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Westerbeke Diesel 63c Four Technical Manual



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 OPERATORS MANUAL
MARINE DIESEL ENGINE
     630                                        UR



                            N NO.045150
                     FIRST EDITION
                       March 2001




  t~ 'WESTERBEKE
     j    WESTERBEKE CORPORATION MYLES STANDISH INDUSTRIAL PARK
     I   150 JOHN HANCOCK ROAD TAUNTON MA 02780-7319 TEL. 1-508-823-7677
         FAX 1-508-884-9688. WEBSITE: WWW.wESTERBEKE.COM

          ~--        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 WARNING:
Exhaust gasses contain Carbon Monoxide, an odorless and
colorless gas. Carllon Monoxide Is poisonous and can cause
unconsciousness and death. Symptoms of Carllon Monoxide
exposure can Include:
-DIzziness                    - Throbbing In Temples
-/lauSlla                     - Museular TwItching
-Headache                     - Vomiting
- Weakness and Sleepiness -Inability to Think Coherently

IF YOU OR ANYONE ELSE EXPERIENCE ANY OF THESE SYMPTOMS,
BET OUT INTO THE FRESH AIR IMMEDIATELY. If symptoms pelSlst,
SBIIk medical attention. Shut down the unit and do not restart
until It has btien Inspected and repaired.


                        This WARNING DECAL Is provided by
                        WESTERBEKE and should be Oxed to a
                        bulkhead near your engIne or generator.
                        WE8TERBEKEalso recommends Installing
                        CARBON MONOXIDE DETECTORS In the
                        Ilvlnglslesplng qualfslS of your vessel.
                        Thsyare Inexpenslvs and easily
                        obtaInable at your local marins stOlB.
                                              SAFETY INSTRUCTIONS
INTRODUCTION                                                          PREVENT BURNS - FIRE
Read this safety manual carefully. Most accidents are
caused by failure to follow fundamental rules and precau-                 A WARNING: Fire can cause injury or death!
tions. Know when dangerous conditions exist and take the
necessary precautions to protect yourself, your personnel,                 Prevent flash fires. Do not smoke or permit flames or
and your machinery.                                                         sparks to occur near the carburetor, fuel line, filter, fuel
The following safety instructions are in compliance with the                pump, or other potential sources of spilled fuel or fuel
American Boat and Yacht Council (ABYC) standards.                           vapors. Use a suitable container to catch all fuel when
                                                                            removing the fuel line, carburetor, or fuel filters.
PREVENT ELECTRIC SHOCK                                                     Do not operate with a Coast Guard Approved flame
                                                                            arrester removed. Backfire can cause severe injury or
                                                                            death.
    A WARNING: Do not touch AC electrical connections                      Do not operate with the air cleaner/silencer removed.
    while engine is running, or when connected to shore                     Backfire can cause severe injury or death.
    power. Lethal voltage is present at these connections!                 Do not smoke or permit flames or sparks to occur near
                                                                            the fuel system. Keep the compartment and the
    Do not operate this machinery without electrical                       engine/generator clean and free of debris to minimize the
     enclosures and covers in place.                                        chances of fire. Wipe up all spilled fuel and engine oil.
    Shut off electrical power before accessing electrical                 Be aware -    diesel fuel will bum.
     equipment.
    Use insulated mats whenever working on electrical                PREVENT BURNS - EXPLOSION
     equipment.
    Make sure your clothing and skin are dry, not damp
     (particularly shoes) when handling electrical equipment.
                                                                          A WARNING: Explosions from fuel vapors can cause
                                                                          injury or death!
    Remove wristwatch and all jewelry when working on
     electrical equipment.                                                 Follow re-fueling safety instructions. Keep the vessel's
    Do not connect utility shore power to vessel's AC                      hatches closed when fueling. Open and ventilate cabin
     circuits, except through a ship-to-shore double throw                  after fueling. Check below for fumes/vapor before run-
     transfer switch. Damage to vessel's AC generator may                   ning the blower. Run the blower for four minutes before
     result if this procedure is not followed.                              starting your engine.
    Electrical shock results from handling a charged capaci-              All fuel vapors are highly explosive. Use extreme care
     tor. Discharge capacitor by shorting terminals together.               when handling and storing fuels. Store fuel in a well-ven-
                                                                            tilated area away from spark-producing equipment and
PREVENT BURNS - HOT ENGINE                                                  out of the reach of children.
                                                                           Do not fill the fuel tank(s) while the engine is running.
    A WARNING: Do not touch hot engine parts or                            Shut off the fuel service valve at the engine when servicing
                                                                            the fuel system. Take care in catching any fuel that might
    exhaust system components. A running engine gets                        spill. DO NOT allow any smoking, open flames, or other
    very hot!                                                               sources of fire near the fuel system or engine when servic-
                                                                            ing. Ensure proper ventilation exists when servicing the
    Always check the engine coolant level at the coolant                   fuel system.
     recovery tank.
                                                                           Do not alter or modify the fuel system.
                                                                           Be sure all fuel supplies have a positive shutoff valve.
    A WARNING: Steam can cause injury or death!                            Be certain fuel line fittings are adequately tightened and
                                                                            free of leaks.
    In case of an engine overheat, allow the engine to cool               Make sure a fire extinguisher is installed nearby and is
     before touching the engine or checking the coolant.                    properly maintained. Be familiar with its proper use.
                                                                            Extinguishers rated ABC by the NFPA are appropriate
                                                                            for all applications encountered in this environment.




                                                             Engines & Generators
                                                SAFETY INSTRUCTIONS
ACCIDENTAL STARTING                                                      TOXIC EXHAUST GASES

    A WARNING: Accidental starting can cause injury                          A WARNING: Carbon monoxide (CO) is a deadly gas!
    or death!
                                                                              Ensure that the exhaust system is adequate to expel gases
     Disconnect the battery cables before servicing the engine/
                                                                               discharged from the engine. Check the exhaust system
      generator. Remove the negative lead first and reconnect
                                                                               regularly for leaks and make sure the exhaust manifolds
      it last.
                                                                               are securely attached and no warping exists. Pay close
     Make certain all personnel are clear of the engine before                attention to the manifold, water injection elbow, and
      starting.                                                                exhaust pipe nipple.
     Make certain all covers, guards, and hatches are re-                    Be sure the unit and its surroundings are well ventilated.
      installed before starting the engine.
                                                                              In addition to routine inspection of the exhaust system,
                                                                               install a carbon monoxide detector. Consult your boat
BAnERY EXPLOSION                                                               builder or dealer for installation of approved detectors.
                                                                              For additional information refer to ABYC T-22 (educa-
    A WARNING: Battery explosion can cause injury                              tional information on Carbon Monoxide).
    or death!
     Do not smoke or allow an open flame near the battery                   A WARNING: Carbon monoxide (CO) is an invisible
      being serviced. Lead acid batteries emit hydrogen, a                   odorless gas. Inhalation produces flu-like symptoms,
      highly explosive gas, which can be ignited by electrical               nausea or death!
      arcing or by lit tobacco products. Shut off all electrical
      equipment in the vicinity to prevent electrical arcing dur-             Do not use copper tubing in diesel exhaust systems. Diesel
      ing servicing.                                                           fumes can rapidly destroy copper tubing in exhaust sys-
     Never connect the negative (-) battery cable to the posi-                tems. Exhaust sulfur causes rapid deterioration of copper
      tive (+) connection terminal of the starter solenoid. Do                 tubing resulting in exhaust/water leakage.
      not test the battery condition by shorting the terminals                Do not install exhaust outlet where exhaust can be drawn
      together. Sparks could ignite battery gases or fuel vapors.              through portholes, vents, or air conditioners. If the engine
      Ventilate any compartment containing batteries to prevent                exhaust discharge outlet is near the waterline, water could
      accumulation of explosive gases. To avoid sparks, do not                 enter the exhaust discharge outlet and close or restrict the
      disturb the battery charger connections while the battery                flow of exhaust. Avoid overloading the craft.
      is being charged.
                                                                              Although diesel engine exhaust gases are not as toxic as
     Avoid contacting the terminals with tools, etc., to prevent              exhaust fumes from gasoline engines, carbon monoxide
      burns or sparks that could cause an explosion. Remove                    gas is present in diesel exhaust fumes. Some of the symp-
      wristwatch, rings, and any other jewelry before handling                 toms or signs of carbon monoxide inhalation or poisoning
      the battery.                                                             are:
     Always turn the battery charger off before disconnecting                 Vomiting                  Muscular twitching
      the battery connections. Remove the negative lead first
                                                                               Dizziness                Intense headache
      and reconnect it last when disconnecting the battery.
                                                                               Throbbing in temples     Weakness and sleepiness
BAnERY ACID
                                                                         AVOID MOVING PARTS
    A WARNING: Sulfuric acid in batteries can cause                          A WARNING: Rotating parts can cause injury
    severe injury or death!
                                                                             or death!
     When servicing the battery or checking the electrolyte
      level, wear rubber gloves, a rubber apron, and eye protec-              Do not service the engine while it is running. If a situa-
      tion. Batteries contain sulfuric acid which is destructive.              tion arises in which it is absolutely necessary to make
      If it comes in contact with your skin, wash it off at once               operating adjustments, use extreme care to avoid touching
      with water. Acid may splash on the skin or into the eyes                 moving parts and hot exhaust system components.
      inadvertently when removing electrolyte caps.




                                                             Engines & Generators

                                                                    ii
                                                 SAFETY INSTRUCTIONS
     Do not wear loose clothing or jewelry when servicing                 ABYC, NFPA AND USCG PUBLICATIONS FOR
      equipment; tie back long hair and avoid wearing loose
      jackets, shirts, sleeves, rings, necklaces or bracelets that         INSTALLING DIESEL ENGINES
      could be caught in moving parts.                                     Read the following ABYC, NFPA and USCG publications
     Make sure all attaching hardware is properly tightened.              for safety codes and standards. Follow their recommenda-
      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 or the drive belt's tension while
      the engine is operating.                                             Order from:
     Stay clear of the drive shaft and the transmission coupling             ABYC
      when the engine is running; hair and clothing can easily                3069 Solomon's Island Rd.
      be caught in these rotating parts.                                      Edgewater, MD 21037
                                                                           NFPA (National Fire Protection Association)
HAZARDOUS NOISE                                                            "Fire Protection Standard for Motor Craft"
                                                                           Order from:
    A WARNING: High noise levels can cause hearing                           NFPA
    loss!                                                                    11 Tracy Drive
                                                                             Avon Industrial Park
     Never operate an engine without its muffler installed.                 Avon, MA 02322
     Do not run an engine with the air intake (silencer)                  USCG (United States Coast Guard)
      removed.                                                             "USCG 33CFR183"
     Do not run engines for long periods with their enclosures            Order from:
      open.
                                                                             U.S. Government Printing Office
                                                                             Washington, D.C. 20404
    A WARNING: Do not wode on machinery when you are
    mentally or physically incapacitated by fatigue!

OPERATORS MANUAL
Many of the preceding safety tips and warnings are repeated
in your Operators Manual along with other cautions and
notes to highlight critical information. Read your manual
carefully, maintain your equipment, and follow all safety
procedures.
ENGINE INSTAu.ATIONS
Preparations to install an engine should begin with a thor-
ough examination of the American Boat and Yacht Council's
(ABYC) standards. These standards are a combination of
sources including the USCG and the NFPA.
Sections of the ABYC standards of particular interest are:
      H-2 Ventilation
      P-l Exhaust systems
      P-4 Inboard engines
      E-9 DC Electrical systems
All installations must comply with the Federal Code of
Regulations (FCR).




                                                              Engines & Generators

                                                                     iii
                             INSTALLATION
When installing WESTERBEKE engines and generators it is important that strict
attention be paid to the following information:

CODES AND REGULATIONS
Strict federal regulations, ABYC guidelines, and safety codes must be complied with
when installing engines and generators in a marine environment.

SIPHON-BREAK
For installations where the exhaust manifold/water injected exhaust elbow is close to
or will be below the vessel's waterline, provisions must be made to install a siphon-
break: in the raw water supply hose to the exhaust elbow. This hose must be looped a
minimum of 20" above the vessel's waterline. Failure to use a siphon-break when
the exhaust manifold injection port is at or below the load waterline will result in
raw water damage to the engine and possible flooding of the boat.
If you have any doubt about the position of the water-injected exhaust elbow relative
to the vessel's waterline under the vessel's various operating conditions, instaU a
siphon-break.
NOTE: A siphon-break requires periodic inspection and cleaning to ensure proper
operation. Failure to properly maintain a siphon-break can result in catastrophic
engine damage. Consult the siphon-break manufacturer for proper maintenance.

EXHAUST SYSTEM
The exhaust hose must be certified for marine use. The system must be designed to
prevent water from entering the exhaust under any sea conditions and at any angle
of the vessels hull.


       A detailed 40 page Marine Installation Manual covering gasoline and
       diesel, engines and generators, Is available from your WESTERBEKE
       dealer.




                                 Engines & Generators

                                         iv
                                                        TABLE OF CONTENTS
Parts Identification ................................................2            Water Heater .....................................................24
Introduction .............................................................3       DC Electrical System ...........................................25
  Warranty Procedures ......................................... 3                   Alternator Troubleshooting ............................ 25
  Serial Number Location .............................. .... 04                     Battery ............................................................ 26
Admiral Control Panel .........................................5                    Wiring Diagrams/Schematics ......................... 27
Captain Control Panel .........................................6                  Dual Output Alternators .................................. .. 29
Fuel, Engine Oil and Coolant ..............................7                      Engine Troubleshooting [Chart] ........................ 31
  Oil Pressure ...................................................... 7             Coolant and Oil Pressure Gauges .................. .32
Preparations for Initial Start-Up ......................... 8                     Hurth HBW Transmissions .... ............................. 33
                                                                                    Fluid Change .................................................. 33
Starting/Stopping Procedure ...............................9                        Control Cables ................................................ 34
Engine Break-In Procedure ............................... 10                        Maintenance .................................................... 35
The Daily Operation ........................................... 11                Borg War ner 'Iiransmlsslon . . .... ............................ 36
Warning Lights, Alarms and Circuit Breaker .... 12                                  Fluid Change .................................................. 37
Maintenance Schedule ......................... ,........... 13                      Maintenance .................................................... 38
Cooling System .................................................. 15              Transmission Troubleshooting ............................39
 Thermostat ...................................................... 16             Engine Adjustments .......................................... .. .41
 Raw Water Pump ............................................ 16                     Drive Belt Adjustment.. ................................. .41
 Heat Exchanger .............................................. 17                   Fuel Injectors ................................................. 41
Fuel System .......................................................19               Testing Oil Pressure ....................................... .42
 Fuel Lift Pump ................................................ 19                 Valve Clearance Adjustment ......................... .43
 Fuel Filters ...................................................... 19             Setting the Idle Speed .................................... .44
 FuellWater Seperator ...................................... 19                     Stop Solenoid .................................................. 44
 Glow Plugs ..................................................... 20              Lay-up and Recommissioning .................... ...... 045
Engine Lubricating Oil ....................................... 21                 Metric Conversions .......................................... 047
  Oil Change ...................................................... 21            Suggested Spare Parts ..................................... 049
  Oil Pressure .................................................... 22            630 Speci",.Icat"Ions .. ..........................................50
Tachometer ........................................................23




                                                                    Engines & Generators

                                                                              1
                                   PARTS IDENTIFICATION
                                                        FILL

                       COOLANT                                                WATER INJECTED
                       PRESSURE CAP                                           EXHAUST ELBOW

                MAN


            ASSEMBLY
                                                                                                             FILTER
  DC CHARGING
. ALTERNATOR                                                        'l__~~----- SILENCER
                                                                                AIR INTAKE

 WATER
 CDNNECTlDN                                                                            ,_.__-         STARTER
                                                                                                      WITH SOLENOID


                                                                                                REAR
                                                                    --J~~~~~""'f-----.---FLEXIBLE
                                                                                                             MOUNT
DRIVE

RAWWATERP~                                                                                        FILTER

CRANKSHAFT                                                                      OIL COOLEIl
PULLEY
                                                                    OIL PRESSURE
                  OIL DRAIN HOSE
                                       LEFT SIDE                    SENDOR



                                                                                   L FILL

                                                                                             THERMOSTAT
                                                                                            _"O>O>I:IYIDLY




 HEAT EXCHANGER                                                                                       ALTERNATOR

 PREHEAT    __----=::::-~~r;~~
 SOLENOID -

  20 AMP
  CIRCUIT
  BREAKER
                                                                                     FRONT


 HBW
 HURTH
 TRANSMISSION
                                                          RIGHT SIDE      MANIFOLD
                                                                          I.D. PLATE
                                                     ENGINE BLOCK
                                                     DRAIN PLUG

                                         TRANSMISSION
                   REAR                  SHIFT LEVER




                                         Engines & Generators

                                                 2
                                                     INTRODUCTION
This WESTERBEKE Diesel Engine is a product of                          PRODUCT SOFTWARE
WESTERBEKE's long years of experience and advanced                     Product software, (technical data, parts lists, manuals,
technology. We take great pride in the superior durability and         brochures and catalogs), provided from sources other than
dependable performance of our engines and generators.                  WESTERBEKE are not within WESTERBEKE's control.
Thank you for selecting WESTERBEKE.
                                                                       WESTERBEKE CANNOT BE RESPONSIBLE FOR THE
In order to get the full use and benefit from your engine, it is       CONTENT OF SUCH SOFTWARE, MAKES NO WAR-
important that you operate and maintain it correctly. This             RANTIES OR REPRESENTATIONS WITH RESPECT
manual is designed to help you do this. Please read this man-          THERETO, INCLUDING ACCURACY, TIMEliNESS OR
ual carefully and observe all the safety precautions through-          COMPLETENESS THEREOF AND WIU IN NO EVENT
out. Should your engine require servicing, contact your                BE liABLE FOR ANY TYPE OF DAMAGE OR INJURY
nearest WESTERBEKE dealer for assistance.                              INCURRED IN CONNECTION WITH OR ARISING OUT
This is your operators manual. A parts catalog is also                 OF THE FURNISHING OR USE OF SUCH SOFTWARE.
provided and a technical manual is available from your                 WESTERBEKE customers should keep in mind the time
WESTERBEKE dealer. If you are planning to install this                 span between printings of WESTERBEKE product software
equipment, contact your WESTERBEKE dealer for                          and the unavoidable existence of earlier WESTERBEKE
WESTERBEKE'S installation manual.                                      product software. The product software provided with
                                                                       WESTERBEKE products, whether from WESTERBEKE or
WARRANTY PROCEDURES                                                    other suppliers, must not and cannot be relied upon exclu-
Your WESTERBEKE Warranty is included in a separate                     sively as the definitive authority on the respective product. It
folder. If, after 60 days of submitting the Warranty Registry          not only makes good sense but is imperative that appropriate
form you have not received a customer identification card              representatives of WESTERBEKE or the supplier in question
registering your warranty, please contact the factory in               be consulted to determine the accuracy and currentness of the
writing with model information, including the engine's                 product software being consulted by the customer.
serial number and commission date.
                                                                       NOTES, CAUTIONS AND WARNINGS
Customer Identification Card                                           As this manual takes you through the operating procedures,
                                                                       maintenance schedules, and troubleshooting of your marine
        '~/WESTERBEICE                                                 engine, critical information will be highlighted by NOTES,
                                                                       CAUTIONS, and WARNINGS. An explanation follows:
                 I                                                     NOTE: An operating procedure essential to note.
 Customer Identification
 MR. ENGINE OWNER
 MAIN STREET                                                            A CAUTION: Procedures which, if not strictly
 HOMETOWN, USA                                                          observed, can result in the damage or destruction of
 Model 63D FOUR                  Ser. #OOOO-E203                        your engine.
 Expires 3/2010 I

                                                                        A WARNING: Procedures which, if not properly fol-
                                                                        lowed, can result in personal injury or loss of life.
The WESTERBEKE engine serial number is an alphanu-
meric number that can assist in determining the date of man-
ufacture of your WESTERBEKE engine. The manufacturer's
date code is placed at the end of the engine serial number and
consists of a character followed by three numbers. The char-
acter indicates the decade (A=1960s, B=1970s, C=1980s,
D=1990s), the first number represents the year in the decade,
and the second and third numbers represent the month of
manufacture.




                                                           Engines & Generators

                                                                   3
                                                     INTRODUCTION
SERIAL NUMBER LOCATION                                                ORDERING PARTS
The engine's model number and serial number are located on            Whenever replacement parts are needed, always provide the
a nameplate mounted on the side of the engine's manifold.             engine model number and serial number as they appear on
The engine's serial number can also be found stamped into             the silver and black nameplate located on the manifold. You
the engine block just above the injection pump. Take the time         must provide us with this information so we may properly
to enter this information on the illustration of the nameplate        identify your engine. In addition, include a complete part
shown below, as this will provide a quick reference when              description and part number for each part needed (see the
seeking technical information and/or ordering repair parts.           separately furnished Parts List). Insist upon WESTERBEKE
                                                                      packaged parts because will fit or generic parts are frequently


'~2iii#il :1#31
                                                                      not made to the same specifications as original equipment.
                                                                      SPARES AND ACCESSORIES
                                                                      Certain spares will be needed to support and maintain your
                                                                      WESTERBEKE engine. Your local WESTERBEKE dealer
                                                                      will assist you in preparing an inventory of spare parts. See
                                                              ~       the SPARE PARTS page in this manual. For engine acces-
NOTE: A carbon monoxide warning decal has been provided
                                                                      sories, see WESTERBEKE's ACCESSORIES brochure.
by WESTERBEKE. Affix this decal in a visible location in the
engine room.

UNDERSTANDING THE DIESEL ENGINE
The diesel engine closely resembles the gasoline engine,
since the mechanism is essentially the same. The cylinders
are arranged above a closed crankcase. The crankshaft is the
same general type as a gasoline engine, and the diesel engine
has the same type of valves, camshaft, pistons, connecting
rods and lubricating system.
Therefore, to a great extent, a diesel engine requires the same
preventive maintenance as a gasoline engine. The most
important factors are proper ventilation and proper mainte-
nance of the fuel, lubricating and cooling systems. Fuel and
lubricating filter elements must be replaced at the time peri-
ods specified, and frequent checking for contaminants (water,
sediment, etc.) in the fuel system is also essential. Another
important factor is the consistent use of the same brand of
high detergent diesel lubrication oil designed specifically for
diesel engines.
The diesel engine does differ from the gasoline engine,
however, in its method of handling and firing of fuel. The
carburetor and ignition systems are replaced by a single
component - the fuel injection pump - which performs the
function of both.




                                                          Engines & Generators

                                                                  4
                                                ADMIRAL CONTROL PANEL
 DESCRIPTION                                                                   When the engine is shut down with the key switch turned off,
                                                                               the water temperature gauge will continue to register the last
 This manually-operated control panel is equipped with a
                                                                               temperature reading indicated by the gauge before electrical
 KEY switch and RPM gauge with an ELAPSED TIME
                                                                               power was turned off. The oil pressure gauge will fall to zero
 meter which measures the engine's running time in hours and
                                                                               when the key switch is turned off. The temperature gauge
 in 1/10 hours. The panel also includes a WATER TEMPER-
                                                                               will once again register the engine's true temperature when
 ATURE gauge which indicates water temperature in degrees
                                                                               electrical power is restored to the gauge.
 Fahrenheit, an OIL PRESSURE gauge which measures the
 engine's oil pressure in pounds per square inch, and a DC                     A separate alarm buzzer with harness is supplied with every
 control circuit VOLTAGE gauge which measures the sys-                         Admiral Panel. The installer is responsible for electrically con-
 tem's voltage. All gauges are illuminated when the key                        necting the buzzer to the four-pin connection on the engine's
 switch is turned on and remain illuminated while the engine                   electrical harness. The installer is also responsible for installing
 is in operation. The panel also contains two rubber-booted                    the buzzer in a location where it will be dry and where it will
 pushbuttons, one for PREHEAT and one for START.                               be audible to the operator should it sound while the engine is
                                                                               running, The buzzer will sound when the ignition key is turned
                                                                               on and should silence when the engine has started and the
                                                                               engine's oil pressure rises above 15 psi (Ll kglcm2).


                                                                                                       OIL PRESSURE GAUGE: THIS GAUGE IS GRADU-
                                                                                                       ATED IN POUNDS PER SQUARE INCH (PSI) AND IS
                                WATER TEMPERATURE GAUGE: THIS GAUGE IS                                 ILLUMINATED WHILE THE KEY SWITCH IS TURNED
                                GRADUATED IN DEGREES FAHRENHEIT AND IS                                 ON. THE ENGINE'S NORMAL OPERATING OIL
                                ILLUMINATED WHILE THE KEY SWITCH IS                                    PRESSURE RANGES BETWEEN 30 - 60 psi
                                TURNED ON. THE ENGINE'S NORMAL OPERATING                               (2.1 - 4.2 kg/cm').
                                TEMPERATURE IS 170" -190" F(77" - SS"C).

RPM GAUGE: REGIS-
TERS REVOLUTIONS
PER MINUTE OFTHE
ENGINE AND CAN BE
RECALIBRATED FOR
ACCURACY FROM THE
REAR OF THE


HOURMETER:                                                                                                                        KEY SWITCH: PROVIDES
REGISTERS ELAPSED                                                                                                                 POWER ONLY TO THE
TIME, AND SHOULD BE
                                                                                                                                  INSTRUMENT PANEL
USED AS A GUIDE FOR                                                                                                               CLUSTER.
THE MAINTENANCE
SCHEDULE. _---------t



                                                                                                       :              I           DC "iIlT'.~T~D.


                                                                     ~
                                                                                                                                  INDICATES THE AMOUNT THE
                                                                                                                                  BATTERY IS BEING CHARGED.
                                                                                ~                                                 SHOULD SHOW 13V TO 14V.
PREHEAT BUTTON: WHEN            ENERGIZES THE
ALTERNATOR'S EXCITER, THE FUEL LIFT PUMP, THE                                       AUTOMATIC ALARM SYSTEM
FUEL SOLENOID ON THE INJECTION PUMP, AND THE
ENGINE'S GLOW PLUGS. IT BYPASSES THE ENGINE'S                 .          :          COOLANT TEMPERATURE ALARM: AN ALARM BUZZER HAS BEEN
                                                           , ~          :           SUPPLIED WITH THE INSTRUMENT PANEL. IF THE ENGINE'S COOLANT
OIL PRESSURE ALARM SWITCH. IN ADDITION, THIS
BUTTON ENERGIZES THE START BUTTON.                                _.                REACHES 210' F (99'C), THIS SWITCH WILL CLOSE SOUNDING THE
                                                                   ---'             ALARM WHICH WILL EMIT A CONTINUOUS SIGNAL.
START BUTTON: WHEN PRESSED, ENERGIZES THE
STARTER'S SOLENOID WHICH CRANKS THE ENGINE.                                         OIL PRESSURE ALARM: AN OIL PRESSURE ALARM SWITCH IS
THIS BUTTON WILL NOT OPERATE ELECTRICALLY                                           LOCATED OFF THE ENGINE'S OIL GALLERY. THIS SWITCH MONITORS
UNLESS THE PREHEAT BUTTON IS PRESSED AND HELD                                       THE ENGINE'S OIL PRESSURE. SHOULD THE ENGINE'S OIL PRESSURE
ATTHE SAME TIME.                                                                    FALL TO 5 -10 psi (0.4 - 0.7 kg/cm'), THE SWITCH WILL CLOSE SOUND-
                                                                                    ING THE ALARM. IN THIS EVENT, THE ALARM WILL EMIT A PULSATING
                                                                                    SIGNAL.




                                                               Engines & Generators
                                                                           5
                                                CAPTAIN CONTROL PANEL
DESCRIPTION                                                             The panel also includes an alann buzzer for low On..
                                                                        PRESSURE or high COOLANT TEMPERATURE. The
This manually-operated control panel is equipped with a                 RPM gauge is illuminated when the KEY switch is turned on
KEY switch, an RPM gauge, PREHEAT and START but-                        and remains illuminated while the engine is in operation.
tons, an INSTRUMENT TEST button and three indicator
lamps, one for ALTERNATOR DISCHARGE, one for low
On.. PRESSURE, and one for high ENGINE COOLANT
TEMPERATURE.




                                                                        ALARM: THE ALARM WILL SOUND IF THE ENGINE'S OIL PRESSURE FALLS
                                                                        BELOW 5 -10 psi (0.4 - 0.7 kg/em'). IN THIS EVENT, THE ALARM WILL EMIT A
                                                                        PULSATING SIGNAL. THE ALARM WILL ALSO SOUND IF THE COOLANT
                                                                        TEMPERATURE IN THE FRESHWATER COOLING CIRCUIT RISES TO
RPM GAUGE: REGISTERS REVOLUTIONS                                        210F (99C). IN THIS EVENT, THE ALARM WILL EMIT A CONTINUOUS SIGNAL.
PER MINUTE OF THE ENGINE AND CAN BE                                     NOTE: THE ALARM WILL SOUND WHEN THE KEY SWITCH IS TURNED ON. THIS
RECALIBRATED FOR ACCURACY FROM                                          SOUNDING IS NORMAL. ONCE THE ENGINE STARTS AND THE ENGINE'S OIL
THE REAR OF THE PANEL.                                                  PRESSURE REACHES 15 psi (1.1 kg/em'), THE ALARM WILL SILENCE.




                                                                                                                         TEST BUTTON: WHEN
                                                                                                                         PRESSED, TESTS THE
                                                                                                                         ALTERNATOR, THE OIL
                                                                                                                         PRESSURE, AND THE
                                                                                                                         COOLANT TEMPERA-
                                                                                                                         TURE CONTROL CIR-
                                                                                                                         CUITS. WHEN PRESSED,
                                                                                                                         THE ALTERNATOR, THE
                                                                                                                         OIL PRESSURE, AND
                                                                                                                         THE WATER TEMPERA-
                                                                                                                         TURE INDICATOR
                                                                                                                         LIGHTS ILLUMINATE IN
                                                                                                                         ADDITION TO SOUND-
                                                                                                                         ING THE ALARM
                                                                                                                         BUZZER.



                                                                                                                         KEY SWITCH: PROVIDES
                                                                                                                         POWER ONLY TO THE
                                                                                                                         INSTRUMENT PANEL
                                                                                                                         CLUSTER.



                                      WATER TEM.PERATUI~E
                                      ALARM LIGHT



                     START BUTTON: WHEN PRESSED, ENERGIZES THE
                     STARTER'S SOLENOID WHICH CRANKS THE ENGINE. THIS                       PREHEAT BUTTON: WHEN PRESSED, ENERGIZES THE
                     BUTTON WILL NOT OPERATE ELECTRICALLY UNLESS THE                        ALTERNATOR'S EXCITER, THE FUEL LIFT PUMP, THE FUEL
                     PREHEAT BUTTON IS PRESSED AND HELD AT THE SAME                         SOLENOID ON THE INJECTION PUMP, AND THE ENGINE'S
                     TIME.                                                                  GLOW PLUGS, AND BYPASSES THE ENGINE'S OIL PRES-
                                                                                            SURE ALARM SWITCH. IN ADDITION, THIS BUTTON ENER-
                                                                                            GIZES THE START BUTTON.




                                                            Engines & Generators

                                                                   6
                       DIESEL FUEL, ENGINE OIL AND ENGINE COOLANT
DIESEL FUEL                                                             ENGINE COOLANT
Use fuel that meets the requirements or specification of Class          WESTERBEKE recommends a mixture of 50% antifreeze
2-D (ASTM), and has a cetane rating of #45 or better.                   and 50% distilled water. Distilled water is free from the
                                                                        chemicals that can corrode internal engine surfaces.
Care Of The Fuel Supply                                                 The antifreeze performs double duty. It allows the engine to
Use only clean diesel fuel! The clearance of the components             run at proper temperatures by transferring heat away from
in your fuel injection pump is very critical; invisible dirt par-       the engine to the coolant, and lubricates and protects the
ticles which might pass through the filter can damage these             cooling circuit from rust and corrosion. Look for a good
finely finished parts. It is important to buy clean fuel, and           quality antifreeze that contains Supplemental Cooling
keep it clean. The best fuel can be rendered unsatisfactory by          Additives (SCAs) that keep the antifreeze chemically bal-
careless handling or improper storage facilities. To assure             anced, crucial to long term protection.
that the fuel going into the tank for your engine's daily use is
                                                                        The distilled water and antifreeze should be premixed before
clean and pure, the following practice is advisable:
                                                                        being poured into the cooling circuit.
Purchase a well-known brand of fuel.
                                                                        NOTE: Look for the new environmentally-friendly long lasting
Insta11 and regularly service a good, visual-type fuel
                                                                        antifreeze that is now available.
filter/water separator between the fuel tank and the engine.
The Raycor 500 FG or 900 FG are good examples of such                   Antifreeze mixtures will protect against an unexpected freeze
filters.                                                                and they are beneficial to the engine's cooling system. They
                                                                        retard rust and add to the life of the circulating pump seal.
ENGINE OIL
Use a heavy duty engine oil with an API classification of CF
or CG-4 or better. Change the engine oil after an initial 50
                                                                                            ANTIFREEZE PROTECTION
hours of break-in operation, and every 100 hours of operation           Antifreeze Concentration     23%       30%       35%       50%
thereafter. For recommended oil viscosity, see the following            Freezing Temperature         14F       BOF      -4F     -40F
chart:                                                                                             (-10G)   (-13C)   (-20G)   (-40G)
      Operating Temperature            Oil Viscosity
         Above 6BoF (20C)      SAE 30, 10W-30 or 15W-40                Coolant Recovery Tank
       41 - 6BoF (5 - 20C)    SAE 20, 10W-30 or 15W-40                A coolant recovery tank kit is supplied with each
                                                                        WESTERBEKE diesel engine. The purpose of this recovery
         Below 41F (5C)         SAE 10W-30 or 15W-40                  tank is to allow for engine coolant expansion and contraction
                                                                        during engine operation, without the loss of coolant and
                                                                        without introducing air into the cooling system. This kit is
 A CAUTION: Do not allow two or more brands of                          provided and must be installed before operating the engine.
 engine oil to mix. Each brand contains its own additives;              NOTE: This tank, with its short run of plastic hose, is best
 additives of different brands could react in the mixture               located at or above the level of the engine's manifold, but it
 to produce properties harmful to your engine.                          can be located below the level of the engine's manifold if the
                                                                        particular installation makes this necessary.
Oil Pressure
The engine's oil pressure, during operation, is indicated
by the oil pressure gauge on the instrument panel. During
normal operation, the oil pressure will range between 35 and
55 psi (2.5 and 3.9 kg/cm2).
NOTE: A newly started, cold engine can have an oil pressure
reading up to 60 psi (4.2 kg/cm2). A warmed engine can have
an oil pressure reading as low as 25 psi (1.8 kg/cm2 ). These
readings will vary depending upon the temperature of the
engine and the load placed on the engine.




                                                            Engines & Generators

                                                                    7
                                PREPARATIONS FOR INITIAL START-UP
PRESTART INSPECTION
Before starting your engine for the first time or after a pro-
longed layoff, check the following items:
D Check the engine oil level. Add oil to maintain the level
    at the high mark on the dipstick.
D Turn on the fuel supply, then check the fuel supply and
  examine the fuel filter/water separator bowl for contami-
                                                                                         COOLANT
  nants.                                                                                 RECOVER
D Check the transmission fluid level.                                                    TANK
                                                                                         CHECK COOLANT HERE
     NOTE: Refer to the specifications pages in this manualfor
    fuel, oil and transmission fluid types and quantities.
D Check the DC electrical system. Inspect wire connections
    and battery cable connections. Make certain the positive
    (+) battery cable is connected to the starter solenoid and
    the negative (-) cable is connected to the engine ground
    stud (this location is tagged).
                                                                                           COOLANT PRESSURE
D Check the coolant level in both the plastic recovery tank                                CAP
    and at the manifold.                                                                     L COOLANT HERE
    NOTE: If the engine has not yet been filled with coolant,
    refer to the COOLING SYSTEM section of this manual.
D Visually examine the engine. Look for loose or missing
    parts, disconnected wires, and unattached hoses. Check
    the threaded connections and engine attachments.               MANIFOLD
D   Examine the air inlet and outlet for air flow obstructions.
    Good ventilation and an ample air supply are necessary
    for proper engine performance.
D   Make sure the mounting installation is secure.
D   Ensure the propeller shaft is securely attached to the
    transmission.
D   Open the through-hull and prime the raw water intake
    strainer. Inspect the raw water supply.


                                    OIL   FILL-------2?'~




                                               DlPSTICK----------
                                               MAKE CERTAIN
                                               IT IS PUSHED ALL
                                               THE WAY IN
                                                                                  Ii:"i""l-----   LOW




                                                           Engines & Generators

                                                                  8
                                    STARTING/STOPPING PROCEDURE
THE STARTING SYSTEM
Westerbeke diesel generators use electric starters assisted by           A CAUTION: Prolonged cranking intervals without
glow plugs for both nonnal and cold weather starting. The                the engine starting can result in the engine exhaust
glow plug is located in the combustion chamber so that its tip           system filling with raw water. This may happen because
is in the injectors nozzle's spray path. When the glow plug is
energized by the PREHEAT button, the plug glows red at the               the pump is pumping raw water through the raw water
tip and assists in igniting the fuel. The result is a rapid start        cooling system during cranking. This raw water can
with less wear on the starter.                                           enter the engine's cylinders by way of the exhaust
                                                                         manifold once the exhaust system fills. Prevent this
Starting Procedure                                                       from happening by closing the raw water supply
1. Place the transmission in neutral and advance the throttle            through-hull shutoff, draining the exhaust muffler, and
   control to slightly open.
                                                                         correcting the cause of the excessive engine cranking.
                                                                         Engine damage resulting from raw water entry is not a
      A CAUTION: Make certain the transmission is                        warrantable issue; the owner/operator should keep this
      in neutral. Starting in gear could result in serious               in mind.
      damage to your transmission, your boat, and
      vessels nearby.                                                   6. Once the engine starts, check the instruments for proper
                                                                           oil pressure and battery charging voltage.
2. Turn the KEY SWITCH to the ON position (2 o'clock).                     NOTE: Never attempt to engage the starter while the
3. Depress the PREHEAT button. The voltmeter, panel                        engine is running.
   lights, gauges, meters and fuel solenoid will be activated.             NOTE: Some unstable running may occur in a cold
   The PREHEAT button should be depressed in accordance                    engine. Depressing the PREHEAT button for 10 -15
   with the following chart:                                               second intervals will help stabilize the engine rpm until
                       Temperature/Preheat                                 the engine operating temperature reaches 170 -190F
                                                                           (77 - 88C) and a propeller load is applied to the engine.
     Atmospheric Temperature              Preheating Time
                                                                           When the engine is running and the PREHEAT button is
                                                                           depressed, a charging load on the DC alternator will be
        41F(5C) or higher              Approx. 5 seconds
                                                                           discernible.
     41F(5C) to 23F (-5C)           Approx. 10 seconds
        23F(-5C) or lower             Approx. 15 seconds              Starting Under Cold Conditions
                                                                        Make sure the lubricating oil is appropriate for the prevailing
NOTE: The START button will not energize unless the PRE-                temperature. Use oil with an API Specification of CF or CG-4,
HEAT button is depressed. Depressing the PREHEAT button                 SAE 30, lOW-3~, 15W-40, or 20W-40.
activates the glow plugs in the cylinder head so use the PRE-           The battery should be fully charged to minimize voltage drop.
HEAT intermittently to avoid overheating the glow plugs.                Use a sufficient amount of preheat to aid in starting. See the
4. While still depressing the PREHEAT switch, depress the               Temperature/Preheat chart elsewhere in this section.
   START switch. This will engage the starter solenoid.
   Upon engine starting, release the START switch and                   Stopping Procedure
   release the PREHEAT switch.                                          1. 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. Tum
                                          12    ,     14                   the engine off using the stop control cable. This opens the
                                     ~6                                    DC circuit to the instrument panel and engine, de-ener-
                                                                           gizing the fuel solenoid on the injection pump, stopping
NOTE: When starting:                      \                                fuel flow from it and stopping the engine.
A voltage drop will occur             U              VOLTS
                                                                        2. Make certain this key switch is in the OFF position (12
                                                                           o'clock). If the key switch is left ON, the battery will
when the preheat button
                                                                           discharge. An engine alarm buzzer is provided to warn
is depressed.
                                                                           the operator of this condition (key switch ON). The best
                                                                           method of preventing the battery from discharging is to
5. Should the engine not start when the START button is                    remove the key from the key switch after stopping the
   depressed for 10 to 20 seconds, release both buttons and                engine.
   wait 30 seconds; repeat the procedure above and preheat                 NOTE: The engine is stopped when the electric solenoid
   longer. Never run the starter for more than 30 seconds.                  that is attached to a lever on the fuel injection pump is
                                                                            de-energized. shutting off the flow offuel.




                                                             Engines & Generators

                                                                    9
                                      ENGINE BREAK-IN PROCEDURE
DESCRIPTION                                                             3. While using the vessel, run the engine at various engine
                                                                           speeds for the first 25 hours. Avoid prolonged periods of
Although your engine has experienced a minimum of one
                                                                           idling.
hour of test operations at the factory to make sure accurate
assembly procedures were followed and that the engine oper-             4. Avoid rapid acceleration, especially with a cold engine.
ated properly, a break-in time is required. The service life of         5. Use caution not to overload the engine. The presence of a
your engine is dependent upon how the engine is operated                   grey or black exhaust and the inability of the engine to
and serviced during its initial 50 hours of use.                           reach its full rated speed are signs of an overload.
Breaking-in a new engine basically involves seating the pis-           .6. During the next 25 hours, the engine may be operated at
ton rings to the cylinder walls. Excessive oil consumption                 varying engine speeds, with short runs at full rated rpm.
and smoky operation indicate that the cylinder walls are                   Avoid prolonged idling during this break-in period.
scored, which is caused by overloading the engine during the
break-in period.                                                       CHECK LIST
Your new engine requires approximately 50 hours of initial             o   Monitor the control panel gauges.
conditioning operation to break in each moving part in order           o   Check for leaks of fuel and engine oil.
to maximize the performance and service life of the engine.
Perform this conditioning carefully, keeping in mind the fol-
                                                                       o   Check for abnormal noise such as knocking, friction,
                                                                           vibration and blow-back sounds.
lowing:
1. Start the engine according to the STARTING PROCE-
                                                                       o   Confirm exhaust smoke:
                                                                           When the engine is cold - white smoke.
    DURE section. Run the engine at fast idle while checking               When the engine is warm - almost smokeless.
    that all systems (raw water pump, oil pressure, battery                When the engine is overloaded - some black smoke and soot.
    charging) are functioning.
2. Allow the engine to warm up (preferably by running at               NOTE: See the TRANSMISSION section of this manualfor
   fast idle) until the water temperature gauge moves into             break-in information on your transmission.
   the 130 - 140F (55 - 60C) range.




                                                         Engines & Generators

                                                                  10
                                             THE DAILY OPERATION
CHECK LIST                                                           FAILURE TO START
Follow this check list each day before starting your engine.         If the engine fails to start when the start button is pressed for
D Visually inspect the engine for fuel, oil, or water leaks.         5 seconds, wait for at least 30 seconds and repeat the starting
D Check the oil level (dipstick).                                    procedure. Make certain the transmission control is in the
                                                                     neutral position as some engines have a neutral safety switch
D Check the coolant level in the coolant recovery tank.              to prevent starting in gear.
    Periodically check the manifold coolant level.
                                                                     Never run the starter for more than 30 seconds. If the engine
D Check the transmission fluid level.                                fails to start, refer to the TROUBLESHOOTING CHART in
D Check your fuel supply.                                            this manual.
D Look for clean fuel in the fuel filter/water separator
    transparent bowl.
D   Check for loose wires at the alternator and make sure its         A CAUTION: Prolonged cranking intervals without the
    mounting is secure.                                               engine starting can result in the engine exhaust system
D   Check the starting batteries (weekly).                            filling with raw water. This may happen because the
                                                                      pump is pumping raw water through the raw water
D   Check drive belts for wear and proper tension (weekly).           cooling system during cranlcing. This raw water can
D Visually inspect the raw water pump for leakage.                    enter the engine's cylinders by way of the exhaust
                                                                      manifold oncs the exhaust sytem fills. Prevent this
STARTING THE ENGINE                                                   from happening by closing the raw wat. supply
NOTE: See STARTING/STOPPING PROCEDURE in this                         through-hull shutoff, draining the exhaust muffler, and
manual for more detailed instructions.                                correcting the cause of the excessive engine cranking.
                                                                      Engine damage resulting from raw water entry is not a
1. Put the transmission in neutral, throttle advanced.                warrantable issue; the owner/operator should keep this
    NOTE: Hydraulically operated transmissions have a                 inm/nd.
    neutral safety switch through which the starter solenoid
    energizing circuit passes. This switch is open when the
    transmission is in gear so the starter solenoid will not
    energize.                                                        Stopping Procedure
                                                                     To stop the engine, bring the throttle to an idle position and
2. Turn the KEY SWITCH to the ON position (2 o'clock).
                                                                     place the transmission in neutral. Allow the engine to idle for
   [The panel is energized, gauges are lite].
                                                                     a few moments to stabilize temperatures. Then shut the
3. Depress the PRESTART BUITON, hold for 5 seconds.                  engine down by turning off the key switch.
   [The fuel lift pump is priming the engine].
                                                                     NOTE: Make certain this key switch is in the OFF
4. Release the PRESTART BUTI'ON and press the START
                                                                     position(120'clock}. If the key switch is left ON, the
   BU'ITON. [The start motor is cranking the engine].
                                                                     energized instrument panel will put a drain on the battery.
5. Release the START BUITON as the engine starts.
6. With the engine running, check the instruments for
   proper oil pressure and battery charging voltage. The
   water temperaturewill rise slowly until the thermostat
   opens.
    NOTE: Never attempt to engage the starter while the
    engine is running.
It is important to closely monitor the panel gauges. Become
aware of the normal engine readings and take immediate
action if these readings start to vary.




                                                           Engines & Generators

                                                                11
                    WARNING liGHTS, ALARMS & CIRCUIT BREAKER
ALTERNATOR WARNINGS                                                  LOW OIL PRESSURE ALARM SWITCH
The Captain Control Panel indicates alternator low discharge         A low oil pressure alarm switch is located off the engine's
with a red warning light.                                            oil gallery. This switch's sensor monitors the engine's oil
The Admiral Control Panel uses a voltmeter to monitor the            pressure. Should the engine's oil pressure fall to 5 - 10 psi
performance of the alternator.                                       (0.4 - 0.7kg/cm2), this switch will activate a pulsating alarm.

COOLANT TEMPERATURE SWITCH
A coolant temperature switch is located on the thermostat
housing. This switch will activate a continuous alarm if the
coolant's operating temperature reaches approximately 210 0 P
(99C);




                                                                                                                OIL FILTER ASSEMBLY

                                                 COOLANT
                                                 TEMPERATURE
                                                                     ENGINE CIRCUIT BREAKER
                                                 SWITCH              The DC harness on the engine is protected by an engine-
                                                                     mounted manual reset circuit breaker (20 amps DC).
                                                                     Excessive current draw or electrical overload anywhere in
                                                                     the instrument panel wiring or engine wiring will cause the
                                                                     breaker to trip. In this event most engines will shut down
                                                                     because the opened breaker disconnects the fuel supply. If
                                                                     this should occur, check and repair the source of the problem.
                                                                     After repairing the fault, reset the breaker and restart the
                                                                     engine.

                       THERMOSTAT
                       ASSEMBLY




                                                        Engines & Generators
                                                                12
                                            MAINTENANCE SCHEDULE
In order to use this Maintenance Schedule, it will be neces-
sary to log your engine hours. Use your engine hourrneter or                 A WARNING: Never attempt to perform any service
record your engine hours by running time.                                    while the engine is running. Wear the proper safety
NOTE: Many of the following maintenance procedures are                       equipment such as goggles and gloves, and use the
simple but others are more difficult and may require the                     correct tools for each job. Disconnect the battery
expert knowledge of a service mechanic.                                      terminals when servicing any of the engine's DC
                                                                             electrical equipment.


        SCHEDULED             CHECK                 HOURS OF OPERATION
                              EACH                                                                      MAINTENANCE DESCRIPTION
       MAINTENANCE
                               DAY     50     100     250    500     750 1000 1250
 Fuel Supply                   D                                                             Diesel No.2 rating of 45 cetane or higher.
 Fuel/Water Separator          D                                                             Check for water and dirt in fuel (drain/replace filter if
                                                                                             necessary).
 Engine Oil Level              D                                                             Oil level should indicate between MAX. and LOW on
                                                                                             dipstick.
 Coolant Level                 D                                                             Check at recovery tank; if empty, check at manifold.
                                                                                             Add coolant if needed.
 Transmission Fluid Level      D                                                             Fluid level should indicate between MAX and LOW
                                                                                             on dipstick.
 Drive Belts                   D                                                             Inspect for proper tension (3/8" to 1/2" deflection)
                              weekly                                                         and adjust if needed. Check belt edges for wear.
 Visuallnspeclion of Engine    D       NOTE: Keep engine surface clean. Dirt and             Check for fuel, oil and water leaks. Inspect wiring
                                       oil will inhibit the engine's ability to remain       and electrical connections. Keep bolts & nuts tight.
                                       cool.                                                 Check for loose belt tension.
 Fuel Filter                           D               D      D       D       D          D   Clean with kerosene at 50 hours then clean every
                                                                                             100 hours. Change at 500 hours.
 Starting Batteries            D                                                             Check electrolyte levels every 50 operating hours
 (and House Batteries)        weekly                                                         and make sure connections are very tight. Clean off
                                                                                             excessive corrosion.
 Engine Oil and Filter                 D       D       D      D       D       D          D   Initial engine oil & filter change,at 50 hours, then
                                                                                             change both every 100 hours.
 Heat Exchanger Zinc Anode             D       D       D      D       D       D          D   Inspect zinc anode, replace if needed. Clear the heat
                                                                                             exchanger end of zinc anode debris.
 Fuel/Water Separator                          D       D      D       D       D          D   Change filter every 200 hours.
 Exhaust System                        D               D              D                  D   Initial check at 50 hours, then every 250 hours.
                                                                                             Inspect for leaks. Check anti-Siphon valve
                                                                                             operation. Check the exhaust elbow for carbon
                                                                                             and/or corrosion buildup on inside passages;
                                                                                             clean and replace as necessary. Check that all
                                                                                             connections are tight. Check casting integrity.
 Engine Hoses                                  D       D       D      D       D          D   Hose should be hard & tight. Replace if soft or
                                                                                             spongy. Check and tighten all hose clamps.
 Throttle and Transmission             D               D              D                  D   Check for loose fittings, cotter pins, etc.
 Control Cable                                                                               Lubricate with WD-40 or equivalent.
 Adjust Engine Idle Speed              D                                                     Adjust to 750 - 1000 rpm
 Raw Water Pump                                        D              D                  D   Remove the pump cover and inspect the impeller,
                                                                                             gasket, cam and cover for wear. Check the bearings,
                                                                                             seals and shaft drive tang.
                                                                                                                                           (continued)



                                                             Engines & Generators

                                                                     13
                                             MAINTENANCE SCHEDULE
                       NOTE: Use the engine hourmeter gauge to log your engine hours or record your
                        engine hours by running time.


       SCHEDULED                CHECK               HOURS OF OPERATION
      MAINTENANCE               EACH                                                          MAINTENANCE DESCRIPTION
                                 DAY    50    100     250   500   750 1000 1250
 Coolant System                                             D            D         Drain, flush, and refill cooling system with
                                                                                   appropriate antifreeze mix.
 DC Alternator                                        D           D           D    Check DC charge from alternator. Check mounting
                                                                                   bracket; tighten electrical connections.
 Transmission Oil Cooler                                                 D         Remove; have professionally cleaned and pressure
                                                                                   tested.
 Engine Transmission                                                     D         Chattering at idle and low rpms is an indication
 Damper Plate                                                                      of damper plate wear. Remove and replace.
 *Fuellnjectors                                                   D                Check and adjust injection opening pressure and
                                                                                   spray condition.{see ENGINE ADJUSTMENTS)
 *Starter Motor                                             D                 D    Check solenoid and motor for corrosion. Remove
                                                                                   and lubricate. Clean and lubricate the starter motor
                                                                                   pinion drive.
 *Preheat Circuit                                           D                 D    Check operation of preheat solenoid. Remove and
                                                                                   clean glow plugs, check resistance value of heater
                                                                                   element (X-X ohms). Reinstall with anti-seize
                                                                                   compound on threads.
 *Engine Cylinder                                           D                 D    Check compression pressure and timing (see Engine
  Compression                                                                      Adjustments) .
 *Adjust the Valve Clearances           D                   D            D         Adjust Valve Clearances (see ENGINE
                                                                                   ADJUSTMENTS).
 *Heat Exchanger                                                         D         Remove, have professionally cleaned and pressure
                                                                                   tested.
 Lubricate Panel Key Switch                   D        D    D     D      D    D    At first 100 hours, then each year at winterizing.
 with "Lockeze"
 Transmission Fluid                     D             D     D     D      D    D    Initial fluid change at 25 hours, then every
                                                                                   300 hours or at winterizing.




*WESTERBEKE recommends this service be performed by an authorized mechanic.




                                                            Engines & Generators
                                                                  14
                                                 COOLING SYSTEM

DESCRIPTION                                                           When the engine is started cold, external coolant flow is pre-
                                                                      vented by the closed thermostat (although some coolant flow
Westerbeke marine diesel engines are designed and equipped
                                                                      is bypassed around the thermostat to prevent the exhaust
for fresh water cooling. Heat produced in the engine by com-
                                                                      manifold from overheating). As the engine warms up, the
bustion and friction is transferred to fresh water coolant
                                                                      thermostat gradually opens, allowing full flow of the engine's
which circulates throughout the engine. This circulating fresh
                                                                      coolant to flow unrestricted to the external portion of the
water coolant cools the engine block, its internal moving
                                                                      cooling system.
parts, and the engine oil. The heat is transferred externally
from the fresh water coolant to raw water by means of a heat          Coolant Recovery Tank
exchanger, similar in function to an automotive radiator. Raw
water flows through the tubes of the heat exchanger while             A coolant recovery tank allows for engine coolant expansion
fresh water coolant flows around the tubes; engine heat trans-        and contraction during engine operation, without any signifi-
ferred to the fresh water coolant is conducted through the            cant loss of coolant and without introducing air into the cool-
tube walls to the raw water which is then pumped into the             ing system. This tank should be located at or above the
exhaust system where finally it is discharged overboard. In           engine manifold level and should be easily accessible.
other words, the engine is cooled by fresh water coolant, this        CHANGING COOLANT
coolant is cooled by raw water, and the raw water carries the
                                                                      The engine's coolant must be changed according to the
transferred heat overboard through the exhaust system. The
                                                                      MAINTENANCE SCHEDULE. If the coolant is allowed to
fresh water coolant and raw water circuits are independent of
                                                                      become contaminated, it can lead to overheating problems.
each other. Using only fresh water coolant within the engine
allows the cooling water passages to stay clean and free from
harmful deposits.                                                      A CAUTION: Proper cooling system maintenance is
FRESH WATER COOLING CIRCUIT                                            critical; a substantial number of engine failures can be
                                                                       traced back to cooling system corrosion.
NOTE: Refer to the ENGINE COOLANT section for the rec-
ommended antifreeze and water mixture to be used as the               Dr~n the engine coolant by loosening the drain plug on the
fresh water coolant.                                                  engme block and opening the manifold pressure cap. Flush
Fresh water coolant is pumped through the engine by a circu-          the system with fresh water, then start the refill process.
lating pump, absorbing heat from the engine. The coolant              NOTE: The drain petcock on the heat exchanger should also
then passes through the thermostat into the manifold, to the          be used to help drain engine coolant.
heat exchanger where it is cooled, and returned to the engine
block via the suction side of the circulating pump.                                                                THERMOSTAT
                                                                                                                   HOUSING
                                                                                           COOLANT PUMP


                                                                                                                           INCOMING RAW
                                                                                                                           WATER




      ZINC
      ANODE




  DRAIN


  DRAIN PETCOCK




                                                       Engines & Generators

                                                                 15
                                                     COOLING SYSTEM
   Refilling the Coolant                                                  Replacing the Thermostat
  After replacing the engine block drain plug, close the heat             Remove the cap screws and disassemble the thermostat hous-
  exchanger's coolant petcock. Then run the engine at idle and            ing as shown. When installing the new thermostat and gas-
  slowly pour clean, premixed coolant into the manifold.                  ket, apply a thin coat of sealant on both sides of the gasket
                                                                          before pressing it into place. Do not over-tighten the cap
  NOTE: Open the air-bleed petcock on the heat exchanger.                 screws.
  When a steady flow of coolant appears at the petcock, close
  the petcock and fill the system until the manifold remains full.        Run the engine and check for normal temperatures and that
                                                                          there are no leaks at the thermostat housing.
  Monitor the coolant in the manifold and add as needed. Fill
                                                                                                                                   AIR BLEED
  the manifold to the filler neck and install the manifold pres-                                                                  .PETCOCK
  sure cap.
  Remove the cap on the coolant recovery tank and fill with
  coolant mix to halfway between LOW and MAX and replace

                                                                                                             ~Ril~:-_~COOLANT
  the cap. Run the engine and observe the coolant expansion
                                                                                                                         TEMPERATURE
  flow into the recovery tank.                                                                                          ,SWITCH
  After checking for leaks, stop the engine and allow it to cool.
  Coolant should draw back into the cooling system as the
  engine cools down. Add coolant to the recovery tank if
  needed. Clean up any spilled coolant.
                                                                                                                                 THERMOSTAT
                                                      /PRfSSURE CAP
   TO COOLANT RECOVERY
)I TANK



                                               COOLANT RETRACTION
                                                                                                  """- II,'-=====#
                                                                          RAW WATER COOLING CIRCUIT
                                                                          The raw water flow is created by a positive displacement
                                                                          impeller pump. This pump draws water directly from the raw
                                                                          water source (ocean, lake, or river) through a hose to the
  "OTE: Periodically check the condition of the manifold pres-            water strainer. The raw water passes from the strainer
  sure cap. Ensure that the upper and lower rubber seals are in           through the raw water pump to the heat exchanger (through
  good condition and check that the vacuum valve opens and                the heat exchanger tubes) where it cools the engine circulat-
  closes tightly. Carry a spare cap.                                      ing fresh water coolant. The raw water is then discharged
                                                                          into the water-injected exhaust elbow, mixing with and cool-
                                                                          ing the exhaust gasses. This mixture of exhaust gas and raw
                                                                          water is discharged overboard by the engine's exhaust gas
  CHECKING
  THE PRESSURE                                                            discharge pressure.
  CAP
                                                                          Raw Water Pump
                                                                          The raw water pump is a self-priming, rotary pump with a
                                                                          non-ferrous housing and a neoprene impeller. The impeller
  THERMOSTAT                                                              has flexible vanes which wipe against a curved cam plate
   A thermostat, located near the manifold at the front of the            within the impeller housing, producing the pumping action.
   engine, controls the coolant temperature as the coolant contin-        On no account should this pump be run dry as water acts as a
   uously flows through the close9 cooling circuit. When the              lubricant for the impeller. There should always be a spare
   engine is first started, the closed thermostat prevents coolant        impeller and impeller cover gasket (an impeller kit) aboard.
   from flowing (some coolant is by-passed through a hole in the          Raw water pump impeller failures occur when lubricant (raw
   thermostat to prevent the exhaust manifold from overheating).          water) is not present during engine operation. Such failures
   As the engine warms up, the thermostat gradually opens. The            are not warrantable, and operators are cautioned to make sure
   thermostat is accessible and can be checked, cleaned, or               raw water flow is present at start-up.
 . replaced easily. Carry a spare thermostat and gasket.                  NOTE: Should a failure occur with the pump ~ internal parts
                                                                          (seals and bearings), it may be more cost efficient to pur-
                                                                          chase a new pump and rebuild the original pump as a spare.
                                                    ~       WESTERBEKE
                                                            Engines & Generators

                                                                     16
                                                     COOLING SYSTEM
    Changing the Raw Water Pump Impeller                                  NOTE: Also follow the above procedure after having run hard
    Close the raw water intake valve. Remove the pump cover               aground.
    and, with the aid of two small screwdrivers, carefully pry the        If the engine temperature gauge ever shows a higher than
    impeller out of the pump. Install the new impeller and gasket.        normal reading, the cause may be that silt, leaves or grass
    Move the blades to conform to the curved cam plate and                may have been caught up in the strainer, slowing the flow of
    push the impeller into the pump's housing. When assem-                raw water through the cooling system.
    bling, apply a thin coating of lubricant to the impeller and
    gasket. Open the raw water intake valve.                                        INCOMING RAW
                                                                                    WATER

            IMPELLER
INSPECTION: CHECK AT THE BASE OF
EACH BLADE BY BENDING VIG1JROllSLY
REPLACE THE IMPELLER IF
                                                                                       SEACOCK
ARE ANY CRACKS.
                                                                                             _--L:.~~'---,- RAW      WATER STRAINER
                                                                                             ~ (OWNER INSTALLED)
                                                                                        ~
                                                                                 ~                        .


                                                                          WASHER~
                                                                                                                          CLEAN OUT EVERY
                                                                                                                          100 HOURS
                                                                      STRAINER
                                                                      FILTER




  WHEN INSTALLING: TAKE CARE TO
                                                                                EXCHANGER
  THE IMPELLER KEYWAY WITH THE SHAFT                                      The heat exchanger is a copper cylinder which encloses a
  KEY. FOLD THE IMPELLER BLADES IN                                        number of small copper tubes. Raw water is pumped through
  EITHER DIRECTION (THEY WILL TURN IN                                     the small copper tubes and the fresh water coolant from the
  THE CORRECT POSITION WHEN THE
  IMPELLER STARTS TO ROTATE).                                             engine is circulated around the copper tubes. The raw water
                                                                          removes heat from the fresh water coolant.

      A CAUTION: If any of the vanes have broken off the                                    II
      impeller, they must be found to prevent blockage in the
                                                                                                                 HEAT EXCHANGER
      cooling circuit. They often can be found in the heat
      exchanger.

    Raw Water Intake Strainer
    NOTE: Always install the strainer at or below the waterline so
    the strainer will always be self-priming.                             ZINC ANODE --~,11
    A clean raw water intake strainer is a vital component of the
    engine's cooling system. Include a visual inspection of this
    strainer when making your periodic engine check. The water        GASKET
    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 washer if necessary.                                                                           WATER
                                                                                                              DRAIN
    5. Reassemble and install the strainer.
    6. Open the seacock.
    7. Run the engine and check for leaks.
                                                             Engines & Generators
                                                                     17
                                                  COOLING SYSTEM
Zinc Anode                                                           If the zinc anodes need replacement, hold the hex boss into
A zinc anode, or pencil, is located in the raw water cooling         which the zinc anode is threaded with a wrench while loos-
circuit within the heat exchanger. The purpose of having the         ening the anode with another wrench. This prevents the hex
zinc anode is to sacrifice them to electrolysis action taking        boss from possibly tearing off the exchanger shell. After
place in the raw water cooling circuit, thereby reducing the         removing the Zinc, note the condition of it. If the zinc is in
effects of electrolysis on other components of the system.           poor condition, there are probably a lot of zinc flakes within
The condition of the zinc anode should be checked monthly            the exchanger. Remove the end of the heat exchanger and
and the anode cleaned or replaced as required. Spare anodes          clean the inside of all zinc debris. Always have a spare heat
should be carried on board.                                          exchanger end gasket in case the present one becomes dam-
                                                                     aged when removing the end cover. Replace the gasket (refer
                                                                     to your e~gine model's heat exchanger end gasket part num-
                                                                     ber), O-nng and cover, and install a new zinc anode.
       .,:'                                                          NOTE: The threads of the' zinc anodes are pipe threads and
                                                                     do not require sealant. Sealant should not be used as it may
                                                                     ~nsulate the zinc from the metal of the heat exchanger hous-
                                                                     mg preventing electrolysis action on the zinc.

                                                                     Heat Exchanger Service
                                                                     After approximately 1000 hours of operation, remove, clean
     NEW         REPLACE        REPLACE     CLEAN AND                and pressure test the engine's heat exchanger. (A local auto-
                                            REUSE                    motive radiator shop should be able to clean and test the heat
                    ZINC ANODES                                      exchanger.)
                                                                     NOTE: Operating in silty and/or tropical waters may require
NOTE: Electrolysis action is the result of each particular           that a heat exchanger cleaning be performed more often than
installation and vessel location; not that of the engine.            every 1000 hours.




                                                         Engines & Generators

                                                                18
                                                       FUEL SYSTEM
DIESEL FUEL                                                              TO FUEL FILTER
Use No.2 diesel fuel with a cetane rating of 45 or higher. Do
not use kerosene or home heating fuel.                                                                                             GROUNO
FUEL FILTER/WATER SEPARATOR
A primary fuel filter of the water separating type must be                       FUEL LIFT PUMP
installed between the fuel tank and the engine to remove
water and other contaminants from the fuel before they can
be carried to the fuel system on the engine.                                                                            INCOMING
Most installers include a fuel filter/water separator with the
                                                                        FUEL FILTERS                                  . FUEL
installation package as they are aware of the problems that             The fuel injection pump and the fuel injectors are precisely
contaminants in the fuel can cause.                                     manufactured and they must receive clean diesel fuel, free
                                                                        from water and dirt. To ensure this flow of clean fuel, the fuel
A typical fuel filter/water separator is illustrated below. This
                                                                        must pass through at least two fuel filters, a fuel filter/water
is the Rayeor Model 500 MA. Keep in mind that if a water
                                                                        separator and the engine's spin-on fuel filter. Visually inspect,
separator type filter is not installed between the fuel supply
                                                                        clean, and change these filters according to the maintenance
tank and engine-mounted fuel system, any water in the fuel
                                                                        schedule in this manual.
will affect the fuel pump, engine filter, and injection equip-
ment. The owner/operator is responsible for making certain
the fuel reaching the engine's injection equipment is free of
impurities. This process is accomplished by installing and
                                                                         A WARNING: Shut off the fuel valve at the tank
maintaining a proper fuel filter/water separator.                        when servicing the fuel system. Take care in catching
                                                                         any fuel that may spill. DO NOT allow any smoking,
                                                                         open flames or other sources of fire near the fuel sys-
                                                                         tem when servicing. Ensure proper ventilation exists
TYPICAL                                                                  when servicing the fuel system.
FUEL
FILTER




                                                                              LOOSEN FITTING ---::l--4~~
                                                                              WHEN PRIMING               ~Ul@~~;;9
                                                                              FILL FILTER

The fuel injection pump is a very important component of
the diesel engine, requiring the utmost care in handling. The
fuel injection pump has been thoroughly bench-tested and the
owner-operator is cautioned not to attempt to service it. If it
requires servicing, remove it and take it to an authorized fuel
injection pump service facility. Do not attempt to disassem-
ble and repair it.                                                      Changing The Fuel Filter
The only adjustment the servicing mechanic should make to               1. Shut off the fuel supply.
the fuel injection pump is the adjustment for engine idle
                                                                        2. Loosen the fuel filter, turning counterclockwise with a
speed (see IDLE SPEED ADJUSTMENT under ENGINE
                                                                           filter wrench. Place the used filter in a container for proper
ADJUSTMENTS).
                                                                           disposal.
FUEL LIFT PUMP                                                          3. Using a rag, wipe clean the sealing face on the housing
Periodically check the fuel connections to and out of the                  bracket so the new filter can be seated properly.
pump and make sure that no leakage is present and that the              4. Lightly oil the sealing O-ring on the new filter. To rein-
fittings are tight and secure. The DC ground connection at                  stall, tum the filter assembly counterclockwise carefully
one of the pump's mounting bolts should be clean and well                   until the o-ring contacts the sealing surface of the housing
secured by the mounting bolt to ensure proper pump opera-                   bracket. Tum 2/3 further with the filter wrench.
tions.
                                                                        5. The key-on preheat sequence will operate the fuel lift
When energized thru the preheat circuit, the fuel lift pump                pump and quickly fill the new filter. It is also possible to
will purge air from the fuel system and provide a continuous               hand prime the filter using the lever on the top.
flow of fuel as the engine is running.
                                                                        6. Run the engine and inspect the filter for fuel leaks.




                                                            Engines & Generators

                                                                   19
                                                     GLOW PLUGS
DESCRIPTION                                                          Re-install the plugs in the engine and test them again. The
                                                                     plugs should get very hot (at the terminal end) within 20 to
The glow plugs are wired through the preheat solenoid.
                                                                     25 seconds. If the plugs don't heat up quickly, check for a
When PREHEAT is pressed at the control panel this solenoid
                                                                     short circuit. When reinstalling the glow plugs, use anti-seize
should "click" on and the glow plug should begin to get hot.
                                                                     compound on the threads.
                                                                     Glow Plug Tightening Torque   7 -11 Ib-H (1.0 -1.5 kg-m)
INSPECTION
To inspect the plug, remove the electrical terminal connec-
tions, then unscrew or unclamp each plug from the cylinder            A    WARNING: 00 not keep a glow plug on for more
head. Thoroughly clean each plug's tip and threads with a             than 30 seconds
soft brush and cleaning solution to remove all the carbon and
oil deposits. While cleaning, examine the tip for wear and                                          TERMINAL END
burn erosion; if it has eroded too much, replace the plug.

TESTING
An accurate way to test glow plugs is with an ohmmeter.
Touch one prod to the glow plug's wire connection, and
the other to the body of the glow plug, as shown. A good
glow plug will have a 1.0- to 1.5-ohm resistance. This                                  Tightening torque:
method can be used with the plug in or out of the engine.
                                                                                       (J.O -1.5 m-kg (7 - llft-lb)
You can also use an ammeter to test the power drain
(8 to 9 amps per plug).


 A    WARNING: These glow plugs will become very hot                                                                            TIP
 to the touch. Be careful not to burn your fingers when
 testing the plugs
                                                                                                         GLOW PLUG
                                                                                                    THE OHMMETER TEST




                                                       Engines & Generators

                                                                20
                                                         ENGINE OIL
ENGINE OIL CHANGE                                                           When installing the new oil filter element, wipe the filter
                                                                            gasket's sealing surface on the bracket free of oil and
1. Draining the Oil Sump. Discharge the used oil through                    apply a thin coat of clean engine oil to the rubber gasket
   the sump drain hose (attached to the front of the engine)
                                                                            on the new oil filter. Screw the filter onto the threaded oil
   while the engine is warm. Drain the used oil completely,
                                                                            filter nipple on the oil filter bracket, and then tighten the
   replace the hose in its bracket, and replace the end cap
                                                                            filter firmly by hand.
   securely.
                                                                            NOTE: The engine oil is cooled by engine coolant flowing
   NOTE: Thread size for the lube oil drain hose capped end                 through passages in the oil filter bracket housing assembly.
   is 114 NPT.
   Always observe the used oil as it is removed. A
   yellow/gray emulsion indicates the presence of water in                                                          OIL FILTER PN#35828
   the oil. Although this condition is rare, it does require
   prompt attention to prevent serious damage. Call a quali-
   fied 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 and/or a siphoning
   of raw water through the raw water cooling circuit into
   the exhaust, filling the engine. This problem is often
   caused by the absence of an anti-siphon valve, its poor
   location or lack of maintenance.




                                                                                                              PRESSURE SWITCH

                                                                                                 OIL FILTER ASSEMBLY

                                                                            NOTE: Generic filters are not recommended, as the mater-
                                                                            ial stando.rds or diameters of important items on generic
                                                                            parts might be entirely different from genuine parts.
                                                                            Immediately after an oil filter change and oil fill, run the
                                                                            engine to make sure the oil pressure is normal and that
                                                                            there are no oil leaks around the new oil filter.

2. Replacing the Oil Filter. When removing the used oil fil-             3. Filling the Oil Sump. Add new oil through the oil filler
   ter, you may find it helpful and cleaner to punch a hole in              cap on the top of the engine or through the side oil fill.
   the upper and lower portion of the old filter to drain the               After refilling, run the engine for a few moments while
   oil from it into a container before removing it. This helps              checking the oil pressure. Make sure there is no leakage
   to lessen spillage. A small automotive filter wrench                     around the new oil filter or from the oil drain system, and
   should be helpful in removing the old oil filter.                        stop the engine. Then check the quantity of oil with the
   NOTE: Do not punch this hole without first loosening the                 lube oil dipstick. Fill to, but not over the high mark on
   filter to make certain it can be removed.                                the dipstick, should the engine require additional oil.
   Place some paper towels and a plastic bag around the fil-
   ter when unscrewing it to catch any oil left in the filter.            A WARNING: Used engine oil contains harmful
   (Oil or any other fluid on the engine reduces the engine's             contaminants. Avoid prolonged skin contact. Clean slein
   cooling ability. Keep your engine clean.) Inspect the old              and nails thoroughly using soap and water. Launder or
   oil filter as it is removed to make sure that the rubber
   sealing gasket comes off with the old oil filter. If this rub-
                                                                          discard clothing or rags containing used oil. Discard
   ber sealing gasket remains sealed against the filter                   used oil properly.
   bracket, gently remove it.




                                                             Engines & Generators

                                                                    21
                                        REMOTE OIL FILTER (OPTIONAL)
INSTALLATION                                                                    NOTE: Westerbeke is not responsible for engine failure due to
lbis popular accessory is used to relocate the engine's oil fil-
                                                                                incorrect installation of the Remote Oil Filter.
ter from the engine to a more convenient location such as an
engine room bulkhead.
NOTE: Refer to ENGINE OIL CHANGE in this manual for                               A CAUTION: It is vital to install the oil lines cor-
instructions on removing the oil filter.                                          rectly. If the oil flows in the reverse direction, the by-
To install, simply remove the engine oil filter and thread on                     pass valve in the filter assembly will prevent the oil
WESTERBEKE's remote oil filter kit as shown. Always                               from reaching the engine causing an intemal engine
install this kit with the oil filter facing down as illustrated.                  failure. If there is no oil pressure reading, shutdown.
Contact your WESTERBEKE dealer for more information.                              immediately and check the h~ose~~jrlctljrJns.


                       APPLY A THIN COAT OF CLEAN OIL TO THE O-RING WHEN
                       INSTALLING THIS KIT. THREAD THE KIT ON, THEN HAND
                       TIGHTEN AN ADDITIONAL 3/4 TURN AFTER THE O-RING
                       CONTACTS THE BASE~



                                                    THE IN CONNECTION HOSE
                                                    MUST ATTACH TO THE OUT
                                                    CONNECTION ATTHE
                                        .t;a~;----REMDITE OIL FILTER.




   THE OUT CONNECTION HOSE
   MUST ATTACH TO THE IN
   CONNECTION AT THE
   REMOTE OIL FILTER.




                                                                                                           APPLY A THIN COAT OF CLEAN OIL TO THE FILTER
                                                                                                           GASKET WHEN INSTALLING. AFTER THE FILTER
                                                                                                           CONTACTS THE BASE, TIGHTEN IT AN ADDITIONAL




                                                                  Engines & Generators

                                                                           22
                                                      TACHOMETER
TACHOMETER/HOUR METER                                                  NOTE: Current model tachometers use a coarse adjustment
The tachometerlhour meter used in propulsion engine instru-            dial to set the tachometer to the crankshaft pulley rpms. The
ment panels contains two separate electrical circuits with a           calibrating screw is then usedfor fine tuning.
common ground. One circuit operates the hour meter and the
other the tachometer. The hour meter circuit operates on 12                                                     LIGHT
volts alternator charging voltage supplied to the (+) terminal
on the back of the instrument.
                                                                                                                        JUMPER WIRE
The tachometer circuit operates on AC voltage 6-8 volts, fed
from one of the diodes in the alternator and supplied to the
tachometer input terminal while the engine is running, and
the alternator producing battery charging voltage 13.0-14.8
                                                                                                                              (+) TERMINAL
volts DC.
The following are procedures to follow when troubleshooting
a fault in either of the two circuits in a tachometerlhour                                                                (-) TERMINAL
meter.                                                                 COARSE
                                                                       ADJUSTMENT                                 TACHINP
                                                                                                                  AC VOLTAGE
Hour meter Inoperative                                                                                    CALIBRATION
Check for the proper DC voltage between (+) and (-)
terminals.                                                             IDLE SPEED ADJUSTMENT
1. Voltage present - meter is defective - repair or replace.
                                                                       & TACHOMETER CHECK (New Installation)
2. Voltage not present - trace (+) and (-) electrical con-
   nections for fault. (Jump 12 volts DC to meter (+)                  Checking the idle speed
   terminal to verify the operation.)                                  NOTE: In a new installation having new instrument panels,
                                                                       the tachometer may not always be correctly calibrated to the
Tachometer Inoperative                                                 engine's rpm. This calibration should be checked in all new
Check for the proper AC voltage between tachometer input               installations.
terminal and (-) terminal with the engine running.                     1. Warm up the engine to normal operating temperature.
1. Voltage present - attempt adjusting meter through calibra-             Remove any specks on the crankshaft pulley with a clean
   tion access hole. No results, repair or replace meter.                 cloth and place a piece of suitable reflecting tape on the
2. AC voltage not present - check for proper alternator DC                pulley to facilitate use of a photoelectric type tachometer.
   output voltage.                                                     2. Start and idle the engine.
3. Check for AC voltage at tach terminal on alternator to              3. Aim the light of the tachometer onto the reflecting tape to
   ground.                                                                 confirm the engine speed. Check the instrument panel
4. Check electrical connections from tachometer input ter-                 tachometer reading. Adjust the tachometer in the panel by
   minal to alternator connection.                                         using the instrument calibration pod as needed to bring
                                                                           the instrument panel tachometer into the same rpm
Tachometer Sticking                                                        reading as the engine.
1. Check for proper AC voltage between "tach inp." termi-              4. Adjust the idle speed if the engine speed is not within the
   nal and (-) terminal.                                                   specified value.
2. Check for good ground connection between meter (-) ter-                 Normal idle speed: 750 - 1000 rpm.
   minal and alternator.
3. Check that alternator is well grounded to engine block at
   alternator pivot bolt.
Tachometer Inaccurate
a. With a hand-held tach on the front of the crankshaft
   pulley retaining nut or with a strobe-type tach, read the
   front crankshaft pulley rpm at idle.
b. Adjust the tachometer with a small Phillips type screw-
   driver through the calibration access hole in the rear of
   the tachometer. Zero the tach and bring it to the rpm
   indicated by the strobe or hand tach. (Verify the rpm at
   idle and at high speed 41G - 3500 rpml70G - 4200 rpm).
   (Adjust the tach as needed.)




                                                             Engines & Generators
                                                                  23
                                                      WATER HEATER
WATER HEATER INSTALLATIONS                                                The pressure cap on the engine's manifold should be
                                                                          installed after the engine's cooling system is filled with
Thi~ engine is equipped with connections for the plumbing of
                                                                          coolant. Finish filling the cooling system from the remote
engme coolant to transfer heat to an on-board water heater.
                                                                          tank after the system is filled and is free of air and exhibits
The water heater should be mounted in a convenient location
                                                                          good coolant circulation. During engine operation, checking
either in a high or low position in relation to the engine, so
                                                                          the engine's coolant should be done at the remote tank and
that .the connecting hoses from the heater to the engine can
                                                                          not at the engine manifold cap. The hose connection from the
run m a reasonably direct line without any loops which might
                                                                          heater to the remote expansion tank should be routed and
trap air.
                                                                          supported so it rises continuously from the heater to the tank,
                               THERMOSTAT                                 enabling any air in the system to rise up to the tank and out
                               ASSEMBLY                                   of the system.


                                                                     DISCONNECT THE EXISTING
                                                                     HOSE AND ATTACH THE
                                                                     HEATER HOSE AT THIS




                                                                                                                   DISCONNECT THE EXISTING HOSE
                                                                                                                   AND ATTACH THE HEATER HOSE
                                                                                                                   ATTHE TEE


                                                                                        \


                                                                      DISASSEMBLE/\'
                                                                      AND REMOVE                           EITHER HOSE TO INLET
                                                                      THE EXISTING                      OUTLET FITTINGS ON THE
Hoses should rise continuously from their low point at the            CONNECTION                     DOMESTIC WATER HEATER
heater to the engine so that air will rise naturally from the
heater to the engine. If trapped air is able to rise to the heater
then an air bleed petcock must be installed at the higher fit- '
ting on the heater for bleeding air while filling the system.             NOTE: An air bleed petcock is located on the engine's
                                                                          heat exchanger. Open this petcock when filling the engine's
NOTE: If any portion of the heating circuit rises above the               coolant system to allow air in the exchanger to escape.
engine's own pressure cap, then a pressurized (aluminum)
                                                                          Close tightly after all the air is removed.
remote expansion tank (Kit #024177) must be installed in the
circuit to become the highest point. Tee the remote expansion
tank into the heater circuit, choosing the higher of the two
connections for the return. Tee at the heater; and plumb a
single line up to the tank's location and the other back to the
engine's return. 1nstall the remote expansion tank in a conve-
nient location so the coolant level can easily be checked. The
 remote expansion tank will now serve as a check and system
fill point. The plastic coolant recovery tank is not used when
the remote expansion tank kit is installed, since this tank
serves the same Junction. Remove and store the plastic
 recovery tank if it has been already installed.




                                                             Engines & Generators
                                                                     24
                                                 DC ELECTRICAL SYSTEM
  ALTERNATOR                                                                1. Start the engine.
  The charging system consists of a DC belt driven alternator               2. After the engine has run for a few minutes, measure the
  with a voltage regulator, an engine DC wiring harness, a                     starting battery voltage at the'battery terminals using a
  mounted DC circuit breaker and a battery with connecting                     multimeter set on DC volts.
  cables. Because of the use of integrated circuits (lC's), the                 a. If the voltage is increasing toward 14 volts, the alterna-
  electronic voltage regulator is very compact and is mounted                      tor is working; omit Steps 3 through 8 and go directly
  internally or on the back of the alternator.                                     to "Checking the Service Battery" on the next page.
                                                                                h. If the voltage remains around 12 volts, a problem
                                                                                   exists with either the alternator or the charging circuit;
    114 GRAY==:!i==~-__                                                            continue with Steps 3 through 8.

                                                                                                              mID
#14PINK~~~~~~~.
#14 BLUE=
                                                                                         MULTIMETER
                                                                                                              o
                                                                                                              COM




                                              SEE WIRING DIAGRAM
             ENGINE                           FOR WIRE CONNECTIONS
             GROUND                           TO OPTIONAL ALTERNATORS.

  ALTERNATOR TROUBLESHOOTING                                                    TESTING THE STARTING
                                                                                BATTERY/ALTERNATOR
   A WARNING: A failed alternator can become very                               (ENGINE RUNNING)
   hot. Do not touch until the alternator has cooled down.
  Use this troubleshooting section to determine if a problem                3. Turn off the engine. Inspect all wiring and connections.
  exists with the charging circuit or with the alternator. If it is            Ensure that the battery terminals and the engine ground
  determined that the alternator or voltage regulator is faulty,               connections are tight and clean ..
  have a qualified technician check it.
  The alternator charging circuit charges the starting battery                   A    CAUTION: To avoid damage to the battery
  and the service battery. An isolator with a diode, a solenoid                  charging circuit, never shut off the engine battery
  or a battery selector switch is usually mounted in the circuit                 switch when the engine is running!
  to isolate the batteries so the starting battery is not discharged
  along with the service battery. If the alternator is charging the         4. If a battery selector switch is in the charging circuit,
  starting battery but not the service battery, the problem is in              ensure that it is on the correct setting.
  the service battery's charging circuit and not with the alterna-
                                                                            S. Turn on the ignition switch, but do not start the engine.
  tor.
                                                                            6. Check the battery voltage. If the battery is in good condi-
  Testing the Alternator                                                       tion, the reading should be 12 to 13 volts.

   A    CAUTION: Before starting the engine make certain                                                      G2ID
   that everyone is clear of moving parts! Keep away from
   sheaves and belts during test procedures.                                                                  G~_-MULTIMETER
                                                                                                             COM



   A WARNING: When testing with a multimeter:
   DC and AC circuits are often mixed together in marine
   applications. Always disconnect a shore power cord,
   isolate DC and AC converters, and shut down the engine
   before performing DC testing. No AC tests should be                      TESTING THE
   made without a proper knowledge of AC circuits.                          ALTERNATOR VOLTAGE         e~~~~g~
                                                                            (IGNITION ON - ENGINE OFF)



                                                                Engines & Generators                     -= GROUND
                                                                       25
                                             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.
                                          MULTI METER   Cl2:5J

                                                        '0
                                                        OM




       TESTING THE STARTING
       BATTERY/ALTERNATOR                                    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 13.5 and 14.5 volts. If your alternator                    GROUND                       TESTING THE SERVICE
   is over- or under-charging, have it repaired at a reliable                                                BATTERY (ENGINE RUNNING)
   service facility.
   NOTE: Before removing the alternator for repair, use a
   voltmeter to ensure that 12 volts DC excitation is present
   at the EXC terminal if the previous test showed only bat-                A CAUTION: To avoid damaging the altemator diodes,
   tery voltage at the B output terminal.                                   do not use a high voltage tester (i.e. a megger) when
                                                                            performing tests on the altemator charging circuit.
   If 12 volts is not present at the EXC terminal, trace the
   wiring and look for breaks and poor connections.

12 VOLT DC CONTROL CIRCUIT                                                 Battery Care
The engine has a 12 volt DC electrical control circuit that is             Review the manufacturer's recommendations and then
shown on the wiring diagrams that follow. Refer to these                   establish a systematic maintenance schedule for your
diagrams when troubleshooting or when servicing the DC                     engine's starting batteries and house batteries.
electrical system.                                                         D Monitor your voltmeter for proper charging during
                                                                               engine operation.
 A CAUTION: To avoid damage to the battery charging                        D Check the electrolyte level and specific gravity with a
                                                                               hydrometer.
 circuit, never shut off the engIne battery switch while
 the engine is running. Shut off the engine battery switch,                D Use only distilled water to bring electrolytes to a proper
                                                                               level.
 however. to avoid electrical shorts when working on the
                                                                           D Make certain that battery cable connections are clean and
 engine's electrical circuit.                                                  tight to the battery posts (and to your engine).
                                                                           D Keep your batteries clean and free of corrosion.
BAnERY
The minimum recommended capacity of the battery used in
the engine's 12 volt DC control circuit is 600 - 900 Cold
Cranking Amps (CCA).                 .
                                                                             A WARNING: Sulfuric acid in lead batteries can
                                                                             cause severe bums on skin and damage clothing. Wear
                                                                             protective gear.



                                                             Engines & Generators

                                                                      26
                                        630 FOUR ENGINE
                                       WIRING DIAGRAM #39144




                         I


        sn:   HOTE   '~'
                     I
                     I
                               I

                     I       ..J


                         I

                     +~                                                               lJ.ll.J'J!.!'-~

                     ~.J:-
                     !lA!lilU
ROTE: An on-off switch
should be installed in this
circuit to disconnect the
starter from the battety in
an emergency and when
leaving the boat Twelve
volt engine starters
typically draw 200 to 300
                                                         "t;"
                                                            . +
                                                              e
                                                                   ALARM
                                                                   lutUIt
                                                                            ADMIRAL
amps when cranking. A                                                       PANEL
switch with a continuous
rating of 175 amps at 12
 VDC will nonnally serve
this function, but a switch
must never be used to
 "make n the starter circuit
                                   I




                                   :l~
                                   I




                                           t'l Itn




                                                                            CAPTAIN
                                                                            PANEL




                     r--
                                                     .....
                                                     ALT




                                                     .....
                                                      .....
                                                                                          I


                                                      .....
                                                       "T.




                                             Engines & Generators

                                                     27
                                                                                       630 FOUR ENGINE
                                                                               WIRING SCHEMATIC #39144
        .....
       12 vDe
          r-,
                         .nAU
                     n".TEI                                                                            NOTES:
  ~------~lrll~I------~Mr-----------~                                                                  I.
                                                                                                        Tllil ' _ T II PI
                                                                                                            nAiTIi. UCWIV
                                                                                                                                               IT A _AI. IEsn c IICU IT "EAlEI LOCATED WUI TIlE
                                                                                                                                                 .ILL CAUS' TH' .IUKU TO TR', All' TfiE E.I'I' WILL
              r-_....,.I,........,I_____~------------------------_+                          -----.,        SI'T _ . THE II
                                                                                                            EHIIE All IIUAU
                                                                                                                                                'I lIMIT I ' lUI' TIIAT THE  ITItUNUT PANEL. W.I .... A.D
                                                                                                                                               &YIlT _TACT IETlIEII ELECT'ICAI. 'EVICES AID                     su... n.
                                                                                                       Z. AI 01_' RITCI'                     IE IIITALLED .'TftEM TI' IAnElT AND STAiTEI TO
                                                                                                            ..._ECT TIlE I.                  AI bII"'1ICl A.D WIIEIf LEAYI  THE 100T.    A awnCH
                                                                                                            "I _COITI_
                                                                                                            WITIIA _ DICIT               . . OF 115 .....,.. AT 12 '1DC WILL 'EIVE THII ,..CTIOfi. T"U
                                                                                                                                         DIED TO _E 01 IIIAI TIE CIICUIT.
                                                                                                       I. Til , I . WIlE AT 'LUI Z I. UIUIE' AI. SHOULD IE INSULATE CA.TAI. 'AlEL OILY 
                                                                                                        TIll .IAY W'.' AT        tL~   Z II UIIUIID AID SHOULD IE  NSULATED. ADNIIAl 'AHEL OIU.


                                                                                                                               10TE:
                                                                                                                               W.I' '01 IAnEl' AnATeMMEII' WILL-MEED
                                                                                                                              . TO I' U,ADED     to   All  IAutE FlOil I 0 IAUI,



                                                                                                                                                          MITSYBISHI             50 AHP ALI
                                                                     LIFT 'UN'




        :;
                            r-+-+_I-____...                     S!-0-e-
                                                                fUlL            IWI.
                                                                                '!o'!! _




       II
                                                              0.'.
                                                              SUDlI




                                                                                                                                                 114 GRA

'1-1         ,,-, .... 11-1"-1'1-1,"-11 11-. ,.-1 11-111-11                        II.. ,                                        PRESTOLI TE\LEECE-HEV ILLE 90 AMP. ALT.
PI:t - -,....,;; ..-1'- - "-ri='II'.:; ....
                                          -,i':,ii..ii - - - - - - 'I=i'-


   'Ar                                                        TAc:NOIUUI
                                                                                            ADMIRAL
     Il1                                                               .W,                  PANEL
     a
                                                                                                                                                                     AC TAP
                                                                                                                                                                   t l . alII'




                                                                        T.
                                                                      '''Ull                                                                                           114 LT. BLU
                                                                                                                                                                     114 PINK




                                                                                                                             110 RED


'1-1                                                                              "-1                                           PRESTOl I IE 72 AMP                                   ALI

                                                                                                                             114 BRN
                                                                                            CAPTAIN
                                                                                            PANEL
                                                                        LA"'P                                                II 4 GRA
                                                                        TUT
                                                                         s.




                                                                                                                      "4 L T. BL

                                                  51 AMP               ALTERNATOR
                                                  STAMDARD ALTERMATOR ON. THE
                                                  636 Ill. &3C Ill. 716 Ill. 826 Ill.
                                                                                                                       UNIVERSAL PROPULSION
                                                  108B n. & I08en.                                                   PRESTOllTE 51 AMP ALT
                                                                                                                                  ALE CONNECTOR
                                                                                                                                 OM THIS SIDE
                                                                                                             .'4 au      ~
                                                                                                                                                        R.
                                                                                                             ITACH>l!J




                                                                                                                              OPT    IONAl AL IERNAIORS 
                                                                                                                               11'10. IUA. 1t0A. LESTEX ALTERNATORS
                                                                                                        A""'IL~IU,.9I. rML.J..!~   jJ    'is   rt lip if      UP   g    !91P     on    "I   Rae "'i5 2Ml..' _




                                                                                                Engines & Generators
                                                                                                      28
                                        DUAL OUTPUT ALTERNATORS                                      SPACER TO MOUNTING
                                                                                                     BRACKET

DESCRIPTION
Dual output and high output alternators are available as
optional equipment on most WESTERBEKE engines. These
alternators can be installed during factory assembly or as
add-on equipment at anytime.
Dual alternators can be configured to charge two banks of
batteries at the same time or, using a battery selector switch,
charge each set of batteries separately.
                                                             TO

INSTALLATION
If an optional dual alternator has already been factory installed,
simply follow the WESTERBEKE wiring diagram and the
engine installation instructions.
If the new dual alternator is being added to an existing "in-
the-boat" engine, carefully follow the alternator installation
instructions below:
1. Disconnect the alternators negative cable from the battery.
2. Remove the alternator and disconnect or tape off the
     output [positive] cable. Do not reuse.
3. Install the new alternator.
4, Attach a new heavy gauge output cable[s] from the
   alternator's output terminal [s]. Using the cable sizes
   indicated.
   LENGTH REQUIRED      UP TO 6'    #4 WIRE
                        UP TO 12'   #2 WIRE                                               DUAL OUTPUT ALTERNATOR
                        UP TO 20'   #0 WIRE                                               [CHARGING ONE BATTERY]
   [ALWAYS USE FINE STRAND CABLE]

5. Make certain that the batteries negative post ground cable
   to the engine block is the same heavy gauge as the
   positive cable.                                                        BATTERY 1

6. Mount the regulator to a flat surface in a cool dry location.
   a. Connect the black wire to the ground terminal on the
      alternator.


     A CAUTION: Do not connect any power source                    TO
     without first grounding the regulator.

   h. Plug the 2-pin connector into the alternator, make certain
      it is firmly seated.
   c. The red "battery sense" wire should be connected to the
      batteries positive [+] post [or the positive cable].
   d. The brown wire "keyed ignition" is the key circuit
    . which actuates the regulator, this wire must connect
      to a switched [+] 12 volt source. Refer to the
      WESTERBEKE WIRING DIAGRAM for the proper                                         /COWNE'CTS TO PINK AND
      connection.                                                                        BLUE LEADS. THE PINK
                                                                                         WIRE CONNECTS TO THE
   Dual Pulleys                                                                         'ALARM BUllER. THE BLUE
                                                                                         WIRE CONNECTS TO THE
   A variety of accessory pulleys for high powered and dual                              OIL PRESSURE SWITCH.
   charging alternators are available from your WESTERBEKE GROUND
   dealer. These are illustrated in the 63D FOUR PARTS MANUAL.                        DUAL OUTPUT ALTERNATOR
                                                                                      [CHARGING TWO BATTERIES]




                                                             Engines & Generators

                                                                     29
                                        DUAL OUTPUT ALTERNATORS
TROUBLESHOOTING                                                       Alternator Testing
NOTE: Before troubleshooting, make certain that the drive             The regulator is functioning properly and the batteries
belts are tight and the batteries are in good condition.              are in good condition.
Regulator Testing                                                     1. Test the voltage at the alternator plug with the engine
                                                                         otT-key on. The voltage at the alternator terminal F and
The red "battery sensing" wire A connects to the battery, it             the voltage in the plug [blue wire F] from the regulator
must always read battery voltage. If battery voltage is not              should read the same.
present, trace the wire for a bad connection.
                                                                      2. Hold a screw driver close [112"] to the alternator pulley.
The orange wire S should read 0 volts with the key off, 12                If voltage is present you should feel the magnetic field. If
volts [approximately] with the key on. If the readings are               .not, the problem may be the brushes [worn] or the rotor
incorrect, trace the wire for a bad connection.                           [open circuit].
The blue wire F supplies current to the alternator fields, its        3. Start the engine, at fast idle the output terminals should
voltage will vary depending on the battery charge or actual              indicate 14.2 volts [no load]. A reading of 12.6 would
load/rpm. The readings can vary from 4 to 12 volts with the              indicate the alternator is not performing properly.
key on, 0 volts with the key off.
                                                                         Apply a load such as an electric bilge pump, the voltage
KEY ON - NO VOLTAGE     REGULATOR IS DEFECTIVE                           should maintain at least 13.8 volts. 13 volts or less
KEY OFF - BATTERY VOLTAGE   REGULATOR IS DEFECTIVE                       indicates the alternator is faulty.
REGULATOR TEST POINTS AND PROPER VOLTAGE
                                           Engine Running
                                                                      NOTES:
Tennlnal/Color Ignition Off IgnRion On
 I Brown       o volts      2 -12 Yolts    14.2 yolts                 D When the engine is first started, it takes a few moments
 A Red         12.6  volts  12 volts       14.2 yolts                     for the alternator to "kick in" and take the load. There
 S Orange       oYolts      o Yolts        6 - 8 Yolts                   is a noticeable change in the sound of the engine and the
 F Blue         oYolts      10 -11 Yolts   4 -12 Yolts                   RPM gauge will excite.
 Alt. Output   12.6 yolts   12 yolts       14.2 volts                 D A slight whine is normal when running with a full load
                                                                         on the alternator.
                                                                      D When the alternator is producing high amperage, it will
                                                                         become very hot.
                                                                      D When replacing the alternator drive belts, always
                                                                         purchase and replace dual belts in matched pairs.




                                                            Engines & Generators

                                                                 30
                                              ENGINE TROUBLESHOOTING
The following troubleshooting table describes certain problems                   NOTE: The engine's electrical system is protected by a 20
relating to engine service, the probable causes of these prob-                   ampere manual reset circuit breaker located on a bracket at
lems, and the recommendations to overcome these problems.                        the back of the engine. The preheat solenoid is mounted on
                                                                                 the same bracket.

               Problem                              Probable Cause                                        VerificationjRemedy
 No panel indications; fuel solenoid       1. Battery switch not on.                     1. Check switch and/or battery connections.
 or fuel pump is not working (key switch
 is on and PREHEAT button is depressed).   2. 20-amp circuit breaker tripped.            2. Reset breaker; if breaker trips again, check preheat solenoid
                                                                                            circuit and check circuit for shorts to ground.
                                           3. 10-amp breaker tripped on                  3. Check the voltage both at and after the breaker on the
                                              preheat solenoid                              preheat solenoid.
                                           4. Loose battery connections.                 4. Check (+) connection to starter solenoid and (-) connection to
                                                                                            engine ground stud. Check battery cable connections.
                                           5. Preheat solenoid not operating.            5. Check solenoid "S" terminal for voltage.
 START button is depressed, no starter     1. Connection to solenoid faulty.             1. Check connection.
 engagement.
                                           2. Gear shift not in neutral.                 2. Gear shift must be in neutral (see NEUTRAL SWITCH under
                                                                                            HURTH HSW TRANSMISSIONS).
                                           3. Faulty switch.                             3. Check switch with ohmmeter.
                                           4. Faulty solenoid.                           4. Check that 12 volts are present at the solenoid connection.
                                           5. Loose battery connections.                 5. Check battery connections.
                                           6. Low battery.                               6. Check battery charge state.
 START button is depressed; panel          1. Poor connections to fuel solenoid.         1. Check connections.
 indications OK; starter solenoid OK;
 fuel solenoid not functioning.            2. Defective fuel solenoid.                   2. Check that 12 volts are present at the (+) connection on the
                                                                                            fuel run solenoid.
 Engine cranks, but does not               1. Faulty fueling system.                     1. Check that fuel valves are open.
 start, fuel solenoid energized.
                                                                                         1a. Check for air in fuel system. Bleed air from fuel system.
                                                                                         1b. Fuel filters clogged. Replace filters and bleed air from
                                                                                             fuel system.
                                           2. Preheat solenoid faulty.                   2. Check solenoid.
                                           3. Low battery power.                         3. Switch to combine house and start batteries.
                                                                                         3a. Replace batteries.
  Engine can't be stopped.                 1. Faulty DC alternator.                      1. Remove Exc. connection at alternator; repair alternator.
                                           2. Disconnect fuel shut-off cable.            2. Check connection at shut-off lever. Pull lever back to close
                                                                                            offthe fuel
                                           3. Fuel run solenoid will not de-energize.    3. Manually disconnect the 12 volt connection to the fuel run
                                                                                            solenoid at the injection pump.
  Battery runs down.                       1. Oil pressure switch.                       1. Observe if gauges and panel lights are activated when engine
                                                                                            is not running. Test the oil pressure switch.
                                           2. High resistance leak to ground.            2. Check wiring. Insert sensitive (0 - .25 amp) meter in battery
                                                                                            lines. (Do not start engine.) Remove connections and replace
                                                                                            after short is located.
                                           3. Low resistance leak.                       3. Check all wires for temperature rise to locate the fault.
                                           4. Poor battery connections.                  4. Check cable connections at battery for loose connections,
                                                                                            corrosion
                                           5. DC alternator not charging                 5. Check connections, check belt tension, test alternator. See
                                              (tachometer not operating).                   DC ELECTRICAL SYSTEM/ALTERNATOR.
  Battery not charging                     1. DC charge circuit faulty.                  1. Perform DC voltage check of generator charging circuit. See
                                                                                            Testing the Battery Charging Circuit.
                                           2. Alternator drive.                          2. Check drive belt tension; alternator should turn freely. Check
                                                                                            for loose connections. Check output with voltmeter. Ensure 12
                                                                                            volts are present at the Exc. terminal.


                                                                                                                                                 (continued)


                                                                     Engines & Generators
                                                                            31
                                          ENGINE TROUBLESHOOTING
              Problem                            Probable Cause                                         VerificationJRemedy
 Engine slows and stops.               1. Fuel lift pump failure.                      1. Fuel lift pump should make a distinct ticking sound. Replace
                                                                                          pump with spare.
                                       2. Switches and/or wiring loose                 2. Inspect wiring for short circuits and loose connections.
                                          or disconnected.                                Inspect switohes for proper operation.
                                       3. Fuel starvation.                             3. Check fuel supply, fuel valves, fuel lift pump.
                                       4. 20 Amp circuit breaker tripping.             4. Check for high DC amperage draw during operation.
                                                                                          Ensure breaker is not overly sensitive to heat which would
                                                                                          cause tripping.
                                       5. Exhaust system is restricted.                5. Check for blockage, collapsed hose, carbon buildup at
                                                                                          exhaust elbow.
                                       6. Water in fuel.                               6. Pump water from fuel tank(s); change filters and
                                                                                          bleed fuel system.
                                       7. Air intake obstruction.                      7. Check air intake filter cartridge.
 Engine overheats/shuts down.          1. Raw water not circulating.                   1. Raw water pump failure. Check impeller - replace.
                                       2. Coolant not circulating.                     2. Obstruction at raw water intake or raw water filter.
                                                                                       2a. Thermostat - remove and test in hot water.
                                                                                           Replace thermostat.
                                                                                       2b. Loss of coolant - check hoses, hose clamps, drain plug, etc.
                                                                                           for leaks.
                                                                                       2c. Broken or loose belts - tighten/replace.
                                                                                       2d. Air leak in system; run engine and open the pressure cap to
                                                                                           bleed air. Add coolant as needed.
 Engine alarm sound pulsates.          1. Loss of oil.                                 1. Check dipstick, look for oil leaks at oil filter and at
                                                                                          oil drain hose connection.
                                       2. Oil pressure switch.                         2. Replace oil pressure switch.
 Engine alarm sounds continuously.     1. Engine coolant.                              1. Check engine coolant level.
                                       2. High temperature switch opens at .           2. Check for satisfactory operation with switch bypassed,
                                          too Iowa temperature.                           check with ohmmeter, replace if faulty.
 Exhaust smoke problems                1. Blue smoke.                                  1. Incorrect grade of engine oil.
                                                                                       1a. Crankcase is overfilled with engine oil (oil is blowing out
                                                                                           through the exhaust).
                                       2. White smoke.                                 2. Engine is running cold.
                                                                                       2a. Faulty injector or incorrect injector timing.
                                       3. Black smoke.                                 3. Improper grade of fuel.
                                                                                       3a. Fuel bum incomplete due to high back-pressure in exhaust or
                                                                                           insufficient air for proper combustion (check for restrictions in
                                                                                           exhaust system; check air intake).
                                                                                       3b. Improperly timed injectors or valves, or poor compression.
                                                                                       3c. Lack of air - check air intake and air filter. Check for proper
                                                                                           ventilation.
                                                                                       3d. Overload.

                           TROUBLESHOOTING COOLANT TEMPERATURE AND OIL PRESSURE GAUGES
If the gauge reading is other than what is normally indicated                  If both of the above gauge tests are positive, the gauge is
by the gauge when the instrument panel is energized, the first                 undoubtedly OK and the problem lies either with the
step is to check for 12 volts DC between the ignition (B+)                     conductor from the sender to the gauge or with the sender.
and the Negative (B-) terminals of the gauge.                                  If either of the above gauge tests are negative, the gauge is
Assuming that there is 12 volts as required, leave the                         probably defective and should be replaced..
instrument panel energized and perform the following steps:                    Assuming the gauge is OK, check the conductor from the
1. Disconnect the sender wire at the gauge and see if the                      sender to the sender terminal at the gauge for continuity.
      gauge reads zero, which is the normal reading for this                   Check that the engine block is connected to the ground.
      situation.                                                               Some starters have isolated ground terminals and if the
2. Remove the wire attached to the sender terminal at the                      battery is connected to the starter (both plus and minus
      sender and connect it to ground. See if the gauge reads                  terminals), the ground side will not necessarily be connected
    . full scale, which is the normal reading for this situation.              to the block.
                                                     -.         WESTERBEKE
                                                                 Eng/nes & Generators

                                                                          32
                                        HURTH HBW TRANSMISSIONS
INITIAL OPERATION                                                       OPERATING TEMPERATURE
All HBW marine transmissions are test-run on a test stand               The maximum permissible ATF temperature should not exceed
with the engine at the factory prior to delivery. For safety            2300 (1100 ). This temperature can only be reached for a short
reasons the fluid is drained before shipment.                           time.
Fill the gearbox with Automatic Transmission Fluid
(DEXTRON III). The fluid level should be up to the index                 A CAUTION: If the transmission fluid temperature is
mark on the dipstick. To check the fluid level, just insert the          too high, stop the engine immediately and check the
dipstick, do not screw it in. Screw the dipstick into the case           transmission fluid.
after the fluid level is checked and tighten. Do not forget the
sealing ring under the hexhead of the dipstick. Check for
leaks and make a visual inspection of the coupling, oil cooler          LOCKING THE PROPELLER
and hoses, and shift cables.                                            Locking of the propeller shaft by an additional brake is not
                                                                        required: use the gear shift lever position opposite your direc-
                                                                        tion of travel for this purpose. Never put the gear shift in the
                                                                        position corresponding to the direction of travel of the boat.
                                                                        WHEN UNDER SAIL OR BEING TOWED
                                                                        Rotation of the propeller without load, such as when the boat
                                                                        is being sailed, being towed, or anchored in a river, as well as
                                                                        operation of the engine with the propeller stopped (for
                                                                        charging the battery), will have no detrimental effects on the
                                                                        transmission
                                                                        DAILY OPERATION
                                                                        o     Check the transmission fluid.
                                                                        o     Visually check the gear shift level linkage and
                                                                              transmission.
                                                                        o     Start the engine in neutral, allowing a few minutes at
                                                                              idle to warm the fluid.
                                                                        o     Shift into gear.
Change the fluid for the first time after about 25 hours of         NOTE: Too Iowan idle speed will produce a chattering noise
operation, then every 300 operating hours or at least once a        from the transmission gear and damper plate. In such cases
year or at winterizing.                                             the idle speed should be increased
Removing the fluid                                                      For additional information refer to the following text in this
                                                                        Transmission Section: SHAFT COUPLINGS, MAINTE-
Push a suction pump hose down through the dipstick hole to
                                                                        NANCE AND TRANSMISSION TROUBLESHOOTING.
the bottom of the housing and suck out the fluid. (If space
allows, use the transmission drain). Remove the drain plug
from the bottom of the transmission and allow the fluid to
                                                                         --
                                                                                  HBW TRANSMISSIONS SPECIFICATIONS
                                                                                  -       --     -   -
drain into a container, then reinstall the plug with its sealing
washer. Wipe down the transmission and properly dispose of               General                     (Hurth Standard Transmission) Case-
the used fluid. After running the engine, shut down and                                              hardened helical gears, with a servo
recheck the fluid level.                                                                             operated multiple disc clutch.
                                                                         Gear ratio (optional)       2.63 : 1 (HBW 150A - 3R)
DRAIN PLUG TORQUE 20 . 25 ft/Ibs
                                                                                                     2.99 : 1 (HBW 150v - 3R)
                                                                                                     2.74: 1 (HBW 250 - 3R)
NOTE : When changing the fluid, take care not to lose the
                                                                         Lubricating Fluid           ATF - type A or Dextran - /I or 11/
drain plug sealing washer. The drain plug will leak without
this sealing washer.                                                     Transmission Sump           HBW 150A 0.59 U.S. qts (0.561 liters)
                                                                         Capacity                    HBW 150V 1.11 U.S. qts (1.05 liters)
                                                                                                     HBW 250       0.75 U.S. qts (0.79 liters)
  A WARNING: Never pull out the dipstick while the                       Propeller ShaH              Right hand - standard
  engine is running. Hot fluid will splash from the dip-                 Direction of Rotation       transmission
  stick hole. This could cause severe burns.




                                                           Engines & Generators
                                                                   33         -
                                               HURTH TRANSMISSIONS
 DESCRIPTION                                                              NOTE: When installing the transmission, make certain that
 The infonnation below is specific to the HBW                             shifting is not impeded by restricted movability of the
 Transmissions, the TRANSMISSION TROUBLESHOOTING                          Bowden cable or rod linkage, by unsuitably positioned guide
 SECTION applies to all models.                                           sheaves, too small a bending radius, etc. In order to mount a
                                                                          support for shift control cable connections, use the two
 CONNECTION OF GEAR BOX WITH PROPELLER                                    threaded holes located above the shift cover on top of the
 HBW recommend a flexible connection between the trans-                   gear housing. Refer to the WESTERBEKE parts list.
 mission gearbox and the propeller shaft if the engine is                 CONTROL CABLES
 flexibly mounted, in order to compensate for angular
 deflections. The installation of a special propeller thrust bear-        The transmission is suitable for single lever remote control.
 ing is not required, since the propeller thrust will be taken by         Upon loosening the retaining screw, the actuating lever can
 the transmission bearing, provided the value specified under             be moved to any position required for the shift control
 SPECIFICATIONS is not exceeded. However, the output                      elements (cable or rod linkage). Make certain that the
 shaft should be protected from additional loads. Special                 actuating lever does not contact the actuating lever cover
 care should be taken to prevent torsional vibration. When                plate: the minimum distance between lever and cover should
 using a universal joint shaft, make certain to observe the               be O.Smm.
 manufacturers instructions.                                              The control cable should be arranged at a right angle to the
 Even with the engine solidly mounted, the use of a flexible              actuating lever when in the neutral position. The neutral posi-
 coupling or *DRIVESAVER" will reduce stress in the gear-                 tion of the shift operating lever on the control console should
 bo::, bearings caused by hull distortions, especially in wooden          coincide with the neutral position of the actuating lever.
 boats or where the distance between transmission output                  The shifting travel, as measured at the pivot point of the
 flange and stem gland is less than about 32 in (812 mm).                 actuating lever, between the neutral position and end
                                                                          pO?itions Aand Bshould be at least 35mm for the outer pivot
                                                                          pomt and 30mm for the inner pivot point.
                                               HURTH HBW .                A greater amount of shift lever travel is in no way
                                                                          detrimental and is recommended. However, if the lever
                                                                          travel is shorter, proper clutch engagement might be impeded
                                                                          which, in tum, would mean premature wear, excessive heat
                                                                          generation and clutch plate failure. This would be indicated
                                                                          by slow clutch engagement or no engagement at all.
                                                                          NOTE Check for proper actuating lever travel at least each
                                                                          season.
                                                                                                         NEUTRAL
                                                                          LEVER TRAVEL                      N
                                                                                         FORWARO
                                                                                               B
                                                                      CHECK FOR EQUAL TRAVEL
                                                                      FROM NEUTRAL THRU
                                                                      FORWARD AND REVERSE



                                                                      SHIFT CO
                                                                      CABLE


                                                                                                                                ACTUATING
                                                                                                                                LEVER
                                    HURTH HBW
                                    COOLER--



   A CAUTION: The position of the mechanism behind
   the actuating lever is factory-adjusted to ensure equal
   shift lever travel from neutral position A and B. If                                       ACTUATING-
                                                                                              LEVER
   this mechanism is in any way tampered with, the
   transmission warranty will be void.                                                                             COVER

*"DRIVESAVER" is a product of Globe Marine, Rockland, MA.


                                                            Engines & Generators                      0.02 in (0.5mm)
                                                                                                      MINIMUM CLEARANCE
                                                                     34
                                             HURTH TRANSMISSIONS
 Operating Temperature                                                     MAINTENANCE
                                                                           Transmission maintenance is minimal. Keep the exterior
   A CAUTION: If the transmission fluid temperature is                     housing clean, check the fluid level as part of your regular
                                                                           routine, and change the fluid every 300 operating hours.
   too high. stop the engine immediately and check the                     Periodically inspect the transmission and the cooler for leaks
   transmission fluid.                                                     and corrosion. Lubricate the cable connections.

 Normal operating temperature of the transmission fluid
                                                                           Lay-up/Winterize
 should be in the range of 122F (50C) to 212F (l00C). A                Storage requires special care. Follow these procedures:
 maximum temperature of 266F (130C) may be only                          o   Drain water from the transmission oil cooler and replace
 reached for a short time.                                                     with a proper mixture of antifreeze coolant.
 Make certain there is enough space around the transmission                    NOTE: This operation will normally occur when the
 to provide good ventilation and cooling.                                      engine raw water cooling system is properly winterized.
 TRANSMISSION COOLER                                                       o   Clean up the transmission and touch up unpainted areas
 Coolers are standard equipment for the HBW 100, 125, 150,                     (use heat resistant paint).
 150A, 150V, and the 250 (no cooler is necessary for the                   o   Fill the transmission with Dextron III ATF fluid to
 HBW 35 and 50).                                                               prevent internal corrosion (extended storage only, twelve
 The cooler is a separate part of the transmission which                       months or more).
 prevents any possibilities of coolant diluting the transmission           o   Loosen attaching hardware from the transmission output
 fluid. However, the continued flow of coolant thru the cooler                 flange and propeller shaft coupling flange before
 will, in time, erode the inside of the cooler causing external                removing the boat from the water. Separate the flanges
 leaks.                                                                        and spray with lubricant.
 A transmission cooler may last ten years or more but, in
 some circumstances, depending on operating hours, tropical
                                                                           o   Inspect the gear shift cable, linkage, and attachments.
                                                                               Look for corrosion of the end fittings, cracks or cuts in
 waters, maintenance, etc. it might only last half that time.                  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 should be topped offwith
                                                                               fluid to prevent internal corrosion. Reduce the fluid level
                                                                               before putting the engine back into service
                                                                           For additional information contact:
                                                                                 HURTH MARINE GEAR
TRANSMISSION COOLER                                                              ZF Industries
                                                                                 3131 S.w. 42nd Street
                                                         INSPECT FOR
                                            ,l'tHIULII(;IIILLl
                                             EROSION AND LEAKAGE                 Fort Lauderdale, FL 33312
                           TRANSMISSION                                          Tel.: (954) 581-4040




                                                                 Engines & Generators

                                                                      35
                       BORG WARNER VELVET DRIVE TRANSMISSION
                                                 OPTIONAL TRANSMISSION
                                                                      SHIFT LEVER POSITION
                                                                      The gear shift control mechanism and linkage must position
                                                                      the actuating lever on the transmission exactly in Forward
                                                                      (F), Neutral (N), and Reverse (R) shifting positions. A detent
                                                                      ball located behind the transmission lever must work freely
                                                                      to center the lever in each position. The gear shift positions at
                                                                      the helm must be coordinated with those of the Velvet Drive
                                                                      actuating lever through shift mechanism adjustments. An
                                                                      improperly adjusted shift mechanism can cause damage to
                                                                      the transmission. The shifting mechanism and transmission
                                                                      actuating lever should be free of dirt and well lubricated to
                                                                      ensure proper operation.

                                                                      Shifting Into Gear
                                                                      Place the gear shift in Neutral before starting the engine.
                                                                      Shifting from one selector position to another selector posi-
                                                                      tion may be made at any time below 1000 rpm and in any
         FROM COOLER                                                  order. Shifts should be made at the lowest practical engine
         CONNECTION                                                   speed. Start the engine and set the throttle at idle speed;
                                                                      allow the transmission fluid to warm up for a few minutes.
SHIPMENT
For safety reasons, the transmission is not filled with               Neutral
transmission fluid during shipment and the selector lever             Move the gear shift lever to the middle position. You should
is temporarily attached to the actuating shaft.                       feel the detent. This centers the actuating lever on the trans-
Before leaving the WESTERBEKE plant, each transmission                mission. With the control in this position, hydraulic power is
undergoes a test run, with Dextron III ATF transmission               completely interrupted and the output shaft of the transmis-
fluid. The residual fluid remaining in the transmission after         sion does not turn.
draining acts as a preservative and provides protection
against corrosion for at least one year if properly stored.
                                                                      NOTE: Some transmissions are equipped with a neutral safety
                                                                      switch Unless the transmission actuating lever is perfectly
TRANSMISSION FLUID                                                    aligned in neutral, the engine starter will not activate.
Check the transmission fluid level on the dipstick. If the
transmission has not been filled, fill with Dextron III and           Forward
continue to use this fluid. During the first 25 hours of              Move the gear shift lever to the forward position. You should
operation, keep a lookout for any leakage at the bell housing,        feel the detent. The actuating lever on the. transmission is in
output shaft and transmission cooler. This fluid should be            the forward position. The output shaft and the propeller shaft
changed after the first 25 hours and approximately every              move the boat in a forward direction.
300 operating hours thereafter and/or at winter lay-up.
                                                                      Reverse
                                                                      Move the gear shift lever to the reverse position. You should
 A CAUTION: Be certain the transmission is filled                     feel the detent. The actuating lever on the transmission is in
 and the correct size cooler is properly installed before             the reverse position. The output shaft and the propeller
                                                                      should move the boat in a reverse direction (astern).
 starting the engine.
                                                                      NOTE: Moving the transmission actuating lever from Neutral
                                                                      Position to Forward is always toward the engine. Reverse is
                                                                      always away from the engine. If boat moves backwards with
                                                                      the gear shift control in the forward position, shut off the
                                                                      engine! This problem may be a result of incorrect movement
                                                                      of the actuating lever by the gear shift lever.




                                                         Engines & Generators

                                                                 36
                        BORG WARNER VELVET DRIVE TRANSMISSION
                                                                       D Clean off the transmission and properly dispose of the
                                                                           used fluid.
                                                                       D Refill the transmission with DEXTRON III ATF. The
                                                                           quantity will vary depending on the transmission model
                                                                           and the installation angle. Fill through the dipstick hole.
                                                                       D   Check the dipstick for the proper fluid level.
                                                                       D   Replace the oil filler cap and dipstick. (Press the dipstick
                                                                           into place and tum clockwise until finger-tight.)
                                                                       D   Run the engine, shutdown and recheck the fluid level.
 FORWARD                     NEUTRAl                REVERSE
      TRANSMISSION ACTUATING LEVER POSITIONS
                                                                        A    WARNING: Never pullout the dipstick while the
                                                                        engine is running. Hot fluid will splash from the dipstick
DAILY OPERATION                                                         hole. This could cause severe burns.
D Check the transmission fluid.
D Visually check the gear shift linkage and transmission.              Oil Capacity
D Start the engine in neutral. Allow a few minutes at idle             Approximately 2.5 quarts (2.36 liters) will fill most transmis-
    for the fluid to warm.                                             sions to the oil level fill mark on the dipstick. Many variables
    NOTE: Too Iowan idle speed will produce a chattering               have a direct relationship to the oil capacity. Additional oil
    noise from the transmission gear and damper plate. In              will be required to fill the oil cooler and the cooler lines. The
    such cases the idle speed should be increased.                     angle of installation will make a difference in the quantity of
                                                                       oil required to fill the transmission.
D   Shift into gear.


 A CAUTION: Shifting gears above 1000 rpm can
 cause damage to the engine damper plate. Pulling the                  DIPSTlCK----~B                         FLUID LEVEL
 throttle back to idle when shifting gears will save wear              MAKE CERTAIN THE
                                                                       RUBBER SEAL IS
 on the transmission and the damper plate.                             SCREWED                                  FUU
                                                                       TIGHT TO THE
                                                                       HANDLE
INSPECTION
D Visually check for oil leaks at the hydraulic connections.
    Check for wear on the hydraulic lines and replace if
    worn.
D   Lubricate the detent ball and shift cable attachments.
D   Inspect the shift linkage.
                                                                       Oil Temperature
D   Inspect the transmission bolts; retorque if necessary.
                                                                       A maximum oil temperature of 190F (88C) is recom-
                                                                       mended. Discontinue operation anytime sump oil tempera-
 A CAUTION: Clutch failure will occur if the transmis-                 ture exceeds 230F (110C).
 sion shift lever does not fully engage the detent ball                PRESSURE GAUGE
 positiOns.                                                            An optional mechanical pressure gauge can be installed at
                                                                       the control panel to constantly monitor the pressure of the
CHANGING THE TRANSMISSION FLUID                                        transmission fluid. A normal reading at 2000 rpm in forward
After the initial 50 hour change, the transmission fluid should        gear should indicate 95 - 120 Ib-in2 (6.7 - 8.4 kg-cm2) and be
be changed at every 300 operating hours thereafter or at win-          constant.
ter haul-out. However, the fluid must be changed whenever it
becomes contaminated, changes color, or smells rancid.
D Remove the oil filler cap and dipstick.
D Remove the oil cooler return line and allow the oil to
    drain into a container.
D Reconnect the oil cooler return line.
D   Use a suction pump to remove the transmission oil
    through the filler cap/dipstick hole.



                                                             Engines & Generators

                                                                  37
                        BORG WARNER VELVET DRIVE TRANSMISSION
MAINTENANCE                                                            WARRANTY NOTES
Transmission maintenance is minimal. Keep the exterior                 Service manuals are available from your BORG WARNER
housing clean, check the fluid level as part of your regular           dealer.
routine, and change the fluid every 300 operating hours.               For assistance, contact:
Periodically inspect the transmission and the cooler for leaks               BORG WARNER
and corrosion. Make certain the air vent is clear and when                   200 Theodory Rice Blvd.
checking the fluid level look for signs of water contamination               New Bedford, MA 02745
(fluid will appear as strawberry cream).                                     Tel.: (508) 979-4881
Lay-up/Winterize                                                       BORG WARNER is aware of the shock loads that can be
                                                                       placed on its gears as the result of mechanical propeller oper-
Storage requires special care. Follow these procedures:
                                                                       ation or fully reversing of the propeller blades while shifting.
o   Drain the water from the transmission oil cooler and               Therefore torque loads and directional changes should be
    replace it with a proper mixture of antifreeze coolant.            made at low engine speeds. If it is found that a failure was
    NOTE: This operation will usually occur when the engine            caused by a shock load, any warranty claim will be denied.
    raw water cooling system is properly winterized.
o   Clean up the transmission and touch-up unpainted areas              A CAUTION: System-related noises or vibrations can
    (use heat resistant paint).                                         occur at low engine speeds which can cause gear rattle
o   Fill the transmission with Dextron III ATF fluid to                 resulting in damage to the engine and/or transmission.
    prevent internal corrosion. (Extended storage only,                 BORG WARNER is not responsible for total system-
    12 months or more).                                                 related torsional vibration of this type.
o   Loosen attaching hardware from the transmission
    output flange and propeller shaft coupling flange before           If any problems occur with the transmission, see
    removing the boat from the water. Separate the flanges             TRANSMISSION TROUBLESHOOTING in this manual.
    and spray with lubricant.
o   Inspect the gear shift cable, linkage, and attachments.
    Look for corrosion of the end fittings, cracks or cuts in
    the conduit, and bending of the actuator rods. Lubricate
    all moving parts.
    NOTE: If the transmission is to be stored for a long time
    (twelve months or more), it should be topped off with
    fluid to prevent internal corrosion. Reduce the fluid level
    before putting the engine back into service.


OIL COOLERS
The continued flow of raw water through the cooler will, in            If water has contaminated the fluid, the transmission fluid
time, erode the inside of the cooler causing cross leaks to            needs to be cleaned out and replaced with fresh fluid. It will
occur. These internal cooler leaks will cause one of the               take several fluid changes to get rid of the contamination.
following two problems:                                                Check your dipstick each time until it appears as pure trans-
                                                                       mission fluid. Change the transmission filter and clean out
1. Transmission fluid will leak into the flow of raw water             the fluid lines that connect to the cooler.
    and be discharged overboard through the engine exhaust.
    A loss of transmission fluid will cause the transmission to        If the transmission fails to shift properly, it will most likely
    fail.                                                              need the attention of a qualified transmission service facility.
2. The raw water will leak into the transmission fluid caus-           A transmission cooler may last ten years or more but, in
    ing an increase in transmission fluid. This contaminated           some circumstances, depending on operating hours, tropical
     fluid will appear as strawberry cream. The transmission           waters, maintenance, etc. it might only last half that time.
    will eventually fail.                                              WESTERBEKE recommends having a spare cooler aboard.
Either case requires an immediate response:
1. Install a new oil cooler.
2. Refill the transmission with DEXTRON III ATF.




                                                          Engines & Generators

                                                                  38
                                TRANSMISSION TROUBLESHOOTING [HURTH]
CONTROL CABLES                                                                        A new cable and perhaps a new linkage mechanism may be
                                                                                      needed. While the cable is loose, shift the transmission in and
The majority of transmission difficulties arise as a result of
                                                                                      out of gear using the lever on the side of the transmission to
improper clutch adjustments (manual transmissions) or
                                                                                      make sure there's no binding inside the case.
problems with control cables (hydraulic transmissions)
rather than from problems with the transmission itself.                               If the transmission passes these tests, crank the engine and
                                                                                      have a helper put it in forward and reverse while you observe
HURTH clutches, in particular, are very sensitive to improper
                                                                                      the propeller shaft; if the shaft isn't turning, the transmission
cable adjustments.
                                                                                      needs professional attention. If it does tum but there's no
If you experience operating problems with the transmission,                           thrust, check to see you still have a propeller on the end of
shut the engine down. First check the transmission-fluid                              the shaft or, if you have a folding or feathering propeller, that
level, then have a helper move the cockpit shift lever through                        it isn't stuck in the "no pitch" position.
the full range - from neutral to full forward, back to neu-
tral, into full reverse, and back to neutral - while you                              NOTE: lfyou suspect a major problem in your transmission,
observe the actuating lever on the transmission. If the remote                        immediately contact your WESTERBEKE dealer or an
is stiff to operate, break the cable loose at the transmission                        authorized marine transmission facility.
and try again. If it is still stiff, check the cable for kinks or
excessively tight bends, and check any linkage for binding.

 Problem                                                Probable Cause                                          Verification/Remedy
 Transmission gears cannot be shifted.        1. Actuating lever is loose.                       1. Tighten damping bolt on actuating lever.
 Fails to move into gear.
                                              2. Shifting cable is broken, bent or               2. Check the cable, reattach or replace.
                                                 unattached. Cable radius is too severe.
                                              3. Actuating lever is binding against the.         3. Detach the shift cable and operate the actuating lever by
                                                 cover plate.                                       hand. Clearance should beO.02 in (0.5mm).
 Transmission shifts into gear, but           1. Output coupling is not turning.                 1. Transmission needs professional attention.
 fails to propel the boat.
                                              2. Propeller shaft is not turning.                 2. The coupling bolts are sheared or the coupling is slipping
                                                 Output coupling is turning.                        on the propeller shaft. Tighten or replace set screws, keys,
                                                                                                    pins and coupling bolts as necessary.
                                              3. Output coupling and                             3. Inspect the propeller; it may be missing or damaged.
                                                 propeller shaft are turning.                       A folding propeller may be jammed. A variable pitch
                                                                                                    propeller may be in "no pitch" position.
 Delay of gear engagement or engages          1. Actuating lever travel Nto B not.               1. Adjust cover plate until the lever is exact mid-position.
 only after an increase in speed.                equal to Nto A.                                    See ACTUATING LEVER TEXT AND DIAGRAM.
                                              2. Actuating lever travel is insufficient.         2. Check shift lever cable length. See ACTUATING LEVER
                                                                                                    DIAGRAM.
                                              3. Actuating lever is binding against cover plate. 3. Check clearance, adjust if necessary.
 Transmission noise becomes louder.           1. Damage starting on flexible coupling due        1. Check alignment, inspect flexible coupling. If noise persists,
                                                 to wear or fatigue, possibly due to misalign-      inspect the darn per plate between the transmission and the
                                                 rnent between engine and transmission.             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.
 Chattering transmission noise,               1. The engine or propeller generates torsional     1. Mount a flexible coupling with another stiffness factor
 mainly at low engine speed.                     vibrations in the drive unit which produces        between the engine and transmission; a coupling with
                                                 a "chattering" noise in the transmission.          a higher stiffness factor might be sufficient.
                                                                                                 2. Inspect the damper plate between the engine and the
                                                                                                    transmission. Replace if necessary.
 Boat fails to attain specified max. speed.   1. Operating temperature is high.                  1. Wrong type of fluid. Use ATF Dextron III, check fluid level.
                                              2. Operating without cooling.                      2. Check cooler. Inspect coolant hoses and coolant flow.
  Oil Leakage.                                1. Corrosion at radial sealing ring and shaft.     1. Transmission needs professional attention.
                                                 Darnage sealing ring.
                                              2. Misalignment of output flanges.                 2. Check alignrnent. Must be within 0.003 in (O.OBmm).




                                                                       Engines & Generators

                                                                                39
                                      TRANSMISSION TROUBLESHOOTING
               Problem                           Probable Cause                                         Verification/Remedy
 Chattering transmission noise,         1. The engine or propeller generates torsional    1. Mount a flexible coupling with another stiffness factor
 mainly at low engine speed.                vibrations in the drive unit which produces      between the engine and transmission; a coupling with
                                            a "chattering" noise in the transmission.        a higher stiffness factor might be sufficient.
 Transmission shifts into gear, but     1. Output coupling is not turning.                1. Transmission needs professional attention.
 fails to propel the boat.
                                        2. Propeller shaft is not turning.                2. The coupling bolts are sheared or the coupling is slipping
                                           Output coupling is turning.                       on the propeller shaft. Tighten or replace set screws, keys,
                                                                                             pins and coupling bolts as necessary.
                                        3. Output coupling and                            3. Inspect the propeller; it may be missing or damaged.
                                           propeller shaft are turning.                      A folding propeller may be jammed.
                                                                                             Variable pitch propeller may be in "no pitch" position.

NOTE: If you suspect a major problem in your transmission,
immediately contact your WESTERBEKE dealer or an
authorized marine transmission facility.




                                                              Engines & Generators

                                                                     40
                                              ENGINE ADJUSTMENTS
DRIVE BELT ADJUSTMENT                                                   FUEL INJECTORS
Proper inspection, service and maintenance of the drive belts           In case of severe vibrations and detonation noise, have the
is important for the efficient operation of your engine (see            injectors checked and overhauled by an authorized fuel
Drive Belts under MAINTENANCE SCHEDULE).                                injection service center. Poor fuel quality, contaminants and
Drive belts must be properly tensioned. Loose drive belts               loss of positive fuel pressure to the injection pump can result
will not provide proper alternator charging and will                    in injector faults. Since fuel injectors must be serviced in a
eventually damage the alternator. Drive belts that are too              clean room enviroment, it is best to carry at least one extra
tight will pull the alternator out of alignment and/or cause            injector as a spare should a problem occur.
the alternator to wear out prematurely. Excessive drive belt            Before removing the old injector, clean the area around the
tension can also cause rapid wear of the belt and reduce the            base of the injector to help prevent any rust or debris from
service life of the coolant pump's bearing. A slack belt or the         falling down into the injector hole. If the injector will not lift
presence of oil on the belt can cause belt slipping, resulting          out easily and is held in by carbon build-up or the like, work
in high operating temperatures and tachometer variations.               the injector side-to-side with the aid of the socket wrench to
The drive belt is properly adjusted if the belt can be deflected        free it, and then lift it out.
no less than 3/8 inch (lOmm) and no more than 112 inch                  The injector seats in the cylinder head on a copper sealing
(12mm) as the belt is depressed with the thumb at the mid-              washer. This washer should be removed with the injector and
point between the two pulleys on the longest span of the belt.          replaced with a new washer when the new injector is
A spare belt or belts should always be carried on board.                installed.
                                                                        INJECTOR TO CYLINDER HEAD TIGHTENING TORQUE
 A WARNING: Never attempt to check or adjust the                        40  4 H-Ib (5.5  0.5 kgf-m)
 drive belt's tension while the engine is in operation.

Adjusting Belt Tension
1. Loosen the alternator adjusting strap bolt and the base
   mounting bolt.
2. With the belt loose, inspect for wear, cracks and frayed
   edges.
3. Pivot the alternator on the base mounting bolt to the left
   or right as required, to loosen or tighten.
4. Tighten the base mounting bolt and the adjusting strap
   bolt.
5. Run the engine for about 5 minutes, then shut down and
   recheck the belt tensions.




                                                          Engines & Generators

                                                                   41
                                                  ENGINE ADJUSTMENTS
                                  NOTE: WESTERBEKE recommends that the following engine adjust-
                                  ments be performed by a competent engine mechanic. The information
                                  below is provided to assist the mechanic.

TESTING OIL PRESSURE                                                    LOW OIL PRESSURE
The lubricating system is a pressure feeding system using an            The specified safe minimum oil pressure is 4.3 - 1.4 psi (0.3 +
oil pump. The engine oil is drawn from the oil sump by the              0.1 kglcm2). A gradual loss of oil pressure usually indicates
oil pump which drives the oil, under pressure, through the oil          worn bearings. For additional information on low oil pressure
filter, oil cooler and various lubricating points in the engine.        readings, see the ENGINE TROUBLESHOOTING chart.
The oil then returns to the oil sump to repeat the continuous
cycle. When the oil pressure exceeds the specified pressure,            OIL PRESSURE SWITCH/SENDER
the oil pushes open the relief valve in the oil pump and                Occasionally a faulty oil pressure sender will give a false
returns to the oil sump, keeping the oil pressure within its            reading. When installing a new sender, apply teflon sealant to
specified range.                                                        the threaded ends being careful not to close off the oil hole in
To test the oil pressure, remove the oil pressure sender, then          the sender.
install a mechanical oil pressure gauge in it's place. After            OIL PRESSURE SENDER AND SWITCH TORQUE
warming up the engine, set the engine speed at approx.                  9 -13 tt-Ib (1.2 -1.8 m-Kg).
3600 rpm and read the oil pressure gauge.




OIL PRESSURE       54.04 Ib/in' (3.8 Kg/em') or more at
                   approx. 3600 + rpm.




                                                           Engines & Generators
                                                                   42
                                                 ENGINE ADJUSTMENTS
                                  NOTE: WESTERBEKE recommends that the following engine adjust-
                                  ments be performed by a competent engine mechanic. The information
                                  below is provided to assist the mechanic.

VALVE CLEARANCE ADJUSTMENT                                               8. Adjust each valve's clearance by inserting a 0.012in
                                                                            (0.03mro) feeler gauge between the rocker arm and the
1. Warm the engine to nonnal operating temperature.                         valve stem. Make sure to adjust all valves when the
2. Pull off the air breather pipe from the rocker cover.                    engine is cold.                                .
   Remove the rocker cover bolts and remove the rocker
   cover to expose the rocker shaft and valve assembly.
3. Remove the glow plugs from each of the cylinders to
   enable the crankshaft to be easily rotated by hand to posi-
   tion each cylinder for valve adjustment.
   Valves are adjusted with the piston in the cylinder being
   adjusted at IDC of its compression stroke.
NOTE: Retorque the cylinder head bolts before adjusting the
engine's valves.
4. Loosen the head bolts in the reverse order of tightening.
                                      3        
                                                 I


                                                                         9. Install the cylinder head cover.
                                                                         HEAD COVER BOLT TORQUE 2 - 3 It -Ib (0.3 - 0.45 m-kg)


                                                                         ENGINE COMPRESSION
                                                                         Check the compression pressure. To do this, warm the
5. Tighten the head bolts in the order shown.                            engine, remove all fuel injectors, or glow plugs, disconnect
                                                                         the fuel shut-off solenoid wire, and install a compression
CYLINDER HEAD BOLTTORQUE     80 - 85 It -Ib (11.0 -11.7 m-kg)
                                                                         adapter in the injector hole or glow plug hole. Connect a
6. Set the piston of No.1 cylinder to IDC (compression)                  compression tester on the adapter and crank the engine with
   and check the valve clearance at each position indicated.             the starter motor until the pressure reaches a maximum value.
   If the clearance is incorrect, adjust to specifications:              Repeat this process for each cylinder. Look for cylinders with
   Intake - No.1 and No.2 cylinders; and                                 dramatically (at least 20%) lower compression than the aver-
   Exhaust - No.1 and No.3 cylinders.                                    age of the others. Compression pressure should not differ by
7. Turn the crankshaft once, setting the piston of No.4                  more than 42.7 psi (3.0 kglcm2) at 200 rpm.
   cylinder at TDC (compression) and adjust to the follow-
   ing specifications:
   Intake - No.3 and No.4 cylinders; and
   Exhaust - No.2 and No.4 cylinders.
                                                                         MEASURING
       WHEN NO 4 CYUNDER IS AT TOP DEAD CENTER                           COMPRESSION
            14 INTAKE   3 udAKE   I
      4 EXHAUST              2 EXHAUST




                                                                         COMPRESSION PRESSURE STANDARD 427 psi al 200 rpm (30.0 kg/em')
                                                                         COMPRESSION PRESSURE LIMIT    384 psi al200 rpm (27.0 kg/em')

                                                                         If a weak cylinder is flanked by healthy cylinder, the problem
                                                                         is either valve or piston related. Check the valve clearances
                                 21NTAKE 1 INTAKE                        for the weak cylinder, adjust as needed and test again.
                                                                         If the cylinder is still low, apply a small amount of oil into
                 3 EXHAUST
                     I
                                      11 EXHtUSTI
                                                                         the cylinder to seal the rings and repeat the test.
               WHEN NO 1 CYliNDER IS AT TOP DEAD CENTER                  If compression comes up - the rings are faulty.


                                                                Engines & Generators

                                                                    43
                                              ENGINE ADJUSTMENTS
                                  NOTE: WESTERBEKE recommends that the following engine adjust-
                                  ments be peiformed by a competent engine mechanic. The information
                                  below is provided to assist the mechanic.

LOW COMPRESSION                                                         INJECTION PUMP
When low compression is found, determine the cause by                   For disassembly, inspection, reassembly and internal adjust-
applying a small amount of oil in the cylinder thru the glow            ments of the injection pump, it is recommended the pump
plug hole. Allow the oil to settle.                                     be taken to a qualified injection service shop authorized to
Install the pressure gauge and repeat the above test. If the            service Diesel KiKi or Zexel injection equipment.
compression reading rises dramatically, the fault is with the
rings. If the compression valve does not rise, the problem is           ENGINE STOP SOLENOID
with the valves.                                                        This solenoid is installed on the top rear of the injection
A slight rise in compression would indicate a problem with              pump and is activated by 12 VDC electrical current.
both rings and the valves.
                                                                        Troubleshooting
NOTE: In case of severe vibrations and detonation noise, have           1. The solenoid does not operate when the
the injectors checked and overhauled by an authorized fuel                 keyswitch is turned "ON".
injection service center. Poor fuel quality, contaminates and
                                                                           a. Are the engine batteries turned "ON"?
loss of positive fuel pressure to the injection pump will result
in injector faults.                                                        b. Is the 20 amp circuit breaker set?
                                                                           c. Is 12 VDC present at the solenoid
When re-installing the glow plugs use anti-seize compound.
                                                                              connection?
                                                                        2. The solenoid does not stop the engine
SETTING THE IDLE SPEED (PROPULSION ENGINE)                                 when the keyswitch is switched "OFF'.           ~SPRING
1. Warm the engine to normal operating temperature.
2. Stick a piece of suitable reflecting tape on the crankshaft
                                                                           a. Check to see if 12 VDC is still present
                                                                                                                           ~PLUNGER
                                                                              at the solenoid electrical lead with the
   pulley.                                                                    key off.
3. Idle the engine.                                                        b.Remove solenoid from injection
4. Use the light of a photoelectric strobe type tachometer on                 pump and ensure plunger and spring
   the reflecting tape and check the value shown by the                       in the solenoid are not sticking.
   tachometer.
NORMAL IDLE SPEED 580 - 630 rpm

    NOTE: The idle speed may vary according to the
                                                                                                                   INJECTION PUMP
    transmission and propeller.
5. To adjust the engine idle speed, loosen the lock nut of the
   idle adjustment bolt and tum the bolt clockwise to
   increase idle speed and counterclockwise to reduce.
    NOTE: Should engine rpm be in question, verify
    tachometerrea4ings as shown at the instrument panel.
    See TACHOMETER.




                                                 THROTTLE STOP
                                                 SCREW

  KEEP LINKAGE
  WELL LUBRICATED




                                                          Engines & Generators

                                                                   44
                                       LAY-UP & RECOMMISSIONING
GENERAL                                                                Fuel System [Gasoline}
Many owners rely on their boatyards to prepare their craft,            Top off your fuel tanks with unleaded gasoline of 89 octane
including engines and generators, for lay-up during the off-           of higher. A fuel conditioner such as STABIL gasoline
season or for long periods of inactivity. Others prefer to             stabilizer should be added. Change the element in your
accomplish lay-up preparation themselves.                              gasoline/water separator and clean the metal bowl.
The procedures which follow will allow you to perform your             Re-install and make certain there are no leaks. Clean
own lay-up and recommissioning, or you may use them as a               up any spilled fuel.
check list if others do the procedures.                                Fuel System [Diesel}
These procedures should afford your engine protection                  Top off your fuel tanks with No.2 diesel fuel. Fuel additives
during a lay-up and also help familiarize you with the                 such as BIOBOR and STABIL should be added at this time to
maintenance needs of your engine.                                      control algae and condition the fuel. Care should be taken
If you have any questions regarding lay-up procedures, call            that the additives used are compatible with the primary fuel
your local servicing dealer; he will be more than willing to           filter/water separator used in the system. Change the element
provide assistance.                                                    in your primary fuel filter/water separator, if the fuel system
                                                                       has one, and clean the separator sediment bowl.
Propeller Shaft Coupling [Propulsion Engine}
                                                                       Change the fuel filter elements on the engine and bleed the
The transmission and propeller half couplings should always
                                                                       fuel system, as needed. Start the engine and allow it to run
be opened up and the bolts removed when the boat is hauled
                                                                       for 5 - 10 minutes to make sure no air is left in the fuel
out of the water or moved from land to water, and during
                                                                       system. Check for any leaks that may have been created in
storage in the cradle. The flexibility of the boat often puts a
                                                                       the fuel system during this servicing, correcting them as
severe strain on the propeller shaft or coupling or both, while
                                                                       needed. Operating the engine for 5 - 10 minutes will help
the boat is taken out or put in the water. In some cases, the
                                                                       allow movement of the treated fuel through the injection
shaft has actually been bent by these strains. This does not
                                                                       equipment on the engine.
apply to small boats that are hauled out of the water when
not in use, unless they have been dry for a considerable               Raw Water COOling Circuit
period of time.                                                        Close the through-hull seacock. Remove the raw water intake
Fresh Water Cooling Circuit                                            hose from the seacock. Place the end of this hose into a five
                                                                       gallon bucket of clean fresh water. Before starting the engine,
A 50-50 solution of antifreeze and distilled water is
                                                                       check the zinc anode found in the primary heat exchanger on
recommended for use in the coolant system at all times.
                                                                       the engine and clean or replace it as required, and also clean
This solution may require a higher concentration of
                                                                       any zinc debris from inside the heat exchanger where the
antifreeze, depending on the area's winter climate. Check the
                                                                       zinc anode is located. Clean the raw water strainer.
solution to make sure the antifreeze protection is adequate.
                                                                       Start the engine and allow the raw water pump to draw the
Should more antifreeze be needed, drain an appropriate
                                                                       fresh water through the system. When the bucket is empty,
amount from the engine block and add a more concentrated
                                                                       stop the engine and refill the bucket with an antifreeze .
mixture. Operate the engine to ensure a complete circulation
                                                                       solution slightly stronger than needed for winter freeze
and mixture of the antifreeze concentration throughout the
                                                                       protection in your area.
cooling system. Now recheck the antifreeze solution's strength.
                                                                       Start the engine and allow all of this mixture to be drawn
Lubrication System                                                     through the raw water system. Once the bucket is empty, stop
With the engine warm, drain all the engine oil from the oil            the engine. This antifreeze mixture should protect the raw
sump. Remove and replace the oil filter and fill the sump              water circuit from freezing during the winter lay-up, as well
with new oil. Use the correct grade of oil. Refer to the               as providing corrosion protection.
ENGINE LUBRICATING OIL pages in this manual for the                    Remove the impeller from your raw water pump (some
oil changing procedure. Run the engine and check for proper            antifreeze mixture will accompany it, so catch it in a bucket).
oil pressure and make sure there are no leaks.                         Examine the impeller. Acquire a replacement, if needed, and
                                                                       a cover gasket. Do not replace the impeller (into the pump)
                                                                       until recommissioning, but replace the cover and gasket.
 A CAUTION: 00 not leave the engine's old engine                       Cylinder Lubrication [Gasoline}
  oil in the sump over the lay-up period. Engine oil and
  combustion depOSits combine to produce harmful                       With the engine running, remove the flame arrester and spray
                                                                       fogging oil into the open air intake. The fogging oil will stall
  chemicals which can reduce the life of your engine's
                                                                       out the engine as it coats the valves, cylinders and spark
  internal parts.                                                      plugs for winter protection.




                                                         Engines & Generators

                                                                  45
                                        LAY-UP & RECOMMISSIONING
Starter Motor                                                            SPARE PARTS
Lubrication and cleaning of the starter drive pinion is advis-           Lay-up time provides a good opportunity to inspect your
able, if access to the starter permits its easy removal. Make            WESTERBEKE engine to see if external items such as drive
sure the battery connections are shut off before attempting to           belts or coolant hoses need replacement. Check your basic
remove the starter. Take care in properly replacing any elec-            spares kit and order items not on hand, or replace those items
trical connections removed from the starter.                             used during the lay-up, such as filters and zinc anodes. Refer
                                                                         to the SPARE PARTS section of this manual.
Cylinder Lubrication [Diesel]
If you anticipate a long lay-up period (12 months or more)               RECOMMISSIONING
WESTERBEKE recommends removing the glow plugs or                         The recommissioning of your WESTERBEKE engine after a
fuel injectors for access to the cylinders. Squirt light                 seasonal lay-up generally follows the same procedures as
lubricating oil into the cylinders to prevent the piston rings           those described in the PREPARATIONS FOR STARTING
from sticking to the cylinder walls. Rotate the engine by hand           section regarding preparation for starting and normal starts.
two revolutions then replace the glow plugs or injectors.                However, some of the lay-up procedures will need to be
Make sure you have a replacement if removing the injector                counteracted before starting the engine.
sealing washer for the injector and fuel line return.                    1. Remove any rags that were placed in the exhaust, intake
                                                                             manifold, or flame arrester.
NOTE: If engine storage is going to be a lengthy one, 12
months or beyond, it is wise to rotate the engine by hand two            2. Remove the raw water pump cover and gasket and discard
complete turns every additional 4 months to allow the injec-                 the old gasket. Install the raw water pump impeller
tion pump components to move. This will help prevent their                   removed during lay-up (or a replacement, if required).
sticking during extended storage periods.                                    Install the raw water pump cover with a new cover gasket.
                                                                         3. Reinstall the batteries that were removed during the lay-
Intake Manifold and Thru-Hull Exhaust[Diesel]                                up, and reconnect the battery cables, making sure the
Place a clean cloth, lightly soaked in lubricating oil, in the               terminals are clean and that the connections are tight.
opening of the intake manifold to block the opening. Do not                  Check to make sure that the batteries are fully charged.
shove the cloth out of sight. (If it is not visible at                   4. Remove the spark plugs, wipe clean, re-gap, and install
recommissioning, and an attempt is made to start the engine,                 to proper tightness. [Gasoline]
you may need the assistance of a servicing dealer.) Make a               5. Check the condition of the zinc anode in the raw water
note to remove the cloth prior to start-up. The through-hull                 circuit and clean or replace the anode as needed. Note
exhaust port can be blocked in the same manner.                              that it is not necessary to flush the antifreeze/fresh water
Intake Manifold [Gasoline]                                                   solution from the raw water coolant system. When the
                                                                             engine is put into operation, the system will self-flush in
Clean the filter screen in the .flame arrester, and place a clean            a short period of time with no adverse affects. Also open
cloth lightly soaked in lube oil around the flame arrester to                up the heat exchanger ends and clear out any accumu-
block any opening. Also place an oil-soaked cloth in the                     lated debris.
through-hull exhaust port, Make a note to remove cloths prior
to start-up!                                                             6. Check the transmission fluid, if it had been topped off
                                                                             during the lay-up, lower the level of the fluid to normal.
Transmission [Propulsion Engine]                                             [Propulsion Engine]
Check or change fluid in the transmission as required. If the            7. Make certain all electrical connections and switches are
engine is to be layed up 12 months or more, fill the transmis-              in the correct position and there are no-loads on the
sion to the very top to prevent corrosion. Lower the fluid to               generator at start up. [Generator]
its normal at recommissioning. Wipe off grime and grease                 8. Start the engine in accordance with the procedures
and touch up unpainted areas. Protect coupling and output                   described in the PREPARATIONS FOR STARTING
flange with an anticorrosion coating, Refer to the                          section of this manual.
TRANSMISSION SECTION in this manual for additional
information.
Batteries
If batteries are to be left on board during the lay-up period,
make sure they are fully charged, and will remain that way,
to prevent them from freezing. If there exists any doubt that
the batteries will not remain fully charged, or that they will
be subjected to severe environmental conditioQ.S, remove
the batteries and store them in a warmer, more compatible
environment.




                                                           Engines & Generators

                                                                    46
                                METRIC CONVERSIONS
                INCHES TO MILLIMETERS                             MILLIMETERS TO INCHES
  Inches          mm     Inches    mm                          mm      Inches   mm      Inches
    1                25.40          15         381.00           1             0.0394      15         0.5906
    2                50.80          20         508.00           2             0.0787      20         0.7874
    3                76.20          25         635.00           3             0.1181      25         0.9843
    4               101.60          30         762.00           4             0.1575      30         1.1811
    5               127.00          35         889.00           5             0.1969      35         1.3780
   10               254.00          40        1016.00          10             0.3937      40         1.5748
         10 MILLIMETERS = 1 CENTIMETER, 100 CENTIMETERS = 1 METER = 39.37 INCHES (3.3 FEET)

                     INCHES TO METERS                                   METERS TO INCHES
 Inches             Meters  Inches  Meters                    Meters      Inches   Meters            Inches
    1            0.0254              7        0.1778           0.1          3.937 27.559 0.7
    2            0.0508              8        0.2032           0.2          7.874 31.496 0.8
    3            0.0762              9        0.2286           0.3         11.811 35.433 0.9
    4            0.1016             10        0.2540           0.4         15.748 39.370 1.0
    5            0.1270             11        0.2794           0.5         19.685 43.307 1.1
    6            0.1524             12        0.3048           0.6         23.622 47.244 1.2
        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   MetersYards
    1            0.91440      6         5.48640       1         1.09361        6       6.56168
    2            1.82880      7         6.40080       2         2.18723        7       7.65529
    3           2.74320       8         7.31520       3         3.28084        8       8.74891
    4           3.65760       9         8.22960       4         4.37445        9       9.84252
    5           4.57200      10         9.14400       5        5.46807        10     10.93614
             MOVE DECIMAL POINT FOR HIGHER VALUES - e.g. 6,000 METERS = 6,561.68 YARDS
                POUNDS TO KILOGRAMS                                 KILOGRAMS TO POUNDS
    Ib            kg      Ib      kg                           kg         Ib      kg                   Ib
    1               0.454            6         2.722            1           2.205          6         13.228
    2               0.907            7         3.175            2           4.409          7         15.432
    3               1.361            8         3.629            3           6.614          8         17.637
    4               1.814            9         4.082            4           8.818          9         19.842
    5               2.268           10         4.536            5          11.023         10         22.046
                   GALLONS TO LITERS                                    LITERS TO GALLONS
, Gallons         Liters Gallons   Liters                     Liters       Gallons  Liters Gallons
    1             3.79     10      37.86                         1            0.26        60         15.66
    2             7.57     20      75.71                         2            0.53        90         23.77
    3            11.36     30     113.57                         5            1.32       120         31.32
    4            15.14     40     151.42                       10             2.64       150         39.62
    5            18.93     50     189.28                       20             5.28       180         47.54
                       PINTS TO LITERS                                   LITERS TO PINTS
  Pints             Liters    Pints    Liters                 Liters       Pints   Liters            Pints
    1               0.47         6              2.84           1           2.11           6          12.68
    2               0.95         7              3.31           2           4.23           7          14.79
    3               1.42         8              3.79           3           6.34           8          16.91
    4               1.89         9              4.26           4           8.45           9          19.02
    5               2.37        10              4.73           5          10.57          10          21.13
                                              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

                                                        47
STANDARD AND METRIC CONVERSION DATA

LENGTH-DISTANCE
  Inches (in) x 25.4 = Millimeters (mm) x .0394 = Inches
  Feet (ft) x .305 = Meters (m) x 3.281 = Feet
  Miles x 1.609 = Kilometers (km) x .0621 = Miles

VOLUME
  Cubic Inches (in3) x 16.387 = Cubic Centimeters x .061 =in 3
  Imperial Pints (IMP pt) x .568 = Liters (L) x 1.76 = IMP pt
  Imperial Quarts (IMP qt) x 1.137 = Liters (L) x.88 = IMP qt
  Imperial Gallons (IMP gal) x 4.546 = Liters (L) x .22 = IMP gal
  Imperial Quarts (IMP qt) x 1.201 = US Quarts (US qt) x .833 = IMP qt
  Imperial Gallons (IMP gal) x 1.201 = US Gallons (US gal) x .833 = IMP gal
  Fluid Ounces x 29.573 ::; Milliliters x .034 ::; Ounces
  US Pints (US pt) x .473 ::; Liters(L) x 2.113 = Pints
  US Quarts (US qt) x .946 ::; Liters (L) x 1.057 = Quarts
  US Gallons (US gal) x 3.785::; Liters (L) x .264 = Gallons

MASS-WEIGHT
  Ounces (oz) x 28.35 = Grams (g) x .035 = Ounces
  Pounds (Ib) x .454 ::; Kilograms (kg) x 2.205 = Pounds

PRESSURE
  Pounds Per Sq In (psi) x 6.895 ::; Kilopascals (kPa) x .145 ::; psi
  Inches of Mercury (Hg) x .4912::; psi x 2.036 = Hg
  Inches of Mercury (Hg) x 3.377 ::; Kilopascals (kPa) x .2961 ::; Hg
  Inches of Water (H20) x .07355::; Inches of Mercury x 13.783::; H20
  Inches of Water (H20) x .03613::; psi x 27.684::; H20
  Inches of Water (H20) x .248 ::; Kilopascals (kPa) x 4.026 ::; H20

TORQUE
  Pounds-Force Inches (in-Ib) x .113 = Newton Meters (Nm) x 8.85 ::;in-Ib
  Pounds-Force Feet (ft-Ib) x 1.356 = Newton Meters (Nm) x .738::; ft-Ib

VELOCITY
  Miles Per Hour (MPH) x 1.609 ::; Kilometers Per Hour (KPH) x .621 ::; MPH

POWER
  Horsepower (Hp) x .745 ::; Kilowatts (Kw) x 1.34 = MPH

FUEL CONSUMPTION
  Miles Per Hour IMP (MPG) x .354 = Kilometers Per Liter (Km/L)
  Kilometers Per Liter (Km/L) x 2.352::; IMP MPG
  Miles Pe( Gallons US (MPG) x .425 = Kilometers Per Liter (Km/L)
  Kilometers Per Liter (Km/L) x 2.352 = US MPG

TEMPERATURE
  Degree Fahrenheit (OF) ::; (OC X 1.8) + 32
  Degree Celsius (0C) ::; (OF - 32) x .56



                               Engines & Generators

                                      48
                                         SUGGESTED SPARE PARTS
                                         WESTERBEKE MARINE DIESEL ENGINES
               CONTACT YOUR WESTERBEKE DEALER FOR SUGGESTIONS AND ADDITIONAL INFORMATION


                                                               HARDWARE KIT




                                                                               MODEL HOSE KIT
                                                                               HOSE KIT/DUFFEL BAG
                                                                               Molded engine replacement ~::=;;;j~
                                                                               hoses pack in a                  fII6II!IJ-".
                                                                               rugged canvas
                                                                               carrying bag


                                          THERMOSTAT
                                          GASKET




                                                    SPARE PARTS KITS
WESTERBEKE also offers two Spare Parts Kits,
each packaged in a rugged hinged toolbox.                                                         B Kit
Kit "A" includes the basic spares.                                                                Impeller Kit
Kit "B" is for more extensive off-shore cruising.                                                 Water Pump Repair Kit
       A Kit                                                                                      Thermostat Kit
       Impeller Kit                                                                               Zinc Anodes
       Heat Exchanger Gasket                                                                      Complete Gasket Kit
       Fuel Filter                                                                                Heat Exchanger Gasket
       Oil Filter                                                                                 Injector
       Drive Belt                                                                                 Fuel Filter
       Zinc Anodes                                                                                Oil Filter
       Fuel Lift Pump Filter                                                                      Drive Belt
                                       WESTERBEKE RECOMMENDS CARRYING ENOUGH SPARE
                                       ENGINE OIL (YOUR BRAND) FOR AN OIL CHANGE
                                       AND A GALLON OF PREMIXED COOLANT



                                                        Engines & Generators

                                                             49
                                           SPECIFICATIONS  630 ENGINE
                    ENGINE SPECIFICATIONS                                                                  FUEL SYSTEM
Engine Type               Diesel, four-cylinder, four-cycle, fresh              General                     Open flow, self priming - one bleed point.
                          water-cooled, vertical in-line overhead valve         Fuel                        No.2 diesel oil (cetane rating of 45 or higher)
                          mechanism (63 hp at 4000 rpm maximum).
                                                                                Fuel Injection Pump         Distributor Type (VE) Diesel KiKi - Zexel
Displacement              134.8 cu.in. (2.21 liter)
                                                                                Fuel Injection Timing       0 TOC (Top Dead Center)
Aspiration                Naturally aspirated
                                                                                Nozzle                      Throttle type
Governor                  Centrifugal type
                                                                                Fuel Filter                 Spin-on (Replaceable) PN#024363
Combustion Chamber        Swirl type
                                                                                Air cleaner                 Metal screen type - cleanable
Bore & Stroke             3.62 x 3.51 inches (92.0 x 89.1 mm)
                                                                                AirFlow                     70.0 cfm (1.9 cmm)
Piston Displacement       144.4 cubic inches (2.37 liters)                      (engine combustion)
Firing Order              1-3-4-2
Direction of Rotation     Clockwise, when viewed from the front                                         ELECTRICAL SYSTEM
Compression Ratio         21 : 1                                                 Starting Battery           12-Volt, (-) negative ground
Dimensions                Height: 24.93 inches (633.2 mm)                        Battery Capacity           400 - 600 Cold Cranking Amps (CCA)
                          Width: 22.63 inches (574.6 mm)                         DC Charging Alternator     51 Amp rated, belt driven
                          Length: 38.75 inches (984.3 mm)
                                                                                 Starter                    12-Volt, reduction gear,
Weight                    614 Ibs (278.7 kgs)
                                                                                 Starting Aid               Glow plugs, sheathed type
Fuel Consumption          1.3 US gph (4.9Iph) at 2500 rpm
                                                                                 DC No-Load Current          2% of rated Amps
Inclination               Continuous 15
                          Temporary 25 (not to exceed 30 min.)                  DC Cranking Current        280 Amps (engine cold)
Power Take Off            35 HP maximum (105 Nibs)
                                                                                                          COOLING SYSTEM
                    TUNE-UP SPECIFICATIONS                                       General                    Fresh water-cooled block, thermostatically-
                                                                                                            controlled with heat exchanger.
Compression Pressure      427 psi (30 kg/cm') at 280 rpm limit
Minimum                   384 psi (27 kg/cm')                                    Operating Temperature      170 -190 F(77 - 88 C)
Valve Timing              Intake Opens 17 BTDC                                  Fresh Water Pump           Centrifugal type, metal impeller, bett-driven
                          Intake Closes 47 ABDC                                 Raw Water Pump             Positive displacement, rubber impeller,
                          Exhaust Opens 51  BBDC                                                           gear-driven.
                          Exhaust Closes 13 ATOC                                Raw Water Flow,            6.0 US gpm (22.7 Ipm) (measured
Spill Timing (Static)     191.5                                                at 3600 rpm                before discharging into exhaust elbow).
Valve Seat Angle          Intake 45                                             System Capacity            10.0 qts (9.46 liters)
                          Exhaust 45                                            (fresh water)
Engine Speed              1800 rpm 60 Hertz
                          1500 rpm 50 Hertz                                                         LUBRICATION SYSTEM
Valve Clearance           Intake 0.012 inches (0.30 mm)                          General                    Pressure fed system
(engine cold)             Exhaust 0.012 inches (0.30 mm)
                                                                                 Oil Filter                 Full flow, paper element, spin-on type
Injector Pressure         1920 + 71 - 0 psi (135 + 5 - 0 kg/cm2)                                            PN# 035828
Engine Timing             Static timed - drop valve method 0.205  .005          Sump Capacity              5.3 U.S. qts (5.0 liters)
                          in BTOC or 0 TOC #1 cylinder. 1mm of cam lift         (not including filter)     plus filter/cooler assembly
                          using measuring device for injection pump.
                                                                                 Operating Oil Pressure     50 - 65 psi (3.5 - 4.57 kg/cm2)
                                                                                 (engine hot)
                                                                                 Oil Grade                  API Specification CF or CG-4,
                                                                                                            SAE 30, 10W-30, 15W-40




                                                                      Engines & Generators

                                                                           50
                    Engines & Generators




1050-WM-OW-2/2001


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