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Westerbeke Four 60 Parts Manual




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MANUAL
7A1 and 11A1
MARINE DIESEL ENGINES
PUBLICATION NO 45145
1st EditionApril 2001
J WESTERBEKE CORPORATION MYLES STANDISH INDUSTRIAL PARK
150 JOHN HANCOCK ROAD TAUNTON MA 027807319 USA
TEL FAX WEBSITE
NMMA Member National Marine Manufacturers Association
MANUAL
7A1 and 11A1
MARINE DIESEL ENGINES
PUBLICATION NO 45145
15t EditionApril 2001
r WESTERBEKE
WSTRBK CORPORATION MYLS STANDISH INDUSTRIAL PARK
150 JOHN HANCOCK ROAD TAUNTON MA 027807319 USA
TEL FAX WEBSITE
NHHA
Member National Marine Manufacturers Association
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
Weacness and Sleepiness Inability to Think YOU OR ANYONE ELSE EXPERIENCE ANY OF THESE SYMPTOMS
GET OUT INTO THE FRESH AIR IMMEDIATELY symptoms persist
seek medical attention Shut down the unit and do not restart
until it has been inspected and repaired
This WARNING DECAL is provided by
WESTERBEKE and should be fixed to a
bulkhead near your engine or generator
WESTERBEKE aso recommends installing
CARBON MONOXIDE DETECTORS in the
quarters of your vessel
They are inexpensive and easily
obtainable at your local marine store
SAFETY PREVENT BURNS FIRE
Read these safety instructions carefuUy 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 fuel line filter fuel pump or
The foUowing safety instructions are in compliance with other potential sources of spilled fuel or fuel vapors Use
the American Boat and Yacht Council ABYC standards a suitable container to catch all fuel when removing the
fuel line or fuel ELECTRIC SHOCK Keep the compartment and the engine clean and free of
debris to minimize the chances of fire Wipe up all spilled
fuel and engine oil
A WARNING lID nDt touch AC electrical Be aware diesel fuel will burn
while engine is running Of wlren connected to shore
power Lethal voltage is present at these connections PREVENT BURNS EXPLOSION
Do not operate this machinery without electrical
enclosures and covers in place A WARNING Explosions from fuel rapors can cause
Shut off electrical power before accessing electrical
injury Of death
equipment
Follow refueling safety instructions Keep the vessels
Use insulated mats whenever working on electrical hatches closed when fueling Open and ventilate cabin
equipment after fueling Check below for fumesvapor before run
Make sure your clothing and skin are dry not damp ning the blower Run the blower for four minutes before
particularly shoes when handling electrical equipment starting your engine
Remove wristwatch and all jewelry when working on All fuel vapors are highly explosive Use extreme care
electrical equipment when handling and storing fuels Store fuel in a wellven
Do not connect utility shore power to vessels AC tilated area away from equipment and
circuits except through a shiptashore double throw out of the reach of children
transfer switch Damage to vessels AC generator may Do not fill the fuel tanks while the engine is running
result if this procedure is not followed Shut off the fuel service valve at the engine when servicing
Electrical shock results from handling a charged the fuel system Take care in catching any fuel that might
capacitor Discharge capacitor by shorting terminals spill DO NOT allow any smoking open flames or other
together with an insulated tool sources of fire near the fuel system or engine when servic
ing Ensure proper ventilation exists when servicing the
PREVENT BURNS HOT ENGINE fuel system
Do not alter or modifY the fuel system
A WARNING lID not touch hot engine parts Of
Be sure all fuel supplies have a positive shutoff valve
Be certain fuel line fittings are adequately tightened and
exhaust system components A running engine gets
free of leaks
very hot
Make sure a fire extinguisher is installed nearby and is
properly maintained Be familiar with its proper use
Extinguishers rated ABC by the NFPA are appropriate
A WARNING Steam can cause injury Of death for all applications encountered in this In case of an engine overheat
allow the engine to cool
before touching the engine or checking the coolant
Engines Generators
SAFETY STARTING TOXIC EXHAUST GASES
A WARNING Accidental starling can cause injury A WARNING Carbon monoxide CO is a deadly gas
or death
Disconnect the battery cables before servicing the engine Ensure that the exhaust system is adequate to expel gases
discharged from the engine Check the exhaust system
Remove the negative lead first and reconnect it last
regularly for leaks and make sure the exhaust manifold
Make certain all personnel are clear of the engine before exhaust elbow is securely attached
starting
Make certain all covers guards and hatches are Be sure the unit and its surroundings are well ventilated
reinstalled before starting the engine Run blowers when running the generator set or engine
Dont run the generator set or engine unless the boat is
BATTERY EXPLOSION equipped with a functioning marine carbon monoxide
detector that complies with ABYC A24 Consult your
boat builder or dealer for installation of approved detectors
A WARNING Battery explosion can cause injury For additional information refer to ABYC T22
or death
educational information on Carbon Monoxide
Do not smoke or allow an open flame near the battery
being serviced Lead acid batteries emit hydrogen a
highly explosive gas which can be ignited by electrical
A WARNING Carbon monoxide CO is an invisible
arcing or by lit tobacco products Shut off all electrical odorless gas Inhalation produces flulike symptoms
equipment in the vicinity to prevent electrical arcing nausea or death
during servicing
Never connect the negative battery cable to the Do not use copper tubing in diesel exhaust systems Diesel
positive connection terminal of the starter solenoid fumes can rapidly destroy copper tubing in exhaust
Do not test the battery condition by shorting the terminals systems Exhaust sulfur causes rapid deterioration of
together Sparks could ignite battery gases or fuel vapors copper tubing resulting in exhaustwater leakage
Ventilate any compartment containing batteries to prevent Do not install exhaust outlet where exhaust can be drawn
accumulation of explosive gases To avoid sparks do not through portholes vents or air conditioners If the engine
disturb the battery charger connections while the battery exhaust discharge outlet is near the waterline water could
is being charged enter the exhaust discharge outlet and close or restrict the
Avoid contacting the terminals with tools etc to prevent flow of exhaust Avoid overloading the craft
burns or sparks that could cause an explosion Remove Although diesel engine exhaust gases are not as toxic as
wristwatch rings and any other jewelry before handling exhaust fumes from gasoline engines carbon monoxide
the battery gas is present in diesel exhaust fumes Some of the
Always turn the battery charger offbefore disconnecting symptoms or signs of carbon monoxide inhalation or
the battery connections Remove the negative lead first poisoning are
and reconnect it last when servicing the battery Dizziness Throbbing in temples
Headache Muscular ACID Nausea Weakness and sleepiness
Vomiting Inability to think coherently
A WARNING Sulfuric acid in batteries can cause AVOID MOVING PARTS
severe injury or death
When servicing the battery or checking the electrolyte
A WARNING Rotating parts can cause injury
level wear rubber gloves a rubber apron and eye or death
protection Batteries contain sulfuric acid which is
destructive If it comes in contact with your skin wash it Do not service the engine while it is running If a
off at once with water Acid may splash on the skin or situation arises in which it is absolutely necessary to
into the eyes inadvertently when removing make operating adjustments use extreme care to avoid
electrolyte caps touching moving parts and hot exhaust system
Engines Generators
SAFETY Do not wear loose clothing or jewelty 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
Keep protective shields and guards in their respective tions when installing your engine
places at all times ABYC American Boat and Yacht Council
Safety Standards for Small Craft
Do not check fluid levels while the engine is operating
Order NOISE ABYC
3069 Solomons Island Rd
A WARNING High noise levels can cause Edgewater MD 21037
hearing loss NFPA National Fire Protection Association
Fire Protection Standardfor Motor Craft
Never operate an engine without its mufiler installed Order from
Do not run engines for long periods with their NFPA
enclosures open 11 Tracy Drive
Avon Industrial Park
A WARNING 011 not WllrIc lin machinery when Yllu are Avon MA 02322
mentally IIr physically incapaCitated by fatigue USCG United States Coast Guard
USCG 33CFR183
Order from
ENGINE US Government Printing to install an engine should begin with a
thor Washington DC 20404
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
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 regulations ABYC guidelines and safety codes must be
complied with engines and generators in a marine installations where the exhaust exhaust elbow is close to or
will be below the vessels waterline provisions must be made to install a the raw water supply hose to the exhaust elbow This hose must be looped a
mini
mum of 20 in 51 cm above the vessels waterline Failure to use a 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 any of the vessels various operating conditions or when
the vessel is not underway install a siphonbreak This precaution is necessary to pro
tect your engine
NOTE A siphonbreak requires periodic inspection and cleaning to ensure proper oper
ation Failure to properly maintain a siphonbreak can result in catastrophic Consult the siphonbreak manufacturer for a proper maintenance 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 40page Marine Installation Manual covering gasoline and diesel
engines and generators is available from your WESTERBEKE dealer
Engines Generators
TABLE OF 2 Cooling System continued
Warranty Procedures 2 Raw Water 22
Product 2 the Raw Water Pump Impeller 22
Notes Caution and Warnings 2 Raw Water Intake 22
Model NolSerial No Location 2 Raw Water Intake 22
Component Locations 3 23
Understanding the Diesel Engine 3 Draining the Cooling System 23
Ordering Parts 3 Air Intake Spares and Accessories 3 24
Protecting Your 3 Air 24
7A1 Diesel Engine 4 Maintenance 24
7A1 Diesel Engine Parts 5 Water Diesel Engine Water Heater Installations 24
11A1 Diesel Engine Parts Fuel System for Initial StartUp 8 Diesel FueL 25
Diesel FueL 8 Fuel Additives 25
Care of the Fuel 8 Care of the Fuel Fuel Additives 8 Fuel Lift 25
Engine OiL 8 Fuel 25
Transmission 8 Replacing the Fuel 25
PreStart 8 Fuel Lines Procedure Fuel FilterlWater 26
Electric Starting 9 Fuel Injection 26
Electric Starting Procedure 9 Fuel 26
Low Battery Electric Starting Bleeding the Fuel System 26
Manual Starting Hand Cranking 9 Spare Parts 26
Automatic Decompression Device IO DC Electrical System 27
Cold Starting Device 10 12 Volt DC Control Circuit 27
Manual Starting 11 Control Panel 27
Starting Under Cold Conditions 12 Engine Circuit 27
Operating the Engine 12 27
Initial StartUp Check List 12 Battery Care 27
Stopping the Engine 12 Checking the Service 27
Engine BreakIn Procedure 13 Alternator 28
Engine BreakIn 13 Testing the 28
BreakIn Check List 13 Checking the Service 29
Transmission 13 7AI Marine Diesel Engine Wiring Diagram 45593 30
Daily Operation 7AI Marine Diesel Engine Wiring Schematic 45593 31
Daily Operation CheckList 13 11A1 Marine Diesel Engine Wiring Diagram 44542 32
Transmission 13 11Al Marine Diesel Engine Wiring Schematic 44542 33
Maintenance Schedule 14 Glow Plugs ModeI7A1 only 34
Exhaust System 16 Engine Adjustments 35
Description 16 Tightening the Cylinder 35
16 Valve Clearance Adjustment 35
Exhaust System Precautions 16 Engine Compression Test 35
Carbon Monoxide 16 Testing the Fuel 36
Carbon Monoxide Warning Decal 16 Removing the Fuel 36
Carbon Monoxide Detectors 17 Fuel Injector Components 36
Insulation 17 Checking the Injection Starting Pressure 36
17 Tightness of the Valve Seat 37
Lubrication System Inspecting the Spray 37
18 Checking the Nozzle Body and Needle 37
Oil Pressure 18 37
Low Oil Pressure Alarm Switch 18 Injector Installation 37
Engine OiL 18 Drive Belt Adjustment 38
Checking the Oil 18 Checking Belt Tension 38
Changing the OiL 19 Adjusting Belt Tension 38
Removing the Old Oil 19 Engine 39
Changing the Oil Filter Model llAl only 19 Hurth HBW Transmission Adding the New Oil 20
Hurth HBW Transmission Testing the Oil Pressure 20 LayUp and Cooling System 21 7A1 11A1 Torque 48
Raw Water Cooling 21 Standard Lubricants 49
Thermostat 21 Metric Conversions the Thermostat 21 Standard and Metric Conversion Oata 51
Coolant Temperature 21 Suggested Spare Parts Kits 52
Engines Generators
WESlERBEKE Diesel Engine is a product of PRODUCT many years of experience and advanced
Product software tech data parts lists manuals We take great pride in the superior durability performance of our engines and generators Thank
and catalogs provided from sources other than
WESTERBEKE are not within WESTERBEKEs control
you for selecting WESlERBEKE
WESTERBEKE CANNOT BE RESPONSIBLE FOR THE
This is the Operators Manual for the 7AI and IIAI Marine CONTENT OF SUCH SOFTWARE MAKES NO
Diesel Engines Most of the information in this manual applies to WARRANTIES OR WITH RESPECT
both models where information applies to only one of the two THERETO INCLUDING ACCURACY TIMEUNESS OR
models the applicable model name will be indicated A Parts COMPLETENESS THEREOF AND WIll IN NO EVENT
Catalog is also provided for your engine and a Service Manual is BE UABLE FOR ANY TYPE OF DAMAGE OR from your WESlERBEKE dealer If you are
planning INCURRED IN CONNECTION WITH OR ARISING OUT
to install this equipment contact your WESlERBEKE dealer for OF THE FURNISHING OR USE OF SUCH Installation Manual
WESlERBEKE customers should keep in mind the time span
In order to get the full use and benefit from your engine between printings of WESlERBEKE product software and the
it is important that you operate and maintain it correctly This unavoidable existence of earlier WESlERBEKE product
manual is designed to help you do this Please read this manual software The product software provided with WESlERBEKE
carefully and observe all the safety precautions throughout products whether from WESlERBEKE or other suppliers must
Should your engine require servicing contact your nearest not and cannot be relied upon exclusively as the definitive
WESlERBEKE dealer for assistance authority on the respective product It not only makes good sense
but is imperative that appropriate of
WARRANTY PROCEDURES WESlERBEKE or the supplier in question be consulted to
Your WESlERBEKE Warranty is included in the documentation determine the accuracy and currentness of the product If you have not received
a customer card being consulted by the your warranty 60 days after submitting the warranty NOTES CAUTIONS AND form please contact
the factory in writing with including the units serial number and As this manual takes you through the operating date
maintenance schedules and of your marine
engine critical information will be highlighted by Card CAUTIONS and WARNINGS An explanation follows
NOTE An operating procedure essential to note
I Engines Generators A CAUTION Procedures which if not strictly
observed can result in the damage Dr destruction of
Customer your engine
WESTERBEKE OWNER
MAIN STREET A WARNING Procedures which if not properly
HOMETOWN USA followed can result in pelSDnai injury or loss of life
Mode17A1
Expires 3116102 MODEL NOSERIAL NO LOCATION
Ser The engines model number and serial number are located on an
plate mounted on the engine block below the
Your WESlERBEKE 7AIIIAI Engine serial number is an exhaust Take the time to enter this information
alphanumeric number that indicates the date of manufacture The on the illustration of the nameplate shown below as his will pro
date code is at the end of the serial number and consists of a vide a quick reference when seeking technical information andor
character followed by three numbers The character indicates the ordering repair parts
decade D 1990s E2000s the fITSt number after the character
represents the year in the decade and the second and third
numbers after the character represent the month of
ENGINE mEITIFICATION PlATE
Engines Generators
LOCATIONS SPARES AND locations in this manual are referenced from the front Certain
spare parts will be needed to support and main
of the engine which is the end at which the raw water pump is tain your WESTERBEKE engine when cruising see
located Left and right sides are detennined as follows imagine SUGGESTED SPARE PARTS KITS Often even a
straddling the engine facing the front of the engine the left side simple item such as a proper fuel filter can be difficult
is at your left the right side is at your right to obtain along the way WESTERBEKE can provide
you with a suggested spares and accessories brochure THE DIESEL ENGINE assist you in preparing an onboard
inventory of the
proper WESTERBEKE parts
The diesel engine closely resembles the gasoline engine since the
mechanism is essentially the same The cylinder is arranged PROTECTING YOUR a closed crankcase The crankshaft is of the same general
type as on a gasoline engine and the diesel engine has the same Care at the factory during assembly and thorough testing have
types of valves camshaft piston connecting rod and lubricating resulted in a WESTERBEKE engine capable of many
system thousands of hours of dependable service However the
manufacturer cannot control how or where the engine is to a great extent a diesel engine requires the same pre in the vessel or the manner in
which the unit is operated and ser
ventive maintenance as a gasoline engine The most important viced in the field This is up to the are proper ventilation and proper
maintenance of the and cooling systems Fuel filter elements must be NOTE Six important steps to ensure long engine at the time periods
specified and frequent checking for Proper engine water sediment etc in the fuel system is also
An efficient welldesigned exhaust system that includes an
essential Another important factor is the consistent use of the antisiphon break to prevent water from entering the engine
same brand of high detergent diesel lubrication oil for diesel engines Changing the engine oil every 100
operating hours
The diesel engine does differ from the gasoline engine however Proper maintenance of all engine components according to the
in its method of handling and firing of fuel The carburetor and maintenance schedule in this systems are replaced by a single component
the fuel Use clean filtered diesel fuel
injection pump which performs the function of both Wmterize your engine according to the LAYUP AND
section in this replacement parts are needed always provide
the engine model number and serial number You must
provide us with this information so we may properly iden
tify your engine In addition include a complete and part number for each part needed see the
Parts List Insist upon Westerbeke packaged parts
because will fit or generic parts are frequently not made to
the same as original Engines Generators
7A1 DIESEL ENGINE ENGINE LUBRICATION SYSTEM
Engine Type Diesel fourcycle one cylinder raw water cooled Lubrication System Forced lubrication by geardriven
pump
vertical inline overhead valve mechanism
Sump capacity 13 qts 125 Naturally aspirated
Operating Oil Pressu re 256569 psi 1840 Mechanical centrifugal type engine System
Direct injected Oil Grade API specification CF or CG4
Bore and Stroke SAE 30 10W30 15W40
323 in x 217 in 820 mm x 550 mm
Lube oil Strainer Fullflow Displacement 177 cu in 290 Clockwise when viewed from the of Rotation
raw water pump end
COOLING SYSTEM
Cooling System Raw watercooled Ratio 201
Torque 110 ftIIbs 15 kgm Operating Temperature 2500 rpm
Raw Water Pump Positive displacement neoprene Starting System Handcrank with automatic
geardriven senpriming
decompression device
Raw Water Row 73w8456 gpm 7 Ipm
Engine Stop Manual type at 3600
Raw Water Connection
NOTE An inserted standard 112 in 127 mm 10
Height 171 in 4337 mm
crank handle increases the Width 149 in 3792 mm
width by 45 in 115 mm
Length 225 in 5713 mm EXHAUST SYSTEM
Dry Weight 151 Ibs 685 kg Emission Control Systems Meets USCG Regulation 33 CFR
Max Angle of Installation Not to exceed 10 Exhaust cast aluminum raw water cooled
Max Angle of Operation Not to exceed 15 in all directions Exhaust Elbow Connection 1112 in 381 mm 10
TUNEUP ELECTRICAL Pressure 4785 psi 336 kgcm standard
Electrical System 12 volts DC negative ground
4350 psi 306 kgcm minimum
circuit breaker Seat Angle Intake 45 Exhaust 45
Battery Charging 30 amp 12 volts beltdriven with
Valve Clearance Intake 0008 in 02 mm Altemator solid state internal cold
Exhaust 0008 in 02 mm
Starting Motor 12 volt solenoid actuated shift
Engine Timing 390 mm BTDC static
Cold Cranking Amps 70 amps71F Pressure 2900 psi 2039 Speed Idle 1000 1200 rpm
TRANSMISSION
Cruise 2000 2500 rpm General HURTH HBW 40 Standard Transmission case
Maximum 2900 3000 rpm hardened helical gears with a
multiple disc clutch
FUEL SYSTEM
Gear Ratio optional 2051
Fuel System Open flow senpriming senbleeding
Propeller 120 x 8 P two blade RH
Fuel No2 diesel oil cetane rating of 45 or higher Propeller used must allow 12 0 x 6 P three blade RH
the engine to reach its rated
Fuel Lift Pump Mechanical 16 ft 05 m lift max rpm at full open throttle in
forward gear underway
Fuel Injection Pump Bosch type
Lubricating Ruid ATF type A or DEXTRON I or 11
Fuel Injector Direct injection
Transmission Sump 037 qts 035 liters
Fuel Injection Timing 39 mm BTDC static Pressure 2900 psi 2039 kgcm
Propeller Shaft Right handstandard Consumption 046 US galhr Direction of load
Fuel Filter Primary replaceable filter
Fuel Supply 14 in 635 mm 10 minimum
and Return Lines 5116 in 794 mm 10 maximum
Air Row 153 cfm 043 cmm
engine Engines Generators
7A1 DIESEL ENGINE PARTS HANCRANK
HANDLE GUIDE
WATER
PUMP
flEXIBLE
MOUNTS
RAW WATER
INTAKE CYLINDER
HEAD
FUEL INJECTOR WATER INJECTED EXHAUST
FUEL INJECTION
PUMP
FUEL FILTER
TRANSMISSION
OUTPUT FLANGE
Engines Generators
11 A1 DIESEL ENGINE ENGINE LUBRICATION SYSTEM
Engine Type Diesel fourcycle one cylinder raw water cooled Lubrication System Forced lubrication by geardriven
pump
vertical inline overhead valve mechanism
Sump Capacity 17 qts 16 Naturally aspirated
Operating Oil Pressure 25569 psi 1840 Mechanical centrifugal type engine System
Direct injected Oil Grade API specification CF or CG4
Bore and Stroke 374 in x 291 in 950 mm x 740 mm SAE 30 10W30 15W40
Oil Riter Fullflow paper element spinon type
Piston Displacement 3195 cu in 5240 Clockwise when viewed from the front
COOLING of Rotation raw water pump end
Cooling System Raw watercooled Ratio 201
Torque 213 ftIIbs 29 kgm Operating Temperature 13D150F 5566C
at 2400 rpm
Raw Water Pump Positive displacement neoprene Starting System Handcrank with automatic
geardriven seHpriming
decompression device
Raw Water Row 73998456 gpm Stop Manual type at 3600
Raw Water Connection
NOTE An inserted standard 112 in 127 mm 10
Height 210 in 532 mm
crank handle increases the Width 213 in 540 mm
width by 45 in 115 mm
Length 238 in 603 mm EXHAUST SYSTEM
Dry Weight 238 Ibs 108 kg Emission Control Systems Meets USCG Regulation 33 CFR 183
Max Angle of Installation Not to exceed 10 Exhaust Cast aluminum raw water cooled
Max Angle of Operation Not to exceed 15 in all directions Exhaust Elbow Connection 1112 in 381 mm 10
TUNEUP ELECTRICAL Pressure 4785 psi 336 kgcm standard
Electrical System 12 volts DC negative ground
4350 psi 306 kgcm minimum
circuit breaker Seat Angle Intake 45 Exhaust 45
Valve Clearance Intake 0008 in 02 mm Battery Charging 30 amp 12 volts cold
Exhaust OOOS in 02 mm Alternator with solid state intemal liming 600 mm BlDC
static Starting Motor 12 volt solenoid actuated Pressure 2537 psi 1783 kgcm
Cold Cranking Amps 60 amps66F 19C
Engine Speed Idle 1000 1200 rpm
Cruise 2000 2500 rpm TRANSMISSION
Maximum 2900 3000 rpm General HURTH HBW 40 Standard Transmission case
hardened helical gears with a FUEL SYSTEM
multiple disc clutch
Fuel System Open flow selfpriming seHbleeding Gear Ratio optional 2051
Fuel No2 diesel oil cetane rating of 45 or higher Propeller 14 Dx8 PtwobladeRH
Propeller used must allow 140 x 6 Pthree blade RH
Fuel Uft Pump Mechanical 16 ft 05 m lift max the engine to reach its rated
rpm at full open throttle in
Fuel Injection Pump Bosch type forward gear underway
Fuel Injector Direct Injection lubricating Ruid ATF type A or DEXTRON I or
Fuel Injection liming 60 mm BTDC static Transmission Sump 037 qts 035 Pressure
25375 psi 1784 kgcm Consumption 046 US gaLhr Propeller Shaft
Right handstandard load Direction of Riter Primary
replaceable filter
Fuel Supply 14 in 635 mm 10 minimum
and Retum Lines 516 in 794 mm 10 maximum
Air Row 277 cfm 078 cmm
engine Engines Generators
11A1
CYLINDER
DIESEL ENGINE PARTS HEAD
fOAArpoc
CIRCUIT BREAKER
TlfROTrtE
CONTROL
STARTER
FUEL INJECTOR
COOlANT
TEPERATURE
SWITCH
FUEL PREPARATIONS FOR INITIAL FUEL PRESTART No2
diesel fuel with a cetane rating of 45 or higher Do not Before starting your engine for the first time or after a prolonged
use kerosene or home heating fuel layup check the following items
D Check the engine oil level The oil level must be between the
Care of the Fuel Supply max and min marks on the dipstick
Use only clean diesel fuel The clearance of the components in D Turn on the fuel supply then check the fuel supply and exam
your fuel injection pump is very critical invisible dirt particles ine the fuel filterwater separator bowl for might pass through the filter
can damage these parts It is important to buy clean fuel and keep it clean D Check the transmission fluid level
The best fuel can become by careless handling or D Check the DC electrical system Inspect wire storage facilities To assure that the
fuel going into the and battery cable connections Make certain the positive
tank for your engines daily use is clean and pure purchase a battery cable is connected to the starter solenoid and brand of fuel Also
install and regularly service a negative cable is connected to the engine ground stud
good Coast Guard approved fuel filterwater separator between this location is tagged
the fuel tank and the engine D Open the raw water intake and make sure the raw water sup
ply reaches the raw water Additives D VIsually examine the engine Look for loose or
missing
If fungus or bacteria is causing fuel problems you should have parts disconnected wires and unattached hoses Check the
an authorized dealer correct these problems Then use a diesel threaded connections Check for fuel leaks
fuel biocide to sterilize the fuel follow the D Make sure the exhaust system is secure and all Use a fuel stabilizer on a regular
basis as well connections are tight
STABIL is an example of such a product
D Make sure there is good ventilation and an ample air OIL These are necessary for
proper engine performance
D Make sure the mounting installation is secure
A CAUTION This engine was shipped from the fac D Make sure the propeller shaft is securely attached to the
to without lubricant in the engine Before operating
fill with the proper engine oil
an engine oil with an API of CF or CG4
Change the engine oil after an initial 50 hours of breakin opera
tion and every 100 hours of operation thereafter oil viscosity see the following chart
Operating Temperature Oil Viscosity
Above 68 F 20 C SAE 30 10W30 or 15W40
41 68 F 5 20 C SAE 20 or 10W30
Below 41 F 5 C SAE10W30
A CAUTION Do not allow two or more brands of
engine oil to mix Each brand contains its own additives
additives of different brands could react in the mixture to
produce properties hannful to your engine
TRANSMISSION FLUID
Use ATF type A or Dextron II or ill transmission lubricating fluid
The transmission sump capacity is 037 qts Engines Generators
STARTING NOTE The Automatic Decompression Device is not used for
The 7AIllA1 diesel engine has a 12 VDC electric starter The nOf77Ul1 electric starting During engine operation the pointer on
engine is started by using a keyswitch on the control panel The this device is in the operating 9 oclock has three positions OFF ON
and START 1 Place the transmission in neutral and advance the throttle con
NOTE Periodically lubricate the keyswitch mechanism with trol to slightly open
LOCKEZE to ensure proper keyswitch functioning 2 Using a IOmm wrench turn the hexhead bolt on the
device so the pointer is in the manual starting position
see I HOUR METER
POINTER IN THE MANUAL
STARTING
tiH HEXHEAD BOLT
ALARM
AUTOMATIC
KEYSWITCH DEVICE
ALARM ET
CONTROL PANEL
3 Turn the keyswitch to the START position The alann on the
Electric Starting Procedure control panel will beep until the engine oil pressure comes up
1 Place the transmission in neutral and advance the throttle con The pointer on the Automatic Decompression Device will
trol to slightly open automatically move clockwise with each crank The pointer
will stop at the 9 oclock position and compression will occur
after 8 cranks Hold the keyswitch in the START position
A CAUTION Make certain the transmission is in neu until either the engine starts or the pointer stops after the 8th
crank Then let go of the key and it will spring back to the
tral Starting in gear could result in serious damage to
your transmission your boat and vessels nearby ON Turn the keyswitch to the ON position The alann buzzer on
the control panel will beep Push the key in to preheat Hold
the key in and turn it to the START position When the
engine starts let go of the key and it will come out of preheat POINTER IN
THE OPERATING
and spring back to the ON position observe that it does this posmON
NOTE If the engine doesn start limit each starting trial to 10
20 seconds Wait for approx 30 seconds before repeating the
start Never operate the starter motor while the engine is still j
running
Some unstable running may occur in a cold engine should smooth out as the nOf77Ul1 operating reached and a load is applied Allow a few minutes for
wannup at a comfortable rpm 1000 rpm then If this attempt at an electric start does not start the engine then a
reduce the rpm and get underway manual start by handcranking will be Battery Electric Starting
Procedure MANUAL STARTING HAND CRANKING
If the battery is discharged and too low for a normal electric start When installing the engine it is important to provide enough
but not completely dead an attempt at an electric start can be space at the front end to allow for manual starting hand by using
the Automatic Decompression Device This device in case of an emergency or when the starting battery has become
works by holding the exhaust valve open and is normally used too low to allow an electrical start
when manually starting the engine
Engines Generators
PROCEDURE
The upper illustration shows the distance 45 in 115 mm that
the standard handcrank handle protrudes from the on the engine An additional 25 in 64 mm minimum
HEXHEAD BOLT
must be allowed for room to insert the handle
If hand cranking must be done from outside the see lower then the standard
AUTOMATIC
handle must be extended to the required length POINTER DEVICE
This modification to the handle must be done by the owner
BULKHEAD
Cold Starting Device
This device provides more fuel from the injection pump There
are two positions for the knob up oft and down activated
When activating this device pull the knob down see To release this device
move the speed control lever down then
release it see NOTE Never pull the Cold Starting Device knob down when the
engine is operating or when restarting a hot engine
HANDLE
COLD STARTING
The engine may be started by handcranking in an emergency or MODEL 7A1 SHOWN DEVICE KNOB
when the starting battery has become too low to allow an A manual start is possible with a completely dead battery
For easy and safe manual starting the engine is fitted with an
Automatic Decompression Device and a Cold Starting Device
Use both of these devices when using the handcrank handle an attempt at a start could be made by using the Device see Low Battery Electric Starting
SfAR1 the electrical power required for the start
would then be considerably less so that a discharged battery if
not completely dead might allow the start
NOTE Oil will be supplied to all the bearing points Decompression Device
The Automatic Decompression Device works by holding the
exhaust valve open The device has three positions as indicated
by the pointer When setting the pointer tum the hexhead bolt
with a 10 mm wrench
A CAUTION Neller use the Automatic Device to stop the engine
Engines Generators
Starting Procedure 4 Crank the engine approximately 10 to 20
times until the engine turns freely Then remove the crank
To manually start the engine follow the procedure described
When starting after cold nights or freezing the engine must first be turned over with no compression S Set the Automatic Decompression
Device pointer to the
follow all of the steps beginning with Step 1 If cold weather is manual starting position see When a factor bypass Steps 13 and begin
with Step 4 ing in this position automatic decompression will occur
A WARNING Always keep hands and feet clear of
moving parts Put the transmission in neutral Do not
use starting aids POINTER IN
THE MANUAl
STARTING
1 Place the transmission in neutral and advance the throttle con PDsmDN
trol to slightly open
NOTE Make sure the stop lever is in the RUN position
2 Set the Automatic Decompression Device pointer to the
Neutral position see Compression is released
when the pointer is in this position
6 Pull down the Cold Starting Device knob Note Do not pull
down this knob when restarting a hot engine
POINTER IN
THE NEUTRAl
PDSmDN
3 Insert the crank handle into the crank handle guide see
Standing to the right of the crank handle put your
right hand on top of the air intake filter for support and grip the
COLD STARTING
crank handle with your left hand with the thumb on your left DEVICE KNOB
hand in the position shown in the 7 Insert the crank handle into the
crank handle guide see
Standing to the right of the crank handle put
your right hand on top of the air intake silencer for support
and grip the crank handle with your left hand with the thumb
on your left hand in the position shown in the S Slowly crank the
engine 4 times then crank
the engine as fast as possible The pointer on the Automatic
Decompression Device will automatically move clockwise
with each crank Compression will occur after 8 cranks
Continue to crank after compression occurs until the engine
starts firing As decompression ends and compression occurs
the pointer will automatically stop at the operating 9 oclock
the engine starts the crank handle will automat
ically disengage Then remove the crank handle
CRANK HANDLE GUIDE
Model7A1 shown
Engines Generators
PROCEDURE
Initial StartUp Check List
o Check for possible leaks from all the connections
o Make sure the cooling water is discharging properly outboard
POINTER IN
from the exhaust outlet
THE OPERATING
POSITION o Make certain that the engine is mounted securely
o Listen for unusual sounds and vibrations
STOPPING THE ENGINE
To stop the engine bring the throttle to an idle position and place
the transmission in neutral Allow the engine to idle for a few
moments to stabilize temperatures Turn the engine off using the
stop control cable then turn off the keyswitch at the control panel
NOTE Make certain this keyswitch is in the OFF position 12
oclock if the keyswitch is left ON the battery will discharge
9 If the engine has not started repeat Steps 59 above and con An engine alarm is provided to warn the operator of this condi
sider cranking at a higher speed tion key switch ON The best method ofpreventing the battery
from discharging is to remove the key from the keyswitch after
A CAUTION Prolonged cranking intervals without stopping the engine
the engine starting can result In the engIne exhaust
system filling with raw water This may happen because
the pump Is pumping raw water through the raw water
cooling system during cranking This raw water can
enter the engines cylinder once the exhaust system fills
Prevent this from happening by closing the raw water
supply throughhull shutoff draining the exhaust muffler
and correcting the cause of the excessive engine crank
ing Remember that engine damage resulting from raw
water entry is not covered by Westerbekes Under Cold sure the lubricating oil is appropriate for the Use oil with an API Specification of CF or CG4
SAE 30 lOW30 or 15W40 The battery should be fully
charged to minimize voltage THE ENGINE A CAUTION Neller stop the engine with the
Allow a few minutes for the engine to wann up at a comfortable automatic decompression dellice or when the engine is
rpm 1500 rpm then reduce the rpm and get under a full Check
the lube oil level a few minutes after stopping the engine
A CAUTION Never pull the cold starting dellice knob because lube oil from the bearings etc continues to drain down
into the oil sump Disregarding this fact and not maintaining the
down when the engine Is operating proper oil level may lead to overfilling causing overheating and
the possibility of engine runaway
After shutdown carefully inspect the engine Check for possible
leaks from all the Engines Generators
ENGINE BREAKIN BREAKIN PROCEDURE 4 Avoid rapid acceleration especially with a cold your engine has
experienced a minimum of one hour of S Use caution not to overload the engine The presence of a
test operations at the factory to make sure accurate assembly pro grey or black exhaust and the inability of the engine to reach
cedures were followed and that the engine operated properly a its full rated speed are signs of an time is required The service life of
your engine is 6 During the second 25 hours the engine may be operated at
dependent upon how the engine is operated and serviced during varying engine speeds with short runs at full rated rpm
its initial 50 hours of use Avoid prolonged idling during this breakin a new engine basically
involves seating the piston
rings to the cylinder walls Excessive oil consumption and smoky
BreakIn Check indicate that the cylinder walls are scored which is Monitor the following during the 50 hour breakin by overloading the
engine during the breakin period o Check for fuel engine oil and water leaks
Your new engine requires approximately 50 hours of initial condi o Check for abnormal noise such as knocking friction operation to
breakin each moving part in order to maxi and blowback sounds
mize the performance and service life of the engine Perform carefully keeping in mind the following
o Confmn the exhaust smoke
When the engine is cold white smoke
1 Start and stop the engine according to the PING PROCEDURE section Run the engine at fast idle When the engine is warm
almost smokeless
while checking that all systems are functioning When the engine is overloaded some black smoke and soot
2 Allow the engine to warm up preferably by running at fast Also see the DAILY OPERATION CHECKllSTfor additional
idle items to check each day
NOTE Some unstable running may occur in a cold engine This The MAINTENANCE SCHEDULE section gives the should abate as normal
operating temperature is procedures to follow after the 50 hour breakin and the propeller load is applied
3 While using the vessel run the engine at various engine Transmission BreakIn
speeds for the first 25 hours Avoid prolonged periods of See the HURTH HBW TRANSMISSION section of this manual for
idling breakin information on your
DAILY OPERATION o Check the starting batteries and stop the engine according to the
instructions given in the o Check drive belt for wear and proper tension PROCEDURE section Also follow the o Check the raw
water pump to make sure its mounting given in the ENGINE BREAKIN PROCEDURE sec secure
tion during the first 50 hours of operation Make sure all periodic After starting the engine check the is performed according to the
o Check for abnormal noise such as knocking vibration and
blowby sounds
Daily Operation Check List o Confmn exhaust smoke
Follow this check list each day before starling your engine When the engine is cold white smoke
o Record the hourmeter reading in your log engine hours When the engine is warm almost smokeless
relate to the maintenance schedule When the engine is overloaded some black smoke and soot
o Visually inspect the engine for fuel oil or water leaks o Make sure the cooling water is discharging properly outboard
o Check the oil level dipstick from the exhaust outlet
o Check the transmission fluid level Check your diesel fuel supply
See DAILY OPERATION in the HURTH HBW Look for clean fuel in the fuel filterwater separator transparent section
bowl
o Check for loose wires at the alternator and make sure its
mounting is secure
Engines Generators
MAINTENANCE SCHEDULE
In order to use this Maintenance Schedule it will be necessary
to log your engine hours Use your engine hounneter or
record your engine hours by running time
A WARNING Never attempt to perfonn any service
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 expert COrtect tools for each job Disconnect the of a service mechanic
tenninals when servicing any of the engines DC
electrical equipment
MAINTENANCE FREQUENCY
COMPONENT AFTER DAILY WEEKLY EVERY EVERY EVERY EVERY EVERY MAINTENANCE DESCRIPTION
ARST OR 100 3IJO 600 1000 2000
50 EVERY HOURS HOURS HOURS HOURS HOURS
HOURS 8 HOURS
Oil level should be between the full and low
Engine oil level
indicating marks on the dipstick Top up if
necessary
Engine oil change
Change the oil see CHANGING THE OIL
under LUBRICATION SYSTEM
Remove the oil strainer and clean it with
Crankcase oil
and strainer diesel fuel Flush the crankcase with the
proper lube oil
Fuel supply
Check the fuel supply Top up if necessary
Fuel filterWater
separator Check for water and dirt in the fuel Drain
and replace the filter if necessary
Fuel lift pump
Clean or replace the two filters See FUEL
LIFT PUMP under FUEL SYSTEM
Fuel filter
Change the filter
Check and adjust the injection opening pres
Fuel injector
sure and spray condition see TESTING THE
FUEL INJECTOR under ENGINE
Remove the pump cover and inspect the
Raw water pump
impeller gaSket cam and cover for wear Check
the bearings and seals the shaft can tum but
not wobble lubricate when Raw water
intake strainer See RAW WATER INTAKE STRAINER under
COOLING SYSTEM
Thermostat
Check the functioning of the thermostat see
COOLING SYSTEM
Engine hosas
Hoses should be hard and tight Replace if soft
and spongy Check and tighten all hose clamps
Air intake filter
Clean
Inspect for leaks Check the antisiphon valve
operation Check that all connections are tight
Check the exhaust elbow for
Exhaust system
carbon andor corrosion buildup on inside pas
sages clean and replace as necessary Warning
A defective exhaust elbow can
cause carbon monoxide leakage
Starting batteries Check electrolyte levels and make sure connec
and house
batteries tions are very tight Clean off excessive corro
sian
DC Alternator
Check the DC charge from the alternator Check
mounting bracket tighten electrical Westerbeke recommends thai this service be performed by an authorized mechanic
Engines Generators
MAINTENANCE SCHEDULE
MAINTENANCE FREQUENCY
COMPONENT AFTER DAILY WEEKLY EVERY EVERY EVERY EVERY EVERY MAINTENANCE DESCRIPTION
FIRST DR 100 300 600 1000 2000
50 EVERY HOURS HOURS HOURS HOURS HOURS
HOURS 8 HOURS
Inspect for proper tension 38 12 in
10 12 mm deflection and adjust if nec
Drive belt
essary Check belt edges for wear see
DRIVE BELT ADJUSTMENT under ENGINE
Check the solenoid and motor for motor
sian Remove and lubricate Clean and
lubricate the starter motor pinion engine
idle speed Adjust to 1000 1200 rpm
Adjust the valve clearances see VALVE
Valve clearances
CLEARANCE ADJUSTMENT under
ENGINE ADJUSTMENTS
Check the compression pressure ENGINE COMPRESSION TEST
under
ENGINE ADJUSTMENTS
Retorque the nuts see TIGHTENING nuts CYLINDER HEAD under
ENGINE ADJUST
level
Engine
Initial fluid change at 25 hours then every
300 hours or at winterizing
Chattering at idle and low rpms is an plate cation of damper
plate wear Remove and
cable Check for loose fittings cotter pins etc
Lubricate with WD40 or inspection
Hardware fasten
Check for oil fuel and water leaks
Inspect and tighten all fastenings and accessi
ings and electrical
connections ble screws bolts and nuts Inspect all wiring
and electrical connections
Keep the engines surface clean Surface dirt
Cleaning the
engine and oil will inhibit the engines ability to
remain
cool
Lubricate Lubricate with LOCKEZE or equivalent every
control panel
keyswitch 100 hours or at winterizing After lubricating
check for smooth operating of the recommends that this service be performed by an authorized
Engines Generators
EXHAUST EXHAUST SYSTEM is important to install a proper exhaust system to avoid engine
Carbon The system must be designed to prevent water from The best protection against carbon monoxide poisoning is a the exhaust
line under any sea conditions and at any inspection of the complete exhaust system Check for leaks
angle of the vessels hull Exhaust system failures are not covered around the exhaust exhaust hose gaskets and
by Westerbekes warranty The installer should have a basic welds Make sure there are no fumes entering your boat from a
knowledge of marine installation requirements nearby vessel Make sure the exhaust lines are not heating recommends
installing an exhaust system having an surrounding areas excessively If excessive heat is present muffler The inline muffler should be
located below the the situation immediately If you notice a change in the sound or
engines exhaust elbow It must accumulate any water that runs appearance of the exhaust system shut down the engine immedi
back down the exhaust line after the engine is shut down Design ately and have the exhaust system inspected and repaired at once
the system so there is an adequate drop in the line between the by a qualified elbow and the throughhull discharge end of the line The
exhaust hose must be certified for marine use
A WARNING Exhaust gasses contain carbon
Monoxide an odorless and colorless gas carbon
A CAUTION An exhaust line that is too long andor Monoxide is pOi5Onous and can cause
and death Symptoms of carbon Monoxide exposure
has a poor gradient can cause water to retum back to
can include
the engine when it is shut off
Dizziness Throbbing In Temples
Nausea Muscular Twitching
Headache Weakness and Sleepiness
A WARNING The exhaust system must be tight Vomiting Inability to Think Coherently
and free of leaks Exhaust gasses are deadly Display IF YOU OR ANYONE ELSE EXPERIENCE ANY OF THESE
the carbon Monoxide waming decal near your engine SYMPTOMS BET OUT lITO FRESH AIR IMMEDIATELY
on your cabin bulkhead or in 50me other prominent If the symptoms persist seek medical attention Shut
location down the engine and rentilate the area with clean air
Do not restart the engine until it has been inspected
For more information about exhaust system design see and INSTALLATION MANUAL for MARINE ENGINES
and GENERATORS Publication 43268 Carbon Monoxide Warning presumes that the installer of this marine diesel
engine A carbon monoxide warning decal has been provided by
is familiar with the safeguards a watercooled marine exhaust sys Westerbeke Display this decal near your engine on your cabin
tem will provide for the engine Failure to design and layout a bulkhead or in some other prominent exhaust system can result in
catastrophic damage to the
diesel engine and possibly result in the sinking of the vessel in
which the unit is For installations where the exhaust elbow is close
to or below the vessels waterline provisions must be made to
install a siphonbreak in the raw water supply hose to the exhaust
elbow The siphonbreak provides an air vent in the raw water
cooling system to prevent raw water from filling the exhaust sys
tem and the engines cylinder when the engine is shut down See
SIPHONBREAK in the COOUNG SYSTEM section for more
information WARNING
Engines Produce CARBON MONOXIDE
Regular Maintenance Required
A CAUTION Falure to use a siphonbreak when the
exhaust elbow is located at or below the load waterline
will result in raw water damage to the engine and possi CARBON MONOXIDE
WARNINO DECAL
ble flooding of the boat
Engines Generators
EXHAUST SYSTEM
Carbon Monoxide Detectors
It is extremely important that a carbon monoxide detectors be
installed in your boats living andor sleeping quarters Make sure it for the marine industry They are inexpensive and avail
able at your marine insulated portions of the exhaust system to ensure there is of the A CAUTION Prolonged cranking intervals without
the engine starting can result in the engine exhaust sys
tem filling with raw water This may happen because
the pump is pumping raw water through the raw water
cooling system during cranking This raw water can
enter the engines cylinder once the exhaust system
fills Prevent this from happening by closing the raw
water supply throughhull shutoff draining the exhaust
muffler and correcting the cause of the excessive
engine cranking Remember that engine damage
resulting from raw water entry is not covered by
Westerbekes Engines Generators
LUBRICATION SYSTEM
DESCRIPTION
The lubricating system is a pressure feeding system using an oil
pump The engine oil is drawn from the oil sump by the oil
pump which drives the oil under pressure through the various
lubricating points in the engine The oil then returns to the oil
sump to repeat the continuous cycle
The geardriven oil pump is built into the oil sump The
oil is pumped through a spinon type oil filter Model IIAI
only to the main bearing and connecting rod bearing
The piston cylinder liner and rocker arms are splash
lubricated There is an oil strainer in the crankcase see
CrankcaseOil Strainer in the MAlNIENANCE SCHEDULE OIL PRESSURE SWITCH
for maintenance information A crankcase breather valve is Model 11A1 silo
integrated into the cylinder heads inlet channel and is ENGINE OIL
Use a heavy duty engine oil with an API of CF
or CG4 or better The SAE grade depends on the ambient
temperature For the recommended oil viscosity see the
following chart
Operating Temperature Oil Viscosity
Above 68 F 20 C SAE 30 10W30 or 15W40
41 68 F 5 20 C SAE 20 or 10W30
Below 41 F 5 C SAE10W30
SPINON OIL FILTER Ht
Model 11A1 only
A CAUTION Do not allow two or more brands of
engine oil to mix Each brand contains its own additives
additives of different brands could react in the mixture
to produce properties harmful to your engine
CHECKING THE OIL
Check the lube oil level see illustration prior to starting With
continuous operation check the oil level daily or every 8 hOUTS
Check the lube oil level a few minutes after stopping the engine
because lube oil from the bearings etc continues to drain down
into the oil sump Disregarding this fact and not maintaining the
proper oil level may lead to overfilling overheating and
BREATHER engine
If a topup is necessary clean the area around the oil filler to
prevent dirt from entering the engine
Oil Pressure Relief Valve
There is an oil pressure relief valve in the sump If the oil pressure
exceeds the maximum specified value the valve opens and some
of the oil returns to the sump keeping the oil pressure below its
maximum specified value
Low Oil Pressure Alarm Switch
A low oil pressure alarm switch is located on the engine block This WBE OIL DIPSTICK
switchs sensor monitors the engines oil pressure Should the engines Model7A1 lion
oil pressure fall below the specified value this switch will activate a
pulsating aIarm on the control panel
Engines Generators
LUBRICATION THE OIL
Change the oil after an initial 50 hours of breakin operation and
every 100 hours of operation thereafter Change the oil only when engine is warm
Always observe the used oil as it is removed A indicates the presence of water in the oil Although is rare it does require prompt attention to
prevent seri
ous damage Call a qualified mechanic should water be present in
the oil Raw water present in the oil can be the result of a fault in
the exhaust system attached to the engine andor a siphoning of
raw water through the raw water cooling circuit into the the engine This problem is often caused by the absence of
an antisiphon valve its poor location or lack of maintenance Modal7A1 Model 11A1
REMOVING THE OLD OIL
A CAUTION Used engine oil contains harmful Changing the Oil Filter Model 11A1 only
contaminants Avoid prolonged skin contact Clean skin When removing the used oil filter you may fmd it helpful and
and nails thoroughly using soap and water Launder Dr cleaner to punch a hole in the upper and lower portion of the old
discard clothing Dr rags containing used oil Discard filter to drain the oil from it into a container before removing it
used oil properly This helps to lessen spillage A small automotive filter wrench
should be helpful in removing the old oil the Old Oil NOTE Do not punch this hole
without first loosening the filter to
1 Remove the oil filler cap see illustration using a 13 mm make certain it can be removed
open end spanner Place some paper towels and a plastic bag around the filter 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
FILLER your engine clean Inspect the old oil filter as it is removed to
CAP make sure that the rubber sealing gasket comes off with the old oil
filter If this rubber sealing gasket remains sealed against the filter
bracket gently remve it
JW 0
SPINON OIL FILTER
Model 11A1 only
2 Model7AI Place a suitable container below the oil drain
plug see then remove the oil drain plug and com
pletely drain the used oil into the container Then remove and
clean the lube oil strainer Always clean this strainer at every
oil change After cleaning replace the strainer and the oil
drain plug
ModelIMI Place a suitable container below the oil drain
When installing the new oil filter element wipe the filter gaskets
cover plate see then remove the cover plate and
sealing surface on the bracket free of oil and apply a thin coat of
completely drain the used oil into the container Then replace
clean engine oil to the rubber gasket on the new oil filter Screw
the cover plate NOTE Be sure to change the spinon oil filter
the filter onto the threaded oil filter nipple and then tighten the
at every oil change see Changing the SpinOn Oil Filter
filter fmnly by hand
below
NOTE Generic filters are not recommended as the material
NOTE With an inclined engine installation the lube oil must standards or diameters of important items on generic parts might
be pumped out otherwise too much oil would remain in the
be entirely different from genuine parts Immediately after an oil
crankcase
filter change and oil fill run the engine to make sure the oil pres
sure is normal and that there are no oil leaks around the new oil
filter
Engines Generators
LUBRICATION SYSTEM
Adding the New 011
1 Add the new oil through the oil fill
2 Replace the oil filler cap When tightening it do not use too
much force otherwise the plastic plug may break
3 After refilling with new oil run the engine for a few moments
Make sure there is no leakage around the oil filler cap or the
new oil filter ModelllAl only then stop the engine Then
check the quantity of oil with the lube oil dipstick Fill to but
not over the MAX mark on the dipstick should the engine
require additional oil
TESTING THE OIL testing make sure the oil level is at the MAX mark on Remove the oil pressure switch see Install a mechanical oil pressure gauge in
the oil pressure
switch hole
3 Warm up the engine then set the engine speed at 3000 rpm
and read the gauge
Operating oil pressure engine hot
256 569 psi 18 40 kglcml
If the oil pressure is too low see Low Oil Pressure under
ENGINE NOTE The oil pressure switch closes at 43 87 psi
03 06 Bar
Engines Generators
COOLING SYSTEM
RAW WATER COOLING SYSTEM
The engine is designed for direct raw water cooling The with a raw water coolant temperature up to 90 F 32 C
The raw water flow is created by a positive displacement impeller
pump that is geardriven by the camshaft This pump draws
cooling water directly from the raw water source ocean lake or
river through a hose
The raw water is pumped through a tee which splits the flow The
tee directs some of the flow to passages in the engine block and
the remainder to a bypass The flow to the engine block the cylinder and through the cylinder head cooling the
engine The flow through the bypass goes directly to the and is at its greatest when the engine is warming
up and the thermostat is not yet open Flow though the bypass
also occurs after the thermostat is open The raw water that is
flowing through the engine block then flows through the thermo MODEL lA1
stat to the exhaust where it mixes with and cools
the exhaust gases This mixture of exhaust gas and raw water is
discharged overboard by the engines exhaust gas discharge coolant temperature switch is located on the cylinder head for
Model 7AI and on the thermostat housing for thermostat located on top of the cylinder head controls the raw
water coolant temperature as the coolant flows through the cool
ing system The thermostat is set to the maximum temperature of
140 F 60 C When the engine is first started the closed ther
mostat prevents coolant from flowing some coolant is a bypass tube to prevent the exhaust manifold from over THERMOSTAT
As the engine warms up the thermostat The thermostat is accessible and can be checked cleaned
or replaced easily Carry a spare thermostat and gasket MODEL the the two cap screws and the thermostat housing then
remove the thermostat from the cylinder head see check the thermostat immerse it in water that is F 60 C The thermostats cone must then be fully
open
this indicates the thermostat is in good a new gasket when reinstalling the thermostat or replacing it
Apply a thin coat of sealant on both sides of the gasket it into place Do not overtighten the cap screws
Run the engine and check for normal temperatures and that there
are no leaks at the thermostat housing
COOLANT TEMPERATURE SWITCH BLEED
HOLE
The coolant temperature switch is located near the thermostat
housing see If the coolants operating temperature
reaches approximately 175 F 80 C this switch will activate
the alarm on the control panel
CYliNDER
HEAD
THERMOSTAT
ASSEMBLY
Model 7A1 sIIown
Engines Generators
COOLING SYSTEM
RAW WATER PUMP RAW WATER INTAKE
The raw water pump is a selfpriming rotary pump with a A flushtype thoughhull fitting is recommended for the raw housing and a neoprene
impeller The impeller has intake It should be located on the boats hull where it will be
flexible vanes which wipe against a curved cam plate within the below the waterline during all angles of the boats operation See
impeller housing producing the pumping action On no account Westerbekes INSTAlL4TION MANUALfor MARINE this pump be run dry as water acts as a
lubricant for the and GENERATORS for complete installation There should always be a spare impeller and gasket an impeller kit onboard Raw water
pump occur when lubricant raw water is not present during
engine operation Such failures are not warrantable and operators A WARNING Do not use a scooptype cautioned to make sure raw water flow is
present at startup fitting for supplying raw water to this engine Ascoop
The neoprene impeller has a limited lifetime and must be type raw water inlet can develop substantial regularly
and force water past the raw water pump flooding the
NOTE Should a failure occur with the pumps internal parts exhaust system and allowing the water to enter the
seals and bearings it may be more cost effective to purchase a engines cylinder Damage caused by raw water entry
new pump and rebuild the original pump as a spare into the engines cylinder ria the exhaust system is not
covered by Westerbekes the Raw Water Pump the raw water intake valve Remove the pump cover and Flooding of the exhaust system due to
water pressure can also
with the aid of two small screwdrivers carefully pry the impeller occur with a flushtype raw water intake on a powerboat that has
out of the pump Install the new impeller and gasket Move the its bow up This pressure can be caused by the boats to conform to the curved
cam plate and push the impeller waterline before the boat reaches its final trim or by the angle of
into the pumps housing When assembling apply a thin coating the boat to the sea surface when its is underway
of lubricant to the impeller and gasket Open the raw water intake
valve RAW WATER INTAKE Never allow the pump to run dry Even a short period
NOTE Always install the strainer at or below the waterline so
of dry running may destroy the impeller 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
Perform the following maintenance after every 100 hours
of operation
1 Close the raw water seacock
2 Remove and clean the strainer filter
3 Clean the glass
4 Replace the sealing washer if necessary
5 Reassemble and install the strainer
6 Open the seacock
7 Run the engine and check for leaks
NOTE Also follow the above procedure after having run
hard aground
If the engine is indicating higher than normal operating tempera
tures ie the alarm is sounding the cause may be that silt leaves
or grass may have been caught up in the strainer slowing the flow
of raw water through the cooling system
RAW WATER PUMP
Engines Generators
COOLING SYSTEM
HOSE FROM THE
RAW WATER INTAKE STRAINER HOSE TO THE
OWNER INSTALLED TYPICAL
HOUSING
For installations where the exhaust elbow is close
to or below the vessels waterline provisions must be made to
install a siphonbreak in the raw water supply hose to the The siphonbreak provides an air vent in the raw water
cooling system to prevent raw water from filling the exhaust sys
tem and the engines cylinder when the engine is shut down
A CAUTION Failure to use a siphonbreak when the
exhaust elbow Is located at or below the load waterline
will result In raw water damage to the engine and possi
ble flooding of the boat
If you have any doubt about the position of the elbow relative to the vessels waterline under any of the
vessels various operating conditions or when the vessel is not
under way install a siphonbreak This precaution is necessary
to protect your engine
The siphonbreak must be installed in the high point of a hose that
is looped a minimum of 20 inches 51 cm above the This siphonbreak must always be above the waterline
all angles of vessel operation to prevent siphoning from Model 11A1 WESTERBEKE has provided two siphonbreak
hoses
these are tagged The hose to the siphonbreak connects to the
raw water line at the thermostat housing The hose from attaches to the exhaust elbow The owner must furnish the siphonbreak and lengths of hose
that may be A siphonbreak requires periodic inspection and cleaning
to ensure proper operation Failure to properly maintain a DRAINING THE COOLING can result in severe engine damage Consult the
When freezing temperatures are expected the cooling system manufacturer for a proper maintenance schedule be drained by
unscrewing the pump cover The raw water coolant
will then flush back down the inlet line
Engines Generators
AIR INTAKE 7AI and llAl marine diesel engines when operating in the
cruise rpm range will typically consume in excess of 1000 cubic
feet of air per hour The engine compartment must be well venti
lated and the air flow into the engine must be Filter
The air fliter cartridge prevents dust and dirt from entering the
engine it also improves oil consumption extends engine life and
quiets the fliter should be cleaned every 100 operating hours Tap the
cartridge on a flat surface to dislodge loose dirt or clean it off air If the cartridge is badly contaminated or oily
replace it
WATER HEATER FROM
WATER
HEATER
WATER HEATER INSTALLATIONS WATER
HEATER
This engine is equipped with connections for plumbing the to transfer heat to an onboard water heater The water
heater should be mounted in a convenient location either in a low
or high position in relation to the engine
Plumb the heater hoses into the raw water line that connects housing to the exhaust see If the exhaust on your engine is close to or
below the vessel s waterline you must also install a the same hose see SiphonBreak under RAW WATER COOL
ING SYSTEM for more information The water heater connec
tions may be located either before or after the THERMOSTAT
HOUSING
WATER HEATER CONNECTIONS
Model llAl shown
Engines Generators
FUEL SYSTEM
DIESEL FUEL FUEL FILTER
Use No2 diesel fuel with a cetane rating of 45 or higher Do not The frequency of a fuel filter change depends on the degree of
use kerosene or home heating fuel contamination of the fuel however it should be performed at least
after every 100 hours of engine ADDITIVES
If fungus or bacteria is causing fuel problems you should have Replacing the fuel filter
an authorized dealer correct these problems Then use a diesel fuel 1 Clean the fuel line with a rag and clamp it off to sterilize the fuel
follow the the fuel lift pump and the fuel filter
Also use on a regular basis a fuel conditioner such as STABIL 2 Pull off the inlet and outlet lines from the filter Make
Follow the instructions for the quantity to add sure dirt does not enter the fuel lines Discard the
used filter
CARE OF THE FUEL SUPPLY 3 Install the new filter making sure the flow arrow on the
Use only clean diesel fuel Purchase a wellknown brand of fuel filter housing is pointed in the proper direction Push the
The clearance of the components in your fuel injection pump is fuel lines as far as possible onto the connection nipples
very critical invisible dirt particles which might pass through the of the new can damage these fmely fmished parts It is important to
After installing the new filter bleed the air from the fuel lines
clean fuel and keep it clean The best fuel can become unsatisfac
using the manual fuel primer see BLEEDING mE FUEL
tory by careless handling or improper storage facilities To assure
SYSTEM
that the fuel going to your engine is clean and pure be sure to filter
it properly Install and regularly service a good fuel filterwater separator having a filter element with a
micron rating of 2 or 1O Install it between the fuel tank and LIFT PUMP
To assure proper suction the engines fuel lift pump should not be
more than 1 ft 300 mm above the bottom of the fuel tank pickup
tube check the fuel connections to and from the fuel lift
pump and make sure that no leakage is preSent and that the fittings
are tight and secure
A WARNING Fuel leakage at the fuel litt pump or its
connections is a fire hazard and should be corrected
Make sure proper entilation exists wheneer sellficing
fuel system fuel lift pump has two filter inserts in the pumps cap To clean
or replace them unscrew the cap and retaining plate and remove
the two filter inserts Note the disassembly sequence to ensure
proper FUEL LIFT PUMP
Engines Generators
FUEL SYSTEM
FUEL LINES FUEL INJECTION PUMP
The fuel return line at the fuel tank should extend down to the The fuel injection pump is a very important component of the
bottom of the tank in the same manner as the fuel pickup tube diesel engine requiring the utmost care in handling The fuel
This must be done in an installation where the fuel tank is located injection pump has been thoroughly benchtested and the
below the engines fuel system This precaution insures against is cautioned not to attempt to service it The only
hard starting due to air displacing fuel siphoning out of the adjustment the servicing mechanic should make to the fuel fuel system
through the return line when the engine is tion pump is the adjustment for engine idle speed see
SPEED ADJUSTMENT under ENGINE ADJUSTMENTS Ifit
requires servicing remove it and take it to an authorized fuel
injection pump service facility Do not attempt to disassemble
A WARNING Shut off the fuel valve at the tank when and repair it
servicing the fuel system Take care in catching any fuel
that may spill DD NOT allow any smoking open flames FUEL INJECTOR
Dr other sources of fire near the fuel system when For information about removing and checking the fuel injector
servicing Ensure proper ventilation exists when see TESTING THE FUEL INJECTOR under ENGINE ADJUST
servicing the fuel system MENTS
In case of severe vibrations and detonation noise have the injec
FUEL FILTERWATER SEPARATOR tors checked and overhauled by an authorized fuel injection recommends
that you install and regularly service a vice center Poor fuel quality contaminants and loss of positive
good quality Coast Guard approved visualtype primary fuel fIlter fuel pressure to the injection pump can result in injector faults
of the type This fuel fIlterwater separator must Since fuel injectors must be serviced in a clean room environ
be installed between the fuel tank and the engine to prevent any ment it is best to carry at least one extra injector as a spare or
water that may be in the fuel from reaching the a problem occur
fuel lift pump and causing damage to the fuel system may also prolong the life of the fuel fIlter that comes installed BLEEDING THE FUEL
SYSTEM
on the fuel line It is the of the to The fuel injection pump is any air in the fuel lines
install this fuel filterwater separator Select a fIlter that has a 2 will bleed out through the fuel return line Bleeding can also be
or 10 micron rating done by using the manual fuel primer on the fuel lift pump see
Most installers include a fuel fIlterwater separator with the In case the engine is shut down due to lack of package as they are
aware of the problems use the manual fuel primer to bleed the system after refilling in the fuel can cause
fuel tank it will not be necessary to disconnect the fuel lines to
bleed the air Also use the manual fuel primer to bleed the
A typical fuel fIlterwater separator is illustrated below This is the system after changing the fuel Model 500 MA Keep in mind that if a water
fIlter is not installed between the fuel supply tank and the Bleeding the fuel system will also be necessary before fuel system any
water in the fuel will affect the engine is layedup during the offseason or for prolonged periods
fuel pump engine filter and injection equipment The of inactivity See LAYUP AND is responsible for making certain the fuel
reaching To use the manual fuel primer work the lever back and forth with
the engines injection equipment is free of impurities This slow complete strokes If pressure isnt felt rotate the engine 112
f I
process is accomplished by installing and maintaining a proper turn this will reposition the fuel pump to improve the pumping
action
fuel fUlcrwMer
SPARE PARTS
While the likelihood of having to service the system at sea is slim
the possibility does exist Therefore we recommend that banjo
washers injector seat washers and a fuel fIlter be carned on board
at all times Purchase needed spare parts from your local
WESTERBEKE dealer or distributor If a leak should develop at
a banjo washer that cannot be corrected by a simple tightening of
the fitting replace the sealing washer with a replacement found in
the hardware kit for your model
FUEL FllTERI
WATER SEPARATOR
owner Engines Generators
DC ELECTRICAL SYSTEM
12 VOLT DC CONTROL CIRCUIT ENGINE CIRCUIT BREAKER
The engine has a 12 volt DC electrical control circuit that is The DC wiring harness on the engine is protected by an engine
shown on the wiring diagrams Refer to these diagrams when mounted manual reset circuit breaker 10 amps DC or when servicing the DC
electrical system current draw or electrical overload anywhere in the instrument
panel wiring or engine wiring will cause the breaker to trip In
this event the engine will shut down because the opened breaker
A CAUTION To avoid damage to the battery charg disconnects the fuel supply If this should occur check and repair
Ing circuit never shut off the engine battery switch the source of the problem After repairing the fault reset the
while the engine is running Shut off the engine battery breaker and restart the engine
switch however to avoid electrical shorts when working
on the engines electrical circuit BATTERY
The minimum recommended capacity of the battery used in the
CONTROL PANEL engines 12 volt DC control circuit is 200 Cold Cranking Amps
The engine is started by using the keyswitch on the control panel CCA
The keyswitch has three positions OFF ON and START PROCEDURE Battery Care
NOTE Push the key in to preheat after turning the key to the Review the and then establish a
ON position systematic maintenance schedule for your engines starting batter
NOTE Periodically lubricate the keyswitch with WCKEZE to ies and service proper operation
o Monitor your voltmeter for proper charging during
The oil temperature alarm beeps when either the engine pressure is too low or the engine is overheated o Check
the electrolyte level and specific gravity with
The hourmeter registers the elapsed engine running time and a be used as a guide for the maintenance schedule o
Use only distilled water to bring electrolytes to a proper level
HOURMmR
o Make certain that battery cable connections are clean and
tight to the battery posts and to your engine
KEYSWITCH
o Keep your batteries clean and free of corrosion
A WARNING Sulfuric acid in lead batteries can
cause severe burns on skin and damage clothing Wear
protective gear
Oil PRESSUREI
COOLANT TEMPERATURE
AlARM Checking the Service Battery
Check the voltage of the service battery This battery should have
PUSH 10
ALARM PREHEAT a voltage between 13 and 14 volts when the engine is running If
not there is a problem in the service battery charging circuit
Troubleshoot the service battery charging circuit by checking the
wiring and connections the solenoid isolator battery switch and
CONTROL PANEL
the battery itself
Engines Generators
DC ELECTRICAL MULTIMETER
A WARNING A failed alternator can become very
hot Do not touch until the alternator has cooled down
Use this section to determine if a with the charging circuit or with If it is
determined that the alternator or voltage regulator is faulty
have a qualified technician check it
The alternator charging circuit charges the starting battery
and the service battery An isolator with a diode a solenoid
or a battery selector switch is usually mounted in the circuit
to isolate the batteries so the starting battery is not discharged TESTING THE with the service battery If the alternator is charging the
battery but not the service battery the problem is in ENGINE RUNNING
the service batterys charging circuit and not with the 3 Tum off the engine
Inspect all wiring and the Alternator Ensure that the battery terminals and the engine ground
connections are tight and clean
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 CAUTION To avoid damage to the battery
charging circuit never shut off the engine battery
switch when the engine is running
A WARNING When testing with a multimeter 4 If a battery selector switch is in the charging circuit
ensure that it is on the correct setting
DC and AC circuits are often mixed together in marine
applications Always disconnect a shore power cord 5 Tum on the ignition switch but do not start the engine
isolate DC and AC converters and shut down the engine 6 Check the battery voltage If the battery is in good condi
tion the reading should be 12 to 13 volts
before performing DC testing No AC tests should be
made without a proper knowledge of AC circuits
Start the engine
2 After the engine has run for a few minutes measure the
starting battery voltage at the battery terminals using a
multimeter set on DC volts
a If the voltage is increasing toward 14 volts the alterna
tor is working omit Steps 3 through 8 and go directly
to Checking the Service Battery on the next page
b If the voltage remains around 12 volts a problem TESTING THE
exists with either the alternator or the charging circuit ALTERNATOR VOLTAGE e3i
continue with Steps 3 through 8 IGNITION ON ENGINE OFF
GROUND
Engines Generators
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 i
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 alternator diodes
tery voltage at the B output terminal do not use a high voltage tester ie a megger wilen
performing tests on the alternator charging circuit
If 12 volts is not present at the EXC terminal trace the
wiring and lookfor breaks and poor Engines Generators
DC ELECTRICAL SYSTEM
7A1 MARINE DIESEL ENGINE
WIRING DIAGRAM 45593
I 4 Bl K
RD tI4RO
WATER TEIF
SWITCH
SEE NOTE 2
I IlL
PRESSUIE SWITCH
I o
I r
5 4
CfICUT
IIIIEAKER WE
IlElAY
RELAY
110 RED
4 RED
GLOW
PLUOS
STARlBI
IIEtAT
SOIENOIl
I 4 V 10
I 2 WHT
12 RED
114 VEL
i14 ORANGE
I 4 Bl II
71 MODEL IS OUIPPED WITH A TIME DELAY RELAY THAT PREVENTS
EXCITATION or THE AlTERNATOR DURING PREHEAT AND CRANKING THE
ALTERNATOR EXCITATION Will OCCUR APPROX 31041NS AFTER THE IGNITION
KE Y HAS BEEN TURNED ON
KEY SWITCH
REMlTE PAfE
WESTERBEKE
Engines Generators
DC ELECTRICAL SYSTEM
7A1 MARINE DIESEL ENGINE
WIRING SCHEMATIC 45593
G 12 VDC
STARTER
STARTER
SOLENOIO
GlOWPLUGS
I PREtAT I
I SOLENOID I
I I
AlTERNATOR
30 87 86
ClRCUT
BREAKER NO
T1rtE
DElAY
RELAY WATER TEMP
SWITCH
3 NC
OIl PRESSURE 6 7 5 3
AlARM HOlfl
METER
START
PREJEAT0
NOTES
THIS PRODUCT IS PROTECTED BY A MANUAL RESET CIRCUIT BREAKER LOCATED NEAR THE
STARTER EXCESSIVE CURRENT WILL CAUSE THE BREAKER TO TRIP AND THE ENGINE WILL
KEY SWITCH SHUT DOWN THE BUILDEROWNER MUST BE SURE THAT THE INSTRUMENT PANEL WIRING AND
ENGINE ARE INSTALLED TO PREVENT CONTACT BETWEEN ELECTRICAL DEVICES AND SEAWATER
AN ONorr 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 or 175 AMPS AT 12 VDC WILL SERVE THIS rUNCTION THIS
SWITCH SHOULD NOT BE USED TO MAKE OR BREAK THE CIRCUIT
Engines Generators
DC ELECTRICAL SYSTEM
11A1 MARINE DIESEL ENGINE
WIRING DIAGRAM 44542
I 4 BL K
I I
10 I
WATER TEJoP
I IlL PIESSUAE SWITCH
I r
STARTER
114 REDWHT
114 VIO
112 WHT
1I2RED
14 y l
II BLK
KEY SWITCH
L REMOTE PAtl
Engines Generators
DC ELECTRICAL SYSTEM
11A1 MARINE DIESEL ENGINE
WIRING SCHEMATIC 44542
vee STARTER
STARTER SOLENOID
CIRCUT
BREAKER
WATER TEMP
SWITCH
DI PRE5SUE B 7 5 3
ALARM HOUR
METER
START
NOTES
I THIS PRODUCT IS PROTECTED BY A MANUAL RESET CIRCUIT BREAKER LOCATED NEAR THE
STARTER EXCESSIVE CURRENT WILL CAUSE THE BREAKER TO TRIP AND THE ENGINE WILL
KEY SWITCH SHUT DOWN THE BUILDEROWNER MUST BE SURE THAT THE INSTRUMENT PANEL WIRING AND
ENGINE ARE INSTALLED TO PREVENT CONTACT BETWEEN ELECTRICAL DEVICES AND SEAWATER
2 AN ONorF 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 or 175 AMPS AT 12 VDC WILL SERVE THIS rUNCTION THIS
SWITCH SHOULD NOT BE USED TO MAKE OR BREAK THE CIRCUIT
Engines Generators
GLOW PLUGS
MODEL 7A1 Reinstall the plugs in the air intake adapter and test them again
The plugs should get very hot at the terminal end within 7 to 15
The glow plugs 2 are wired through the preheat solenoid When seconds If the plugs dont heat up quickly check for a short cir
PREHEAT is pressed at the control panel this solenoid should cuit When reinstalling the glow plugs use antiseize on and the glow plug
should begin to get hot
on the inspect the plug remove the electrical terminal connections A WARNING Do not keep a glow plug on for more
then unscrew each plug from the air intake adapter Thoroughly than 30 each plugs tip and threads with a soft brush and to remove all
the carbon and oil deposits While clean Glow plug tightening torque 7 11 ftIb 10 15 mkg
ing examine the tip for wear and burn erosion if it has eroded too
much replace the TERMINAL
An accurate way to test glow plugs is with an ohmmeter Touch
one prod to the glow plugs wire connection and the other to the
body of the glow plug as shown A good glow plug will have a
055 ohm resistance This method can be used with the plug in or
out of the engine You can also use an ammeter to test the power TESTING AGLOW PLUG
drain 5 6 amps per plug WITH AN OHMMETER
A WARNING These glow plugs will become very hot
to the touch Be careful not to bum your fingers when TIP
testing the plugs
TESTING A GLOW PLUG
USING A TEST UGHT
Engines Generators
ENGINE ADJUSTMENTS
NOTE WESTERBEKE recommends that the following engine adjustments
be performed by a competent engine mechanic The information below
is provided to assist the THE CYLINDER HEAD 5 For each valve insert a 02 mm 0008 in feeler gauge
between the valve stem and the rocker arm and adjust the
After the initial breakin period 50 hours
clearance until a slight drag is felt on the gauge when it is
retorque the cylinder head nuts Do this when the engine is cold
pulled out
1 Remove the cylinder head cover and gasket 6 Tighten the locknut while holding the setting screw with
2 Retighten the four cylinder head nuts in an Xpattern a screwdriver
sequence as shown in the illustration Start with any nut 7 Recheck the clearance
Before applying the torque to a nut loosen it 114 to 112 a
tum then apply the torque See TORQUE
for the proper torque
3 Reinstall the cylinder head cover and gasket Insert new
plastic washers under the two nuts and tighten to the
specified torque
ENGINE COMPRESSION TEST
To check the engines compression pressure warm up the engine
shut off the raw water throughhull remove the fuel injector and
VALVE CLEARANCE ADJUSTMENT install a compression adapter in the injector hole Connect a com
pression tester on the adapter and crank the engine with the starter
Check the valve clearances after the first 50 hours of operation and motor until the pressure reaches a maximum value
every 600 hours thereafter
Compression pressure at 350 rpm
NOTE Tighten the cylinder head bolts to their specified torque Minimum 4350 psi 306 kgcm 2
before adjusting the valve clearances see TIGlffENING THE Standard 4785 psi 336 HEAD
Adjust the valve clearances when the engine is cold The
clearance is 02 mm 0008 in for both intake and exhaust valves
1 Remove the cylinder head
2 Check to make sure the automatic device is in its normal operating position ie not activated
see ADAPTER
INJECTOR HOLE
POINTER If the pressure is weak the problem is either valve or piston
lH AUTOMATIC DECOMPRESSION related Check the valve clearance adjust as needed and test
DEVICE IN THE NORMAL
OPERATING POSITION again If the compression is still low apply a small amount of oil
into the cylinder to seal the rings and repeat the test If the
compression comes up the rings are faulty
An abnormally high reading indicates heavy carbon a condition that might
be accompanied by high pressure and noise
NOTE In case of severe vibrations and detonation noise have the
injector checked and overlwuled by an authorized fuel injection
3 Set the piston at the TDC of the compression stroke service center Poor fuel quality contaminants and loss ofpositive
4 Loosen the locknuts on the valve setting screws fuel pressure to the injection pump will result in injector faults
see Engines Generators
ENGINE ADJUSTMENTS
NOTE WESTERBEKE recommends that the following engine adjustments
be performed by a competent engine mechanic The information below is
provided to assist the THE FUEL INJECTOR Checking The Injection Starting The fuel injector must be
serviced in a clean room 1 Set the nozzle tester in a clean place where there
no dust or dirt
2 Mount the nozzle and the nozzle holder on the
Removing the Fuel Injector nozzle tester
1 Disconnect the high pressure fuel line from the injector 3 Use new fuel that has an approximate temperature of
then loosen the line at its attachment to the injection 68F 20C
pump and move it out of the way of the injector Avoid 4 Bleed the air in the nozzle line by pumping the nozzle
bending the line tester handle several times
2 Remove the fuel return line in its entirety from the top of 5 Slowly lower the nozzle tester handle and check the
the injector Take care not to lose the two sealing reading on the pressure gauge when the injection starts
washers and banjo bolt that attaches the fuel return line
to the injector Injection starting pressure
2850 2900 Ibin2 200 203 kglcm2
3 Remove the fuel injector holder bracket mounting nuts
then remove the holder bracket
4 Remove the fuel injector A CAUTION Keep hands away from the nozzle spray
The spray nozzle velocity Is such that It may psnettate
NOTE Clean the area around the base ofthe injector prior to
dBflJy into tllB fingBIS and hands destroying tissue If
lifting it out ofthe cylinder head to help prevent any rust or
it enters the bloodstream It may CBIISB blood pOisoning
debris from falling down into the injector hole ifthe injector
will not lift out easily and is held in by carbon buildup or the
like worlc the injector sidetaside with the aid ofa 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 injector is Remove the gaskets FUEL
INJECTOR
6 Remove the Injector fuel injector consists of the following parts
INJECTION PRESSURE TEST
NOZZLE HOLOER
6 If the injection starting pressure is not within the specified
ADJUSTING SHIMS range adjust it by replacing the shim with one of a more
appropriate thickness
If the thickness of a shim is increased 0004 in 01 mm
PRESSURE SPRINGI the injection pressure increases approximately 145lblin2
101 kglcm2
VALVE CONE
PRESSURE PIECEe
ADJUSTING SHIM
FUEL INJECTOR ADJUSTING SHIM
FUEL INJECTOR
COMPONENTS Engines Generators
ENGINE ADJUSTMENTS
NOTE WESTERBEKE recommends that the following engine adjustments
be peiformed by a competent engine mechanic The information below is
provided to assist the of the Valve Seat Checking the Nozzle Body and Needle Valve
Apply a pressure of 2600 Iblin2182 kglcm2 and check if fuel 1 Check for damage to the valve seat of the needle valve
leaks from the injection nozzle holes If fuel leaks disassemble and check for damage to other parts
wash and recheck the injector nozzle or replace it 2 Check for damage to the nozzle body Hold the nozzle
body upright and insert fourfifths of the needle valve
Then release the needle valve and check that it drops into
the valve seat under its own weight
Reassembly
Be sure to do the following when reassembling thefuel injector
1 Tighten the nozzle body onto the nozzle holder to the
specified torque
Nozzle torque
29 36 ftIb 40 50 kgm
CHECKING THE TIGHTNESS OF THE VALVE the Spray Pattern
1 Mount the nozzle and nozzle holder on the nozzle tester
2 Bleed the air in the nozzle line by pumping the nozzle
tester handle several times
3 Keep the reading on the pressure gauge of the nozzle
TIGHTENING THE
tester just below the injection starting pressure while NomE BODY ONTO
pumping the handle of the nozzle tester as quickly as THE NomE HOLDER
possible so that a pulsating whistling sound is heard
Check the atornition of the fuel injected from the
nozzle see 2 After assembling the fuel injector check the injection
starting pressure and the spray pattern
Injector Installation
The fuel injector installation sequence is the reverse of the
removal sequence Make sure to include the following
1 Use new gaskets do not reuse the old gaskets
2 Replace the copper sealing washer for each injector
3 Tighten the fuel injector holder bracket mounting nuts to
NORMAl FAUlTY FAUlTY
the specified torque
PAmAN PAmAN PAmRN Bracket mounting nuts torque
FUELIIUECTOR SPRAY PAnERNS 6 9 ftIb 08 12 kgm
Normal Pattern The fuel is sprayed uniformly and finely from
all five injection nozzle holes
Faulty Pattern The number of fuel sprays and fineness of the
injected fuel is substandard If the condition of the injected fuel is
substandard disassemble wash and recheck the injection nozzle
or replace it
Engines Generators
ENGINE ADJUSTMENTS
NOTE WESfERBEKE recommends that the following engine adjust
ments be performed by a competent engine mechanic The infonnation
below is provided to assist the BELT drive belt must be properly tensioned A loose drive belt will
not provide proper alternator charging and will eventually damage
the a1temator A drive belt that is too tight will pull the of alignment andor cause the alternator to wear out Excessive drive belt tension can also
cause rapid wear of
the belt A slack belt or the presence of oil on the belt can cause
belt slipping resulting in high operating temperatures and rpm GOOD
3 Pivot the alternator on the base mounting bolt to the left
or right as required to loosen or tighten
A WARNING Never attempt to check or adjust the 4 Tighten the base mounting bolt and the adjusting strap
bolt securely
drive belts tension while the engine Is in operation
5 Run the engine for about 5 minutes then shut down and
Checking Belt Tension recheck the belt tension
1 To check the belt tension press the belt at the approxi
mate midpoint Gust above the bellhousing between the
alternator pulley and the flywheel pulley with a force of
221bs 10 kg 98 N The belt deflection should be 38
112 10 12 rnm deep
ALTERNATOR
PUUEY
flYWHEEL
PULLEY
FLYWHEEL
Adjusting Belt Tension
1 To adjust the belt tension loosen the alternator adjusting
strap bolt and the base mounting bolt
2 With the belt loose inspect the belt for damage wear
cracks and frayed edges If the belt is damaged replace
it If it is nearly worn out and deeply sunk in the pulley
groove replace it
Engines Generators
ENGINE following chart provides information based
upon certain problem indicators the probable causes of and the to overcome them
1 Engine will not start
Problem Probable Cause Remedy
Fuel supply failure If squirting cannot be heard
check by cranking engine 1 No fuel in tank 1 Fill tank
and listening for the 2 Vent hole in tank cap plugged 2 Replace cap
squirting in 3 Fuel filter clogged 3 Replace filter
the fuel injector 4 Faulty injector nozzle 4 Checkreplace nozzle
5 Faulty injection pump 5 pump
6 Fuel line blocked 6 Check fuel lines and remove blockage
7 Broken fuel line or leaking connection 7 Replace connections
If squirting can be heard
1 Starting fuel button not pulled 1 Pull button
2 Gasoline instead of diesel in tank 2 Drain gasoline flush system fill with diesel
3 Air intake blocked 3 Check system for blockage
Poor compression 1 Automatic decompression 1 CheCkreplace automatic decompression device
device malfunction
2 Incorrect valve clearance 2 Adjust valve clearance
3 Valves not seating properly 3 valves
4 Cylinder head loose 4 lighten cylinder head nuts
5 Piston rings stuck in grooves 5 Check rings and clean the piston
6 Worn cylinder and piston 6 Overhaul the engine
7 Rusty exhaust valve 7 Spray lubricating oil into the cylinder activate the
automatic decompression device then start
8 Valves sticking 8 Free valves
Difficult to crank the engine 1 Lube oil too thick 1 Change to correct viscosity
2 Bearings seized 2 Overhaul the engine
3 Piston seized 3 Overhaul the engine
2 Engine starts but fires or soon stops
Faulty fuel supply 1 Fuel filter clogged 1 Replace filter
2 Water in fuel 2 Drain fuel fill with clean fuel
3 Faulty injector nozzle 3 CheCkreplace nozzle
4 Faulty injection pump 4 pump
5 Fuel line clogged 5 Check the fuel lines and remove the blockage
6 Fuel lines or connections leak 6 Replace Faulty air intake andor 1 exhaust system 1 Checkclean exhaust system
exhaust system 2 air intake 2 Checkclean air intake system
Poor Compression See Poor Compression under
Engine will not Start
Engines Generators
ENGINE Engine lacks power andor makes black smoke
Problem Probable Cause Remedy
Operating conditions 1 Engine overloaded 1 Reduce the load
2 Power reduction due to altitude andor
ambient temperature has not
been considered
3 Clogged air filter 3 Faulty fuel supply 1 Gasket under injector missing or 1 Correct the number of
gaskets
too many gaskets are installed
2 Fuel filter clogged 2 Replace filter
3 Faulty injection nozzle 3 Checkreplace nozzle
4 Faulty injection pump 4 pump
Engine condition 1 Excessive carbon on piston and 1 Decarbonize
cylinder head
2 Faulty piston rings 2 Checkreplace piston ring set
3 Worn piston and cylinder 3 Overhaul engine
4 Worn bearings 4 Overhaul engine
4 Faulty running
Engine overheats 1 Engine oveoaded 1 Reduce load
2 Faulty raw water pump impeller 2 Replace impeller
3 Faulty thermostat 3 Checkreplace thermostat
4 Clogged raw water intake strainer 4 Clean the strainer
5 Lube oil level too high 5 Drain to proper level
6 Faulty injector nozzle 6 Checkreplace nozzle
Knocking 1 Injector needle sticking 1 Replace nozzle
2 Fuel timing too far advanced 2 Adjust timing
3 Broken piston ring 3 Replace piston ring set
4 Worn piston 4 Replace piston and liner
5 Worn bearings 4 Replace bearings
6 Loose flywheel 6 Tighten flywheel nut
Engine is hunting 1 Engine is overheating 1 See Engine Overheats above
2 Air in fuel lines 2 Check fuel system for leaking connections
3 Governor sticking or defective 3 Free the governor or replace
4 Fuel filter clogged 4 Replace filter
Engine stops suddenly 1 Fuel tank is empty 1 Fill tank
2 Vent hole in fuel tank cap is plugged 2 Replace tank cap
3 Vapor lock fuel is too hot 3 Cool the fuel
4 Clogged injector 4 Replace nozzle
5 Fuel line is broken 5 Replace
6 Seized piston 6 Replace piston and liner
7 Seized crankshaft 7 crankshaft and bearings
Engines Generators
ENGINE Problem Probable Cause Remedy
Blue smoke 1 Breather valve is clogged 1 Replace breather
2 Oil seal at intake valve is defective 2 Replace oil seal
3 Worn valvesvalve guides 3 Replace valves and guides
4 Worn 4 Replace piston and cylinder
White smoke 1 Fuel timing is too late 1 Adjust timing
2 Injector nozzle is worn out 2 Replace nozzle
3 Low engine operating temperature 3 Clean thermostat
Oil in exhaust discharge 1 Rings not seated 1 Initial 50 hours of operation required to seat rings
2 Low compression bad valve 2 valves
5 Low Oil Pressure
Low oil pressure 1 Incorrect oil viscocity 1 Change oil to correct viscocity
2 Faulty pressure relief valve 2 Replace pressure relief valve
3 Incorrect oil filter 3 Install correct oil filter
Engines Generators
HURTH HBW 7Al and llAl diesel engines each use a The control cable or rod should be arranged at a right angle to
HURTH Model HBW 40 transmission Installation operation the actuating lever when in the neutral position The neutral and infonnation for
this transmission tion of the shift lever on the control console should coincide with
is included in the following instructions the neutral position of the actuating lever
The shifting travel as measured at the pivot points of the ing lever between the neutral
position and end positions A and B
NOTE When installing the transmission make certain that shift should be at least 35 mm for the outer pivot point and 30 mm for
ing is not impeded by restricted movability of the cable or rod the inner pivot by unsuitably positioned guide sheaves too small a bend
A greater amount of shift lever travel is in no way detrimental and
ing radius or other restrictions In order to mount a support for is recommended However if the lever travel is shorter proper
shift control cable connections use the two threaded holes located clutch engagement might be impeded which in tum would mean
above the cable bracket mounted on the gear housing Refer to premature wear excessive heat generation and clutch plate failure
the WESfERBEKE Parts list This would be indicated by slow clutch engagement or no engage
ment at all
Shaft Couplings
NOTE Check for proper actuating lever travel at least recommends a flexible connection between the and the propeller shaft if the
engine is in order to compensate for angular deflections of a special propeller thrust bearing is not the propeller thrust will be absorbed by the
provided the value specified under is
not exceeded However the output shaft should be additional loads Special care should be taken to prevent tor
sional vibration When using a universal joint shaft make certain
to observe the manufacturers with the engine solidly mounted the use of a flexible cou
pling or DRNESAVER will reduce stress in the gearbox by hull distortions especially in wooden boats or where
the distance between the transmission output flange and the stem
gland is less than about 32 in 812 mm
Shift Control and Actuating Lever
The transmission is suitable for single lever remote control the retaining screw the actuating lever can be moved to
ACTUATING
LEVER
any position required for the shift control cable or rod certain that the actuating lever does not contact the actuat
ing lever cover plate the minimum distance between lever and
cover should be 002 in 05 mm see
COVER
A Caution The position of the mechanism behind
the actuating lever is to ensure equal
actuating lever travel from Neutral position N to Reverse
position A and Forward position B this mechanism is mm
002 in 05
MINIMUM DISTANCE
in any way tampered with the transmission warranty will
be mid
DRIVESAVER is a product oGlobe Marine Rocldand MA
Engines Generators
HURTH HBW OPERATION LOCKING THE PROPELLER
All HBW maine transmissions are testrun on a test stand with the Locking of the propeller shaft by an additional brake is not
engine at the factory prior to delivery For safety reasons the fluid required use the gear shift lever position opposite your direction
is drained before shipment of travel for this purpose Never put the gear shift in the position
Fill the gearbox with Automatic Transmission fluid DEXTRON corresponding to the direction of travel of the boat
111 The fluid level should be up to the index mark on the dip
stick To check the fluid level just insert the dipstick do not WHEN UNDER SAIL OR BEING TOWED
screw it in Screw the dipstick into the case after the fluid level is Rotation of the propeller without a load such as when the boat is
checked and tighten Do not forget the sealing ring under the being sailed being towed or anchored in a river as well as of the dipstick
Check for leaks and make a visual tion of the engine with the propeller stopped for charging the of the coupling oil cooler and hoses
and shift cables tery will have no detrimental effects on the DIPSTICK DAILY
OPERATION
o Check the transmission fluid level
o Visually check the gear shift linkage and o Start the engine in
neutral allowing a few minutes at idle to
CHECKING TRANSMISSION
FLUID OPERATING
warm the fluid
o Shift into gear
NOTE Too Iowan idle speed will produce a chattering noise
from the transmission gear and damper plate In such cases the
I idle speed should be increased
For additional information refer to the following text in this
FLUID LEVEL Transmission section SHAFT COUPliNGS MAINTENANCE
and TRANSMISSION DRAIQl
Operating FLUID CHANGE A WARNING if the transmission fluid temperature is
too high stop the engine immediately and check the
Change the fluid for the first time after about 25 hours of opera transmission fluid
tion then every 300 operating hours or at winterizing
Normal operating temperature of the transmission fluid should be
Removing the Fluid in the range of 1220 F 500 C to 2120 F 100 C A maximum
temperature of 266 F 1300 C may be only reached for a short
Push a suction pump hose down through the dipstick hole to the
time
bottom of the housing and suck out the fluid If space allows use
the transmission drain Remove the drain plug from the bottom Make certain there is enough space around the transmission to
of the transmission and allow the fluid to drain into a container provide good ventilation and cooling
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
TRANSMISSION
Drain plug torque 20 2S Mb 277 346 Nm
General HURTH HBW 40 Standard NOTE When changing the fluid take care not to lose the drain
case hardened helical gears with a servo
plug sealing washer The drain plug will leak without this sealing operated multiple disc clutch
washer
Gear Ratio optional 2051
Lubricating Fluid ATF type A or DEXTRON I or 1
A WARNING Never pullout the dipstick while the Transmission Sump 037 qts 035 liters
engine is running Hot fluid will splash from the dipstick Capacity
hole This could cause sever bums
Propeller Shaft Right handstandard transmission
Direction of Rotation
Engines Generators
HURTH HBW maintenance is minimal Keep the exterior check the fluid level as part of your regular routine and
change the fluid every 300 operating inspect the transmission for leaks and the cable requires special care Follow these procedures
o Clean up the transmission and touch up unpainted areas use
heat resistant paint
o Fill the transmission with Dextron III ATF fluid to prevent
internal corrosion extended storage only twelve months or
more
o Loosen attaching hardware from the transmission output
flange and propeller shaft coupling flange before removing the
boat from the water Separate the flanges and spray with
lubricant
o Inspect the gear shift cable linkage and attachments Look
for corrosion of the end fittings cracks or cuts in the conduit
and bending of the cable rods Lubricate all moving parts
NOTE If the transmission is to be stored for a long time
twelve months or more it sJwuld be topped off with fluid to
prevent internal corrosion Reduce the fluid level before
putting the engine back into service
For additional information contact
HURTH MARINE GEAR
ZF Industries
Marine US Headquarters
3131 SW 42nd Street
Fort Lauderdale FL 33312
Tel Fax Engines Generators
HURTH HBW TRANSMISSION CABLES A new cable and perhaps a new linkage mechanism may
needed While the cable is loose shift the transmission in and out
The majority of transmission difficulties arise as a result of prob
of gear using the actuating lever on the side of the transmission to
lems with control cables rather than from problems with the trans
make sure theres no binding inside the case
mission itself
If the transmission passes these tests crank the engine and have a
If you experience operating problems with the transmission shut
helper put it in forward and reverse while you observe the pro
the engine down First check the transmission fluid level then
peller shaft if the shaft isnt turning the transmission needs pro
have a helper move the cockpit shift lever through the full range
fessional attention If it does tum but theres no thrust check to
from neutral to full forward back to neutral into full reverse
see if you still have a propeller on the end of the shaft or if you
and back to neutral while you observe the actuating lever on
have a folding or feathering propeller that it isnt stuck in the no
the transmission If the remote is stiff to operate break the cable pitch at the transmission and try again If it is still stiff check
cable for kinks or excessively tight bends and check any linkage NOTE If you suspect a major problem in your binding
immediately contact your WESTERBEKE dealer or an authorized
marine transmission facility
Problem Probable Cause Remedy
Transmission gears cannot 1 Actuating lever is loose 1 Tighten damping bolt on actuating lever
be shifted Fails to move 2 Shifting cable is broken bent or unattached 2 Check the cable reattach or replace
into gear Cable radius is too severe
3 Actuating lever is binding against cover 3 Detach the shift cable and operate the actuating lever by
plate hand Clearance should be 002 in 05 mm
Transmission shifts into 1 Output coupling is not turning 1 Transmission needs professional attention
gear but fails to propel 2 Propeller shaft is not turning Output 2 The coupling bolts are sheared or the coupling is slipping
the boat coupling is tuming on the propeller shaft Tighten or replace set screws keys
pins and coupling bolts as necessary
3 Output coupling and propeller shaft are 3 Inspect the propeller it may be missing or damaged A
both turning folding propeller may be jammed Avariable pitch propeller
may be in no pitch position
Delay of gear engagement 1 Actuating lever travel Nto B not equal to 1 Adjust cover plate until the lever is exact mid position
or engages only after an Nto A Refer to diagram Refer to actuating lever text and diagram
increase in speed 2 Actuating lever travel is insufficient 2 Check actuating lever cable length Refer to lever diagram
3 Actuating lever is binding against cover plate 3 Check clearance adjust if necessary
Chattering transmission 1 The engine or propeller generates torsional 1 Mount a flexible coupling with another stiffness factor
noise mainly at low engine vibrations in the drive unit which produces between the transmission coupling and the driveshaft A
speed a chattering noise in the transmission higher stiffness factor might be sufficient
2 Inspect the damper plate between the engine and the
transmission Replace if necessary
Transmission noise becomes 1 Damage starting on flexible coupling due to 1 Check alignment inspect flexible coupling If noise
louder wear or fatigue possibly due to misalign persists inspect the damper plate between the trans
ment between engine and the drive shaft mission and the engine Replace if necessary
2 Beginning damage of bearings in trans 2 Transmission needs professional attention
mission due to torsional vibrations running
without fluid overload wrong alignment
of transmission or excessive engine output
Boat tails to attain specified 1 Operating temperature is high 1 Wrong type of fluid use ATF type A or DEXTRON I or III
max speed Check fluid level
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 008 mm
Engines Generators
LAYUP AND Change the fuel ftlter elements on the engine see FUEL
SYSTEM and bleed the fuel system as needed Start the engine
Many owners rely on their boatyards to prepare their craft and allow it to run for 510 minutes to make sure there is no air
including engines and generators for layup during the off season left in the fuel system Check for any leaks that may have been
or for long periods of inactivity Others prefer to accomplish created in the fuel system during this servicing correcting them as
layup preparation themselves needed Operate the engine for 510 minutes This will allow
The procedures which follow will allow you to perfonn your own movement of the treated fuel through the injection equipment of
layup and or you may use them as a check list the engine
if others do the procedures should afford your engine protection during LongTerm LayUp Procedure over 12 and also help familiarize
you with the maintenance needs For a longtenn layup follow the fuel system layup procedures
of your engine described above then do the following
If you have any questions regarding layup procedures call your Disconnect the fuel supply line from the fuel tank at the fuel lift
local servicing dealer he will be more than willing to provide pump Fill a suitable container with a 0132 US gallon 05
mixture of 910 diesel fuel and 1110 oil Connect a
short suction pipe between the container and the fuel lift SHAFT COUPLING Set the speed control
lever to full load set the automatic
The transmission and propeller half couplings should always be decompression device to its neutral position then handcrank the
opened up and the bolts removed when the boat is hauled out of engine approximately 20 times Put the speed control lever back
the water or moved from land to water and during storage in the to the idle The flexibility of the boat often puts a severe strain on
propeller shaft or coupling or both while the boat is taken out or RAW WATER COOLING CIRCUIT
put in the water In some cases the shaft has actually been bent Remove the impeller from your raw water pump and allow the
by these strains This does not apply to small boats that are raw water in the cylinder head coolant chamber to drain out
hauled out of the water when not in use unless they have been Allow it to drain completely Examine the impeller Acquire a
dry for a considerable period of time replacement if needed and a cover gasket Do not replace the
impeller into the pump until but replace SYSTEM cover and gasket Drain the water lift
muffler
With the engine warm drain all the engine oil from the oil sump
Fill the sump with the correct amount of oil for your engine refer AIR INTAKE THROUGHHULL EXHAUST
to the section of this manual Use an oil with Remove the air intake silencer and place a clean cloth lightly
an API specification of CF or CG4 Run the engine and check soaked in lubricating oil in the air intake opening to block the
for proper oil pressure and make sure there are no leaks 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 need the assistance of a servicing dealer Make a note to
A Caution Do not leave the engines old engine remove the cloth prior to startup The throughhull exhaust port
oil in the sump over the layup period Engine oil and can be blocked in the same manner
combustion deposits combine to produce harmful
chemicals which can reduce the life of your engines CYLINDER AND VALVES
intemal parts To protect the cylinder and valves remove the air intake silencer
Then spray fogging oil into the cylinder head air intake opening
FUEL SYSTEM Rotate the engine two revolutions using the hand crank Spray
fogging oil into the air intake again Replace the air intake
Top off your fuel tanks with No2 diesel fuel Fuel additives such silencer
as BlOBOR AND STABIL should be added at this time to control
algae and condition the fuel Care should be taken that the addi If you anticipate a long layup period 12 months or more
tives used are compatible with the primary fuel filterwater separa WESTERBEKE recommends removing the fuel injector for
tor used in the system Change the ftlter element in your primary access to the cylinder then squirting light lubricating oil into the
fuel ftlterwater separator if the fuel system has one and clean the cylinder to prevent the piston rings from sticking to the sediment bowl
Reinstall and make certain there are no walls After squirting the oil move the piston by a quick Clean up any spilled fuel
start or the hand crank to distribute the oil Make sure you have
replacements for the injector and return line sealing washers
Engines Generators
LAYUP AND MOTOR and cleaning of the starter drive pinion is advisable
Thoroughly clean the outside of the engine then store the
Make sure the battery connections are shut off before attempting engine in a dry place protected against the weather
to remove the starter Take care in properly replacing connections removed from the starter
The of your WESTERBEKE engine after a
sonallayup generally follows the same procedures as those
If batteries are to be left on board during the layup period make described in the PREPARATIONS FOR INITIAL STARTUP
sure they are fully charged and will remain that way to prevent section regarding preparation for starting and normal starts
them from freezing If there is any doubt the batteries will not However some of the layup procedures will need to be
remain full charged or that they will be subjected to severe counteracted before starting the conditions remove the batteries and store
them in a 1 Remove the oilsoaked cloths from the air intake more compatible environment and the
throughhull exhaust port
2 Remove the raw water pump cover and gasket and
A WARNING Lead acid batteries emit hydrogen a discard the old gasket
gas which can be ignited by electrical Install the raw water pump impeller that was removed
arcing or a lighted cigarette cigar or pipe Do not during layup or a replacement if required Install the
smoke or allow an open flame near the battery being raw water pump cover with a new cover gasket
serviced Shut off all electrical equipment in the vicin 3 Reinstall the batteries that were removed during the
ity to prevent electrical arCing during servicing layup and reconnect the battery cables making sure the
terminals are clean and that the connections are tight
Check to make sure that the batteries are fully or change the fluid in the transmission as required Wipe
off grime and grease and touch up any unpainted areas Protect A CAUTION Wear rubber gloves a rubber apron
the coupling and the output flange with an coating and eye protection when servicing batteries Lead
Check that the transmission vent is open acid batteries emit hydrogen a highly explosive gas
For additional information see in the HURTH which can be ignited by electrical arcing or a lighted
HBW TRANSMISSION section cigarette cigar or pipe Do not smoke or allow an
open flame near the battery being serviced Shut off
SPARE PARTS all electrical equipment in the vicinity to prevent
electrical arcing during time provides a good opportunity to inspect engine to see if external items such as the drive 4 Start the
engine in accordance with the or coolant hoses need replacement Check your basic spares
FOR INITIAL STARTUP and and order items not on hand or replace those items used PROCEDURE sections of this the layup such as
filters See SUGGESTED the keyswitch with WCKEZE to ensure that the functions freely with no binding
Engines Generators
7A1 11 A1 TORQUE MOOEl7A1 MODEL 11A1
Component
SPANNER TIGHTENING TORQUE Nm SPANNER TIGHTENING TORQUE Nm
SIZE SIZE
mm MIN MAX mm MIN MAX
Cylinder head 13 30 33 17 52 56
Connecting rod 13 30 33 14 52 56
Cylinder head cover 13 8 12 13 8 12
Main bearing plate 13 30 33 13 30 33
Fuel lift pump 13 30 33 13 30 33
Fuel injection pump 13 30 33 13 30 33
Delivery valve pump 14 34 39 14 34 39
High pressure pump 17 18 22 17 18 22
High pressure fuel linefuel injector 17 25 30 17 25 30
Injector clamp 10 8 12 13 20 23
Governor on crankshaft 14 55 60 14 55 60
Aywheel 36 216 226 46 390 410
Gear end cover 6 34 38 6 34 38
Push rod guide 4 8 10 4 8 10
Crank handle guide 10 8 12 10 8 12
Oil pump 5 16 20 5 16 20
Sump plate crossslotted 9 11 crossslotted 9 11
Banjo bolt on fuel lift pump 17 25 35 17 25 35
Banjo bolt on tank 12 8 10 12 8 10
Rocker bracket 13 30 33 17 52 56
Oil filter
Engines Generators
STANDARD HARDWARE
BOLT HEAD MARKINGS
Metric bolt class numbers identify bolts by their strength with 109 the
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 is used
3 Reduce torques by 30 or more when threading capscrews into aluminum
STANDARD BOLT NUT TORQUE METRIC BOLT NUT TORQUE SAE Glade 5 SAE Glade 67
Body SIze TDIqIII Torque Torque Bon Grada46 Grade 4B Grade BB 98 Grade 109
Inches TIIread FHb Nm FtlbNm RLbNm Ola Wrench Size ALbNm ALbNm FILbNm RLbNm
1420 8 11 10 14 12 16
28 10 14 14 19 M3 55mm 03 05 05 01 1 13 15 2
M4 7mm 08 11 1 15 2 3 345
516 18 17 23 1926 24 33 M5 8mm 15 25 23 45 6 65 9
24 19 26 27 31
38 16 31 42 3446 44 60
M8 10mm 3 4 4 55 75 10 11 15
24 35 41 4966 M9 13mm 7 95 10 13 18 25 3526
711614 4966 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 6385 fl 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 120163 170 231
M18 27mm 81 110 118 160 225 305 321 435
5t8 11 150 203 167 226 210 285 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 295400 42569 M24 36mm 203 275 288 390 553 750 789 1070
M27 41 mm 295 400 417 565 811 1100 1154 1565
78 9 395 536 440 591 605 820 M30 46mm 402 545 568 770 1103 1495 1571 2130
14 435 590 675 915
1 8 590800 660 895 910 1234 M33 51 mm 546 740 774 1050 1500 2035 2139 2900
14 660895 990 1342 M36 55mm 700 950 992 1345 1925 2610 2744 3720
SEALANTS LUBRICANTS
Use LlaUID TEFLON for sealing pipe plugs and fillings that connect passages Do nat
use tape sealants
Oil based PERMATEX 12 and its HIGH TACK equivalent are excellent all
purpose sealers They are effective in just about any jOint in contact with BOIis raw water oil or fuel
Ughtly oil head bolts and other fasteners as you assemble them Bolts and
A light coating of OIL or LlaUID TEFLON can be used on rubber gaskets plugs that penetrate the water jacket should be sealed with PERMATEX 2
and Orings HIGH TACK
LOCTITE hydraulic red sealant should be used on oil adapter hoses and the oil When assembling the flywheel coat the bolt threads with LOCTITE blue
filter assembly
Antiseize compounds and thread locking adhesives such as LOCTITE protect
Coat both surfaces of the oil pan gasket with high temp RED SILICONE sealer threaded components yet allows them to came apart when installing
gaskets that seal around water coolant passages coat both LOCTITE offers levels of locking according to the job
sides with WHITE SILICONE grease LITHIUM based grease is waterproof ideal for water pump bearings and
ADHESIVE SPRAYS are useful for holding gaskets in position dur ing boxes
ing assembly Heavily oil all sliding and reCiprocating components when assembling
gasket sealers such as HYLOMAR work well in applications requir use clean engine all
ing nonhardening properties HYLOMAR is particlarly effective on
copper cylinderhead gaskets as it resists fuel oil and water
Engines Generators
METRIC CONVERSIONS
INCHES TO MILUMETERS MILUMETERS TO INCHES
Inches mm Inches mm mm Inches mm Inches
1 2540 15 38100 1 00394 15 05906
2 5080 20 50800 2 00787 20 07874
3 7620 25 63500 3 01181 25 09843
4 10160 30 76200 4 01575 30 11811
5 12700 35 88900 5 01969 35 13780
10 25400 40 101600 10 03937 40 15748
10 MILLIMETERS 1 CENTIMETER 100 CENTIMETERS 1 METER 3937 INCHES 33 FEET
INCHES TO METERS METERS TO INCHES
Inches Meters Inches Meters Meters Inches Meters Inches
1 00254 7 01778 01 3937 07 27559
2 00508 8 02032 02 7874 08 31496
3 00762 9 02286 03 11811 09 35433
4 01016 10 02540 04 15748 10 39370
5 01270 11 02794 05 19685 11 43307
6 01524 12 03048 06 23622 12 47244
TO CONVERT METERS TO CENTIMETERS MOVE DECIMAL POINT TWO PLACES TO THE RIGHT
YARDS TO METERS METERS TO YARDS
Yards Meters Yards Meters Meters Yards Meters Yards
1 091440 6 548640 1 109361 6 656168
2 182880 7 640080 2 218723 7 765529
3 274320 8 731520 3 328084 8 874891
4 365760 9 822960 4 437445 9 984252
5 457200 10 914400 5 546807 10 1093614
MOVE DECIMAL POINT FOR HIGHER VALUES eg 6000 METERS 656168 YARDS
POUNDS TO KILOGRAMS KILOGRAMS TO POUNDS
Ib kg Ib kg kg Ib kg Ib
1 0454 6 2722 1 2205 6 13228
2 0907 7 3175 2 4409 7 15432
3 1361 8 3629 3 6614 8 17637
4 1814 9 4082 4 8818 9 19842
5 2268 10 4536 5 11023 10 22046
GALLONS TO LITERS LITERS TO Uters Gallons Uters Uters Gallons
Liters Gallons
1 379 10 3786 1 026 60 1566
2 757 20 7571 2 053 90 2377
3 1136 30 11357 5 132 120 3132
4 1514 40 15142 10 264 150 3962
5 1893 50 18928 20 528 180 4754
PINTS TO UTERS UTERS TO PINTS
Pints Uters Pints Uters Uters Pints Liters Pints
1 047 6 284 1 211 6 1268
2 095 7 331 2 423 7 1479
3 142 8 379 3 634 8 1691
4 189 9 426 4 845 9 1902
5 237 10 473 5 1057 10 2113
TEMPERATURE
32 40 50 60 70 75 85 95 105 140 175 212 OF
I I I I I I I I I I I I
I I I I I I I I I I I I
0 5 10 15 20 25 30 35 40 60 80 100 C
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 Centimters x 061 in3
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 I b 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 DC X 18 32
Degree Celsius DC OF 32 x 56
Engines Generators
SUGGESTED SPARE PARTS KITS
Carry only Genuine WESTERBEKE Spare Parts
SPARE PARTS offers two Spare Parts Kits
each packaged in a rugged hinged toolbox
Kit A includes the basic spares
Kit B is for more extensive offshore A includes
Drive Belt
Raw Water Pump Impeller and Gasket
Fuel Filter
Fuel Lift Pump Screens 2 and Gasket
Oil Filter Model lOAI only
Fuel Hardware Kit to fix a leak
Air Intake Filter
Kit B Includes
Drive Belt
Raw Water Pump Impeller and Gasket
Raw Water Pump Repair Kit
Fuel Filter
Fuel Lift Pump Screens 2 and Gasket
Oil Filter Model lOAI only
Fuel Hardware Kit to fix a leak
Thermostat Kit
Complete Gasket Kit
Fuel Injector
Air Intake Filter
Engines Generators
Engines

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