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Westerbeke Diesel 108b Six Parts Manual




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OPERATORS MANUAL
638 and 63C FOUR
71 8 and 71 C FOUR
828 FOUR
1088 and 108C SIX
MARINE DIESEL ENGINES
PUBLICATION NO 038922
EDITION FIVE
OCTOBER 2006
WESTERBEKE CORPORATION 150 JOHN HANCOCK ROAD
MYLES STANDISH INDUSTRIAL PARK TAUNTON MA 02780
WEBSITE A gasses contain carbon Monoxide an odorless and
colorless gas Carbon Monoxide is poisonous and can and death Symptoms of Carbon can Throbbing in Muscular
Vomiting
Weakness and Sleepiness Inability to Think YOU OR ANYONE ELSE EXPERIENCE ANY OF THESE SYMPTOMS
GET OUT INTO THE FRESH AIR IMMEDIATELY If symptoms persist
seek medical attention Shut down the unit and do not restart
until it has been Inspected and repaired
A WARNING DECAL is provided by
WESTERBEKE and should be nxed to a
WA RNINGI
bulkhead near your engine or generator
WESTERBEKE also recommends installing
CARBON MONOXIDE DETECTORS in the
quarters of your vessel
Cenerators Produye CARBON M9NOXIDE The u are ineensive and easilu
Regular Mntenance Required
l J obtainable at your local marine store
CALIFORNIA
PROPOSITION 65 WARNING
Marine diesel and gasoline engine
exhaust and some of its constituents
are known to the State of California
to cause cancer birth defects
and other reproductive harm
SAFETY Do not operate with the air removed
Backfire can cause severe injury or death
Read this safety manual carefully Most accidents are
caused by failure to follow fundamental rules and precau Do not smoke or permit flames or sparks to occur near
the fuel system Keep the compartment and the
tions Know when dangerous conditions exist and take the
clean and free of debris to minimize the
necessary precautions to protect yourself your personne4 chances of fire Wipe up all spilled fuel and engine oil
and your following safety instructions are in compliance with Be aware Diesel fuel will bum
the American Boat and Yacht Council ABYC standards
PREVENT BURNS ELECTRIC SHOCK A WARNING Explosions from fuel vapors can cause
injury or death
A WARNING Do not touch AC electrical connections
while engine is running Lethal voltage is present at All fuel vapors are highly explosive Use extreme care
when handling and storing fuels Store fuel in a
these connections
area away from Do not operate this machinery without electrical equipment and out of the reach of children
enclosures and covers in place Do 110t fill the fueltanks while the engine is mnning
Shut off electrical power before accessing electrical Shut off the fuel service valve at the engine when servicing
equipment the fuel system Take care in catching any fuel that might
Use insulated mats whenever working on electrical spill DO NOT allow any smoking open flames or other
equipment sources of fire near the fuel system or engine when
servicing Ensure proper ventilation exists when servicing
Make sure your clothing and skin are dry not damp the fuel system
particularly shoes when handlipg electrical equipment
Do not alter or modify the fuel system
Remove wristwatch and all jewelry when working on
electrical equipment Be sure all fuel supplies have a positive shutoff valve
Electrical shock results from handling a charged Be certain fuel line fittings are adequately tightened and
capacitor Discharge capacitor by shorting terminals free of leaks
together Make sure a fire extinguisher is installed nearby and is
properly maintained Be familiar with its proper use
PREVENT BURNS HOT ENGINE Extinguishers rated ABC by the NFPA are appropriate
for all applications encountered in this A WARNING Do not touch hot engine parts Dr ACCIDENTAL STARTING
exhaust system components A running engine gets
very hot A WARNING Accidental starting can cause injury
Dr death
Always check the engine coolant level at the coolant
recovery tame
To prevent accidental starting when servicing the
generator remove the 8 amp fuse from the control panel
A WARNING Steam can cause injury or death Disconnect the battery cables before servicing the engine
generator Remove the negative lead first and reconnect
In case of an engine overheat allow the engine to cool it last
before touching the engine or checking the coolant Make certain all personnel are clear of the engine before
BURNS FIRE Make certain all covers guards and hatches are
reinstalled before starting the engine
A WARNING Fire can cause injury Dr death
Prevent flash fires Do not smoke or permit flames or
sparks to occur near the carburetor fuel line filter fuel
pump or other potential sources of spilled fuel or fuel
vapors Use a suitable container to catch all fuel when
removing the fuel line carburetor or fuel filters
Engines Generators
SAFETY STARTING TOXIC EXHAUST GASES
A WARNING Accidental starting can cause injury A WARNING Carbon monoxide CO Is a deadly gas
or death
Ensure that the exhaust system is adequate to expel gases
Disconnect the battery cables before servicing the engine
discharged from the engine Check the exhaust system
generator Remove the negative lead first and reconnect
regularly for leaks and make sure the exhaust
it last
elbow L securely attached
Make certain all personnel are clear of the engine before
starting Be sure the unit and its surroundings are well ventilated
Run blowers when running the generator set or engine
Make certain all covers guards and hatches are
reinstalled before starting the engine Do not run the generator set or engine unless the boat is
equipped with a functioning marine carbon monoxide
detector that complies with ABYCA24 Consult your
BATTERY EXPLOSION boat builder or dealer for installation of approved
detectors
A WARNING Battery explosion can cause injury For additional information refer to ABYC T22
or death educational information on Carbon Monoxide
Do not smoke or allow an open flame near the battery
being serviced Lead acid batteries emit hydrogen a A WARNING Carbon monoxide CO is an invisible
highly explosive gas which can be ignited by electrical odorless gas Inhalation produces flulike symptoms
arcing or by lit tobacco products Shut off all electrical nausea or death
equipment in the vicinity to prevent electrical arcing
during servicing Do not use copper tubing in diesel exhaust systems Diesel
Never connect the negative battery cable to the fumes can rapidly destroy copper tubing in exhaust
positive connection terminal of the starter solenoid systems Exhaust sulfur causes rapid deterioration of
Do not test the battery condition by shorting the terminals copper tubing resulting in exhaustwater leakage
together Sparks could ignite battery gases or fuel vapors Do not install exhaust outlet where exhaust can be drawn
Ventilate any compartment containing batteries to prevent through portholes vents or air conditioners If the engine
accumulation of explosive gases To avoid sparks do not exhaust discharge outlet is near the waterline water could
disturb the battery charger connections while the battery enter the exhaust discharge outlet and close or restrict the
is being charged flow of exhaust Avoid overloading the craft
Avoid contacting the terminals with tools etc to prevent Although diesel engine exhaust gases are not as toxic as
bums or sparks that could cause an explosion Remove exhaust fumes from gasoline engines carbon monoxide
wristwatch rings and any other jewelry before handling gas is present in diesel exhaust fumes Some of the
the battery symptoms or signs of carbon monoxide inhalation or
Always tum the battery charger off before disconnecting poisoning are
the battery connections Remove the negative lead first Vomiting Inability to think coherently
and reconnect it last when disconnecting the battery
Dizziness Throbbing in ACID Headache Muscular twitching
Nausea Weakness and sleepiness
A WARNING Sulfuric acid in batteries can cause AVOID MOVING PARTS
severe injury or death
When servicing the battery or checking the electrolyte A WARNING Rotating parts can cause injury
level wear rubber gloves a rubber apron and eye or death
protection Batteries contain sulfuric acid which is
destructive If it comes in contact with your skin wash it Do not service the engine while it is running If a
off at once with water Acid may splash on the skin or situation arises in which it is absolutely necessary to
into the eyes inadvertently when removing electrolyte make operating adjustments use extreme care to avoid
caps touching moving parts and hot exhaust system
Engines Generators
SAFETY Do not wear loose clothing or jewelry when servicing ABye NFPA AND USCG PUBLICATIONS FOR
equipment tie back long hair and avoid wearing loose
jackets shirts sleeves rings necklaces or bracelets that
INSTALLING DIESEL ENGINES
could be caught in moving parts Read the following ABYC NFPA and USCG publications
for safety codes and standards Follow their
Make sure all attaching hardware is properly tightened
when installing your engine
Keep protective shields and guards in their respective
places at all times ABYC American Boat and Yacht Council
Safety Standards for Small Craft
Do not check fluid levels or the drive belts tension while
the engine is operating Order from
Stay clear of the drive shaft and the transmission coupling ABYC
when the engine is running hair and clothing can easily 3069 Solomons Island Rd
be caught in these rotating parts Edgewater MD 21037
NFPA National Fire Protection NOISE Fire Protection Standard for Motor Craft
Order from
A WARNING High noise levels can cause hearing NFPA
loss 11 Tracy Drive
Avon Industrial Park
Never operate an engine without its muffler installed Avon MA 02322
Do not run an engine with the air intake silencer USCG United States Coast Guard
removed USCG 33CFR183
Do not run engines for long periods with their enclosures Order from
open
US Goverument Printing Office
Washington DC 20404
A WARNING Do not work on machinery when you are
mentally or physically incapacitated by MANUAL
Many of the preceding safety tips and wamings are repeated
in your Operators Manual along with other cautions and
notes to highlight critical information Read your maintain your equipment and foHow all ENGINE AND GENERATOR to install an engine should begin with
thorough examination of the American Boat and ABYC standards These standards are a
combination of sources including the USCG and the of the ABYC standards of particular interest are
H2 Ventilation
Pl Exhaust Systems
PA Inboard Engines
E9 DC Electrical Systems
All installations must comply with the Federal Code FCR
Engines Generators
installing WESTERBEKE engines and generators it is important that be paid to the following AND federal regulations ABYC guidelines and safety codes
must be complied with
when installing engines and generators in a marine installations where the exhaust injected exhaust elbow is close to
or will be below the vessels waterline provisions must be made to install a siphon
break in the raw water supply hose to the exhaust elbow This hose must be looped a
minimum of 20 above the vessels waterline Failure to use a siphonbreak when
the exhaust manifold injection port is at or below the load waterline will result in
raw water damage to the engine and possible flooding of the boat
If you have any doubt about the position of the exhaust elbow relative
to the vessels waterline under the vessels various operating conditions install A siphonbreak requires periodic inspection and cleaning to ensure
proper AVAILABLE FROM
YOUR Failure to properly maintain a siphonbreak can result in catastrophic DEALER
engine damage Consult the siphonbreak manufacturer for proper SYSTEM
The exhaust hose must be certified for marine use The system must be desigued to
prevent water from entering the exhaust under any sea conditions and at any angle
of the vessels hull
A detailed 40 page Marine Installation Manual covering gasoline and
diesel engines and generators is available from your WESTERBEKE
dealer
Engines Generators
TABLE OF Remote Oil Filter Optional Water Heat Connections 22
Warranty Procedures 3 Wiring Diagram Serial Number Location 4 Wiring Schematic Control Panel Glow Plugs
Control Panel Starter Motor Engine Oil and Coolant Dual Output Alternators for Initial StartUp
Alternator 34
The Daily Operation Engine BreakIn Procedure 10 Service Schedule 41
Warning Lights Alarms and Circuit Breaker 11 Cylinder Head Torque Schedule 12 Engine Adjustments
System 14 Oil Pressure 44
FueliWater Separator 14 Tachometer Fuel Filters 14 Engine System 15 ZF Marine Transmission Changing Coolant 15
Borg Warner Transmission 49
Thermostat 16
Raw Water Intake 16 LayUp and Raw Water Pump 17 Torque Data Heat Exchanger 18 Metric Chart Zinc
Anode 18 Suggested Spare Parts Lubricating Oil 19
Changing the Oil 19
Changing the Oil 19
Engines Generators
PARTS TYPICAL
FILL
COOlANT WATER INJECTED
PRESSURE CAP EXHAUST ELBOW
ASSEMBLY
FILTER
DC AIR INTAKE
REAR
FLEXIBLE
MOUNT
DRIVE
Oil PRESSURE
OIL DRAIN HOSE
LEFT SIDE SENDOR
Fill
THERMOSTAT
FUEL LIFT PUMP
ALTERNATOR
PREHEAT
SOLENOID
ZOAMP
CIRCUIT
BREAKER
FRONT
HURTH
TRANSMISSION
MANIFOLD
10 PLATE
ENGINE BLOCK
DRAIN PLUG
REAR SHIFT LEVER
Engines Generators
WESTERBEKE Diesel Engine is a product of PRODUCT long years of experience and advanced Product software
technical data parts lists We take great pride in the superior durability and brochures and catalogs provided from sources other performance
of our engines and generators WESTERBEKE are not within WESTERBEKEs you for selecting WESTERBEKE
WESTERBEKE CANNOT BE RESPONSIBLE FOR THE
In order to get the full use and benefit from your engine it is CONTENT OF SUCH SOFTWARE MAKES NO that you operate and maintain it correctly
This RANTIES OR WITH is designed to help you do this Please read this man THERETO INCLUDING ACCURACY TIMELINESS OR
ual carefully and observe an the safety precautions through COMPLETENESS THEREOF AND WILL IN NO EVENT
out Should your engine require servicing contact your BE UABLE FOR ANY TYPE OF DAMAGE OR WESTERBEKE dealer for assistance
INCURRED IN CONNECTION WITH OR ARISING OUT
This is your operators manual A parts catalog is also OF THE FURNISHING OR USE OF SUCH and a technical manual is available from your
WESTERBEKE customers should keep in mind the dealer If you are planning to install this span between printings
ofWESTERBEKE product contact your WESTERBEKE dealer for and the unavoidable existence of earlier installation manual
product software The product software provided with
WARRANTY PROCEDURES WESTERBEKE products whether from WESTERBEKE or
other suppliers must not and cannot be relied upon exclu
Your WESTERBEKE Warranty is included in a separate sively as the definitive authority on the respective product It
folder If after 60 days of submitting the Warranty Registry not only makes good sense but is imperative that you have not received a
customer card of WESTERBEKE or the supplier in your warranty please contact the factory in be consulted to determine the
accuracy and currentness of the
writing with model information including the engines product software being consulted by the number and commission date
NOTES CAUTIONS AND Card
As this manual takes you through the operating
maintenance schedules and of your marine
engine critical information will be highlighted by NOTES
CAUTIONS and WARNINGS An explanation follows
NOTE An operating procedure essential to note
Customer MR ENGINE OWNER
NUUNSTREET A CAUTION Procedures which if nDt strictly
HOMETOWN observed can result in the damage Dr destruction of
Model Ser your engine
A WARNING Procedures which if not properly fol
lowed can result in personal injury or loss of life
Engines Generators
INTRODUCTION
SERIAL NUMBER LOCATION ORDERING PARTS
The engines model number and serial number are located on Whenever replacement parts are needed always provide the
a nameplate mounted on the side of the engines manifold engine model number and serial number as they appear on
The engines serial number can also be found stamped into the silver and black nameplate located on the manifold You
the engine block on the flat sutface of the block just above must provide us with this infonnation so we may properly
and inboard of the injection pump Take the time to enter this identify your engine In addition include a complete part
information on the illustration of the nameplate shown below description and part number for each part needed see the
as this will provide a quick reference when seeking technical separately furnished Parts List Insist upon WES1ERBEKE
information andlor ordering repair parts packaged parts because will fit or generic parts are frequently
not made to the same as original equipment
SPARES AND ACCESSORIES
Certain spares will be needed to support and maintain your
WES1ERBEKE engine Your local WES1ERBEKE dealer
will assist you in preparing an inventory of spare parts
See the SPARE PARTS page in this manual For engine
accessories see WESTERBEKES ACCESSORIES brochure
UNDERSTANDING THE DIESEL ENGINE RAW WATER COOLING SYSTEM
The diesel engine closely resembles the gasoline engine SiphonBreak
since the mechanism is essentially the same The cylinders For installations where the water injected exhaust elbow is
are arranged above a closed crankcase The crankshaft is the close to or will be below the vessels waterline provisions
same general type as a gasoline engine and the diesel engine must be made to install a siphonbreak in the raw water
has the same type of valves camshaft pistons connecting supply hose to the water injected exhaust elbow The siphon
rods and lubricating system break provides an air vent in the raw water cooling system to
Therefore to a great extent a diesel engine requires the same prevent raw water from filling the exhaust system and the
preventive maintenance as a gasoline engine The most engines cylinders when the engine is shutdown
important factors are proper ventilation and proper mainte
nance of the fuel lubricating and cooling systems Fuel and
lubricating filter elements must be replaced at the time A CAUTION Failure to use a siphonbreak when
periods specified and frequent checking for contaminants the exhaust manifold injection port is at or below the
water sediment etc in the fuel system is also essential load waterline will result in raw water damage to the
Another important factor is the consistent use of the same engine and possible flooding of the boat
brand of high detergent diesel lubrication oil designed
specifically for diesel engines
The diesel engine does differ from the gasoline engine If you have any doubt about the position of the water
however in its method of handling and firing of fuel The injected exhaust elbow relative to the vessels waterline under
carburetor and ignition systems are replaced by a single the vessels various operating conditions install a siphon
component the fuel injection pump which performs the break This precaution is necessary to protect your engine
function of both The siphonbreak must be installed in the highest point of a
hose that is looped a minimum of 20 inches 51cm above
the vessels waterline This siphonbreak must always be
GLOW PLUG above the waterline during all angles of vessel operation to
ENERGIZED BY THE PREHEAT prevent siphoning
NOTE A siphonbreak requires periodic inspection and
cleaning to ensure proper operation Failure to properly
l DIESEL FUEL SPRAY
maintain a siphonbreak can result in catastrophic engine
damage Consult the siphonbreak manufacturer for proper
SIPHONBREAK WITH STAINLESS
LOOP FOR 314 HOSE
PART Engines Generators
ADMIRAL CONTROL PANEL
DESCRIPTION When the engine is shut down with the key switch turned off
the water temperature gauge will continue to register the last
This control panel is equipped with a temperature reading indicated by the gauge before electrical
KEY switch and RPM gauge with an ELAPSED TIME power was turned off The oil pressure gauge will fall to zero
meter which measures the engines running time in hours and when the key switch is turned off The temperature gauge
in 1110 hours The panel also includes a WA1ER 1EMPER will once again register the engines true temperature when
ATURE gauge which indicates water temperature in degrees electrical power is restored to the gauge
Fahrenheit an OIL PRESSURE gauge which measures the
engines oil pressure in pounds per square inch and a DC A separate alarm buzzer with harness is supplied with every
control circuit VOLTAGE gauge which measures the sys Admiral Panel The installer is responsible for electrically con
tems voltage All gauges are illuminated when the key necting the buzzer to the fourpin connection on the engines
switch is turned on and remain illuminated while the engine electrical harness The installer is also responsible for installing
is in operation The panel also contains two rubberbooted the buzzer in a location where it will be dry and where it will
pushbuttons one for PREHEAT and one for START be audible to the operator should it sound while the engine is
running The buzzer will sound when the ignition key is turned
on and should silence when the engine has started and the
engines oil pressure rises above 15 psi 11 kglcm2
Oil PRESSURE GAUGE THIS GAUGE IS GRADU
ATED IN POUNDS PER SQUARE INCH PSI AND IS
WATER TEMPERATURE GAUGE THIS GAUGE IS ILLUMINATED WHILE THE KEY SWITCH IS TURNED
GRADUATED IN DEGREES FAHRENHEIT AND IS ON THE ENGINES NORMAL OPERATING OIL
IlWMINATED WHILE THE KEY SWITCH IS PRESSURE RANGES BElWEEN 30 60 psi
TURNED ON THE ENGINES NORMAL OPERATING 21 42 kgem
TEMPERATURE IS 170 190 F77 aac
RPM GAUGE REGIS
TERS MINUTE OF THE
ENGINE AND CAN FOR
ACCURACY FROM THE
REAR OF THE SWITCH ELAPSED
POWER ONLY TO THE
TIME AND SHOULD BE
INSTRUMENT PANEL
USED AS A GUIDE FOR
CLUSTER
THE DC VOLTMETER
INDICATES THE AMOUNT THE
BATTERY IS BEING PRESSED ENERGIZES THE SHOULb SHOW
13VTO EXCITER THE FUEL LIFT PUMP THE AUTOMATIC ALARM SYSTEM
FUEL SOLENOID ON THE INJECTION PUMP AND THE
ENGINES GLOW PLUGS IT BYPASSES THE ENGINES COOLANT TEMPERATURE ALARM AN ALARM BUZZER HAS BEEN
OIL PRESSURE ALARM SWITCH IN ADDITION THIS SUPPLIED WITH THE INSTRUMENT PANEL IF THE ENGINES ENERGIZES THE
START BUTTON REACHES 210 F99C THIS SWITCH WILL CLOSE SOUNDING THE
ALARM WHICH WILL EMIT A CONTINUOUS SIGNAL
START BUTTON WHEN PRESSED ENERGIZES THE
STARTERS SOLENOID WHICH CRANKS THE ENGINE Oil PRESSURE ALARM AN OIL PRESSURE ALARM SWITCH IS
THIS BUTTON WILL NOT OPERATE ELECTRICALLY LOCATED OFF THE ENGINES OIL GALLERY THIS SWITCH THE PREHEAT
BUTTON IS PRESSED AND HELD THE ENGINES OIL PRESSURE SHOULD THE ENGINES OIL PRESSURE
AT THE SAME TIME FALL TO 5 10 psi OA 07 kgem THE SWITCH WILL CLOSE SOUND
ING THE ALARM IN THIS EVENT THE ALARM WILL EMIT A PULSATING
SIGNAL
Engines Generators
CAPTAIN CONTROL The panel also includes an alarm buzzer for low OIL
PRESSURE or high COOLANT 1EMPERATURE The
This control panel is equipped with a
RPM gauge is illuminated when the KEY switch is turned on
KEY switch an RPM gauge PREHEAT and START but
and remains illuminated while the engine is in an JNSTRLMEITT JEST button and three one for AL1ERNATOR DISCHARGE one for low
OIL PRESSURE and one for high ENGINE ALARM THE ALARM WILL SOUND IF THE ENG1NES
OIL PRESSURE FALLS
BELOW 5 10 psi 04 07 kgem IN THIS EVENT THE ALARM WILL EMIT A
PULSATING SIGNAL THE ALARM WILL ALSO SOUND IF THE COOLANT
RPM GAUGE REGISTERS REVOLUTIONS TEMPERATURE IN THE FRESHWATER COOLING CIRCUIT RISES TO
PER MINUTE OF THE ENGINE AND CAN BE 210 a F 99C IN THiS EVENT THE ALARM WILL EMIT A CONTINUOUS FOR ACCURACY FROM
NOTE THE ALARM WILL SOUND WHEN THE KEY SWITCH IS TURNED ON THIS
THE REAR OFTHE PANEL SOUNDING IS NORMAL ONCE THE ENGINE STARTS AND THE ENGINES OIL
PRESSURE REACHES 15 pSi 11 kgem THE ALARM WILL SILENCE
Oil PRESSURE ALTERNATOR
ALARM LIGHT ALARM LIGHT
TEST BUTTON WHEN
PRESSED TESTS THE
ALTERNATOR THE OIL
PRESSURE AND THE
COOLANT TEMPERA
TURE CONTROL CIR
CUITS WHEN PRESSED
THE ALTERNATOR THE
OIL PRESSURE AND
THE WATER TEMPERA
TURE INDICATOR
LIGHTS ILLUMINATE IN
ADDITION TO SOUND
ING THE ALARM
BUZZER
KEY SWITCH PROVIDES
POWER ONLY TO THE
lNSTRUMErijT PANEL
CLUSTER
WATER TEMPERATURE
ALARMUGHT
START BUTTON WHEN PRESSED ENERGIZES THE
STARTERS SOLENOID WHICH CRANKS THE ENGINE THIS BUTTON WHEN PRESSED ENERGIZES THE
BUTTON WILL NOT OPERATE ELECTRICALLY UNLESS THE ALTERNATORS EXCITER THE FUEL LIFT PUMP THE FUEL
PREHEAT BUTTON IS PRESSED AND HELD AT THE SAME SOLENOID ON THE INJECTION PUMP AND THE ENGINES
TIME GLOW PLUGS AND BYPASSES THE ENGINES OIL PRES
SURE ALARM SWITCH IN ADDITION THIS BUTTON ENER
GIZES THE START BUTTON
Engines Generators
DIESEL FUEL ENGINE OIL AND ENGINE FUEL ENGINE COOLANT
Use fuel1hat meets 1he requirements or specification of Class WESTERBEKE recommends a mixture of 50 ASTM and has a cetane rating of 45 or
better and 50 distilled water Distilled water is free from the
chemicals that can corrode internal engin Of The Fuel Supply The antifreeze performs double duty It
allows the engine to
Use only clean diesel fuel The clearance of1he components run at proper temperatures by transferring heat away from
in your fuel injection pump is very critical invisible dirt the engine to the coolant and lubricates and protects the
particles which might pass through 1he filter can damage cooling circuit from rust and corrosion Look for a good
these finely finished parts It is important to buy clean fuel quality antifreeze 1hat contains Supplemental Cooling
and keep it clean The best fuel can be rendered Additives SCAs that keep the antifreeze by careless handling or improper
storage balanced crucial to long term To assure that the fuel going into the tank for your The distilled water and antifreeze
should be premixed daily use is clean and pure the following practice being poured into the cooling circuit
is a wellknown brand of fuel NOTE Lookfor the new long lasting
antifreeze that is now and regularly service a good visualtype separator between the fuel tank and the engine PURCHASING Raycor 500 FG or
900 FG are good examples of such
filters Rather than preparing the mixture WESTERBEKE
recommends buying the premixed antifreeze so that so that
ENGINE OIL when adding coolant the mixture will always be correct
There are two common types of antifreeze Ethylene Glycol
Use a heavy duty engine oil with an API of Cf
green and Propylene Glycol redpurple either can be used
or CG4 or better Change the engine oil after an initial 50
but do not mix the two and if changing from one to of breakin operation and every 100 hours of operation
flush the engine For recommended oil use sAE 15W40
oil viscosity and stay with 1he same brand of oil thruout Premixed antifreeze for DIESEL Engines
the life of the engine Specification ASTM 5345
MAINTENANCE
Change the engine coolant every five years regardless of the
A CAUTION Do not allow two Dr mDre brands of number of operating hours as the chemical additives that
engine oil to mix Each brand contains its own additives protect and lubricate the engine have a limited life
additives of different brands could reacl in the mixture
to produce properties harmful tD your engine
COOLANT RECOVERY TANK
A coolant recovery tank kit is supplied with each generator
The purpose of this recovery tank to allow for engine
coolant expansion and contraction during engine operation
without the loss of coolant and without introducing air into
the cooling system
Engines Generators
PREPARATIONS FOR INITIAL starting your engine for the first time or after a
prolonged layoff check the following items
COOlANT
o Check the engine oil level Add oil to maintain the level RECOVERY
at the high mark on the dipstick TANK
o Turn on the fuel supply then check the fuel supply and
examine the fuel filterwater separator bowl for
Check the transmission fluid level
o Check the DC electrical system Inspect wire connections
and battery cable connections Make certain the positive
battery cable is connected to the starter solenoid and
the negative cable is connected to the engine ground
stud this location is tagged
o Check the coolant level in both the plastic recovery tank
and at the manifold
NOTE If the engine has not yet been filled with coolant
refer to the COOliNG SYSTEM section of this manual
D Visually examine the engine Look for loose or missing
parts disconnected wires and unattached hoses Check
the threaded connections and engine Make certain there is proper ventilation around the
engine An ample supply is necessary for proper engine
Make sure the mounting installation is secure
D Ensure the propeller shaft is securely attached to the
Open the thruhull and make certain raw water is primed
to the raw water strainer OIL DIPSTICK
PRESS IN TIGHT
FULL MAX
SIDE OIL FILL
Engines Generators
STARTING STOPPING FAILURE TO START
Follow this check list each day before starting your engine If the engine fails to start when the start button is pressed for
D Visually inspect the engine for fuel oil or water leaks 5 seconds wait for at least 30 seconds and repeat the starting
procedure Make certain the transmission control is in th
D Check the engine oil level dipstick neutral position as some engines have a neutral safety SWItch
D Check the coolant level in coolant recovery tank to prevent starting in gear
Periodically check the manifold coolant leveL Never run the starter for more then 30 seconds If the engine
D Check the transmission fluid level fails to start refer to the CHART in
D Check your fuel supply this manual
D Look for clean fuel in the fuel filterwater separator
transparent bowL
Check for loose wires at the alternator and make sure its
A CAUTION Prolonged cranking intervals without
the engine starting can result in the engine exhaust
mounting is secure
system filling with raw water This may happen because
D Check the starting batteries weekly the pump is pumping raw water through the raw water
D Check drive belts for wear and proper tension weekly cooling system during cranking This raw water can
D Visually inspect the raw water pump for leakage enter the engines cylinders by way of the THE ENGINE
manifold once the exhaust system tills Prevent this
1 Place the transmission in neutral throttle advanced from happening by clOSing the raw water supply
throughhull shutoff draining the exhaust muffler and
NOTE Hydraulically operated transmissions have a correcting the cause of the excessive engine cranking
neutral safety switch through which the starter solenoid
energizing circuit passes This switch is open when the Engine damage resulting from raw water entry is not a
transmission is in gear so the starter solenoid will not warrantable issue the should keep this
energize in mind
2 Tum the KEY SWITCH to the ON position 2 oclock
If the panel is energized gauges are lit and the alarm STOPPING PROCEDURE
buzzer will pulse
To stop the engine bring the throttle to an idle position and
3 Press the PREHEAT BUTfON and hold for 5 to 15 place the transmission in neutral Allow the engine to idle for
seconds depending how cold it is The foellift pump is a few moments to stabilize temperatures then shut the
priming the engine and the preheat is activated engine down by turning off the key switch
4 Continue pressing the PREHEAT BUTTON and press
the START BUTTON The starter motor is cranking the
engine
5 Release the START and PREHEAT BUTTON as the NOTE When starting
engine starts The alarm buzzer should silence as the oil A voltage drop will occur
pressure rises when the preheat button
6 With the engine running check the instruments for is depressed
proper oil pressure and battery charging voltage Also
check for overboard discharge of exhaust water The
water temperature will rise slowly until the thermostat
opens Do not engage the gear shift until the temperature
is close to nonnal
NOTE Never attempt to engage the starter while the
engine is ntnning
It is important to closely monitor the panel gauges
Become aware of the normal engine readings and take
immediate action if these readings start to vary
If a smart regulator is part of the charging system
allow about 50 second for the RPM gauge to Engines Generators
ENGINE BREAKIN 3 While using the vessel run the engine at various engine
speeds for the first 25 hours Avoid prolonged periods of
Although your engine has experienced a minimum of one
idling
hour of test operations at the factory to make sure procedures were followed and that the engine oper 4 Avoid rapid acceleration especially
with a cold engine
ated properly a breakin time is required The service life of 5 Use caution not to overload the engine The presence of a
your engine is dependent upon how the engine is operated grey or black exhaust and the inability of the engine to
and serviced during its initial 50 hours of use reach its full rated speed are signs of an a new engine basically involves
seating the pis 6 During the next 25 hours the engine may be operated at
ton rings to the cylinder walls Excessive oil consumption varying engine speeds with short runs at full rated rpm
and smoky operation indicate that the cylinder walls are Avoid prolonged idling during this breakin which is caused by overloading the
engine during the
breakin period CHECK LIST
Your new engine requires approximately 50 hours of initial D Monitor the control panel operation to break in each moving part in order
D Check for leaks of fuel and engine oil
to maximize the performance and service life of the engine D Check for abnormal noise such as knocking this conditioning carefully keeping in
mind the fol vibration and blowback D Confinn exhaust smoke
1 Start the engine according to the STARTING PROCE When the engine is cold white smoke
DURE section Run the engine at fast idle while checking When the engine is warm almost smokeless
that all systems raw water pump oil pressure battery When the engine is overloaded some black smoke and soot
charging are Allow the engine to wann up preferably by running at
NOTE See the TRANSMISSION section of this manual for
breakin information on your fast idle until the water temperature gauge moves into
the 130 140F 55 60C range
Engines Gmerators
WARNING LIGHTS ALARMS CIRCUIT BREAKER
ALTERNATOR WARNINGS LOW OIL PRESSURE ALARM SWITCH
The Captain Control Panel indicates alternator low discharge A low oil pressure alarm switch is located off the engines
with a red warning light oil gallery This switchs sensor monitors the engines oil
The Admiral Control Panel uses a voltmeter to monitor the pressure Should the engines oil pressure fall to 5 10 psi
performance of the alternator 04 07 kgcm2 this switch will activate a pulsating alarm
COOLANT TEMPERATURE SWITCH ENGINE CIRCUIT BREAKER
A coolant temperature switch is located on the thermostat The DC harness on the engine is protected by an engine
housing This switch will activate a continuous alarm if the mounted manual reset circuit breaker 20 amps DC
coolants operating temperature reaches approximately Excessive current draw or electrical overload anywhere in
210F 99C the instrument panel wiring or engine wiring will cause the
breaker to trip In this event most engines will shut down
because the opened breaker disconnects the fuel supply If
this should occur check and repair the source of the problem
After repairing the fault reset the breaker and restart the
CONTROL PANEL
TYPICAL ARRANGEMENT
COOLANT SEND OR
THERMOSTAT
ASSEMBLY
Engines Generators
MAINTENANCE SCHEDULE
A WARNING Never attempt to perform any service while the engine is
running Wear the proper safety equipment such as goggles and gloves and
use the correct tools for each job Disconnect the battery terminals when
servicing any of the engines DC electrical equipment
NOTE Many of the following maintenance jobs are simple but others are more
difficult and may require the expert knowledge of a service mechanic
CHECK HOURS OF EACH EXPLANATION OF
DAY 50 100 250 500 750 1000 1250 Supply 0
Diesel No2 rating of 45 cetane or Separator 0 Check for
water and dirt in fuel filter
if Oil Level 0 Oil level should indicate between MAX and LOW on
Level 0 Check at recovery tank if empty check at manifold
Add coolant if needed
Drive Belts 0 Inspect for proper tension 38 to 112 deflection
weekly and adjust if needed Check belt edges for wear
Visual Inspection of Engine 0 NOTE Please keep engine surface clean Dirt Check for fuel oil and water leaks Inspect wiring
and oil will inhibit the engines ability to and electrical connections Keep bolts nuts tight
remain cool Check for loose belt tension
Fuel Filter 0 0 0 0 0 0 Initial change at 50 hrs then change every 250 hrs
Starting Batteries 0 Every 50 operating hours check electrolyte levels
and House Batteries weekly and make sure connections are very tight Clean off
excessive Oil and filter 0 0 0 0 0 0 0 Initial engine oil filter change at 50 hrs then
change both every 100 hours
Heat Exchanger Zinc Anode 0 0 0 0 0 Inspect zinc anode replace if needed clear the heat
exchanger end of zinc anode Separator 0 0 0 0 0 0 Change every 200 System
0 0 0 0 Initial check at 50 hrs then every 250 hrs Inspect
for leaks Check antiSiphon valve operation Check
the exhaust elbow for carbon andor corrosion
buildup on inside passages clean and replace as
necessary Check that all connections are tig ht
Engine Hoses 0 0 0 0 Hose should be hard tight Replace if soft or
spongy Check and tighten all hose clamps
Engines Generators
MAINTENANCE SCHEDULE
NOTE Use the engine hour meter gauge to log your engine hours or record your
engine hours by running time
CHECK HOURS OF OPERATION
SCHEDULED EACH EXPLANATION OF SCHEDULED
MAINTENANCE DAY 50 100 250 SOD 750 1000 1250 MAINTENANCE
Raw Water Pump 0 0 0 Remove the pump cover and inspect impeller gas
ket cam and cover for wear Check the bearings
and seals the shaft can turn but not wobble
Lubricate when Coolant System 0 Drain flush and refill cooling system with
appropriate antifreeze mixture compatible with
various cooling system metals
Electric Fuel lift Pump 0 0 0 0 0 0 Periodically check the wiring connections and
inspect the fuel line connections
Inlet Fuel Filter 0 0 0 0 0 Replace
DC Alternator 0 0 0 Check DC charge from alternator Check the
mounting bracket tighten electrical connections
0 Check and adjust injection opening pressure and
spray condition see ENGINE Starter Motor 0 0 Check solenoid and motor for corrosion
Remove
and lubricate Clean and lubricate the starter motor
pinion drive
Preheat Circuit 0 0 Check operation of preheat solenoid Remove and
clean glow plugs check resistance 46 ohms
Reinstall with anti seize compound on threads
Englne Cylinder D 0 Check compression pressure and timing
Compression see Engine Torque Cylinder Head 0
0 0 At first 50 hours then every 500 hours
Holddown bolts see ENGINE Adjust the Valve Clearances 0 0
0 Adjust Valve Clearances
see ENGINE Heat Exchanger 0 Remove have cleaned and
pressure recommends this service be performed by an authorized Engines Generators
FUEL SYSTEM
DIESEL FUEL
Use No2 diesel fuel with a cetane rating of 45 or higher Do
not use kerosene or home heating fueL
FUEL FILTERWATER fuel filter of the water separating type must be
installed between the fuel tank and the engine to remove
water and other contaminants from the fuel before they can
be carried to the fuel system on the engine
Most installers include a fuel filterwater separator with the FUEL package as they are aware of the problems that The fuel
injection pump and the fuel injectors are in the fuel can cause manufactured and they must receive clean diesel
fuel free
from water and dirt To ensure this flow of clean fuel the fuel
A typical fuel filterwater separator is il1ustrated below This
must pass through at least two fuel filters a fuel the Raycor Model 500 MA Keep in mind that if a water
separator and the engines spinon fuel filter Visually type filter is not installed between the fuel supply
tank and fuel system any water in the fuel
clean and change these filters according to the affect the fuel pump engine filter and injection equip schedule in this manual
ment The is responsible for making certain
the fuel reaching the engines injection equipment is free This process is accomplished by installing and
A WARNING Shut off the fuel valve at the a proper fuel filterwater separator when servicing the fuel system Take care in
catching
any fuel that may spill DO NOT allow any smoking
open flames or other sources of fire near the fuel sys
tem when servicing Ensure proper ventilation when servicing the fuel
LOOSEN FITTING l A
WHEN PRIMING
FILL FILTER
The fuel injection pump is a very important component of
the diesel engine requiring the utmost care in handling The
fuel injection pump has been thoroughly benchtested and is cautioned not to attempt to service it If it
SPIN ON
requires servicing remove it and take it to an authorized fuel FUEL pump service facility Do not
attempt to disassem
ble and repair it Changing The Fuel Filter 0 24363
FUEL LIFT PUMP 1 Shut off the fuel check the fuel connections to and out of the
2 Loosen the fuel filter turning with a
pump and make sure that no leakage is present and that the filter wrench Place the used filter in a container for are tight and
secure The DC ground connection at disposal
one of the pumps mounting bolts should be clean and well 3 Using a rag wipe clean the sealing face on the the mounting bolt to ensure
proper pump opera bracket so the new filter can be seated 4
Lightly oil the sealing Oring on the new filter To rein
When energized thru the preheat circuit the fuel lift pump staJ tum the filter assembly purge air from the fuel system and provide a
continuous until the aring contacts the sealing surface of the housing
flow of fuel as the engine is running bracket Tum 213 further with the filter wrench
5 The keyon preheat sequence will operate the fuel lift
INLET FUEL FILTER pump and quickly fill the new filter It is also poSsible to
To ensure clean fuel enters the fuel lift pump there is an hand prime he filter using the lever on the top
inline filter at the incoming fuel line This filter should be
6 Run the engine and inspect the filter for fuel every 200 operating hours
Engines Generators
COOLING SYSTEM
FRESH WATER COOLING CIRCUIT CHANGING COOLANT
NOTE Refer to the ENGINE COOLANT page for the The engines coolant must be changed according to antifreeze and water mixture to
be used as MAINTENANCE SCHEDULE If the coolant is allowed to
the fresh water coolant become contaminated it can lead to ovetbeating water coolant is pumped through the
engine by a
circulating pump absorbing heat from the engine The A CAUTION Proper cooling system maintenance is
coolant then passes through the thermostat into the manifold triflcal a substantial number of engine failures can be
to the heat exchanger where it is cooled and returned to the traced back to cooling system block via the suction side of the circulating
pump
When the engine is started cold external coolant flow is Drain the engine coolant by removing the drain plug on the
prevented by the closed thermostat although some coolant engine block and opening the manifold pressure cap Flush
flow is bypassed around the thermostat to prevent the exhaust tQe system with fresh water then reinstall the drain and from overheating As the
engine warms up the the refill process Refer to the illustration gradually opens allowing full flow of the to flow unrestricted to the
external portion of the NOTE The drain petcock on the heat exchanger can also be
cooling system used to help drain engine Recovery Tank
A WARNING Beware of the hot engine coolant
A coolant recovery tank allows for engine Coolant expansion Wear protective gloves
and contraction during engine loss of coolant and without introducing air into
the cooling system This tank should be located at or above Refilling the Coolant
the engine manifold level and should be easily accessible
After replacing the engine block drain plug close the heat
exchangers coolant petcock Then run he engine at idle and
slowly poor clean premixed coolant into the manifold
Monitor the coolant in the manifold and add as needed Fill
the manifold to the filler neck and install the manifold
pressure cap
Remove the cap on the coolant recovery tank and fill with
coolant mix to halfway between LOW and MAX and replace
COOLANT the cap Run the engine and observe the coolant expansion
RECOVERY flow into the recovery tank
TANK After checking for leaks stop the engine and allow it to cool
Coolant should draw back into the cooling system as the
NOTE PeriodicaUy check the condition of the manifold engine cools down Add coolant to the recovery tank if
pressure cap Ensure that the upper and lower rubber seals needed and check the coolant in the manifold Clean up any
are in good condition and check that the vacuum valve opens spilled coolant
and closes tightly Carry a spare cap
TO COOLANT KEEP THE
SEAL RECOVERY TANK COOLANT PASSAGE
CLEAR
FROM COOLANT COOLANT EXPANSION
RECOVERY TANK PRESSURE
CHECKING THE PRESSURE CAP
Enfline Generators
COOLING SYSTEM
THERMOSTAT RAW WATER INTAKE STRAINER
A thennostat located near the manifold at the front of the NOTE Always install the strainer at or below the waterline so
engine controls the coolant temperature as the coolant the strainer will always be continuously flows through the closed cooling
circuit When
the engine is first started the closed thennostat prevents A clean raw water intake strainer is a vital component of the
coolant from flowing some coolant is bypassed through a engines cooling system Include a visual inspection of this
hole in the thennostat to prevent the exhaust manifold from strainer when making your periodic engine check The water
overheating As the engine wanns up the thennostat in the glass should be clear
gradually opens The thennostat is accessible and can be Perfonn the following maintenance after every 100 hours of
checked cleaned or replaced easily Cany a spare thennostat operation
and gasket 1 Close the raw water seacock
Replacing the Thermostat 2 Remove and clean the strainer filter
Remove the cap screws and disassemble the thennostat 3 Clean the glass
housing as shown When installing the new thennostat and 4 Replace the washer jf necessary
gasket apply a thin coat of sealant on both sides of the 5 Reassemble and install the strainer
gasket before pressing it into place Do not overtighten the
cap screws 6 Open the seacock
Run the engine and check for nonnal temperatures and that 7 Run the engine and check for leaks
there are no leaks at the thennostat housing NOTE Also follow the above procedure after having run hard
aground
If the engine temperature gauge ever shows a higher than
nonnal reading the cause may be that silt leaves or grass
may have been caught up in the strainer slowing the flow of
raw water through the cooling system
SEALlNG
WASHER
INSPfCTAND
CLEAN EVERY
100 TYPICAL RAW WATER STRAINER
OWNER INCOMING
RAW WATER
THERMOSTAT ASSEMBLY
TYPICAL
SEACOCK
Engines Generators
COOLING SYSTEM
RAW WATER PUMP Changing the Raw Water Pump Impeller
The raw water pump is a selfpriming rotary pump with a Close the raw water intake valve Remove the pump housing and a Neoprene impeller
The impeller and with the aid of two small screwdrivers carefully pry the
has flexible blades which wipe against a curved cam plate impeller out of the pump Install the new impeller and gasket
within the impeller housing producing the pumping action Move the blades to confonn to the curved cam plate and
On no account should this pump be run dry There should push the impeller into the pumps housing When
always be a spare impeller and impeller cover gasket aboard assembling apply a thin coating of lubricant to the impeller
an impeller kit Raw water pump impeller failures occur and gasket Open the raw water intake valve
when lubricant raw water is not present during Such failures are not warrantable and operators
are cautioned to make sure raw water flow is present at start
up The raw water pump should be inspected periodically for
A CAUTION If any of the vanes have broken off the
brokeno tom impeller blades See MAINTENANCE impeller they must be found to prevent blockage in the
SCHEDULE cooling circuit They often can be found in the heat
exchanger or in the discharge fitting of the pump
NOTE Should a failure occur with the pump s iliternal parts
seals and bearings it may be more cost efficient to
purchase a new pump and rebuild the original pump as a
spare
RAW WATER PUMP
AIR INTAKE
NOTE To operate efficiently a diesel engine must intake a
continuous volume ofclear air Hard starting an erratic idle ALIGN WITH THE
and black ezaust smoke are all symptoms of a restricted air SLOT IN THE
I
l INSPECTION CHECK ATTHE BASE OF
EACH BLADE BY BENDING VIGOROUSLY
REPLACE THE IMPELLER IF THERE
RAW WATER IN ARE ANY CRACKS
WHEN INSTALLING TAKE CARE TO ALIGN
THE IMPELLER KEYWAY WITH THE SHAFT
KEY FOLD THE IMPELLER BLADES IN
EITHER DIRECTION THEY WILL TURN IN
THE CORRECT POSITION WHEN THE
PUMP STARTS APPLY LIQUID SOAP
AT ASSEMBLY
Engines Generators
COOLING SYSTEM
Zinc Anode If the zinc anodes need replacement hold the hex boss into
A zinc anode or pencil is located in the raw water cooling which the zinc anode is threaded with a wrench while within the heat exchanger
The purpose of having the ening the anode with another wrench This prevents the hex
zinc ode is to sacrifice them to electrolysis action taking boss from possibly tearing off the exchanger shell After
place ill the raw water cooling circuit thereby reducing the removing the Zinc note the condition Qf it If the zinc is in
effects of electrolysis on other components of the system poor condition there are probably a lot of zinc flakes within
The condition of the zinc anode should be checked monthly the exchanger Remove the end of the heat exchanger and
and the anode cleaned or replaced as required Spare anodes clean the inside of all zinc debris Always have a spare heat
should be carried on board exchanger end gasket in case the present one becomes dam
aged when removing the end cover Replace the gasket refer
tc your engine models heat exchanger end gasket part num
ber Oring and cover and install a new zinc anode
NOTE The threads of the zinc anodes are pipe threads and
do not require sealant Sealant should not be used as it may
insulate the zinc from the metal of the heat exchanger hous
ing preventing electrolysis action on the zinc
Heat Exchanger Service
After approximately 1000 hours of operation remove clean
NEW REPLACE REPLACE CLEAN AND and pressure test the engines heat exchanger A local auto
REUSE motive radiator shop should beable to clean and test the heat
ZINC ANODES exchanger
NOTE Operating in silty andor tropical waters may require
OTE Eectrolysis action is the result of each particular that a heat exchanger cleaning be perfonned more often and vessel location not
that of the engine every 1000 hours
IR BLEED
ZINC ANODE PETCOCK
DO NOT USE SEALANT
ON THE THREADS
TYPICAL HEAT EXCHANGER
ASSEMBLY
COVER WATER
SECURING CLEAN our EVERY DRAIN
BOLT 100 HOURS
INSPECT CLfAN OUT DEBRis
BOTH ENDS
HEAT EXCHANGER
NOTE When installing the heat exchanger end covers Be
sure that the end cover securing bolts sealing Oring is
installed Failure to install this sealing Oring can result in
end plate failuresea water leakage
Engines Generators
ENGINE LUBRICATING OIL
DESCRIPTION ENGINE Oil CHANGE
The lubricating system is a pressure feeding system using 1 Draining the Oil Sump Discharge the used oil througn
an oil pump The engine oil is drawn from the oil sump by the sump drain hose attached to the front of the engine
while the engine is wann Drain the used oil completely
the oil pump which drives the oil under pressure through
replace the hose in its bracket and replace the end cap
the oil filter oil cooler and various lubricating points in the
engine The oil then returns to the oil sump to repeat the securely
continuous cycle When the oil pressure exceeds the speci NOTE Thread size for the lube oil drain hose capped end
fied pressure the oil pushes open the relief valve in the oil is 114NPT
pump and returns to the oil sump keeping the oil pressure Always observe the used oil as it is removed A
within its specified range yellowgray emulsion indicates the presence of water in
the oil Although this condition is rare it does require
LUBRICATION DIAGRAM prompt attention to prevent serious damage Call a
qualified mechanic should water be present in the oil
Raw water present in the oil can be the result of a fault in
the exhaust system attached to the engine andor a
siphoning of raw water through the raw water cooling
circuit into the exhaust filling the engine This problem
is often caused by the absence of an antisiphon valve its
poor location or lack of maintenance
2 Replacing the Oil Filter When removing the used oil
filter you may find it helpful and cleaner to punch a hole
in the upper and lower portion of the old filter to drain
OIL PRESSURE the oil from it into a container before removing it This
RELIEF VALVE helps to lessen spillage A small automotive filter wrench
should be helpful in removing the old oil filter
OIL PUMP NOTE Do not punch this hole without first loosening the
jilter to make certain it can be removed
Place some paper towels and a plastic bag around the
filter when unscrewing it to catch any oil left in the filter
OILDRArNW Oil or any other fluid on the engine reduces the engines
cooling ability Keep your engine clean Inspect the old
OIL PRESSURE oil filter as it is removed to make sure that the rubber
sealing gaSket comes off with the old oil filter If this
The engines oil pressure during operation is indicated rubber sealing gasket remains sealed against the filter
by the oil pressure gauge on the instrument panel During bracket gently remove it
nonnal operation the oil pressure will range between 40 and
60 psi 28 and 42 kglcm2
NOTE A newly started cold engine can have an oil pressure
reading up to 60 psi 42 kglcm 2 A warmed engine can have amm1116
an oil pressure reading as low as 35 psi 25kgcm2 These SOCKET
readings will vary depending upon the temperature of the
engine and the rpms
A CAUTION oD not allow two Dr more brands of
engine oil to mix Each brand contains its own addi
tives additives of different brands could react in the
mixture to produce properties harmful to your engine
Engines Generators
ENGINE LUBRICATING OIL
When installing the new oil filter element wipe the filter 3 Filling the Oil Sump Add new oil through the oil filler
gaskets sealing surface on the bracket free of oil and cap on the top of the engine or through the side oil fill
apply a thin coat of clean engine oil to the rubber gasket Mter refilling run the engine for a few moments while
on the new oil filter Screw the filter onto the threaded oil checking the oil pressure Make sure there is no leakage
filter nipple on the oil filter bracket and then tighten the around the new oil filter or from the oil drain system and
filter firmly by hand stop the engine Then check the quantity of oil with the
lube oil dipstick Fill to but not over the high mark on
NOTE The engine oil is cooled by engine coolant flowing the dipstick should the engine require additional oil
through passages in the oil jilter bracket housing assembly
ENGINE OIL
A WARNING Used engine oil contains harmful Use a heavy duty engine oil with an API of Avoid prolonged skin contact Clean
skin CG4 CHA or CI4 Change the engine oil after an initial 50
and nails thoroughly using soap and water Launder Dr hours ofbreakin operation and every 100 hours of clothing Of rags containing
used oil Discard thereafter For reconnnended oil use SAE 15W40
used oil properly oil viscosity WESTERBEKE reconnnends the use of
synthetic oil
NOTE Generic jilters are not recommended as the
material standards or diameters of important items on
generic parts might be entirely different from genuine
parts Immediately after an oil jilter change and oil fill
run the engine to make sure the oil pressure is nonnal
and that thefl are no oil leaks around the new oil filter
Engines Generators
REMOTE OIL FILTER NOTE Westerbeke is lWt responsible for engine failure due to
fhls popular accessory is used to relocate the engines oil fil incorrect installation of the Remote Oil Filter
ter from the engine to a more convenient location such as an
ngine room bulkhead
NOTE Refer to ENGINE OIL CHANGE in this rnarwalfor A CAUTION It is vital to Install the oil lines on removing the oil
filter rectlylf the 011 flows In the reverse direction the by
lro install simply remove the engine oil filter and thread on pass valve in the filter assembly will pf1vent the oil
WBSTERBEKBs remote oil filter kit as shown Always from reaching the engine causing an Intemal this kit with the oil
filter facing down as illustrated
failure If there is no 011 pressure reading your WESTERBEKB dealer for more information immediately and check the
APPLY A THIN COAT OF ClEAN OIL TO THE ORING WHEN
INSTALLING THIS KIT THREAD THE KIT ON THEN HAND
TIGHTEN AN AODlTIONAL 34 TURN AFTER THE ORING
CONTACTS THE BASE
THE IN CONNECTION HOSE
MUST ATTACH TO THE OUT
CONNECTION ATTl1E
RIMOTI Oil FILTER
THE OUT CONNECTION
MUST ATTACH TO THE IN
CONNECTION AT THE
REMOTE Oil FILTER
APPLY A THIN COAT OF CLEAN OIL TO THE FIlTER
GASKET WHEN INSTALLING AFTER TliE FILTER
CQNTACTS IHE BASE TIGHTEN IT AN
i Engines Generators
WATER HEATER CONNECTION KIT 71B C 82B FOUR 107 B C
The models refered to in this manual are equipped with connections for the plumbing of engine freshwater coolant
to a domestic hot water heater One connection to is located on the lower side ofthe exhaust manifold The return is located on the center outer
surface of the heat exchanger Both of these connections have
square head 12 NPT plugs in them to plumb a domestic hot water heater into the engines freshwater both of these plugs and install the appropriate
hose nipple 12 NPT x 34 ID to route hose to and return
from the domestic water 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
Air Bleed Petcock
Heat Exchanger
HEATER BELOW ENGINE
Hoses should rise continuously from their low point at the heater to the engine so that trapped air will rise 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
NOTE If any portion of the heating circuit rises above the engines own pressure cap
then a pressurized aluminum remote expansion tank must be installed in the circuit to
become the highest point The remote expansion tanks part number is 24177 Tee the
remote expansion tank into the heater circuit at the heater connection choosing the
higher of the two for the return Tee right at the heater and plumb a single line up to the
tanks location and the other back to the engines retUrn install the remote expansion
tank in a convenient location such as In a sail locker so the fresh water coolant level can
easily be checked The remote expansion tank will now serve as a check and system fill
point The plastic coolant recovery tank is not used when the remote expansion tank kit
is installed since this tank serves the same Engines Generators
The pressure cap on the engines manifold should be installed once the engines cooling system is filled with
coolant Finish filling the cooling system from the remote tank once the system is filled and is free of air and exhibits
good coolant circulation During engine operation checking the engines coolant should be done at the remote
tank and not at the engine manifold cap
The hose connection from the heater to the remote expansion tank should be routed and supported so as to from the heater to the tank enabling any air
in the system to rise
NOTE An air bleed petcock is located at the top center of the engines heat exchanger
Open this petccek when filling the freshwater system to allow air in the exchanger to
escape Close tightly once all air is removed
Pressure Cap is Rated Lower
than Manifold Cap
Heater Coils Located
Above Manifold Pressure
eat Exchanger
HEATER ABOVE ENGINE
Engines Generators
WATER HEATER CONNECTIONS 71 C 828 FOUR
FOR PRODUCTION MODELS FROM MARCH 2004 ON
WESTERBEKE provides easy access for connecting to an NOTE An air bleed petcock is located on the engineV heat
onboard hot water system These connections allow for the exchanger and on the thermostat housing Open these
engines hot water coolant to flow to the ships hot water petcocks when filling the engine s coolant system to allow air
tank heating the fresh water and then cycling back to the to escape Close both tightly after all the air is water heater should be
mounted in a convenient location NOTE If any portion 0 the heating circuit rises above the
either in a high or low position in relation to the engine so engine S closed cooling system pressure cap then a
that the connecting hoses from the heater to the engine can pressurized aluminum remote expansion tank Kit 024177
run in a reasonably direct line without any loops which might must be installed in the circuit to become the highest point
trap air Tee the remote expansion tank into the heater circuit choos
ing the higher athe two the return Tee at
Hoses should rise continuously from their low point at the the heater and plumb a single line up to the tanks to the engine so that
air will rise naturally from the and the other back to the engines return Install the remote
heater to the engine If trapped air is able to rise to the heater expansion tank in a convenient location so the fresh water
then an air bleed petcock must be installed at the higher coolant level can easily be checked The remote on the heater for bleeding
air while filling the system tank will now serve as a check and system fill point The
plastic coolant recovery tank is not used when the remote
expansion tank kit is installed since this tank serves the
same TD CONNECT TO THE WATER HEATER
DISCONNECT THE EXISTING HOSE
AND ATTACH THE HEATER HOSE AT
AIR BLEED THIS COUPLING
PETCOCK
REMOVE THE EXISTING BYPASS HOSE
THERMOSTAT
HOUSING
DISCONNECT THE EXISTING HOSE
AND ATTACH THE HEATER HOSE
TO THIS FITTING
Engines Generators
WATER HEATER CONNECTION KIT 638 AND 63C ONLY
HOSE CONNECTION TO THE TANK RETURN HOSE CONNECTION FROM THE TANK
Remove the hex head plug at the thermostat assembly and Locate the hose and piping that comes off the engines fresh
install the WATER HEATER CONNECTION KIT Attach water pump and cut into the smaller hose that leads to the oil
the heater hose to the water heater connection kit and check cooler
that all connections are tight Install the T fitting reconnect the cooler hose and install
the hot water tank return hose to the bottom of the T fitting
as shown below Make certain all connections are tight
THERMOSTAT HOUSING
58 T FITTING
TO OIL COOLER
A7TACH HOT WATER HOSE
FROM HOT WATER TANK
MAKE CERTAIN
THE RESTRICTOR
NIPPLE IS INSTALLED
OWNER INSTALLED
HEATER HOSE
TO HOT WATER TANK
WATER HEATER CONNECTION the manifold cap and replace any lost coolant Run A CAUTION Bewam of the hot engine cooant
the engine at idle 1800 rpm for generators with the heat wear proper petcock open slowly add coolant as needed
Once coolant flows from the petcock close it and replace the
manifold cap When circulation is present to and from the hot
water tank feel hoses recheck the manifoldit should be
topped off with coolant Also fill the coolant recovery tank
A WARNING With the engine running stay clear of
the drive belts Generator keep ben guards in place
half fulL With the engine running inspect for leaks and
check for normal temperature
NOTE For additional information on the proper installation
of your hot water system refer to your operators manual or contact your
WESTERBEKE dealer
Engines Generators
WIRING DIAGRAM
I A
UI MOonS E
EE HOT 2
I J
LIFT An onoff switch
should be installed In this
circuit to disconnect the
starter from the battery in
811 emergency and when
leaving the boat Twelve
volt engine draw 200 to 300
amps when cranking A
ALARM
SUllER
ADMIRAL
PANEL
switch with a of 175 amps at 12
VDC will normally serve
this function but a switch WIRING DIAGRAM 39144
must never be used to I
make the starter circuit I
I Ll
tlO lU
CAPTAIN
PANEL
r I
tl8 tII
I I
1 I
I I
1 1
I I
1 I
tie eLl I
8 aUI
Enaines Generators
WIRING SCHEMATIC
12 VDe SSRr StdHR 0
I I I I T IS PROTECTED SY A RESET CIRCuIT SRrR
PftItUT XCUIYE CURRENT WILL THE SRUKEIt 10 nl9 A
r SOL TItE
IIISUED TO
PREVEII
SURE THAT THE tNST
T eErrEE ELECTRIC
Ill I
r I
1 AN QIjorr SWITCH SHOULD BE INSTALtED BUWtEfI TH 8AfTrR AN TARTR TO
I O i rUHT CHnH
SWITCH SHOUl HOi BE uSO TO jE OR 8RtAf THE UICUIT
AlHtUtATOA
J THE PINK WIRt AT PlUG 1 IS UNUSED AND SHOULD at HiULATED CAPUN PAN 0111
4 THE GRAY WIRE AT PLUG 2 IS UNUSEO AIriII StlQIJtO BE INSULATED ONUl PANE ONIY
99 AMP All
NOTE
18E fOR BATTERY AnATCMEIIY win NHD
TO BE UOEO TO AN AUGE HOW 10 GAUGE
114 BRN
14 BRN UNIVERSAL PROPULSlfrN
PREHouTE 51 AMP AT
PRESTOlIE 1 Z AMP Al I
14 GRA
CAPTAIN
PANEL 14 PINK
t I 0 REO
14 LI 6L
lESIH 100 AMP ALT
ALE CONNECTOR
ON THIS SIO
1111
WIRING SCHEMATIC 39144
MALE CONNECTOR t14 tT BLU 14 PHIK
011 THIS SlOE
tTACHllj A REO
51 AMP ALTERNATOR
sr ANDARO ALTERNATOR ON IHE
l4 GSA
NOT USED lJ tl4aU
68 a Be a 716 01 826
I aee 11l loec 11l
14 RrO
CASE GH
I SCOCT JUWPU FfI
uS WITH TWO eHTAIS
OPT IONAL AL TE RNA TORS
13iA 160 191A LESTU ALTERNATORS
IAlblSU ON lH W50S 6glV GxrtV HgV 821CfV IOgVI IOSIVl Engines Generators
GLOW Reinstall the plugs in the engine and test them again The
plugs should get very hot at the terminal end within 7 to 15
The glow plugs are wired through the preheat solenoid
seconds If the plugs dont heat up quickly check for a short
When PREHEAT is pressed at the control panel this solenoid
circuit When reinstalling the glow plugs use click on and the glow plug should begin to get hot
compound on the inspect the plug remove the electrical terminal cOJmec A WARNING 00 not keep a gowplug on for more
tions then unscrew or unclamp each plug from the cylinder than 30 Thoroughly clean each plugs tip and threads with a
GLOW PLUG TIGHTENING TORQUE
soft brush and cleaning solution to remove all the carbon and 10 15 MKG 7 11 FTLB
oil deposits While cleaning examine the tip for wear and
burn erosion if it has eroded too much replace the plug
I TERMINAL accurate way to test glow plugs is with an one prod to the glow plugs wire connection and the
other t the body of the glow plug as shown A good glow
plug WIll have a 10 15 ohm resistance This method can be
used with the plug in or out of the engine You can also use TESTING WITH
an multimeter to test the power drain 8 9 amps per plug AN OHMMETER
PREHEAT ON
A WARNING These glow plugs will become very hot
to the touch Be careful not to burn your fingers when
testing the plugs
USING A
TEST LIGHT
GLOW PLUG
Engines Generators
STARTER starter is a new type small lightweight and is called a
highspeed starter The pinion shaft is
separate from the motor shaft the pinion slides only on the
pinion shaft A reduction gear is installed between the motor
shaft and a pinion shaft The pinion sliding part is not
exposed outside the starter so that the pinion may slide
JEM without becoming fouled with dust and grease The
motor shaft is supported at both ends on ball bearings The IGNITION
mechanism switch and overrunning clutch inner circuit
are identical to conventional ones
SOLENOID
To test the ignition circuit locate the ignitions terminal it
MOTOR is one of the small terminal studs and is wired to the ignition
circuit Use a screwdriver dont touch the blade to jump
from that ignition terminal to the positive battery connection
TYPICAL terminal on the solenoid
STARTER MOTOR If the starter cranks the fault lies with the ignition
REFER TO THE WIRING
DIAGRAM IN THIS MANUAL circuit
If the solenoid clicks but nothing happens the motor is probably faulty
A WARNING The following emergency starting
procedures must not be used with gasoline engines
SOLENOID
Sparks could cause an explosion and fire
Prior to testing make certain the ships batteries are at full
charge and that the starting system wiring are clean and tight Pay particular attention to
the ground wire connections on the engine block IGNITION
TERMINAL
To check the wiring try cranking the starter for a few
seconds never more than 10 seconds at a time then run your
hand along the wires and terminals looking for warm spots
that indicate resistance Repair or replace any trouble spots
Using a multimeter test the voltage between the positive
terminal stud on the start solenoid and the engine block If nothing happens at all the solenoid is not
current Check the battery isolation switch and inspect the
If you read 12 volts the starter is faulty wiring connections it is also possible that the solenoid is
defective
A WARNING There will be arching and sparks will
fly when jumping terminals Be certain the engine
space is free of potentially explosive fumes especially
gasoline and that there are 11 flammable solvents Dr
materials stored nearby
Engines Generators
STARTER MOTOR
EMERGENCY START
A WARNING When performing these procedures Corrosion to the starter brushes andor the solenoid contacts
position yourself safely away from the moving parts of can cause the sporadic problem of the engine starting one
the engine in case the engine startsup Also warn time but not another If corrosion is the problem the starter
other crew members of the danger will need to be rebuilt
It is however sometimes possible to get started by taping the
starter lightly with a small hammer
With the battery switch off and no ignition tap lightly on the
casing as shown then try to start the engine
CAREFULLY NOT TO HIT
FITTINGS OR WIRE POSITIVE
TERMINAL I
M TERMINAL
TAP LIGHTLY again by
jumping the two large terminal studs Hold blade finnly between the studs Do not allow blade to touch the solenoid or starter casing this
would cause a short
A WARNING There will be arching as the full If that fails tum the battery switch on and have a crew
member tum the ignition on and off rapidly as you tap again
starting current should be flowing thru the blade of with the hammer This may loosen the brushes and allow
the screwdriver contact to start the engine When you reach a repair facility
the starter will need to be repaired
If the starter spins the solenoid is faulty SERVICE
If the starter fails to spin the motor is probably faulty WESTERBEKE uses a standard starter motor which can be
If no arching occurred there is no juice reaching the serviced or rebuilt at any starter motor automotive
center
NOTE Starter motors are either inertia type or preengaged If replacing the starter motor make certain the new motor is
In the preengaged model the solenoid also moves an arm certified for marine use Automotive starters do not meet
that engages the starter motor to the flywheel of the engine USCG standards If in doubt contact your a screwdriver to bypass the
solenoid on such a starter dealer
will run the motor without engaging the flywheel Tum the
starter switch on to provide power to the solenoid Hopefully TO REMOVE FOR SERVICE
it will create enough magnetic field for the arm to move even 1 Disconnect the negative battery cable
though the contacts inside the solenoid are bad 2 If necessary remove any components to gain full access
to the starter motor
3 Label and disconnect the wiring from the starter Do not
allow wires to touch tape over the terminals
4 Remove the starter mounting bolts
5 Remove the starter from the engine In some cases the
starter will have to be turned to a different angle to clear
En Jines Generators
DUAL OUTPUT ALTERNATORS SPACER TO MOUNTING
output and high output alternators are available as
optional equipment on most WESTERBEKE engines can be installed during factory assembly or as
addon equipment at anytime
Dual alternators can be configured to charge two banks of
batteries at the same time or using a battery selector each set of batteries separately an optional dual alternator has already
been factory follow the WESTERBEKE wiring diagram and the
engine installation the new dual alternator is being added to an existing engine carefully follow the alternator below
1 Disconnect the alternators negative cable from the
battery
2 Remove the alternator and disconnect or tape off the
output positive cable Do not reuse
3 Install the new Attach a new heavy gauge output cables from the
alternators output terminal s Using the cable sizes
indicated
DUAL OUTPUT ALTERNATOR
LENGTH REQUIRED UP iJPro 12 2 WIRE CHARGING ONE BATTERY
UP TO 20 lWIRE
ALWAYS USE FINE STRAND CABLE1
S Make certain that the batteries negative post ground
BATTERY 1
cable to the engine block is the same heavy gauge as
the positive cable
6 Mount the regulator to a flat surface in a cool dry
location
a Connect the black wire to the ground terminal on the
alternator
A CAUTION Do not connect any power source with
out first grounding the regulator
b Plug the 2pin connector into the alternator make
certain it is firmly seated
c The red battery sense wire should be connected to
BATTERY SENSE
the batteries positive post or the positive cable TO BATTERY POSITIVE POST
d The brown wire keyed ignition is the key circuit
which actuates the regulator this wire must connect IJlOlY ONNECTS TO PINK AND
to a switched 12 volt source Refer to the st BLUE LEADS THE PINK
WIRE CONNECTS TO THE
WESTERBEKE WIRING DIAGRAM for the proper ALARM BUZZER THE BLUE
connection WIRE CONNECTS TO THE
OIL PRESSURE SWITCH
Dual Pulleys
A variety of accessory pulleys for high powered and dual DUAL OUTPUT alternators are available from your
CHARGING TWO Engines Generators
DUAL OUTPUT Alternator Testing
NOTE Before make certain that the drive The regulator is functioning properly and the are tight and the batteries are in good
condition are in good Testing 1 Test the voltage at the alternator plug with
the engine
offkey on The voltage at the alternator terminal F and
The red battery sensing wire A connects to the battery it the voltage in the plug blue wire F from the always read battery voltage
If battery voltage is not should read the trace the wire for a bad connection
2 Hold a screw driver close 112 to the alternator pulley
The orange wire S should read 0 volts with the key off 12 If voltage is present you should feel the magnetic field If
volts with the key on If the readings are not the problem may be the brushes wornJor the trace the wire for a bad connection
open circuit
The blue wire F supplies current to the alternator fields its 3 Start the engine at fast idle the output terminals will vary depending on
the battery charge or actual indicate 142 volts no load A reading of 126 The readings can vary from 4 to 12 volts with the
indicate the alternator is not performing properly
key on 0 volts with the key off
Apply a load such as an electric bilge pump the voltage
KEY ON NO VOLTAGE REGULATOR IS DEFECTIVE should maintain at least 138 volts 13 volts or less
KEY OFF BATTERY VOLTAGE REGULATOR 15 DEFECTIVE indicates the alternator is TEST POINTS AND PROPER Ignition Off
Ignition On Engine Running
NOTES
I Brown o volts 2 12 volts 142 volts When the engine is first started it takes a few moments
A Red 126 volts 12 volts 142 volts for the alternator to kick in and take the load There
5 Orange ovolts ovolts 6 holts is a noticeable change in the sound of the engine and the
F Blue ovolts 10 11 volts 4 12 volts RPM gauge will excite
Alt Output 126 volts 12 volts 142 volts D A slight whine is normal when running with a full load
on the alternator
D When the alternator is producing high amperage it will
become very hot
D When replacing the alternator drive belts always
purchase and replace dual belts in matched pairs
Engines Generators
DUAL OUTPUT 5 Make certain that the batteries negative post ground cable
to the engine block is the same heavy gauge as the
Dual output and high output alternators are available as
positive equipment on most WESTERBEKE engines can be installed during factory assembly or as 6 Mount the regulator to a flat
surface in a cool dry equipment at anytime a Connect the black wires to the mounting bolt on
Dual alternators can be configured to charge two banks of alternator at the same time or using a battery selector each
set of batteries separately
A CAUTION Do not connect any power source
without first grounding the an optional dual alternator has already been simply follow the WESTERBEKE wiring diagram b
Plug the 2pilf connector into the alternator the engine installation instructions and make certain it
is fmnly seated
If the new dual alternator is being added to an existing in c The red battery sense wire should be connected to the
theboat engine carefully follow the alternator and regulator batteries positive post or the positive below
d The brown wire keyed ignition is the key circuit
1 Disconnect the alternators negtive cable from the bat which actuates the regulator this wire must connect
tery t a switched 12 volt source Such as the oil
pressure switch
2 Remove the alternator and disconnect or tape off the
output positive cable Do not reuse e A brown wire from the electric tachometer connects to
the regulator
3 Install the new Attach a new heavy gauge output cables from the Dual Pulleys
alternators output terminal s Using the cable sizes
indicated A variety of accessory pulleys for high powered and dual
charging alternators are available from your WESTERBEKE
LENGTH REQUIRED UP TO 6 4 WIRE dealer
UP TO 12 2 WIRE
UP TO 20 0 WIRE
14 BWElI14 PINK BALMAR 100 AMP AlTERNATOR
ALWAYS USE FINE STRAND CABLE IGNITIONB
14 4 RED TO STARTING
BATTERY 8 WHEN 14 RED
USING TWO BATTERIES SENSE
18 BROWN
NOTUSED
MALE CONNECTOR U0
THEJDE o
14 BWE14 PINK
IGNITiON B1
14 BROWN
TACHOMETER 114 BLUE
FIELD AlTERNATOR MOUNT GROUND
4 RED TO STARTING
BA1TERY Bf WHEN
USING TWO
114BWE
FlEW
14 WHITE
STATOR
ngineS Generators
ALTERNATORS SEE WIRING DIAGRAM
FOR WIRE CONNECTIONS
TO OPTIONAL ALTERNATORS 50AMP
NOTE FOR CORRECT WIRING HARNESS CONNECTIONS TO THE ALTERNATOR
REFER TO THE WIRING DIAGRAMS IN THIS MANUAL
DESCRIPTION VOLTAGE REGULATOR
The following infonnation applies to the standard alternators The integral voltage regulator is an electronic switching
that are supplied with WESTERBEKES Marine Engines device which senses the system voltage level and switches
and Marine Generators the voltage applied to the field in order to maintain a proper
system voltage
ELECTRICAL CHARGING CIRCUIT The regulator design utilizes allsilicon semi conductors and
The charging system consists of an alternator with a voltage thickfilm assembly techniques After the voltage has been
regulator an engine DC wiring harness a DC circuit breaker adjusted to the proper regulating value the entire circuit is
and a battery with connecting cable and wires Because of encapsulated to protect the circuit and the components from
the use of integrated circuits Ies the electronic voltage possible damage due to handling or vibration and moisture
regulator is very compact and is mounted internally or on the encountered in a vessel
back of the alternator
It is desirable to test the charging system alternator and
ALTERNATOR voltage regulator in the boat using the wiring harness and Use this section to determine if a problem
electrical loads that are a pennanent part of the system exists with the charging circuit or with the alternator If it is
Inboat testing will then provide the technician with an determined that the alternator or voltage regulator is faulty
operational test of the charging system as well as the major have a qualified technician check it
components of the electrical system
LOW CIRCUIT
ALTERNATOR DESCRIPTION If the starter only moans or makes a clicking sound instead
The stator is connected to a threephase fullwave bridge of spinning the engine to life it is likely a low battery or a
rectifier package which contains six diodes The bridge faulty connection in the starting circuit and not an alternator
converts the AC generated in the stator to a DC output for problem
battery charging and accessories such as a radio heater
lights refrigerator depth sounder etc A simple test is to try starting again with a cabin light on if
the light dims significantly or goes out the battery is dead If
Power to the regulator and the field of the integral regulator the light remains bright look for a poor connection in the
alternator is provided by the field diode or diode trio starting circuit
package contained in the alternator
These alternators produce a rated output of 50 or 51 amps
Rated output is achieved at approximately 6000 alternator
rpm at an ambient temperature of75F 238C The
A WARNING A working alternator runs hot a failed i
alternator can become very hot Do not touch the
alternators are designed to operate in an ambient temperature
range of 40 to 212F 400 to 100C alternator until it has cooled
I Engines Generators
ALTERNATORS INSPECTION 3 Thrn off the engine Inspect all wiring and starting the actual alternator
and voltage regulator Ensure that the battery terminals and the engine the following checks are recommended
connections are tight and clean
4 If a battery selector switch is in the charging circuit
1 Make certain your alternator is securely mounted ensure that it is on the correct setting
2 Check the drive belt for proper tension Replace the belt S furn on the ignition switch but do not start the
if it is worn or glazed engine
3 Check that all terminals connectors and plugs are clean 6 Check the battery voltage If the battery is in good
and tight loose or corroded connections cause high condition the reading should be 12 to 13 volts
resistance and this could cause undercharging or damage to the charging system Badly
corroded battery cables could prevent the battery from
reaching a fully charged condition
4 Check the condition of the battery and charge if
necessary A low or discharged battery may cause false
or misleading readings on the invessel tests
NOTE An isolator with a diode a solenoid or a battery
selector switch is usually mounted in the circuit to isolate
the batteries so the starting battery is not discharged
along with the house batteries If the isolator is charging MEASURING
BATTERY VOLTAGE
the starting battery but not the house battery the IGNITION ON
alternator is Ok and the problem is in the battery ENGINE OFF
charging THE ALTERNATOR
Testing The Output Circuit
A CAUTION Before starling the engine make 1 Connect the positive probe to the output terminal B and
cerlain that everyone Is clear of moving parts Keep connect the negative probe to the ground terminal E on
away from sheaves and belts during test procedures the alternator
2 Wiggle the engine wiring harness while observing the
1 Start the engine voltmeter The meter should indicate the After the engine has run for a few
minutes measure the battery voltage and should not vary If no reading is
starting battery voltage at the battery terminals using a obtained or if the reading varies check the alternator
multimeter set on DC volts output circuit for loose or dirty connections or
damaged wiring
a If the voltage is increasing toward 14 volts the
alternator is working omit Steps 3 through 8 and go 3 Start the engine
directly to Checking the Servic Battery 4 Repeat the same measurement the negative probe to E
bIfthe voltage remains around 12 volts a problem the positive probe to B with the engine running The
exists with either the alternator or the charging circuit voltage reading should be between 135 and 145 volts
continue with Steps 3 through 8 If your alternator is over or have it
repaired at a reliable service shop
5 If the previous test reads only battery voltage at
terminal B use the meter to measure the DC excitation
terminal If 12 volts is not present at exciter terminal
R inspect the wiring for breaks and poor connections
Jump 12 volts from a 12 volt source such as the
battery and operate the alternator If voltage output is
1314 volts then the alternator is OK
MEASURING
BATTERY
VOLTAGE
ENGINE RUNNING
Enaloes Generators
ALTERNATORS TESTING THE
OUTPUT CIRCUIT
ENGINE RUNNING
5 If no reading is obtained an open exists in the
lead or in the excitation circuit of
the regulator Disconnect the lead from exe terminal R
Connect the positive multimeter probe to the excitation
lead and the negative multimeter probe to ground
terminal E If the multimeter now indicates an
TO STARTER approximate battery voltage the voltage regulator is
SOLENOIO defective and must be replaced If no voltage is
indicated check the excitation circuit for loose or dirty
connections or damaged wiring
CHECKING THE SERVICE BATTERY
Check the voltage of the service battery This battery should
have a voltage between 13 and 14 volts when the engine is
running If not there is a problem in the service battery
BATTERY
charging circuit Troubleshoot the service battery charging
circuit by checking the wiring and connections the solenoid
isolator battery switch and the battery itself
When the problem has been solved and before the alternator
is back in operation take the time to tighten and clean the
terminal studs Also clean the connecting tenninals from the
TESTING
THE EXCITATION CIRCUIT wiring harness
1 Connect the positive multimeter probe to the
excitation terminal R on the alternator and the negative ALTERNATOR REPAIR
probe to the ground terminal E on the alternator If tests indicate a failed alternator it will need to be
2 Turn the ignition switch to the on position and note disassembled and repaired Any good alternator service
the multimeter reading The reading should be 13 to shop can do the job
25 volts see NOTE WESTERBEKES Service Manual has detailed
instructions for the disassembly and repair of their
standard altemators
BATTERY CARE
The minimum recommended capacity of the battery used in
the engines 12 volt DC control circuit is 600900 Cold
Cranking Amps CCA
Review the and then
establish a systematic maintenance schedule for your
engines starting batteries and house batteries
3 If the reading is between 75 and 11 volts the Monitor your voltmeter for proper charging during
rotor field circuit probably is shorted or grounded engine operation
Check the electrolyte level and specific gravity with a
4 If the reading is between 60 and 70 volts the rotor hydrometer
field circuit probably is open
Use only distilled water to bring electrolytes to a proper
level
Make certain that battery cable connections are clean and
tight to the battery posts and to your engine
IEnafnes Generators
ENGINE following table describes certain problems NOTE The engine 8 electrical system is protected by a 20
relating to engine service the probable causes of these prob ampere manual reset circuit breaker located on a bracket at
lems and the to overcome these problems the back of the engine The preheat solenoid is mounted on
the same bracket
Problem Probable Cause No panel indications fuel solenoid 1 Battery
switch not on 1 Check switch andor battery connections
or fuel pump is no working key switch
is on and PREHEAT button is depressed 2 20amp circuit breaker tripped 2 Reset breaker if breaker trips again check preheat solenoid
circuit and check circuit for shorts to ground
3 10amp breaker tripped on 3 Check the voltage both at and after the breaker on the
preheat solenoid preheat solenoid
4 Loose battery connections 4 Check connection to starter solenoid and connection to
engine ground stud Check battery cable connections
5 Preheat solenoid not operating 5 Check solenoid S terminal for voltage
START button is depressed no starter 1 Connection to solenOid faulty 1 Check connection
engagement
2 Gear shift not in neutrel 2 Gear shift must be in neutral see NEUTRAL SWTCHunder
HURTH 3 Faulty switch 3 Check switch with ohmmeter
4 Faulty solenoid 4 Check thaI 12 volts are present at the solenoid connection
5 Loose battery connections 5 Check battery connections
6 Low battery 6 Check battery charge state
START button is depressed panel 1 Poor connections to fuel solerlOid 1 Check connections
indications OK starter solenoid OK
fuel solenoid not functioning 2 Defective fuel solenoid 2 Check that 12 volts are present at the connection on the
fuel run solenoid
Engine cranks but does not 1 Faulty fueling system 1 Check that fuel valves are open
start fuel solenoid energized
1a Check for air in fuel system Bleed air from fuel system
1b Fuel filters clogged Replace filters and bleed air from
fuel system
2 Preheat solenoid faulty 2 Check solenoid
3 Low battery power 3 Switch to combine house and start batteries
3a Replace batteries
Engine cant be stopped 1 Faulty DC alternator 1 Remove Exc connection at alternator repair alternator
2 Disconnect fuel shutoff cable 2 Check connection at shutoff lever Pull lever back to close
offthe fuel
3 Fuel nm solenoid will not deenrgize 3 Manually disconnect the 12 volt connection to the fuel run
solenoid at the injection pump
Battery runs down 1 Oil pressure switch 1 Observe if gauges and panel lights are activated when engine
is not running Test the oil pressure switc
2 High resistance leak to ground 2 Check wiring Insert sensitive 0 25 amp meter in battery
lines Do not start engine Remove connections and replace
after short is located
3 Low resistance leak 3 Check all wires for temperature rise to locate the fault
4 Poor battery connections 4 Check cable connections at battery for loose connections
corrosion
5 DC altemator not cHarging 5 Check connections check belt tension test altemator See
tachometer not operating DC ELECTRICAL Battery not charging 1 DC charge circuit faulty
1 Pertorm DC voltage check of generator charging circuit See
Testing the BattelJl Charging Circuit
2 Alternator drive 2 Check drive belt tension alternator should furn freely Check
for loose connections Check output with voltmeter Ensure 12
volts are present at the Exc terminal
Engines Generators
ENGINE Problem Probable Cause Engine slows and stops 1
Fuel lift pump failure 1 Fuel lift pump should make a distinct ticking sound Replace
pump with spare
2 Switches andor wiring loose 2 Inspect wiring for short circuits and loose connections
or disconnected Inspect switches for proper operation
3 Fuel starvation S Check fuel supply fuel valves fuel lift pump
4 20 Amp circuit breaker tripping 4 Check for high DC amperage draw during operation
Ensure breaker is not overly sensitive to heat which would
cause tripping
5 Exhaust system is restricted 5 Check for blockage collapsed hose carbon buildup at
exhaust elbow
6 Water in fuel 6 Pump water from fuel tanks change filters and
bleed fuel system
7 Air intake obstruction 7 Check air Intake filter cartridge
Engine down 1 Raw water not circulating 1 Raw water pump failure Check impeller replace
2 Coolant not circulating 2 Obstruction at raw water intake or raw water filter
2a Themnostat remove and tesl in hot water
Replace thermostat
2b Loss of coolant check hoses hose clamps drain plug etc
for leaks
2e Broken or loose belts 2d Air leak in system run engine and
open the pressure cap to
bleed air Add coolant as needed
Engine alarm sound pulsates 1 Loss of oil 1 Check dipstick look for oil leaks at oil filter and at
oil drain hose connection
2 Oil pressure switch 2 Replace oil pressure switch
Engine alarm sounds continuously 1 Engine coolant 1 Check engine coolant level
2 High temperature switch opens at 2 Check for satisfactory operation with switch bypassed
too Iowa temperature check with ohmmeter replace if faully
Exhaust smoke problems 1 Blue smoke 1 Incorrect grade of engine 011
1a Crankcase is overfilled with engine oil oil is blowing out
through the eXhaust
2 White smoke 2 Engine is running cold
2a Faully injector or incorrect injector timing
3 Black smoke 3 Improper grade of fuel
3a Fuel bum incomplete due to high backpressure in exhaust or
insufficient air for proper combustion check for restrictions in
exhaust system check air Intake
3blmproperly timed injectors or valves or poor compression
3c Lack of air check air intake and air filter Check for proper
ventilation
3d Overload
COOLANT TEMPERATURE AND OIL PRESSURE GAUGES
If Ihe gauge reading is other dlatl what is normally indicated If both of the above gauge tests are positive the gauge is
by Ihe gauge when Ihe instrument panel is energized the first undoubtedly OK and the problem lies either with the
step is to check for 12 volts DC between dle ignition B conductor from the sender to the gauge or with the sender
and Ihe Negative B terminals of Ihe gauge If either of the above gauge tests are negative the gauge is
Assuming Ihat Ihere is 12 volts as required leave Ihe probably defective and should be panel energized and perrorm Ihe
following steps Assuming the gauge is OK check the conductor from the
1 Disconnect the sender wire at Ihe gauge and see if the sender to the sender terminal at the gauge for continuity
gauge reads zero which is dle normal reading for this Check that the engine block is connected to the ground
situation Some starters have isolated ground terminals and if the
2 Remove the wire attached to the sender terminal at Ihe battery is connected to the starter both plus and minus
sender and connect it to ground See if the gauge reads le11Ilinals the ground side will not necessarily be connected
full scale which is the normal reading for driB situation to the block
Engines Generators
SERVICE After Every 100 Hours of Operation
1 Change the engines lubrication oil and oil filter
2 Adjust the alternator and water pump drive belt tension if required
3 Lubricate panel keyswitch use Lockeze only
4 Inspect the syphonbreak assembly for proper operation When After Every 250 Hours of the fuel filter elements in the onengine fuel filter and in
the optional separator
NOTE Items marked by an asterisk should be performed by a competent After Every 500 Hours of Torque the cylinder head holddown bolts
2 Adjust the valve Drain flush and refill the fresh water cooling Check the condition of the starter motor drive pinion lubricate pinion
5 Check the resistance of the glow plugs Check circuit operation
6 Check raw water pump for internal wear Examine the pumps cover cam and internal housing Replace worn
parts as needed Check for leaks at seals or gaskets and repair them as needed
7 Check the internal condition of the water injected exhaust elbow Inspect exhaust and water passages Remove
any carbon andor corrosion build up Replace elbow if Mter Every 800 Hours of Operation
1 Remove and check fuel injectors
Injector spray psi 71 psi
135 kgcm2 5 Poor fuel quality and shorten the injector and injector pump
service undesirable injection after dripping
2 Check the compression pressure Remove each glow plug and check each cylinders compression
pressure The engines speed is at 280 rpm
3 Check the alternator for proper operation
4 Check the tightness of bolts nuts and clamps
Engines Generators
SERVICE SCHEDULE
This section contains a scheduled preventive maintenance program and several adjustment procedures can petform without the benefit of sophisticated
and eXlJensive tools and the preventive maintenance in accordance with the schedules listed in the following to these schedules will ensure the
equipment is maintained in the best possible condition and
that it will petform to expectations Those items marked by an asterisk are recommended to be
performed by an authorized dealer or before each US
I Check the oil sump level Maintain the oil level at or near the upper level mark on dipstick
2 Check the coolant level in the plasic recovery tank Maintain this level at or above the level marked
3 Check 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
5 Check the fuel supply Fill tanks with a good grade of No2 diesel fuel if required
6 Check the primary filterwater separator Drain and service as required A primary filterwater
separator is optional but strongly 7 Check the engines gauges or lights for proper oil pressure operating temperature and starting
battery charging voltage once the engine is operating
8 Check the alternators output gauge if installed for proper DC the condition of the zinc anode in the heat exchangers sea water circuit Clean or
replace the
anode as required Keep the area inside the heat exchanger clean of zinc anode After Initinl 50 Hours of Operation
1 Change the engines lubrication oil and oil filter
2 Replace the secondary fuel filter and the filter element in the base of the fuel pump Service the
primary system filter is Torque the cylinder head holddown bolts
4 Adjust valve clearances
5 Adjust the alternator and water pump drive belt tension if required
6 Lubricate the throttle and the control cable check for proper operation and movement
7 Change the lubricant
8 Adjust the engines idle speed 750 1000 rpm
WESTERBEKE
Engines Generators
SERVICE SCHEDULE
CYLINDER HEAD BOLT TORQUING
Servicing After Every 1000 Hours of Operation
1 Remove clean and pressure test the primary heat exchanger A local automotive radiator shop should be able
to clean and test the heat exchanger
NOTE Operating in silty andor tropical waters may require that a heat exchanger cleaning be
performed more often than every 1000 hours
2 Check the injection pumps timing
CyUnder Head Bolt Torquing
Tighten the cylinder head bolts according to the sequence shown in the illustration for your model The engine
should be at room temperature Prior to applying torque to each bolt loosen it one half tum then apply the required
torque
13 9 5 4 8 12
828 FOUR
1088 and 108C SIX
Tightening Torque
63 B C Four 71C Four 80 85 ftlb
108 BC Six 110 to 117 mkg
7IB Four 82B Four 85 89 ftlb
118 to 125 mkg
638 63C FOUR and 71C FOUR and 718 FOUR
Engines Generators
SERVICE SCHEDULE
CYLINDER HEAD BOLT TORQUING
Tighten the cylinder head bolts to the specified torque before making valve adjustments
When No1 cylinder IS at top dead enler
J 1 When No1 cylinder is at top dead center
TINCEX liN
I i
1 31IN J rEX
1 EX i fiN
When NoA cylinder IS a t top dead center
63BXCFOUR 71BCFOUR 108BXC SIX
Clearance Intake Exhaust 0012 inch 030 to adjust
1 Position the piston 1 cylinder approximately IDC Top Dead Center of its compression stroke Adjust the
valve clearance on the values for the cylinders specified
4 Cylinder Model
Intake valves No 1 and No2 valves No1 and No3 cylinders
6 Cylinder Model
Intake valves No1 2 and 4 valves No1 3 and 5 cylinders
2 Tum the crankshaft 3600 one and adjust the valve clearances
on the valves for the cylinders specified
4 Cylinder Model
Intake valves NO3 and NO4 valves NO2 and No4 cylinders
6 Cylinder Model
Intake valves No3 5 and 6 valves No2 4 and 6 Engines Generators
ENGINE ADJUSTMENTS
NOTE WESTERBEKE recommends that the following engine adjust
ments be performed by a competent engine mechanic The information
below is provided to assist the mechanic
ENGINE IDLING SPEED INJECTION PUMP SERVICE
The engine idling speed is preset at the factory but once the For disassembly inspection reassembly and internal
boat is operating in the water other variables such as pro adjustments of the injection pump it is recommended the
peller size shaft length and the transmission can affect the pump be taken to a qualified injection service shop
idle speed authorized to service Diesel KiKi or Zexel injection
The normal idle speed for these engines is 650950 RPM equipment
however simply put the idle speed should feel comfortable
It should be quiet and smooth not racing but not so low that ENGINE STOP SOLENOID
it causes transmission damper plate chatter This solenoid is insralled on the top rear of the injection
pump and is activated by 12 VDC electrical current
SETTING THE IDLING SPEED
To adjust the engine idle speed engine running loosen the
locknut of the idle adjustment bolt and tum the bolt 1 The solenoid does not operate when
clockwise to increase idle speed and to the keyswitch is turned ON
reduce Once the speed is set to your satisfaction tighten the a Are the engine batteries turned ON
locknut b Is the 20 amp circuit breaker set
c Is 12 VDC present at the solenoid
connection
2 The solenoid does not stop the engine when SPRING
the keyswitch is switched OFF r
a Check to see if 12 VDC is still present
at the solenoid electrical lead with the
PLUNGER
key off
bRemove solenoid from injection
pump and ensure plunger and spring
in the solenoid are not sticking
FUEL INJECTION PUMP TOP
ENGINE COMPRESSION
If a weak cylinder is flanked by healthy cylinder the problem
Check the compression pressure To do this warm the
is either valve or piston related Check the valve clearances
engine remove all fuel injectors or glow plugs disconnect
for the weak cylinder adjust as needed and test again
the fuel shutoff solenoid wire and install a compression
If the cylinder is still low apply a small amount of oil into
adapter in the injector hole or glow plug hole Connect a
the cylinder to seal the rings and repeat the test
compression tester on the adapter and crank the engine with
If compression comes up the rings are faulty
the starter motor until the pressure reaches a maximum value
Repeat this process for each cylinder Look for cylinders with
dramatically at least 20 lower compression than the
average of the others Compression pressure should not differ
by more than 427 psi 30 kgcm2 at 200 GAUGE
Engines Generators
METER NOTE Current model tachometers use a coarse meter used in propulsion engine instru dial to
set the tachometer to the crankshaft pulley rpms The
calibrating screw is then used for fine tuning
ment panels contains two separate electrical circuits with a
common ground One circuit operates the hour meter and the
other the taehometer The hour meter circuit operates on 12
volts alternator charging voltage supplied to the terminal
on the baek of the tachometer circuit operates on AC voltage 68 volts fed
from one of the diodes in the alternator and supplied to input telminal while the engine is running and
the alternator producing battery charging voltage 130148 DC
The following are proeedures to follow when fault in either of the two cireuits in a meter Inoperative
for the proper DC voltage between and TACHOMETER CHECK
New Voltage present meter is defective repair or replace NOTE In a new installation having new instrument panels
the tachometer may not always be correctly calibrated to the
2 Voltage not present trace and electrical con
engines rpm This calibration should be checked in all new
nections for fault Jump 12 volts DC to meter
terminal to verify the operation
1 Warm up the engine to nonnal operating Inoperative Remove any specks on the crankshaft pulley with
a clean
Check for the proper AC voltage between tachometer input cloth and place a piece of suitable reflecting tape on the
tenninal and tenninal with the engine running pulley to facilitate use of a photoelectric type Voltage present attempt adjusting
meter through calibra 2 Start and idle the engine
tion access hole No results repair or replace meter 3 Aim the light of the tachometer onto the reflecting tape to
2 AC voltage not present check for proper alternator DC confirm the engine speed Check the instrument panel
output voltage tachometer reading Adjust the tachometer in the panel by
3 Check for AC voltage at tach tenninal on alternator to using the instrument coarse adjustment to calibrate the
ground instrument reading to the closest RPM that the photo tach
is showing Then use the fine calibration adjustment to
4 Check electrical connections from tachometer input ter bring the instrument to the exact reading as the photo tach
minal to alternator connection
4 Set the tachometer to the idle speed the engine idle Sticking has been factory adjusted and the
idle screws and high
1 Check for proper AC voltage between tach inp speed screws have been locked in place
terminal and terminal r
2 Check for good ground connection between meter
terminal and Check that alternator is well grounded to engine block at
alternator pivot Inaccurate
ill
ii I
a With a handheld tach on the front of the crankshaft j I
pulley retaining nut or with a strobetype tach read the
front crankshaft pulley rpm at idle
b Adjust the tachometer with a small Phillips type screw
driver through the calibration access hole in the rear of
the tachometer Zero the tach and bring it to the rpm I
indicated by the strobe or hand tach Verify the rpm at
idle and at high speed and adjust the tach as needed
Engines Generators
OIL PRESSURE
NOTE WESTERBEKE recommends that the following engine
adjustments he peifomled by a competent engine mechanic
The infomtation below is provided to assist the OIL PRESSURE
The lubricating system is a pressure feeding system using an The engines oil pressure during operation is indicated
oil pump The engine oil is drawn from the oil sump by the by the oil pressure gauge on the ins1n1ment panel During
oil pump which drives the oil under pressure through the normal operation the oil pressure will range between 40 and
oil filter and various lubricating points in the engine The oil 85 psi
then returns to the oil sump to repeat the continuous cycle
When the oil pressurc exceeds the specified pressure the oil NOTE A newly started cold engine can have an oil open the relief
valve in the oil pump and returns to reading up to 85 psi A warmed engine can have an oil
the oil sump keeping the oil pressure within its specified pressure reading as low as 25 psi These readings win vary
range depending upon the temperature of the engine and the OIL PRESSURE
Low OH Pressure
To test the oil pressure remove the oil pressure sender then The specified safe minimum oil pressure is 5 10 psi A
install a mechanical oil pressure gauge in its place After gradual loss of oil pressure usually indicates worn up the engine
set the engine speed at 1800 rpm and For additional information on low oil pressure readings see
read the oil pressure gauge the ENGINE chart
Oil Pressure Between 55 and 75 psi at 1800 rpm
Note A newly started cold engine may have an oil pressure up to 70 or 80
Testing Oil Pressure
psi A warmed engine can have an oil pressure as low as 40 psi Oil pressure To test oil pressure remove the oil pressure sender then
will vary depending on the load placed on the generator install a mechanical oil pressure gauge in its place After
warming up the engine set the engine speed at idle and read
the oil pressure gauge
OIL PRESSURE
SWITCH
MECHANICAL
OIL PRESSURE
GAUGE
TYPICAL Engines Generators
638 AND 63C FOUR MARINE DIESEL ENGINES
ENGINE COOLING SYSTEM
Engine Type Diesel fourcycle fresh watercooled vertical General Fresh watercooled block
inline 63 hp at 3600 rpm maximum controlled with raw water heat exchanger sys
Governor Integral ofthe injection pump mechanical tem
flywheel type Operating Temperature 170 190 F77 88 G
Valve mechanism Overhead Fresh Water Pump Gentrifugal type metal impeller
Ghamber Swirl chamber type Raw Water Pump Positive displacement rubber Stroke
350 x 351 inches 889 x 891 mm Displacement 1348 cubic inches 221 liters
Raw Water Row 120 US gpm 454lpm measured
at 3600 rpm before discharging into exhaust Order 1342
System Capacity 10 qts 99 of Rotation Glockwise when viewed from the front fresh Torque 931bft 1092
at 2900 rpm LUBRICATION Ratio 21 1
General Pressure fed rotor type driven by spiral Pressure 427 psi 300 kgcm at 200 rpm
from Seat Angle Intake 45 Exhaust 45 Oil Filter Full flow paper element
spinon type
Valve Clearance Intake 012 inches 03 mm Sump Capacity 53 US qts 50 cold Exhaust 012
inches 03 mm not including Height 2530 inches 6426 mm Operating Oil Pressure
30 60 psi 21 42 kgem at maximum
Width 2119 inches 5382 mm engine rpm and at normal operating temperature
Length 3875 inches 9843 mm
Oil Grade API Specification CF CG4 CH4 or Gontinuous 14
Temporary 25 not to exceed 30 min
ELECTRICAL SYSTEM
Dry Weight 6111bs 192 kgs
Starting Battery 12Volt negative ground Speed Idle speed 7501000 rpm
Cruising Speed 2500 3000 rpm Battery Gapacity 400 600 Cold Cranking Amps CCA
Fuel Consumption 12 US gph 45Iph at 2500 rpm approx Starter 12Volt actuated shift reduction geared
when the propeller allows 3600 rpm at full open Starting Aid Glow plugs
throttle while underway in forward gear DC NoLoad Current 100 Amps at 115 volts 3000 rpm min
FUEL SYSTEM Cold Cranking Current 280 300 Amps at 10 volts 250 rpm min
Aiternator 12 Volt DC 50 amps
Fuel No2 diesel oil cetane rating of 45 or higher
Regulator Intemal regulation built into Pump Diesel KiKi mechanical governed
Fuel Injection Timing 0 TOC Top Dead Center TRANSMISSION SYSTEM
Nozzle Throttle type
General ZFIHURTH Standard Transmission Pressure 1920 psi 135 kgcm2
hardened helical gears with Pump 12 volt plunger type
multiple disc clutch
Fuel Filter Spinon Replaceable Gear ratio standard 271
on engine Propeller Shaft right handed standard cleaner
Metal screen type cleanable direction of rotation
Air Flow Propeller 20 Dx 14 P2 blade or 18 Dx 16 P3 blade
engine combustion 1400 cfm 39 cmm at 3600 rpm Propeller should allow the engine to reach its full
engine cooling 250 cfm 70 cmm rated RPM 3600 000 100 at full open
throttle while underway
EXHAUST SYSTEM Lubricating Fluid ATF Dexron II or Dexron III
Exhaust Elbow 70 degree elbow Transmission Sump 079 US qts 075 liters approximate
Capacity Fill to ful mark on Size 3 inch ID hose
Muffler Size 12 inch x 12 inch min
Engines Generators
71 BAND 71 CFOUR MARINE DIESEL ENGINES
ENGINE COOLING SYSTEM
Engine Type Diesel fourcycle four cylinder fresh General Fresh watercooled block
watercooled vertical inline controlled with raw water heat exchanger sys
71 hp at 3600 rpm maximum tem
Govemor Integral of the injection pump mechanical Operating Temperature 170 190 F 77 88 C
flywheel type Fresh Water Pump Centrifugal type metal impeller mechanism Overhead
Raw Water Pump Positive displacement rubber Chamber Swirl chamber type
Stroke 350 x 40 inches 889 x 1016 mm Raw Water Row
100 US gpm 378Ipm Displacement 1540 cubic inches 25 liters at 3600 rpm before discharging into exhaust
Order 1 342 System Capacity 115 qts 109 liters
fresh of Rotation Clockwise when viewed from the front
Maximum Torque 1181bft 1531 kgm LUBRICATION SYSTEM
at 2200 Ratio 21 1 General Pressure fed rotor type driven by spiral
gears
from Pressure 427 psi 300 kgcm at 200 rpm
Oil Riter Full flow paper element spinon type
Valve Seat Angle Intake 45 Exhaust 30
Sump Capacity 63 US qts 60 liters
Valve Clearance Intake 012 inches 03 mm not including cold Exhaust 012 inches 03 mm
Operating Oil Pressure 30 60 psi 21 42 kgem at Height 269 inches 6842 mm
engine rpm and at normal operating temperature
Width 222 inches 5636 mm
Length 395 inches 10033 mm Oil Grade API Specification CF CG4 CH4 or Continuous 140
ELECTRICAL SYSTEM
Temporary 25 not to exceed 30 min
Dry Weight 652 Ibs 2959 kgs BFour Starting Battery 12Volt negative ground
687 Ibs 3118 kgs CFour Battery Capacity 400 600 Cold Cranking Amps CCA
Engine Speed Idle speed 7501000 rpm Starter 12Volt actuated shift reduction geared
Cruising Speed 2500 3000 rpm Starti ng Aid Glow plugs
Fuel Consumption 14 US gph 52Iph at 2500 rpm approx DC NoLoad Current 100 Amps at 115 volts 3000 rpm min
when the propeller allows 3600 rpm at full
open throttle while underway in forward gear Cold Cranking Current 250 300 Amps at 10 volts 250 rpm min
Alternator 12 Volt DC 50 amps
FUEL SYSTEM Regulator Intemal regulation built into No2 diesel
oil cetane rating of 45 or Pump Diesel KiKi mechanical govemed TRANSMISSION Timing 00
TOC Top Dead Center General ZFIHURTH Standard Transmission case
Nozzle Throttle type hardened helical gears with
multiple disc Pressure 1920 psi 135 kgem
Gear ratio standard 2741
Lift Pump 12 volt plunger type
Propeller Shaft right handed standard Riter Spinon Replaceable di rection of rotation
on engine
Propeller 20 Dx 14 P2 blade or 200 x 12 P3 blade
Air cleaner Metal screen type cleanable Propeller should allow the engine to reach its full
AirFlow rated RPM 3600 000 1 00 at full open
engine combustion 1604 cfm 45 cmm at 3600 rpm throttle while underway
Lubricating Fluid ATF Dexron II or Oexron III
EXHAUST SYSTEM Transmission Sump 079 US qts 075 liters Elbow 70 degree elbow
Capacity Fill to full mark on Size 3 inch 10 hose
Muffler Size 12 inch x 12 inch min
Engines Generators
828 FOUR MARINE DIESEL ENGINE
ENGINE FUEL SYSTEM
Engine Type Diesel fourcycle fresh General Open flow self priming 1 bleed point
watercooled vertical inline overhead valve Fuel No2 diesel oil cetane rating of 45 or higher
mechanism
Fuel Injection Pump ZEXEL Model VE Distributor Diesel Naturally aspirated
Fuel Injection Timing 0 TOC Top Dead Chamber Swirl type
Nozzle Th rottle type
Bore Stroke 374 x 413 inches 95 x 105 mm
Fuel Filter Spinon type full flow
Piston Displacement 182 cubic inches 298 liters on Order 13 4 2
Air cleaner Metal screen type of Rotation Clockwise when viewed from the front Air Flow
946 cfm 27 Ratio 21 1 engine Height 273 inches 6940 mm
Width 255 inches 6477 mm COOLING SYSTEM
Length 388 inches 9858 mm General Fresh watercooled block 6781bs 307 kgs
controlled with heat Continuous 15
Operating Temperature 170 190 F 77 88 C
TemporarY 25 not to exceed 20 min
Fresh Water Pump Centrifugal type metal impeller Power Take Off 40 Hp Maximum Raw Water Pump
Positive displacemen rubber impeller
beltdriven
TUNEUP Raw Water Flow 150 gpm 567lpm Pressure 427 psi 30 kgem at 200 rpm
at 2600 rpm before discharging into exhaust of difference between System
capacity 130 qts 123 472 psi 30 kgem Timing Intake Opens 17 BTDC
Intake Closes 47 ABDC LUBRICATION SYSTEM
Exhaust Opens 51 BB DC General Pressure fed system
Exhaust Closes 13 ATDC Oil Filter Full flow paper element spinon type
Valve Seat Angle Intake 45 Sump Capacity 65 US qts 615Iiters
Exhaust 30 not including filter plus filtercooler Clearance Intake 0012 inches 03 mm
Operating Oil Pressure 50 60 psi 35 42 kgem
Exhaust 0012 inches 03 mm engine hot
Injector Pressure 1920 71 0 psi 135 5 0 kgem Oil Grade API Specification CF CG4 CH4 or CI4
Engine Timing Static timed drop valve method
0205 005 inches BTOC ELECTRICAL SYSTEM
Starting BatterY 12Volt negative ground
EXHAUST EMISSIONS SYSTEMS
BatterY Capacity 600 800 Cold Cranking Amps Control Indirect Fuel Injection
Starter 12Volt Starting Aid Glow
plugs sheathed type
BatterY Charging 51 Amps
Engines Generators
1088 AND 108C FOUR MARINE DIESEL ENGINES
ENGINE COOLING SYSTEM
Engine Type Diesel fourcycle four cylinder fresh General Fresh watercooled block
watercooled vertical inline controlled with raw water heat exchanger sys
108 hp at 3600 rpm maximum tem
Governor Integral of the injection pump mechanical Operating Temperature 170 190 F 77 88 C
flywheel type Fresh Water Pump Centrifugal type metal impeller mechanism Overhead
Raw Water Pump Positive displacement rubber Chamber Swirl chamber type
Stroke 362 x 340 inches 919 x 1016 mm Raw Water Row 140
US gpm 53Ipm Displacement 2472 cubie inches 405 liters at 3600 rpm before discharging into exhaust
Order 1 53624 Sys1em Capacity 16 qts 151 liters
fresh of Rotation Clockwise when viewed from the Iront
Maximum Torque 1881bft 260 kgm LUBRICATION SYSTEM
at 2900 Ratio 21 1 General Pressure fed rotor type driven by spiral
gears
from Pressure 427 psi 300 kgem at 200 rpm
Oil Filter Full flow paper element spinon type
Valve Seat Angle Intake 45 Exhaust 30
Sump Capacity 119 US qts 113 liters
Valve Clearance Intake 012 inches 03 mm not including cold Exhaus1 012 inches 03 mm
Operating Oil Pressure 30 60 psi 21 42 kgcm at Height 293 inches 7429 mm
engine rpm and at normal operating temperature
Width 269 inches 6826 mm
Length 533 inches 113538 mm Oil Grade API Specification CF CG4 CH4 or Continuous 14
Temporary 25 not to exceed 30 min
ELECTRICAL 9321bs 4228 kgs Starting Battery 12Volt negative ground
Engine Speed Idle speed 7501000 rpm Battery Capacity 400 600 Cold Cranking Amps CCA
Cruising Speed 2500 3000 rpm Starter 12Volt actuated shift reduction geared
Fuel Consumption 21 US gph 79Iph at 2500 rpm approx Starting Aid Glow plugs
DC NoLoad Current 100 Amps at 115 volts 3000 rpm min
FUEL SYSTEM Cold Cranking Current 250 300 Amps at 10 volts 250 rpm min
Fuel No2 diesel oil cetane rating 0145 or higher Alternator 12 Volt DC 50 Pump Diesel KiKi
mechanical governed Regulator Internal regulation built into Injection Timing 0 TOC Top Dead
Throttle type TRANSMISSION Pressure 1920 psi 135 kgcm
General ZFIHURTH Standard Transmission case
LiftPump 12 volt plunger type hardened helical gears with Finer
Spinon Replaceable multiple disc clutch
on engine Gear ratio standard 2041
Air cleaner Metal screen type cleanable Propeller Shaft right handed standard
direction of combustion 257 cfm 29 cmm at 3600 rpm Propeller
20 Dx 14 P2 blade or 200 x 10 P3 blade
engine COOling 250 elm 70 cmm at 3600 rpm Propeller should allow the engine to reach its full
rated RPM 3600 000 100 at full open
EXHAUST SYSTEM throttle while underway
Lubricating Fluid ATF Dexron II or Dexron III
Exhaust Elbow 70 deg ree elbow
Transmission Sump 079 US qts 075 liters Size 3 inch 10 hose Capacity
Fill to full mark on Size 12 inch x 12 inch min
Engines Generators
ZF MARINE NOTE When installing the transmission make certain that
The information below is specific to the ZF shifting is not impeded by restricted movability of the
the TRANSMISSION SECTION Bowden cable or rod linkage by unsuitably positioned guide
applies to aU models sheaves too small a bending radius etc In order to mount a
support for shift control cable connections use the OF GEAR BOX WITH PROPELLER threaded holes located above the shift
cover on top of the
HEW recommend a flexible connection between the gear housing Refer to the WESTERBEKE parts gearbox and the propeller shaft if
the engine is CONTROL mounted in order to compensate for The installation of a special propeller thrust The transmission is suitable
for single lever remote is not required since the propeller thrust will be Upon loosening the retaining screw the actuating lever can
taken by the transmission bearing provided the value be moved to any position required for the control under is not exceeded
cable or rod linkage Make certain that the shift lever does
However the output shaft should be protected from not contact the actuating lever cover plate the loads Special care should be
taken to prevent distance between lever and cover should be vibration When using a universal joint shaft make The control cable or
rod should be arranged at right angle to
certain to observe the manufacturers instructions the actuating shift lever when in the neutral position The
Even with the engine solidly mounted the use of flexible neutral position of the operating lever on the control or DRIVESAVER will reduce
stress in the should coincide with the neutral position of this bearings caused by hull distortions especially in The
shifting travel as measured at the pivot point of the
wooden boats or where the distance between transmission actuating lever between the neutral position and end
output flange and stem gland is less than about 800mm positions A and B should be at least 35mm for the outer and
30mm for the inner pivot point
A greater amount of shift lever travel is in no way
ZF 15M detrimental and is recommended However if the lever
travel is shorter proper clutch engagement might be impeded
which in tum would mean premature wear excessive heat
generation and clutch plate failure This would be indicated
by slow clutch engagement or no engagement at all
NOTE Checkfor proper lever travel at least each season
NEUTRAL
CONTROL
CABLE
A CAUTION The position of the mechanism behind SHIFT
the actll6ting lever is to ensure equal LEVER
shift lever travel from neutral position Aand B If
this mechanism is in any way tampered with the I COVER
transmission warranty will be void
DID v AVER is a product of Globe Marine Rockland MA
O5rnrn J
MINIMUM DISTANCE
Engines Generators
ZF MARINE INITIAL OPERATION OPERATING HBW marine transmissions are testrun on atest stand
The maximum pennissible ATF temperature should not exceed
with the engine at the factory prior to delivery For safety 230 110 This temperature can only be reached for a short
reasons the fluid is drained before shipment time
FilI the gearbox with Automatic Transmission Fluid
DEXRON n or DEXTRON ill The fluid levl should be A CAUTION If the transmission Huld temperature Is
up to the index mark on the dipstick To check the fluid level too high stop the engine immediately and check the
just insert the dipstick do not screw it in Screw the dipstick transmissiou Huld
into the case after the fluid level is checked and tighten Do
not forget the sealing ring under the hexhead of the for leaks and change the fluid after the first 25 hours LOCKING THE make a visual
inspection of the coupling oil cooler and Locking of the propeller shaft by an additional brake is not
hoses and shift cables required use the gear shift lever position opposite your direc
tion of travel for this pUlpose Never put the gear shift in the
position corresponding to the direction of travel of the boat
WHEN UNDER SAIL OR BEING TOWED
Rotation of the propeller without load such as when the boat is
being sailed being towed or anchored in a river as well as
operation of the engine with the propeller stopped for charg
ing the battery will have no detrimental effects on the trans
mission
DAILY OPERATION
o Check the transmission fluid
FLUID LEVEL VIsually check the gear shift linkage and
o Start the engine in neutral allowing a few minutes at
idle to wann the fluid
I o Shift into gear
FLUID CHANGE NOTE Too low an idle speed will produce a chattering noise
Change the fluid for the first time after about 25 hours of from the transmission gear and damper plate In such then every 250 operating
hours or at least once a the idle speed should be or when you change engine oil For additional
infonnation refer to the following text in this
Transmission Section SHAFT COUPLINGS the fluid AND TRANSMISSION a suction pump hose down
through the dipstick hole to
the bottom of the housing and suck out the fluid If space
allows use the transmission drain Remove the drain plug ZF TRANSMISSIONS the bottom of the transmission and allow the fluid to
drain into a container then reinstall the plug with its sealing General ZF Standard Transmission Case
washer Wipe down the transmission and properly dispose of hardened helical gears with a
the used fluid After running the engine shut down and multiple disc the fluid level
Gear Ratio optional ZF 15MA 1881 or 2631
Drain plug torque 20 25 fIIbs Note There are a variety ZF 10MA 1791
of gear ratios available If 12MA 2631
Only a few are listed ZF 15MIV 2131 or 2721
NOTE When changing the fluid take care not to lose the
drain plug sealing washer The drain plug wiilleak without Lubricating Fluid ATF Type A or Dextron II or III
this sealing washer Propeller Shaft Righthand rotation for above models
Direction of Rotation listed
A WARNING Never pull out the dipstick while the
engine is running Hot fluid will splash from the dip
stick hole This could cause severe burns
Engines Generators
ZF INITIAL OPERATION
For safety reasons the transmission is not filled with Set the shifting lever to neutral position N Start the fluid during shipment
and the selector lever is and let it run long enough in idle to fill the cooler and attached to the actuating shaft
with transmission fluid Shift into gear forward and leaving the WESTERBEKE plant each transmission shifting should be
smooth and positive Direct changes a test run with Dextron II ATF transmission fluid forward to reverse are permissible since the multiple
disc
The residual fluid remaining in the transmission after clutch permits changing at high rpm including acts as a preservative and
provides protection reversing at high speeds in the event of corrosion for at least one year if properly stored After
initial operation make a visuaI inspection of the output
coupling oil cooler and hoses and the cable connections to
the LOCKING THE PROPELLER
Locking of the propellyr shaft by an additional brake is not
required use the gear shift lever position opposite your
direction of travel for this purpose Never put the gear shift in
the position corresponding to the direction of travel of the
FILTER boat
ASSEMBLY
WHEN UNDER SAIL OR BEING TOWED
Rotation of the propeller without a load such as when the
OUTPUT boat is being sailed being towed or anchored in a river as
COUPLING 0 well as operation of the engine with the propeller stopped
ZF63 for charging the battery will have no detrimental effects on
the COOLER
NOTE When the boat is being sailed engine stopped the
The oil cooler mounted above the transmission provides
gear shift must be in the neutral position The propeller is at
continuous cooling for the transmission fluid Raw water
idle and can through the tubes of the cooler and The transmission fluid is cooled as it flows around DAILY OPERATION
the tubes and back into the o Check the transmission fluid
WESTERBEKE RECOMMENDS Visually check the gear shift linkage and
RAW WATER
HAVING A SPARE COOLER CONNECTION Start the engine in neutral allowing a few minutes at idle
ABOARD to warm the fluid
D Shift into gear
NOTE Too Iowan idle speed will produce a chattering noise
FLUID CONNECTIONS from the transmission gear and damper plate In such cases
RAW WATER the idle speed should be ZF COOLER
Operating FLUID The operating temperature of the transmission should not
Fill the transmission with Dextron III ATF The fluid level exceed 176F 80C A connection for a temperature probe
should be up to the mark on the dipstick After checking the is provided At maximum output of the engine the fluid may
level press the dipstick into the case and it to tighten reach 220F 104 0c
During the first 25 operating hours inspect the bell shaft and transmission cooler for leakage The fluid
should be changed after the first 25 hours and every 300 A CAUTION If the transmission fluid temperature is
hours thereafter too high stop the engine immediately and check the
transmission SWITCH
These transmissions are equipped with a neutral This is to prevent the engine from starting in gear
Unless the transmission selector lever is perfectly aligned in
neutral the engine starter will not Engines Generators
ZF CHANGING THE TRANSMISSION FLUID Replacing the Fluid
Pour in new Dextron 1II ATF fluid and check the quantity
with the dipstick
Transmission fluid quantities will vary with the use of cool
erslength of hoses andthe angle of the Approximate
Quantities
ZF 45 212 quarts 20 Liters
ZF 63 32 quarts 30 Liters
ZF 63V 42 quarts 40 Liters
Reinsert the filter assembly into the housing Press it in place
and tighten the Allen screw
NOTE Some ZF transmissions use a Tn handle in place ofa
16MM8 SCREW screw on their filter assemblies
After running the engine shut down and recheck the fluid level
A WARNING Never pullout the dipstick while the
engine is running Hot fluid will splash from the dipstick
hole This could cause severe burns
MAINTENANCE
ORINGS
ZF45 Transmission maintenance is minimal Keep the exterior
housing clean check the fluid level as part of your regular
routine and change the fluid every 300 operating hours
Periodically inspect the transmission and the cooler for leaks
FILTER and corrosion Make certain the air vent is clear and when
checking the fluid level look for signs of water fluid will appear as
strawberry cream
Filter Element Storage requires special care Follow these procedures
The ZF transmission has a filter element located opposite the D Drain water from the transmission oil cooler and replace
dipstick This filter must be replaced whenever the fluid is with a proper mixture of antifreeze coolant
changed NOTE This operation wiU nonnally occur when the
Remove the filter by loosening the screw on the cover using engine raw water cooling system is properly winterized
a 6mm Allen wrench
Clean up the transmission and touch up unpainted areas
1vist and pull out the filter and remove the element Place use heat resistant paint
the new filter onto the cover and lock it into place by turning
it clockwise Check the Orings for damage and replace if
o Fill the transmission with Dextron III ATF fluid to
prevent internal corrosion extended storage only twelve
necessary Replacement filters can be obtained from your
months or more
local WESTERBEKE dealer or ZF dealer
Loosen attaching hardwarf from the transmission output
Removing the Fluid flange and propeller shaft coupling flange before
Push a suction pump hose down through the pipe hole under removing the boat from the water Separate the flanges
the filter to the bottom of the housing and suck out the fluid and spray with lubricant
Remove the oil return line from the cooler and allow the oil o Inspect the gear shift cable linkage and attachments
to drain into a container then reconnect the oil return line Look for corrosion of the end fittings cracks or cuts in
the conduit and bending of the actuator rods Lubricate
Wipe down the transmission and properly dispose of the used all moving parts
fluid
NOTE If the transmission is to be stored for a long time
twelve months or more it slwuid be topped offwith
fluid to prevent internal corrosion Reduce thf fl1lii level
before putting the engine back into service
Engines Generators
IF CONNECTIONS SHAFT COUPLINGS
The transmission is suitable for a single lever gear shift WESTERBEKE recommends a flexible conneCtion between
Upon loosening the retaining screw the actuating lever see the transmission and the propeller shaft if the engine is can be moved to any
position required for the bly mounted in order to compensate for angular elements cable or rod linkage Make certain that the The
installation of a special propeller thrust bearing is not
actuating lever does not contact the lever hub the minimum required since the propeller thrust will be absorbed by the
distance between the lever and the hub should be O02in transmission bearing provided the value specified
is not exceeded However the output
The control cable or rod should be arranged at a right angle shaft should be protected from additional loads Special care
to the actuating lever when in the neutral position The should be taken to prevent torsional vibration When using a
neutral position of the gear shift lever on the control console universal joint shaft make certain to observe the coincide with the neutral
position of the lever on the turers Even with the engine solidly mounted the use of a
flexible
The shifting travel as measured at the pivot point of the coupling or DRNESAVER will reduce stress in the lever between the neutral position
and end positions box bearings caused by hull distortions especially in wooden
A and B should be at least I38in 3Smm for the outer and boats or where the distance between the transmission 3Omm for the inner pivot point
coupling and stem gland is less than about 800nnn
NOTE When installing the transmission make certain tlwt
N shifting is not impedRd by restricted movability of the cable
or rod linkage by unsuitably positioned guide sheaves too
small a bending radius or other r5trictions In order to
mount a support for shift control cable connections use the
two threaded lwles located on the cable bracket mounted on
PROPELLEa the gear lwusing Refer to the WESTERBEKE parts list
ROTATION
ARH N For additional infonnation contact
NNEUTRAL
BLH A ZF Industries
Marine US Headquarters
3131 SW 42nd Street
Fort Lauderdale FL 33312
Thl 954 5814040
Fax 954 5814077
FOR ADDITIONAL INFORMATION
greater amount of actuating lever travel is in no and is recommended However if the lever travel
IGEAR
is shorter proper clutch engagement might be impeded SHIFT
which in tum would mean premature wear excessive and clutch plate failure This would be indicated
by slow clutch engagement or no engagement at all see
CONTROL CABLES under Check for proper actuating lever travel at least each TYPICAL STEERING A CAUTION The position of the
mechanism behind
the actuating lever is to ensure equal
shift lever travel from neutral position to Aand B If
this mechanism is in any way tampered with the
transmission wananty will be void
Engines Generators
ZF MARINE OPERATING TEMPERATURE MAINTENANCE
Transmission maintenance is minimal Keep the exterior
housing clean check the fluid level as part of your regular
A CAUTION If the transmission fluid temperature is routine and change the fluid every 300 operating hours
too high stop the engine immediately and check the Periodically inspect the transmission and the cooler for leaks
transmission fluid and corrosion Make certain the air vent is clear and when
checldng the fluid level look for signs of water Norn1al operating temperature of the transmission fluid fluid will appear as
strawberry cream
should be in the range of 1220 F 500 C to 2120 F 1000 C
A maximum temperature of 2660 F 1300 C may b only reached for a short time Storage requires
special care Follow these procedures
Make certain there is enough space around the transmission Drain water from tlle transmission oil cooler and replace
to provide good ventilation and cooling with a proper mixture of antifreeze coolant
TRANSMISSION COOLER NOTE 11zis operation will nonnally occur when the
Coolers are standard equipment for the ZF 10M ZF 12M engine raw water cooling systm is properly winterized
ZF 15M ZF 15MA ZF 15MIV and the ZF 25M o Clean up the transmission and touch up unpainted areas
The cooler is a separate part of the transmission which use heat resistant paint
prevents any possibilities of coolant diluting the transmission Fill the transmission with De1ron III ATF fluid to
fluid However the continued flow of coolant thru the cooler prevent internal corrosion extended storage only twelve
will in time erode the inside of the cooler causing external months or more
leaks
A transmission cooler may last ten years or more but in
o Loosen attaching hardware from the transmission output
flange and propeller shaft coupling flange before
some depending on operating hours tropical removing the boat from the water Separate the flanges
waters maintenance etc it might only last half that time and spray with lubricant
WESTERBEKE recommends having a spare cooler aboard Inspect the gear shift cable linkage and attachments
Look for corrosion of the end fittings cracks or cuts in
the conduit and bending of the actuator rods Lubricate
all moving parts
NOTE If the transmission is to be stored for a long time
twelve months or more it should be topped offwith
fluid to prevent inte172al corrosion Reduce the fluid level
before putting the engine back into COOLER
PERIODICAUY INSPECTFOR
EROSION AND LEAKAGE
GEAR
SHIFT
For additional infonnation contact
ZF MARINE GEAR
ZF Industries
Marine US Headquarters
3131 SW 42nd Street
Fort Lauderdale FL 33312
Tel 954 5814040
Fax 954 5814077
Engines Generators
TRANSMISSION ZF
CONTROL CABLES
The majority of transmission difficulties arise as a result of A new cable and perhaps a new linkage mechanism may be
improper clutch adjustments manual or needed While the cable is loose shift the transmission in and
problems with control cables hydraulic out of gear using the lever on the side of the transmission to
rather than fTom problems with the transmission itself make sure theres no binding inside the case
ZF clutches in particular are very sensitive to improper If the transmission passes these tests crank the engine and
cable adjustments have a helper put it in forward and reverse while you observe
If you experience operating problems with the transmission the propeller shaft if the shaft isnt turning the the engine
down First check the needs professional attention If it does tum but theres no
level then have a helper move the cockpit shift lever through thrust check to see you still have a propeller on the end of
the full range from neutral to full forward back to the shaft or if you have a folding or feathering propeller that
neutral into full reverse and back to neutral while you it isnt stuck in the no pitch the actuating lever on the
transmission If the remote NOTE lfyou suspect a major problem in your stiff to operate break the cable loose at the
transmission immediately contact your WESTERBEKE dealer or an
and try again If it is still stiff check the cable for kinks or autlwrized marine transmission tight bends and check any
linkage for binding
Problem Probable Cause Transmission gears cannot be shifted 1
Actuating lever is loose 1 Tighten damping bolt on shifting lever
Fails to move into gear
2 Shifting cable is broken bent or 2 Check the cable reattach or replace
unattached Cable radius is too severe
3 Actuating lever is binding against the 3 Detach the shift cable and operate the actuating lever by
hand Clearance should be 002 in 05mm
Transmission shifts into gear 1 Output coupling is not tuming 1 Transmission needs professional attention
but fails to propel the boat
2 Propeller shaft is not turning 2 The coupling bolts are sheared or the coupling is slipping
Output coupling is turning on the propeller shaft TIghten or replace set screws keys
pins and coupling bolts as necessary
3 Output coupling and 3 Inspect the propeller It may be missing or damaged
propeller shaft are turning A folding propeller may be jammed A variable pitch
propeller may be in no pitch position
Delay of gear engagement or engages 1 Actuating lever travel Nto B not 1 Adjust cover plate until the lever is exact only
after an increase in speed equal to Nto A See ACTUATING LEVER TEXT AND DIAGRAM
2 Actuating level travel in insufficient 2 Check shift lever cable length See ACTUATING LEVER
DIAGRAM
3 Actuating lever is binding against cover plate 3 Check clearance adjust if necessary
Transmission noise becomes louder 1 Damage starting on flexible coupling due 1 Check alignment inspect flexible coupling If noise
perSists
to wear or fatigue possibly due to inspect the damper plate between the transmission and the
misalignment between engine and engine Replace if necessary
2 Beginning damage of bearings in 2 Transmission needs professional attention
transmission due to torsional vibrations
running without fluid overload wrong
alignment of transmission or excessive
engine output
Chattering transmission noise 1 lhe engine or propeller generates torsional 1 Mount aflexible coupling with another stiffness
factor
mainly at low engine speed vibrations in the drive unit which produces between the engine and transmission a coupling
with
a chattering noise in the transmiSsion a higher stiffness factor might be sufficient
2 Inspect the damper plate between the engine and the
transmission Replace if necessary
Boat falls to attain specified max speed 1 Operating temperature is high 1 Wrong type of fluid Use Dextron III check fluid level
2 Operating without cooling 2 Check cooler Inspect coolant hoses and coolant flow
Oil Leakage 1 Corrosion at radial sealing ring and shaft 1 Transmission needs professional attention
Damaged sealing ring
2 Misalignment of output flanges 2 Check alignment Must be within 0003 in
Engines Generators
BORG WARNER VELVET DRIVE TRANSMISSION
OPTIONAL TRANSMISSION
SHIFT LEVER POSITION
The gear shift control mechanism and linkage must position
the actuating lever on the transmission exactly in Forward
F Neutral N and Reverse R shifting positions A detet
ball located behind the transmission lever must work freely
to center the lever in each position The gear shift positions at
the helm must be coordinated with those of the Velvet Drive
actuating lever through shift mechanism adjustments An
improperly adjusted shift mechanism can cause damage to
the transmission The shifting mechanism and transmission
actuating lever should be free of dirt and well lubricated to
ensure proper operation
Shifting Into Gear
Place the gear shift in Neutral before starting the engine
Shifting from one selector position to another selector posi
tion may be made at any time below 1000 rpm and in any
BORG WARNER order Shifts should be made at the lowest practical engine
VELVET nRIVE speed Start the engine and set the throttle at idle speed
allow the transmission fluid to warm up for a few safety reasons the transmission is not filled with fluid during shipment and the
selector lever Move the gear shift lever to the middle position You should
is temporarily attached to the actuating shaft feel the detent This centers the actuating lever on the trans
Before leaving the WESlERBEKE plant each transmission mission With the control in this position hydraulic power is
undergoes a test run with Dextron III ATF transmission completely interrupted and the output shaft of the The residual fluid remaining
in the transmission after sion does not acts as a preservative and provides corrosion for at least one year if properly stored
NOTE Some transmissions are equipped with a neutral safety
switch Unless the transmission actuating lever is fLUID aligned in neutral the engine starter will
not the transmission fluid level on the dipstick If has not been filled fill with Dextran III and to use this fluid During the first 25
hours of Move the gear shift lever to the forward position You keep a lookout for any leakage at the bell housing feel the detent
The actuating lever on the transmission is in
output shaft and transmission cooler This fluid should be the forward position The output shaft and the propeller shaft
changed after the first 25 hours and approximately every move the boat in a forward operating hours thereafter andlor at winter layup
Reverse
Move the gear shift lever to the reverse position You should
A CAUTION Bs CBrtain the transmission Is filled feel the detent The actuating lever on the transmission is in
and the correct size cooler is properly instaled before the reverse position The output shaft and the propeller
starting the engine should move the boat in a reverse direction astern
NOTE Moving the transmission actuating lever from Neutral
Position to Forward is always toward the engine Reverse is
always away from the engine If boat moves backwards with
the gear shift control in the forward position shut off the
engine This problem may be a result of incorrect movement
of the actuating lever by the gear shift lever
I Engines Generators
BORG WARNER VELVET DRIVE TRANSMISSION
o Clean off the transmission and properly dispose of the
used fluid
o Refill the transmission with DEXTRON III ATF The
quantity will vary depending on the transmission model
and the installation angle Fill through the dipstick hole
D Check the dipstick for the proper fluid level
Replace the oil filler cap and dipstick press the dipstick
into place and tum clockwise until o Run the engine shutdown and recheck the
fluid level
FORWARD NEUTRAl REVERSE
TRANSMISSION ACTUATING LEVER POSITIONS
A WARNING Never pullout the dipstick while the
engIne is running Hot fluId will splash from the OPERATION hole This could cause severe burns
o Check the transmission fluid
o Visually check the gear shift linkage and transmission Oil Capacity
o Start the engine in neutral Allow a few minutes at idle Approximately 25 quarts 236 liters will fill most transmis
for the fluid to warm sions to the oilleveI fill mark on the dipstick Many variables
NOTE Too Iowan idle speed will produce a chattering have a direct relationship to the oil capacity Additional oil
noise from the transmission gear and damper plate In will be required to fill the oil cooler and the cooler lines The
such cases the idle speed should be increased angle of installation will make a difference in the quantity of
oil required to fill the Shift into gear
A CAUTION Shifting gears above 1000 rpm can
cause damage to the engine damper plate Pulling the FLUID LEVEL
throttle back to Idle when shifting gears will save wear MAKE CERTAIN THE
RUBBER SEAL IS
on the transmission and the damper plate SCREWED FULL
TIGHT HANDLE
o Visually check for oil leaks at the hydraulic connections
Check for wear on the hydraulic lines and replace if
worn
o Lubricate the detent ball and shift cable attachments
Inspect the shift linkage
Oil Temperature
o Inspect the transmission bolts retorque if necessary
A maximum oil temperature of 190F 88C is recom
mended Discontinue operation anytime sump oil tempera
A CAUTION Clutch failure will occur if the transmis ture exceeds 230F 1lOC
sIon shift lever does not fully engage the detent ball PRESSURE GAUGE
posItions An optional mechanical pressure gauge can be installed at
the control panel to constantly monitor the pressure of the
CHANGING THE TRANSMISSION FLUID transmission fluid A normal reading at 2000 rpm in forward
After the initial 50 hour change the transmission fluid should gear should indicate 95 120 Ibin2 67 84 kgcm2 and be
be changed at every 300 operating hours thereafter or at win constant
ter haulout However the fluid must be changed whenever it
becomes contaminated changes color or smells rancid
o Remove the oil filler cap and dipstick
Remove the oil cooler return line and allow the oil to
drain into a container
o Reconnect the oil cooler return line
o Use a suction pump to remove the transmission oil
through the filler capdipstick hole
EnClines Generators
BORG WARNER VELVET DRIVE WARRANTY maintenance is minimaL Keep the exterior
Service manuals are available from your BORG clean check the fluid level as part of your regular and change the fluid every 300
operating hOUTS For assistance inspect the transmission and the cooler for leaks BORG corrosion Make certain the air
vent is clear and when 200 Theodory Rice the fluid level look for signs of water contamination New Bedford MA 02745
fluid will appear as strawberry cream Tel 508 BORG WARNER
is aware of the shock loads that can be
placed on its gears as the result of mechanical propeller oper
Storage requires special care Follow these procedures ation or fully reversing of the propeller blades while shifting
o Drain the water from the transmission oil cooler and Therefore torque loads and directional changes should be
replace it with a proper mixture of antifreeze coolant made at low engine speeds If it is found that a failure was
NOTE This operation will usually occur when the engine caused by a shock load any warranty claim will be denied
raw water cooling system is properly winterized
o Clean up the transmission and touchup unpainted areas A CAUTION noises or vibrations can
use heat resistant paint occur at low engine speeds which can cause gear rattle
o Fill the transmission with Dextron III ATF fluid to resulting in damage to the engine andor prevent internal corrosion
Extended storage only BORG WARNER is not responsible for total system
12 months or more related torsional vibration of this type
o Loosen attaching hardware froin the transmission
output flange and propeller shaft coupling flange before If any problems occur with the transmission see
removing the boat from the water Separate the flanges TRANSMISSION in this manual
and spray with lubricant
o Inspect the gear shift cable linkage and attachments
Look for corrosion of the end fittings cracks or cuts in
the conduit and bending of the actuator rods Lubricate
all moving parts
NOTE ljthe transmission is to be storedfor a long time
twelve months or more it slwuld be topped offwith
fluid to prevent internal corrosion Reduce the fluid level
before putting tlze engine back into COOLERS
The continued flow of raw water through the cooler will in If water has contaminated the fluid the transmission fluid
time erode the inside of the cooler causing cross leaks to needs to be cleaned out and replaced with fresh fluid It will
occur These internal cooler leaks will cause one of the take several fluid changes to get rid of the two problems
Check your dipstick each time until it appears as pure trans
mission fluid Change the transmission filter and clean out
1 Transmission fluid will leak into the flow of raw water the fluid lines that connect to the cooler
and be discharged overboard through the engine exhaust
A loss of transmission fluid will cause tlze transmission to If the transmission fails to shift properly it will most likely
faiL need the attention of a qualified transmission service facility
2 The raw water will leak into the transmission fluid caus A transmission cooler may last ten years or more but in
ing an increase in transmission fluid This contaminated some depending on operating hours tropical
fluid will appear as strawberry cream The transmission waters maintenance etc it might only last half that time
will eventually fail WESTERBEKE recommends having a spare cooler case requires an immediate response
1 Install a new oil cooler
2 Refill the transmission with DEXTRON III ATF
Engines Generators
LAYUP Fuel System owners rely on their boatyards to prepare their craft Top off
your fuel tanks with unleaded gasoline of 89 engines and generators for layup during the or higher A fuel conditioner such as StaBil or
for long periods of inactivity Others prefer stabilizer should be added Change the element in your
to accomplish layup preparation themselves separator and clean the metal bowL procedures which follow will allow you to
perform your and make certain there are no leaks Clean up any spilled
own layup and or you may use them as a fuel
check list if others do the procedures Fuel System procedures should afford your engine protection Top off
your fuel tanks with No2 diesel fueL Fuel a layup and also help familiarize you with the such as BioBor and StaBil should be added at
this time needs of your engine control algae and condition the fueL Care should be taken
If you have any questions regarding layup procedures call that the additives used are compatible with the primary fuel
your local servicing dealer he will be more than willing to filterwater separator used in the system Change the assistance
in your primary fuel filterwater separator if the fuel system
has one and clean the separator sediment Shaft Coupling Propulsion Engine
Change the fuel filter elements on the engine and bleed the
The transmission and propeller half couplings should always fuel system as needed Start the engine and allow it to run
be opened up and the bolts removed when the boat is hauled
for 5 10 minutes to make sure no air is left in the fuel
out of the water or moved from land to water and during system Check for any leaks that may have been created in
storage in the cradle The flexibility of the boat often puts a the fuel system during this servicing correcting them as
severe strain on the propeller shaft or coupling or both while needed Operating the engine for 5 10 minutes will help
the boat is taken out or put in the water In some cases the allow movement of the treated fuel through the has actually been bent by these
strains This does not equipment on the engine
apply to small boats that are hauled out of the water when
not in use unless they have been dry for a considerable Raw Water Cooling of time Close
the throughhull seacock Remove the raw water intake
Fresh Water Cooling Circuit Propulsion Engine hose from the seacock Place the end of this hose into a five
gallon bucket of clean fresh water Before starting the engine
A 5050 solution of antifreeze and distilled water is check the zinc anode found in the primary heat exchanger for use in the coolant
system at all times the engine and clean or replace it as required and also clean
This solution may require a higher concentration of
any zinc debris from inside the heat exchanger where depending on the areas winter climate Check the zinc anode is located Clean the raw water
to make sure the antifreeze protection is adequate
Start the engine and allow the raw water pump to draw the
Should more antifreeze be needed drain an appropriate fresh water through the system When the bucket is empty
amount from the engine block and add a more concentrated stop the engine and refill the bucket with an Operate the engine to ensure a
complete circulation solution slightly stronger than needed for winter freeze
and mixture of the antifreeze concentration throughout the protection in your area
cooling system Now recheck the antifreeze solutions strength
Start the engine and allow all of this mixture to be System through the raw water system Once the
bucket is empty stop
With the engine warm drain all the engine oil from the oil the engine This antifreeze mixture should protect the raw
sump Remove and replace the oil filter and fill the sump water circuit from freezing during the winter layup as well
with new oil Use the correct grade of oil Refer to the as providing corrosion LUBRICATING OIL pages in this manual for the
Remove the impeller from your raw water pump some
oil changing procedure Run the engine and check for proper antifreeze mixture will accompany it so catch it in a bucket
oil pressure and make sure there are no leaks Examine the impeller Acquire a replacement if needed and
a cover gasket Do not replace the impeller into the pump
until but replace the cover and gasket
A CAUTION 00 not leave the enginets old engine oil Intake Manifold and ThruHull Exhaust
in the sump over the layup period Lubricating oil and
Place a clean cloth lightly soaked in lubricating oil in the
combustion deposits combine to produce harmful
opening of the intake manifold to block the opening Do not
chemicals which can reduce the life of your nginets shove the cloth out of sight If it is not visible at
internal parts and an attempt is made to start the engine
you may need assistance of the servicing dealer Make a
note to remove the cloth prior to startup The thruhull
exhaust port can be blocked in the same manner
Engines Generators
LAYUP Motor Spare and cleaning of the starter drive pinion is advisable Layup time
provides a good opportunity to inspect your
if access to the starter permits its easy removal Make sure the Westerbeke engine to see if external items such as drive belts
battery connections are shut off before attempting to remove or coolant hoses need replacement Check your basic spares
the starter Take care in properly replacing any electrical kit and order items not on hand or replace those items removed from the
starter during the layup such as filters and zinc anodes Refer to the
SPARE PARTS section of this Lubrication Diesel you anticipate a long layup period 12 months or more
The of your Westerbeke engine after a
WESTERBEKE recommends removing the fuel injectors for seasonal layup generally follows the same procedures as
access to the cylinders Squirt light lubricating oil into the those described in the PREPARATIONS FOR STARTING to prevent the piston rings
from sticking to the tion regarding preparation for starting and normal walls
However some of the layup procedures will need to be
Make sure you have a replacements for the injector and return counteracted before starting the engine
line sealing washers 1 Remove the oilsoaked cloths from the intake Manifold Gasoline
2 Remove the raw water pump cover and gasket and
Clean the filter screen in the flame arrester and place a clean discard the old gasket Install the raw water pump lightly soaked in lube
oil around the flame arrester to removed during layup or a replacement if any opening Also place an oilsoaked cloth in the
Install the raw water pump cover with a new cover exhaust port Make a note to remove cloths prior 3 Reinstall the batteries that were
removed during the
to startup layup and reconnect the battery cables making sure the
terminals are clean and that the connections are Lubrication Gasoline Check to make sure that the
batteries are fully fogging oil into the open air intake with the removed while the engine is running The fogging oil
will stall out the engine and coat the valves cylinders and spark A CAUTION Wear rubber gloves a rubber apron
plugs for winter protection and eye protection when servicing batteries Lead acid
NOTE The spark plugs will need to be removed for cleaning batteries emit hydrogen a highly explosive gas which
and regapping at spring can be ignited by electrical arcing Dr a
cigarette cigar or pipe Do not smoke Dr allow an open
If batteries are to be left on board during the layup period Bame near the battery being serviced Shut off all
make sure that they are fully charged and will remain that way electrical equipment in the vicinity to prevent electrical
to prevent them from freezing If there is any doubt that the arcing during 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 4 Remove the spark plugs wipe clean regap and install
proper tightness gasoline
5 Check the condition of the zinc anode in the raw water
circuit and clean or replace the anode as needed Note
A WARNING Lead acid batteries emit hydrogen a that it is not necessary to flush the water
gas which can be ignited by electrical solution from the raw water coolant system When the
arcing or a lighted Cigarette cigar or pipe Do not engine is put into operation the system will selfflush in a
smoke or allow an open flame near the battery being short period of time with no adverse affects It is
advisable as either an end of season or serviced Shut off all electrical equipment in the vicinity service to inspect the area where
the zinc is located in the
to prevent electrical arcing during servicing heat exchanger and clear any and all zinc debris from that
area
6 Start the engine in accordance with procedures Propulsion Engine in the PREPARATIONS FOR STARTING section
of this
Check or change the fluid in the transmission as required Wipe manual
off grime and grease and touch up any unpainted areas Protect
the coupling and the output flange with an Check that the transmission vent is open information refer to the TRANSMISSION SECTION
Engines Generators
TORQUE DATA
Lbft km
Cylinder head bolts
63 BC Four 108BC Six 7lC Four 80 85 110117
7IB Four 82B Four 85 90 118 125
Connecting rod caps
63BC Four 7lC Four 50 S4 69 75
71B Four 82B Four 59 65 82 90
108 BC Six 5S 60 76 83
Main Bearing Caps All Models 80 85 110117
Injection Pump Gear All Models 29 52 47
Oil Pan Bolts
63BC Four 59 07 12
7lBC Four 82B Four 108 BC Six 12 17 16 23
Crankshaft Pulley Nut
63BC Four 14S 181 2025
7lBC Four 82B Four 253 289 35 40
108 BC Six 282 304 3942
Glow Plugs All Models 7 11 10 15
Intake Manifold All Models 12 17 16 24
Exhaust Manifold
63BC Four 12 17 1624
71BC 82B Four and 108BC Six 2024 27 33
Oil Pressure Switch Sender All Models 913 12 18
Injection HIP Line Nut All Models 18 22 25 30
Fresh Water Pump Mounting Bolts All Models 913 12 18
Timing Gear Cover All Models 12 17 1623
Flywheel bolts
63BC Four 108 BC Six 95 137 l31 190
7lB Four 82B Four 112118 155 163
71CFour 130 144 179199
Water Temperature Sender Switch All Models 18 29 25 40
Fuel Injector
71C Four 82B Four 43 50 60 70
Back Plate All Models 24 3S 33 48
Engines Generators
DECIMAL TO METRIC EQUIVALENT of Fractions of
Decimal in Metric mm Decimal in Metric mm
an inch an inch
1164 0015625 39688 3364 0515625 1309687
132 003125 079375 1732 053125 1349375
364 0046875 119062 3564 0546875 1389062
116 00625 158750 9116 05625 1428750
564 nF 198437 3764 0578125 1468437
332 009375 238125 1932 059375 1508125
764 0109375 277812 3964 0609375 1547812
18 0125 3175 58 0625 1587500
964 0140625 357187 4164 0640625 1627187
532 015625 396875 2132 065625 1666875
1164 0171875 436562 4364 0671875 1706562
3116 01875 476250 1116 06875 1746250
1364 0203125 515937 4564 0703125 1785937
732 021875 555625 2332 071875 1825625
1564 375 595312 4764 0734375 1865312
14 0250 635000 34 0750 1905000
1764 0265625 674687 4964 0765625 1944687
932 028125 714375 2532 078125 1984375
1964 0296875 754062 I 1164 0796875 2024062
516 03125 793750 1316 08125 2063750
2164 0328125 833437 5364 0828125 03437
1132 034375 873125 2732 084375 2143125
2364 0359375 912812 5564 0859375 2182812
38 0375 952500 78 0875 2222500
0390625 992187 5764 0890625 2262187
1 040625 1031875 2932 090625 2301875
2764 0421875 1071562 5964 0921875 2341562
716 04375 1111250 1516 09375 2381250
2964 0453125 1150937 6164 0953125 2420937
1532 046875 1190625 3132 096875 2460625
3164 0484375 1230312 6364 0984375 2500312
12 0500 1270000 1 100 2540000
Engines Generators
STANDARD AND METRIC CONVERSION Inches in x 254 Millimeters mm x 0394 Inches
Feet ft x 305 Meters m x 3281 Feet
Miles x1609 Kilometers km x 0621 EQUIVALENTS
1 Degree of Latitude 60 Nm 111120 km
1 Minute of Latitude 1 Nm 1852 km
VOLUME s
Cubic Inches inS x 16387 Cubic Centimeters x 061 In
Imperia Pints IMP pt x 568 Liters L x176 IMP pt
Imperial Quarts IMP qt x 1137 Liters L x88 IMP qt
Imperial Gallons IMP gal x 4546 Liters L x 22 IMP gal
Imperial Quarts IMP qt x1201 US Quarts US Qt x 833 IMP qt
Imperial Gallons IMP gal x 1201 US Gallons US gal x 833 IMP gal
Fluid Ounces x 29573 Milliliters x 034 Ounces
US Pints US pt x 473 LitersL x 2113 Pints
US Quarts US qt x 946 Liters L x 1057 Quarts
US Gallons US gal x 3785 Liters L x 264 Ounces oz x 2835 Grams g x 035 Ounces
Pounds Ib x 454 Kilograms kg x 2205 Pounds Per Sq In psi x 6895 Kilopascals kPa x 145 psi
Inches of Mercury Hg x 4912 psi x2036 Hg
Inches of Mercury Hg x 3377 Kilopascals kPa x 2961 Hg
Inches of Water H20 x 07355 Inches of Mercury x13783 H20
Inches of Water H20 x 03613 psi x 27684 H20
Inches of Water H20 x 248 Kilopascals kPa x 4026 H20
TORQUE
PoundsForce Inches inlb x 113 Newton Meters Nm x 885 inIb
PoundsForce Feet ftlb x 1356 Newton Meters Nm x 738 fHb
VELOCITY
Miles Per Hour MPH x1609 Kilometers Per Hour KPH x 621 MPH
POWER
Horsepower Hp x 745 Kilowatts Kw x 134 MPH
FUEL CONSUMPTION
Miles Per Hour IMP MPG x 354 Kilometers Per Liter KmL
Kilometers Per Liter KmL x 2352 IMP MPG
Miles Per Gallons US MPG x 425 Kilometers Per Liter KmL
Kilometers Per liter KmL x 2352 US
Degree Fahrenheit OF oG X 18 32
Degree Celsius OC OF 32 x 56
LIQUID WEIGHTS
Diesel oil t us galon 713 Ibs
Fresh Water 1 US gallon 833 Ibs
Gasoline 1 US gallon 61 Ibs
Salt Water 1 US gallon 856 Ibs
Engines Generators
SUGGESTED SPARE PARTS
MARINE ENGINES
CONTACJ YOUR WESTERBEKE DEALER ANDADDITlONAL INFORMATION
GLOW PLUGS
WESTERBEKE RECOMMENDS CARRYING ENOUGH SPARE
ENGINE OIL YOUR BRAND fOR AN OIL CHANGE
AND A GAUON Of PREMIXED LINE SPARE PARTS KITS
WESTERBEKE also offers two Spare Parts Kits KIT B
each packaged in a rugged hinged toolbox ZINC ANODES
Kit A includes the basic spares DRIVE BELTS
Kit B is for more extensive offshore CIUlsmg OIL FILTER
KIT A FUEL FILTER
ZINC ANODES HEAT EXCHANGER GASKET
DRIVE BELTS IMPELLER KIT
OIL FILTER INJECTOR
FUEL FILTER OVERHAUL GASKET KIT
HEAT EXCHANGER GASKET AIR FILTER
IMPELLER KIT GLOW PLUG
FUEL SYSTEM HARDWARE IIT FUEL SYSTEM HARDWARE KIT
FUEL PUMP INLET FILTER FUEL PUMP INLET FILTER
Engines Generators
Engines 08WMDW1 006

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