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Westerbeke Diesel 44c Four Technical Manual




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OPERATORS MANUAL
DIESEL ENGINE
55A FOUR
PUBLICATION 041562
2nd Edition I February 1997
l WESTERBEKE
WESTERBEKE CORPORATION 150 JOHN HANCOCK ROAD
MYLES STANDISH INDUSTRIAL PARK TAUNTON MA 02780
WEBSITE
AlMMA Member National Marine Manufacturers Association
CALIFORNIA
Proposition 65 engine exhaust and some
of its constituents are known to
the State of California to cause
cancer birth defects and harm
II WESJERBEKE
I Engines Generators
SAFETY PREVENT BURNS FIRE
Read this safety manual carefully Most accidents are caused
by failure to foUow fundamental rules and when dangerous conditions exist and take the A WARNING Fire can cause injury or
precautions to protect yourself your personne
and your machinery Prevent flash fires Do not smoke or permit flames or
The foUowing safety instructions are in compliance with sparks to occur near the carburetor fuel line filter fuel
the American Boat and Yacht Council ABYC standards pump or other potential sources of spilled fuel or fuel
vapors Use a suitable container to catch all fuel when
PREVENT ELECTRIC SHOCK removing the fuel line carburetor or fuel filters
Do not operate with a Coast Guard Approved flame
arrester removed Backfire can cause severe injury or
A WARNING Do not touch AC electrical connections death
while engine is running or when connected to shore Do not operate with the air removed
power Lethal voltage is present at these connections Backfire can cause severe injury or death
Do not smoke or permit flames or sparks to occur near the
Do not operate this machinery without electrical fuel system Keep the compartment and the enclosures and covers in place
ator clean and free of debris to minimize the chances of
Shut off electrical power before accessing electrical fire Wipe up all spilled fuel and engine oil
equipment Be aware diesel fuel will bum
Use insulated mats whenever working on electrical
equipment PREVENT BURNS EXPLOSION
Make sure your clothing and skin are dry not damp
particularly shoes when handling electrical equipment
Remove wristwatch and all jewelry when working on
A WARNING Explosions from fuel vapors can cause
injury or death
electrical equipment
Do not connect utility shore power to vessels AC
circuits except through a shiptoshore double throw Follow refueling safety instructions Keep the vessels
transfer switch Damage to vessels AC generator may hatches closed when fueling Open and ventilate cabin
result if this procedure is not followed after fueling Check below for fumesvapor before running
the blower Run the blower for four minutes before start
Electrical shock results from handling a charged capacitor ing your engine
Discharge capacitor by shorting terminals together
All fuel vapors are highly explosive Use extreme care when
PREVENT BURNS HOT ENGINE handling and storing fuels Store fuel in a
area away from equipment and out of the
reach of children
A WARNING Do not touch hot engine parts or Do not fill the fuel tanks while the engine is running
exhaust system components A running engine gets
Shut off the fuel service valve at the engine when servicing
very hot the fuel system Take care in catching any fuel that might
spill DO NOT allow any smoking open flames or other
Always check the engine coolant level at the coolant sources of fire near the fuel system or engine when servicing
recovery tank Ensure proper ventilation exists when servicing the fuel
system
A WARNING Steam can cause injury or death Do not alter or modify the fuel system
Be sure all fuel supplies have a positive shutoff valve
In case of an engine overheat allow the engine to cool Be certain fuel line fittings are adequately tightened and
before touching the engine or checking the coolant free of leaks
Make sure a fire extinguisher is installed nearby and is
properly maintained Be familiar with its proper use
Extinguishers rated ABC by the NFPA are appropriate
for all applications encountered in this 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 manifolds
it last are securely attached and no warping exists Pay close
attention to the manifold water injection elbow and
Make certain all personnel are clear of the engine before
exhaust pipe nipple
starting
Be sure the unit and its surroundings are well ventilated
Make certain all covers guards and hatches are re
installed before starting the engine In addition to routine inspection of the exhaust system
install a carbon monoxide detector Consult your boat
BATTERY EXPLOSION builder or dealer for installation of approved detectors
For additional information refer to ABYC T22 educa
A WARNING Battery explosion can cause injury tional information on Carbon Monoxide
or death
A WARNING Carbon monoxide CO is an invisible
Do not smoke or allow an open flame near the battery odorless gas Inhalation produces flulike symptoms
being serviced Lead acid batteries emit hydrogen a nausea or death
highly explosive gas which can be ignited by electrical
arcing or by lit tobacco products Shut off all electrical Do not use copper tubing in diesel exhaust systems Diesel
equipment in the vicinity to prevent electrical arcing during fumes can rapidly destroy copper tubing in exhaust sys
servicing tems Exhaust sulfur causes rapid deterioration of copper
Never connect the negative battery cable to the posi tubing resulting in exhaustwater leakage
tive connection terminal of the starter solenoid Do not Do not install exhaust outlet where exhaust can be drawn
test the battery condition by shorting the terminals through portholes vents or air conditioners If the engine
together Sparks could ignite battery gases or fuel vapors exhaust discharge outlet is near the waterline water could
Ventilate any compartment containing batteries to prevent enter the exhaust discharge outlet and close or restrict the
accumulation of explosive gases To avoid sparks do not flow of exhaust Avoid overloading the craft
disturb the battery charger connections while the battery is
being charged Although diesel engine exhaust gases are not as toxic as
exhaust fumes from gasoline engines carbon monoxide
Avoid contacting the terminals with tools etc to prevent gas is present in diesel exhaust fumes Some of the symp
bums or sparks that could cause an explosion Remove toms or signs of carbon monoxide inhalation or poisoning
wristwatch rings and any other jewelry before handling are
the battery
Vomiting
Always tum the battery charger off before the battery connections Remove the negative lead first Dizziness
and reconnect it last when servicing the battery Throbbing in temples
Muscular ACID
Intense headache
A WARNING Sulphuric acid in batteries can cause Weakness and sleepiness
severe injury or death AVOID MOVING PARTS
When servicing the battery or checking the electrolyte
level wear rubber gloves a rubber apron and eye protec A WARNING Rotating parts can cause injury
tion Batteries contain sulfuric acid which is destructive If or death
it comes in contact with your skin wash it off at once
with water Acid may splash on the skin or into the eyes Do not service the while it is running If a
inadvertently when removing electrolyte caps situation arises in which it is absolutely necessary to make
Engines Generators
SAFETY INSTRUCTIONS
operating adjustments use extreme care to avoid touching ABYC NFPA AND USCG PUBLICATIONS FOR
moving parts and hot exhaust system components
INSTALLING GASOLINE AND DIESEL ENGINES AND
Do not wear loose clothing or jewelry when servicing
equipment avoid wearing loose jackets shirts sleeves
GENERATORS
rings necklaces or bracelets that could be caught in Read the following ABYC NFPA and USCG publications
moving parts for safety codes and standards Follow their recommenda
tions when installing your WESTERBEKE Make sure all attaching hardware is properly tightened
Keep protective shields and guards in their respective ABYC American Boat and Yacht Council
places at all times Safety Standards for Small Craft
Do not check fluid levels or the drive belts tension while Order From
the is operating ABYC
15 East 26th treet
Stay clear of the drive shaft and the transmission coupling
New York NY 10010
when the engine is running hair and clothing can easily
be caught in these rotating parts NFPA National Fire Protection Association
Fire Protection Standard for Motor NOISE Order From
NFPA
A WARNING High noise levels can cause hearing 1 Batterymarch Park
PO Box 9101
loss Quincy MA 022699101
Never operate a generator without its muffler installed USCG United States Coast Guard
USCG 33CFR183
Do not run an engine with the air intake silencer
removed Order From
US Government Printing Office
Do not run engines or generators for long periods with Washington DC 20404
their enclosures open
A WARNING 00 not work on machinery when you
are mentally or physically incapaCitated by MANUAL
Many of the preceding safety tips and warnings are repeated
in your Operators Manual along with other cautions and
notes to highlight critical information Read your maintain your equipment and follow all ENGINE AND to install a gasoline engine or generator
should
begin with a thorough examination of the American Boat and
Yacht Councils ABYC standards These standards are from
a combination of sources including the USCG and the of the ABYC standards of particular interest are
H2 Gasoline fuel systems
Pl Exhaust systems
P4 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 below the vessels waterline provisions must be made to install a siphonbreak in
the raw water supply hose to the exhaust elbow This hose must be looped a minimum
of 18 above the vessels waterline Failure to use a siphonbreak when the injection port is at or below the load waterline will result in raw water
damage to the engine and possible flooding of the SYSTEM
The exhaust hose must be certified for marine use The system must be designed 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 2 Engine Oil Change 15
Warranty Procedures 2 Fuel System 16
Product Software 2 Fuel Filters 16
Notes Cautions and Wamings 2 Fuel Water Separator 16
Serial Number Location 3 Fuel Injection Pump Control 16
Understanding the Diesel Engine 3 Priming Bleeding the Fuel System 17
Ordering Parts 3 Air Cleaner 17
Control Panels 4 DC Electrical System 18
Admirals Panel 4 Charging Voltage 18
Captains Panel 5 Alternator Drive Belt Adjustment 19
Diesel Fuel Engine Oil and Engine Coolant 6 Battery Care 19
Diesel FueL 6 DC Wiring Diagrams 20
Engine Oil 6 Water Heater 22
Engine Coolant 6 Water Heater Installations For Initial StartUp 7 Engine Adjustments 23
Prestart Inspection 7 Adjusting Valve Clearances Procedure 8 Timing Belt Inspection and 24
BreakIn Procedure 9 Compression Test 26
The Daily Routine 10 Fuel Injection Nozzle Test 26
Check List 10 HBW Transmission 27
Start Your Engine 10 Borg Warner Velvet Drive Transmission Schedule 11 Engine 31
Engine Coolant 13 Water Temperature and
Changing the Coolant 13 Oil Pressure Gauges 32
Thermostat 13 Layup and 33
Raw Water System 14 WESTERBEKE 55A Torque 35
Raw Water Cooling Circuit 14 Standard Hardware Torques 36
Raw Water Pump 14 WESTERBEKE 55A FOUR 37
Zinc Anode 14 WESTERBEKE 55A FOUR Parts Raw Water Pump Belt Adjustment 14
WESTERBEKE
WESTERBEKE CORPORATION AVON INDUSTRIAL PARK
AVON MA 02322 TEL FAX 508 5599323
WESTERBEKE Marine Diesel Engine is a product PRODUCT SOFTWARE
of WESTERBEKE S long years of experience and ad Product software tech data parts lists technology We take
great pride in the superior brochures and catalogs provided from sources other and dependable performance of our
engines WESTERBEKE are not within generators Thank you for selecting WESTERBEKE
CONTROL
In order to get the full use and benefit from your WESTERBEKE CANNOT BE RESPONSIBLE FOR
engine it is important that you operate and maintain it THE CONTENT OF SUCH SOFTWARE MAKES NO
correctly This manual is designed to help you do this WARRANTIES OR WITH
Please read this manual carefully and observe all the RESPECT THERETO INCLUDING precautions throughout Should
your engine re TIMELINESS OR COMPLETENESS THEREOF AND
quire servicing contact your nearest WESTERBEKE WILL IN NO EVENT BE LIABLE FOR ANY TYPE OF
dealer for assistance DAMAGE OR INJURY INCURRED IN is your operators manual A
Parts Catalog is WITH OR ARISING OUT OF THE FURNISHING OR
also provided and a Technical Manual is available from USE OF SUCH WESTERBEKE dealer Also if you are planning
WESTERBEKE customers should also keep in mind
to install this equipment contact your WESTERBEKE the time span between printings of for WESTERBEKES
installation manual product software and the unavoidable existence of earlier
WESTERBEKE manuals In summation product PROCEDURES ware provided with
WESTERBEKE products whether
Your WESTERBEKE Warranty is included in a from WESTERBEKE or other suppliers must not and
separate folder If you have not received a customer cannot be relied upon exclusively as the card registering
your warranty 60 days after authority on the respective product It not only the warranty registration form please
contact good sense but is imperative that appropriate factory in writing with model information including
tives of WESTERBEKE or the supplier in question be
the units serial number and commission date consulted to determine the accuracy and currentness of
the product software being consulted by the customer
TYPICAL CUSTOMER CARD
NOTES CAUTIONS AND WARNINGS
As this manual takes you through the operating proce
dures maintenance schedules and of
WESTERBEKE CORPORATION AVON INDUSTRIAL PARK
AVON MA 02322 TEL 508 5587700 FAX 508 5599323 your marine engine critical information will be high
Customer lighted by NOTES CAUTIONS and WARNINGS An
WESTERBEKE OWNER explanation follows
MAIN STREET
HOMETOWN USA NOTE An operating procedure essential to note
Model 55A Four Ser U5389048
A CAUTION Procedures which if not strictly
observed can result in the damage or destruction of
your engine
Expires 72097
A WARNING Procedures which if not properly
followed can result in personal injury or loss of
life
IVVI WESTERBEKE
I Engines Generators
INTRODUCTION
NUMBER LOCATION ORDERING PARTS
An nameplate that displays the engine Whenever replacement parts are needed always pro
model number and engine serial number is mounted on vide the engine model number and engine serial number
the side of the engine manifold Take the time to enter as they appear on the silver and black information on the blank decal provided below
This nameplate located on the manifold You must provide us
will provide a quick reference when seeking technical in with this information so we can identify your engine In
formation andor ordering parts addition include a complete part description and part
number for each part needed see the separately furnished
Parts Catalog Also insist upon WESTERBEKE pack
aged parts because will fit or generic parts are frequently
not made to the same as original equip
ment
NOTE Component locations in this manual are refer
enced from the front of the engine which is the THE DIESEL ENGINE drive belt end Left and right sides are
determined as
follows imagine straddling the engine facing in the
The diesel engine closely resembles the gasoline same direction as the front of the engine the left side
engine since the mechanism is essentially the same is at your left the right side is at your right
The cylinders are arranged above a closed crankshaft is of the same general type as that of a PROTECTING YOUR engine and the diesel engine
has the same
types of valves camshaft pistons connecting rods and Care at the factory during assembly and thorough system
have resulted in a WESTERBEKE diesel engine capable
of many thousands of hours of dependable service How
To a great extent a diesel engine requires the same ever the manufacturer cannot control how or where maintenance as a gasoline engine
Most engine is installed in the vessel or the manner in are proper ventilation and proper maintenance the unit is operated
and serviced in the field This is up
of the fuel lubricating and cooling systems Replacement to the fuel and lubricating filter elements at the time and frequent checking for
contamination NOTE Six important steps to ensure long engine life
water sediment etc in the fuel system are essential o Proper engine installation and important is the consistant use of a brand of diesel
lubrication oil designed specifically for o An efficient welldesigned exhaust system that in
diesel engines cludes an antisiphon break to prevent water from
entering the engine
The diesel engine does differ from the gasoline in its method of handling and firing of fuel The o Changing the engine oil and oil filters
every 200 and ignition systems are done away erating hours
with and in their place is a single component the fuel o Proper maintenance of all engine pump which performs the function of both
according to the maintenance schedule in this
manual
o Use clean filtered diesel fueL
o Winterize your engine according to the Layup and
section in this manual
II WSJERBEKE
I Engines Generators
CONTROL offers two optional panels select You will notice that when the engine is shut down with
the instruction page that applies to the panel you pur the Key Switch turned OFF the water temperature gauge
chased will continue to register the last temperature reading in
dicated by the gauge before electrical power was PANEL OFF The oil pressure gauge will
also hold its reading
This control panel is equipped with a The temperature gauge will once again register the en
KEY SWITCH and RPM gauge with an ELAPSED gines true temperature when electrical power is restored
TIME meter which measures the engines running time to the gauge
in hours and in 1110 hours The panel also includes a
A separate alarm buzzer with harness is supplied with
WATER TEMPERATURE gauge which indicates water
every Admiral Panel The installer is responsible in degrees Fahrenheit an OIL PRESSURE
electrically connecting the buzzer to the fourpin connec
gauge which measures the engines oil pressure in
tion on the engines electrical harness The per square inch and a DC control circuit VOLT
is also responsible for installing the buzzer in a location
AGE gauge which measures the systems voltage All
where it will be dry and where it will be audible to the
gauges are illuminated when the key switch is turned ON
operator should it sound while the engine is running
and remain illuminated while the engine is in operation
The buzzer will sound when the ignition key is turned
The panel also contains two rubberbooted push buttons
ON and should silence when the engine has started and
one for PREHEAT and one for START
the engines oil pressure rises above 15 psi
WATER TEMPERATURE GAUGE THIS GAUGE IS OIL PRESSURE GAUGE THIS GAUGE IS GRADU
GRADUATED IN DEGREES FAHRENHEIT AND IS ATED IN POUNDS PER SQUARE INCH PSI AND IS
ILLUMINATED WHILE THE KEY SWITCH IS ILLUMINATED WHILE THE KEY SWITCH IS
TURNED ON THE ENGINES NORMAL OPERATING TURNED ON THE ENGINES NORMAL OPERATING
TEMPERATURE IS 170190 F OIL PRESSURE RANGES BETWEEN 3060 PSI
RPM GAUGE REGIS
TERS MINUTE OF THE
ENGINE AND CAN FOR
ACCURACY FROM
THE REAR OF KEY SWITCH
PROVIDES
HOUR METER REGIS
TERS ELAPSED TIME POWER ONLY TO THE
INSTRUMENT PANEL
AND SHOULD BE USED
AS A GUIDE FOR THE CLUSTER THE
SWITCH SHUTS THE
ENGINE DOWN THE KEY IS
TURNED OFF
DC VOLTMETER
INDICATES THE AMOUNT
THE BATTERY IS BEING
PREHEAT BUTTON WHEN PRESSED ENERGIZES CHARGED SHOULD
THE ALTERNATORS EXCITER THE FUEL LIFT SHOW 13V TO 14V
PUMP THE FUEL SOLENOID ON THE INJECTION AUTOMATIC ALARM SYSTEM
PUMP AND THE ENGINES GLOW PLUGS IT BY
PASSES THE ENGINES PROTECTIVE OIL PRES HIGH WATER TEMPERATURE ALARM AN ALARM BUZZER HAS
SURE ALARM SWITCH IN ADDITION THIS BEEN SUPPLIED WITH THE INSTRUMENT PANEL IF THE ENERGIZES THE START
BUTTON FRESH WATER COOLANT REACHES 210 F 98C THIS SWITCH
WILL CLOSE SOUNDING THE ALARM WHICH WILL EMIT A CON
TINUOUS SIGNAL
LOW OIL PRESSURE ALARM A LOW OIL PRESSURE ALARM
START BUTTON WHEN PRESSED ENERGIZES SWITCH IS LOCATED OFF THE ENGINES OIL GALLERY THIS
THE STARTERS SOLENOID WHICH CRANKS THE SWITCH MONITORS THE ENGINES OIL PRESSURE SHOULD THE
ENGINE THIS BUTTON WILL NOT OPERATE ENGINES OIL PRESSURE FALL TO 5 10 PSI THE SWITCH UNLESS THE PREHEAT
BUTTON CLOSE SOUNDING THE ALARM IN THIS EVENT THE ALARM WILL
IS PRESSED AND HELD AT THE SAME TIME EMIT A PULSATING SIGNAL
lvvl WESJERBEKE
I Engines Generators
CONTROL PANELS
PANEL COOLANT TEMPERATURE and an alarm buzzer
This control panel is equipped with for low OIL PRESSURE or high WATER TEMPERA
a KEY SWITCH an RPM gauge PREHEAT and TURE The RPM gauge is illuminated when the key
START buttons an INSTRUMENT TEST button three switch is turned ON and remains illuminated while the
indicator lamps one for ALTERNATOR DISCHARGE engine is in for low OIL PRESSURE and one for high ENGINE
ALARM THE ALARM WILL SOUND IF THE ENGINES OIL PRESSURE
FALLS BELOW 15 PSI IN THIS EVENT THE ALARM WILL EMIT A
PULSATING SIGNAL THE ALARM WILL ALSO SOUND IF THE WATER
RPM GAUGE REGISTERS REVOLUTIONS PER TEMPERATURE IN THE FRESHWATER COOLING CIRCUIT RISES TO
MINUTE OF THE ENGINE AND CAN BE RECALI 205F IN THIS EVENT THE ALARM WILL EMIT A CONTINUOUS SIGNAL
BRATED FOR ACCURACY FROM THE REAR OF NOTE THE ALARM WILL SOUND WHEN THE KEY SWITCH IS TURNED
THE PANEL ON THIS SOUNDING IS NORMAL ONCE THE ENGINE STARTS AND THE
ENGINES OIL PRESSURE REACHES 15 PSI THE ALARM WILL SILENCE
TEST BUTTON WHEN
PRESSED TESTS THE
ALTERNATOR THE OIL
PRESSURE AND THE
WATER TEMPERATURE
CONTROL CIRCUITS
WHEN PRESSED THE
ALTERNATOR THE OIL
PRESSURE AND THE
WATER TEMPERATURE
INDICATOR LIGHTS IL
LUMINATE IN ADDITION
TO SOUNDING THE
ALARM BUZZER
KEY SWITCH PROVIDES
POWER ONLY TO THE IN
STRUMENT PANEL CLUSTER
THE KEY SWITCH SHUTS THE
ENGINE DOWN WHEN THE
KEY IS TURNED OFF
PREHEAT BUTTON WHEN PRESSED ENERGIZES
START BUTTON WHEN PRESSED ENERGIZES THE ALTERNATORS REGULATOR THE FUEL LIFT
THE STARTERS SOLENOID WHICH CRANKS THE PUMP THE FUEL SOLENOID ON THE INJECTION
ENGINE IT WILL NOT OPERATE ELECTRICALLY PUMP AND THE ENGINES GLOW PLUGS IT BY
UNLESS THE PREHEAT BUTTON IS PRESSED AND PASSES THE ENGINES OIL PRESSURE ALARM
HELD AT THE SAME TIME SWITCH IN ADDITION THIS BUTTON ENERGIZES
THE START BUTTON
WESJERBEKE
I Engines Generators
DIESEL FUEL ENGINE OIL
AND ENGINE FUEL ENGINE COOLANT
Use fuel that meets the requirements or specification The use of an antifreeze mixture of 5050 is recom
of Class 2D ASTM and has a cetane rating of 45 mended for yearround use Use antifreeze that is com
or better patible with aluminium components and never mix
different brands of antifreeze Do not use straight water
Care Of The Fuel Supply this can be detrimental to the cooling system compo
Use only clean diesel fuel The clearance of the compo nents
nents in your fuel injection pump is very critical invisi NOTE Lookfor the new long
ble dirt particles which might pass through the filter can lasting antifreeze that is now these finely finished parts It is important to buy
clean fuel and keep it clean The best fuel can be ren Antifreeze mixtures will protect against an by careless handling or improper
freeze and they are beneficial to the engines facilities To assure that the fuel going into the system They retard rust and add to the life
of the circu
tank for your engines daily use is clean and pure the lating pump practice is advisable
ANTIFREEZE a wellknown brand of fuel Antifreeze concentration 23 35 50 60
14F 4F 40F 58F
Install and regularly service a good visualtype filterl Freezing Temperature
5C 20C 40C 50C
water separator between the fuel tank and the 500 FG or 900 FG is a good example of such COOLANT RECOVERY TANK
a filter
A coolant recovery tank kit is supplied with each
WESTERBEKE diesel engine The purpose of this re
ENGINE OIL covery tank is to allow for engine coolant expansion
Use a heavy duty engine oil with an API of and contraction during engine operation without the loss
CF or CG4 or better Change the engine oil after an of coolant and without introducing air into the 50 hours of breakin operation and
every 200 hours
of operation thereafter For recommended oil viscosity system
see the following chart
Operating Temperature Oil Viscosity
Above 68F 20C SAE 30 or 10W30
4168F 520C SAE 20 or 10W30
Below 41F 5C SAE 10W30
A CAUTION 00 not allow two or more brands
of engine oil to mix Each brand contains its own
additives additives of different brands could react
in the mixture to produce properties harmful to
your engine COOLANT RECOVERY TANK
PREPARATIONS FOR INITIAL INSPECTION o Check the DC electrical system Inspect wire
Before starting your engine for the first time or after a connections and battery cable layoff check the following items
o Visually examine the unit Look for loose or missing
o Check the engine oil level add oil to maintain the parts disconnected wires unattached hoses and
level at the high mark on the dipstick check threaded Check the fuel supply and examine the fuel o
Check the coolant level in the plastic recovery tank
bowls for contaminants and at the manifold
o Check the transmission fluid level NOTE If the engine has not yet been filled with coolant
refer to the Engine Coolant section of this manual
NOTE Refer to the pages in this manual for
fuel oil and transmission types and OIL
DIPSTICK
FULL
COOLANT
RECOVERY
LDW1lJ TANK
MANIFOLD
PRESSURE CAP
lvvl WESJERBEKE
I Engines Generators
the transmission in neutral and advance the throttle
A CAUTION Prolonged cranking intervals without
the engine starting can result in the engine to slightly open system filling with raw water This may
happen be
cause the pump is pumping raw water through the
A CAUTION Make certain the transmission is raw water cooling system during cranking This raw
water can enter the engines cylinders by way of the
in neutral Starting in gear could result in serious
exhaust manifold once the exhaust system fills Pre
damage to your transmission your boat and
vent this from happening by closing the raw water
vessels nearby supply throughhull shutoff draining the exhaust
muffler and correcting the cause of the excessive
Tum the KEY SWITCH to the ON position 2 0 clock
engine cranking Engine damage resulting from raw
PREHEAT Depress the PREHEAT switch The voltmeter water entry is not a warrantable issue the
panel lights gauges and meters and fuel solenoid will be
should keep this in The PREHEAT switch should be depressed in Once the engine starts check instruments for proper with the
following chart pressure and battery charging voltage
NOTE Never attempt to engage the starter while the
engine is running
Atmospheric Temperature Preheating Time
41 F 5C or higher Approx 10 seconds NOTE Some unstable running may occur in a cold engine
Depressing the Preheat switch for 1015 second intervals
41 F 5C to 23F 5C Approx 15 seconds
will help stabilize the engine RPM until the operating tem
23F5C or lower Approx 20 seconds perature reaches 170190F 7788C and a propeller
Limit of continuous use 30 seconds before cranking load is applied to the engine When the engine is running
and the preheat switch is depressed a charging load on
START While still depressing the PREHEAT switch de the DC alternator will be the START switch This will engage the start sole
noid Upon engine firing release the START switch Do
STARTING UNDER COLD release the PREHEAT switch until the oil pressure Make certain the lubricating oil conforms with the ratings for
reaches 15 psi Then as long as the high water tempera the prevailing temperature Check the table on the engine
ture and low oil pressure protective circuits do not acti oil section of this manual
vate the engine will remain energized and continue The battery should be fully charged to minimize voltage
to run drop
Use a sufficient amount of preheat to aid in starting
See chart on this page
NOTE When starting STOPPING PROCEDURE
A voltage drop will occur
To stop the engine bring the throttle to an idle position
when the preheat switch
and place the transmission in neutral Allow the engine to
is depressed
idle for a few moments to stabilize temperatures Tum
the key to the OFF position This opens the DC circuit to
the instrument panel and engine deenergizing the fuel
solenoid on the injection pump stopping fuel flow from
Should the engine not start when the START switch is it and stopping the for 10 to 20 seconds release both switches and
Made certain the key switch is in the OFF position
wait 30 seconds repeat the procedure above and preheat
12 oclock If the Key Switch is left ON the Never run the starter for more than will discharge An engine alarm buzzer is
provided to
30 seconds warn the operator of this condition Key Switch ON
The best method of preventing the battery from discharge
is to remove the key from the Key Switch after stopping
the engine
VVI WESJERBEKE
I Engines GeneratDrs
BREAKIN PROCEDURE
THE FIRST 50 HOURS 4 Avoid rapid acceleration especially with a cold
Although your engine has experienced a minimum of one engine
hour of test operations to ensure accurate assembly and S Use caution not to overload the engine The operation of all systems breakin time
is required of a gray or black exhaust and the inability of the
The service life of your engine is dependent upon how engine to reach its full rated speed are signs of an
the engine is operated and serviced during its initial 50 of use
6 During the next 25 hours the engine may be operated
Your new engine requires approximately 50 hours of ini at varying engine speeds with short runs at full rated
tial conditioning operation to break in each moving part rpm A void prolonged idling during this breakin pe
in order to maximize the performance and service life of riod
the engine Perform this conditioning carefully keeping
in mind the following Breakingin a new engine basically involves seating
the piston rings to the cylinder walls This cannot be
1 Start the engine according to the Starting Procedure accomplished by long periods of running at idle nor by
section in this manual run the engine at fast idle early running at full rpm Idle running may glaze the
while checking that all systems raw water pump oil cylinder walls resulting in excessive oil consumption
pressure battery charging are functioning and smoky operation Excessive speed or heavy over
2 Allow the engine to warm up preferably by running loading especially with a cold engine may cause scoring
at fast idle until the water temperature gauge moves of the cylinder walls producing similar results Operate
into the 130 140F range the engine in moderation during the 50hour breakin pe
riod Dont baby the engine but do not abuse it
3 While using the vessel run the engine at varying en
gine speeds for the first 25 hours NOTE See the Transmission section of this manual for
breakin information on your rVtTl WESJERBEKE
I Engis Generators
THE DAILY ROUTINE
CHECK LIST START YOUR ENGINE
Each day before starting your engine take a few NOTE See Procedure in this manual for
moments to run this check list more detailed Visually inspect the engine for fuel oil or water 1 Put
transmission in neutral throttle advanced
leaks
2 Tum KEY to the ON position 2 oclock
o Check the oil level dipstick
3 Depress PREHEAT 10 to 15 seconds
o Check the transmission fluid level
4 While pressing PREHEAT push START As engine
o Check for loose wires at the alternator fires release START
o Check the starting batteries level weekly 5 Hold PREHEAT until oil pressure reaches 15 psi
andor alarm shuts off
o Check drive belts for wear and proper tension
weekly NOTE Should engine fail to start wait 30 seconds repeat
the above procedure and PREHEAT longer
o Log your engine running time These hours relate to
scheduled maintenance 6 Allow a few minutes for the engine to warm at a
comfortable rpm approx 1200 rpm then reduce the
o Check fuel supply always keep fuel tanks as full as
rpm shift into gear and get underway
possible
o Look for clean fuel in the fuelwater separator bowl
o Check the coolant level in the plastic recovery tank
NOTE Excessive loss of coolant indicates a cooling sys
tem leak Check the entire system If necessary use a
cooling system pressure tester to pressurize the to locate the area of leakage In cases of loss refill the system as outlined in Initial StartUp in
this manual
lvvl WESTERBEKE
r 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 A complete service
manual is availablefrom your WESTERBEKE dealer
CHECK HOURS OF MAINTENANCE EXPLANATION OF
SCHEDULED
EACH
MAINTENANCE
DAY 50 100 250 500 750 1000 1250
Fuel Supply 0 Diesel No2 octane rating of 45 cetane or better
FuelWater Separator 0 Check for water and dirt in fuel if
necessary
Engine Oil Level 0 Oil level should indicate between MAX and LOW
on dipstick
Transmission Fluid Level 0 Fluid level should indicate between MAX and
LOW on dipstick
Coolant Level 0 Check at recovery tank if empty check at
manifold Add coolant if needed
Drive Belts 0 Inspect for proper tension h to Is depression
and adjust if needed Check belt edges for wear
Visual Inspection of Engine 0 NOTE Please keep engine surface clean Dirt and Check for fuel oil and water leaks Inspect
wiring and electrical connections Keep bolts
oil will inhibit the engines ability to remain cool
nuts tight
Throttle and Transmission
Control Cable
0 0 0 0 Check for loose fittings cotter pins etc
Lubricate with WD40 or equivalent
Adjust Engine Idle Speed 0 Adjust to 7501000 rpm
Fuel Filter 0 0 0 Initial change at 50 hrs then change every
250 hrs
Starting Batteries
and House Batteries
0 Every 50 operating hours check electrolyte levels and make sure connections are very tight
Clean off excessive corrosion
Engine Oil 0 Initial engine oil filter change at 50 hrs then change both every 100 hours
Adjust the Valve Clearances 0 0 0 Initial adjustment at 50 hrs then every 50Q hrs
Do not retorque the cylinder head
Lubricate Panel Key Switch
with Lockeze
0 0 0 0 0 0 At 1st 100 hrs then each year at TransmiSSion Fluid 0 0 0
0 0 Initial fluid change at 50 hrs then every 250
hrs or at Air Cleaner 0 0 Replace element filter Clean or replace
elements
Exhaust System 0 0 0 0 Initial check at 50 hrs then every 250 hrs
Inspect for leaks Tight connections check
siphon brake operation Check the exhaust
elbow for carbon andor corrosion buildup on
inside passages clean and replace as
recommends this service be performed by an authorized mechanic
VVI WESJERBEKE
I Engines GeneratDrs
MAINTENANCE SCHEDULE
Continued
NOTE Use engine hour meter gauge to log your engine hours
or record your engine hours by running time
CHECK HOURS OF OPERATION
SCHEDULED MAINTENANCE EXPLANATION OF SCHEDULED
EACH
MAINTENANCE
DAY 50 100 250 500 750 1000 1250
Engine Hoses D D D D D D Hose should be hard tight Replace if soft or
spongy Check tighten all hose clamps
Heat Exchanger
Zinc Anode
D D D D D D D Clean or replace Open heat exchanger end cap
and clean out debris
Electric Fuel Lift Pump Filter
if applicable
D D D D D D Initial filter change at 50 hours then change
filter every 250 hours
Raw Water Pump D D D Remove pump cover and inspect impeller for
wear replace if needed Also replace gasket
Lubricate both when Coolant System D D Drain flush and refill cooling system
with
appropriate antifreeze mix
D Check and adjust injection opening pressure and
spray condition see Engine Starter Motor D D Check solenoid and motor for
corrosion
Remove and lubricate Start motor pinion drive
Clean and lubricate
Preheat Circuit D D Check operation of preheat solenoid Remove
and clean glow plugs check resistance
46 ohms
Engine Cylinder Compression
and Valve Clearance
D D Incorrect valve clearance will result in poor
engine performance check compression
pressure and timing and adjust valve clearances
DC Alternator D D D Check DC charge from alternator Check mount
ing bracket tighten electrical Heat Exchanger D Remove have cleaned and
press ure tested
Transmission Oil Cooler D Remove have cleaned and
pressure tested
Engine Transmission
Damper Plate
D Chattering at idle and low rpms is an indication
of damper plate wear Remove and replace
Engine Timing Belt D Remove and replace
NOTE Failure to replace the timing belt at the
recommended interval could result in timing
belt failure resulting in major damage to the
recommends this service be performed by an authorized Il WSJERBEKE
I Engines Genetors
ENGINE THE COOLANT Start the engine and bring it to operating engines coolant must be changed every
eight to Monitor the coolant in the manifold and add as months depending on the engines use If the Fill the
manifold to the filler neck and install the is allowed to become contaminated it can lead cap
to overheating problems Remove the cap on the coolant recovery tank fill with
A coolant recovery tank allows for engine coolant expan coolant to halfway between LOW and MAX and replace
sion and contraction during engine operation without any sig the cap
nificant loss of coolant and without introducing air into the Run the engine and observe the coolant expansion flow
cooling system This tank should be located at or above the into the recovery tank
engine manifold level and be easily accessible
After checking for leaks stop the engine and allow
COOLANT it to cool Coolant should draw back into the cooling
RECOVERY
TANK CAP system as the engine cools down Add coolant to the
recovery tank if needed Clean up any spilled coolant
COOLANT
NOTE Periodically check the condition of the pressure cap
RECOVERY Ensure that the upper and lower rubber seals are in good
TANK
condition and check that the vacuum valve opens and
closes tightly Carry a spare cap
THERMOSTAT
A thermostat located near the manifold at the front of the
COOLANT EXPANSION engine controls the coolant temperature as it contin
uously flows through the closed cooling circuit When
the engine is first started the closed thermostat prevents
coolant from flowing some coolant is bypassed through
a hole in the thermostat to prevent the exhaust the engine coolant by loosening the drain plug on from overheating As the engine warms
up the thermo
the engine block and opening the manifold pressure cap stat gradually opens The thermostat is accessible and can
Flush the system with fresh water then start the refill be checked cleaned or replaced easily Carry a See the Parts photos in this man
thermostat and gasket
ual for locations
WATER
NOTE The petcock on the heat exchanger can also be TEMPERATURE
ALARM
used to drain engine coolant
A WARNING Beware of the hot engine coolant WATER
TEMPERATURE
Wear protective gloves SENDER
TO REFILL WITH COOLANT
With the enginge running in idle slowly pour coolant into the Open the air bleed petcock on the heat exchanger
to help remove air from the system When a steady flow
of coolant appears at the drain plug opening close the
water drain plug and continue to fill the system until the
manifold remains full Close the petcock on the when antifreeze flows from it
THERMOSTAT
Il WSJlBEKE
I Engines GeneratDrs
ENGINE OIL CHANGE
DRAIN THE SUMP filter when unscrewing it to catch any oil left in the filter
The engine oil should be warm Remove the oil drain Inspect the old oil filter as it is removed to make sure that
hose from its attachment bracket and lower it into a con the rubber sealing gasket comes off with the old oil and allow the oil to drain
or attach a pump to the If this rubber sealing gasket remains sealed against the
end of the drain hose and pump out the old oil Make sure engine block gently remove it When installing the new
the oil drain hose is capped and properly secured in its oil filter element wipe the filter gaskets sealing after all the old oil has
been drained on the engine block free of oil and apply a thin coat of
clean engine oil to the rubber gasket on the new oil filter
NOTE Thread size for the lube oil drain hose capped end Screw the filter onto the threaded oil filter stub and
is 14 NPT tighten the filter firmly by hand
Always observe the old oil as it is removed A yellow
gray emulsion indicates the presence of water in the oil
Although this condition is rare it does require to prevent serious damage Call a competent
SPINON
OIL if water is present in the oil Raw water present
in the oil can be the result of a fault in the exhaust to the engine andor a siphoning of raw water
through the raw water cooling circuit into the the engine This problem is often caused by the
poor location of the syphon brake See WESTERBEKES
q Manual COOLER
NOTE Use genuine WESTERBEKE oil filters generic
filters are not REFILL THE OIL SUMP
Add fresh oil through the filler cap After refilling
the oil run the engine for a few moments while checking
the engines oil pressure Make sure there is no leakage
around the new oil filter or from the oil drain system and
then stop the engine Then check the quantity of oil with
OIL DRAIN HOSE
the lube oil dipstick If the engine requires additional oil
OIL CONTAINER fill to but not over the high mark on the dipstick
A WARNING Used engine oil contains harmful
contaminants Avoid prolonged skin contact Clean FULLra
skin and nails thoroughly using soap and water
LOW 1frI
Launder or discard clothing or rags containing used
oil Discard used oil THE OIL FILTER
When removing the used oil filter you may find it helpful
and cleaner to punch a hole in the upper and lower portion of
the old filter to drain the oil from it into a container it This helps to lessen spillage An automotive fil
ter wrench should be helpful in removing the old oil filter
Place some paper towels and a plastic bag around the
VVI WESTERBEKE
rEngines Generators
FUEL SYSTEM
FUEL WATER SEPARATOR
A WARNING Shut off the fuel valve at the tank A primary fuel filter of the water separating type must be
when servicing the fuel system Take care in installed between the fuel tank and the engine to remove
catching any fuel that may spill DO NOT allow any water and other contaminants from the fuel before they
smoking open flames or other sources of fire near can be carried to the fuel system on the engine
the fuel system when servicing Ensure proper venti
lation exists when servicing the fuel system Most installers include a type of filterwater separator
with the installation package as they are aware of the
problems that contaminants in the fuel can cause
FUEL FILTERS
The fuel injection pump and the fuel injectors are A typical fuel filterwater separator is illustrated in manufactured and they must
receive clean diagram This is the Raycor Model 500 MA Keep in
diesel fuel free from water and dirt To ensure this flow mind that if a water separator type filter is not installed
of clean fuel the fuel must pass through at least two fuel between the fuel supply tank and fuel
filters a fuelwater separator and the engines spinon fuel system any water in the fuel will affect the fuel pump
filter Visually inspect clean and change these filters engine filter and injection equipment The to the maintenance schedule in this manual
operator is responsible for making certain the fuel
reaching the engines injection equipment is free of
impurities This process is accomplished by installing
and maintaining a proper system
ORING
SPINON
FUEL FILTERWATER
L Shut fuel supply off
2 Loosen the fuel filter turning with
a filter wrench
3 Using a rag wipe clean the sealing face on the
housing bracket so the new filter can be seated
properly
4 Lightly oil the sealing Oring on the new filter
To reinstall turn the filter assembly carefully until the Oring contacts the sealing surface FUEL INJECTION PUMP CONTROL
of the housing bracket Turn 23 further with the filter The fuel injection pump is precisely adjusted most
wrench of the adjustments are sealed so be careful not to break
5 Turn on the fuel and manually prime the fuel filter them When an adjustment is necessary contact your
using the priming pump on top ofthe housing Use WESTERBEKE dealer
a slow steady pumping action until resistance is felt NOTE There is no warranty on engines with broken high
The filter is now primed and the engine is ready rpm governor adjustment seals
to start
NOTE The idle adjustment screw can be readjusted to pro
NOTE The cartridge contains fuel Take care not to spill vide for a satisfactory idle speed with each specific installa
it during disassembly Peiform the fuel system air after replacing the spinon filter
fVtTf WESJERBEKE
Engines Generators
FUEL SYSTEM
ADDITIVES
If fungus or bacteria is causing fuel problems you should
A CAUTION When using the preheat an authorized dealer correct these problems Then
keep in mind that the preheat elements glow plugs
use a diesel fuel biocide to sterilize the fuel follow the
are also energized take care not to overheat Once the fuel filter assembly is free of
air and the bleed
screw tightened use the preheat button or slowly pump
SPARES the primer pump for 10 to 20 seconds to force any air
While the likelihood of having to service the fuel system between the filter housing and injection pump out of the
at sea is slim the possibility does exist Therefore we system to the tank via the return that banjo washers injector seat washers
and a fuel filter be carried on board at all times See the In cases where excessive amounts of air exist in the
Spares And Accessories brochure Purchase needed fuel system follow the above procedure but in from your local WESTERBEKE dealer or
loosen all the high pressure injector lines not If a leak should develop at a banjo washer and crank the engine starter motor
as fuel spurts from
that cannot be corrected by a simple tightening of the between the nut and the line tighten the injector lines in
fitting replace the sealing washer with a replacement sequence and then tighten the bleed screw
found in the engine fuel hardware kit for your model NOTE Do not attempt this procedure on a hot BLEEDING THE FUEL SYSTEM
The onengine fuel system is virtually self priming
A WARNING Always wear protective clothing
safety glasses and gloves when bleeding high pres
Under ordinary circumstances the engines electric fuel
sure injector lines
lift pump which is energized by the key will supply a continuous flow of fuel from the
tank This fuel is drawn through the fuelwater separator AIR CLEANER
to the engine lift pump the primary spinon fuel filter Dual air cleaner filters are located on the top of the
and the injection pump engine manifold These filters should be inspected
cleaned andor replaced at maintenance periods With
the engine turned off remove the single hex bolt lift the
manifold top and the dual air cleaner filters become
accessible When reassembling make certain the filters
are positioned properly and do not overtighten when
refastening the bolt
FUEL LIFT PUMP
A WARNING 00 not allow smoking or open flames
near the fuel system when servicing Also provide
proper it becomes necessary to bleed air from the system use
the following the bleed screw by turning the thumbscrew on
the fuel filter 1 or 2 turns Energize the preheat button
key ON for 10 to 20 seconds or do it manually using
the palm of your hand to pump the primer pump on the
top of the fuel filter housing When fuel flows freely
AIR CLEANER
from the bleed screw tighten but do not screw
DC ELECTRICAL SYSTEM
DESCRIPTION
The charging system consists of an alternator with a mounted A WARNING Before starting the engine make certain
voltage regulator an engine DC wiring harness a mounted that everyone is clear of moving parts Keep away from
DC circuit breaker and a battery and connection wires sheaves and belts during test procedures
Because of the use of integrated circuits ICs the electronic
voltage regulator is very compact and is mounted internally
or on the back of the alternator 5 Start the engine
6 The voltage reading for a properly operating alternator
Alternator should be between 135 and 145 volts If your alternator
is over or have it repaired at a reliable
If you suspect that the alternator is not producing enough service shop
voltage to charge the engines battery check the following
NOTE Before removing the alternator for repair use your
voltmeter to ensure that i 2 volts DC excitation is present at
A WARNING Afailed alternator can become very the R terminal if the previous test showed only battery volt
hot 00 not touch until the alternator has cooled down age at the B output terminal
o Make certain your alternator is securely mounted 14 o Check the drive belts for proper tension
o Inspect for loose or disconnected wires at the alternator eF NOTE An isolator with a diode a solenoid or a battery 14 PINKJBlUE
tHH4I
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 the starting
battery but not the house battery the alternator is OK and
the problem is in the battery charging circuit
A WARNING Shut off the engine battery switch or TYPICAL 51 AMP
ALTERNATOR CONNECTIONS
disconnect from the battery when working on the engine
electrical system
14 Checking for Proper Voltage f10RED
14 If you suspect the alternator has failed perform the following
tests with the engine off
1 Using a voltmeter connect the voltmeter red wire clip to
the output terminal B
2 Connect the voltmeter negative wire to any ground on the
engine
3 Check the battery voltage It should read 12 to 12 volts
4 Check the voltage between the alternator positive ter
minal B and any engine ground If the circuit is good the
voltage at the alternator should be the same as the battery
l2I CCC3l 14 PINKJBlUE
unless theres an isolator in the circuit then the reading
would be zero rrJ 14 BROWN
A CAUTION To avoid damage to the battery charging
circuit never shut off the engine battery switch when
the engine is running
OPTIONAL 72 AMP
rvvl WESIERBEKE ALTERNATOR CONNECTIONS
I Engines Generators
DC ELECTRICAL
Continued
SYSTEM
DRIVE BELT ADJUSTMENT BATTERY CARE
Review the and then
A CAUTION Drive belts must be properly establish a systematic maintenance schedule for your
tensioned Loose drive belts will not provide proper engine starting batteries and house batteries
alternator charging and will eventually damage the
alternator o Monitor your voltmeter for proper charging during
engine operation
Drive belts that are too tight will pull the alternator
out of alignment andor cause the alternator to wear o Check the electrolyte level and specific gravity with a
out prematurely hydrometer
o Use only distilled water to bring electrolytes to a
Belt tension adjustment is made by pivoting the proper level
alternator on its base mounting bolt
o Make certain that battery cable connections are clean
1 Loosen the alternator adjusting strap bolt and the base and tight to the battery posts and to your engine
mounting bolt
o Keep your batteries clean and free of corrosion
2 Pivot the alternator on the base mounting bolt to the
left or right as required
3 Tighten the base mounting bolt and the adjusting
A WARNING Sulfuric acid in lead batteries can
cause severe burns on skin and damage clothing
strap bolt Wear protective gear
4 Operate the engine for about 5 minutes at idle then
shut down and recheck belt tension
A CAUTION Use only genuine WESTERBEKE Drive
Belts poor quality belts will lead to premature wear
and belt elongation resulting in alternator damage
BELT TENSION
II WESJERBEKE
I Engines Generators
DC ELECTRICAL SYSTEM
WIRING DIAGRAM 39144
110 R R
IU PHI
I Illl
MOOnS
i6i 11
SEE NOTE
BAnERY
NOTE
AN ONOFF SWITCH
SHOULD BE IN
STALLED BETWEEN ADMIRAL
THE BATIERY AND PANEL
STARTER TO DIS
CONNECT THE BAT
TERY IN AN EMER
GENCY AND WHEN
LEAVING THE BOAT
A SWITCH WITH OF 175
AMPS AT 12 VDC
WILL SERVE THIS
SWITCH SHOULD
NOT BE USED TO
MAKE OR BREAK
THE CIRCUIT
CAPTAIN
PANEL
o III ORN
Ia BlK I
118BlK I
L
111I8l11 JI
MTI WESJERBEKE
I Engines Generators
Revised
October 2000
DC ELECTRICAL SYSTEM
WIRING DIAGRAM 39144
AL TERIfATOR I
LIFT PUMP
I R TERM I fUn I
U jDacl
SOL I
0 III
SENDER I 1
12080 308ITI ONLY I
L I
NOTES
I THIS PRODUCT IS PROTECTED BT A MANUAL RESET CIRCUIT BRAKER LOCATEO NEAR THE
STARTER EXCESSIVE CURRENT WILL CAUSE THE BREAKER TO TRIP AND THE NGINE WILL
SHUT DOWIf THE aUILOEROWNER MUST BE SURE THAT THE INSTRUMENT PANEL IRING AND
NGIIf ARE INSTAllED TO PREVENT CONTACT BETWEN LEeTAICAL DEVICES AND SEAWATER
l AN ONOff SWITCH SHOULD BE INSTALLED BETWN THE IArTUY AND STARTER TO
DISCONNECT THE BATTERY IN AN MRGENCY AND WHN LEAVING THE SOAT A SWITCH
WITH A CONTINUOUS RATING or115 AMPS AT 11 YDC WILL SERVE THIS FUNCTION THIS
SWITCH SHOULD NOT SE USED TO MAlE OR BREAK THE CIRCUIT
3 THE PINK WIRE AT PLUG 2 IS UMUSD AND SHOULD 8E IrcULATD CAPTAIN PArcEL ONLY
THE GRAT WIRE AT PLUG 2 IS UNUSED AND SHOULD 8E INSULATED ADMIRAL PANEL ONLY
ADMIRAL
AT rACHONTER
PANEL MITSUBISHI 50 AMp ALT
NET S GND
110 RN
114 P R
II 4 GRA
90 AMP ALT
NOTE
WIRE rOR BATTERT ATTATCHMENT WILL NEED
TO BE UPGRADED TO AN 8 GAUGE FROM 10 GAUGE
IICTA
IU BRN
CAPTAIN
PANEL
LAMP
TEST
1104 PINK
n 03
51 AMP ALTERNATOR PRESTQLITE 72 AMP At T
STANDARD ALTERNATOR ON THE
mBlJi6Cc B IlI B2B
It 14 BRN
0UNIVERSAI PROPUlSION
PRESTOI I TE 51 AMP AL T
OPTIONAL AI TERNATORS
USA ISOA ItoA LESlU Q THE tsaR UItIY nrIY lOCIY eZltIY IOgYI lomYI ONP
vvl WESTERBEKE
I Engines Generators
Revised
21 October 2000
WATER HEATER
WATER HEATER INSTALLATIONS The pressure cap on the engines manifold should be in
This engine is equipped with connections for the plumb stalled after the engines cooling system is filled with
ing of engine coolant to heat an onboard water heater coolant Finish filling the cooling system from the remote
The water heater should be mounted in a convenient lo tank after the system is filled and is free of air and exhib
cation either in a high or low position in relation to the its good coolant circulation During engine so that the connecting hoses from the
heater to checking the engines coolant should be done at
the engine can run in a reasonably direct line without any the remote tank and not at the engine manifold cap The
loops which might trap air hose connection from the heater to the remote expansion
tank should be routed and supported so it rises continu
ously from the heater to the tank enabling any air in the
system to rise up to the tank and out of the system
J REMOTE EXPANSION
TANK 1124117
I I
I I
COOLER
HEATER BELOW THE ENGINE
Hoses should rise continuously from their low point at
the heater to the engine so that air will rise the heater to the engine If trapped air is able to rise
to the heater then an air bleed petcock must be installed
at the higher fitting on the heater for bleeding air while I
filling the system i
NOTE If any portion of the heating circuit rises above
the engines own pressure cap then a pressurized
HEATER ABOVE THE remote expansion tank Kit 024177 must
be installed in the circuit to become the highest point NOTE An air bleed petcock is located on the engines
Tee the remote expansion tank into the heater circuit heat exchanger Open this petcock when filling the en
choosing the higher of the two connections for the return gines fresh water system to allow air in the exchanger to
Tee at the heater and plumb a single line up to the tanks escape Close tightly after all the air is and the other back to the engines return
Install
the remote expansion tank in a convenient location
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 this tank serves the same II WESIERBEKE
I Engines Generators
ENGINE VALVE CLEARANCES 7 Using a small screwdriver or magnet remove the
adjusting disc
1 Remove the cylinder head rocker cover
8 Select an appropriate disc thickness depending on the
2 Manually rotate the engine crankshaft and bring 1
clearance measured Install it and verify proper
piston up on TDC of its compression stroke clearance
NOTE When this occurs the intake and exhaust cam
lobes will face upwards
EXAMPLE Intake Valve The thickness of the disc
removed plus the clearance measured minus the
standard clearance will give the thickness of the new
3 Measure the valve clearance of 1 cylinder by using a adjusting disc
thickness gauge 40 mm 030 025 mm 405 mm
0157 in 0012 0010 in 0159 in
Standard Valve Clearances Engine Cold
Intake 020 030mm 0008 0012 in
Exhaust 030 040mm 0012 0016 in
VALVE
CLEARANCE
NOTE The number marked on the disc indicates
its thickness Example 3825 means 3825mm 01056
in Adjusting discs are available in 25 different
thicknesses between 340 and 460mm 01339
01811 in range at variations of 0050 mm 0002
If the valves clearances are not within standard in
values continue using the following procedure to
adjust the valves 9 Measure and adjust as needed the valves in cylinders
3 4 and 2 following the instructions above
4 Rotate the valve cam lobe so that it points straight
upward
CAM Rotate the tappet so that one of the notches is facing
the exhaust manifold This allows for better access to
the adjusting disc
VALVE
6 Using the tappet holder WESTERBEKE 41978 CLEARANCE
press the tappet down to the position where the
adjusting disc becomes 23
ENGINE ADJUSTMENTS
BELT INSPECTION AND Timing Belt 1 Check the rotation
of the timing belt tensioner pulley
1 Before removing the timing belt and timing belt Check for play or abnormal noise
tensioner rotate the engine crankshaft by hand and
NOTE Do not clean the timing belt tensioner with clean
align the three timing marks as shown in the
ing solvents If dirty use a clean rag to wipe it clean
Avoid scratching the suiface the belt travels over
A CAUTION After removal of the timing belt
DO NOT rotate the crankshaft or camshaft the
pistons will damage the opened valves
OAMAGE
nMGAA
WEAR
OAMAGE
WEAR
I
TIMING
MARKS
Timing Belt Camshaft And Injection Pump Gears
1 Check the gear teeth for any indication of damage
wear deformation etc Replace if any faults are
found
NOTE If the timing belt is to be reused draw an arrow on
the belt pointing in the direction of the belts it in the same direction
Timing Belt Installation
1 Check to ensure that the timing marks on the gears
are properly aligned with the marks on the case
DIRECTION 2 Loosely install the timing belt tensioner locking bolt
ARROW and spring Push the timing belt tensioner toward the
lock bolt to the left as far as it will go and then tighten
the locking bolt to temporarily hold the tensioner
in Replace the timing belt if it is contaminated with oil
grease or water
2 Check for damage wear peeling cracks or
hardening Replace if suspect
LOCKING
BOLT
NOTE Never forcefully twist the timing belt turn it inside
out or bend it
TIMING BELT
TENSIONER
Il WESTERBEKE
I Engines Generators
ENGINE ADJUSTMENTS
Install the timing belt 7 Recheck the timing mark positions between the three
gears and the gear case Check the timing belt
NOTE If reinstalling the original belt be sure to deflection at the point on the belt shown in the
install with the arrow in the correct direction of belt
illustration with a pushing force of 10 kg 22Ib
rotation
Standard Deflection unit cold
108129 mm 043051 in
DIRECTION
ARROW
4 Release the timing belt tensioner lock bolt to allow
the tensioning spring tensionor to bring pressure on
the timing belt
8 Install the timing belt left cover with its rubber seal
9 Install the timing belt right cover with its rubber seal
Bolt torque for timing belt cover bolts
0710 mkg 57 ftIb
10 Install the crankshaft pulley and torsional damper
onto the timing belt drive gear with the semicircular
woodruff key Tighten the attachment
Crankshaft pulley bolt torque
2333 mkg 1724 ftIb
5 Turn the crankshaft twice in the direction of normal
engine rotation clockwise to equalize tension on the NOTE When installing the torsional damper onto the
timing belt timing belt drive gear align the mark on the damper
with the knock pin on the gear
NOTE Do not turn the engine in reverse of its normal
rotation
6 Tighten the timing belt tensioner lock bolt TIMING BELT
COVER RIGHT
Lock bolt torque 3247 mkg 2334 ftIb
TIMING BELT
COVER LEFT
IVVJ WESJERBEKE
r Engines Generators
ENGINE ADJUSTMENTS
TEST FUEL INJECTION NOZZLE TEST
1 Warm the engine up to operating temperature When the injection starting pressure is too high or too
low or the fuel spray pattern is improper an abnormal
2 Stop the engine
fuel combustion takes place in the engine leading to
3 Remove all four glow plugs lowered power output blackish exhaust smoke and un
wanted combustion noise Further it can cause a piston
4 Disconnect the DC power connection to the fuel
seizure or piston damage if not corrected In such cases
shutoff solenoid on the injection pump
the injection nozzle test should be performed and the
5 Install the compression tester glow plug adapter in faulty nozzles replaced as required
the gloy plug opening of 1 cylinder Connect the
Use an injection nozzle tester to check the static injection
compression gauge to the glow plug adapter
starting pressure and condition of the spray pattern every
6 Crank the engine with the starter and allow the gauge 800 operating hours
to reach its maximum reading
Injection nozzle pressure is 1920 psi 71 psi
7 Record the reading and proceed to the next cylinder 135 kgcm2 5 kgcm2
8 Compare readings to the table below Take corrective
action as needed A WARNING When testing a nozzle beware that
high pressure might blow off the light oil and cause
Compression pressure kgcm 2lbin2rpm injury Keep away from the nozzle end
Standard 30 426 200
Limit 27 384 200
GOOO the compression test shut off the
raw water supply to the engine mounted raw water pump
This is to prevent filling of the exhaust system with raw
water while peiforming the test
lvvl WESTERBEKE
I Engines Generators
HBW OPERATION LOCKING THE PROP
All HBW marine transmissions are testrun on a test Locking of the propeller shaft by an additional brake is
stand with the engine at the factory prior to delivery not required use the gear lever position opposite your di
For safety reasons the fluid is drained before shipment rection of travel for this purpose Never put the gear lever
in the position corresponding to the direction of travel of
Fill the gearbox with Automatic Transmission Fluid
the boat
DEXRON II or DEXTRON Ill The fluid level should be
up to the index mark on the dipstick To check the fluid
level just insert the dipstick do not screw it in Screw
CONTROL CABLES
the dipstick into the case after the fluid level is checked The gearbox is suitable for single lever remote control
and tighten Do not forget the sealing ring under the hex Upon loosening the retaining screw the shift lever can be
head of the dipstick Check for leaks and change the fluid moved to any position required for the control the first 25 hours
cable or rod linkage Make certain that the shift lever
does not contact the shift lever cover plate the minimum
TRANSMISSION
IN OPERATION distance between lever and cover should be O5mm
The control cable or rod should be arranged at a right
angle to the shift lever when in the neutral position The
neutral position of the operating lever on the control con
sole should coincide with the neutral position of the shift
lever on the gear box
The shifting travel as measured at the pivot point of the
shift lever between the neutral position and end 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
detrimental and is recommended However if the shift
lever travel is shorter proper clutch engagement might be
The neutral position of the operating lever on the control
impeded which in tum would mean premature wear ex
console must coincide with the neutral position of the
cessive heat generation and clutch plate failure lever on the transmission Shifting is initiated
would be indicated by slow clutch engagement or no
by a cable or rod linkage via the actuating lever and an
engagement at cam The completion of the gear changing op
eration is controlled within the gear NOTE Checkfor proper shift lever travel at least each
Gear changing should be smooth not too slow and con without Direct changes from for
ward to reverse are permissible since the permits gear changing at high rpm including sud
den reversing at top speeds in the event of danger
WHEN UNDER SAIL OR BEING TOWED
of the propeller without load such as when the
boat is sailing being towed or anchored in a river as
well as operation of the engine with the propeller stopped
for charging the battery will have no detrimental ef
fects on the When the boat is sailing engine stopped the gear
COVER PLATE HUB
lever must be in neutral position The propeller is at idle
and can free wheel
HBW TRANSMISSION
Continued
Checking the Bowden Cable or Rod Linkage
A CAUTION The position of the cover plate The Bowden cable or rod linkage should be checked at
underneath the actuating lever is to regular intervals Check the neutral position of the operat
ensure equal shift lever travel from neutral position ing lever on the control console and the actuating lever
to A and B If this side shift cover is removed or in on the gearbox The minimum lever travel from the
any way tampered with the transmission warranty neutral position to the operating positions 0 A 0 B
will be void Authorized Hurth personnel only may should be 35mm for the outer and 30mm for the inner
adjust or remove this cover pivot point Make certain that these minimum values are
safely reached Check the cable or rod linkage for easy
NOTE When installing the gearbox make certain that movability ad proper is not impeded by restricted movability of the
Bowden cable or rod linkage by unsuitably positioned
Connection of Gearbox with sheaves too small a bending radius etc In order
to mount a support for shift control cable connections HBW recommends a flexible connection between the
use the two threaded holes located above the shift cover gearbox and the propeller shaft if the engine is flexibly
on top of the gear housing Refer to the WESTERBEKE mounted in order to compensate for angular list
The installation of a special propeller thrust bearing is not
required since the propeller thrust will be taken by transmission bearing provided the value
specified under
is not exceeded However the Fluid shaft should be protected from additional loads Special
To ensure troublefree operation of the gearbox only care should be taken to prevent torsional vibration When
use Automatic Transmission Fluid ATF Dexron II using a universal joint shaft make certain to observe the
or Ill Even with the engine solidly
mounted the use of a flexi
ble coupling reduces stresses in the gearbox bearings
Add the fluid quantity for the proper model transmission caused by hull distortions especially in wooden boats or
to the gearbox After filling check the fluid level with where the distance between the gearbox output flange
the dipstick Adjust level as needed Install the dipstick and the stem gland is less than about 800mm
with the sealing washer operate unit check fluid check
for leaks
Transmission Fluid Quantity
HBW 150 059 Quarts 056 Liters
HBW 150V 110 Quarts 105 Liters
HBW250 184 Quarts 175 Change
Change the fluid for the first time after about 50 hours of
operation then every 250 operating hours or at least once
a year or when you change engine oil When changing
the fluid also check the gearbox cooling device and or replace it as necessary If the transmission is
not used for periods of more than
NOTE When changing the fluid take care not to lose the one year it should be completely filled with fluid of the
drain plug sealing washer The drain plug will leak with same grade to prevent corrosion Protect the input shaft
out this sealing washer and the output flange by means of an anticorrosive coat
ing as Il WESJERBEKE
I Engines Generators
BORG WARNER VELVET DRIVE
OPERATION NOTE If the boat moves backwards with the Fluid
control in the forward position shut off the engine This
problem may be the result of incorrect movement of the
Check transmission fluid level on the dipstick If the shift lever by the shift has not been filled fill with Dextron III and
continue to use this fluid During the first 50 hours of DAILY keep a lookout for any leakage at the bell
housing output shaft and transmission cooler This o Check transmission fluid
fluid should be changed after the first 50 hours and o Visually check transmission and gear shift every 1000 operating hours or at
o Start engine in neutral Allow a few minutes for fluid
to warm
NOTE Some transmissions are equipped with a switch Unless the transmission shift lever I per NOTE Too Iowan idle speed will produce a
aligned in neutral the engine starter will not noise from the gear and damper plate In such cases the
activate idle speed should be increased
o Shift into Into Gear
Place the transmission selector control in Neutral the engine Shifting from one selector position to
A WARNING Shifting gears above 1000 rpm can
damage the engine and selector position may be made at any time below
1000 rpm and in any order Shifts should be made at the
lowest practical engine speed Start the engine and st SHIFT LEVER POSITION
the throttle at idle speed allow the transmission fluid to The selector control mechanism and linkage must position
warm up for a few minutes the shift lever on the transmission exactly in Forward F
Neutral N and Reverse R shifting positions A ball located behind the transmission
shift lever must work
Move selector lever to the middle position You should
freely to center the lever in each position The selector con
feel the detent Center the shift lever on the transmission
trol positions at the helms must be coordinated with those
through the linkage to the selector lever With the control
of the Velvet Drive shift lever through shift mechanism ad
in this position hydraulic power is completely interupted
justments An improperly adjusted shift mechanism can
and the output shaft of the transmission does not turn
cause damage to the transmission The shifting and transmission shift lever should be free of
dirt to ensure
Move selector lever to the forward position You should proper the detent The shift lever on the transmission is in
the forward position The output shaft and the propeller
NOTE Do not remove detent ball
shaft move the boat in a forward selector lever to the reverse position You should
feel the detent The shift lever on the transmission is in
the reverse position The output shaft and the move the boat in a reverse direction Moving the transmission shift lever from to Forward is always
towards the engine Re
FORWARD NEUTRAL REVERSE
verse is always away from the engine
NOTE Be aware of any unusual noises or vibrations to determine the cause
lvvl WESIERBEKE
I Engines Generators
BORG WARNER VELVET DRIVE
TRANSMISSION OIL FILLER CAP
D Visually check for oil leaks at hydraulic connections AND DIPSTICK
ASSEMBLY
Check wear on hydraulic lines and replace if worn
D Lubricate detent ball and shift cable attachments
OIL FILLER CAP
D Inspect shift linkage AND DIPSTICK M
ASSEMBLY HOLE
D Inspect transmission bolts retorque if necessary
A CAUTION Clutch failure will occur if the trans
mission shift lever does not fully engage the detent
ball positions
Transmission Fluid Storage requires special care Follow these the initial 50 hour change the transmission fluid
D Drain water from the transmission oil cooler and
should be changed at 1000 operating hours or at winter replace with a proper mixture of antifreeze However fluid must be changed whenever
it NOTE This operation will occur normally when the
becomes contaminated changes color or smells rancid engine raw water cooling system is properly winterized
D Remove oil filler cap and dipstick D Clean up the transmission and touch up unpainted
D Remove oil cooler return line and allow oil to drain areas use heat resistant paint
into a container D Fill the transmission with Dextron II or III fluid to
prevent internal corrosion
D Reconnect oil cooler return line
D Loosen attaching hardware from the Use a suction pump to remove transmission oil output flange and propeller shaft coupling
flange
through the filler capdipstick hole before removing the boat from the water Separate
D Clean off the transmission and properly dispose of the flanges
the used fluid D Spray the flanges with an anticorrosive coating
D Refill the transmission with Dextron II or III trans WARRANTY NOTES
mission fluid The quantity will vary depending on
Service manuals are available from your BORG
the transmission model and installation angle Fill
WARNER dealer
through the dipstick hole
BORG WARNER is aware of the shock loads that can be
D Check dipstick for proper fluid level placed on its gears as the result of mechanical propeller
D Replace oil filler capdipstick Dipstick is pressed operation or fully reversing of propeller blades while
into place and turned clockwise until shifting Therefore torque loads and directional changes
should be made at low engine speeds If it is found that
D Run engine then shutdown and recheck fluid level the failure was caused by a shock load the warranty
claim will be denied
A WARNING Never pull the dipstick with the en Oil temperature maximum is 190F 105C during
gine running Hot fluid will splash from the dipstick operation If oil temperature runs too high consult your
hole This could cause severe burns BORG WARNER A
CAUTION noises or vibrations
can occur at low engine speeds which can cause
gear ranle resulting in damage to the engine andor
transmission BORG WARNER is not responsible for
total torsional vibration of this type
tvv WESIERBEKE
Engines Generators
ENGINE following table describes certain NOTE The engines electrical system is protected by a
problems the probable causes of the problems and the 20Ampere manual reset circuit breaker located on to overcome the
problems bracket on the left front side of the engine The preheat
solenoid is mounted on the same bracket
Problem Probable Cause Key Switch on PREHEAT switch 1 Battery
switch not on 1 Check switch andor battery connections
depressed no panel indications
fuel solenoid electrical fuel pump 2 20Amp circuit breaker tripped 2 Reset breaker if breaker trips again check preheat sole
and preheat solenoid not energized noid circuit and check circuit for shorts to ground
3 10 Amp breaker tripped 3 Check voltage at and after breaker
4 Loose battery connections 4 Check connection on starter solenoid and connection to
engine ground stud Check battery cable connections
5 Preheat solenoid not operating 5 Check Solenoid
Key Switch on PREHEAT switch 1 Connection to solenoid faulty 1 Check connection at solenoid
depressed START switch
depressed no starter engagement 2 Faulty START switch 2 Check switch with ohmmeter
3 Faulty solenoid 3 Check that 12 volts are present at starter solenoid
activation connection
4 Neutral safety switch open 4 Shift lever in neutral check switch
5 Loose battery connection 5 Check battery connection
S Low batteries 6 Check battery charge state
START switch is depressed panel 1 Poor connections to fuel solenoid 1 Check connections
indications OK start 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
No ignition 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 engine fuel
system
1b Filters clogged Replace filters and bleed fuel system of air
2 Preheat solenoid faulty 2 Check solenoid
No ignition Fuel solenoid energized 1 Starting battery failure 1 Check start batteries
Engine cranks slowly then fails
1a Switch to combine house and start batteries
1b Replace batteries
2 Water in engine 2 Exhaust system failure raw water has backed into cylin
ders Water must be removed from engine a serious
problem that can be corrected
Engine cant be stopped 1 STOP switch failure 1 Check switch will not open run circuit Manually move the
shutoff lever on the injection pump side Test switch with
ohmmeter
2 Fuel run solenoid will not deenergize 2a Manually disconnect the 12 volt connection to the fuel run
solenoid at the injection pump
2b Loosen high pressure injector lines at each injector Be
ware of fuel spray
3 Check DC alternator for feedback 3 Disconnect the R terminal
through regulator circuit
Engine 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 or dis 2 Inspect all wiring for short circuits and loose connections
connected Inspect switches for proper operation
3 Fuel Starvation 3 Check fuel supply fuel valves fuel lift pump
4 20amp circuit breaker tripping 4 Check for high DC amperage draw during operation En
sure switch 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
Battery not charging 1 Alternator drive 1 Check drive belt tension Alternator should turn freely
Check for loose connections Check output with voltmeter
Il WESJERBEKE
I Engines Generators
ENGINE Continued
Ensure 12 volts are present at the R terminal
Problem Probable Cause Battery runs down 1 Oil pressure
switch 1 Observe if gauges and panel lights are activated when en
gine is not running Test the oil pressure switch
2 High resistance leak to ground 2 Check wiring Insert sensitive 025 amp meter in battery
lines Do not start engine Remove connections and re
place after short is located
3 Low resistance leak
3 Check all wires for temperature rise to locate the fault
4 Alternator 4 Disconnect alternator at output after a good battery
charging If leakage stops remove alternator and bench
test Repair or replace
5 Poor battery connections 5 Check cable connections at battery
Engine overheat 1 Raw water not Circulating 1 Broken or loose belt at raw water pump
NOTE Shut engine down immediately 2 Coolant not circulating 2 Raw water pump failure Check impeller replace
2a Obstruction at raw water intake or raw water filter
2b Thermostat remove and test in hot water Replace
thermostat
2c Loss of coolant check hoses hose clamps drain plug
etc for leaks
2d Broken or loose belts 2e Air leak in system run engine
and open cooling system
petcocks heat exchanger manifold etc to bleed air
Add coolant as needed
Exhaust smoking problems 1 Blue smoke 1 Incorrect grade of engine oil
1a Crankcase overfilled with engine oil
oil is blowing out through the exhaust
2 White smoke 2 Engine is running cold
2a Faulty injector or incorrect injector timing
3 Black or gray smoke 3 Improper grade of fuel
3a Fuel burn incomplete due to high back pressure in exhaust
or insufficient air for proper combustion Check for re
strictions in exhaust system check air intake
3b Improperly timed injectors or valves or poor compression
Transmission will not shift in or out 1 Transmission failure 1a Check cable connections at steering station and at trans
of gear or drive the vessel mission lever
1b Check transmission fluid
1c Check shaft couplings or engine damper plate
1d Check drive damper
2 Transmission oil cooler failure 2a Replace oil cooler
WATER TEMPERATURE AND OIL PRESSURE GAUGES
If the gauge reading is other than what is normally If both of the above gauge tests are positive the gauge is
indicated by the gauge when the instrument panel is undoubtedly OK and the problem lies either with the first step is
to check for 12 volts DC conductor from the sender to the gauge or with the
between the ignition B and the Negative B of the gauge
If either of the above gauge tests are negative the that there is 12 volts as required leave the is probably defective
and should be panel energized and perform the following
Assuming the gauge is OK check the conductor from the
steps
sender to the sender terminal at the gauge for Disconnect the sender wire at the gauge and see if the
Check that the engine block is connected to the ground
gauge reads zero which is the normal reading for this
Some starters have isolated ground terminals and if the
situation
battery is connected to the starter both plus and minus
2 Connect the sender terminal at the gauge to ground terminals the ground side will not necessarily be
and see if the gauge reads full scale which is the connected to the block
normal reading for this situation
1VV1 WESJERBEKE
I Engines Generators
LAYUP AND small amount of oil on the rubber sealing gasket at the
Many owners rely on their boatyards to prepare their base of the filter Fill the sump with the correct including engines and generators
for layup during of oil for your engine model Refer to the offseason or for long periods of inactivity Others TIONS section of this
manual Use an oilwith an API
prefer to accomplish layup preparation themselves specification of CF or CG4 Run the engine and check for
proper oil pressure and make sure there are not leaks
The following procedures will allow you to perform your
Stop the engine check oil level and add oil as needed to
own layup and or you may use them
bring level to dipstick full mark
as a check list for others These procedures should afford
your engine protection during a layup and also you with the maintenance needs of your en ACAUTION Do not leave the engines old engine
gine oil in the sump over the layup period Engine oil and
combustion depOSits combine to produce harm
If you have any questions regarding layup procedures
ful chemicals which can reduce the life of the en
call your local servicing dealer he will be more than
gines internal to provide SHAFT COUPLING FUEL SYSTEM
The transmission and propeller half couplings should al Top off your fuel tanks with No2 diesel fuel Fuel addi
ways be opened up and the bolts removed when the boat tives should be added at this time to control algae and a
is hauled out of the water or moved from land to water fuel conditioner such as STABIL Care should be taken
and during storage in a cradle The flexibility of the boat that the additives used are compatible with the primary
often puts a severe strain on the propeller shaft or cou filterwater separator used in the system Change the
pling or both while the boat is taken out or put in the element in your primary fuel filterwater separator if
water In some cases the shaft has actually been bent by the fuel system contains one and clean the strains This does not apply to small
boats that are sediment bowl
hauled out of the water when not in use unless they have Change the fuel filter elements on the engine and bleed
been dry for a considerable period of time the system as needed Start the engine and allow it to run
for 510 minutes to make sure no air is left in the fuel
FRESH WATER COOLING SYSTEM system Check for any leaks that may have been created
A 5050 solution of antifreeze and fresh water is recom in the fuel system during this servicing correcting them
mended for use in the freshwater cooling system at all as This solution may require a higher antifreeze depending on the areas winter
climate RAW WATER CIRCUIT
Check the solution to make sure the antifreeze protection Close the throughhull fitting Remove the raw water in
is adequate take hose from the fitting Place the end of this hose into
Should more antifreeze be needed drain an appropriate a 5gallon bucket of clean fresh water Before starting the
amount from the engine block and add a more concen engine check the zinc anode found in the heat mixture Operate the engine to ensure
a complete on the engine and clean or replace it as required and mixture of the antifreeze concentration the raw water strainer
if one is installed in the inside of
throughout the cooling system Now recheck the anti the hull
freeze solutions strength Start the engine and allow the raw water pump to draw
fresh water through the system When the bucket SYSTEM empty stop the engine and refill the bucket
with an anti
With the engine warm drain all the engine oil from the freeze solution slightly stronger then needed for winter
oil sump Remove and replace the oil filter Place some freeze protection in your area
paper towels and a plastic bag around the filter to catch
Start the engine again and allow all of this mixture to be
the oil during its removal
drawn through the raw water system Once the bucket is
When installing the new oil filter be sure to apply a empty stop the engine This antifreeze mixture should
tvvl WESTERBEKE
I Engines Generators
LAYUP AND the raw water circuit from freezing during the layup as well as providing corrosion
protection If batteries are to be left on board during the layup pe
Rempve the impeller from your raw water pump some anti riod make sure they are fully charged and will remain
freeze mixture will accompany it so catch it in a bucket that way to prevent them from freezing If you have any
Examine the impeller Acquire replacement if needed doubt that the batteries will not remain fully charged or
that they will be subjected to severe environmental con
and a cover gasket Do not replace the impeller into the
ditions remove the batteries and store them in a warmer
pump until but replace the cover and
more compatible MANIFOLD AWARNING Lead acid baneries emit hydrogen a
Open the intake manifold and inspect the filter elements
highly explosive gas which can be ignited by elec
trical arcing or lighted tobacco products Do not
inside Clean with low pressure compressed air or replace
smoke or allow an open flame near the banery being
if needed Do not leave filters installed during
serviced Shut off all electrical period Filter elements should be stored in a clean
in the vicinity to prevent electrical arcing during
dry area Place an oil rag in the intake opening to keep
servicing Wear rubber gloves a rubber apron and
dampness out eye protection when servicing MOTOR
and cleaning of the starter drive pinion is
advisable if access to the starter permits its removal The of your WESTERBEKE engine
Make sure the battery connections are shut off before at after a seasonal layup generally follows the same to remove the starter Take care
in properly re dures as those presented in the PREPARATION FOR
STARTING section regarding preparation for starting and
placing any electrical connections removed from the
normal starts However some of the layup will need to be counteracted before
starting the LUBRICATION 1 Remove the oilsoaked cloths from the intake mani
fold and from the throughhull exhaust port
It is not necessary to remove the glow plugs from the
cylinder head to squirt light engine oil into the cylinders 2 Remove the raw water pump cover and gasket Dis
for the few months of normal layup However if you card the gasket Install the raw water pump impeller a longer layup period 12 months
or more moved during layup or a replacement if required
we recommend that this procedure be performed The Install the raw water pump cover with a new cover gas
light oil in the cylinders will prevent the pistons rings ket
from sticking to the cylinder walls With oil in the cylin 3 Reconnect the shaft coupling and check for proper
ders tum the engine over by hand two revolutions alignment
4 Reinstall the batteries that were removed during layup and reconnect the battery cables
making sure the
Check or change fluid in the transmission as required terminals are clean and that the connections are tight
Wipe off grime and grease and touch up unpainted areas Check to make sure the batteries are fully coupling and output flange with
5 Check the condition of the zinc anode in the raw wa
coating Check that transmission vent is open
ter circuit and clean or replace the anode as needed Note
that it is not necessary to flush the water solution from the raw water coolant system
When
Layup time provides a good opportunity to inspect your the engine is put into operation the system will engine to see if external items
such as in a short period of time with no adverse belts or coolant hoses need replacement Check
6 Start the engine in accordance with procedures in the
your basic spares kit and order items not on hand or re PREPARATION FOR INITIAL STARTUP section of this
place those items used during the layup such as filters manual
and zinc anodes
VVI WSJERBEKE
I Engines GeneratolS
WESTERBEKE 55A FOUR
TORQUE Ibft Head Bolts Cylinder
head bolts are not
retorqued Bolts are torqued
only during engine Rod Cap Bolts 5154 7075
Main Bearing Cap Bolts 6165 Pump Drive Gear 4352
6070
Oil Pan Bolts 57 Pulley Bolts 1724
2333
Glow Plugs 1115 Manifold Bolts 1220
Manifold Bolts 1620 and Senders 913
HIP Line Nuts 1317 Pump Mounting Bolts 2334 Belt
Covers 57 Bolts 130137 Cap Bolts
1520 2027
Block Oil Jets 913 Cover Bolts 57
0710
Back Plate Bolts 1217 1623
Rear Oil Seal Housing 57 0710
Oil Strainer PickUp 57 Belt Drive Gear Bolt 116123
Assembly 1217 1623
Oil Cooler Assembly Bolts MIO 2324 3247
M6 57 0710
lvvl WESJERBEKE
I Engines Generators
STANDARD HARDWARE TORQUES
NOTE Unless stated otherwise for a specific assembly use the
following torque values when tightening standard hardware
Pitch lbft kgm
Grade 4
6mm bolt headnut 1 2951 0407
8mm bolt headnut 125 72116 1016
10mm bolt headnut 125 137224 1931
10mm bolt headnut 15 130217 1830
12mm bolt headnut 125 ISO 253398 3555
12mm bolt headnut 15 253398 3555
12mm bolt headnut 175 217362 3050
13mm bolt headnut 15 325506 4570
14mm bolt headnut 15 362579 5080
14mm bolt headnut 2 340557 4777
16mm bolt headnut 15 542796 75110
16mm bolt headnut 2 514767 6mm bolt headnut 1 4365 0609
8mm bolt headnut 125 108159 1522
10mm bolt headnut 125 217325 3045
IOmm bolt headnut 15 195304 2742
12mm bolt headnut 125 ISO 362579 5080
12mm bolt headnut 15 362506 5070
12mm bolt headnut 175 347492 7T 8T and 88
6mm bolt headnut 1 5887 0812
8mm bolt headnut 125 145217 2030
IOmm bolt headnut 125 289398 4055
10mm bolt headnut 15 268376 3752
12mm bolt headnut 125 ISO 542759 75105
12mm bolt headnut 15 506651 7090
12mm bolt headnut 175 434615 6085
13mm bolt headnut 15 579868 80120
14mm bolt headnut 15 7231085 100150
14mm bolt headnut 2 6871013 95140
16mm bolt headnut 15 10851664 150230
16mm bolt headnut 2 10131591 5 Cap Screw
114 UNC 911 1215
114 UNF 1113 1518
5116 UNC 1820 2528
5116 UNF 2123 2932
38 UNC 2833 3746
38 UNF 3035 4148
716 UNC 4449 6168
716 UNF 5055 6976
1I2UNC 6873 94101
112 UNF 7380 101111
lvvl WESJmBEKE
r Engines Genetors
WESTERBEKE 55A FOUR ENGINE COOLING SYSTEM
Engine Type Diesel fourcycle freshwater General block cooled vertical
inline 55 hp at 3600 rpm controlled with raw water exchanger system
maximum
Operating Temperature 170 190F 77 Integral of the injection pump mechanical
flyweig ht type Fresh Water Pump Centrifugal type metal impeller Mechanism Overhead
Sea Water Pump POSitive displacement rubber impeller
belt Chamber Swirl chamber type
Sea Water Flow at 3600 rpm 160 gpm 605 Ipm Stroke 338 x 370 inches 860 x 940 mm measured before Displacement
1332 cubic inches 218 liters ing into exhaust elbow
Firing Drder 1342 System Capacity 95 US qts 100 liters
fresh of Rotation Clockwise when viewed from the front
Maximum Torque 93 Ibft 129 kgm ELECTRICAL SYSTEM
at 1920 rpm Starting Battery 12volt negative Ratio
227 1 Battery Capacity 300 400 Cold Cranking amps CCA Pressure 427 psi 3D kgcm2
at 200 rpm
Starter Motor 12volt 16kw solenoid actuated shift
Valve Seat Angle Intake 45 Exhaust 45 reduction gear
Valve Clearance Intake 008 0012 in020 030mm Starting Aid Glow plug
engine cold Exhaust 0012 0016 in 030 040mm
DC NoLoad Current 100 amps at 115 volts 3000 rpm Height 2678 inches 6802 mm
Width 500 inches 5461 mm Cold Cranking Current 280 300 amps at 10 volts 250 rpm min
Length 350 inches 8890 mm
Alternator Standard 12volt DC 50 Continuous 14 Temporary 25
not to exceed 30 min Regulator Internal regulator built into Weight 470 Ibs
2132 kgs Speed Idle speed 750 1000 rpm
General Hurth Standard Transmission Case
Cruising speed 2500 3000 rpm hardened helical gears with a servo
No load 4200 4500 rpm operated multiple disc clutch
Fuel Consumption 15 US gph 56 Iph running at 2500 rpm Gear ratio standard 274 1 HBW250 3R
approximate when the propeller allows
3600 rpm at full open throttle while Propeller Shaft Direction Right handed standard transmission
unerway in forward gear of Rotation
Propeller 20 Dx 13 P 2 blade or 20 Dx 11 P 3 blade
FUEL SYSTEM using standard transmission propeller should allow the engine to reach its
2741 reduction full rated rpm 3600 000 100 at full
Fuel No2 diesel oil open throttle while underway in
forward
cetane rating of 45 or higher Pump Zexel mechanical governed
Lubricating Fluid ATF type A or Dextran I OR 11
Injection Timing OOTDC Transmission Sump 079 US qts 075 liters approximate
Th rottle Pressure 1920 psi 71 psi
ENGINE OIL SYSTEM
135 kgcm 2 5 kgcm2
General Pressure feed rotor type driven by spiral
Lift Pump 12 volt plunger type gears from camshaft
Fuel Filter on engine Spinon type replaceable Oil Filler Full flow paper element spinon type
Air Cleaner Replaceable paper filter element Sump Capacity 45 US qts 59 liters including
filter
Air Flow Operating Oil Pressure 30 60 psi 21 42 kgcm2 at
combustion 140 cfm 39 cmm at 3600 rpm engine rpm and at normal cooling
250 cfm 70 cmm temperature
Oil Grade API Specification CF or CG4
EXHAUST Elbow 45 elbow
Exhaust Hose Size 212 inch 10 hose
Muffler Size min 14 inch x 14 inch
IVtTI WESJERBEKE
Engines Generators
Revised
October 2000
WESTERBEKE CORPORATION AVON INDUSTRIAL PARK
AVON MA 02322 TEL 508 5887700 FAX 508 5599323
Member National Marine

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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.