
GROUND
TO ENGINE
BLOCK I
OIL 3 1
USED IN SOME
GRONO TO I
1
ENGINE BLOCK
t ill
NEUTRAL
SAFETY SWITCH
USED ON SOME
I PUMP
r irt1
12VDC
1 i
il I D
It
52 6 C 0 1 1
Ill I 16 1lmi3 3
It It It
111
1l1i
FJE3l
RTi I F
ALARM BUZZER
I
T ilI I
I I
OIL PRESS WATERTE
GAUGE GAUGE I I
e 21E II
IYEL
I I
I I I
I I IGRN cJGt
V Gl II I
0 14GRN
I I Z
i lJiTART PREHEAT
KEY SWITCH SWITCH SWITCH
VOLTMETER
oel Diesel Engines 50
Admirals Panel DC Control Circuit Wiring Diagram 36844
page 2 of 2
SCHEMATIC DIAGRAM
NEUTRA
11 I
11 PI 11
1KEY
r sw I
eo p
ALARM
I PREHEAT 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 SALT WATER
2 AN ONOFF SWITCH SHOULD BE INSTALLED BETWEEN THE BATTERY AND STARTER TO 015
CDNNECTTHE BATTERY IN AN EMEAGENCYANO 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 21S UNUSED AND SHOULD BE 51 Westerbeke Diesel Engines
COOLING marine diesel engines are designed and equipped for fresh water cooling Heat produced in
the engine by combustion and friction is transferred to fresh water which circulates throughout the engine
This circulating fresh water cools the engine block and its internal moving parts The heat is transferred ex
ternally from the fresh water to sea water by means of a heat exchanger similar in function to an automo
tive radiator Sea water flows through the tubes of the heat exchanger while fresh water flows around the
tubes engine heat transferred to the fresh water is conducted through the tube walls to the sea water which
is then pumped into the exhaust system where finally it is discharged overboard In other words the engine
is cooled by fresh water the fresh water is cooled by sea water and the sea water carries the over the side through the exhaust system The fresh
water and sea water circuits are independent of
each other Using only fresh water within the engine allows the cooling water passages to stay clean and
free from harmful deposits The two independent circuits and their components are discussed in the follow
ing Water Circuit
NOTE Refer to paragraphs A and B in this section for the recommended antifreeze and water
mixture to be used as the fresh water coolant and for information on filling the fresh water
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
the thermostat into the exhaust manifold to the heat exchanger where it is cooled and then is returned to
the engine block through the suction side of the fresh water circulating pump When the engine is started
cold external fresh water flow is prevented by the closed thermostat although some fresh water flow is
bypassed around the thermostat to prevent exhaust manifold from overheating As the engine warms up
the thermostat gradually opens allowing full flow of the engines fresh water coolant to flow unrestricted to
the external portion of the cooling system
A Fresh Water Coolant Antifreeze Mixture
A freshwater and antifreeze mixture should be used yearround in the cooling system Water when it sufficiently to split the heat exchanger and crack
the engine block A mixture of
proper concentration will prevent freezing see page 53 for an mixture chart
Use soft water with few impurities such as tap water potable water or rainwater Never use hard or foul
water Use of hard water or water containing impurities will lead to the collection of scale in the engine and
heat exchanger which will reduce the cooling systems of poor quality or without rust inhibitors will cause corrosion within the cooling system Always
use antrrreeze which is compatible wah aluminum cooling system components and is made by a Never mix different brands of sure that the cooling
system of the engine is well cleaned before adding antifreeze for year round use is ZEREX or PRESTONE with rust inhiMors
In order to control the concentration of the mixture mix the antifreeze and freshwater thoroughly before ad
ding it to the cooling Diesel Engines 52
ANTIFREEZE CONCENTRATION DATA
Antifreeze
Concentration 13 23 30 35 45 50 60
Freezing F 23 14 5 4 22 40 58
Temperature C 5 10 15 20 30 40 50
NOTE An antifreeze concentration should be selected on the basis of a temperature which
is about 10 F 5 C lower than the actual atmospheric temperature expected
B Filling the Fresh Water System
A coolant recovery tank kit is supplied wtth each Westerbeke diesel engine The purpose of this recovery
tank is to allow lor engine coolant expansion and contraction during engine operation without the loss of
coolant and without introducing air into the cooling system
This coolant recovery tank should be installed at or above engine manifold level in a location where it can
be easily monitored and where coolant can be easily added if needed see the figure below A mounting bracket is supplied with each kit along with a
30inch 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 Tank 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 olthe engine coolant allowing some of the coolant in the recovery tank to be drawn back into the system Iree of air and without loss
Periodically check that the passage A between the 90 litting
on the manifold and the filler neck in the manifold is clear so coolant can flow in either
53 Westerbeke Diesel Engines
COOLANT RECOIIERY TAI
1 i
1 I
I 1
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 of the 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 exhaust manifold from overheating during the engines warmup Replacement thermostats must have
this design Diesel Engines 54
Sea Waler Circuit
The sea water flow is created by a bel
driven positive displacement neoprene
impeller pump The pump draws sea
water directly from the ocean through the
sea cock and sea water strainer and pas
ses the water to the heat exchangers sea
water inlet The sea water passes through
the heat exchangers lUbes from which
heat from the fresh water system is ab
sorbed and then the sea water is dis
charged from the cooling through the wet
exhaust system Be sure to clean zinc CLEAN
NEW OR
debris from the area inside of the heat ex ANODE REPLACE
REPLACE where the zinc anode is Zinc Anode Condttions
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 itsell 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 selfpriming geardriven rotary pump with a nonferrous housing and a The impeller has flexible vanes which wipe against a
curved cam plate within the impeller the pumping action On no account should this pump be run dry There should always be a and impeller cover gasket
aboard an impeller kit Sea water failures occur when lubricant sea
water is not present Such failures are not warrantable and the operators are cautioned to make sure sea
waler flow is present at and Waler Pump Drive Bel Tension
IWARNING
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 lile of the fresh water pump and alternator shaft bearings Excessive slack
or the presence 01 oil on the belt can cause belt slipping resulting in high operating tempera
ture as well as insufficient alternator output
55 Weslerbeke Diesel Engines
The alternator and water pump drive belts isare properly adjusted Wthe 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 Selt Diesel Engines below is a typical Westerbeke engines cooling system Both fresh water and
sea water flow
through their independent cooling circutts 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
ELBOW
EXHAUST
WATER
COOLANT
RECOVERY
TANK
HEAT
CONTROllER
OVERHEAT ALARM
FRESH WATER PUMP
IMCOMING SEA VATER
Typical Cooling System
57 Westerbeke Diesel Hoi Water
All engine covered in this manual are
equipped with a domestic hot water con
nection If the wishes to
connect a hot water heater remove the
bypass hose and connect a heater as
described in the instructions With the bypass hose Part
30962 removed there remain two con
necting points A and e for hoses to run to
and from the water heater These connec
tions assure a How of hot water through
the heater at all times but do not effect the
flow of coolant through the engine
Flow The heater should be mounted conveniently either in a high or low position in relation to the
engine 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 Connection point A on the Flow Control housing should connect to the lower
of the two connections on the water heater while the upper connection on the heater returns to connection
e nearest to the heat exchanger
REMOTE EXPRNSION TRNK
PRESSURE CAP IS RATED
LOWER THRN MANIFOLD CAP HEATER COILS ABOVE
PRESSURE CRP ON ENGINE
MANIFOLD
HEATER COILS BELOW
REMOVE RETURN BEND FROM PRESSURE CAP ON ENGINE
ENGINE fLOW CONTROLLER MANIFOLD
AIR BLEED PET COCK
HEATER BELOW ENGINE HEATER ABOVE illustrations shown above are Flow Control designs that have
been adapted to operate with the single
pass manifolds installed on the W 358 the W 388 and the W 428 Diesel Engines 58
Hoses 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 c hec ked
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 routed and supported so as
to rise continuously from the heater to the lank enabling any air in the system to rise
Refer to the illustrations on the previous page
59 Westerbeke Diesel Engines
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 viscosity best suited to the atmospheric temperature Use of an allseason oil SAE 10W
30 with minimum viscosity change under different temperatures is suggested
Atmospheric Temperature Viscosity
68 F 20 C or higher SAE 30 or 10W30
41 F 5 C 68 F 20 C SAE 20 or 10W30
41 F5 C or lower SAE 10W30
NOTE Do not use an engine lubricating oil with an SAE number greater than 30 in the en
gine
Oil Pressure
The engines oil pressure during operation is indicated by the oil pressure gauge on the Admirals Panel
see page 37
During normal operation the oil pressure will range between 35 and 60 psi At idle speed the oil pressure
will range between 20 and 35 psi At the time of cranking the oil pressure will rise with speed
NOTE A newly started cold engine can have an oil pressure reading upwards of 60 psi A
warmed engine can have an oil pressure reading as low as 35 psi These readings will vary
depending upon the speed at which the engine is Diesel Engines 60
Engine Oil Change to include IiIter
1 Draining the Oil Sump
Remove the oil drain hose from its attachment brack
et and lower it into a container and allow the oil to
drain or attach a pump to the end of the drain hose
and pump the old oil out Make sure the oil drain hose
is properly secured in its holder after all of the old oil
has been observe the old oil as it is removed A yel
lowgray emulsion indicates the presence of water in
the oil Although this condition is rare it does attention to prevent serious damage Call a
competent mechanic should water be present in the
oil Sea water present in the oil can be the result of a
fault in the exhaust system attached to the engine
andor a siphoning through the sea water cooling cir
cuit into the exhaust filling it up into the engine refer
to the installation illustrations on page 26
2 Replacement of the Oil Filter
When removing the used oil filter you may find it help
ful 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 removing it This helps to A small style automotive filter wrench
should be helpful in removing the old oil filter Place
some paper towels and a plastic bag around the fil
ter when unscrewing it to catch any oil left in the fil
ter Oil or any other fluid on the engine reduces the
engines cooling ability Please keep your engine
clean Inspect the old oil filter as it is removed to
make sure that the rubber sealing gasket came off
with the old oil filter If this rubber sealing gasket
remains sealed against the engine block gently
remove it The replaceable oil filter re
quires no cleaning inside so it may be properly dis
posed of
When installing the new oil filter element wipe the filter gaskets sealing surface on the engine block free of
oil and apply a thin coat of clean engine oil to the rubber gasket on the oil filter Screw the filter onto the
threaded oil filter stub and then tighten the filter 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 change and oil fill run the engine to make sure the oil pressure is normal and that
there are no oil leaks around the new oil filter
Westerbeke Diesel Engines
3 Filling the Oil Sump
Add fresh oil through the oil filler cap on the valve cover
refer to the photographs on pages 6 and 7 for the W Oil Filler Cap
35B pages 8 and 9 for the W 38B and pages 10 and 11
Rocker over
for the W 42B for the location olthe oil filler cap and lube
oil dipstick After refilling the oil run the engine for a
few moments while checking the engines oil sure there is no leakage around the new oil filter
or from the oil drain system and then stop the engine
Then check the quanttty of oil wtth the lube oil dipstick
Oil Dipstick
Fill to but not over the high mark on the dipstick should
the engine require additional oil
Upper Liit
INor l Levelfl l
0 il
Lii tr
Diesel Engines 62
JS TRANSMISSION
gear ratio is 247 to 1 The JS transmission is made of a lightweight aluminum alloy suitable for the marine environment This manual transmission
rotates op
posite to the engine when in forward gear The JS transmits its power with casehardened helical gears and
in reverse an intermediate gear The reversing process is carried out by a servo double disc system For
safety reasons the transmission is NOT filled with lubricating oil lor shipment Before leaving the each transmission is thoroughly tested with oil in
the transmission This testing among other all internal parts with a coating 01 oil This oil acts as a preservative providing reliable corrosion for
at least one year if the transmission is property stored
BEll
GEAR BOX
tOH1ROl
LEVER
OIL IlRAIH
Allen Wrench size is
JS transmission is an type Fill the transmission up to or near the top of the
machined notch cut on the dipstick with SAE 20 W20 or SAE 30 weight engine oil exclusively are not to be used in this transmission DO NOT mix grades
of oil Lubricating oils may have an of CC CD SC SO or SE
The oil capacity for the JS transmission is approximately 10 quart 10 liter Check the oil level daily after
the engine has been warmed and stopped The oil level shOUld be maintained at the top of the machined
flat on the dipstick when the dipstick is completely inserted into the transmission housing Make sure the
two Oring gaskets on the dipstick are in good shape These Orings will help keep the dipstick in place
Change the transmission oil after the lirst 30 hours 01 engine operation and thereafter every 250 hours or
once per year minimum The JS has a 6 mm Allen wrench drain plug for draining the old oil To make sure
most of the old oil will drained from the transmission run the engine in NEUTRAL for approximately 10 to 15
minutes so the oil may warm and flow better from the transmission This oil may also be removed by insert
ing a small tube through the dipstick opening where the oil is added and attaching a pump onto the tube
so the oil may be sucked out The operating oil temperature must not exceed 2500 F 120 0 C
63 Wasterbeke Diesel between the coupling and the propeller shafts coupling can create Make sure the alignment procedures
outlined in the Propeller Shaft Coupling the Propeller
and the Alignment of the Engine sections of this manual are followed pages 24 and only controls required to operate is a single lever remote The
cable should be attached to the
gear box lever using the cable bracket sup GEAR BOX SHIFT LEVER
plied with the unit Both the gear box lever
and the remote control lever must be in the
NEUTRAL position when the cable is at
tached 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 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
positions
REVERSE fORIIARD
NOTE lithe throw distance or travel NEUTRAL
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 clutches will
wear prematurely and the transmis
sion may not properly engage will
over heat and eventually fail
NOTE Excessive throw distance in the
remote control lever is not detrimental
to the transmission Note that the posi
tion of the remote control lever should
align with the NEUTRAL marking on its
bracket when the transmission is real
ly in NEUTRAL
Weslerbeke Diesel Engines shift the transmission from NEUTRAL into FORWARD exert a heavy push to the remote control lever A
gentle throw may not carry enough force to actually shift the internal gears A gentle throw is
signalled by the transmission not engaging into the desired drive Make sure the remote control lever is lubri
cated at lease once each operating season Shift the transmission while the engine is running at 1000 rpm
or below
CAUTION
NEVER remove or loosen the twobolt 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 JS transmission should be left in NEUTRAL while sailing Leaving the transmission in NEUTRAL while
sailing alleviates unnecessary drag on the vessel because the propeller is able to freewheel spin However
to lock the propeller shaft and to prevent it from rotating place the transmission into FORWARD any seal on the transmission shows signs of leaking
have the transmission looked at by a qualnied Wester
beke Dealer This problem especially concerning the rear seal Is often attributed to an improper alignment
of the coupling and the propeller shafts coupling Refer to the Alignment of the Engine sec
tion of this manual page 24
Never loosen the gear box lever cover screws except in the course of qualified servicing this upsets olthe 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 JS transmission is sea watercooled Sea water enters the transmission through a
stainless steel inlet
pipe located at the base of the bell housing This water helps to cool the lubricating oiL
65 Westerbeke Diesel Engines
OPTIONAL HBW 100 150 150V DIPSTICK
FIll PORT
DIPSTICKFIll PORT
HBW 150V HBW 100 and 150
All HBW models turn right hand propellers
All HBW models have their own oil sumps and dipsticks
All HBW models use ATF lubricant
All HBW models should be shifted into gear in one swift
motion not allowed to slip in Of Gearbox 33G CABLE SHIFTING LEVER
1 The gearbox is sui table for o
A B
single lever remote control
using 33C cable j TRANSMISSION
o The cable should attach at right
angles to the actuating lever
using the cable bracket
supplied
o o
3 Both gear box lever and remote lever must be in
neutral position when cable is attached so that
travel of gearbox lever will be equal forward or
reverse
4 Check that actuating lever hub does not touch
cover plate hub Maintain at least 05 mm
0002 clearance
5 Over travel of the actuating lever does no harm OSmm
However if the travel is too short to give full Control of
engagement premature wear excessive heat Gearbox
generation and gear failure may result
Westerbeke Diesel Engines 66
DIPSTICK
6 The position of the cover plate
underneath the actuating lever
is factory adjusted to ensure TO CHECK OIL LEVEL
equal lever travel from neutral
TRANSMISSION IN OPERATION
to A and B DO NOT LOOSEN THE
CAPSCREWS HOLDING THIS ASSEMBLY
Doing this voids transmission
warranty VENT
kc II I
I i
7 Fill gearbox with automatic I
tr ansmission fluid to the level it
indicated by the dipstick mark
See the illustration to the right
8 Note that to check oil level
the dipstick drops on the FLUID LEVEL
housing It does not screw in
9 The HBW gear box can be free
wheeled in Neutral To stop
prope 11 er shaf t ro t a t
10n whl
1 e DRAIN PLUG
under sail place the gear into
Reverse Dipstick Oil Levels
NOTE The transmission is vented through a small hole in the dipstick Keep
this vent cleared
Each engine model can be fitted with any of the transmissions listed below
Transmission Gear Ratios
HBW 100 151 21 251
HBW 150 151 21 251
HBW 150V 151 21 251
These transmissions each have their own oil sumps and dipsticks The HBW transmis
sion uses Automatic Transmission Fluid ATF type A or Dextron II
67 Westerbeke Diesel Engines
Warner Hydraulic FROM COOLER
2101 ONLY
SHIFT LEVER DIPSTICK ASSEMBLY
FROM 10131014
COOLER FROM COOLER 1011018
EXCEPT 2101
1 CONTROL LEVER POSITION
The position of the control lever on transmission when in be shifted to the point where it covers the letter p on the
case casting and is located in its proper position by the poppet
ball The Warranty is cancelled if the shift lever poppet spr ing
andor ball is permanently removed or if the the control lever is
changed in any manner or repositioned or if linkage between and transmission shift lever does not have sufficient travel
in both directions This does not apply to transmissions equipped
with Warner Gear electrical shift control
2 properties of the oil used in the transmission are to the proper function of the hydraulic system Therefore
it is extremely important that the recommended oil fluid ATF Type A or Dexron II be used
NOTE Be sure the cooler is properly installed when required and
the transmission contains oil before cranking or starting the engine
Westerbeke Diesel Engines 68
Filling and Checking the Hydraulic System
The oil level should be maintained at the full mark on the oil level prior to starting engine Check daily before The hydraulic circuit includes the
transmission oil lines and any gauge lines connected to the circuit The
complete hydr aulic circui t must be filled when filling and this requires purging the system of air before the
oil level check can be made The air will be purged from the system
if the oil level is maintained above the pump suction opening while
the engine is running at approximately 1500 RPM The presence of air
bubbles on the dipstick indicates that the system has not been purged
of air
New applications or a problem installation should be checked to make
sure the oil does not drain back into the transmission from the cooler
and cooler lines Check the oil level for this drain back check after the engine has been shut off and again after the
engine has been stopped for more than one hour overnight A noticeable increase in the oil level after this indicates that the oil is
draining from the cooler and cooler
lines The external plumbing should be changed to prevent any drain
back
Starling the Engine
Move the shift lever to the center position where the enters the chamfered hole in the side of the shift lever and pro
perly locates lever in neutral position before starting engine
from any selector position to any other selector position may
be made at any time and in any order if the engine speed is below 1000
RPM however it is recommended that all shifts be made at the engine speed Move the shift lever to the extreme where the spring loaded ball enters
the chamfered hole in the
side of the shift lever and properly locates lever in transmission shift lever to the extreme rearward position where
the spr ingloaded ball enter s the chamfered hole in the side of the
shift lever and properly locates it in the reverse position
sail with the propeller turning or at trolling speeds with one
of two engines shut down the design of the gear maintains and lubrication Attempting to place the gear into forward or
reverse while under sail to stop propeller shaft rotation will have
no effect TO stop propeller shaft rotation while under sail a
mechanical shaft brake would be needed
69 Westerbeke Diesel Engines
Cooling passages inside of the cooler will sometimes become clogged and
this will reduce cooling capacity and cause overpressur ing Back
flushing of the cooler will sometimes help to flush the from the cooler passages The cooler and hose should be
thoroughly flushed or replaced in the event a failure has particles from the failure tend to collect in the case of the
cooler and gradually flow back into the lube system Replace oil
cooler to prevent contamination of the new hoses may collapse and reduce or completely shut off all flow to
the cooler Collapsed hoses are usually caused by aging of the hoses
or improper hose installation Hose installation should be made with
no sharp bends Hoses should be routed so there is no possibility for
engine shifting to cause hoses to pull loose or become pinched A
visual inspection of hoses while under way will sometimes allow detec
tion of faulty or complete loss of water flow can be caused by a faulty
water pump A rubber water pump impeller will sometimes fail and
after such a failure the cooler passages may be restricted by the par
ticles of rubber from the failed impeller Water pump cavitation may
be caused by improper or faulty plumbing or an air leak on the inlet
side of the pump The water pump may not prime itself or may lose its
prime when inlet plumbing is not properly is possible for cross leaks to occur inside the cooler to flow into the water or water flow into the oil
fluid levels at each days use will help spot such a hap
pening undetectable loss of fluid andor emulsified fluid
Westerbeke Diesel Engines 70
Annual Checks
1 PROPELLER AND OUTPUT SHAFT ALIGNMENT This check should also be
made any time the propeller strikes a heavy object and after any acci
dent where the boat is stopped suddenly Shaft alignment should also
be checked after the boat has been lifted by a hoist or moved on a
trailer
2 SHIFT LEVER POSITIONING The selector controls must position the
shift lever exactly in F N and R selection positions with the ball
poppet centered in the shift lever hole for each position
3 BOLT TORQUE Check all bolts for COOLER CONNECTIONS Check water lines oil lines and leakage Make sure lines are securely fastened to
CHANGING OIL A seasonal oil change is recommended in Work boats require more frequent changes Change oil any time
the oil becomes contaminated changes color or becomes Automatic transmission fluids ATF Type A is use
Daily Checks
1 Check transmission oil level
2 Check for any signs of oil leakage in the bellhousing at gasket
sealing surfaces or at the output shaft oil seal
3 A quick visual check of the general condition of the equipment may
cause faulty equipment to be detected
4 Listen for any unusual noises and investigate to determine the
cause of any such noises
Note Low engine idle speed can produce drive damper chatter
Winter Checks
Drain water from transmission oil cooler This will prevent
freezing in cooler climates and prevent harmful deposits from
collecting
General Checks
1 Check coupling alignment each time a transmission is replaced in
the boat
71 Westerbeke Diesel Engines
2 Check shift linkage adjustment to ensure that the transmission
shift lever is positioned so that the spring loaded ball enters
the chamfered hole in the side of the shift lever
3 Connect an oil cooler into the cooler circuit before cranking or
starting the engine various cooler circuits have been used and
the correct cooler connections should be found from service
literature prior to makeing the cooler Use a cooler or sufficient size to ensure proper cooling
5 Check engine rotation and transmission pump setting and the pro
peller rotation prior to assembling the transmission to engine
6 Check oil pressue and temperature when transmission function
indicates that a problem exist
7 Use the recommended fluid for filling the Fill the transmission prior to starting the engine
9 Check oil level immediately after the engine has been shut off
10 Use a clean container for handling transmission fluid
11 Replace cooler and lines after a transmission failure prior to
installing a new or rebuilt Check fluid level at operating Westerbeke Diesel Engines 72
Walter VDrives
Flange Alignment Direct Coupled Models
Install the propeller shaft flange on
to the propeller shaft and tighten the two
clamping bolts on the spli t hub none on
RVlOD A selflocking set screw is pro GEAR SHAFT SET SCREW
vided for the propeller shaft flange FLANGE
Spot dr ill the propeller shaft and then
securely tighten the set screw Many are ruined by improper shaft FEELER
flange alignment Accurate alignment will GAGE
ensure a smooth operating drive train and
eliminate many problems that arise due Final alignment should not
be attempted until the boat has been
allowed to settle in the water After
CLAMPING
the engine has been installed adjust the BOLTS
mounts per instructions FLANGE the pilot diameters of the gear
shaft flange and the propeller shaft
flange engage freely Butt the flange
faces together Without rotating either flange check with a feeler
gauge in at least four places as shown in the illustration If the
maximum feeler gauge that can slip between the flange faces at any
point is 003 the unit is properly aligned If a thicker gauge can
be inserted at any point the engine must be readjusted until is obtained Turn the propeller shaft flange 14 of a turn
without moving the gear shaft change Try inserting the 003 feeler
gauge as descr ibed above The gap will not change i f the is straight If it increases the shaft or flange is bent and
must be removed and straightened Rotate the propeller shaft flange
in two more 14 turn increments and repeat the procedure The must be rechecked to ensure that they still engage the two flanges
together with the heat treated bolts and spe
cial high collared lockwashers supplied
Engine Alignment Independent Models
The engine must be adjusted so that the alignment of the is within 3 An accurate steel rule should be used for this
purpose as shown in the illustration On short installations using a
flexible joint assembly the faces of the flexible joint must be
parallel within 18 Measure this in at least four places around the
diameter without rotating the assembly With long installations using
the 36 tubular drive shaft also on all RVlODS the distance from
the 33A spool adapter to the bores in the universal joint which is
welded to the tubular shaft must be measured on both sides of the
joint Rotate the shaft exactly 14 of a turn and measure to the same
joint The four distances must be equal within 18 DO not measure
73 Westerbeke Diesel Engines
to the joint end that is
on the spool adapter
This distance will not
vary wi th misalignment
Slnce the joint is
bolted and cannot move
Put the 31A alignment
gauge on the machined
diameter
Z YNCO
lJftClIN of the 24
cover and slide it com
pletely around It will
indicate how the engine
must be moved to center
the spline shaft in the
oil seal Remeasure
the joints to see if
they are still parallel within 18 It is
important that both alignments be It is possible for the spline shaft
to be perfectly centered and the flexible joint
to be out more than 3 Premature failure of the
26 selfaligning bearing and seals may occur due
to misalignment The zerk fitting located on
the cross of the universal joint should be
greased with a light alemite lubricant The
above procedure should be repeated after the boat
has been placed in operation It is possible for
the engine to slightly shift and settle espe
cially if it has rubber mounts
Flange Alignmenl Independenl Models
Install the propeller shaft flange on to the
propeller shaft and tighten the two clamping bolts
on the split hub none on RVIO A selflocking LOCKING NUT
ADJUST I SChEW
set screw is provided for the propeller shaft
LOOSEN
flange spot drill the propeller shaft and secure AOJUS T BRACK T5
ly tighten the set screws MOlJjTING
All Vdrives are supplied with 3way adjustable brackets 2way on the RVIO and RV20 as
standard equipment The brackets must face down
ward as shown in the illustration to propeller thrust The mounting plates can
be removed and rever sed to fi t wider eng ine bed
RVIO Before installing the Vdrive loosen all
the nuts on the mounting brackets and check to see
that the studs are in the center of the slots Re
tighten the nuts place the Vdrive on the engine bed lining it up
Wby eye to the propeller shaft flange as closely as possible Firmly
bolt it down through the holes provided in the mounting the locking nuts on the adjusting screws Slightly loosen the
nuts on the mounting brackets just enough to be able to move the v
drive
Many good installations are ruined by improper propeller shaft
flange alignment Accurate alignment will ensure a smooth train and eliminate many problems that arise due to misalign
Weslerbeke Diesel Engines 74
ment Final alignment should not be attempted until the boat has been
allowed to settle in the water Adj ust the Vdr i ve until the of the gear shaft flange and the propeller shaft flange
engage freely Butt the flange faces together Without flange check with a feeler gauge in at least four places as
shown in the illustration If the maximum feeler gauge that can slip
between the flange faces at any point is 003 the unit is If a thicker gauge can be inserted at any point the Vdrive
must be readjusted until proper alignment is obtained Turn the pro
peller shaft flange 14 of a turn without moving the gear shaft
flange Try inserting the 003 feeler gauge as described above The
gap will not change if the propeller shaft is straight If it
increases the shaft or flange is bent and must be removed Rotate the propeller shaft flange in two more 14 and repeat the procedure The pilot
diameters must be
rechecked to ensure that they still engage freely Tighten the nuts
on the mounting brackets and the locking nuts on the adjusting the set screws from the brackets none on RVIO or RV20 spot
drill and securely tighten Recheck the flange alignment to make sure
the Vdrive did not move out of alignment Secure the two with the heat treated bolts and special high collared lock
washers supplied
ADJUSTING SCREW
LOCKING NUT
GEAR SHAFT
FLANGE
SET SCREw
7
TO ADJUST
LOOSEN SLIGHTLY
BRACKETS
a i MOUNTING
4 HOLE
FEELER
GAGE
0
MOUNTING PLATE
FLANGE ALIGNMENT
Water and Switch Connections
Hook up the water lines to the two pipe connections on the and exhaust lines are Generally one line
from the seacock to the Vdr i ve and another from the Vdr i ve to the
intake of the engine water circulating pump are utilized In some
cases scuppers through the hull are connected to and from the Vdrive
to provide independent watercooling and are actuated by the movement
of the water With closed cooling systems the Vdrive should into the system between the cooler and the suction side
of the water pump Proper operating temperatures are from 140 to
ISOF although safe operating temperatures may be as high as 210F
On the models equipped with an oil circulating pump the 49 oil
75 Westerbeke Diesel drop switch and the 12 volt H9A warning light should be
hooked up per the wiring diagram The switch may be grounded to any
part of the Vdrive or engine either terminal may be used for Fill
Pullout the 21 oil level the 12 breather cap and fill the 12 BREATHER CAP ATER mAIN
Vdrive with SAE i30 motor oil through the UNSCREW FOR
Oil Filll
12A breather elbow On the RVIO only WATER LINE
L LEVEL
c GA
the oil may be added by removing the plug J
I PULL UP TO
REMlVE
in the 60 top cover See table below oil capaci ties The amount
varies with the angle of oil level should be checked wi th the
oil level gauge fully inserted in the
unit The proper level is between the H
and L marks on the gauge Add a 2 ounce
tube of Molykote molybdenum is supplied with each Vdrive for 12A BREATHER
ELBOW
extra lubrication and breakin It provi
des protection against scoring or galling
of gears bearings and other moving Molykote after breakin is not required Reinstall the
breather cap The oil level should be rechecked after the unit has
been run and allowed to sit for about a minute Add oil if necessary
RVIO RV20 RV30 RV40 RV48
Oil capaci ty 1 pint 2 pints 3 pints 4 pints 4
Dealer Preparation
The propeller shaft and engine alignment must be checked if necessary before the boat is delivered Final align
ment should not be attempted until the boat is allowed to settle in
the water The oil level must be checked and oil added if the boat is being run the water connections should be checked
for leaks The oil pressure drop switch and warning light if the
V dd ve is equipped wi th an oil circulating pump should be checked
for proper operation Do not transport the boat with the coupling connected Damage to the shaft shaft log and Vdrive
can result
Weslerbeke Diesel Engines 76
Operation
A pressure drop warning light is
mounted on the instrument panel on
Vdrives equipped with an oil cir
culating pump The warning light will
stay on until the boat gets under way
and the engine speed increases to suf
ficient RPM for the pump to This normally occurs 1200 RPM but the actual
speed may vary by as much as 400 RPM
Extended cruising at low RPM such as
when trolling is not harmful to the
Vdrive even though the warning light
may stay lit Normal operation is
between 6 to 12 PSI The light will
go on when the oil pressure drops
below 2 PSI Loss of oil oil level are the major
causes of pressure drop The oil
level should immediately be restored
and while running the boat the unit should be checked for leaks If
the oil level is normal and the light stays lit when the boat cruising speed the wir ing should be checked for loose connections If the wiring
is correct and the light remains
lit the 49 pressure drop switch which is mounted on the side of the
Vdr i ve see should be checked for proper oper ation
The switch can easily be removed and an accurate oil pressure in its place If the pressure is normal the switch should
be replaced If the pressure is below normal the oil lines should be
checked for blockage The pump should be inspected and replaced if
necessary The pump is standard on the RV48 and an optional feature
on other models not available on the RVIO
The oil level should be checked several times during the on Vdrives whitout pumps see OIL FILL
A clatter or rattle in the Vdrive at low RPM is due to the over
riding of the propeller during the compression stroke of the annoying it is not harmful It may be reduced by adjusting
the idle speed andor tuning up the engine for smoother operation
OIL CHANGE AND JOINT LUBE
After the first 100 hours of operation and every season andor
500 hours thereafter the oil should be changed Run the boat to warm
up the Vdrive to operating temperature Turn off the engine Remove
the plug in the 6B bottom cover that is opposite the 438 oil
strainer Reinstall after draining Disconnect the oil hose leading
from the 438 strainer leave the elbow on the strainer Unscrew the
strainer and clean the outside surface Reinstall the strainer and
reconnect the oil hose Unscrew the two 22 magnetic plugs that are
located on diagonally opposite corners of the lC main housing
77 Westerbeke Diesel Engines
The plugs can be checked to see if
they are magnetic only after the inside face with a such as a screwdriver Clean
them and reinstall Usually there
are four plugs in the bottom part of
the main housing Only two of these
are magnetic The other two need not
be removed see Refill
wi th SAE 30 motor oil to the proper
level see INSTALLATION OIL FILL
The Zerk fitting on the external uni
versal joint should be greased with a
light alemite lubricant see ENGINE
AL I GNMENT
2 WATER DRAIN
For protection from freezing during winter layup remove the
small pipe plugs located diagonally opposite on the front and back
of the housing marked Water Drain see illutration On the RVIO
only one of the water lines going into the 6 watercooled bottom
cover must be disconnected to drain the water
3 FLANGE AND ENGINE REALIGNMENT
When the boat is launched after being in drydock the lineup of
the vdrive to the propeller shaft flange and the engine to the V
drive should be rechecked and corrected i f necessary Some engines
with rubber mounts may sag and must be raised with adjustments or
shims for proper alignment see Flange Alignment and n
Westerbeke Diesel Engines 78
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 by
breaker is tripped 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 fuellifl pump
preheat solenoid and at the R terminal on the
alternator when the preheat
button is pushed
79 Westerbeke Diesel probable Cause switch is de 1 Connection to starter 1
Check connection S at the
pressed no starter solenoid faulty starter solenoid for 12 with the SWITch
depressed
2 Faully START 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 voltage 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 Check for 12Volts at pump
5 Fuellilters are clogged 5 Cleanreplace to stop 1 Mechanical Run 1 Stop engine by man
linkage is ually moving the
disconnected RUN linkage to STOP
That failing
shut OFF fuel and Diesel Engines 80
Problem Probable Cause Stops 1 Fuel starvation 1 Check to see that the
Fuel shutoff is turned shutoff 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 out of the
fuel bottom of the fuel tanks
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 output 1 Check drive belt tension
is low Perform an output check
wh 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 orand
at the engine
81 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 belts 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 No2 diesel fuel if required
6 Check the primary filterwater separator Drain and service as required A primary filterWater 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 voltage
9 Check to make sure the propeller shaft is securely connected to the transmission 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 of zinc anode Diesel Engines 82
Servicing Alter 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 secondary fuel fil
ter Change the fuel filter element and clean the optional filterwater sediment or Ha separator has been
installed and il the model type permits cleaning
3 Torque the cylinder head bolts
4 Adjust valve clearances
5 Adjust the alternator and water pump drive belt tension if required
6 Lubricate the throttle the RUN linkage cable and the remote control cable
7 Change the oil
8 Adjusts the engines idle speed as needed
9 Check to make sure the propeller shaft is securely connected to the transmission Alter Every 100 Hours of Operation
1 Change the engines lubrication oil and oil filter
2 Adjust the alternator and water pump drive belt tension if required
3 Check the transmission fluid or oil Alter Every 250 Hours of Operation
1 Replace the fuel filter elements in the electric fuel lift pump and in the secondary fuel
filter
2 Change the Alter Every SOO Hours 01 Operation
1 Torque the cylinder head bolts
2 Adjust the valve clearances
3 Drain flush and refill the fresh water cooling system The illustration on pages 6 to 11 show the heat
exchanger and the zinc anode location The drain plug for the fresh water system is next to the zinc
anode
4 Check the condition of the starter motor drive pinion lubricate the pinion
83 Westerbeke Diesel Engines
5 Check the resistance of the glow plugs 4 to 6 ohms
6 Check the sea water pump for internal wear Examine the pumps cover cam and internal housing
Replace worn parts as needed Check for leaks and repair as needed
NOTE Items highlighted by an asterisk should be performed by a competent Aller Every 800 Hours 01 Operation
1 Remove and check fuel injectors
Injector spray pressure
1991 psi 140 psi
140 kgcm 2 10 kglcm 2
Eliminate undesirable injection conditions including POOR
aller dripping
2 Check the engines compression pressure
Remove each glow plug and check each
ir 10104i dI
cylinders compression pressure The engines GOOD
cranking speed is at 280 rpm
Standard Minimum
455 psi 3697 psi
32 kgcm 2 26 kglcm2 Maximum difference between cyfinders 355 psi 25 kgcm2
3 Check the alternator for proper operation
4 Check the tightness of bolts nuts and Aller 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 Diesel Engines 84
Torquing Cylinder Head Bolts CN 35B THREE 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
FRONT OF ENGINE
done Before applying the specHied torque to
the bolt loosen it 14 to 12 of a turn and then
apply the torque Follow this procedure ac
cording to the numbered sequence shown in 0 0 0
7 5 11
the illustration to the right
4 6 8
Bolts and 11 are tightened be 0 0 0
1ween 795 to 868Ibft 11 to 12 kgm
02 01 03
Bolts 12 and 3 are tightened be1ween 506 to
578 Ibft 7 to 8 Cylinder Head Bolts W 38B FOUR and W 42B FOUR 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 Before applying the spec Hied FRONT OF ENGINE
torque to the bolt loosen IT 14 to 12 of a turn
and then apply the torque Follow this proce
dure according to the numbered sequence 0 0 0 0
shown in the illustration to the right 6 1 5 11
14 8 2 1 13
Bolts and 11 are tightened be 0 10 0 4 0 3 0 9 0
1ween 795 to 868Ibft 1110 12 kgm 0 0 0 0
Bolts 12 and 3 are tightened be1ween 506
to 578 Ibft 7 to 8 kgm
85 Westerbeke Diesel Clearance Adjustment rN 35B THREE Engine
CAUTION
Adjust the valve clearance when the
engine is cold Valves are adjusted by TOC MRRK Cylinder Koll
cylinder in the firing order of the en
gine
Tighten the cylinder head bolts to the
specified torque before adjusting the
valves See page 85
1 Pull off the air breather pipe from the rock TO C MA RK
er cover and take off the rocker cover C y li n d e r
bolts and the rocker cover No3 1
2 Adjust the valve clearances at TDC Top
TOC MARK
Dead Center for each cylinder when they
Cylinder No2l
are on their compression stroke see
below Remember the engines firing
order is 132 You may find that turning the engines crankshaft is more easily accomplished when the
engines glow plugs are removed before the crankshaft is rotated
A Align the timing mark on the gear case with the timing mark on the crankshaft pulley indicated for
cylinder NO1 the one next to the three injection timing marks In this position the NO1 cylinder is
at ks top Timing Mark while dead center on ks compression stroke Check both intake and exhaust
valve clearances for this cylinder If the valves have no specified clearance adjust by means of the ad
justing screws Remember to align the timing marks properly if not the valve may be pushed up by
the piston depending on the position of the cam lobe Be sure to check the valves for this cylinder
they both should be closed
B Next the No3 cylinder Turn the crankshaft clockwise 240 so the TDC mark for the NO3 cylinder on
the front crankshaft pulley is at the position shown in the illustration above
Now adjust the intake and exhaust valves for
cylinder No3 Be sure to check the valves
for this cylinderthey both should be closed ADJUST VALVES TO 0010 INCHES
025 MMJ
C Last is the No2 cylinder Turn the crankshaft
clockwise another 240 to position the TDC
mark on the crankshaft pulley at the position shown in the illustration shown
above Now adjust the intake and exhaust
valves for cylinder NO2 Be sure to check
the valves for this cylinder they both should
be each valves clearance by inserting a 0010
inch 025 mm feeler gauge between the rocker
arm and the valve Diesel Engines 86
Valve Clearance Adjustment W 38B FOUR and W 42B FOUR Engines
CAUTION
Adjust the valve clearance when the
engine is cold
TDC MARK Position for
Tighten the cylinder head bolts to the Cylinder
No1 and 4
specHied torque before adjusting the
valves See page 85
1 Pull off the air breather pipe from the rock
er cover and take off the rocker cover
bolts and the rocker cover
2 Adjust the valve clearances atTDC fop TOC MARK
Dead Center for each cylinder when they Po i t ion for
are on their compression stroke Remem Cy 1 i n d r s
berthe engines firing order is 1342 The No2 and 3
CRANKSHAFT
engines valves must be adjusted in this PULLEY
order while the valves are closed You
may find that turning the engines
crankshaft is more easily accomplished
when the engines glow plugs are
removed before the crankshaft is rotated
A Rotate the engine in the normal direction of rotation placing the NO1 cylinder at the top of its compres
sion stroke The TDC mark on the crankshaft pulley should be in line with the pointer on the front of the
gear case cover and the valves for the No1 cylinder should be closed Now adjust the intake and ex
haust valves for cylinder NO1
B After adjusting the valves for cylinder No1 rotate the front crankshaft pulley clockwise 180 so the TDC
mark on the pulley is positioned approximately in the position shown in the illustration shown above for
cylinder No3 Now adjust the intake and
exhaust valves for cylinder NO3
C Rotate the crankshaft pulley clockwise
another 180 and adjust the valve clearances ADJUST VALVES TO 0010 INCHES
for the Intake and exhaust valves for cylinder 025 MMJ
D Rotate the crankshaft pulley clockwise
another 180 and adjust the valve clearances
for the intake and exhaust valves for cylinder
each valves clearance by inserting a 0010
inch 025 mm feeler gauge between the rocker
arm and the valve stem
87 Westerbeke Diesel Pump Timing Adjustment Spill Timing
If your engines fuel injection timing is not property adjusted the engine will not operate property and will be
difficult to start Have the injection pump delivery rate checked by a fuel Injection shop Ad
just the injection timing as follows
NOTE The fuel shutoff lever must be In the RUN posHion while making the adjustment or no
fuel will flow from 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 high pressure fuel line to the delivery holder Attach H 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 the engines crankshaft in Hs
normal direction of rotation to posi
DELIVERY VALVE SPRING
tion piston No1 at the beginning of
its compression stroke
DELIV
VALVE
Move the throttle lever to Hs full open
position and operate the electric lift
pump Slowly rotate the as viewed from the
front catching the fuel from the No
BAR REL fuel line until the Instant the stops flowing no drips RACK
At this instant the 230 BTDC timing PLUNGER
mark on the crankshaft pulley
be directly aligned wHh the PINION
timing indicator on the front of the
gear case refer to the pages 86 and 87 TAPPET
PLUNGER SPRING
If the specified injection timing 230 BTDC cannot be attained adjust the timing by increasing or decreas
ing the thickness of shim material under the injection pumps mounting flange to change the injection timing
point Changing the shim thickness by 0004 inch 001 mm changes the injection timing by degree To advance the timing decrease the shim thickness as
required To retard the timing increase
the shim thickness as required Refer to your engines Parts List for shim part Diesel Engines 88
LAYUP AND owners rely on their boatyards to prepare their cralt including engines and generators for layup
during the offseason or lor 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 il 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 Shall 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 Irom land to water and during storage in a cradle 01 the boat often puis a severe strain on the
propeller shalt or coupling or both while the boat is
taken out or put in the water In some cases the shalt has actually been bent by these strains This does
not apply to small boats that are hauled out 01 the water when not in use unless they have been dry for period of time
Fresh Water Cooling System
A 5050 solution 01 antifreeze and fresh water is recommended for use in the fresh water cooling system at
all times This solution may require a higher concentration of antifreeze depending on the areas Check the solution to make sure the antifreeze
protection is more antifreeze be needed drain an appropriate amountfrom 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 lubrication System
With rhe engine warm drain all the lubricating oil from the oil sump Remove and replace the oil filter Place
some paper towels and a plastic bag around the filter to catch the oil during its installing the new oil filter be sure to apply a small amount of
oil on the rubber sealing gasket at the
base of the filter Fill the sump with the correct amount of oil for your engine Refer to section of this manual page 13 forthe W 358 page 16 for the
W 38B and page 19 for
the W 42B Use an oii with an API specification 01 CC or CD Run the engine and check for proper oil pres
sure and make sure there are no leaks
89 Weslerbeke 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 lubrication System
Fill the transmission completely full of the same oil that was use during its operating season DO NOT mix
grades of oil Filling the transmission immerses the internal components in oil which protects
them against corrosion during the layup 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 make sure no air is left in the fuel system Check for any leaks that may
have been created in the fuel system during this servicing correcting them as needed
Sea Water the throughhull sea cock Remove the sea water intake hose from the sea cock Place the end of
this hose into a 5gallon bucket of clean fresh water Before starting the engine check the zinc anode found
in the primary heat exchanger on the engine and clean or replace it as required and also clean any zinc
debris from inside the heat exchanger where the zinc anode is located Clean the sea strainer if one is in
stalled 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 wah 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 Diesel Engines 90
Intllke Manifold and ThroughHull a clean clolh 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
10 startup The throughhull exhaust part can be blocked in the same and cleaning of the starter drive pinion is advisable if access to the starter
permits its easy
removal Make sure the battery connections are shut off before attempting to remove the starter Take care
in properly replacing any electrical connections removed from the 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 Make sure you have replacements for the injector and return
line sealing time provides a good opportunity to inspect your Westerbeke engine to see ff external items such
as drive belts or coolant hoses need replacement Check your basic spares kit and order items not on hand
or replace those items used during the layup such as filters and zinc batteries are to be left on board during the layup period make sure they are
fully charged and will remain
thaI 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 01 your Westerbeke engine after a seasonal layup generally follows the same proce
dures as lhose presented in the PREPARATIONS FOR STARTING seclion page 33 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 Ihe 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
91 Weslerbeke Diesel Engines
3 Drain the transmission of all oil Fill the transmission to the proper level with the correcttype of oil specified
in your engines SYSTEM section of this manual
IWARNINGI
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 make sure that the batteries are
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 ofthis
manual page Diesel Engines 92
TABLE OF STANDARD HARDWARE TIGHTENING stated otherwise for a specific assembly use the following torque values when tightening
Pitch Ibft kgm
Grnde 4T
6mm bolt headnut 1 29 51 04 07
Bmm bolt headnut 125 72 116 10 16
10mm bolt headnut 125 137 224 19 31
10mm bolt headnut 15 130 217 18 30
12mm boll 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 514767 71 6mm bolt headnut 1 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 aT ad ll
Smm bolt headnut 58 87 08 12
Bmm bolt headnut 125 145 217 20 30
lOmm bolt headnut 125 289 398 40 55
1Dmm bolt headnut 15 268 37S 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 QapSQ9W
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 37 46
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 93
Westerbeke Diesel Engines
TORQUE head bolt M10 507 579 70 80
M12 796 868 110120
See the Torquing Cylinder Head Bolts section of this manual on page pulley nut 1085 1808 200 250
Main bearing cap bolt 362 434 50 rod cap nut 231 253
32 35
Flywheel bolt WITh separate washers 832 904 115 bolt washer attached 950 1000
130 140
Oil pan drain plug 362 434 50 60
Oil filter 80 94 11 13
or tighten firmly by valve holder injection pump 289 362 40 50
Nozzle mounting bolt 108 145 15 20
Nozzle holder and retaining nut 434 579 60 80
Glow plug 108 145 15 20
NOTE M8 indicates Metric 8 mm thread Diesel Engines 94
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 Impeller 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
Oil and a Gallon of Premixed parts whose Ine 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 ora Major Overhaul Kit the pumps part number is found on the cover of the 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 if you are planning a long ocean voyage consult your local for a listing of the Westerbeke dealers located on your
route
95 Westerbeke Diesel Engines
INDEX
Injection Pump Timing MAINTENANCE AND Valve Clearance 0N 35B THREE Engine Valve Clearance 0N 38B FOUR and W 42B FOUR Engines 87
Admirals Panel Panel Control Circutt DC Wiring Diagram 36844 50 and 51
Alignment of the Engine Installation Checks and Water Pump Drive Belt Tension CONCENTRATION DATA Alarm System B
Batteries Layup and Specification Tension Alternator and Water Pump Drive Engine Installation Checks Torquing Cylinder Head 0N 35B THREE Engine
Torquing Cylinder Head 0N 38B FOUR and W 42B FOUR Engines Procedures Engine C
CAUTIONS
SHIPPING ENGINE WITHOUT ENGINE OIL 21
LIFTING SUNGS 22
TIGHTENING THE EXHAUST ELBOW CLAMP 29
THROUGHHULL FITTINGS 30
PROLONGED ENGINE CRANKING 39
SHUTTING DOWN THE ENGINE 41
PROLONGED ENGINE CRANKING 44
BATTERY CIRCUIT 46
THE BATTERIES 46
TESTING THE ALTERNATOR 46
EXCESSIVE BELT TENSION 55
TRANSMISSION GEAR BOX LEVER COVER BOLTS 65
ADJUSTING VALVE CLEARANCES 86
ADJUSTING VALVE CLEARANCES 87
LEAVING OLD ENGINE OIL IN SUMP OVER LAYUP 90
Captains Panel Captains Panel Control Circuit DC Wiring Diagram 36467 48 and 49
Change Engine Oil to include filter Charging Voltage Test CHECKS INSTALLATION Westerbeke Diesel Engines
96
Circuit Fresh Water 52
Circutt Sea Water 55
Clearance Adjustment Valve 0N 358 THREE Engine 86
Clearance Adjustment Valve 0N 388 FOUR and W 428 FOUR Engines 87
Connecting Pressure Sensing Devices to Oil Galleries Installation Checks 30
CONTENTS TABLE OF 3
Cooling JS Transmission 65
COOLING SySTEM 52
Cooling System Installation Checks 30
Controls JS Transmission 64
Coupling Propeller Shalt Installation Checks 24
Coupling Propeller Shalt Layup and 89
Cylinder Head Bolts Torquing 0N 358 THREE Engine 85
Cylinder Head Bolts Torquing 0N 38B FOUR and W 42B FOUR Engines 85
Cylinder Lubrication Layup and 91
DC Wiring Diagram 36844 Admirals Panel Control Circuit 50 and 51
DC Wiring Diagram 38467 Captains Panel Control Circuit 48 and OF INSTRUMENT PANELS of Starting System 34
Diesel Engine Understanding the 5
Diesel Fuel IMPORTANT PRODUCT SOFTWARE 1
Domestic HoI Waler 58
Drain Hose Oil Installation Checks 30
ELECTRICAL SYSTEM 46
Electrical System Installation Checks 32
Engine Alignment of the Installation Checks 24
Engine Bolts Installation Checks 23
Engine Breakin Procedures 41
Engine Diesel Understanding the 5
Engine Foundation lor the Installation Checks 23
Engine Lubrication System Layup and 89
Engine Oil 60
Engine Oil Change to include filter 61
Engine Oil Viscosity SAE Number 60
ENGINE 79
EqUipment Inspection of 2
Exhaust BackPressure Installation Checks 27
Exhaust Elbow Installation Installation Checks 29
Exhaust System Installation Checks 26
Exhaust System Failures Installation Checks 28
91 Westerbeke Diesel Engines
FORWARD for the Engine Installation Checks Water Circuit Water Cooling System Layup and 89
Fuel Diesel Filters Filter Elements Replacing Injection Pump System Installation Checks System Layup and System Priming the SYSTEM G
GENERAL W 35B W 38B W 42B H
HARDWARE TIGHTENING TORQUES TABLE OF STANDARD Bolts Torquing Cylinder W 35B THREE Engine Bolts Torquing Cylinder W 38B FOUR and W 42B FOUR Engines
Oil Drain Installation Checks Water Domestic Warner PRODUCT SOFTWARE DISCLAIMER 1
INDEX Pump Fuel Pump Timing Adjustment of Equipment CHECKS PANELS DESCRIPTION Manifold and ThroughHull Exhaust Layup and System Sea Water
Installation Checks J
JS Transmission Diesel Engines 98
LAYUP AND 89
Lifting Rigging and Installation Checks 22
Location Installation Checks JS Transmission SYSTEM 60
AND ADJUSTMENTS 69
Motor Starter Layup and 91
Oil Change to include filter Engine 61
Oil Drain Hose Installation Checks 30
Oil Engine 60
Oil Engine Viscosity SAE Number 60
Oil Galleries Connecting Pressure Sensing Devices to Installation Checks 30
Oil Pressure 60
OPTIONAL TRANSMISSIONS 66
Ordering Parts 5
Panel 37
Panel Captains 35
PANELS DESCRIPTION OF INSTRUMENT 35
Parts Ordering 5
PARTS SPARE FOR STARTING 33
Pressure Oil 60
Pressure Sensing Devices to Oil Galleries Connecting Installation Checks 30
Priming the Fuel System 44
PROCEDURE STARTING 39
PROCEDURE STOPPiNG 41
PRODUCT SOFTWARE DISCLAIMER IMPORTANT 1
Propeller Installation Checks 24
Propeller Shaft Coupling Installation Checks 24
Propeller Shaft Coupling Layup and 89
Pump Fuel Injection 45
Pump Sea Water 55
Pump Timing Adjustment Injection 88
99 Westerbeke Diesel Engines
Layup and the Fuel Filter Elements and Lifting Installation Checks S
Sailing Operation JS Transmission JS Transmission Water Circuit Water Circuit Layup and Water Pump Water Intake System Installation Checks
Coupling Propeller Installation Checks Coupling Propeller Layup and JS Transmission DISCLAIMER IMPORTANT PRODUCT 1
Spares Layup and PARTS Motor Layup and PREPARATION FOR PROCEDURE System Description 01 Under Cold Conditions Under Normal Conditions
PROCEDURE W 35B W 38B W 42B T
TABLE OF CONTENTS OF STANDARD HARDWARE TIGHTENING TORQUES Charging Voltage Adjustment Injection Pump Cylinder Head Bolts 0N 35B THREE
Engine Cylinder Head Bolts W 38B FOUR and W 42B FOUR Engines Lubrication System Layup and OPTIONAL Warner Hydraulic ENGINE Weslerbeke
Diesel Engines 100
Under Cold Conditions Starting 42
Under Normal Conditions Starting the Diesel Engine 5
Valve Clearance Adjustment 0N 35B THREE Engine 86
Valve Clearance Adjustment 0N 38B FOUR and W 42B FOUR Engines 87
VDrives 32
Viscosity SAE Number Engine Oil 60
Voltage Test Charging 47
IWARNINGsl
DIESEL FUMES 28
FLAMES NEAR BATTERIES 32
SERVICING BATTERIES 32
ADJUSTING DRIVE BELT TENSION 55
SERVICING BATTERIES 92
Walter VDrives 73
Warner Hydraulic Transmissions 68
Water Domestic Hot 58
Water Fresh Circuit 52
Water Sea Circuit 55
Water Intake System Sea Installation Checks 31
Water Pump Sea 55
Water Pump Belt Tension Alternator and 55
Wiring Diagram 36844 Admirals Panel Control Circuit DC 50 and 51
Wiring Diagram 36467 Captains Panel Control Circuit DC 48 and 49
101 Westerbeke Diesel Engines
YOUR Diesel Engines 102
YOUR NOTES
103 Weslerbeke Diesel Engines
YOUR Diesel Engines 104

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