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Westerbeke Diesel 35c Three Technical Manual




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LP MANUAL
FOR THE
44A FOUR 35C THREE
AND THE
448 FOUR 350 THREE
MARINE DIESEL ENGINES
PUBLICATION NO 44180
2nd Edition I October 2001
WESTERBEKE CORPORA TION 150 JOHN HANCOCK ROAD
MYLES STANDISH INDUSTRIAL PARK TAUNTON MA 02780
WEBSITE AIIIl Mmber Nali01llll MIlIiM ArociDlion
CALIFORNIA
PROPOSITION 65 WARNING
Diesel engine exhaust and some
of its constituents are known to
the State of California to cause
cancer birth defects and other
reproductive harm
A gasses contain Carbon Monoxide an odorless and
colorless gas Carbon Monoxide is poisonous and can and death Symptoms of Carbon can Throbbing in Muscular
Vomiting
Weakness and Sleepiness Inability to Think YOU OR ANYONE ELSE EXPERIENCE ANY OF THESE SYMPTOMS
GET OUT INTO THE FRESH AIR IMMEDIATELY If symptoms persist
seek medical attention Shut down the unit and do not restart
until it has been inspected and repaired
SAFETY PREVENT BURNS FIRE
Read this safety manual carefully Most accidents are
caused by failure to follow fundamental rules and precau A WARNING Fire can cause injury or death
tions Know when dangerous conditions exist and take the
necessary precautions to protect yourself your personnel Prevent flash fires Do not smoke or permit flames or
and your machinery sparks to occur near the carburetor fuel line filter fuel
The following safety instructions are in compliance with pump or other potential sources of spilled fuel or fuel
the American Boat and Yacht Council ABYC standards vapors Use a suitable container to catch all fuel when
removing the fuel line carburetor or fuel ELECTRIC SHOCK Do not operate with a Coast Guard
Approved flame
arrester removed Backfire can cause severe injury or
death
A WARNING 00 not touch AC electrical connections Do not operate with the air removed
while engine is running or when connected to shore Backfire can cause severe injury or death
power Lethal voltage is present at these connections Do not smoke or permit flames or sparks to occur near
the fuel system Keep the compartment and the
Do not operate this machinery without electrical clean and free of debris to minimize the
enclosures and covers in place chances of fire Wipe up all spilled fuel and engine oil
Shut off electrical power before accessing electrical Be aware diesel fuel will bum
equipment
Use insulated mats whenever working on electrical PREVENT BURNS EXPLOSION
equipment
Make sure your clothing and skin are dry not damp
particularly shoes when handling electrical equipment
A WARNING Explosions from fuel vapors can cause
injury or death
Remove wristwatch and all jewelry when working on
electrical equipment Follow refueling safety instructions Keep the vessels
Do not connect utility shore power to vessels AC hatches closed when fueling Open and ventilate cabin
circuits except through a shiptoshore double throw after fueling Check below for fumesvapor before run
transfer switch Damage to vessels AC generator may ning the blower Run the blower for four minutes before
result if this procedure is not followed starting your engine
Electrical shock results from handling a charged capaci All fuel vapors are highly explosive Use extreme care
tor Discharge capacitor by shorting terminals together when handling and storing fuels Store fuel in a wellven
tilated area away from equipment and
PREVENT BURNS HOT ENGINE out of the reach of children
Do not fill the fuel tanks while the engine is running
A WARNING 00 not touch hot engine parts or Shut off the fuel service valve at the engine when serviCing
the fuel system Take care in catching any fuel that might
exhaust system components A running engine gets spill DO NOT allow any smoking open flames or other
very hot sources of fire near the fuel system or engine when servic
ing Ensure proper ventilation exists when servicing the
Always check the engine coolant level at the coolant fuel system
recovery tank
Do not alter or modify the fuel system
Be sure all fuel supplies have a positive shutoff valve
A WARNING Steam can cause injury or death Be certain fuel line fittings are adequately tightened and
free of leaks
In case of an engine overheat allow the engine to cool Make sure a fire extinguisher is installed nearby and is
before touching the engine or checking the coolant 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
Make certain all personnel are clear of the engine before attention to the manifold water injection elbow and
starting exhaust pipe nipple
Make certain all covers guards and hatches are re Be sure the unit and its surroundings are well ventilated
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 infonnation refer to ABYC T22 educa
A WARNING Battery explosion can cause injury tional infonnation on Carbon Monoxide
or death
Do not smoke or allow an open flame near the battery A WARNING Carbon monoxide CO is an invisible
being serviced Lead acid batteries emit hydrogen a odorless gas Inhalation produces flulike symptoms
highly explosive gas which can be ignited by electrical nausea or death
arcing or by lit tobacco products Shut off all electrical
equipment in the vicinity to prevent electrical arcing dur Do not use copper tubing in diesel exhaust systems Diesel
ing servicing fumes can rapidly destroy copper tubing in exhaust sys
Never connect the negative battery cable to the posi tems Exhaust sulfur causes rapid deterioration of copper
tive connection terminal of the starter solenoid Do tubing resulting in exhaustwater leakage
not test the battery condition by shorting the terminals Do not install exhaust outlet where exhaust can be drawn
together Sparks could ignite battery gases or fuel vapors through portholes vents or air conditioners If the engine
Ventilate any compartment containing batteries to prevent exhaust discharge outlet is near the waterline water could
accumulation of explosive gases To avoid sparks do not enter the exhaust discharge outlet and close or restrict the
disturb the battery charger connections while the battery flow of exhaust Avoid overloading the craft
is being charged
Although diesel engine exhaust gases are not as toxic as
Avoid contacting the tenninals with tools etc to prevent exhaust fumes from gasoline engines carbon monoxide
burns or sparks that could cause an explosion Remove gas is present in diesel exhaust fumes Some of the symp
wristwatch rings and any other jewelry before handling toms or signs of carbon monoxide inhalation or poisoning
the battery are
Always tum the battery charger off before disconnecting Vomiting Muscular twitching
the battery connections Remove the negative lead first
Dizziness Intense headache
and reconnect it last when disconnecting the battery
Throbbing in temples Weakness and ACID
AVOID MOVING PARTS
A WARNING Sulfuric acid in batteries can cause A WARNING Rotating parts can cause injury
severe injury or death
or death
When servicing the battery or checking the electrolyte
level wear rubber gloves a rubber apron and eye protec Do not service the engine while it is running If a situa
tion Batteries contain sulfuric acid which is destructive tion arises in which it is absolutely necessary to make
If it comes in contact with your skin wash it off at once operating adjustments use extreme care to avoid touch
with water Acid may splash on the skin or into the eyes ing moving parts and hot exhaust system components
inadvertently when removing electrolyte caps
Engines Generators
SAFETY Do not wear loose clothing or jewelry when servicing ABYC NFPA AND USCG PUBLICATIONS FOR
equipment tie back long hair and avoid wearing loose
jackets shirts sleeves rings necklaces or bracelets that
INSTALLING DIESEL ENGINES
could be caught in moving parts Read the following ABYC NFPA and USCG publications
for safety codes and standards Follow their recommenda
Make sure all attaching hardware is properly tightened
tions when installing your engine
Keep protective shields and guards in their respective
places at all times ABYC American Boat and Yacht Council
Safety Standards for Small Craft
Do not check fluid levels or the drive belts tension while
the engine is operating Order from
Stay clear of the drive shaft and the transmission coupling ABYC
when the engine is running hair and clothing can easily 3069 Solomons Island Rd
be caught in these rotating parts Edgewater MD 21037
NFPA National Fire Protection NOISE Fire Protection Standard for Motor Craft
Order from
A WARNING High noise levels can cause hearing NFPA
loss 11 Tracy Drive
Avon Industrial Park
Never operate an engine without its muffler installed Avon MA 02322
Do not run an engine with the air intake silencer USCG United States Coast Guard
removed USCG 33CFR183
Do not run engines for long periods with their enclosures Order from
open
US Government Printing Office
Washington DC 20404
A WARNING Do not work on machinery when you are
mentally Dr 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 to install an engine should begin with a thor
ough examination of the American Boat and Yacht standards These standards are a combination of
sources including the USCG and the of the ABYC standards of particular interest are
H2 Ventilation
Pl Exhaust systems
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 will be below the vessels waterline provisions must be made to install a siphon
break in the raw water supply hose to the exhaust elbow This hose must be looped a
minimum of 20 above the vessels waterline Failure to use a siphonbreak when
the exhaust manifold injection port is at or below the load waterline will result in
raw water damage to the engine and possible flooding of the boat
If you have any doubt about the position of the exhaust elbow relative
to the vessels waterline under the vessels various operating conditions install A siphonbreak requires periodic inspection and cleaning to ensure
Failure to properly maintain a siphonbreak can result in damage Consult the siphonbreak manufacturer for proper 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 Water Heater DC Electrical System 25
Warranty Procedures 3 Alternator 25
Serial Number Location 4 Battery 26
Control Panels Wiring 27
Admirals Panel 5 Engine Captains Panel 6 Tachometer Fuel Engine Oil and Engine Coolant 7 Engine
Adjustments Oil Pressure 7 Testing Engine Compression for Initial StartUp 8 Fuel Injectors 35
Valve Adjustments Procedure Lights Alarms and Circuit Breaker 10 JS and BW Transmission 37
Engine Breakin Procedure 11 Borg Warner Velvet Drive Transmission 39
The Daily Operation Hurth HBW Transmission 42
RPMs Guide 12 PRM Newage Transmissions Schedule 13 Transmission 47
Cooling System 15 Propeller Chart 48
Thermostat 16 LayUp an d R 49
Raw WaterPump 16 44 Four Engine 51
Heat Exchanger 17 35 Three Engine 52
Air 18
Fuel System 19 44 Four and 35 Three Torque 53
Fuel Lift Pump 19 Standard Hardware Fuel Filters 19 Sealants Lubricants Fuel Water Separator 16 Standard and
Metric Conversion Data 55
Clow Plugs 20 Suggested Spare Parts Lubricating Oil Spare Parts Kits Oil Change 21
Oil Pressure 22 European Maritime Council Registration 57
Remote Oil Filter 23
Engines Generators
PARTS 44A FOUR35C THREE
COOLANT PRESSURE CAP
WATER INJECTED
EXHAUST ELBOW THERMOSTAT
ASSEMBLY
20ACIRCUIT
BREAKER
WATER HEATER
REAR
FRONT
SIDE OIL FILL
ZINC
ANODE OIL FILTER
OIL COOLER
RIGHT SIDE
AIR INTAKEAIR FILTER
OIL FILL
FRONT
PREHEAT SOLENOID
DC ALTERNATOR
FUEL FILTER
RAW WATER PUMP
REAR
UNIT ID PLATE START MOTOR
LEFT SIDE
ATFDRAIN
Engines Generators
WESTERBEKE Diesel Engine is a product of PRODUCT long years of experience and advanced Product software
technical data parts lists We take great pride in the superior durability and brochures and catalogs provided from sources other performance
of our engines and generators WESTERBEKE are not within WESTERBEKEs you for selecting WESTERBEKE
WESTERBEKE CANNOT BE RESPONSIBLE FOR THE
In order to get the full use and benefit from your engine it is CONTENT OF SUCH SOFIWARE MAKES NO that you operate and maintain it correctly
This RANTIES OR WITH is designed to help you do this Please read this man THERETO INCLUDING ACCURACY TIMEliNESS OR
ual carefully and observe all the safety precautions through COMPLETENESS THEREOF AND WILL IN NO EVENT
out Should your engine require servicing contact your BE liABLE FOR ANY TYPE OF DAMAGE OR WESTERBEKE dealer for assistance
INCURRED IN CONNECTION WITH OR ARISING OUT
This is your operators manual A parts catalog is also OF THE FURNISHING OR USE OF SUCH and a technical manual is available from your
WESTERBEKE customers should keep in mind the dealer If you are planning to install this span between printings of
WESTERBEKE product contact your WESTERBEKE dealer for and the unavoidable existence of earlier installation manual
product software The product software provided with
WARRANTY PROCEDURES WESTERBEKE products whether from WESTERBEKE or
other suppliers must not and cannot be relied upon exclu
Your WESTERBEKE Warranty is included in a separate sively as the definitive authority on the respective product It
folder If after 60 days of submitting the Warranty Registry not only makes good sense but is imperative that you have not received a
customer card of WESTERBEKE or the supplier in your warranty please contact the factory in be consulted to determine the
accuracy and currentness of the
writing with model information including the engines product software being consulted by the number and commission date
NOTES CAUTIONS AND Card As this manual takes you through the operating procedures
maintenance schedules and of your marine
Customer engine critical information will be highlighted by NOTES
CAUTIONS and WARNINGS An explanation follows
NOTE An operating procedure essential to note
MR ENGINE OWNER
MAIN STREET A CAUTION Procedures which if not strictly
HOMETOWN USA observed can result in the damage or destruction of
Model 35C THREE Ser UOOOOD802 your engine
Expires 101698
A WARNING Procedures which if not properly fol
lowed can result in personal injury or loss of life
The WESTERBEKE engine serial number is an number that can assist in determining the date of man
ufacture of your WESTERBEKE engine The code is placed at the end of the engine serial number and
consists of a character followed by three numbers The char
acter indicates the decade A1960s B1970s the first number represents the year in the decade
and the second and third numbers represent the month Engines Generators
NUMBER LOCATION ORDERING PARTS
The engines model number and serial number are located on Whenever replacement parts are needed always provide the
a nameplate mounted on the side of the engines manifold engine model number and serial number as they appear on
The engines serial number can also be found stamped into the silver and black nameplate located on the manifold You
the engine block just above the injection pump Take the time must provide us with this information so we may properly
to enter this information on the illustration of the nameplate identify your engine In addition include a complete part
shown below as this will provide a quick reference when description and part number for each part needed see the
seeking technical information andor ordering repair parts separately furnished Parts List Insist upon WESTERBEKE
packaged parts because will fit or generic parts are 143i
not made to the same as original equipment
SPARES AND MODEL SPEC AVO MA USA SERNO
0 Certain spares will be needed to support and maintain your
WESTERBEKE engine Your local WESTERBEKE dealer
will assist you in preparing an inventory of spare parts See
the SPARE PARTS page in this manual For engine acces
sories see WESTERBEKEs ACCESSORIES THE DIESEL ENGINE
The diesel engine closely resembles the gasoline engine
since the mechanism is essentially the same The cylinders
are arranged above a closed crankcase The crankshaft is the
same general type as a gasoline engine and the diesel engine
has the same type of valves camshaft pistons and lubricating to a great extent a diesel engine requires the maintenance as a gasoline engine The
factors are proper ventilation and proper mainte
nance of the fuel lubricating and cooling systems Fuel filter elements must be replaced at the time peri
ods specified and frequent checking for contaminants etc in the fuel system is also essential factor is the consistent use of the same brand of
high detergent diesel lubrication oil designed specifically for
diesel engines
The diesel engine does differ from the gasoline in its method of handling and firing of fuel and ignition systems are replaced by a the fuel
injection pump which performs the
function of both
Engines Generators
ADMIRAL CONTROL PANEL
DESCRIPTION When the engine is shut down with the key switch turned off
the water temperature gauge will continue to register the last
This control panel is equipped with a
temperature reading indicated by the gauge before electrical
KEY switch and RPM gauge with an ELAPSED TIME
power was turned off The oil pressure gauge will fall to zero
meter which measures the engines running time in hours and
when the key switch is turned off The temperature gauge
in 1110 hours The panel also includes a WA1ER 1EMPER
will once again register the engines true temperature when
ATURE gauge which indicates water temperature in degrees
electrical pOVler is restored to the gauge
Fahrenheit an OIL PRESSURE gauge which measures the
engines oil pressure in pounds per square inch and a DC A separate alarm buzzer with harness is supplied with every
control circuit VOLTAGE gauge which measures the sys Admiral Panel The installer is responsible for electrically con
tems voltage All gauges are illuminated when the key necting the buzzer to the fourpin connection on the engines
switch is turned on and remain illuminated while the engine electrical harness The installer is also responsible for installing
is in operation The panel also contains two rubberbooted the buzzer in a location where it will be dry and where it will
pushbuttons one for PREHEAT and one for START be audible to the operator should it sound while the engine is
running The buzzer will sound when the ignition key is turned
on and should silence when the engine has started and the
engines oil pressure rises above 15 psi 11 kglcm2
OIL PRESSURE GAUGE THIS GAUGE IS GRADU
ATED IN POUNDS PER SQUARE INCH PSI AND IS
WATER TEMPERATURE GAUGE THIS GAUGE IS ILLUMINATED WHILE THE KEY SWITCH IS TURNED
GRADUATED IN DEGREES FAHRENHEIT AND IS ON THE ENGINES NORMAL OPERATING OIL
ILLUMINATED WHILE THE KEY SWITCH IS PRESSURE RANGES BETWEEN 30 60 psi
TURNED ON THE ENGINES NORMAL OPERATING 21 42 kgem
TEMPERATURE IS 170 190 Fn 88C
RPM GAUGE REGIS
TERS MINUTE OF THE
ENGINE AND CAN FOR
ACCURACY FROM THE
REAR OFTHE 1 SWITCH ELAPSED
POWER ONLY TO THE
TIME AND SHOULD BE INSTRUMENT PANEL
USED AS A GUIDE FOR CLUSTER
THE
DC VOLTMETER
INDICATES THE AMOUNT THE
BATTERY IS BEING PRESSED ENERGIZES THE SHOULb SHOW
13V TO EXCITER THE FUEL liFT PUMP THE AUTOMATIC ALARM SYSTEM
FUEL SOLENOID ON THE INJECTION PUMP AND THE
ENGINES GLOW PLUGS IT BYPASSES THE ENGINES COOLANT TEMPERATURE ALARM AN ALARM BUZZER HAS BEEN
OIL PRESSURE ALARM SWITCH IN ADDITION THIS SUPPliED WITH THE INSTRUMENT PANEL IF THE ENGINES ENERGIZES THE START
BUTTON REACHES 210 F ggC THIS SWITCH WILL CLOSE SOUNDING THE
ALARM WHICH WILL EMIT A CONTINUOUS SIGNAL
START BUTTON WHEN PRESSED ENERGIZES THE
STARTERS SOLENOID WHICH CRANKS THE ENGINE Oil PRESSURE ALARM AN OIL PRESSURE ALARM SWITCH IS
THIS BUTTON WILL NOT OPERATE ELECTRICALLY LOCATED OFF THE ENGINES OIL GALLERY THIS SWITCH THE PREHEAT BUTTON
IS PRESSED AND HELD THE ENGINES OIL PRESSURE SHOULD THE ENGINES OIL PRESSURE
AT THE SAME TIME FALL TO 5 10 psi 04 07 kgem THE SWITCH WILL CLOSE SOUND
ING THE ALARM IN THIS EVENT THE ALARM WILL EMIT A PULSATING
SIGNAL
Engines Generators
CAPTAIN CONTROL The panel also includes an alarm buzzer for low OIL
PRESSURE or high COOLANT lEMPERATURE The
This control panel is equipped with a RPM gauge is illuminated when the KEY switch is turned on
KEY switch an RPM gauge PREHEAT and START but and remains illuminated while the engine is in an INSTRUMENT 1EST button and
three one for ALlERNATOR DISCHARGE one for low
OIL PRESSURE and one for high ENGINE ALARM THE ALARM WILL SOUND IFTHE ENGINES
OIL PRESSURE FALLS
BELOW 5 10 psi 04 07 kgem IN THIS EVENT THE ALARM WILL EMIT A
PULSATING SIGNAL THE ALARM WILL ALSO SOUND IF THE COOLANT
TEMPERATURE IN THE FRESHWATER COOLING CIRCUIT RISES TO
RPM GAUGE REGISTERS REVOLUTIONS 210F 99C IN THIS EVENT THE ALARM WILL EMIT A CONTINUOUS SIGNAL
PER MINUTE OF THE ENGINE AND CAN BE NOTE THE ALARM WILL SOUND WHEN THE KEY SWITCH IS TURNED ON FOR ACCURACY FROM
SOUNDING IS NORMAL ONCE THE ENGINE STARTS AND THE ENGINES OIL
THE REAR OF THE PANEL PRESSURE REACHES 15 psi 11 kgem THE ALARM WILL SILENCE
TEST BUTTON WHEN
PRESSED TESTS THE
ALTERNATOR THE OIL
PRESSURE AND THE
COOLANT TEMPERA
TURE CONTROL CIR
CUITS WHEN PRESSED
THE ALTERNATOR THE
OIL PRESSURE AND
THE WATER TEMPERA
TURE INDICATOR
LIGHTS ILLUMINATE IN
ADDITION TO SOUND
ING THE ALARM
BUZZER
KEY SWITCH PROVIDES
POWER ONLY TO THE
INSTRUMENT PANEL
CLUSTER
WATER TEMPERJlTI
ALARM LIGHT
START BUTTON WHEN PRESSED ENERGIZES THE
STARTERS SOLENOID WHICH CRANKS THE ENGINE THIS PREHEAT BUTTON WHEN PRESSED ENERGIZES THE
BUTTON WILL NOT OPERATE ELECTRICALLY UNLESS THE ALTERNATORS EXCITER THE FUEL LIFT PUMP THE FUEL
PREHEAT BUTTON IS PRESSED AND HELD AT THE SAME SOLENOID ON THE INJECTION PUMp AND THE ENGINES
TIME GLOW PLUGS AND BYPASSES THE ENGINES OIL PRES
SURE ALARM SWITCH IN ADDITION THIS BUTTON ENER
GIZES THE START BUTTON
Engines Generators
DIESEL FUEL ENGINE OIL AND ENGINE COOLANT
DIESEL FUEL ENGINE COOLANT
Use fuel that meets the requirements or specification of Class WESTERBEKE recommends a mixture of 50 antifreeze
2D ASTM and has a cetane rating of45 or better and 50 distilled water Distilled water is free from the
chemicals that can corrode internal engine surfaces
Care Of The Fuel Supply The antifreeze perfonns double duty It allows the engine to
Use only clean diesel fuel The clearance of the components run at proper temperatures by transferring heat away from
in your fuel injection pump is very critical invisible dirt par the engine to the coolant and lubricates and protects the
ticles which might pass through the filter can damage these cooling circuit from rust and corrosion Look for a good
finely finished parts It is important to buy clean fuel and quality antifreeze that contains Supplemental Cooling
keep it clean The best fuel can be rendered by Additives SCAs that keep the antifreeze chemically bal
careless handling or improper storage facilities To assure anced crucial to long tenn protection
that the fuel going into the tank for your engines daily use is
The distilled water and antifreeze should be premixed before
clean and pure the following practice is advisable
being poured into the cooling circuit
Purchase a wellknown brand of fuel
NOTE Look for the new long lasting
Install and regularly service a good visualtype fuel
antifreeze that is now available
filterwater separator between the fuel tank and the engine
The Raycor 500 FG or 900 FG are good examples of such Antifreeze mixtures will protect against an unexpected freeze
filters and they are beneficial to the engines cooling system They
retard rust and add to the life of the circulating pump seal
ENGINE OIL
Use a heavy duty engine oil with an API of CF
ANTIFREEZE PROTECTION
or CG4 or better Change the engine oil after an initial 50
hours of breakin operation and every 100 hours of operation Antifreeze Concentration 23 30 35 50
thereafter For recommended oil viscosity see the following Freezing Temperature 14F 8F 4F 40F
chart 10C 13C 20C 40C
Operating Temperature Oil Viscosity
Above 68F 20C SAE 30 10W30 or 15W40 COOLANT RECOVERY TANK
A coolant recovery tank kit is supplied with each
41 68F 5 20C SAE 20 10W30 or 15W40
WESTERBEKE diesel engine The purpose of this recovery
Below 41F 5C SAE 10W30 or 15W40 tank is to allow for engine coolant expansion and contraction
during engine operation without the loss of coolant and
without introducing air into the cooling system This kit is
A CAUTION Do not allow two or more brands of provided and must be installed before operating the engine
engine oil to mix Each brand contains its own additives NOTE This tank with its short run of plastic hose is best
additives of different brands could react in the mixture located at or above the level of the engines manifold but it
to produce properties harmful to your engine can be located below the level of the engines manifold if the
particular installation makes this necessary
OIL PRESSURE
The engines oil pressure during operation is indicated
by the oil pressure gauge on the instrument panel During
nonnal operation the oil pressure will range between 35 and
55 psi 25 and 39 kglcm2
NOTE A newly started cold engine can have an oil pressure
reading up to 60 psi 42 kglcm2 A warmed engine can have
an oil pressure reading as low as 25 psi 18 kglcm2 These
readings will vary depending upon the temperature of the
engine the load placed on the engine and the RPMs
TRANSMISSION FLUID
Refer to the TRANSMISSION SECTION of this manual for
type of fluid and quantity for each transmission model
Engines Generators
PREPARATIONS FOR INITIAL starting your engine for the first time or after a pro
longed layoff check the following items
D Check the engine oil level Add oil to maintain the level PLASTIC RECOVERY TANK
at the high mark on the dipstick
D Turn on the fuel supply then check the fuel supply and
examine the fuel filterwater separator bowl for contami CAP
nants
D Check the transmission fluid level
NOTE Refer to the previous page for fue oil and
transmission fluid
D Check the DC electrical system Inspect wire connections
and battery cable connections Make certain the positive
battery cable is connected to the starter solenoid and
the negative cable is connected to the engine ground Il
stud this location is tagged
D Check the coolant level in both the plastic recovery tank
and at the manifold
NOTE If the engine has not yet been filled with coolant
refer to the COOLING SYSTEM section of this manual
D Visually examine the engine Look for loose or missing
parts disconnected wires and unattached hoses Check OIL FILL CAP
the threaded connections and engine Make certain there is proper ventilation around the
engine An ample supply is necessary for proper engine
Make sure the mounting installation is secure
D Ensure the propeller shaft is securely attached to the
Open the throughhull and prime the raw water intake
strainer Inspect the raw water supply
Engines Generators
PROCEDURE
THE STARTING SYSTEM 5 Should the engine not start when the START button is
depressed for 10 to 20 seconds release both buttons and
The 44N35Cdiesel engine has a 12V DC electric starter
wait 30 seconds repeat the procedure above and preheat
The start circuitry is designed so that the PREHEAT button longer Never run the starter for more than 30 seconds
must be depressed for the time specified in the preheat chart
Then while keeping the PREHEAT button engaged the
START button is depressed to crank the engine A CAUTION Prolonged cranking intervals Procedure
the engine starting can result in the engine exhaust
system filling with raw water This may happen because
1 Place the transmission in neutral and advance the throttle
control to slightly open the pump is pumping raw water through the raw water
cooling system during cranking This raw water can
enter the engines cylinders by way of the exhaust
A CAUTION Make certain the transmission is manifold once the exhaust system fills Prevent this
in neutral Starting in gear could result in serious from happening by closing the raw water supply
damage to your transmission your boat and throughhull shutoff draining the exhaust muffler and
vessels nearby correcting the cause of the excessive engine cranking
Engine damage resulting from raw water entry is not a
2 Tum the KEY SWITCH to the ON position 2 oclock
warrantable issue the should keep this
3 Depress the PREHEAT switch The voltrrieter panel
in mind
lights gauges meters and fuel solenoid will be activated
The PREHEAT switch should be depressed in accor
dance with the following chart 6 Once the engine starts check the instruments for proper
oil pressure and battery charging voltage
Atmospheric Temperature Preheating Time NOTE Never attempt to engage the starter while the
41F5C or higher Approx 10 seconds
engine is running
41F5C to 23F 5C Approx 15 seconds NOTE Some unstable running may occur in a cold
23F5C or lower Approx 20 seconds engine Depressing the PREHEAT button for 10 15
Limit of continuous use 30 seconds before cranking second intervals will help stabilize the engine rpm until
the engine operating temperature reaches 170 190F
NOTE The START button will not energize unless the PRE 77 88C and a propeller load is applied to the engine
HEAT button is depressed Depressing the PREHEAT button When the engine is running and the PREHEAT button is
activates the glow plugs in the cylinder head so use the PRE depressed a charging load on the DC alternator will be
HEAT to avoid overheating the glow plugs While still depressing the PREHEAT button depress the
START button This will engage the starter solenoid
Starting Under Cold Conditions
Upon engine starting release the START switch Do not Make sure the lubricating oil is appropriate for the prevailing
release the PREHEAT switch until the oil pressure reaches temperature Use oil with an API Specification of CF or CG4
5 10 psi Then as long as the high water temperature and SAE 30 lOW30 or 15W40
low oil pressure protective circuits do not activate the engine The battery should be fully charged to minimize voltage drop
will remain energized and continue to run Use a sufficient amount of preheat to aid in starting See the
chart elsewhere in this section
Stopping When starting To stop the engine bring the throttle to an idle position and
A voltage drop will occur place the transmission in neutral Allow the engine to idle for
when the preheat button a few moments to stabilize temperatures Turn the engine off
is depressed using the stop control cable If your engine is equipped with
an optional fuel shut off solenoid turn off the key switch at
the control panel
NOTE Make certain this key switch is in the OFF position
12 oclock If the key switch is left ON the battery will
discharge An engine alarm buzzer is provided to warn the
operator of this condition key switch ON The best method
of preventing the battery from discharging is to remove the
key from the key switch after stopping the engine
Engines Generators
WARNING LIGHTS ALARMS CIRCUIT BREAKER
ALTERNATOR WARNINGS LOW OIL PRESSURE ALARM SWITCH
The Captain Control Panel indicates alternator low discharge A low oil pressure alarm switch is located off the engines
with a red warning light oil gallery This switchs sensor monitors the engines oil
The Admiral Control Panel uses a voltmeter to monitor the pressure Should the engines oil pressure fall to 5 10 psi
performance of the alternator 04 07 kgcm2 this switch will activate a pulsating alarm
COOLANT TEMPERATURE SWITCH
A coolant temperature switch is located on the thermostat
housing This switch will activate a continuous alarm if the
coolants operating temperature reaches approximately 210 0 P
99C
DlL PRESSURE SWITCH
SENDOR
ENGINE CIRCUIT The DC harness on the engine is protected by an
mounted manual reset circuit breaker 20 amps DC
SWITCH Excessive current draw or electrical overload anywhere in
the instrument panel wiring or engine wiring will cause the
breaker to trip In this event most engines will shut down
because the opened breaker disconnects the fuel supply If
this should occur check and repair the source of the problem
After repairing the fault reset the breaker and restart the
SENDORS engine
The coolant temperature and oil pressure sendors are not
installed in the 44N35C engines as standard equipment
Both sendors are however included in the Admiral
Instrument Panel Kit
These sendors with connecting gauges can be added as
accessories to either engine at any time and are easily
installed to the prewired engine
Engines Generators
ENGINE BREAKIN 3 While using the vessel run the engine at various engine
speeds for the first 25 hours Avoid prolonged periods of
Although your engine has experienced a minimum of one
idling
hour of test operations at the factory to make sure procedures were followed and that the engine oper 4 Avoid rapid acceleration
especially with a cold engine
ated properly a breakin time is required The service life of S Use caution not to overload the engine The presence of a
your engine is dependent upon how the engine is operated grey or black exhaust and the inability of the engine to
and serviced during its initial 50 hours of use reach its full rated speed are signs of an a new engine basically involves
seating the pis 6 During the next 25 hours the engine may be operated at
ton rings to the cylinder walls Excessive oil consumption varying engine speeds with short runs at full rated rpm
and smoky operation indicate that the cylinder walls are Avoid prolonged idling during this breakin which is caused by overloading
the engine during the
breakin period CHECK LIST
Your new engine requires approximately 50 hours of initial o Monitor the control panel operation to break in each moving part in order
o Check for leaks of fuel and engine oil
to maximize the performance and service life of the engine o Check for abnormal noise such as knocking this conditioning carefully
keeping in mind the fol vibration and blowback o Confirm exhaust
smoke
1 Start the engine according to the STARTING PROCE When the engine is cold white smoke
DURE section Run the engine at fast idle while checking When the engine is warm almost smokeless
that all systems raw water pump oil pressure battery When the engine is overloaded some black smoke and soot
charging are Allow the engine to warm up preferably by running at
NOTE See the TRANSMISSION section of this manual for
breakin information on your fast idle until the water temperature gauge moves into
the 130 1400 P 55 60C range
Engines Generators
THE DAILY LIST STARTING THE ENGINE
Follow this check list each day before starting your engine NOTE See PROCEDURE in this
D Record the hounneter reading in your log engine hours manual for more detailed relate to the maintenance schedule
1 Put the transmission in neutral throttle advanced
D Visually inspect the engine for fuel oil or water leaks
D Check the oil level dipstick NOTE Hydraulically operated transmissions have a
neutral safety switch through which the starter solenoid
D Check the coolant level in the coolant recovery tank energizing circuit passes This switch is open when the
Periodically check the manifold coolant level transmission is in gear so the starter solenoid will not
D Check the transmission fluid level energize
D Check your diesel fuel supply 2 Tum the KEY to the ON position 2 oclock
D Look for clean fuel in the fuel filterwater separator trans 3 Depress PREHEAT 10 to 15 seconds
parent bowl
4 While pressing PREHEAT push START As the engine
D Check for loose wires at the alternator and make sure its fires release START
mounting is secure
S Hold PREHEAT until the oil pressure reaches 15 psi
D Check the starting batteries weekly andor the alarm shuts off
D Check drive belts for wear and proper tension weekly
NOTE Some unstable running may occur in a cold
D Check the raw water pump to make sure its mounting is engine This condition should abate as normal operating
secure temperature is reached and loads are applied
NOTE Should the engine fail to start wait 30 seconds
then repeat the above procedure and PREHEAT longer
6 Allow a few minutes for the engine to warm at a com
fortable rpm 1000 rpm then reduce the
rpm and get Engines Generators
MAINTENANCE SCHEDULE
In order to use this Maintenance Schedule it will be neces
sary to log your engine hours Use your engine hourrneter or A WARNING Never attempt to perform any your engine hours by running time
while the engine is running Wear the proper safety
NOTE Many of the following maintenance procedures are equipment such as goggles and gloves and use the
simple but others are more difficult and may require the correct tools for each job Disconnect the knowledge of a service
mechanic terminals when servicing any of the engines DC
electrical equipment
SCHEDULED CHECK HOURS OF OPERATION
EACH MAINTENANCE DESCRIPTION
MAINTENANCE
DAY 50 100 250 500 750 1000 1250
Fuel Supply 0 Diesel No2 rating of 45 cetane or higher
FuelWater Separator 0 Check for water and dirt in fuel filter
if necessary
Engine Oil level 0 Oil 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
Transmission Fluid level 0 Fluid level should indicate between MAX and LOW
on dipstick
Drive Belts 0 Inspect for proper tension 38 to 12 deflection
weekly and adjust if needed Check belt edges for wear
Visual Inspection of Engine 0 NOTE Keep engine surface clean Dirt and Check for fuel oil and water leaks Inspect wiring
oil will inhibit the engines ability to remain and electrical connections Keep bolts nuts tight
cool Check for loose belt tension
Fuel Filter 0 0 0 0 0 0 Change at 50 hours then every 250 hours
Starting Batteries 0 Check electrolyte levels every 50 operating hours
and House Batteries weekly and make sure connections are very tight Clean off
excessive corrosion
Engine Oil and Filter 0 0 0 0 0 0 0 Initial engine oil filter change at 50 hours then
change both every 100 hours
Heat Exchanger Zinc Anode 0 0 0 0 0 0 0 Inspect zinc anode replace if needed Clear the heat
exchanger end of zinc anode debris
FuelWater Separator 0 0 0 0 0 0 Change filter every 200 hours
Exhaust System 0 0 0 0 Initial check at 50 hours then every 250 hours
Inspect for leaks Check antisiphon valve opera
tion Check the exhaust elbow for carbon andor
corrosion buildup on inside passages clean and
replace as necessary Check that all connections are
tig ht Check casti ng integ rity
Engine Hoses 0 0 0 0 0 0 Hose should be hard tight Replace if soft or
spongy Check and tighten all hose clamps
Throttle and Transmission 0 0 0 0 Check for loose fittings cotter pins etc
Control Cable Lubricate with WD40 or equivalent
Adjust Engine Idle Speed 0 Adjust to 750 1000 rpm
Raw Water Pump 0 0 0 Remove the pump cover and inspect the impeller
gasket cam and cover for wear Check the bearings
and seals the shaft can turn but not wobble
Lubricate when
continued
Engines Generators
MAINTENANCE SCHEDULE
NOTE Use the engine hourmeter gauge to log your engine hours or record your
engine hours by running time
SCHEDULED CHECK HOURS OF OPERATION
MAINTENANCE EACH MAINTENANCE DESCRIPTION
DAY 50 100 250 500 750 1000 1250
Coolant System D D Drain flush and refill cooling system with appro
priate antifreeze mix
DC Alternator D D D Check DC charge from alternator Check mounting
bracket tighten electrical connections
Air Intake Filter D D D D D D Clean every 100 operating hours
Transmission Oil Cooler D Remove have cleaned and pressure
tested
Engine Transmission D Chattering at idle and low rpms is an indication
Damper Plate of damper plate wear Remove and replace
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 Clean and lubricate the starter motor
pinion drive
Preheat Circuit D D Check operation of preheat solenoid Remove and
clean glow plugs Reinstall with antiseize
compound on threads
Engine Cylinder D D Check compression pressure and timing see Engine
Compression Adjust the Valve Clearances D D
D Adjust Valve Clearances see ENGINE
Heat Exchanger D Remove have cleaned and pressure
tested
Lubricate Panel Key Switch D D D D D D At first 100 hours then each year at winterizing
with Lockeze
Transmission D D D D D D Initial fluid change at 25 hours then every
Fluid 300 hours or at recommends this service be performed by an
authorized Engines Generators
COOLING When the engine is started cold external coolant flow is pre
vented by the closed thermostat although some coolant marine diesel engines are designed and equipped
is bypassed around the thermostat to prevent the exhaust
for fresh water cooling Heat produced in the engine by com
manifold from overheating As the engine warms up the
bustion and friction is transferred to fresh water coolant
thermostat gradually opens allowing full flow of the circulates throughout the engine This circulating fresh
coolant to flow unrestricted to the external portion of the
water coolant cools the engine block its internal moving
cooling and the engine oil The heat is transferred the fresh water coolant to raw water by means of a heat Coolant Recovery similar in
function to an automotive radiator Raw
water flows through the tubes of the heat exchanger while A coolant recovery tank allows for engine coolant water coolant flows around
the tubes engine heat trans and contraction during engine operation without any to the fresh water coolant is conducted through the
cant loss of coolant and without introducing air into the cool
tube walls to the raw water which is then pumped into the ing system This tank should be located at or above the
exhaust system where finally it is discharged overboard In engine manifold level and should be easily words the engine is cooled by fresh
water coolant this CHANGING is cooled by raw water and the raw water carries the
The engines coolant must be changed according to heat overboard through the exhaust system The
MAINTENANCE SCHEDULE If the coolant is allowed to
fresh water coolant and raw water circuits are independent of
become contaminated it can lead to overheating other Using only fresh water coolant within the engine
allows the cooling water passages to stay clean and free from
harmful deposits A CAUTION Proper cooling system maintenance is
FRESH WATER COOLING CIRCUIT critical a substantial number of engine failures can be
traced back to cooling system Refer to the ENGINE COOlANT section for the rec
ommended antifreeze and water mixture to be used as the
fresh water coolant To drain out the old engine coolant loosen the water coolant is pumped through
the engine by a circu pressure cap and unfasten the drain hose as shown below
lating pump absorbing heat from the engine The coolant NOTE The drain petcock on the heat exchanger should also
then passes through the thermostat into the manifold to the be used to help drain engine coolant
heat exchanger where it is cooled and returned to the enaine
block via the suction side of the circulating pump
A WARNING Beware of the hot engine coolant
Wear protective gloves
ENGINE BLOCK
RELEASE THE COOLANT LINE
FROM THE OIL COOLER TO
DRAIN THE COOLANT FROM
OIL FILTER
THE ENGINE BLOCK
Engines Generators
COOLING SYSTEM
Refilling the Coolant Replacing the Thermostat
After replacing the engine block drain plug close the heat Remove the cap screws and disassemble the thermostat hous
exchangers coolant petcock Then pour clean premixed ing as shown When installing the new thermostat aud gas
coolant into the manifold and when the coolant is visable in ket apply a thin coat of sealant on both sides of the gasket
the manifold start the engine and run it at slow idle before pressirig it into place Do not overtighten the cap
NOTE Open the airbleed petcock on the heat exchanger screws
When a steady flow of coolant appears at the petcock close
Run the engine and check for normal temperatures and that
the petcock and fill the system until the manifold remains full
there are no leaks at the thermostat housing
Monitor the coolant in the manifold and add as needed Fill
the manifold to the filler neck and install the manifold pres
sure cap
Remove the cap on the coolant recovery tank and fill with
coolant mix to halfway between LOW and MAX and replace
the cap Run the engine and observe the coolant expansion
flow into the recovery tank
After checking for leaks stop the engine and allow it to cool
Coolant should draw back into the cooling system as the
engine coolll down Add coolant to the recovery tank if
needed Cle up any spilled coolant
TO COOLANT KEEP THE
RECOVERY TANK COOLANT PASSAGE
CLEAR
THERMOSTAT TEMPERATURE
ASSEMBLY SENDOR
OPTIONAL
COOL4NT EXPANSION
FROM COOLANT
RECOVERY TANK PRESSURE
RAW WATER COOLING CIRCUIT
The raw water flow is created by a positive displacement
impeller pump This pump draws water directly from the raw
water source ocean lake or river through a hose to the
water strainer The raw water passes from the strainer
NOTE Periodically check the condition of the manifold through the raw water pump to the heat exchanger through
pressure cap Ensure the upper and lower rubber seals are in the heat exchanger tubes where it cools the engine circulat
good condition Check to ensure ing fresh water coolant The raw water is then discharged
the vacuum valve opens and into the exhaust elbow mixing with and cool
closes tightly Carry a spare ing the exhaust gasses This mixture of exhaust gas and raw
cap Check also to ensure the water is discharged overboard by the engines exhaust gas
coolant passage is clear so discharge pressure
coolant within the system is
able to expand and contract Raw Water Pump
to and from the coolant recovery tank The raw water pump is a selfpriming rotary pump with a
nonferrous housing and a neoprene impeller The impeller
THERMOSTAT has flexible vanes which wipe against a curved cam plate
A thermostat located near the manifold at the front of the within the impeller housing producing the pumping action
engine controls the coolant temperature as the coolant contin On no account should this pump be run dry as water acts as a
uously flows through the closed cooling circuit When the lubricant for the impller There should always be a spare
engine is first started the closed thermostat prevents coolant impeller and impeller cover gasket an impeller kit aboard
from flowing some coolant is bypassed through a hole in the Raw water pump impeller failures occur when lubricant raw
thermostat to prevent the exhaust manifold from overheating water is not present during engine operation Such failures
As e engine warms up the thermostat gradually opens The are not warrantable and operators are cautioned to make sure
thermostat is accessible and can be checked cleaned or raw water flow is present at startup
replaced easily Carry a spare thermostat and gasket NOTE Should a failure occur with the pumpr internal parts
seals and bearings it may be more cost efficient to pur
chase a new pump and rebuild the original pump as a spare
WESTERBEKE
Engines Generators
Revised February 2002
COOLING SYSTEM
Changing the Raw Water Pump Impeller NOTE Also follow the above procedure after having run hard
Close the raw water intake valve Remove the pump cover aground
and with the aid of two small screwdrivers carefully pry the If the engine temperature gauge ever shows a higher than
impeller out of the pump Install the new impeller and gasket normal reading the cause may be that silt leaves or grass
Move the blades to conform to the curved cam plate and may have been caught up in the strainer slowing the flow of
push the impeller into the pumps housing When assem raw water through the cooling system
bling apply a thin coating of lubricant to the impeller and
gasket Open the raw water intake STRAINER
FILTER I
f
TYPICAL RAW WATER INTAKE STRAINER
Owner Installed
HEAT EXCHANGER
The heat exchanger is a copper cylinder which encloses a
number of small copper tubes Raw water is pumped through
the small copper tubes and the fresh water coolant from the
engine is circulated around the copper tubes The raw water
A CAUTION If any of the vanes have broken off the removes heat from the fresh water coolant
impeller they must be found to prevent blockage in the
cooling circuit They often can be found in the heat
exchanger
HEAT EXCHANGER
Raw Water Intake Strainer
NOTE Always install the strainer at or below the waterline so HEAT EXCHANGER
GASKET
the strainer will always be A clean raw water intake strainer is a vital component of the
engines cooling system Include a visual inspection of this
strainer when making your periodic engine check The water
in the glass should be clear PETCOCK
Perform the following maintenance after every 100 hours of
operation CLEAN
DEBRIS
1 Close the raw water seacock
2 Remove and clean the strainer filter
ZINC
3 Clean the glass
ANODE
4 Replace the washer if necessary
5 Reassemble and install the strainer
6 Open the seacock
7 Run the engine and check for leaks
Engines Generators
COOLING SYSTEM
Zinc Anode If the zinc anodes need replacement hold the hex boss into
which the zinc anode is threaded with a wrench while loos
zic oe or pencil is located in the raw water cooling
ening the anode with another wrench This prevents the hex
CIrCUIt wIthin the heat exchanger The purpose of having
boss from possibly tearing off the exchanger shell After
zinc odes is to sacrifice them to electrolysis action taking
removing the zinc note the condition of it If the zinc is in
place In the raw water cooling circuit thereby reducing the
poor condition there are probably a lot of zinc flakes of electrolysis on other components of the system
the exchanger Remove the end of the heat exchanger and
The condition of the zinc anode should be checked monthly
clean the inside of all zinc debris Always have a spare heat
and the anode cleaned or replaced as required Spare anodes
exchanger end gasket in case the present one becomes dam
should be carned on board
aged when removing the end cover Replace the gasket refer
to your engine models heat exchanger end gasket part num
ber Oring and cover and install a new zinc anode
NOTE The threads of the zinc anodes are pipe threads and
do not require sealant Sealant should not be used as it may
insulate the zinc from the metal of the heat exchanger hous
ing preventing electrolysis action on the zinc
Heat Exchanger Service
After approximately 1000 hours of operation remove clean
and pressure test the engines heat exchanger A local auto
NEW REPLACE CLEAN REUSE motive radiator shop should be able to clean and test the heat
exchanger
NOTE Operating in silty andor tropical waters may require
NOTE Electrolysis action is the resultof each particular that a heat exchanger cleaning be performed more often and vessel location not
that of the engine every 1000 hours
AIR INTAKE I marine diesel engine running at high speed will more than 6000 cubic feet of air per hour Not only
must the engine room be well ventilated the air flow into the
engine must be Filter
CARTRIDGE
The air filter cartridge prevents engine room dust and dirt
from entering the filter should be cleaned every 100 operating hours Tap
the cartridge on a flat surface to dislodge loose dirt or clean
off with compressed air If the cartridge is badly oily replace it
Engines Generators
FUEL SYSTEM
DIESEL FUEL FUEL FILTERS
Use No2 diesel fuel with a cetane rating of 45 or higher Do The fuel injection pump and the fuel injectors are precisely
not use kerosene or home heating fuel manufactured and they must receive clean diesel fuel free
from water and dirt To ensure this flow of clean fuel the fuel
FUEL FILTERWATER SEPARATOR must pass through at least two fuel filters a fuel primary fuel filter of the
water separating type must be separator and the engines spinon fuel filter Visually between the fuel tank and the engine to remove
clean and change these filters according to the and other contaminants from the fuel before they can schedule in this manual
be carried to the fuel system on the engine
Most installers include a fuel filterwater separator with package as they are aware of the problems that A WARNING Shut off the fuel
valve at the in the fuel can cause when servicing the fuel system Take care in catching
A typical fuel filterwater separator is illustrated below This any fuel that mlY spill DO NOT allow any smoking
is the Raycor Model 500 MA Keep in mind that if a water open flames or other sources of fire near the fuel type filter is not
installed between the fuel supply tem when servicing Ensure proper ventilation exists
tank and fuel system any water in the fuel when servicing the fuel system
will affect the fuel pump engine filter and injection equip
ment The is responsible for making certain
the fuel reaching the engines injection equipment is free This process is accomplished by installing a proper fuel filterwater FILTER
WATER SEPERATOR
FUEL
IION PUMP
The fuel injection pump is a very important component of
the diesel engine requiring the utmost care in handling The I BOWL I
fuel injection pump has been thoroughly benchtested and the ENGINE FUEL is cautioned not to attempt to service it If it
Periodically check the fuel connections and the bowl for
requires servicing remove it and take it to an authorized fuel leakage Clean the filter element with kerosene or diesel pump service facility
Do not attempt to disassem after the first 50 hours then follow the and repair it
SCHEDULE for cleaning and only adjustment the servicing mechanic should make to
the fuel injection pump is the adjustment for engine idle the filter element
speed see IDLE SPEED ADJUSTMENT under ENGINE 1 Shut off the fuel
2 Unscrew the retainer ring that holds the filter bowl to the
FUEL LIFT PUMP housing and allow the bowl to come away from the
check the fuel connections to and out of the
pump and make sure that no leakage is present and that the 3 Remove and replace the filter element and clean the are tight and secure
The DC ground connection at 4 Replace the sealing 0 ring and reassemble the bowl to
one of the pumps mounting bolts should be clean and well the housing Thread the retainer ring on carefully so as not
secured by the mounting bolt to ensure proper pump opera to cross thread When retainer contacts the 0 ring
tions tighten 114 12 turns by hand Open the fuel supply and
When energized thru the preheat circuit the fuel lift pump run the engine to inspect for leaks
will purge air from the fuel system and provide a of fuel as the engine is running
Engines Generators
GLOW Reinstall the plugs in the engine and test them again The
plugs should get very hot at the terminal end within 7 to 15
The glow plugs are wired through the preheat solenoid
seconds If the plugs dont heat up quickly check for a short
When PREHEAT is pressed at the control panel this solenoid
circuit When reinstalling the glow plugs use antiseize com
should click on and the glow plug should begin to get hot
pound on the inspect the plug remove the electrical terminal connec
A WARNING Do not keep a glow plug on for more
tions then unscrew or unclamp each plug from the cylinder than 30 Thoroughly clean each plugs tip and threads with a
Glow Plug Tightening Torque 7 11 HIb 10 15 mkg
soft brush and cleaning solution to remove all the carbon and
oil deposits While cleaning examine the tip for wear and
bum erosion if it has eroded too much replace the plug
An accurate way to test glow plugs is with an one prod to the glow plugs wire connection and the
other t the body of the glow plug as shown A good glow
TESTING A GLOW PLUG
plug wIll have a 04 06 ohm resistance This method can be
WITH AN OHMMETER
used with the plug in or out of the engine You can also use
an ammeter to test the power drain 5 6 amps per plug
A WARNING These glow plugs will become very hot TIP
to the touch Be careful not to burn your fingers when
testing the plugs
TESTING A GLOW PLUG
USING A TEST LIGHT
I Enaines Generators
ENGINE LUBRICATING OIL
LUBRICATION DIAGRAM 2 Replacing the Oil Filter When removing the used oil fil
ter you may find it helpful and cleaner to punch a hole in
OIL PRESSURE the upper and lower portion of the old filter to drain the
oil from it into a container before removing it This helps
to lessen spillage A small automotive filter wrench
should be helpful in removing the old oil filter
NOTE Do not punch this hole without first loosening the
OIL PRESSURE l H I filter to make certain it can be removed
SWITCH
Place some paper towels and a plastic bag around the fil
OIL ter when unscrewing it to catch any oil left in the filter
Oil or any other fluid on the engine reduces the engines
cooling ability Keep your engine clean Inspect the old
oil filter as it is removed to make sure that the rubber
sealing gasket comes off with the old oil filter If this rub
ber sealing gasket remains sealed against the filter
bracket gently remove it
ENGINE OIL CHANGE
1 Draining the Oil Sump Discharge the used oil through
the sump drain hose attached to the front of the engine
while the engine is warm Drain the used oil completely
replace the hose in its bracket and replace the end cap
securely
NOTE Thread size for the lube oil drain hose capped end
is 114NPT SEALING GASKET
APPLY CLEAN ENGINE OIL
WHEN INSTALLING
SPIN ON
TURN ON HAND INCH
SOCKET
When installing the new oil filter element wipe the filter
gaskets sealing surface on the bracket free of oil and
apply a thin coat of clean engine oil to the rubber gasket
on the new oil filter Screw the filter onto the threaded oil
filter nipple on the oil filter bracket and then tighten the
filter firmly by hand
NOTE Generic filters are not recommended as the mater
Oll ORAl HOSE
ial standards or diameters of important items on generic
parts might be entirely different from genuine parts
Immediately after an oil filter change and oil fill run the
engine to make sure the oil pressure is normal and that
Always observe the used oil as it is removed A there are no oil leaks around the new oil filter
yellowgray emulsion indicates the presence of water in
the oil Although this condition is rare it does require 3 Filling the Oil Sump Add new oil through the oil filler
prompt attention to prevent serious damage Call a quali cap on the top of the engine or through the side oil fill
fied mechanic should water be present in the oil Raw After refilling run the engine for a few moments while
water present in the oil can be the result of a fault in the checking the oil pressure Make sure there is no leakage
exhaust system attached to the engine andor a siphoning around the new oil filter or from the oil drain system and
of raw water through the raw water cooling circuit into stop the engine Then check the quantity of oil with the
the exhaust filling the engine This problem is often lube oil dipstick Fill to but not over the high mark on
caused by the absence of an antisiphon valve its poor the dipstick should the engine require additional oil
location or lack of Engines Generators
OIL PRESSURE
OIL PRESSURE TESTING OIL PRESSURE
The engines oil pressure during operation is indicated The lubricating system is a pressure feeding system using
by the oil pressure gauge on the instrument panel During an oil pump The engine oil is drawn from the oil sump by
normal operation the oil pressure will range between 40 and the oil pump which drives the oil under pressure through
60 psi 28 and 42 kglcm2 the oil filter oil cooler and various lubricating points in the
engine The oil then returns to the oil sump to repeat the
NOTE A newly started cold engine can have an oil pressure
continuous cycle When the oil pressure exceeds the speci
reading up to 60 psi 42 kglcnf A warmed engine can have
fied pressure the oil pushes open the relief valve in the oil
an oil pressure reading as low as 35 psi 25 kglcm2 These
pump and returns to the oil sump keeping the oil pressure
readings will vary depending upon the temperature of the
within its specified range
engine and the rpms
To test the oil pressure remove the oil pressure sender then
install a mechanical oil pressure gauge in its place After
warming up the engine set the engine speed at 3000 rpm
and read the oil pressure gauge
Oil Pressure 350 Ibill 38 kgem or more at 3000 rpm
Sender and Switch Torgue 9 13 ftIb 12 18 m kg
OIL LINE
LOW OIL PRESSURE
The specified safe minimum oil pressure is 43 14 psi 03
01 kglcm2 A gradual loss of oil pressure usually indicates
a worn bearings For additional information on low oil pres
sure readings see the ENGINE chart
OIL PRESSURE SWITCH
TESTING OIL
PRESSURE
OIL PRESSURE SENDOR
AS AN ACCESSORY
WITH GAUGE STANDARD
WITH THE ADMIRAL
INSTRUMENT PANEL
OIL PRESSURE RELIEF VALVE
An oil pressure relief valve is located on the engine block
just below the injection pump This valve opens at t
appoximately 50 psi 343 kpa and maintains that pressure OIL PRESSURE
LOCATED JUST
UNDER THE
FUEL INJECTION
PUMP ON THE
ENGINE BLOCK
Enaines Generators
REMOTE OIL FILTER To install simply remove the engine oil filter and thread on
WESTERBEKEs remote oil filter kit as shown Always
This popular accessory is used to relocate the engines oil fil install this kit with the oil filter facing down as from the engine to a
more convenient location such as an
engine room bulkhead Contact your WESTERBEKE dealer for more Refer to ENGINE OIL CHANGE in
this manualfor NOTE Westerbeke is not responsible for engine failure due on removing the oil filter
incorrect installation of the Remote Oil Filter
FASTEN SECURELY TO A A THIN COAT OF CLEAN OIL TO THE ORING WHEN SCREWS ARE OWNER
THIS KIT THREAD THE KIT ON THEN HAND
TIGHTEN AN ADDITIONAL 34 TURN AFTER THE THE BASE
NOTE THE IN AND OUT MARKINGS
ON THE ADAPTER WHEN THE HOSES ARE
REMOVED FOR INSTALLATION SO THEY
WILL BE RECONNECTED APPLY A THIN COAT DF CLEAN OIL TO THE
TER GASKET WHEN INSTALLING AFTER THE
FILTER CDNTACTS THE BASE TIGHTEN IT AN
ADDITIONAL 34 TURN
A CAUTION It is vital to install the oil lines cor
rectly If the oil flows in the reverse direction the by
pass valve in the filter assembly will prevent the oil
from reaching the engine causing an Intemal engine
failure If there is no oil pressure reading shutdown
immediately and check the hose Engines Generators
WATER HEATER
WATER HEATER INSTALLATIONS The pressure cap on the engines manifold should be
installed aftr the engines cooling system is filled with
This engine is equipped with connections for the plumbing of
coolant Finish filling the cooling system from the remote
engine coolant to transfer heat to an onboard water heater
tank after the system is filled and is free of air and exhibits
The water heater should be mounted in a convenient location
good coolant circulation During engine operation checking
either in a high or low position in relation to the engine so
the engines coolant should be done at the remote tank and
that the connecting hoses from the heater to the engine can
not at the engine manifold cap The hose connection from the
run in a reasonably direct line without any loops which might
heater to the remote expansion tank should be routed and
trap air supported so it rises continuously from the heater to the tank
enabling any air in the system to rise up to the tank and out
THESE HOSES ARE of the IF THERE
IS NO WATER HEATER
WATER HEATER
BELOW ENGINE
Hoses should rise continuously from their low point at the NOTE An air bleed petcock is located on the engines
heater to the engine so that air will rise naturally from the heat exchanger Open this petcock when filling the engines
heater to the engine If trapped air is able to rise to the helter coolant system to allow air in the exchanger to escape
then an air bleed petcock must be installed at the higher fit Close tightly after all the air is removed
ting on the heater for bleeding air while filling the system
NOTE If any portion of the heating circuit rises above the
engines own pressure cap then a pressurized aluminum
remote expansion tank Kit 024177 must be installed in the
circuit to become the highest point Tee the remote expansion
tank into the heater circuit choosing the higher of the two
connections for the return Tee at the heater and plumb a
single line up to the tanks location and the other back to the
engines return Install the remote expansion tank in a conve
nient location so the coolant level can easily be checked The
remote expansion tank will now serve as a check and system
fill point The plastic coolant recovery tank is not used when
the remote expansion tank kit is installed since this tank
serves the same function Remove and store the plastic
recovery tank if it has been already Engines Generators
DC ELECTRICAL SYSTEM
ALTERNATOR 1 Start the engine
The charging system consists of a DC belt driven alternator 2 After the engine has run for a few minutes measure the
with a voltage regulator an engine DC wiring harness a starting battery voltage at the battery terminals using a
mounted DC circuit breaker and a battery with connecting multimeter set on DC volts
cables Because of the use of integrated circuits Ies the a If the voltage is increasing toward 14 volts the alterna
electronic voltage regulator is very compact and is mounted tor is working omit Steps 3 through 8 and go directly
internally or on the back of the alternator to Checking the Service Battery on the next page
b If the voltage remains around 12 volts a problem
exists with either the alternator or the charging circuit
14 GRAY
continue with Steps 3 through 8
14 BLUE
MULTIMETER
SEE WIRING DIAGRAM
FOR WIRE CONNECTIONS
TO OPTIONAL ALTERNATOR TESTING THE STARTING
ENGINE RUNNING
A WARNING A failed alternator can become very
hot Do not touch until the alternator has cooled down GROUND
Use this section to determine if a problem 3 Tum off the engine Inspect all wiring and connections
exists with the charging circuit or with the alternator If it is Ensure that the battery terminals and the engine ground
determined that the alternator or voltage regulator is faulty connections are tight and clean
have a qualified technician check it
The alternator charging circuit charges the starting battery A CAUTION To avoid damage to the battery
and the service battery An isolator with a diode a solenoid charging circuit never shut off the engine battery
or a battery selector switch is usually mounted in the circuit switch when the engine is running
to isolate the batteries so the starting battery is not discharged
along with the service battery If the alternator is charging the 4 If a battery selector switch is in the charging circuit
starting battery but not the service battery the problem is in ensure that it is on the correct setting
the service batterys charging circuit and not with the alterna
S Tum on the ignition switch but do not start the engine
6 Check the battery voltage If the battery is in good condi
Testing the Alternator tion the reading should be 12 to 13 volts
A CAUTION Before starting the engine make certain
that everyone is clear of moving parts Keep away from
sheaves and belts during test procedures
A WARNING When testing with a multimeter
DC nd AC circuits are often mixed together in marine
applications Always disconnect a shore power cord
isolate DC and AC converters and shut down the engine
TESTING THE
before performing DC testing No AC tests should be ALTERNATOR VOLTAGE
made without a proper knowledge of AC circuits IGNITION ON ENGINE OFF
Engines Generators GROUND
DC ELECTRICAL SYSTEM
7 Now check the voltage between the alternator output ter Checking the Service Battery
minal B and ground If the circuit is good the voltage at
Check the voltage of the service battery This battery should
the alternator will be the same as the battery or if an isola
have a voltage between 13 and 14 volts when the engine is
tor is in the circuit the alternator voltage will be zero If
running If not there is a problem in the service battery
neither of the above is true a problem exists in the circuit
charging circuit Troubleshoot the service battery charging
between the alternator and the battery Check all the
circuit by checking the wiring and connections the solenoid
connections look for an opening in the charging circuit
isolator battery switch and the battery itself
MUlTIMETE G
TESTING THE STARTING
ENGINE
ENGINE RUNNING c GROUND
8 Start the engine again Check the voltage between the
alternator output and ground SERVICE BATTERY
The voltage reading for a properly operating alternator
should be between 135 and 145 volts If your alternator GROUND TESTING THE SERVICE
is over or have it repaired at a reliable
BATTERY ENGINE RUNNING
service facility
NOTE Before removing the alternator for repair use a
voltmeter to ensure that 12 volts DC excitation is present
at the EXC terminal if the previous test showed only bat A CAUTION To avoid damaging the altemator diodes
tery voltage at the B output terminal a
do not use high voltage tester ie a megger when
performing tests on the altemator charging circuit
If 12 volts is not present at the EXC terminal trace the
wiring and lookfor breaks and poor VOLT DC CONTROL CIRCUIT Battery Care
The engine has a 12 volt DC electrical control circuit that is Review the and then
shown on the wiring diagrams that follow Refer to these establish a systematic maintenance schedule for your
diagrams when or when servicing the DC engines starting batteries and house system
o Monitor your voltmeter for proper charging during
engine operation
A CAUTION To avoid damage to the battery charging o Check the electrolyte level and specific gravity with a
hydrometer
circuit never shut off the engine battery switch while
the engine is running Shut off the engine battery Switch o Use only distilled water to bring electrolytes to a proper
level
however to avoid electrical shorts when working on the
engines electrical circuit
o Make certain that battery cable connections are clean and
tight to the battery posts and to your o Keep your batteries clean and free of
minimum recommended capacity of the battery used in
the engines 12 volt DC control circuit is 600 900 Cold
Cranking Amps CCA
A WARNING Sulfuric acid In lead batteries can
caUSII severe burns on skin and damage clothing Wear
protective gear
Engines Generators
MARINE ENGINE
WIRING DIAGRAM 39144
SEE NOTE
I I
LIFT PUMPS
An onoff switch
should be installed in this I
circuit to disconnect the
starter from the battery in
an emergency and when
leaving the boat Twelve
volt engine starters p
typically draw 200 to 300 ALARM ADMIRAL
amps when cranking A
C BUZZER
PANEL
switch with a of 175 amps at 12
VDC will normally serve
this function but a switch
must never be used to
make the starter circuit
0 AED
CAPTAIN
PANEL
11 elK
e BLK
slIe
Engines Generators
27 Revised December 2002
MARINE ENGINE
WIRING SCHEMATIC 39144
12 VDC START
SOL SURfER NOTES
r THIS PRODUCT IS PRQTICTED BY A MANUAL RESET CIRCUIT BREAKER
LOCATED NEAR STARTER ExCESSIVE CURRENT WilL CAUSE THE BREAKER TO TRIP AND THE
ENGINE Will
SHUT DCWN THE BUILDEROWNER MUST BE SURE THAT THE INSTRUMENT PANEL WIRING AND
1 ENGINE ARE INSTALLED TO PREVENT CONTACT BETWEEN ELECTRICAL DEVICES AND SEAWATER
I 2 AN QNOFF SWITCH SHOULD BE INSTALLED BETWEEN THE BATTERY AND STARTER TO
DISCONNECT THE BATTERY IN AN EMERGENCY AND WHEN LEAVING THE BOAT A SWITCH
WITH A CONTINUOUS RATING OF 175 AMPS AT 12 voe Will SERVE THIS FUNCTION THI
SWITCH SHOULD NOT BE USED TO MAKE OR BREAK THE CIRCUIT
THE PINK WIRE AT PLUG 2 IS UNUSED AND SHOULD BE INSULATED CAPTAIN PANEL ONLY
4 THE GRAY WIRE AT PLUG 2 IS UNUSED AND SHOULD I3E INSULATED ADMIRAL PANEL ONLY
LIFT PUMP
MITSU81SHI 50 AMP ALT
FUEL lfHN
BIJC
SENDER
14 GRA
90 AMP ALT
BAT TACHOMETER
ADMIRAL
KEY GNO
PANEL OUltO
AC TA
SATTUY
14 eRtl
U RED
VOL TMETER NOTE
GNI WIRE FOR 6ATTERY ATTATCHMENT WILL NEED
o ALARM TO BE UPGRADED TO AN 8 GAUGE FROM 10 GAUGE
GAUGE
PRESTOllTE 72 AMP ALI
14 8RN
CAPTAIN
PANEL
LAMP 14 GRA
TEST
14 PINK
14 LT BL
51 AMP ALTERNATOR
STANDARD ALTERNATOR ON THE UNIVERSAL PROPULSION
638 Il 63C Il liB Il 828 or PRESTOLlTE 51 AMP ALL
1088 D 108CD
ALE CONNECTOR
ON THIS SIDE
TCH RED
OPT IONAl ALTERNATORS
135A 160A liOA LESTEK ALTERNATORS
0 63C n 718 II IlZ8Jb 198ft XI 10llC iI 0HLV
Engines Generators
Revised December 2002
MARINE ENGINE
WIRING SCHEMATIC 200360
CATALINA YACHTS
STARTER
12 VDC SOLENOID STARTER
r
I I I
I I I I M
I I
I
L J
PREHEAT
SOLENOID
r GLOWPLUGS
I I
II I
SI I
I I
ALTERNATOR
OUTPUT
LIJ q
1011 r
C r rJv
Q01 I 11
IDI I
C I I
LIFT PUMP
P 1
en c
wu WATER TEMP
Q
SENDER
en 0
WATER TEMP
SWITCH
TO THE B TO THE TO THES TO THE I TO THE t TO THE P TO THES TO THES TO THE c TO THE TACH
TERM OF START TERM OF TERM OF TERM OF TERM OF TERM OF TERM OF TERM OF GROUND
KETSWITCH SWITCH KETSWITCH KEYSWITCH THE ALARM THE ALARM THE TACH W T GUAGE THE ALARM
BUZZER BUZZER BUZZER
Enqines Generators
r
I II
l I I
a 10
IIJ
n I
II I
I
110 WHT I
TO THE START SWITCH II
114 GRH n Z
TO THE TACHOMETER GROUND
i a
TO THE B TERM OF KEYSWITCH
TO THES TERM OF KEYSWITCH
110 RED
114 PUR
Pi 111
z e m Z
TO THE 5 TERM OF WT GUAGE
0 THE P TERM OF ALARM BUZZER
114 VEL
114 L T BLU
fill o THE C TERM OF ALARM BUZZER 114 TAN 0
nz m
iiJln
TO THE I TERM OF KEYSWITCH 110 REDWHT
114 BRH
iii TO THES TERM OF TACH eo
o THE TERM OF ALARM BUZZER 114 PINK
II I
ENGINE following table describes certain problems NOTE The engine s electrical system is protected by a 20
relating to engine service the probable causes of these prob ampere manual reset circuit breaker located on a bracket at
lems and the to overcome these problems the back of the engine The preheat solenoid is mounted on
the same bracket
Problem Probable Cause No panel indications fuel solenoid 1 Battery switch
not on 1 Check switch andor battery connections
or fuel pump is not working key switch
is on and PREHEAT button is depressed 2 20amp circuit breaker tripped 2 Reset breaker if breaker trips again check preheat solenoid
circuit and check circuit for shorts to ground
3 10amp breaker tripped on 3 Check the voltage both at and after the breaker on the
preheat solenoid preheat solenoid
4 Loose battery connections 4 Check connection to starter solenoid and connection to
engine ground stud Check battery cable connections
5 Preheat solenoid not operating 5 Check solenoid S terminal for voltage
START button is depressed no starter 1 Connection to solenoid faulty 1 Check connection
engagement
2 Gear shift not in neutral 2 Gear shift must be in neutral see NEUTRAL SWITCH under
HURTH HSW 3 Faulty switch 3 Check switch with ohmmeter
4 Faulty solenoid 4 Check that 12 volts are present at the solenoid connection
5 Loose battery connections 5 Check battery connections
6 Low battery 6 Check battery charge state
START button is depressed panel 1 Poor connections to fuel solenoid 1 Check connections
indications OK starter solenoid OK
fuel solenoid not functioning 2 Defective fuel solenoid 2 Check that 12 volts are present at the connection on the
fuel run solenoid
Engine cranks but does not 1 Faulty fueling system 1 Check that fuel valves are open
start fuel solenoid energized
1a Check for air in fuel system Bleed air from fuel system
1b Fuel filters clogged Replace filters and bleed air from
fuel system
2 Preheat solenoid faulty 2 Check solenoid
3 Low battery power 3 Switch to combine house and start batteries
3a Replace batteries
Engine cant be stopped 1 Faulty DC altemator 1 Remove Exc connection at alternator repair alternator
2 Disconnect fuel shutoff cable 2 Check connection at shutoff lever Pull lever back to close
off the fuel
3 Fuel run solenoid will not deenergize 3 Manually disconnect the 12 volt connection to the fuel run
solenoid at the injection pump
Battery runs down 1 Oil pressu re switch 1 Observe if gauges and panel lights are activated when engine
is not running Test the oil pressure switch
2 High resistance leak to ground 2 Check wiring Insert sensitive 0 25 amp meter in battery
lines Do not start engine Remove connections and replace
after short is located
3 Low resistance leak 3 Check all wires for temperature rise to locate the fault
4 Poor battery connections 4 Check cable connections at battery for loose connections
corrosion
5 DC altemator not charging 5 Check connections check belt tension test alternator See
tachometer not operating DC ELECTRICAL Battery not charging 1 DC charge circuit faulty 1
Perform DC voltage check of generator charging circuit See
Testing the Battery Charging Circuit
2 Alternator drive 2 Check drive belt tension alternator should turn freely Check
for loose connections Check output with voltmeter Ensure 12
volts are present at the Exc terminal
continued
Engines Generators
ENGINE Problem Probable Cause Engine slows and stops 1
Fuel lift pump failure 1 Fuel lift pump should make a distinct ticking sound Replace
pump with spare
2 Switches andor wiring loose 2 Inspect wiring for short circuits and loose connections
or disconnected Inspect switches for proper operation
3 Fuel starvation 3 Check fuel supply fuel valves fuel lift pump
4 20 Amp circuit breaker tripping 4 Check for high DC amperage draw during operation
Ensure breaker is not overly sensitive to heat which would
cause tripping
5 Exhaust system is restricted 5 Check for blockage collapsed hose carbon buildup at
exhaust elbow
6 Water in fuel 6 Pump water from fuel tanks change filters and
bleed fuel system
7 Air intake obstruction 7 Check air intake filter cartridge
Engine down 1 Raw water not circulating 1 Raw water pump failure Check impeller replace
2 Coolant not circulating 2 Obstruction at raw water intake or raw water filter
2a Thermostat remove and test in hot water
Replace thermostat
2b Loss of coolant check hoses hose clamps drain plug etc
for leaks
2c Broken or loose belts 2d Air leak in system run engine and
open the pressure cap to
bleed air Add coolant as needed
Engine alarm sound pulsates 1 Loss of oil 1 Check dipstick look for oil leaks at oil filter and at
oil drain hose connection
2 Oil pressure switch 2 Replace oil pressure switch
Engine alarm sounds continuously 1 Engine coolant 1 Check engine coolant level
2 High temperature switch opens at 2 Check for satisfactory operation with switch bypassed
too Iowa temperature check with ohmmeter replace if faulty
Exhaust smoke problems 1 Blue smoke 1 Incorrect grade of engine oil
1a Crankcase is 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 smoke 3 Improper grade of fuel
3a Fuel burn incomplete due to high backpressure in exhaust or
insufficient air for proper combustion check for restrictions in
exhaust system check air intake
3b Improperly timed injectors or valves or poor compression
3c Lack of air check air intake and air filter Check for proper
ventilation
3d Overload
COOLANT TEMPERATURE AND OIL PRESSURE GAUGES
If the gauge reading is other than what is normally indicated If both of the above gauge tests are positive the gauge is
by the gauge when the instrument panel is energized the first undoubtedly OK and the problem lies either with the
step is to check for 12 volts DC between the ignition B conductor from the sender to the gauge or with the sender
and the Negative B terminals of the gauge If either of the above gauge tests are negative the gauge is
Assuming that there is 12 volts as required leave the probably defective and should be panel energized and perform the following
steps Assuming the gauge is OK check the conductor from the
1 Disconnect the sender wire at the gauge and see if the sender to the sender terminal at the gauge for continuity
gauge reads zero which is the normal reading for this Check that the engine block is connected to the ground
situation Some starters have isolated ground terminals and if the
2 Remove the wire attached to the sender terminal at the battery is connected to the starter both plus and minus
sender and connect it to ground See if the gauge reads terminals the ground side will not necessarily be connected
full scale which is the normal reading for this situation to the block
WESTERBEKE
Engines Generators
METER NOTE Current model tachometers use a coarse meter used in propulsion engine instru
dial to set the tachometer to the crankshaft pulley rpms The
ment panels contains two separate electrical circuits with a calibrating screw is then used for fine ground One circuit operates the hour
meter and the
other the tachometer The hour meter circuit operates on 12
volts alternator charging voltage supplied to the terminal
on the backofthe tachometer circuit operates on AC voltage 68 volts fed
from one of the diodes in the alternator and supplied to input terminal while the engine is running and
the alternator producing battery charging voltage 130148 DC
The following are procedures to follow when a fault in either of the two circuits in a
INP
Hour meter Inoperative AC VOLTAGE
Check for the proper DC voltage between and IDLE SPEED ADJUSTMENT
1 Voltage present meter is defective repair or replace
TACHOMETER CHECK New Voltage not present trace and electrical con
nections for fault Jump 12 volts DC to meter
Checking the idle speed
terminal to verify the operation NOTE In a new installation having new instrument panels
the tachometer may not always be correctly calibrated to Inoperative engine rpm This calibration
should be checked in all new
Check for the proper AC voltage between tachometer input and terminal with the engine running
1 Warm up the engine to normal operating Voltage present attempt adjusting meter through calibra Remove any specks on the crankshaft
pulley with a clean
tion access hole No results repair or replace meter cloth and place a piece of suitable reflecting tape on the
2 AC voltage not present check for proper alternator DC pulley to facilitate use of a photoelectric type tachometer
output voltage 2 Start and idle the engine
3 Check for AC voltage at tach terminal on alternator to 3 Aim the light of the tachometer onto the reflecting tape to
ground confirm the engine speed Check the instrument panel
4 Check electrical connections from tachometer input ter tachometer reading Adjust the tachometer in the panel by
minal to alternator connection using the instrument coarse adjustment to calibrate the
instrument reading to the closest RPM that the photo Sticking is showing Then use the fine
calibration adjustment to
1 Check for proper AC voltage between tach inp termi bring the instrument to the exact reading as the photo tach
nal and terminal 4 Adjust the idle speed if the engine speed is not within the
2 Check for good ground connection between meter ter specified value
minal and Check that alternator is well grounded to engine block at
alternator pivot Inaccurate
a With a handheld tach on the front of the crankshaft pul
ley retaining nut or with a strobetype tach read the front
crankshaft pulley rpm at idle
b Adjust the tachometer with a small Phillips type screw
driver through the calibration access hole in the rear of
the tachometer Zero the tach and bring it to the rpm
indicated by the strobe or the hand tach Verify the rpm
at idle and at high speed rpm Adjust the tach as
needed
Engines Generators
ENGINE THE IDLE SPEED DRIVE BELT ADJUSTMENT
1 Loosen the locknut on the idle adjustment bolt on the Proper inspection service and maintenance of the drive belts
fuel injection pump is important for the efficient operation of your engine see
2 Adjust the bolt so that the throttle control lever will hold Drive Belts under MAINTENANCE SCHEDULE
the engine at a quiet idle 750 1000 RPM Drive belts must be properly tensioned Loose drive belts
3 Tighten the locknut will not provide proper alternator charging and will eventu
ally damage the alternator Drive belts that are too tight will
4 Race the engine several times to ensure the idle speed
pull the alternator out of alignment andor cause the alterna
remains as set tor to wear out prematurely Excessive drive belt tension can
NOTE Should the engine rpm be in question verify the also cause rapid wear of the belt and reduce the service readings as shown at
the instrument panel with a of the coolant pumps bearing A slack belt or the presence of
mechanical or strobetype tachometer at the engine crank oil on the belt can cause belt slipping resulting in high oper
shaft See TACHOMETER ating temperatures and tachometer variations
IDLE ADJUSTMENT BOLT The drive belt is properly adjusted if the belt can be deflected
no less than 38 inch IOrnm and no more than 112 inch
12rnrn as the belt is depressed with the thumb at the mid
point between the two pulleys on the longest span of the belt
A spare belt or belts should always be carriej on board
A WARNING Never attempt to check or adjust the
drive belts tension while the engine is in operation
ENGINE STOP ADJUSTMENT
Adjusting Belt Tension
POSITON CABLE SO THAT THE
1 Loosen the alternator adjusting strap bolt and the base
STOP CONTROL CABLE STOP CONTROL WILL SHUT THE mounting bolt
ENGINE DOWN 2 With the belt lose inspect for wear cracks and frayed
edges
FUEL SHUTOFF SOLENOID OPTIONAL 3 Pivot the alternator on the base mounting bolt to the left
The optional fuel shutoff solenoid allows the engine to be or right as required to loosen or tighten
shut down using the instrument panel key switch The 4 Tighten the base mounting bolt and the adjusting has been factory set and
does not require 5 Run the engine for about 5 minutes
then shut down and
recheck the belt tensions
RECOMMENDED RPM RANGE
Model Idle RPM Cruise RPM Max RPM
44AJFOUR 8001000 25003000 35003600
44BIFOUR 8001000 20002500 29003000
35CITHREE 10001200 25003000 35003600
35DITHREE 10001200 20002500 29003000
OPTIONAL FUEL
SOLENOID
Engines Generators
ENGINE ADJUSTMENTS
NOTE WESTERBEKE recommends that the following engine adjust
ments be peiformed by a competent engine mechanic The information
below is provided to assist the ENGINE COMPRESSION FUEL certain the oil level dipstick is at the
correct level and In case of severe vibrations and detonation noise have the
the air intake filter is clean The battery and starter motor injectors checked and overhauled by an authorized fuel
must also be in good condition injection service center Poor fuel quality contaminants and
1 Warm the engine to normal operating temperature loss of positive fuel pressure to the injection pump can result
in injector faults Since fuel injectors must be serviced in a
2 Move the control lever to a position for shutting off the
clean room enviroment it is best to carry at least one extra
fuel Disconnect the wires if a fuel shutdown solenoid is injector as a spare should a problem occur
used
Before removing the old injector clean the area around the
3 Remove all the glow plugs from the engine and install
base of the injector to help prevent any rust or debris from
the compression gaugeadapter combination to the cylin
falling down into the injector hole If the injector will not lift
der on which the compression is to be measured out easily and is held in by carbon buildup or the like work
the injector sidetoside with the aid of the socket wrench to
free it and then lift it out
The injector seats in the cylinder head on a copper sealing
washer This washer should be removed with the injector and
replaced with a new washer when the new injector is
installed
Injector to Cylinder Head Tightening Torque 40 4 ftlb 55 05 kgfm
TESTING ENGINE
COMPRESSION
PRESSURE
GAUGE
ADAPTER
WPLUGHDLE FUEL INJECTOR
4 Close the raw water seacock Crank the engine and allow the gauge to reach a
maximum reading then record that reading
6 Repeat this process for each cylinder
Compression pressure 427 psi 30 kgfcm2 at 290 rpm
Maximum permissible difference between cylinders is 427 psi
3 lfthe readings are below the limit the engine needs
repair
7 Reinstall the glow plugs use antiseize compound on
the threads and reset the fuel shutoff to the run position
8 Open the raw water seacock low compression is found determine the cause by
applying a small amount of oil in the cylinder thru the glow
plug hole Allow the oil to the pressure gauge and repeat the above test If reading rises dramatically the fault is with the
rings If the compression valve does not rise the problem is
with the valves
A slight rise in compression would indicate a problem with
both the rings and the valves
Engines Generators
ENGINE ADJUSTMENTS
NOTE WESTERBEKE recommends that the following engine adjust
ments be performed by a competent engine mechanic The information
below is provided to assist the mechanic
VALVE CLEARANCE ADJUSTMENT b With No1 piston at top dead center on the compression
stroke the rocker arms will not be moved when the
Make the following adjustments when the engine is cold crankshaft is turned approximately 200 in both directions
1 Remove the cylinder head cover c If the rocker arms move No1 piston is at top dead
2 Slightly loosen the cylinder head bolts and retighten them center on the intake or exhaust stroke In such a case
to the specified torque in the number sequence shown turn the crankshaft 3600 in the direction of engine
below Tightening Torque 65 4 Ibft 88 5 Nm
rotation again No1 piston is now at top dead center on
the compression stroke
04 02 os
FRONT
44 FOUR
4 Loosen the lock nut for the adjusting screw With a feeler
gauge inserted between the rocker arm and valve cap
adjust the valve clearance by turning the adjusting screw
35 THREE Make certain to adjust all the valves
3 Find top dead center compression position for No1
piston by using the procedure that follows 025mm
00098 INCHES
a Turn the crankshaft until IDe mark on the crankshaft INTAKE EXHAUST
pulley is aligned with the mark on the timing gear case
TOC TOP DEAD CENTER
MARK FOR NO1
AND NO4 PISTONS 5 Install the cylinder head cover
Head Cover Bolt Torque 2 3 ftIb 03 045 mkg
TOC MARK FOR
NO2 AND NO3 PISTONS
Engines Generators
JS AND BW If the throw distance or travel of the remote cable is too
short the gear box lever cannot fully engage the gear ration is 247 to 1 This manual
into FORWARD or REVERSE In this situation the rotates opposite to the engine when in forward
missions internal clutches will wear prematurely and the
gear The transmission transmits its power with casehard
transmission may over heat and eventually fail
ened helical gears and in reverse an intermediate gear The
reversing process is carried out by a servo double disc sys Excessive throw distance in the remote control level is not
tem For safety reasons the transmission is NOT filled with detrimental to the transmission Note that the position of oil for shipment
Before leaving the factory each remote control lever should align with the NEUTRAL is thoroughly tested with oil in the transmission
ing on its bracket when the transmission is really in
This testing among other things provides all the internal with a coating of oil This oil acts as a preservative pro
viding reliable protection against corrosion for at least one JS GEAR BOX SHIFT LEVER
year if the transmission is properly stored
The transmission is an type Fill up to or near the top of the machined notch cut
on the dipstick with SAE 20W20 or SAE 30 weight engine
oil exclusively Multigrade oils are not to be used in DO NOT mi giades of oil Lubricating oils
may have an API specification of CF or CG4
GEAR d
SHIFT f
The oil capacity for the transmission is approximately 10
quart 10 liter Check the oil level daily after the engine has
CABLE
been warmed and stopped The oil level should be main
tained at the top of the machined flat on the dipstick when
the dipstick is completely inserted into the transmission hous REVERSE FORWARD
ing Make sure the two Oring gaskets on the dipstick are in NEUTRAL
good shape These Orings will keep the dipstick in the transmission oil after the first 25 hours of engine and thereafter every 250 hours
or once a year min To shift the transmission fron NEUTRAL into The transmission has a 6 mm Allen Hex wrench drain exert
a heavy push to the remote control lever A gentle throw
plug for draining the oil To make sure most of the oil will may not carry enough force to actually shift the from the transmission warm
the oil by running the sions internal gears A gentle throw is signalled by the trans
engine in NEUTRAL for approximately 10 to 15 minutes mission not engaging into the desired drive Make sure the
This oil may also b removed by attaching a pump into the remote control lever is lubricated at least once each opening so the oil may
be sucked out The operating season Shift the transmission while the engine is running at
oil temperature must not exceed 250F 120C 1200 rpm or only controls required to operate the transmission is a
A CAUTION NEVER remove or loosen the level remote controlled cable The cable should be gear box lever cover from transmission
The position of
attached to the gear box lever using the cable bracket this plate and the actuating level inside of the
supplied with the unit Both the gear box lever and the
transmission has been finely adjusted at the factory to
remote control lever must be in the NEUTRAL position
when the cable is attached to the gear box lever This allows ensure equal throw distance of internal remote cable an equal throw distance
to shift the gear box Loosening of this covers capscrews voids the
into FORWARD or into REVERSE from the NEUTRAL transmission without running out of cable Allow inches of cable throw
from the NEUTRAL position on
the gear box lever to each of the two
Enaines Generators
37 Revised October 2001
JS AND BW SAILING OPERATION SERVICE
The transmission should be left in its NEUTRAL position If any seal on the transmission shows signs of leaking have
while sailing Leaving the transmission in NEUTRAL while the transmission looked at by a qualified WESTERBEKE
sailing alleviates unnecessary drag on the vessel because the dealer This problem especially concerning the rear seal is
propeller is able to freewheel spin However if the trans often contributed to an improper alignment of the
mission is left in its FORWARD gear while sailing the coupling and the propeller shafts coupling
transmission will not be damaged Leaving the transmission Disassembly of the transmission in the field is not recom
in NEUTRAL is just good sailing practice mended If an overhaul or repair is needed the work should
be done by an authorized WESTERBEKE service center
COOLING
The transmission is raw watercooled Raw water enters the MAINTENANCE
transmission through a stainless steel inlet pipe located at the Transmission maintenance is minimal Keep the exterior
base of the bell housing This water helps to cool the trans housing clean check the fluid level as part of your regular
missions lubricating oil routine and change the fluid every 300 operating hours
Periodically inspect the transmission and the cooler for leaks
and corrosion Make certain the air vent is clear and when
checking the fluid level look for signs of water fluid will appear
as strawberry cream
BELL HOUSING
Storage requires special care Follow these procedures
NOTE This operation will usually occur when the engine raw
water water cooling system is properly winterized
oClean up the transmission and touchup any unpainted
areas use heat resistant paint
Fill the transmission with SAE 30 engine oil to prevent
COUPLING internal corrosion only 12 months
or more
oLoosen attaching hardware from the transmission output
flange and propeller shaft coupling flange before
removing the boat from the water Seperate the flanges
RAW WATER and spray with lubricant
COOLING o Inspect the gear shift cable linkage and attachments
Look for corrosion of the end fittings cracks or cuts in
the conduit and bending of the actuator rods Lubricate
JS and BW TRANSMISSIONS all moving parts
NOTE If the transmission is to be stored for a long time
tWelve months or more it should be topped off with oil to
prevent internal corrosion Reduce the oil level before putting
JS AND BW TRANSMISSIONS the engine back into service
General Casehardened helical gears with an
intermediate reverse gear Reversing out
by servo double disc system
Gear ratio optional 247 1
Propeller ShaH Right hand standard transmission
Direction of Rotation
Propeller See propeller Lubricating Oil SAE 20WI20 or SAE 30 exclusively Do
not mix grades of oil or use API CF CG4 or SJ
Transmission Sump 1 qt 1 liter
Capacity
Engines Generators
38 Revised October 2001
BORG WARNER VELVET DRIVE TRANSMISSION
OPTIONAL TRANSMISSION 44 FOUR ONLY
SHIFT LEVER POSITION
OIL ULlfll The gear shift control mechanism and linkage must position
the actuating lever on the transmission exactly in Forward
F Neutral N and Reverse R shifting positions A detent
ball located behind the transmission lever must work freely
to center the lever in each position The gear shift positions at
the helm must be coordinated with those of the Velvet Drive
actuating lever through shift mechanism adjustments An
improperly adjusted shift mechanism can cause damage to
the transmission The shifting mechanism and transmission
actuating lever should be free of dirt and well lubricated to
ensure proper operation
Shifting Into Gear
Place the gear shift in Neutral before starting the engine
BORG WARNER Shifting from one selector position to another selector posi
VELVET DRIVE tion 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 set the throttle at idle speed
allow the transmission fluid to warm up for a few safety reasons the transmission is not filled with trans fluid during shipment and the
selector lever is tem Move the gear shift lever to the middle position You attached to the actuating shaft feel
the detent This centers the actuating lever on the trans
Before leaving the WESTERBEKE plant each transmission mission With the control in this position hydraulic power is
undergoes a test run with Dextron III ATF transmission fluid completely interrupted and the output shaft of the transmis
The residual fluid remaining in the transmission after drain sion does not tum
ing acts as a preservative and provides protection against
NOTE Some transmissions are equipped with a neutral for at least one year if properly stored
switch Unless the transmission actuating lever is FLUID aligned in neutral the engine starter
will not the transmission fluid level on the dipstick If has not been filled fill with Dextron III and to use this fluid During the
first 25 hours of opera Move the gear shift lever to the forward position You should
tion keep a lookout for any leakage at the bell housing out feel the detent The actuating lever on the transmission is in
put shaft and transmission cooler This fluid should be the forward position The output shaft and the propeller shaft
changed after the first 25 hours and approximately every 300 move the boat in a forward hours thereafter andor at winter layup
Reverse
Move the gear shift lever to the reverse position You should
A CAUTION Be certain the transmission is filled feel the detent The actuating lever on the transmission is in
the reverse position The output shaft and the propeller
and the correct size cooler is properly installed before
should move the boat in a reverse direction astern
starting the engine
NOTE Moving the transmission actuating lever from Neutral
Position to Forward is always toward the engine Reverse is
always away from the engine If boat moves backwards with
the gear shift control in the forward position shut off the
engine This problem may be a result of incorrect movement
of the actuating lever by the gear shift lever
Engines Generators
BORG WARNER VELVET DRIVE TRANSMISSION
D Clean off the transmission and properly dispose of the
used fluid
D Refill the transmission with DEXTRON III ATF The
quantity will vary depending on the transmission model
and the installation angle Fill through the dipstick hole
D Check the dipstick for the proper fluid level
D Replace the oil filler cap and dipstick Press the dipstick
into place and tum clockwise until D Run the engine shutdown and recheck the
fluid NEUTRAL REVERSE
TRANSMISSION ACTUATING LEVER POSITIONS A WARNING Never pull out the dipstick while the
engine is running Hot fluid will splash from the OPERATION hole This could cause severe burns
D Check the transmission fluid
D Visually check the gear shift linkage and transmission Oil Capacity
D Start the engine in neutral Allow a few minutes at idle Approximately 25 quarts 236 liters will fill most transmis
for the fluid to warm sions to the oil level fill mark on the dipstick Many variables
NOTE Too Iowan idle speed will produce a chattering have a direct relationship to the oil capacity Additional oil
noise from the transmission gear and damper plate In will be required to fill the oil cooler and the cooler lines The
such cases the idle speed should be increased angle of installation will make a difference in the quantity of
oil required to fill the Shift into gear
MAKE CERTAIN THE
RUBBER SEAL IS
A CAUTION Shifting gears above 1000 rpm can SCREWED
cause damage to the engine damper plate Pulling the TIGHT TO THEl
HANDLE
throttle back to idle when shifting gears will save wear
on the transmission and the damper plate
Visually check for oil leaks at the hydraulic connections
Check for wear on the hydraulic lines and replace if worn
D Lubricate the detent ball and shift cable Inspect the shift linkage
D Inspect the transmission bolts retorque if necessary
A CAUTION Clutch failure will occur if the transmis
sion shift lever does not fully engage the detent ball Oil Temperature
positions A maximum oil temperature of 190F 88C is recom
mended Discontinue operation anytime sump oil THE TRANSMISSION FLUID ture exceeds 230F the initial 50 hour
change the transmission fluid should PRESSURE GAUGE
be changed at every 300 operating hours thereafter or at win
ter haulout However the fluid must be changed whenever it An optional mechanical pressure gauge can be installed at
becomes contaminated changes color or smells rancid the control panel to constantly monitor the pressure of the
transmission fluid A normal reading at 2000 rpm in forward
D Remove the oil filler cap and dipstick gear should indicate 95 120 Ibin2 67 84 kgcm2 and be
D Remove the oil cooler return line and allow the oil to constant
drain into a container
D Reconnect the oil cooler return line
D Use a suction pump to remove the transmission oil
through the filler capdipstick hole
Engines Generators
BORG WARNER VELVET DRIVE WARRANTY maintenance is minimal Keep the exterior
Service manuals are available from your BORG clean check the fluid level as part of your regular and change the fluid every 300 operating
hours For assistance inspect the transmission and the cooler for leaks Richmond and Velvet Drive
and corrosion Make certain the air vent is clear and when 1208 Old Norris Road
checking the fluid level look for signs of water contamination Liberty SC 29657
fluid will appear as strawberry cream Tel 800 BORG WARNER
is aware of the shock loads that can be
placed on its gears as the result of mechanical requires special care Follow these procedures
operation or fully reversing of the propeller blades while
o Drain the water from the transmission oil cooler and shifting Therefore torque loads and directional changes
replace it with a proper mixture of antifreeze coolant should be made at low engine speeds If it is found that a
NOTE This operation will usually occur when the engine failure was caused by a shock load any warranty claim will
raw water cooling system is properly winterized be denied
o Clean up the transmission and touchup unpainted areas
use heat resistant paint A CAUTION noises or vibrations can
o Fill the transmission with Dextron III ATF fluid to pre occur at low engine speeds which can cause gear rattle
vent internal corrosion resulting in damage to the engine andor Loosen attaching hardware from the
transmission BORG WARNER is not responsible for total system
output flange and propeller shaft coupling flange before related torsional vibration of this type
removing the boat from the water Separate the flanges
and spray with lubricant If any problems occur with the transmission see
o Inspect the gear shift cable linkage and attachments TRANSMISSION in this manual
Look for corrosion of the end fittings cracks or cuts in
the conduit and bending of the actuator rods Lubricate
all moving parts
NOTE If the transmission is to be stored for a long time
twelve months or more it should be topped offwith
fluid to prevent internal corrosion Reduce the fluid level
before putting the engine back into COOLERS
The continued flow of raw water through the cooler will in If water has contaminated the fluid the transmission fluid
time erode the inside of the cooler causing cross leaks to needs to be cleaned out and replaced with fresh fluid It will
occur These internal cooler leaks will cause one of the take several fluid changes to get rid of the two problems
Check your dipstick each time until it appears as pure
1 Transmission fluid will leak into the flow of raw water transmission fluid Change the transmission filter and clean
and be discharged overboard through the engine exhaust out the fluid lines that connect to the cooler
A loss of transmission fluid will cause the transmission to If the transmission fails to shift properly it will most likely
fail need the attention of a qualified transmission service facility
2 The raw water will leak into the transmission fluid A transmission cooler may last ten years or more but in
causing an increase in transmission fluid This some depending on operating hours tropical
contaminated fluid will appear as strawberry cream The waters maintenance etc it might only last half that time
transmission will eventually fail WESTERBEKE recommends having a spare cooler case requires an immediate response
1 Install a new oil cooler
2 Refill the transmission with DEXTRON III ATF
Engines Generators
ZF MARINE NOTE When installing the transmission make certain that
The infonnation below is specific to the ZF shifting is not impeded by restricted movability of the
the TRANSMISSION SECTION Bowden cable or rod linkage by unsuitably positioned guide
applies to all models sheaves too small a bending radius etc In order to mount a
support for shift control cable connections use the OF GEAR BOX WITH PROPELLER threaded holes located above the shift
cover on top of the
HBW recommend a flexible connection between the gear housing Refer to the WESTERBEKE parts gearbox and the propeller shaft if
the engine is CONTROL mounted in order to compensate The installation of a special propeller thrust The transmission is suitable for
single lever remote is not required since the propeller thrust will be Upon loosening the retaining screw the actuating lever can
taken by the transmission bearing provided the value be moved to any position required for the control under is not exceeded
cable or rod linkage Make certain that the shift lever does
However the output shaft should be protected from not contact the actuating lever cover plate the loads Special care should be
taken to prevent distance between lever and cover should be vibration When using a universal joint shaft make The control cable or
rod should be arranged at right angle to
certain to observe the manufacturers instructions the actuating shift lever when in the neutral position The
Even with the engine solidly mounted the use of flexible neutral position of the operating lever on the control or DRIVESAVER will reduce
stress in the should coincide with the neutral position of this bearings caused by hull distortions especially in The
shifting travel as measured at the pivot point of the
wooden boats or where the distance between transmission actuating lever between the neutral position and end
output flange and stem gland is less than about 800mm positions A and B should be at least 35mm for the outer and
30mm for the inner pivot point
A greater amount of shift lever travel is in no way
ZF 15M detrimental and is recommended However if the lever
travel is shorter proper clutch engagement might be impeded
which in tum would mean premature wear excessive heat
generation and clutch plate failure This would 1e indicated
by slow clutch engagement or no engagement at all
NOTE Checkfor proper lever travel at least each season
NEUTRAL
A CAUTION The position of the mechanism behind SHIFT
the actuating lever is to ensure equal LEVER
shift1ever travel position A and B If
this mechanism is in any way tampered with the COVER
transmission warranty will be void
Engines Generators
OSmm F
MINIMUM DISTANCE
ZF MARINE OPERATION OPERATING HBW marine transmissions are testrun on a test
stand The maximum permissible ATF temperature should not exceed
with the engine at the factory prior to delivery For safety 230 110 This temperature can only be reached for a short
reasons the fluid is drained before shipment time
Fill the gearbox with Automatic Transmission Fluid
DEXRON II or DEXTRON III The fluid level should be A CAUTION fluid temperature is
up to the index mark on the dipstick To check the fluid level too high stop the engine immediately and check the
just insert the dipstick do not screw it in Screw the dipstick transmission fluid
into the case after the fluid level is checked and tighten Do
not forget the sealing ring under the hexhead of the for leaks and change the fluid after the first 25 hours LOCKING THE
make a visual inspection of the coupling oil cooler and Locking of the propeller shaft by an additional brake is not
hoses and shift cables required use the gear shift lever position opposite your direc
tion of travel for this purpose Never put the gear shift in the
DIPSTICK position corresponding to the direction of travel of the boat
WHEN UNDER SAIL OR BEING TOWED
Rotation of the propeller without load such as when the boat is
being sailed being towed or anchored in a river as well as
FLUID OPERATING operation of the engine with the propeller stopped for charg
ing the battery will have no detrimental effects on the trans
mission
DAILY OPERATION
o Check the transmission fluid
FLUID LEVEL o Visually check the gear shift linkage and Inttl
o Start the engine in neutral allowing a few minutes at
idle to warm the fluid
FLUI DRAIN
I o Shift into gear
FLUID CHANGE NOTE Too low an idle speed will produce a chattering noise
from the transmission gear and damper plate In such cases
Change the fluid for the first time after about 25 hours of
the idle speed should be then every 250 operating hours or at least once a
year or when you change engine oiL For additional information refer to the following text in
this
Transmission Section SHAFT COUPLINGS the fluid AND TRANSMISSION a suction
pump hose down through the dipstick hole to
the bottom of the housing and suck out the fluid If space
allows use the transmission drain Remove the drain plug ZF TRANSMISSIONS the bottom of the transmission and
allow the fluid to
drain into a container then reinstall the plug with its sealing General ZF Standard Transmission Case
washer Wipe down the transmission and properly dispose of hardened helical gears with a
the used fluid After running the engine shut down and multiple disc the fluid level
Gear Ratio optional ZF 15MA 1881 or 2631
Drain plug torque 20 25 fUlbs Note There are a variety ZF 10MA 1791
of gear ratios available ZF 12MA 2631
Only a few are listed ZF 15MIV 2131 or 2721
NOTE When changing the fluid take care not to lose the
drain plug sealing washer The drain plug will leak without lubricating Fluid ATF Type A or Dextran or III
this sealing washer Propeller Shaft Righthand rotation for above
models
Direction of Rotation listed
A WARNING Never pull out the dipstick while the
engine is running Hot fluid will splash from the dip
stick hole This could cause severe burns
Engines Generators
ZF MARINE OPERATING TEMPERATURE MAINTENANCE
Transmission maintenance is minimal Keep the exterior
housing clean check the fluid level as part of your regular
A CAUTION If the transmission fluid temperature is routine and change the fluid every 300 operating hours
too high stop the engine immediately and check the Periodically inspect the transmission and the cooler for leaks
transmission fluid and corrosion Make certain the air vent is clear and when
checking the fluid level look for signs of water Normal operating temperature of the transmission fluid fluid will appear as
strawberry cream
should be in the range of 1220 F 50 C to 2120 F 1000 C
A maximum temperature of 2660 F 1300 C may b only reached for a short time
Storage requires special care Follow these procedures
Make certain there is enough space around the transmission o Drain water from the transmission oil cooler and replace
to provide good ventilation and cooling with a proper mixture of antifreeze coolant
TRANSMISSION COOLER NOTE This operation will normally occur when the
Coolers are standard equipment for the ZF lOMZF 12M engine raw water cooling system is properly winterized
ZF 15M ZF 15MA ZF 15MIY and the ZF 25M o Clean up the transmission and touch up unpainted areas
The cooler is a separate part of the transmission which use heat resistant paint
prevents any possibilities of coolant diluting the transmission o Fill the transmission with Dextron III ATF fluid to
fluid However the continued flow of coolant thru the cooler prevent internal corrosion extended storage only twelve
will in time erode the inside of the cooler causing external months or more
leaks o Loosen attaching hardware from the transmission output
A transmission cooler may last ten years or more but in flange and propeller shaft coupling flange before
some depending on operating hours tropical removing the boat from the water Separate the flanges
waters maintenance etc it might only last half that time and spray with lubricant
WESTERBEKE recommends having a spare cooler aboard o Inspect the gear shift cable linkage and attachments
Look for corrosion of the end fittilgs cracks Qr cuts in
the conduit and bending of the actuator rods Lubricate
all moving parts
NOTE lfthe transmission is to be storedfor a long time
twelve months or more it should be topped offwith
fluid to prevent internal corrosion Reduce the fluid level
before putting the engine back into PERIODICALLY INSPECT FOR
EROSION AND LEAKAGE
tGEAR
SHIFT
For additional information contact
ZF MARINE GEAR
ZF Industries
Marine US Headquarters
3131 SW 42nd Street
Fort Lauderdale FL 33312
Tel 954 5814040
Fax 954 5814077
Engines Generators
PRM NEWAGE MODELS 80 AND 120
Push a suction pump hose down through the dipstick hole
to the bottom of the housing and suck out the fluid If space
allows use the transmission drain Remove the drain plug
THE MODEL 720 HAS A BREATHER from the bottom of the transmission I with sealing washer
FITTING ON THE TOP OF THE CASE and allow the fluid to drain into a container then reinstall the
plug with its sealing washer Wipe down the transmission and
properly dispose of the used fluid After running the engine
shut down and recheck the fluid level
rllDnrV 72 HEX PLUG
MODEL 80 MODEL 720 USES NOTE When changing the fluid take care not to lose the
A 8MM HEX PLUG drain plug sealing washer The drain plug will leak without
this sealing washer
A WARNING Never pullout the dipstick while the
engine is running Hot fluid will splash from the dipstick
hole This could cause severe burns
DAILY OPERATION
Check the transmission fluid
FULL 0
Visually check the gear shift linkage and o
Start the engine in neutral allowing a few minutes at
LOW idle to warm the fluid
0 Shift into gear
NOTE Too low an idle speed will produce a chattering noise
GEAR SHIFTING
from the transmission gear and damper plate In such cases
SEAUNG WASHER the idle speed should be increased
The engine must be at idle Pause in neutral before
selecting ahead or astern Transmission models PRM 80 and
120 are ideal for single lever engine controls controlling
both the throttle and the gear shift at one time
INITIAL the dipstick and fill the gear box with automatic A WARNING When shifting gears bring the fluid ATF Dextron m Fill the
transmission throttle to idle and pause in neutral before shifting
with the recommended capacity of fluid ahead or astern
Model PRM8010 US pint 06L
Model PRM 12014 US pints 08L
NOTE Always clean the area around the dipstick plug before LOCKING THE with fluid Replace the dipstick by screwing it down Locking
of the propeller shaft by an additional brake is not
Run the engine to warm up the fluid and after shutting down required use the gear shift lever position opposite your
the engine recheck the fluid level direction of travel for this purpose Never put the gear shift
in the position corresponding to the direction of travel of the
CHANGING THE TRANSMISSION FLUID boat
Change the fluid for the first time after about 25 hours of WHEN UNDER SAIL OR BEING then every 250 operating hours or at least once
a year or when you change engine oil Check for leaks and Rotation of the propeller without load such as when the boat
make a visual inspection of the shift cables and shaft is being sailed being towed or anchored in a river as well as
coupling operation of the engine with the propeller stopped for
charging the battery will have no detrimental effects on the
Engines Generators
PRM NEWAGE MODELS 80 AND 120 N
CABLES I
NOTE When installing the transmission make certain that 35
Ir 30
shifting is not impeded lJy restricted movability of the 3011
Bowden cable or rod linkage lJy unsuitably positioned guide I J
sheaves too small a bending radius etc 11
1 0 II
The control cable or rod should be arranged at right angle to ACTUATING D i
SHIFT LEVER SHIFT CABLE AND BRACKET
the actuating shift lever when in the neutral position The
neutral position of the operating lever on the control coincide with the neutral position of this lever A greater amount of shift
lever travel is in no way
The shifting travel as measured at the pivot point of the detrimental and is recommended However if the lever between the neutral
position and end travel is shorter proper clutch engagement might be A and B should be at least 35mm for the outer and
which in tum would mean premature wear excessive heat
30mm for the inner pivot point generation and clutch plate failure This would be indicated
by slow clutch engagement or no engagement at NOTE Checkfor proper lever travel at least
each season
Problem Probable Cause Excessive noise at low speeds 1 Engine idle speed too low
1 Increase idling speed
Excessive noise at all speeds 1 Defective coupling 1 coupling if necessary
2 Shaft misalignment 2 Check alignment with feeler gauge
3 Prop out of balance 3 Remove check pitch balance and weight
Fluid needs constant topping off 1 Power too high 1 Compare engine and transmission data
2 Ruid leak 2 Inspect seals drain check for fluid leaks
Difficulty in moving lever control 1 Poor installation of cable 1 coupling if necessary
2 Faulty cable 2 Check alignment with feeler gauge
Escape of pressure from gearbox 1 Defective breather 1 Inspect breather Model 120 contact a Distributor or your
when dipstick is removed Model 120 WESTERBEKE
If a major problem should occur contact your certain the transmission fluid is changed annually dealer or a NEWAGE distributor To
avoid the fluid should become contaminated by water or the warranty rights do not undertake repair work on the
gearbox suffers major mechanical damage the gearbox gearbox without first contacting NEWAGE
must be thoroughly flushed out and refilled with fresh fluid TRANSMISSIONS liMITED or a NEWAGE the correct
or your WESTERBEKE TRANSMISSIONS LTD has distributors around
the world Listed here are those in the United States Warranty
Newage transmission limited warrants that all PRM Marine Gear Supply Inc Transmissions will be free from
defects in material and
418 Boston Street worlananship under normal use and service for a period or
Topsfield MA 01933 twentyfour months
Tel 9788875599 All PRM Transmissions must be correctly installed aligned
and Jet
1111 NW Ballard Way
Seattle WA 98107
Tel Marine
223 Southwes133 Court
PO Box 21086
Ft Lauderdale FL contact your Westerbeke dealer
Engines Generators
TRANSMISSION I
CONTROL CABLES
The majority of transmission difficulties arise as a result of A new cable and perhaps a new linkage mechanism may be
improper clutch adjustments manual or needed While the cable is loose shift the transmission in and
problems With control cables hydraulic out of gear using the lever on the side of the transmission to
rather than from problems with the transmission itself make sure theres no binding inside the case
PRM clutches in particular are very sensitive to improper If the transmission passes these tests crank the engine and
cable adjustments have a helper put it in forward and reverse while you observe
If you experience operating problems with the transmission the propeller shaft if the shaft isnt turning the the engine
down First check the needs professional attention If it does turn but theres no
level then have a helper move the cockpit shift lever through thrust check to see you still have a propeller on the end of
the full range from neutral to full forward back to the shaft or if you have a folding or feathering into full
reverse and back to neutral while you that it isnt stuck in the no pitch the actuating lever on the transmission If the
remote NOTE If you suspect a major problem in your stiff to operate break the cable loose at the transmission
immediately contact your WESTERBEKE dealer or an
and try again If it is still stiff check the cable for kinks or authorized marine transmission tight bends and check any
linkage for binding
Problem Probable Cause Transmission gears cannot be shifted 1
Actuating lever is loose 1 Tighten damping bolt on shifting lever
Fails to move into gear
2 Shifting cable is broken bent or 2 Check the cable reattach or replace
unattached Cable radius is too severe
3 Shift lever is binding against cover plate 3 Detach the shift cable and operate the lever by hand
Clearance should be 002 in 05mm
Transmission shifts into gear 1 Output coupling is not tuming 1 Transmission needs professional attention
but fails to propel the boat
2 Propeller shaft isnot turning 2 The coupling bolts are sheared or the coupling is Slipping
Output coupling is tuming on the propeller shaft Tighten or replace set screws keys
pins and coupling bolts as necessary
3 Output coupling and 3 Inspect the propeller It may be missing or damaged
propeller shaft are turning A folding propeller may be jammed A variable pitch
propeller may be in no pitch position
Delay of gear engagement or engages 1 Lever travel Nto B not equal to N to A 1 Adjust cover plate until the lever is exact only
after an increase in speed Refer to diagram Refer to SHIFT LEVER TEXT AND DIAGRAM
2 Shift level travel in insufficient 2 Check shift lever cable length See SHIFT LEVER DIAGRAM
3 Shift lever is binding against cover plate 3 Check clearance adjust if necessary
Transmission noise becomes louder 1 Damage starting on flexible coupling due 1 Check alignment inspect flexible coupling If noise
persists
to wear or fatigue possibly due to inspect the damper plate between the transmission and the
misalignment between engine and engine Replace if necessary
driveshaft
2 Beginning damage of bearings in 2 Transmission needs professional attention
transmission due to torsional vibrations
running without fluid overload wrong
alignment of transmission or excessive
engine output
Chattering transmission noise 1 The engine or propeller generates torsional 1 Mount a flexible coupling with another stiffness
factor
mainly at low engine speed vibrations in the drive unit which produces between the transmission coupling with and the
driveshaft
a chattering noise in the transmission A higher stiffness factor might be sufficient
2 Inspect the damper plate between the engine and the
transmission Replace if necessary
Boat fails to attain specified max speed 1 Operating temperature is high 1 Wrong type of fluid Use ATF Check fluid level
2 Operating without cooling 2 Check cooler Inspect coolant hoses and coolant flow
Oil Leakage 1 Corrosion at radial sealing ring and shaft 1 Transmission needs professional attention
Damaged sealing ring
2 Misalignment of output flanges 2 Check alignment Must be within 0003 in If you suspect a major problem in your contact your
WESTERBEKE dealer or an
authorized marine transmission facility
Engines Generators
PROPELLER CHART
TRANSMISSION PROPELLER PROPELLER
RATIO BLADE RH
44A FOUR
40 hp3600 rpm 201 170 x 10P 2 Blade
170 x BP 3 Blade
2471 1BO x 11P 2 Blade
1BO x 9P 3 Blade
2721 1BO x 13P 2 Blade
1BO x 11P 3 Blade
2991 200 x 13P 2 Blade
200 x 11P 3 Blade
35C THREE
29 hp3600 rpm 201 140x 10P 2 Blade
140 x BP 3 Blade
2471 x 11P 2 Blade
160 x 9P Blade
2631 x 13P 2 Blade
170 x 11P 3 Blade
2991 1BO x 13P 2 Blade
1BO x 11P 3 Blade
44B FOUR
39 hp3000 rpm 201 170 x 11P 2 Blade
170 x 9P 3 Blade
2471 200 x 13P 2 Blade
200 x 11P 3 Blade
2721 200 x 14P 2 Blade
200 x 12P 3 Blade
2991 220 x 15P 2 Blade
220 x 13P 3 Blade
35C THREE
31 hp3000 rpm 201 160 x 10P 2 Blade
160 x BP 3 Blade
2471 x 13P 2 Blade
1BO x 11P 3 Blade
2721 200 x 12P 2 Blade
200 x 10P 3 Blade
2991 220 x 13P 2 Blade
220 x 11P 3 Blade
NOTE For reductions not included consult the WESTERBEKE
factory for Engines Generators
LAYUP Fuel System owners rely on their boatyards to prepare their craft
Top off your fuel tanks with unleaded gasoline of 89 engines and generators for layup during the off or higher A fuel conditioner such as
STABIL or for long periods of inactivity Others prefer to stabilizer should be added Change the element in layup preparation themselves
separator and clean the metal bowl
The procedures which follow will allow you to perform your Reinstall and make certain there are no leaks Clean
own layup and or will serve as a checklist up any spilled fuel
if others do the procedures Fuel System Diese
These procedures should provide protection for your Top off your fuel tanks with No2 diesel fuel Fuel during a layup and also
help familiarize such as BlOB OR and STABIL should be added at this time to
you with its maintenance needs control algae and condition the fuel Care should be taken
If you have any questions regarding layup procedures call that the additives used are compatible with the primary fuel
your local servicing dealer He will be more than willing to filterwater seperator used in the system Change the assistance
in your primary fuel filterwater seperator if the fuel system
has one and clean the seperator sediment Shaft Coupling Propulsion Engine
Change the fuel filter elements on the engine and bleed the
The transmission and propeller half couplings should always
fuel system as needed Start the engine and allow it to run
be opened up and the bolts removed when the boat is hauled
for 5 10 minutes to make sure no air is left in the fuel
out of the water or moved from land to water and during
system Check for any leaks that may have been created in
storage in the cradle The flexibility of the boat oftens puts a the fuel system during this servicing correcting them as
severe strain on the propeller shaft or coupling or both while
needed Operating the engine for 5 10 minutes will help
the boat is taken out or put in the water In some cases the
allow movement of the treated fuel through the has actually been bent by these strains This does not
equipment on the engine
apply to small boats that are hauled out of the water when
not in use unless they have been dry for a considerable Raw Water Cooling of time
Close the throughhull fitting Remove the raw water intake
Fresh Water Cooling Circuit hose from the fitting Place the end of this hose into a five
gallon bucket of clean fresh water Before starting the engine
A 5050 solution of antifreeze and distilled water is recom
check the zinc anode found in the primary heat exchanger on
mended for use in the fresh water cooling system at all times
the engine and clean or replace it as required and also clean
This solution may require a higher concentration of antifreeze
any zinc debis from inside the heat exchanger where the on the areas winter climate Check the solution to
anode is located Clean the raw water sure the antifreeze protection is adequate
Start the engine and allow the raw water pump to draw the
Should more antifreeze be needed drain an appropriate amount
fresh water through the system When the bucket is empty
from the engine block and add a more concentrated mixture
stop the engine and refill the bucket with an the engine to ensure a complete circulation and mix
solution slightly stronger than needed for winter freeze
ture of the antifreeze concentration throughout the cooling
protection in your area
system Then recheck the antifreeze solutions strength
Start the engine and allow all of this mixture to be System through the raw water system Once
the bucket is empty stop
With the engine warm drain all the engine oil from the oil the engine This antifreeze mixture should protect the raw
sump Remove and replace the oil filter and fill the sump water circuit from freezing during the winter layup as well
with new oil Use the correct grade of oil Refer to the as providing corrosion LUBRICATING OIL pages in this manual for
Remove the impeller from your raw water pump some
engine oil change antifreeze mixture will accompany it so catch it in a bucket
Run the engine and check for proper oil pressure and make Examine the impeller Get a replacement if needed and a
sure there are no leaks cover gasket Do not replace the impeller into the pump
until but replace the cover and gasket
A CAUTION Do not leave th engines old engine Intake Manifold and ThruHull Exhaust
Place a clean cloth lightly soaked in lubricating oil in the
oil in the sump over the layup period Engine oil and
opening of the intake manifold to block the opening Do not
combustion depOSits combine to produce harmful
shove the cloth out of sight If it is not visable at
chemicals which can reduce the life of your engines and an attempt is made to start the engine
internal parts you may need assistance of the servicing dealer Make a
note to remove the cloth prior to startup The thruhull
exhaust port can be blocked in the same manner
Engines Generators
LAYUP Motor Spare and cleaning of the starter drive pinion is Layup time
provides a good opportunity to inspect if access to the starter permits its easy removal WES1ERBEKE engine to see if external items such as
drive
Make sure the battery connections are shut off before belts or coolant hoses need replacement Check your to remove the starter Take
care in properly spares kit and order items not on hand or replace those any electrical connections removed from the starter used
during the layup such as filters and zinc anodes Refer
to SPARE PARTS section of this you anticipate a long layup period 12 months or more recommends removing the glow plugs or
The of your WES1ERBEKE engine after a
fuel injectors for access to the cylinders Squirting light seasonal layup generally follows the same procedures oil into the cylinders to
prevent the piston rings those presented in the PREPARATIONS FOR STARTING
from sticking to the cylinder walls Rotate the engine by hand section regarding preparation for starting and normal starts
two revolutions then replace the glow plugs or injectors However some of the layup procedures will need to be
Make sure you have a replacement if removing the injector counteracted before starting the washer for the njector and fuel return line
1 Remove the oilsoaked cloths from the intake Manifold GasolineJ 2 Remove the raw water pump cover and
gasket and discard
Clean the filter screen in the flame arrester and place a clean the old gasket Install the raw water pump lightly soaked in lube oil around
the flame arrester to removed during layup or a replacement if any opening Also place an oilsoaked clqth in the Install the
raw water pump cover with a new cover exhaust port Make a note to remove cloths prior
to startup 3 Reinstall the batteries that were removed during the lay
up and reconnect the battery cables making sure the
Intake Manifold and ThruHull terminals are clean and that the connections are tight
Place a clean cloth lightly soaked in lubricating oil in the Check to make sure that the batteries are fully of the intake manifold to block
the opening Do not
shove the cloth out of sight If it is not visible at and an attempt is made to start the engine you may A CAUTION Wear rubber gloves a
rubber apron
need the assistance of a servicing dealer Make a note to and eye protection when servicing batteries Lead acid
remove the cloth prior to startup The throughhull exhaust batteries emit hydrogen a highly explosive gas which
port can be blocked in the same manner
can be ignited by electrical arcing Dr a cigarette cigar Dr pipe Do not smoke Dr allow
If batteries are to be left on board during the layup period open flame near the battery being serviced Shut off
make sure they are fully charged and will remain that way all electrical equipment in the vicinity to prevent
to prevent them from freezing If there exists any doubt that
electrical arcing during batteries will not remain fully charged or that they will
be subjected to severe environmental conditions remove
the batteries and store them in a warmer more compatible 4 Remove the spark plugs wipe clean regap and install
proper tightness gasoline
5 Check the condition of the zinc anode in the raw water
A Warning Lead acid batteries emit hydrogen a circuit and clean or replace the anode as needed Note that
gas which can be ignited by electrical it is not necessary to flush the water
arcing Dr a lighted cigarette cigar Dr pipe Do not solution from the raw water coolant system When the
engine is put into operation the system will selfflush in a
smoke Dr allow an open flame ngar the battery being
short period of time with no adverse affects It is
serviced Shut off all electrical equipment in the advisable as either an end of season or vicinity to prevent electrical arcing
during servicing service to inspect the area where the zinc is located in the
heat exchanger and clear any and all zinc debris from that
Propulsion EngineJ
6 Start the engine in accordance with procedures or change the fluid in the transmission as required
in the PREPARATIONS FOR INmALSTARTUP section of
Wipe off grime and grease and touch up any unpainted areas this the coupling and the output flange with an coating Check that the
transmission vent is open information refer to the Engines Generators
44A 448 FOUR ENGINE FUEL SYSTEM
Engine Type Diesel fourcycle fresh water General Open flow self priming
cooled vertical inline overhead valve
mechanism Fuel No2 diesel oil cetane rating of 45 or 1073 cubic
inches 1758 liter Fuel Injection Pump Inline plunger type Naturally aspirated
Nozzle Throttle Chamber Swirl type Fuel Filter
Spinon Stroke 307 x 362 inches 78 x 92 mm Air cleaner Replaceable paper filter Order
1 3 42 AirAow 140 cfm 39 cmm at 3600 rpm
engine combustion 93 cfm 262 cmm at 3000 of Rotation Clockwise when viewed from the front
Fuel Lift Pump 12 volt DC lift capacity of 5 15 mm solid Ratio inches mm Height 186 inches 4724 mm
COOLING SYSTEM
Engine Only Width 230 inches 5842 mm
Length256 inches 9144 mm General Fresh watercooled block
controlled with heat 331 Ibs 150 kgs without
Operating Temperature 170 190 F77 88 C
Fuel Consumption 25 glhr 97Itrlhr at 3600 rpm
Fresh Water Pump Centrifugal type metal impeller Continuous 15
Temporary 25 not to exceed 30 min Raw Water Pump Positive displacement rubber impeller
beltdriven
TUNEUP Raw Water Flow 44AJFour 95 gpm at 3600 rpm
measured Pressure 427 psi 30 kgcm at 280 rpm discharge into exhaust 44BFour 80 gpm at 3000 rpm
Minimum 384 psi 27 kgcm elbow liming Intake Opens
System Capacity 80 US qts 76 liters
Intake Closes Fresh liming Static 17 spill
Valve Seat Angle 45
LUBRICATION SYSTEM
General Pressure fed Speed 3600 rpm 44AlFour
3000 rpm 44BFour Oil Filter Full flow paper element spinon type
Valve Seat Angle Intake 45 Sump Capacity 52 US qts 54 liters
Exhaust 30 not including filter
Valve Clearance 025 inches 00098 mm Operating Oil Pressure 50 60 psi 35 42 cold
engine hot
Injector Pressure 1991 71 0 psi 140 5 0 kgfcm Oil Grade API Specification CF or CG4
SAE 30 10W30 15W40
Engine liming 17 BTDC
ELECTRICAL Battery 12 Volt negative Capacity 400 600 Cold Cranking Amps CCA
DC Charging Alternator 51 Amp rated Aid Glow plugs sheathed type
Starter 12 Volt reduction gear
Rev July 2002
Engines Generators
35C 350 THREE ENGINE FUEL SYSTEM
Engine Type Diesel fourcycle fresh water General Open flow self priming
cooled vertical inline overhead valve
mechanism Fuel No2 diesel oil cetane rating of 45 or 804 cubic
inches 1318 liter Fuel Injection Pump Inline plunger type Naturally aspirated
Nozzle Throttle Chamber Swirl type Fuel Riter
Spinon Stroke 307 x 362 inches 78 x 92 mm Air cleaner Replaceable paper filter Order
AirFlow 837 cfm 23 cmm at 3600 rpm
1 3 2
engine combustion 697 cfm 19 cmm at 3000 of Rotation Clockwise when viewed from the front
Fuel Lift Pump 12 volt DC lift capacity of 5 15 mm solid Ratio inches mm Height 216 inches 5406 mm
COOLING SYSTEM
Engine Only Width 201 inches 5105 mm
Length 224inches 596 mm General Fresh watercooled block
controlled with heat 276 Ibs 276 kgs without
Operating Temperature 170 190 Fn 88 Continuous 15
Temporary 25 not to exceed 30 min Fresh Water Pump Centrifugal type metal impeller beltdriven
Raw Water Pump Positive displacement rubber impeller
TUNEUP Pressure 427 psi 30 kgcm at 280 rpm
Raw Water Row 35CThree 95 gpm at 3600 rpm
Minimum 384 psi 27 kgcm measured before
discharge into exhaust 35DThree 80 gpm at 3000 rpm
Valve liming Intake Opens elbow Approximate
Intake Closes
System Capacity 50 US qts 47 liming Static 17 spill Fresh Water
Valve Seat Angle 45
17 BTDC
LUBRICATION SYSTEM
Engine liming
General Pressure fed Pressure 1991 71 0 psi 140 5 0 kgfcm
Oil Riter Full flow paper element spinon type
Valve Seat Angle Intake 45
Exhaust 30 Sump Capacity 39 US qts 37 liters
not including filter
Valve Clearance 00098 inches 025 mm
engine cold Operating Oil Pressure 50 60 psi 35 42 kgcm
engine hot
Engine Speed 3600 rpm 35ClThree
3000 rpm 35DlThree Oil Grade API Specification CF or CG4
ELECTRICAL Battery 12 Volt negative Capacity 400 600 Cold Cranking Amps CCA
DC Charging Altemator 51 Amp rated Aid Glow plugs sheathed type
Starter 12 Volt reduction gear
Rev July 2002
Engines Generators
44 FOUR AND 35 THREE TORQUE MAJOR BOLTS AND NUTS
TORQUE
Width Clamp
Bolt or Nut Diameter Pitch across flats length kg m ft Ib Bracket
3853 2738 366
Back Plate 3348 2435 Rod Cap M9 10
14 355025 2772 Pump 1624 1217
Coolant Pump Pulley 16 24 1217 172
Coolant Temperature Sender 1218 913 122
Coolant Temperature Switch 1218 913 Pulley Nut M18 15
27 17525 12718 Head Bolt M10 125 14 87 905 65 4 88
Damper Plate 19 27 1420 89
Delivery Valve Holder 19 4505 3254 44 5
Engine Mounts 3247 2334 311
Exhaust Manifold 1624 1217 72
Flywheel Bolt M12 125 19 29 13505 984 1325
Fuel Filter Assembly 4668 3349 447
Fuel Injection Nozzle Holder M20 15 21 5505 4044 545
Fuel Injection Pipe Nut M12 15 305 224 295
Fuel LeakOff Pipe Nut M12 15 18 275025 20 2 2725
Fuel Solenoid Locknut 4005 289362 3918
Glow Plug M10 125 12 60 175025 1272 17225
Glow Plug Connection Plate M4 07 8 0125 0025 09 02 Manifold
1624 1217 162
Main Bearing Cap Bolt M10 125 17 81 525 025 382 51525
Oil Filter M20 15 1201 87 07 121
Oil Pan Bolt M8 125 12 25 2803 20322 2753
Oil Pan Drain Plug M14 15 22 10 40 05 294 395
Oil Pressure Sender 1218 913 122
Oil Pressure Switch PT18 26 11 1 02 7214 102
Pressure Refief Valve M22 15 22 33 5005 364 495
Rear Plate Bolt stamping M8 125 12 16 115 015 8311 113 15
Rear Plate Bolt standard M12 125 17 28 65 01 477 Nut for Delivery M16 075
19 375 025 272 3725
Valve Holder Body
Rocker Cover Bolt M8 125 12 40 115015 8311 Shaft Bracket Bolt M8 125
12 581 1505 11 4 147 5
Sliding Sleeve Shaft M10 125 14 295 3606 264 356
Special Nut for M12 10 17 205 144 205
Torque Spring Set
Starter B Terminal M8 125 12 11 01 807 1081
Stop Solenoid M30 15 36 4505 3254 Housing
03045 23 M16 15 17 315 2304 166 3 226 4
Engines Generators
STANDARD HARDWARE
BOLT HEAD MARKINGS
Bolt strength classes are embossed on the head of each bolt Metric bolt class numbers identify bolts by their strength with 109
Customary inch bolts are identifed by markings two to grade eight The marks correspond to two marks less than the actual grade
Le a grade seven bolt will display five embossed 1 Use the torque values listed below when specific torque values are not available
2 These torques are based on clean dry threads Reduce torque by 10 when engine oil istJsed
3 Reduce torques by 30 or more when threading capscrews into aluminum
STANDARD BOLT NUT TORQUE METRIC BOLT NUT TORQUE SAE Grade 5 SAE Grade 67
SAE Grade 8
Capsrew Body Size Torque Torque Torque Boll Grade 46 Grade 48 Grade 88 98 Grade
Inches Thread ALbNm FHbNm FHbNm Dia Wrench Size ALbNm FHbNm FILbNm FILb Nm
14 20 8 11 10 14 12 16
28 10 14 14 19 M3 55mm 03 05 05 07 1 13 15 2
M4 7mm 08 11 1 15 2 3 3 45
51618 17 23 19 26 24 33 M5 8mm 15 25 2 3 45 6 65 9
24 19 26 27 37
31816 31 42 34 46 44 60 M8 10mm 3 4 4 55 75 10 11 15
24 35 47 49 66 M9 13mm 7 95 10 13 18 25 35 26
71614 49 66 55 75 70 95 Ml0 16mm 14 19 18 25 37 50 55 75
20 55 75 78 106
12 13 75 102 85 115 105 142 M12 18mm 26 35 33 45 63 85 97 130
20 85 115 120 163 M14 21 mm 37 50 55 75 103 140 151 205
M16 24mm 59 80 85 115 159 215 232 315
916 12 110 149 120 163 155 210
18 120 163 170 231
M18 27mm 81 110 118 160 225 305 321 435
5811 150 203 167 226 210 285 M20 30mm 118 160 166 225 321 435 457 620
18 170 231 240 325 M22 33mm 159 215 225 305 435 590 620 840
314 10 270 366 280 380 375 508
16 295 400 420 569 M24 36mm 203 275 288 390 553 750 789 1070
M27 41 mm 295 400 417 565 811 1100 1154 1565
78 9 395 536 440 597 605 820 M30 46mm 402 545 568 770 1103 1495 1571 2130
14 435 590 675 915
1 8 590 800 660 895 910 1234 M33 51 mm 546 740 774 1050 1500 2035 2139 2900
14 660 895 990 1342 M36 55mm 700 950 992 1345 1925 2610 2744 3720
NOTE Formula to convert FtLbs to Nm Newton Meters multiply FtLbs by 1356
SEALANTS based PERMATEX 2 and its HIGH TACK equivalent are excellent all Use LIQUID TEFLON for sealing pipe plugs and fillings that
connect sealers They are effective in just about any joint in contact with passages Do not use tape raw water oil or fuel
A light coating of OIL or LIQUID TEFLON can be used on rubber gaskets BOLTS Orings
Lightly oil head bolts and other fasteners as you assemble them Bolts and
LOCTITE hydraulic red sealant should be used on oil adapter hoses and the oil plugs that penetrate the water jacket should be sealed with PERMATEX
2 or
filter assembly HIGH TACK
Coat both surfaces of the oil pan gasket with high temp RED SILICONE sealer When assembling the flywheel coat the bolt threads with LOCTITE blue
When installing gaskets that seal around water coolant passages coat both Antiseize compounds and thread locking adhesives such as LOCTITE protect
sides with WHITE SILICONE grease threaded components yet allows them to came apart when necessary
LOCTITE offers levels of locking according to the ADHESIVE SPRAYS are useful for holding gaskets in position dur
ing assembly LITHIUM based grease is waterproof ideal for water pump bearings and
stuff
ing gasket sealers such as HYLOMAR work well in applications requir
ing nonhardening properties HYLOMAR is particlarly effective on Heavily oil all sliding and reciprocating components when assembling
Always
copper cylinderhead gaskets as it resists fuel oil and water use clean engine oil
Engines Generators
STANDARD AND METRIC CONVERSION Inches in x 254 Millimeters mm x 0394 Inches
Feet ft x 305 Meters m x 3281 Feet
Miles x 1609 Kilometers km x 0621 Cubic Inches in3 x 16387 Cubic Centimeters x 061 i n3
Imperial Pints IMP pt x 568 Liters L x 176 IMP pt
Imperial Quarts IMP qt x 1137 Liters L x88 IMP qt
Imperial Gallons IMP gal x 4546 Liters L x 22 IMP gal
Imperial Quarts IMP qt x 1201 US Quarts US qt x 833 IMP qt
Imperial Gallons IMP gal x 1201 US Gallons US gal x 833 IMP gal
Fluid Ounces x 29573 Milliliters x 034 Ounces
US Pints US pt x 473 LitersL x 2113 Pints
US Quarts US qt x 946 Liters L x 1057 Quarts
US Gallons US gal x 3785 Liters L x 264 Ounces oz x 2835 Grams g x 035 Ounces
Pounds Ib x 454 Kilograms kg x 2205 Pounds Per Sq In psi x 6895 Kilopascals kPa x 145 psi
Inches of Mercury Hg x 4912 psi x 2036 Hg
Inches of Mercury Hg x 3377 Kilopascals kPa x 2961 Hg
Inches of Water H20 x 07355 Inches of Mercury x 13783 H20
Inches of Water H20 x 03613 psi x 27684 H20
Inches of Water H20 x 248 Kilopascals kPa x 4026 H20
TORQUE
PoundsForce Inches inIb x 113 Newton Meters Nm x 885 inIb
PoundsForce Feet ftIb x 1356 Newton Meters Nm x 738 Miles Per Hour MPH x 1609 Kilometers Per Hour KPH x 621 MPH
POWER
Horsepower Hp x 745 Kilowatts Kw x 134 MPH
FUEL CONSUMPTION
Miles Per Hour IMP MPG x 354 Kilometers Per Liter KmL
Kilometers Per Liter KmL x 2352 IMP MPG
Miles Per Gallons US MPG x 425 Kilometers Per Liter KmL
Kilometers Per Liter KmL x 2352 US Degree Fahrenheit OF OC X 18 32
Degree Celsius 0C OF 32 x 56
Engines Generators
SUGGESTED SPARE PARTS
WESTERBEKE MARINE DIESEL ENGINES
CONTACT YOUR WESTERBEKE DEALER FOR SUGGESTIONS AND ADDITIONAL
HARDWARE KIT
RAW WATER PUMP AIR INTAKE FILTER
WATER SEPERATOR FILTER
FUEL LIFT
PUMP
WESTERBEKE RECOMMENDS CARRYING ENOUGH SPARE
ENGINE OIL YOUR BRAND FOR AN OIL CHANGE 5 OTS
AND A GALLON OF PREMIXED COOLANT
SPARE PARTS also offers two Spare Parts Kits
each packaged in a rugged hinged toolbox B Kit
Kit A includes the basic spares Impeller Kit
Kit B is for more extensive offshore cruising Water Pump Repair Kit
AKit Thermostat Kit
Impeller Kit Zinc Anodes
Heat Exchanger Gasket Complete Gasket Kit
Fuel Filter with Gasket Heat Exchanger Gasket
Oil Filter Injector
Drive Belt Fuel Filter with Gasket
Zinc Anodes Oil Filter
Drive Belt
I I EnaitJes Generators
EUROPEAN MARITIME COUNCIL REGISTRATION
EUROPEAN ECONOMIC COUNCIL
Declaration of of Council Directives EMC 89336IEEC 9
Standards to Which Conformity is declared EN500811
EN500822
Name and Address Westerbeke Corporation
150 John Hancock Road
Myles Standish Industrial Park
Taunton MA 02780 USA
Type of Equipment Marine Diesel Name
Westerbeke Marine Diesel 44AFour I Options
The equipment listed is only for use in Marine Applications aboard boats
2 The equipment listed must be located below decks on the vessel and permanently installed in its location
3 The equipment listed must be wired to the grounding system of the vessel
I the undersigned hereby declare that the equipment specified above conforms to the above Directives

Place Taunton USA
April 3 2000 Carleton F Bryant Chief Operating Officer
INTERNATIONAL MARINE CERTIFICATION INSTITUTE
Rond Point Schuman 6 Box 6 B 1040 BRUXELLES BELGIQUE tel 32 0 22387892 fax 32 0 2238noo
CERTiFiCATE
We hereby certify that the enginess stated below meet the EC Directive 9425EC
1999IMC1 Power Rating Report
I MANUFACTURER I Westerbeke Corporation I
I ADDRESS I 150 John Hancock Road Myles Standish Industrial Park Taunton MA 02780 USA I
MODEL NAME 44AFour I
Engine Type Inboard
Fuel Tvpe Diesel
Aspiration Type Natural
Rating Level Highest Output 1 2 3 4 Lowest Output 5
Crankshaft Power
Propeller shaft Power
at RPM min 3600
CertHication Number WESTEBIDOOh
Signed 7 Jr
Name Lars E Granholm
Title Manaaina Director
EU NotHied Body No 0609
Date verHication statement
Power rating is in accordance with IMCI Proceedure Compliance verHied in accordance with ISO 8665 and ISO 15584 only for
inboard petrol en ines This application form has not been lodaed with any other not Hied body
Company Westerbeke Corporation
Date 3April2000
Name Carl F Brvant
Title I Chief Operating Officer
Signature I 7
v C
Engines Generators
EUROPEAN MARITIME COUNCIL REGISTRATION
EUROPEAN ECONOMIC COUNCIL
INTERNATIONAL MARINE CERTIFICATION INSTITUTE
Rond Point Schuman 6 Box 6 B t040 BRUXELLES BELGIQUE tel 32 OJ 22387892 fax 32 OJ 22387700
CERTKFKCATE
We hereby certify that the enginess stated below meet the EC Directive 9425EC
19991MC1 Power Rating Report
I MANUFACTURER I Westerbeke Corporation I
I ADDRESS I 150 John Hancock Road Myles Standish Industrial Park Taunton MA 02780 USA
I MODEL NAME I 3SCThree
EnaineType Inboard
Fuel Type Diesel
Aspiration Type Natural
Ratina Level Hiahest Output 1 jgL 3 J4 Lowest OutputS
Crankshaft Power
Propeller shaft Power
at RPM min 3600
CertHication Number Signed
I rU 7
Name Lars E Granholm
litle Managing Director
EU NotHied Body No 0609
Date
verHication statement
Power rating is in with IMCI I verHied in I wijh ISO 8665 and ISO 15584 only for
inboard petrol en lines This application form has not been lodged with any other notHied body
Company
Date
Name Carl F Bryant
litle 7 Chief Operatina Officer
Signature 1YYA or
Engines Generators
Engines Generators

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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.