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Westerbeke Diesel 30c Three Technical Manual



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OPERATOR'S MANUAL




            WESTER8EKE


 358 THREE, 388 FOUR, 428 FOUR

           MARINE DIESEL
             ENGINES




             Publication # 37435

                  Edition One

                  March 1988




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

The following symbols appear in this manual to call attention      ·   Use Extreme Care When Handling Engine Filel
to and emphasize conditions potentially dangerous to the               (A constant danger of explosion or fire exists)
operator,
                                                                       Do not fill fuel tank{s) 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 possible
serious personal injury or loss of life.
                                                                   ·   Do Not Alter or Modify the Filel System
                                                                       Be sure all fuel supplies have a positive shut-off 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 environment.
and equipment.

Fuels, exhaust gases, batteries, electrical equipment, and
moving and hot parts are potential hazards that could result in    ·   Use Extreme Care When Servicing Batteries
serious personal injury or death. Follow recommended proce-
dures carefully.                                                       Wear rubber gloves, a rubber apron, and eye protection
                                                                       when servicing batteries.
Always operate bilge blowers for at least five minutes before
starting a gasoline-fueled engine; ensure no gasoline fumes are        Lead acid batteries emit hydrogen, a highly-explosive gas,
present before starting.                                               which can be ignited by electrical arcing or by a lighted
                                                                       cigarette, cigar, or pipe. Do not smoke or allow an open
                                                                       flame near the battery being serviced. Shut off all electri-
 ·   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 vessel's AC circuits,       moving parts.
     except through a ship-to-shore double-throw transfer
     switch. Damage to vessel's AC generator may result if this        Make sure 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 drive-belt's tension while
                                                                       the unit is operating.

                                                                       Do not work on the equipment when mentally or physical-
 ·   Exhaust Gases Are Toxic                                           ly incapacitated by fatigue.

     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 well-ventilated.
                                               IMPORTANT

                                  PRODUCT SOFTWARE DISCLAIMER

Product software 01 all kinds, such as brochures, drawings, technical data, operator's and workshop
manuals, parts lists and parts price lists (and other related information), instructions and specifications
provided from sources other than Westerbeke, Is not within Westerbeke's control and, accordingly, is
provided to Westerbeke customers only as a courtesy and service. WESTERBEKE CANNOT BE RESPON-
SIBLE FOR THE CONTENT OF SUE:H SOFTWARE, MAKES NO WARRANTIES OR REPRESENTATIONS
WITH RESPECT THERETO, INCLUDING THE ACCURACY, TIMELINESS OR COMPLETENESS THEREOF,
AND WILL IN NO EVENT BE LIABLE FOR ANY TYPE OF DAMAGES OR INJURY INCURRED IN CONNEC-
TION WITH, OR ARISING OUT OF, THE FURNISHING OR USE OF SUCH SOFTWARE.

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

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

In summation, product software provided WITh Westerbeke products, whether from Westerbeke or other sup-
pliers, must not and cannot be relied upon exclusively as the definitive authority on the respective product.
It not only makes good sense, but is imperative that appropriate representatives of Westerbeke or the sup-
plier in question be consulted to determine the accuracy and currency of the product software being con-
sulted by the customer.




                                                           1                        Westerbeke Diesel Engines
                                                   FOREWORD

Thank you for selecting a Westerbeke marine product for your use. We at Westerbeke are pleased to have
you as a customer.

Read this manual carefully and observe ali safety precautions included throughout. Operating procedures,
periodic 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 return.

Should your unit require special attention, contact your Westerbeke dealer for assistance. The Westerbeke
Service Organization is trained to provide the support necessary to ensure long-term dependable perfor-
mance.

If, within 60 days of submitting the Warranty Registration Form for your unit, you have not received a Cus-
tomer Identification Card (see below) registering your warranty, please contact the factory in writing with
Model information, including the engine's serial number and commission date.



                 from:    WESTERBEKE CORPORATION
                          AVON INDUSTRIAL PARK
                          AVON. MA 02322




                                                            Tit'"   ,,~   ..... "",   ,~'" ~5~-""   .,,,,,,,, .".<0 ··
                                         CUSTOMER IDENTIFICATION
                                           Adam Smith
                                           85 Maple Street
                         Mail To:          Alden, 1M 12234

                                           Model    W 358 THREE             Ser. It 1234C7G6
                                           Expires 117/88




Inspection of Equipment

The engine is shipped from the factory mounted securely and properly crated. Accessory equipment is
shipped in a separate small box, usually packed within the engine's crate.

Before accepting shipment of the engine from the transportation company, the craie should be opened and
the contents inspected lor concealed damage. if either visible or concealed damage is noted, you should
require 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. Claims
concerning loss or damage must be rnade to the carrier, not to the Westerbeke Corporation.




Westerbeke Diesel Engines
                        TABLE OF CONTENTS

Section ..........................................................................Page


W 358 THREE MARINE DIESEL ENGINE
GENERAL SPECIFICATIONS .......................................... 12

W 35B THREE SYSTEM SPECiFiCATIONS .................... 13

W 38B FOUR MARINE DIESEL ENGINE
GENERAL SPECIFICATIONS .......................................... 15

W 38B FOUR SYSTEM SPECiFiCATIONS ...................... 16

W 42B FOUR MARINE DIESEL ENGINE
GENERAL SPECIFICATIONS .......................................... 18

W 428 FOUR SYSTEM SPECiFiCATIONS ...................... 19

INSTALLATION CHECKS ................................................ 21

PREPARATION FOR STARTING ..................................... 33

DESCRIPTION OF INSTRUMENT PANELS .................... 35

STARTING PROCEDURE ................................................ 39

STOPPING PROCEDURE ................................................ 41

FUEL SYSTEM ................................................................. 43

ELECTRICAL SYSTEM ..................................................... 46

CAPTAINS PANEL DC CONTROL CIRCUIT
WIRING DIAGRAM # 36467 ................................... .48 & 49

ADMIRALS PANEL DC CONTROL CIRCUIT
WIRING DIAGRAM #36844 ..................................... 50 & 51

COOLING SySTEM .......................................................... 52

LUBRICATION SYSTEM .................................................. 60

JS TRANSMISSION ........................................................ 63

OPTIONAL TRANSMISSIONS ......................................... 66

ENGINE TROUBLESHOOTING ....................................... 79

MAINTENANCE & ADJUSTMENTS .............................·.... 82




                                                3                                    Westerbeke Diesel Engines
                                            TABLE OF CONTENTS
                                               (CONTINUED)


                    LAY-UP & RECOMMISSIONING ......................................89

                    TABLE OF STANDARD HARDWARE
                    TIGHTENING TORQUES ..................................................93

                    TORQUE SPECiFiCATIONS .............................................94

                    SPARE PARTS ..................................................................95

                    INDEX ................................................................................96




Westerbeke Diesel Engines                                     4
                                                  GENERAL

Introduction

This 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 to
satisfactory repair; therefore, a troubleshooting table is included.


Understanding 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, and
lubricating system.

Therefore, 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 essential.
Another important factor is the use of the same brand of high detergent diesel lubricating oil designed specifi-
cally for diesel engines. Be careful not to put gasoline in the diesel fuel tank(s). 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 injectors.

The diesel engine does differ from the gasoline engine, however, in its handling and firing of fuel. The car-
buretor and ignition systems are done away with and in their place are two components - the fuel injection
pump and the fuel injectors.


Ordering Parts

When contacting your Westerbeke dealer, parts distributor, or the factory concerning your Westerbeke unit,
always provide the engine's model and serial number, and transmission number as they appear on the black
and silver "Westerbeke" plate Which is mounted on the engine's 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 equipment.

Note that component locations in the manual are referenced from the front of the engine which is the pul-
ley/drive belt end. (The flywheel/transmission 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 right.

Westerbeke engines and generator sets afe thoroughly checked and given a final run under various load
conditions 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 engine
capable 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 owner/operator.




                                                            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 Connection




Westerbeke 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 Pl,!mp


   Instrument
   Connections

                                                                                            Side Lube
  Secondary                                                                                 Oil Fill
  Fuel Filter ---....;::....

   Zinc Anode                                                                               Shut-off
                                                                                            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




                                   Starter




Westerbeke Diesel Engines
                                 W 388 FOUR Marine Diesel Engine




                                                    Top Engine Oil Fill
                            Air Intake SilElnCler


   Fuel Lift pump



Connections


 Secondary
 Fuel Filter'----
      Zinc Anode - -
                                                                                             _"___'_ Oil




                                                                                          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




                                    Starter




Westerbeke Diesel Eng ines                    10
                                  W 428 FOUR Marine Diesel Engine




                                                  Top             Oil Fill




   Fuel Lift pump




Fuel Filler
      Zinc Anode
                                                                                                        Oil




                                                                                             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 SPECIFICATIONS

   Engine Type                               Diesel, four-cycle, three-cylinder, fresh water-cooled,
                                             vertical, in-line (32 hp at 3600 rpm, maximum)

   Governor                                  Mechanical, centrifugal weight type

   Valve Mechanism                           Overhead

   Combustion Chamber                        Swirl chamber type

   Bore & Stroke                             3.07 x 3.07 inches (78 x 78 mm)

   Piston Displacement                       68.23 cubic inches (1.118 liters)

   Firing Order                              1-3-2

   Direction of Rotation                     Clockwise, when viewed from the front

   Maximum Torque (at 2300 rpm)              41 Ibs-ft (5.67 kgs-m)

   Compression Ratio                         23:1

   Compression Pressure                      455 psi (32 kg/cm2) at 320 rpm

   Valve Seat Angle                          Intake 45°
                                             Exhaust 45°

   Valve Clearance                           Intake 0.010 inches (0.25 mm)
   (engine cold)                             Exhaust 0.010 inches (0.25 mm)

   Dimensions                                Height: 21.25 inches (539.75 mm)
                                             Width: 18.37 inches (466.60 mm) Max.
                                             Length: 30.10 inches (764.54 mm)

   Inclination                               Continuous 14°
                                             Temporary 25° (not to exceed 30 min.)

   Dry Weight                                3681bs (166.9 kgs)

   Fuel Consumption                          0.42 U.S. gph (1.59 Iph) running at
                                             2500 rpm (approximate)

   Idle Speed                                800 - 1000 rpm

   Cruise RPM                                2500 - 3000 rpm




Westerbeke Diesel Engines                   12
                                W 35B THREE SYSTEM SPECIFICATIONS

FUEL SYSTEM                                     Open flow, totally self-bleeding

  Fuel                                          No.2 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 kg/cm2)

  Lift Pump (with filter element)                12-Volt DC; lift capac~y 6 ft (1.8 m)

   Fuel Filter (on engine)                       Canistertype, with replaceable element

   Air Cleaner                                   Metal screen type - cleanable

   Air Flow (engine combustion)                  71 cfm (2.0 cmm)


COOLING SYSTEM

   General                                       Fresh water-cooled block,
                                                 thermostatically-controlled
                                                 w~h sea water exchanger system


   Operating Temperature                         170 _190" F (77 - 88' C)

   Fresh Water Pump                              Centrifugal type, metal impeller, belt.'LUGS
                                                         ~"                                     WATER
                                                                                                TEMP
                                                                                                                                           "'ATER
                                                                                                                                           TEMP.
                            [l'!".O~6                t::'I.   _il'
                                                                                                SENDER                                     SWITCH
                             OfP£"D'~~       01<     \:1llP'
                                                                                              -~;
                                                                                                ·. lo<'TIONAL
                             NU .. aEI< ,,,ST.
                             ,'"iNDERS'
                                                                                                               PA"tU
                                                     ~               CIRCUIT

                                                    ·;l{*"'
                                                        " ' ''---+-----1-,
                                                              '       '0'
                            PflEHEh 1
                            SOLENOtO
                                                   r



                                                                                                                                 ,
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              -:---ti':r 0
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                                        . +---                                           <'SO""                     "8    OP~



                                                                                                                    ' . cuE

                                                                                                                          ~
                                                                                                                                                        -   1-- -    -




                    ~ ,r '", , 15-
                           ~

                           TEST SwiTCH
                                                         STIlRT
                                                                                                    I'L.Se>              Ifl~i

                                                                                                                       I['r---,
                                                                                                                                                              ro-~
                                                                                                                                                              ,/
                                                                                                                                                            ,- - I)
                  .
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                                                                                        ~A~pl ~.         '14    "   I ~';~I                         I
                  .-
                                                                                                                    48
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                       I
                                    ,         ,    ~E"


                                                         PREHEAT
                                                                                         LA~tPt
                                                                                         W T.

                                                                                                    ',4s,Ur
                                                                                                                          £!,
                                                                                                                                                              TACHOMETER

                                                                                                                                                                           I
                   """'" I                               S"ITCH
                                                                                        "18 Bl<                                                                            I
                                                                                        .,~   Gc'                                      I                                   I
                                                                                        "BBL"                                                                              I
          I                                                                             "oSL'                                                                              I
          ~------------------------------~


Westerbeke Diesel Engines                                                                                           48
Captains Panel DC Control Circuit Wiring Diagram #36467
                     page 2 of 2



        r:;:    '2VOC                SCHEMATIC




                                                                 ,




                                         , C.B
                                         ) IQA
                                                    ,----:---"1;"


                                  hi "      " " "
                                              " !
                                           X· " ,,!
                                                        " "

                                           ~       n

                        5TIIOIT            .~                "
                        SW'TCH                           n

                                           :;
                                           '",
                                  "         Go
                                  "        ALARM




  START' I,TURN KEY TO ON POSITION. THE ALARt~ WILL SOUND,OIL PRESSURE .'\NO
                BATTERY CHARGE INQICATORS HILL LIGHT,

               2.PUSH pqEHEAT SWITCH FOR. 15 TO 50 SECONDS                   AS REQUIRED, ALARM 'WILL STOP,

               3,WHILE CONTINUING TO PUSH              PREHEAT SWITCH,PUSH THE START SWITCH ALSO.
                I-/rlEN 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 STARTER,EXCESSIVE CURRENT DRAIN WILL CAUSE THE BREAKER TO 7RIf' AND THE
   ENGINE WILL SHUT OO\iN. THE BUILDER./eWNE>:! MUST 8E SURE THAT THE ICiSTHUMENT
   PANEl,WIRING AND ENGINE >'IRE INSTALLED TO PREVENT CONTACT BETWEE\J ELECTRICAL
   DEVICES AND SALTWATER.


  2.AN ON-OFF SWITCH SHOULD              BE       INSTALLEO BET'

                                                                                                                                               ;1            i
                                                                                                                                      z


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                                                                                                                                                      <
                                                                                                                                      <
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                                                             ~ ~! 'It~ 'It!"'! 'It:""
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                                                                                         :::':::::::i~,~,:::t~
                                                                                                                    1_

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                                                                                                                                                                                      \\jJ)/
                                                      .                RTi! I                                                            F)
                                                                                                                                                  ~ ALARM BUZZER
                                                                                                                    I


                                                                                     I       ,-'      -+------;--,
                                                                                                                                                                                I
                                                                                                                        T -- --il-I- I
                                                                                                                           I                                        :       I
                                               OIL PRESS                   -WATERTE~
                                                 GAUGE                                           GAUGE                   I                                                                I



                                                -NI ~,
                                                  -e               >'21~E,>                           ~_ II
                                                                                                                         I
                                                                                                                         I"'~YEL
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                                                                                             I I I~"GRN!                         \,        ·cJ~G>t'._.
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                                                                                         W:::
                                                          :0 ",' "14GRN.



                                ~-,---,-".--c/,:.,c,o:~                    I                                            I         Z~
                                                 ~                      !             \               /               lJiTART                      PREHEAT
                                           KEY SWITCH                                        ~                                  S,WITCH               SWITCH
                                                                                             VOLTMETER                           .~                    (~

                                                                                                                                 ~' .. ~oel'.               -           I




Westerbeke Diesel Engines                                                                                                       50
           Admirals Panel DC Control Circuit Wiring Diagram #36844
                                 page 2 of 2


                                            SCHEMATIC DIAGRAM




                      NEUTRA
                  Isw.

                T
                ,,1
  1"1\          ~I,
                           "
                           1=1   PI   1'1


                  I
         1KEY
   W
   .
     "r sw        I

                  I
                                            e,o   p

                                            · ALARM

    ~-
         ~I
    I PREHEAT $W,



NOTE:

1. THIS PRODUCT IS PROTECTED BY A MANUAL RESET CIRCUIT BREAKER LOCATED NEAR THE
   STARTER. EXCESSIVE CURRENT DRAIN WILL CAUSE THE BREAKER TO TRIP AND THE ENGINE
   WILL SHUT DOWN. THE BUILDER/OWNER MUST BE SURE THAT THE INSTRUMENT PANEL,
  WIRING, AND ENGINE ARE INSTALLED TO PREVENT CONTACT BETWEEN ELECTRICAL
  DEVICES AND SALT WATER.

2. AN ON~OFF SWITCH SHOULD BE INSTALLED BETWEEN THE BATTERY AND STARTER TO 015-
   CDNNECTTHE BATTERY IN AN EMEAGENCY,ANO 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 INSULATED.




                                                      51              Westerbeke Diesel Engines
                                            COOLING SYSTEM
Description

Westerbeke marine diesel engines are designed and equipped for fresh water cooling. Heat produced in
the engine by combustion and friction is transferred to fresh water which circulates throughout the engine.
This circulating fresh water cools the engine block and 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 transferred
heat over the side through the exhaust system. The fresh water and sea water circuits are independent of
each other. Using only fresh water within the engine allows the cooling water passages to stay clean and
free from harmful deposits. The two independent circuits and their components are discussed in the follow-
 ing paragraphs.


Fresh Water Circuit

      NOTE: Refer to paragraphs A and B in this section for the recommended antifreeze and water
      mixture to be used as the fresh water coolant, and for information on filling the fresh water
      system.

Fresh water is pumped through the engine by a belt-driven circulating pump, absorbing heat from the en-
gine. The fresh water coolant circulates through the engine's block absorbing heat, then passes through
the thermostat into the exhaust manifold, to the heat exchanger where it is cooled, and then is returned to
the engine block through the suction side of the fresh water circulating pump. When the engine is started
cold, external fresh water flow is prevented by the closed thermostat (although some fresh water flow is
bypassed around the thermostat to prevent exhaust manifold from overheating). As the engine warms up,
the thermostat gradually opens, allowing full flow of the engine's fresh water coolant to flow unrestricted to
the external portion of the cooling system.


    A. Fresh Water Coolant (Antifreeze) Mixture.

A freshwater and antifreeze mixture should be used year-round in the cooling system. Water, when it freezes,
expands sufficiently to split the heat exchanger and crack the engine block. A water/antWreeze mixture of
proper concentration will prevent freezing (see page 53 for an antifreeze/water mixture chart).

Use soft water with few impurities, such as tap water (potable water) or rainwater. Never use hard or foul
water. Use of hard water or water containing impurities will lead to the collection of scale in the engine and
heat exchanger which will reduce the cooling system's efficiency.

Antifreeze of poor quality or without rust inhibitors will cause corrosion within the cooling system. Always
use antrrreeze which is compatible wah aluminum cooling system components and is made by a reliable
manufacturer. Never mix different brands of antifreeze.

Make sure that the cooling system of the engine is well cleaned before adding antifreeze. Recommended
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 system.




Westerbeke 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 stainless
steel mounting bracket is supplied with each kit along with a 30-inch length of clear plastic hose and clamps
to connect the hose between the engine's manifold fitting to the hose spud on the base of the recovery tank.


                         FUNCTION OF MANIFOLD PRESSURE CAP

               From Coolant Tank            COOLANT RETRACTION




              to Coolant Tank                  COOLANT EXPANSION




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

When 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 engine's
cooling 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 direction.




                                                          53                         Westerbeke Diesel Engines
                      COOLANT RECOIIERY TA"I<




                                 :   '1       :    i: '
                              . , \"
                                   ,'\            .
                                                  'I'
                                                    " \   .,
                             .'\'
                             1\'\                   "I '
                                                  '\1
                                 ,
                             . \", ,
                                   (,
                                          I           '   1
                                                          !
                                                              1I




                             Coolant Recovery Tank, Recommended Installation

Fill 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 coolant's expansion flow into the plastic recovery tank.

6. Check for leaks between the pressure cap/filler 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 engine's temperature comes
   down.

7. Add coolant to the recovery tank, as required, to top off the fresh water coolant system.


Thermostat

Generally, thermostats are of two types. One is simply a choking device which opens and closes as the
engine's temperature rises and falls. The second type has a bypass mechanism. Usually this is a disc on
the bottom 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 engine's warm-up. Replacement thermostats must have
this design characteristic.




Westerbeke 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 exchanger's sea
water inlet. The sea water passes through
the heat exchanger's lUbes, from which




                                                                     i
                                                                                       .....
heat from the fresh water system is ab-
sorbed, and then the sea water is dis-
charged from the cooling system
overboard through the water-injected wet
exhaust system, Be sure to clean zinc                                                                 CLEAN
                                                   NEW                                                  OR
debris from the area inside of the heat ex-       ANODE                            REPLACE
                                                                   REPLACE                           REPLACE
changer where the zinc anode is posi-
tioned,

                                                                  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 self-priming, gear-driven rotary pump with a non-ferrous housing and a neoprene
impeller. The impeller has flexible vanes which wipe against a curved cam plate within the impeller housing,
producing the pumping action, On no account should this pump be run dry, There should always be a spare
impeller and impeller cover gasket aboard (an impeller kit), Sea water failures occur when lubricant (sea
water) is not present. Such failures are not warrantable and the operator's are cautioned to make sure sea
waler flow is present at start-up.


Alternator and Waler Pump Drive Bel! Tension



                                                    IWARNING!

       Never attempt to adjust the drive belt's tension while the engine is in operation,


                                                        CAUTION

      Excessive alternator and water pump drive belt tension can cause rapid wear of the belt and
      reduce the service 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 belt(s) is/are properly adjusted Wthe belt can be deflected no less than
3/8 inch and no more than 1/2 inch (10 mm, 12 mm) as the belt is depressed with the thumb at the midpoint
between the two pulleys on the longest span of the belt. (See the figure below.) A spare drive belt should
be carried on board.




                                 Alternator and Water Pump Selt Tension




Westerbeke Diesel Engines                            56
Illustrated below is a typical Westerbeke engine's cooling system. Both fresh water and sea water flow
through their independent cooling circutts. Refer to your engine's Parts List for part numbers and part
descriptions 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 1/8 NPT fitting.




                      WATER INJECTED
                          ELBOW


                                             EXHAUST




                                                                         WATER
   COOLANT
   RECOVERY
     TANK



              HEAT




                               CONTROllER

                                              OVERHEAT ALARM


                                                               FRESH WATER PUMP


                                                                                          f
                                                                                  IMCOMING SEA VATER




                                        Typical Cooling System




                                                  57                        Westerbeke Diesel Engines
Domestic Hoi Water

All engine covered in this manual are
equipped with a domestic hot water con-
nection. If the owner/operator wishes to
connect a hot water heater, remove the
bypass hose and connect a heater as
described in the instructions presented
below.


General: 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 Controller

Installation: 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




                                                                                          A


                                                         AIR BLEED PET COCK




                      HEATER BELOW ENGINE                                                         HEATER ABOVE ENGINE




The 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 engines.




Westerbeke Diesel Engines                              58
Hoses should rise continuously from their low point at the heater to the engine so that trapped air will rise
naturally from the heater to the engine. If trapped air 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 engine's own pressure cap, then a
      pressurized (aluminum) remote expansion tank must be installed in the circuit to become the
      highest point. The remote expansion tank's 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 SYSTEM

Engine Oil

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


Engine Oil Viscosity (SAE Number)

Use an oil having a viscosity best suited to the atmospheric temperature. Use of an all-season oil SAE 10W-
30 with minimum viscosity change under different temperatures is suggested.


                          Atmospheric Temperature                            Viscosity

                          68' F (20' C) or higher                   SAE 30 or 10W-30
                          41' F (5' C) - 68' F (20' C)              SAE 20 or 10W-30
                          41' F(5' C) - or lower                         SAE 10W-30


      NOTE: Do not use an engine lubricating oil with an SAE number greater than 30 in the en-
      gine.


Oil Pressure

The engine's 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 proportionately with speed.

      NOTE: A newly started, cold engine can have an oil pressure reading upwards of 60 psi. A
      warmed engine can have an oil pressure reading as low as 35 psi. These readings will vary
      depending upon the speed at which the engine is running.




Westerbeke 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 drained.

Always observe the old oil as it is removed. A yel-
low/gray emulsion indicates the presence of water in
the oil. Although this condition is rare, it does require
prompt attention to prevent serious damage. Call a
competent mechanic should water be present in the
oil. Sea water present in the oil can be the result of a
fault in the exhaust system attached to the engine
and/or a siphoning through the sea water cooling 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 lessen
spillage. A small style automotive filter wrench
should be helpful in removing the old oil filter. Place
some paper towels and a plastic bag around the fil-
ter when unscrewing it to catch any oil left in the fil-
ter. (Oil or any other fluid on the engine reduces the
 engine's cooling ability. Please keep your engine
 clean.) Inspect the old oil filter as it is removed to
 make sure that the 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 cartridge-type 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 gasket's sealing surface on the engine block free of
oil and apply a thin coat of clean engine oil to the rubber gasket on the oil filter. Screw the filter onto the
threaded oil filter stub, and then tighten the filter 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 engine's oil pressure.
Make 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 Li.it
                                                               INor ·· l   Leve~l~fl~__ l~~~~==~~~
                                                                               ----.. -- -   0 il
                                                                           Li.i t."r    ===== --.
                                                                            Crankcase




Westerbeke Diesel Engines                               62
                                             JS TRANSMISSION
                                                 (Standard)
General

The transmission's gear ratio is 2.47 to 1. The JS transmission is made of a lightweight, high-strength, cor-
rosion-resistant 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 case-hardened 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 factory,
however, each transmission is thoroughly tested with oil in the transmission. This testing, among other things,
provides all internal parts with a coating 01 oil. This oil acts as a preservative, providing reliable protection
against corrosion for at least one year if the transmission is property stored.




                                                                                   BEll
                                                                                   flOIlSlltG



                                GEAR BOX
                                tOH1ROl
                                LEVER




                                                                                OIL IlRAIH
                                                                                HOG


                                                                              (Allen Wrench size is
                                                                              6mm)

Lubrication

The JS transmission is an immersion-lubricated type. Fill the transmission up to or near the top of the
machined notch cut on the dipstick with SAE 20 W/20 or SAE 30 weight engine oil exclusively. Multigrade
oils are not to be used in this transmission. DO NOT mix grades of oil! Lubricating oils may have an API
specification of CC, CD, SC, SO, or SE.

The oil capacity for the JS transmission is approximately 1.0 quart (1.0 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 O-ring gaskets on the dipstick are in good shape. These O-rings 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 Engines
Alignment

Misalignment between the transmission's coupling and the propeller shaft's coupling can create serious
problems. 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 25.


Controls

The only controls required to operate the
transmission is a single lever remote control
cable. The cable should be attached to the
gear box lever using the cable bracket 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 position
without running out of cable. Allow ap-
proximately 1 1/2 inches of cable throw from
the NEUTRAL position on the transmission's
 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
      transmission's 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                           64
Shifting

To shift the transmission from NEUTRAL into FORWARD, exert a heavy push to the remote control lever. A
gentle throw may not carry enough force to actually shift the transmission's internal gears. A gentle throw is
signalled by the transmission not engaging into the desired drive. Make sure the remote control lever is 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 two-bolt 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 cover's
      capscrews voids the transmission's warranty.


Sailing Operation

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 gear.


Service

If 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 transmission's coupling and the propeller shaft's 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 critical
adjustments.

Disassembly 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 center.

Cooling

The JS transmission is sea water-cooled. 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 transmission's lubricating oiL




                                                      65                        Westerbeke Diesel Engines
                                    OPTIONAL TRANSMISSIONS

                                 HBW 100, 150, 150V Transmissions




                                        DIPSTICK/
                                        FIll PORT

                                                                         DIPSTICK/FIll 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 slowly.

Control 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             \----C""O'"
2.     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 0.5 mm
       (0.002") clearance.
                                                                                                :r--
5.     Over travel of the actuating lever does no harm.                                    O.Smm

       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
                                                                       L'l' .
                                                                             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  wh'l
                                          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        1.5:1            2:1                             2.5:1

                     HBW 150        1.5:1            2:1                             2.5:1

                     HBW 150V       1.5:1            2:1                             2.5:1

       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 Transmissions



                                                  FROM COOLER
                                                   (2.10:1 ONLY)
            SHIFT LEVER                                                        DIPSTICK ASSEMBLY




             FROM       10-13/10-14
            COOLER                                           FROM COOLER       10.1]/10.18
                                                             (EXCEPT 2.10:1)



1.      CONTROL LEVER POSITION
The position of the control lever on transmission when in forward
should 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
and/or ball is permanently removed, or if the the control lever is
changed in any manner, or repositioned, or if linkage between remote
control 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.      LUBRICATION

The properties of the oil used in the transmission are extremely
important to the proper function of the hydraulic system. Therefore,
it is extremely important that the recommended oil, automatic
transmission 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 dipstick.
Check oil level prior to starting engine. Check daily before starting
engine.  The hydraulic circuit includes the transmission, oil cooler,
cooler lines and any gauge lines connected to the circuit.         The
complete   hydr aulic circui t  must   be  filled  when   filling  the
transmission 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 only,
immediately after the engine has been shut off and again after the
engine has been stopped for more than one hour           (overnight is
excellent). A noticeable increase in the oil level after this waiting
period 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 spring-loaded
ball enters the chamfered hole in the side of the shift lever and pro-
perly locates lever in neutral position before starting engine.


  Shifting

Shifts 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 lowest
feasible engine speed.   Move the shift lever to the extreme forward
position where the spring loaded ball enters the chamfered hole in the
side of the shift lever and properly locates lever in forward
position.
Move transmission shift lever to the extreme rearward position where
the spr ing-loaded ball enter s the chamfered hole in the side of the
shift lever and properly locates it in the reverse position.


  Freewheeling

Under sail with the propeller turning, or at trolling speeds with one
of two engines shut down, the design of the gear maintains adequate
cooling 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 Problems

Water 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 foreign
material from the cooler passages.     The cooler and hose should be
thoroughly flushed or replaced in the event a failure has occurred.
Metallic 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 transmission.

Water 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 hoses.

Reduction 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 installed.

It is possible for cross leaks to occur inside the cooler, permitting
oil to flow into the water or water flow into the oil.       Checking
transmission fluid levels at each days use will help spot such a hap-
pening, undetectable loss of fluid and/or 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 tightness.

4.  COOLER CONNECTIONS: Check water lines, oil lines and connections
for leakage.    Make sure lines are securely fastened to prevent
shifting.
5.  CHANGING OIL:   A seasonal oil change is recommended in pleasure
boats. Work boats require more frequent changes. Change oil any time
the oil becomes contaminated, changes color or becomes rancid
smelling.  Automatic transmission fluids (ATF), Type A is recommended
for 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 installation.

4.     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 transmission.

8.     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 transmission.

12. Check fluid level at operating temperature.




     Westerbeke Diesel Engines      72
                                          Walter V-Drives


  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
RV-lOD). A self-locking 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 good
installations 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 to
misalignment.   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  manufacturer's   instructions            FLANGE ALIGNMENT
until 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 proper
alignment is obtained. Turn the propeller shaft flange 1/4 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 propeller
shaft 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 1/4 turn increments and repeat the procedure.               The pilot
diameters must be rechecked to ensure that they still engage freely.
Secure 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 flexible
joint 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 1/8". 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 RV-lOD'S) 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 1/4 of a turn and measure to the same
joint. The four distances must be equal within 1/8".   (DO not measure




                                                 73         Westerbeke Diesel Engines
                                    to the joint end that is
                                   on the spool adapter.
                                   This distance will not
                 "~H',,,,,",,,,,,, vary wi th misalignment
                     .- ?'!   ~ RI":,~

                                   Slnce    the     joint    is
                                   bolted and cannot move.)
                                   Put the #31A alignment
                                   gauge on the machined
                                   diameter
                               Z' Y.'NCO
                               -lJ'ft[ClIN('   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.       Re-measure
                                   the joints to see if
they are still parallel within 1/8".                     It is
important   that      both         alignments    be    checked
thoroughly.   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 self-aligning 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 RV-IO).    A self-locking          /" LOCKING NUT
                                                                             ADJUST I!\,(, SChEW


set screw is provided for the propeller shaft
                                                                   LOOSEN                ~
                                                                                        TO
flange. spot drill the propeller shaft and secure-                   AOJUS T BRACK.[ T5

ly tighten the set screws.                                                  , MOlJ>jTING
    All V-drives are supplied with 3-way adjustable                         \ HOLE

mounting brackets (2-way on the RV-IO and RV-20) as                          \
standard equipment.   The brackets must face down-
ward as shown in the illustration to properly
absorb propeller thrust.    The mounting plates can
be removed and rever: sed to fi t wider: eng ine bed
                                                            RV'IO &. RV-20
centers. Before installing the V-drive, 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 V-drive 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 plates.
Loosen 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 operating
drive 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 V-dr i ve until 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 V-drive
must be readjusted until proper alignment is obtained. Turn the pro-
peller shaft flange 1/4 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 and
straightened.  Rotate the propeller shaft flange in two more 1/4 turn
increments 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 screws.
Remove the set screws from the brackets (none on RV-IO or RV-20), spot
drill and securely tighten. Recheck the flange alignment to make sure
the V-drive did not move out of alignment.      Secure the two flanges
together with the heat treated bolts and special high collared lock-
washers supplied.


                                                              ~     .-ADJUSTING SCREW
                                                          /    ~/LOCKING NUT

   GEAR SHAFT
     FLANGE
                                   SET SCREw
                                                    \~
                                                     ~. ~:;.?.
                                                       /7               ,;
                                                                            i
                                                                                 TO ADJUST
                                                                         "".\.L.OOSEN SLIGHTLY
                                                                                        BRACKETS

                                                    (.(             a       i              MOUNTING




                                                    ll~'
                                                                    .4'"                     HOLE
     FEELER'
     GAGE
                                                              a "
                                                               p
                                                                        0       .....
                                                              dP
                                                          ~7@~
                                                                         o


                                                                                        \MOUNTING PLATE
                FLANGE ALIGNMENT


  Water and Switch Connections

    Hook up the water lines to the two pipe connections on the V-drive
(intake and exhaust lines are interchangeable).    Generally, one line
from the seacock to the V-dr i ve and another from the V-dr 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 V-drive
to provide independent water-cooling and are actuated by the movement
of the water.    With closed cooling systems, the V-drive should be
incorporated into the system between the cooler and the suction side
of the water pump.    Proper operating temperatures are from 140· to
ISO'F, although safe operating temperatures may be as high as 210"F.
On the models equipped with an oil circulating pump, the #49 oil



                                               75                    Westerbeke Diesel Engines
pressure 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 V-drive or engine (either terminal may be used for the
ground).



Oil Fill

    Pullout the #21 oil level gauge.
Unscrew the #12 breather cap and fill the          "12 BREATHER CAP  ,\ATER mAIN
V-drive with SAE i30 motor oil through the            (UNSCREW FOR
                                                         Oil Filll
#12A breather elbow.   On the RV-IO only,                WATER LINE
                                                                         ~"    ()L LEVEL
                                                                       c         GA(£
the oil may be added by removing the plug                             J
                                                                       I      (PULL UP TO
                                                                                REM:lVE)
in the #60 top cover. See table below for
approximate oil capaci ties.   The amount
varies with the angle of installation.
The 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 disulfide),
which is supplied with each V-drive for      #12A BREATHER
                                                 ELBOW
extra lubrication and break-in. It provi-
des protection against scoring or galling
of gears, bearings and other moving parts.
Additional Molykote after break-in 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.

                             RV-IO      RV-20        RV-30        RV-40        RV-48

Oil capaci ty                1 pint    2 pints      3 pints      4 pints     4 pints
(Approx. )


Dealer Preparation

    The propeller shaft and engine alignment must be checked and
corrected, 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 required.
While 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 propeller
shaft coupling connected.  Damage to the shaft, shaft log and V-drive
can result.




 Weslerbeke Diesel Engines               76
 Operation
    A pressure drop warning light is
mounted on the instrument panel on
V-drives 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 maintain
pressure.     This normally occurs at
approximately 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
V-drive, 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 and/or
insufficient 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 reaches
normal cruising speed, the wir ing should be checked for loose and/or
corroded connections.     If the wiring is correct and the light remains
lit, the #49 pressure drop switch, which is mounted on the side of the
V-dr i ve (see illustration), should be checked for proper oper ation.
The switch can easily be removed and an accurate oil pressure gauge
installed 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 RV-48 and an optional feature
on other models (not available on the RV-IO).
     The oil level should be checked several times during the season,
especially on V-drives whitout pumps (see OIL FILL).
     A clatter or rattle in the V-drive at low RPM is due to the over-
riding of the propeller during the compression stroke of the engine.
Although annoying, it is not harmful.     It may be reduced by adjusting
the idle speed and/or tuning up the engine for smoother operation.


  Maintenance

1.   OIL CHANGE AND JOINT LUBE

    After the first 100 hours of operation and every season and/or
500 hours thereafter, the oil should be changed. Run the boat to warm
up the V-drive 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 removal.
Touch the inside face with a metallic
object, 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 illustration). 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 lay-up, remove the
small pipe plugs (located diagonally opposite) on the front and back
of the housing marked "Water Drain" (see illutration).  On the RV-IO
only, one of the water lines going into the #6 water-cooled bottom
cover must be disconnected to drain the water.


3.   FLANGE AND ENGINE REALIGNMENT
    When the boat is launched after being in drydock, the line-up of
the v-drive to the propeller shaft flange and the engine to the V-
drive should be rechecked and corrected i f necessary.  Some engines
with rubber mounts may sag and must be raised with adjustments or
shims for proper alignment    (see "Flange Alignment" and "Engine
Alignment n) ·




 Westerbeke Diesel Engines           78
                                     ENGINE TROUBLESHOOTING

Introduction

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

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




Problem                                  Probable Cause                    Verffication/Remedy

Key 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 housing.




PREHEAT 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 Engines
Problem                     probable Cause                Verification/Remedy

START switch is de-         1. Connection to starter      1. Check connection S at the
pressed: no starter            solenoid faulty.              starter solenoid for 12 volts
engagement.                                                  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 solenoid's
                                                             S terminal with no activation.


Engine cranks,              1. Shut-off valve at          1. Return shut-off 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
                                                             ff.

                            4. Fuel pump is not           4. Check pump operation.
                               operating.                    Check for 12-Volts at pump.

                            5. Fuellilters are clogged.   5. Clean/replace fillers.




Failure 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 air.




Weslerbeke Diesel Engines               80
Problem              Probable Cause                Verification/Remedy

Engine Stops.        1. Fuel starvation.           1. Check to see that the
                         Fuel shut-off is turned      shut-off 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 tank(s),
                                                      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 hose.



Battery runs down.   1. Alternator output          1. Check drive belt tension.
                        is low.                       Perform an output check
                                                      w~h 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 or/and
                                                      at the engine.




                                 81                 Westerbeke Diesel Engines
                                  MAINTENANCE AND ADJUSTMENTS

Introduction

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


Preventive Maintenance

Perform the preventive maintenance in accordance with the schedules listed in the following paragraphs.
Adherence to these schedules will ensure the equipment is maintained in the best possible condition and
that it will perform to expectations. Those items marked by an asterisk (*) are recommended to be per-
formed by an authorized dealer or distributor.


Daily (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
     ADD.

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

  5. Check the fuel supply. Fill tank(s) with a good grade of No.2 diesel fuel, if required.

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

  7. Check the engine's gauges or lights for proper oil pressure, operating temperature, and starting bat-
     tery charging voltage once the engine is operating.

  8. Check the alternator's output gauge (if installed) for proper DC voltage.

  9. Check to make sure the propeller shaft is securely connected to the transmission coupling.


Monthly

Check the condition of the zinc anode in the heat exchanger's sea water circuit. Clean or replace the anode,
as required. Keep the area inside the heat exchanger clean of zinc anode debris.




Westerbeke Diesel Engines                            82
Servicing Alter Initial 50 Hours 01 Operation

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

  2. Replace the fuel filter element in the electric fuel lift pump and in the engine-mounted secondary fuel fil-
     ter. Change the fuel filter element and clean the optional filter/water 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 transmission's remote control cable.

  7. Change the transmission's oil.

  8. Adjusts the engine's idle speed as needed.

  9. Check to make sure the propeller shaft is securely connected to the transmission coupling.


Servicing Alter Every 100 Hours of Operation

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

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

  3. Check the transmission fluid or oil level.


Servicing Alter Every 250 Hours of Operation

  1. Replace the fuel filter elements in the electric fuel lift pump and in the engine-mounted secondary fuel
    filter.

  2. Change the transmission's oil.


Servicing 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 pump's 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 mechanic.


Servicing Aller Every 800 Hours 01 Operation

 *1. Remove and check fuel injectors.

    Injector spray pressure:

    1991 psi + 140 psi
    (140 kg/cm 2 + 10 kglcm 2)

Eliminate undesirable injection conditions including                                        POOR
aller dripping.

 *2. Check the engine's compression pressure.
     Remove each glow plug and check each
                                                               (i~~.
                                                                  f~~~:4
                                                                     i'r.,. . .10104i   --~dI\
                                                                                  .......
                                                                                      '

     cylinder's compression pressure. The engine's                                          GOOD
     cranking speed is at 280 rpm.

          Standard        Minimum

           455 psi         369.7 psi
         (32 kg/cm 2 )   (26 kglcm2)      (Maximum difference between cyfinders: 35.5 psi (2.5 kg/cm2 )

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

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


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

 *2. Check the injection pump's timing.




Westerbeke Diesel Engines                              84
Torquing Cylinder Head Bolts       CN 35B THREE Engine)
Tighten 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 1/4 to 1/2 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 # 4,5,6,7,8,9,10 and 11 are tightened be-                             0             0                0
1ween 79.5 to 86.8Ib-ft (11 to 12 kg-m).
                                                                       02            01               03
Bolts # 1,2 and 3 are tightened be1ween 50.6 to
57.8 Ib-ft (7 to 8 kg-m).




Torquing Cylinder Head Bolts (W 38B FOUR and W 42B FOUR Engine)

Tighten 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 1/4 to 1/2 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 # 4,5,6,7,8,9,10 and 11 are tightened be-              0    10   0        4    0    3       0    9    0
1ween 79.5 to 86.8Ib-ft (1110 12 kg-m).                           0         0             0           0
Bolts # 1,2 and 3 are tightened be1ween 50.6
to 57.8 Ib-ft (7 to 8 kg-m).




                                                     85                             Westerbeke Diesel Engines
Valve Clearance Adjustment      rN 35B THREE Engine)
                 CAUTION

      Adjust the valve clearance when the
      engine is cold. Valves are adjusted by                          TOC MRRK ( Cylinder Ko.ll
                                                              \
      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.                   No.3 1

2. Adjust the valve clearances at TDC (Top
                                                                         TOC MARK
   Dead Center) for each cylinder when they
                                                                         (Cylinder No.2l
   are on their compression stroke (see
   below). Remember the engine's firing
   order is 1-3·2. You may find that turning the engine's crankshaft is more easily accomplished when the
   engine's 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 NO.1 (the one next to the three injection timing marks). In this position, the NO.1 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 No.3 cylinder: Turn the crankshaft clockwise 240° so the TDC mark for the NO.3 cylinder, on
     the front crankshaft pulley, is approximately
     at the position shown in the illustration above.
     Now adjust the intake and exhaust valves for
     cylinder No.3. Be sure to check the valves
     for this cylinder-they both should be closed.           ADJUST VALVES TO 0.010 INCHES
                                                              (0.25 MMJ
  C. Last is the No.2 cylinder: Turn the crankshaft
     clockwise another 240° to position the TDC
     mark on the crankshaft pulley approximately
     at the position shown in the illustration shown
     above. Now adjust the intake and exhaust
    valves for cylinder NO.2. Be sure to check
    the valves for this cylinder - they both should
     be closed.


Adjust each valve's clearance by inserting a 0.010
inch (0.25 mm) feeler gauge between the rocker
arm and the valve stem.




Westerbeke 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.
                                                                                       No.1 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 engine's firing order is 1-3-4-2. The No.2 and 3
                                                                        CRANKSHAFT
  engine's valves must be adjusted in this                                 PULLEY
  order while the valves are closed. You
  may find that turning the engine's
  crankshaft is more easily accomplished
  when the engine's glow plugs are
  removed before the crankshaft is rotated.

  A. Rotate the engine in the normal direction of rotation placing the NO.1 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 No.1 cylinder should be closed. Now adjust the intake and ex-
     haust valves for cylinder NO.1.

  B. After adjusting the valves for cylinder No.1, 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 No.3. Now adjust the intake and
     exhaust valves for cylinder NO.3.

  C. Rotate the crankshaft pulley clockwise
    another 180" and adjust the valve clearances                ADJUST VALVES TO 0.010 INCHES
    for the Intake and exhaust valves for cylinder              (0.25 MMJ
    No.4.

  D. Rotate the crankshaft pulley clockwise
    another 180" and adjust the valve clearances
    for the intake and exhaust valves for cylinder
    NO.2.


Adjust each valve's clearance by inserting a 0.010
inch (0.25 mm) feeler gauge between the rocker
arm and the valve stem.




                                                     87                         Westerbeke Diesel Engines
Injection Pump Timing Adjustment (Spill Timing)

If your engine's 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 well-established fuel Injection shop. Ad-
just the injection timing as follows:

      NOTE: The fuel shut-off 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 high-pressure fuel
line from between the No.1 injector and the No.1 fuel delivery valve holder. Remove the NO.1 fuel delivery
valve holder and remove the delivery valve spring beneath the holder. Reinstall only the delivery valve holder
and re-attach 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 HOLDER

Rotate the engine's crankshaft in Hs
normal direction of rotation to posi-
                                          DELIVERY VALVE SPRING
tion piston No.1 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 crankshaft
clockwise (as viewed from the
front), catching the fuel from the No.
                                             BAR REL '-::::"':17'TtJt;1
1 fuel line, until the Instant the fuel
completely stops flowing (no drips).                                      7';I"'-::'-~-CONTROL RACK
At this instant, the 230 BTDC timing        PLUNGER
mark on the crankshaft pulley
                                             CONTROL
should be directly aligned wHh the           PINION
timing indicator on the front of the
gear case (refer to the illustrations
on 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 pump's mounting flange to change the injection timing
point. Changing the shim thickness by 0.004 inch (0.01 mm) changes the injection timing by approximately
one degree. To advance the timing, decrease the shim thickness, as required. To retard the timing, increase
the shim thickness, as required. Refer to your engine's Parts List for shim part numbers.




Weslerbeke Diesel Engines                                 88
                                    LAY-UP AND RECOMMISSIONING

General

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

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

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

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


Propeller 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. The
flexibility 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 a
considerable period of time.


Fresh Water Cooling System

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

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


Engine 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 removal.)

When installing the new oil filter, be sure to apply a small amount of oil on the rubber sealing gasket at the
base of the filter. Fill the sump with the correct amount of oil for your engine. (Refer to the"SYSTEM
SPECIFICATIONS" section of this manual, page 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 engine's old lubricating oil in the sump over the lay-up period. Lubricating
      oil and combustion deposits combine to produce harmful chemicals which can reduce the
      life of your engine's internal parts.


Transmission 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 transmission's internal components in oil which protects
them against corrosion during the lay-up period.


Fuel System

Top off your fuel tanks with NO.2 diesel fuel. Fuel additives should be added at this time to control algae
and condition the fuel. Care should be taken that the additives used are compatible with the primary fil-
ter/water separator used in the system. Change the element in your primary fuel filter/water separator, if the
fuel system contains one, and clean the separator sediment bowl.

Change the fuel filter elements on the engine and bleed the fuel system, as needed. Start the engine and
allow it to run for 5 - 10 minutes to 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 Circuit

Close the through-hull sea cock. Remove the sea water intake hose from the sea cock. Place the end of
this hose into a 5-gallon bucket of clean fresh water. Before starting the engine, check the zinc anode found
in the primary heat exchanger on the engine and clean or replace it as required, 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 lay-up, as well as providing corrosion protection.

Remove the impeller from your sea water pump (some antifreeze mixture will accompany it, so catch it in a
bucket). Examine the impeller. Acquire a replacement, if needed, and a cover gasket. Do not replace the
impeller (into the pump) until recommissioning, but replace the cover and gasket.




Weslerbeke Diesel Engines                             90
Intllke Manifold and Through-Hull Exhaust

Place 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 recommissioning, and an attempt is made to
start the engine, you may need the assistance of a servicing dealer.) Make a note to remove the cloth prior
10 start-up. The through-hull exhaust part can be blocked in the same manner.

Starter Molor

Lubrication 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 starter.


Cylinder Lubrication

It is not necessary to remove the fuel injectors from the cylinder head to squirt light lubricating oil into the
cylinders for the few months of normal lay-up. However, if you anticipate a longer lay-up period (12 months
or more), we recommended that this procedure be performed. The light oil in the cylinders will prevent the
pistons rings from sticking to the cylinder walls. Make sure you have replacements for the injector and return
line sealing washers.


Spares

Lay-up time provides a good opportunity to inspect your Westerbeke engine to see 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 lay-up, such as filters and zinc anodes.


Batleries

If batteries are to be left on board during the lay-up 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 fully
charged, or that they will be subjected to severe environmental conditions, remove the batteries and store
them in a warmer, more compatible environment.


Recommissioning

The recommissioning 01 your Westerbeke engine after a seasonal lay-up generally follows the same proce-
dures as lhose presented in the "PREPARATIONS FOR STARTING" seclion, page 33, regarding preparation
for starting and normal starts. However, some of the lay-up procedures will need to be counteracted before
slarting the engine.

1. Remove the oil-soaked cloths from the intake manifold and from the through-hull exhaust port.

2. Remove Ihe sea water pump cover and gasket and discard the old gasket. Install the sea water pump
   impeller removed during lay-up (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 engine's "SYSTEM SPECIFICATIONS" section of this manual.



                                                   IWARNINGI

      Wear rubber gloves, a rubber apron, and eye protection when servicing batteries.

      Lead acid batteries emit hydrogen, a highly-explosive gas, which can be ignited by electrical
      arcing or a lighted cigarette, cigar, or pipe. Do not smoke or allow an open flame near the
      battery being serviced. Shut off all electrical equipment in the vicinity to prevent electrical ar-
      cing during servicing.

3. Reinstall the batteries that were removed during the lay-up, and reconnect the battery cables, making
   sure the terminals are clean and that the connections are tight. Check to make sure that the batteries are
   fully-charged.

4. Check the condition of the zinc anode in the sea water circuit and clean or replace the anode as needed.
   Note that it is not necessary to flush the antifreeze/fresh water solution from the sea water coolant sys-
   tem. When the engine is put into operation, the system will self-flush in a short period of time with no ad-
   verse affects.

5. Start the engine in accordance with procedures in the "PREPARATIONS FOR STARTING" section ofthis
   manual, page 33.




Weslerbeke Diesel Engines                                 92
                     TABLE OF STANDARD HARDWARE TIGHTENING TORQUES


Unless stated otherwise for a specific assembly. use the following torque values when tightening standard
hardware.
                                      Pitch                     Ib-ft                    kg-m
Grnde 4T
     6mm bolt head/nut                  1                     2.9 - 5.1               0.4- 0.7
     Bmm bolt head/nut                  1.25                 7.2- 11.6                1.0 - 1.6
    10mm bolt head/nut                  1.25                13.7 - .22.4              1.9 - 3.1
    10mm bolt head/nut                  1.5                 13.0 - 21.7               1.8 - 3.0
    12mm boll head/nut                  1.25 (ISO)          25.3 - 39.8               3.5 - 5.5
    12mm bolt head/nut                  1.5                 25.3 - 39.8               3.5 - 5.5
    12mm bolt head/nut                  1.75                21.7 - 36.2               3.0 - 5.0
    13mm bolt head/nut                  1.5                 32.5 - 50.6               4.5 - 7.0
    14mm bolt head/nut                   1.5                36.2 - 57.9               5.0 - 8.0
    14mm bolt head/nut                  2                   34.0 - 55.7               4.7 - 7.7
    16mm bolt head/nut                   1.5                54.2 - 79.6               7.5-11.0
    16mm bolt head/nut                  2                   51.4-76.7                 7.1 -10.6

Grade6T
    6mm bolt head/nut                  1                   4.3 -    6.5              0.6 -   0.9
     8mm bolt head/nut                 1.25               10.8 -   15.9              1.5 -   2.2
    10mm bolt head/nut                 1.25               21.7 -   32.5              3.0 -   4.5
   10mm bolt head/nut                  1.5                19.5 -   30.4              2.7 -   4.2
   12mm bolt head/nut                  1.25 (ISO)         36.2 -   57.9              5.0 -   8.0
   12mm bolt head/nut                  1.5                36.2 -   50.6              5.0 -   7.0
   12mm bolt head/nut                  1.75               34.7 -   49.2              4.8 -   6.8

Grade 7T aT a[]d !l.!l
    Smm bolt head/nut                                        5.8 - 8.7                0.8 - 1.2
    Bmm bolt head/nut                 1.25                 14.5- 21.7                 2.0 - 3.0
   lOmm bolt head/nut                 1.25                 28.9 - 39.8                4.0 - 5.5
   1Dmm bolt head/nut                 1.5                  26.8 - 37.S               3.7 - 5.2
   12mm bolt head/nut                 1.25 (ISO)           54.2 - 75.9                7.5-10.5
   12mm bolt head/nut                 1.5                  50.6 - 65.1                7.0 - 9.0
   12mm bolt head/nut                 1.75                 43.4 - 61.5               6.0 - 8.5
   13mm bolt head/nut                 1.5                 .57.9 - 86.8                8.0 -12.0
   14mm bolt head/nut                 1.5                  72.3 -108.5              10.0 -15.0
   14mm bolt head/nut                 2                    68.7 -101.3               9.5 - 14.0
   16mm bolt head/nut                 1.5                108.5 - 166.4              15.0 - 23.0
   16mm bolt head/nut                 2                  101.3 - 159.1              14.0 - 22.0

Grade (; QapSQ[9W
          1/4 UNC                                             9   11
                                                                   -                 1.2 - 1.5
          1/4 UNF                                            11    -
                                                                  13                 1.5- 1.8
          5/16 UNC                                           18    -
                                                                  20                 2.5 - 2.8
          5/16 UNF                                           21    -
                                                                  23                 2.9 - 3.2
          3/8 UNC                                            28    -
                                                                  33                 3.7 - 4.6
          3/8 UNF                                            30    -
                                                                  35                 4.1 - 4.8
          7/16 UNC                                           44    -
                                                                  49                 6.1 - 6.8
          7/16 UNF                                           50    -
                                                                  55                 6.9 - 7.6
          1/2 UNC                                            68    -
                                                                  73                 9.4-10.1
          1/2 UNF                                            73 - 80                10.1-11.1




                                                    93                      Westerbeke Diesel Engines
                                         TORQUE SPECIFICATIONS




Cylinder head bolt                   (M10)                  50.7 - 57.9              7.0 - 8.0

                                    (M12)                    79.6 - 86.8            11.0-120


               (See the" Torquing Cylinder Head Bolts" section of this manual on page 85.)

Crankshaft pulley nut                                       108.5 -180.8           20.0 - 25.0

Main bearing cap bolt                                        36.2 - 43.4             5.0 - 5.5

Connecting rod cap nut                                       23.1 - 25.3             3.2 - 3.5

Flywheel bolt - WITh separate washers                        83.2 - 90.4            11.5 - 12.5

Flywheel bolt - washer attached                             95.0 -100.0             13.0 -14.0

Oil pan drain plug                                           36.2 - 43.4             5.0 - 6.0

Oil filter                                                    8.0 - 9.4              1.1 -1.3
                                                    (or tighten firmly by hand)

Delivery valve holder (injection pump)                       28.9 - 36.2             4.0 - 5.0

Nozzle mounting bolt                                         10.8 -14.5              1.5 - 2.0

Nozzle holder and retaining nut                              43.4 - 57.9             6.0 - 8.0

Glow plug                                                    10.8 -14.5              1.5 - 2.0




        * NOTE: M8 indicates Metric, 8 mm thread diameter




Westerbeke 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 engine's Parts List for part numbers when ordering spare parts.

Listed 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 Alternator/Sea 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 Antifreeze.


Other parts, whose Ine expectancy cannot be accurately predetermined, 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 pump's part number is found on the cover of the pump).

  9. Battery Terminal Connectors


The spare parts listed directly above are those we recommend be carried on board during long ocean
voyages. 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 Westerbeke
dealer for a listing of the Westerbeke dealers located on your route.




                                                     95                       Westerbeke Diesel Engines
                                                                              INDEX
         A

Adjustment, Injection Pump Timing ............................................................................................................88
ADJUSTMENTS, MAINTENANCE AND ......................................................................................................82
Adjustment, Valve Clearance 0N 35B THREE Engine) ..............................................................................86
Adjustment, Valve Clearance 0N 38B FOUR and W 42B FOUR Engines) ................................................ 87
Admirals Panel .............................................................................................................................................37
Admirals Panel Control Circutt DC Wiring Diagram # 36844 ........................_                                    .............................. 50 and 51
Alignment of the Engine (Installation Checks) ............................................................................................24
Alternator ......................................................................................................................................................46
Alternator and Water Pump Drive Belt Tension ..........................................................................................55
ANTIFREEZE CONCENTRATION DATA. ....................................................................................................53
Automatic Alarm System .............................................................................................................................31


          B

Batteries (Lay-up and Recommissioning) ...................................................................................................91
Battery Specification ....................................................................................................................................46
Belt Tension, Alternator and Water Pump Drive .........................................................................................55
Bolts, Engine (Installation Checks) .............................................................................................................23
Bolts, Torquing Cylinder Head 0N 35B THREE Engine) ............................................................................85
Bolts, Torquing Cylinder Head 0N 38B FOUR and W 42B FOUR Engines) ..............................................85
Break-in Procedures, Engine ......................................................................................................................41


          C

                                                                           CAUTIONS

          SHIPPING ENGINE WITHOUT ENGINE OIL ......................................................................'" 21
          LIFTING SUNGS ................................................................................................................... 22
          TIGHTENING THE EXHAUST ELBOW CLAMP ..................................................................... 29
          THROUGH-HULL FITTINGS .................................................................................................. 30
          PROLONGED ENGINE CRANKING ...................................................................................... 39
          SHUTTING DOWN THE ENGINE .......................................................................................... 41
          PROLONGED ENGINE CRANKING ...................................................................................... 44
          BATTERY CIRCUIT ............................................................................................................... 46
          QUICK-CHARGING 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 LAY-UP .......................................................... 90

 Captains Panel .............................................................................................................................................35
 Captains Panel Control Circuit DC Wiring Diagram # 36467 ....................................................... 48 and 49
 Change, Engine Oil, (to include filter) .........................................................................................................61
 Charging Voltage Test .................................................................................................................................47
 CHECKS, INSTALLATION ...........................................................................................................................21




 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 (Lay-up and Recommissioning) ....................................................................... 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 (Lay-up and Recommissioning) ............................................................................... 91




DC Wiring Diagram # 36844, Admirals Panel Control Circuit ....................................................... 50 and 51
DC Wiring Diagram # 38467, Captains Panel Control Circuit ...................................................... 48 and 49
DESCRIPTION OF INSTRUMENT PANELS ............................................................................................... 35
Description of Starting System ................................................................................................................... 34
Diesel Engine, Understanding the ................................................................................................................ 5
Diesel Fuel ................................................................................................................................................... 43
DISCLAIMER, IMPORTANT PRODUCT SOFTWARE .................................................................................. 1
Domestic HoI Waler .................................................................................................................................... 58
Drain Hose, Oil (Installation Checks) .........................................·............................................................... 30


         E

ELECTRICAL SYSTEM ................................................................................................................................ 46
Electrical System (Installation Checks) ...................................................................................................... 32
Engine, Alignment of the (Installation Checks) .......................................................................................... 24
Engine Bolts (Installation Checks) .............................................................................................................. 23
Engine Break-in Procedures .................................................·..................................................................... 41
Engine, Diesel, Understanding the ............................................................................................................... 5
Engine, Foundation lor the (Installation Checks) ...................................................................................... 23
Engine Lubrication System (Lay-up and Recommissioning) .................................................................... 89
Engine Oil .................................................................................................................................................... 60
Engine Oil Change (to include filter) .......................................................................................................... 61
Engine Oil Viscosity (SAE Number) ........................................................................................................... 60
ENGINE TROUBLESHOOTING .................................................................................................................. 79
EqUipment, Inspection of .............................................................................................................................. 2
Exhaust Back-Pressure (Installation Checks) ............................................................................................ 27
Exhaust Elbow Installation (Installation Checks) ....................................................................................... 29
Exhaust System (Installation Checks) ........................................................................................................ 26
Exhaust System Failures (Installation Checks) .......................................................................................... 28




                                                                                 91                                      Westerbeke Diesel Engines
         F

FORWARD ......................................................................................................................................................2
Foundation for the Engine (Installation Checks) ........................................................................................23
Fresh Water Circuit ......................................................................................................................................52
Fresh Water Cooling System (Lay-up and Recommissioning) ........................................................ ,......... 89
Fuel, Diesel ...................................................................................................................................................43
Fuel Filters ....................................................................................................................................................43
Fuel Filter Elements, Replacing ...................................................................................................................44
Fuel Injection Pump .....................................................................................................................................45
Fuel System (Installation Checks) ...............................................................................................................31
Fuel System (Lay-up and Recommissioning) .............................................................................................90
Fuel System, Priming the .............................................................................................................................44
FUEL SYSTEM .............................................................................................................................................43


         G

GENERAL. ......................................................................................................................................................5
GENERAL SPECIFICATIONS W 35B ..........................................................................................................12
GENERAL SPECIFICATIONS W 38B ..........................................................................................................15
GENERAL SPECIFICATIONS W 42B ..........................................................................................................18


         H

HARDWARE TIGHTENING TORQUES, TABLE OF STANDARD ...............................................................93
Head Bolts, Torquing Cylinder (W 35B THREE Engine) ............................................................................85
Head Bolts, Torquing Cylinder (W 38B FOUR and W 42B FOUR Engines) ..............................................85
Hose, Oil Drain (Installation Checks) ..........................................................................................................30
Hot Water, Domestic ...................................................................................................................................58
Hydraulic Transmissions, Warner ...............................................................................................................68




IMPORTANT PRODUCT SOFTWARE DISCLAIMER .................................................................................... 1
INDEX ...........................................................................................................................................................96
Injection Pump, Fuel .....................................................................................................................................45
Injection Pump Timing Adjustment .............................................................................................................88
Inspection of Equipment ...............................................................................................................................2
INSTALLATION CHECKS ............................................................................................................................21
INSTRUMENT PANELS, DESCRIPTION OF...............................................................................................35
Intake Manifold and Through-Hull Exhaust (Lay-up and Recommissioning) ............................................91
Intake System, Sea Water (Installation Checks) .........................................................................................31


         J

JS Transmission ...........................................................................................................................................63




Weslerbeke Diesel Engines                                                        98
         l

LAY-UP AND RECOMMISSIONING ........................................................................................................... 89
Lifting, Rigging and (Installation Checks) .................................................................................................. 22
Location (Installation Checks) .................................................................................................................... 21
Lubrication (JS Transmission) ............................................................................................,....................... 63
LUBRICATION SYSTEM ............................................................................................................................. 60


         IV!

MAINTENANCE AND ADJUSTMENTS ...................................................................................................... 69
Motor, Starter (Lay-up and Recommissioning) .......................................................................................... 91


         o
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, Admirals............................................................................................................................................ 37
Panel, Captains ........................................................................................................................................... 35
PANELS, DESCRIPTION OF INSTRUMENT .............................................................................................. 35
Parts, Ordering .............................................................................................................................................. 5
PARTS, SPARE ............................................................................................................................................ 95
PREPARATION 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 (Lay-up and Recommissioning) ........................................................................ 89
Pump, Fuel Injection ................................................................................................................................... 45
Pump, Sea Water ........................................................................................................................................ 55
Pump Timing Adjustment, Injection ........................................................................................................... 88




                                                                                 99                                     Westerbeke Diesel Engines
         R

Recommissioning (Lay-up and Recommissioning) ...................................................................................91
Replacing the Fuel Filter Elements ..............................................................................................................44
Rigging and Lifting (Installation Checks) ....................................................................................................22


         S

Sailing Operation (JS Transmission) ..........................................................................................................65
Service (JS Transmission) ...........................................................................................................................65
Sea Water Circuit .........................................................................................................................................55
Sea Water Circuit (Lay-up and Recommissioning) ....................................................................................90
Sea Water Pump ..........................................................................................................................................55
Sea Water Intake System (Installation Checks) ..........................................................................................31
Shaft Coupling, Propeller (Installation Checks) ..........................................................................................24
Shaft Coupling, Propeller (Lay-up and Recommissioning) ........................................................................89
Shifting (JS Transmission) ...........................................................................................................................65
SOFTWARE DISCLAIMER, IMPORTANT, PRODUCT .................................................................................. 1
Spares (Lay-up and Recommissioning) .....................................................................................................91
SPARE PARTS .............................................................................................................................................95
Starter Motor (Lay-up and Recommissioning) ...........................................................................................91
STARTING, PREPARATION FOR ................................................................................................................33
STARTING PROCEDURE ............................................................................................................................39
Starting System, Description 01 ...................................................................................................................34
Starting Under Cold Conditions ..................................................................................................................42
Starting Under Normal Conditions ..............................................................................................................42
STOPPING PROCEDURE ...........................................................................................................................41
SYSTEM SPECIFICATIONS W 35B ............................................................................................................13
SYSTEM SPECIFICATIONS W 38B ............................................................................................................16
SYSTEM SPECIFICATIONS W 42B ............................................................................................................19


         T

TABLE OF CONTENTS .................... ,.............................................................................................................3
TABLE OF STANDARD HARDWARE TIGHTENING TORQUES ................................................................93
Test, Charging Voltage ................................................................................................................................47
Timing Adjustment, Injection Pump ................................................ ,...........................................................88
Thermostat .... ,.................................................................................. ,...........................................................54
TORQUE SPECiFiCATIONS ............................. ,..........................................................................................94
Torquing Cylinder Head Bolts 0N 35B THREE Engine) .............................................................................85
Torquing Cylinder Head Bolts (W 38B FOUR and W 42B FOUR Engines) .............................................. 85
Transmission Lubrication System (Lay-up and Recommissioning) ..........................................................90
TRANSMISSIONS, OPTIONAL. ........................ ,............................................................................... ,.......... 66
Transmissions, Warner Hydraulic ............ ,..................................................................................................68
TROUBLESHOOTING, ENGINE ................................. ,...............................................................................79




 Weslerbeke Diesel Engines                                                      100
         u
Under Cold Conditions, Starting ................................................................................................................ 42
Under Normal Conditions, Starting ............................................................................................................ 42
Understanding the Diesel Engine ................................................................................................................. 5


         v
Valve Clearance Adjustment 0N 35B THREE Engine) ............................................................................... 86
Valve Clearance Adjustment 0N 38B FOUR and W 42B FOUR Engines) ................................................. 87
V-Drives ....................................................................................................................................................... 73
Ventilation .................................................................................................................................................... 32
Viscosity (SAE Number), Engine Oil .......................................................................................................... 60
Voltage Test, Charging ............................................................................................................................... 47


         W

                                                                         IWARNINGsl

          DIESEL FUMES ..................................................................................................................... 28
          FLAMES NEAR BATTERIES .................................................................................................. 32
          SERVICING BATTERIES ....................................................................................................... 32
          ADJUSTING DRIVE BELT TENSION ·············.....····.·.········.·····.··..·.···········.··.·.....·····.············ 55
          SERVICING BATTERIES ....................................................................................................... 92

Walter V-Drives ............................................................................................................................................ 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 NOTES




Westerbeke Diesel Engines       102
YOUR NOTES




    103      Weslerbeke Diesel Engines
                            YOUR NOTES




Westerbeke Diesel Engines       104


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