Friday, December15, 2017 L-36.com

Westerbeke Diesel 63c Four Technical Manual




NOTE: DO NOT HIT REFRESH!!! These files are big and can take a long time to load. This file is 5.75 MB. Give it time.
If there is text in the file, you can scroll it while the image loads. Enjoy

View PDF

Image Preview



Ad by Google

PDF to Text

to It IJ
t
o q
OPERATORS MANUAL
MARINE DIESEL ENGINE
630 UR
N NO045150
FIRST EDITION
March 2001
t WESTERBEKE
j WESTERBEKE CORPORATION MYLES STANDISH INDUSTRIAL PARK
I 150 JOHN HANCOCK ROAD TAUNTON MA 027807319 TEL FAX WEBSITE Member National Marine Manufacturers Association
CALIFORNIA
PROPOSITION 65 WARNING
Diesel engine exhaust and some
of its constituents are known to
the State of California to cause
cancer birth defects and other
reproductive harm
A gasses contain Carbon Monoxide an odorless and
colorless gas Carllon Monoxide Is poisonous and can and death Symptoms of Carllon can Throbbing In
Museular Vomiting
Weakness and Sleepiness Inability to Think YOU OR ANYONE ELSE EXPERIENCE ANY OF THESE SYMPTOMS
BET OUT INTO THE FRESH AIR IMMEDIATELY If symptoms 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
recommends Installing
CARBON MONOXIDE DETECTORS In the
qualfslS of your vessel
Thsyare Inexpenslvs and easily
obtaInable at your local marins stOlB
SAFETY PREVENT BURNS FIRE
Read this safety manual carefully Most accidents are
caused by failure to follow fundamental rules and precau A WARNING Fire can cause injury or death
tions Know when dangerous conditions exist and take the
necessary precautions to protect yourself your personnel Prevent flash fires Do not smoke or permit flames or
and your machinery sparks to occur near the carburetor fuel line filter fuel
The following safety instructions are in compliance with 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 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 removed
while engine is running or when connected to shore Backfire can cause severe injury or death
power Lethal voltage is present at these connections Do not smoke or permit flames or sparks to occur near
the fuel system Keep the compartment and the
Do not operate this machinery without electrical clean and free of debris to minimize the
enclosures and covers in place chances of fire Wipe up all spilled fuel and engine oil
Shut off electrical power before accessing electrical Be aware diesel fuel will bum
equipment
Use insulated mats whenever working on electrical PREVENT BURNS EXPLOSION
equipment
Make sure your clothing and skin are dry not damp
particularly shoes when handling electrical equipment
A WARNING Explosions from fuel vapors can cause
injury or death
Remove wristwatch and all jewelry when working on
electrical equipment Follow refueling safety instructions Keep the vessels
Do not connect utility shore power to vessels AC hatches closed when fueling Open and ventilate cabin
circuits except through a shiptoshore double throw after fueling Check below for fumesvapor before run
transfer switch Damage to vessels AC generator may ning the blower Run the blower for four minutes before
result if this procedure is not followed starting your engine
Electrical shock results from handling a charged capaci All fuel vapors are highly explosive Use extreme care
tor Discharge capacitor by shorting terminals together when handling and storing fuels Store fuel in a wellven
tilated area away from equipment and
PREVENT BURNS HOT ENGINE out of the reach of children
Do not fill the fuel tanks while the engine is running
A WARNING 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 Engines Generators
SAFETY STARTING TOXIC EXHAUST GASES
A WARNING Accidental starting can cause injury A WARNING Carbon monoxide CO is a deadly gas
or death
Ensure that the exhaust system is adequate to expel gases
Disconnect the battery cables before servicing the engine
discharged from the engine Check the exhaust system
generator Remove the negative lead first and reconnect
regularly for leaks and make sure the exhaust manifolds
it last
are securely attached and no warping exists Pay close
Make certain all personnel are clear of the engine before attention to the manifold water injection elbow and
starting exhaust pipe nipple
Make certain all covers guards and hatches are re Be sure the unit and its surroundings are well ventilated
installed before starting the engine
In addition to routine inspection of the exhaust system
install a carbon monoxide detector Consult your boat
BAnERY EXPLOSION builder or dealer for installation of approved detectors
For additional information refer to ABYC T22 educa
A WARNING Battery explosion can cause injury tional information on Carbon Monoxide
or death
Do not smoke or allow an open flame near the battery A WARNING Carbon monoxide CO is an invisible
being serviced Lead acid batteries emit hydrogen a odorless gas Inhalation produces flulike symptoms
highly explosive gas which can be ignited by electrical nausea or death
arcing or by lit tobacco products Shut off all electrical
equipment in the vicinity to prevent electrical arcing dur Do not use copper tubing in diesel exhaust systems Diesel
ing servicing fumes can rapidly destroy copper tubing in exhaust sys
Never connect the negative battery cable to the posi tems Exhaust sulfur causes rapid deterioration of copper
tive connection terminal of the starter solenoid Do tubing resulting in exhaustwater leakage
not test the battery condition by shorting the terminals Do not install exhaust outlet where exhaust can be drawn
together Sparks could ignite battery gases or fuel vapors through portholes vents or air conditioners If the engine
Ventilate any compartment containing batteries to prevent exhaust discharge outlet is near the waterline water could
accumulation of explosive gases To avoid sparks do not enter the exhaust discharge outlet and close or restrict the
disturb the battery charger connections while the battery flow of exhaust Avoid overloading the craft
is being charged
Although diesel engine exhaust gases are not as toxic as
Avoid contacting the 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 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
SAFETY Do not wear loose clothing or jewelry when servicing ABYC NFPA AND USCG PUBLICATIONS FOR
equipment tie back long hair and avoid wearing loose
jackets shirts sleeves rings necklaces or bracelets that INSTALLING DIESEL ENGINES
could be caught in moving parts Read the following ABYC NFPA and USCG 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 belts tension while
the engine is operating Order from
Stay clear of the drive shaft and the transmission coupling ABYC
when the engine is running hair and clothing can easily 3069 Solomons Island Rd
be caught in these rotating parts Edgewater MD 21037
NFPA National Fire Protection NOISE Fire Protection Standard for Motor Craft
Order from
A WARNING High noise levels can cause hearing NFPA
loss 11 Tracy Drive
Avon Industrial Park
Never operate an engine without its muffler installed Avon MA 02322
Do not run an engine with the air intake silencer USCG United States Coast Guard
removed USCG 33CFR183
Do not run engines for long periods with their enclosures Order from
open
US Government Printing Office
Washington DC 20404
A WARNING Do not wode on machinery when you are
mentally or physically incapacitated by MANUAL
Many of the preceding safety tips and warnings are repeated
in your Operators Manual along with other cautions and
notes to highlight critical information Read your maintain your equipment and follow all to install an engine should begin with a thor
ough examination of the American Boat and Yacht standards These standards are a combination of
sources including the USCG and the of the ABYC standards of particular interest are
H2 Ventilation
Pl Exhaust systems
P4 Inboard engines
E9 DC Electrical systems
All installations must comply with the Federal Code FCR
Engines Generators
installing WESTERBEKE engines and generators it is important that be paid to the following AND federal regulations ABYC guidelines and safety codes
must be complied with
when installing engines and generators in a marine installations where the exhaust injected exhaust elbow is close to
or will be below the vessels waterline provisions must be made to install a in the raw water supply hose to the exhaust elbow This hose must be
looped a
minimum of 20 above the vessels waterline Failure to use a siphonbreak when
the exhaust manifold injection port is at or below the load waterline will result in
raw water damage to the engine and possible flooding of the boat
If you have any doubt about the position of the exhaust elbow relative
to the vessels waterline under the vessels various operating conditions instaU A siphonbreak requires periodic inspection and cleaning to ensure
Failure to properly maintain a siphonbreak can result in damage Consult the siphonbreak manufacturer for proper SYSTEM
The exhaust hose must be certified for marine use The system must be designed to
prevent water from entering the exhaust under any sea conditions and at any angle
of the vessels hull
A detailed 40 page Marine Installation Manual covering gasoline and
diesel engines and generators Is available from your WESTERBEKE
dealer
Engines Generators
TABLE OF Water Heater DC Electrical System Warranty Procedures 3 Alternator 25
Serial Number Location 04 Battery 26
Admiral Control Panel Wiring 27
Captain Control Panel Dual Output Alternators 29
Fuel Engine Oil and Coolant Engine Chart 31
Oil Pressure 7 Coolant and Oil Pressure Gauges for Initial StartUp 8 Hurth HBW Transmissions 33
Fluid Change Procedure Control Cables 34
Engine BreakIn Procedure 10 Maintenance 35
The Daily Operation 11 Borg War ner 36
Warning Lights Alarms and Circuit Breaker 12 Fluid Change Schedule 13 Maintenance 38
Cooling System 15 Transmission Thermostat 16 Engine Adjustments 41
Raw Water Pump 16 Drive Belt Adjustment 41
Heat Exchanger 17 Fuel Injectors 41
Fuel System 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 Layup and 045
Engine Lubricating Oil 21 Metric Conversions 047
Oil Change 21 Suggested Spare Parts 049
Oil Pressure 22 630 Engines Generators
PARTS FILL
COOLANT WATER INJECTED
PRESSURE CAP EXHAUST ELBOW
ASSEMBLY
FILTER
DC CHARGING
ALTERNATOR l SILENCER
AIR INTAKE
WATER
CDNNECTlDN STARTER
WITH SOLENOID
REAR
OIL OIL PRESSURE
OIL DRAIN HOSE
LEFT SIDE SENDOR
L FILL
THERMOSTAT
HEAT EXCHANGER ALTERNATOR
PREHEAT SOLENOID
20 AMP
CIRCUIT
BREAKER
FRONT
HURTH
TRANSMISSION
RIGHT SIDE MANIFOLD
ID PLATE
ENGINE BLOCK
DRAIN PLUG
TRANSMISSION
REAR SHIFT LEVER
Engines Generators
WESTERBEKE Diesel Engine is a product of PRODUCT long years of experience and advanced Product software
technical data parts lists We take great pride in the superior durability and brochures and catalogs provided from sources other performance
of our engines and generators WESTERBEKE are not within WESTERBEKEs you for selecting WESTERBEKE
WESTERBEKE CANNOT BE RESPONSIBLE FOR THE
In order to get the full use and benefit from your engine it is CONTENT OF SUCH SOFTWARE MAKES NO that you operate and maintain it correctly
This RANTIES OR WITH is designed to help you do this Please read this man THERETO INCLUDING ACCURACY TIMEliNESS OR
ual carefully and observe 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 WESTERBEKE dealer for assistance
INCURRED IN CONNECTION WITH OR ARISING OUT
This is your operators manual A parts catalog is also OF THE FURNISHING OR USE OF SUCH and a technical manual is available from your
WESTERBEKE customers should keep in mind the dealer If you are planning to install this span between printings of
WESTERBEKE product contact your WESTERBEKE dealer for and the unavoidable existence of earlier installation manual
product software The product software provided with
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 you have not received a
customer card of WESTERBEKE or the supplier in your warranty please contact the factory in be consulted to determine the
accuracy and currentness of the
writing with model information including the engines product software being consulted by the number and commission date
NOTES CAUTIONS AND Card As this manual takes you through the operating procedures
maintenance schedules and of your marine
engine critical information will be highlighted by NOTES
CAUTIONS and WARNINGS An explanation follows
I NOTE An operating procedure essential to note
Customer 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 OOOOE203 your engine
Expires 32010 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 number that can assist in determining the date of man
ufacture of your WESTERBEKE engine The code is placed at the end of the engine serial number and
consists of a character followed by three numbers The char
acter indicates the decade A1960s B1970s the first number represents the year in the decade
and the second and third numbers represent the month Engines Generators
NUMBER LOCATION ORDERING PARTS
The engines model number and serial number are located on Whenever replacement parts are needed always provide the
a nameplate mounted on the side of the engines manifold engine model number and serial number as they appear on
The engines serial number can also be found stamped into the silver and black nameplate located on the manifold You
the engine block just above the injection pump Take the time must provide us with this information so we may properly
to enter this information on the illustration of the nameplate identify your engine In addition include a complete part
shown below as this will provide a quick reference when description and part number for each part needed see the
seeking technical information andor ordering repair parts separately furnished Parts List Insist upon WESTERBEKE
packaged parts because will fit or generic parts are 131
not made to the same 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 WESTERBEKEs ACCESSORIES brochure
by WESTERBEKE Affix this decal in a visible location in the
engine THE DIESEL ENGINE
The diesel engine closely resembles the gasoline engine
since the mechanism is essentially the same The cylinders
are arranged above a closed crankcase The crankshaft is the
same general type as a gasoline engine and the diesel engine
has the same type of valves camshaft pistons and lubricating to a great extent a diesel engine requires the maintenance as a gasoline engine The
factors are proper ventilation and proper mainte
nance of the fuel lubricating and cooling systems Fuel filter elements must be replaced at the time peri
ods specified and frequent checking for contaminants etc in the fuel system is also essential factor is the consistent use of the same brand of
high detergent diesel lubrication oil designed specifically for
diesel engines
The diesel engine does differ from the gasoline in its method of handling and firing of fuel and ignition systems are replaced by a the fuel
injection pump which performs the
function of both
Engines Generators
ADMIRAL CONTROL PANEL
DESCRIPTION When the engine is shut down with the key switch turned off
the water temperature gauge will continue to register the last
This control panel is equipped with a
temperature reading indicated by the gauge before electrical
KEY switch and RPM gauge with an ELAPSED TIME
power was turned off The oil pressure gauge will fall to zero
meter which measures the engines running time in hours and
when the key switch is turned off The temperature gauge
in 110 hours The panel also includes a WATER TEMPER
will once again register the engines true temperature when
ATURE gauge which indicates water temperature in degrees
electrical power is restored to the gauge
Fahrenheit an OIL PRESSURE gauge which measures the
engines oil pressure in pounds per square inch and a DC A separate alarm buzzer with harness is supplied with every
control circuit VOLTAGE gauge which measures the sys Admiral Panel The installer is responsible for electrically con
tems voltage All gauges are illuminated when the key necting the buzzer to the fourpin connection on the engines
switch is turned on and remain illuminated while the engine electrical harness The installer is also responsible for installing
is in operation The panel also contains two rubberbooted the buzzer in a location where it will be dry and where it will
pushbuttons one for PREHEAT and one for START be audible to the operator should it sound while the engine is
running The buzzer will sound when the ignition key is turned
on and should silence when the engine has started and the
engines oil pressure rises above 15 psi 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 ENGINES NORMAL OPERATING OIL
ILLUMINATED WHILE THE KEY SWITCH IS PRESSURE RANGES BETWEEN 30 60 psi
TURNED ON THE ENGINES NORMAL OPERATING 21 42 kgcm
TEMPERATURE IS 170 190 F77 SSC
RPM GAUGE REGIS
TERS MINUTE OFTHE
ENGINE AND CAN FOR
ACCURACY FROM THE
REAR OF KEY SWITCH ELAPSED
POWER ONLY TO THE
TIME AND SHOULD BE
INSTRUMENT PANEL
USED AS A GUIDE FOR CLUSTER
THE I DC

INDICATES THE AMOUNT THE
BATTERY IS BEING CHARGED
SHOULD SHOW 13V TO 14V
PREHEAT BUTTON WHEN ENERGIZES EXCITER THE FUEL LIFT PUMP THE AUTOMATIC ALARM SYSTEM
FUEL SOLENOID ON THE INJECTION PUMP AND THE
ENGINES GLOW PLUGS IT BYPASSES THE ENGINES COOLANT TEMPERATURE ALARM AN ALARM BUZZER HAS BEEN
SUPPLIED WITH THE INSTRUMENT PANEL IF THE ENGINES COOLANT
OIL PRESSURE ALARM SWITCH IN ADDITION THIS
BUTTON ENERGIZES THE START BUTTON REACHES 210 F 99C THIS SWITCH WILL CLOSE SOUNDING THE
ALARM WHICH WILL EMIT A CONTINUOUS SIGNAL
START BUTTON WHEN PRESSED ENERGIZES THE
STARTERS SOLENOID WHICH CRANKS THE ENGINE OIL PRESSURE ALARM AN OIL PRESSURE ALARM SWITCH IS
THIS BUTTON WILL NOT OPERATE ELECTRICALLY LOCATED OFF THE ENGINES OIL GALLERY THIS SWITCH THE PREHEAT
BUTTON IS PRESSED AND HELD THE ENGINES OIL PRESSURE SHOULD THE ENGINES OIL SAME TIME
FALL TO 5 10 psi 04 07 kgcm THE SWITCH WILL CLOSE SOUND
ING THE ALARM IN THIS EVENT THE ALARM WILL EMIT A PULSATING
SIGNAL
Engines Generators
CAPTAIN CONTROL The panel also includes an alann buzzer for low On
PRESSURE or high COOLANT TEMPERATURE The
This control panel is equipped with a RPM gauge is illuminated when the KEY switch is turned on
KEY switch an RPM gauge PREHEAT and START but and remains illuminated while the engine is in an INSTRUMENT TEST button and
three one for ALTERNATOR DISCHARGE one for low
On PRESSURE and one for high ENGINE ALARM THE ALARM WILL SOUND IF THE ENGINES
OIL PRESSURE FALLS
BELOW 5 10 psi 04 07 kgem IN THIS EVENT THE ALARM WILL EMIT A
PULSATING SIGNAL THE ALARM WILL ALSO SOUND IF THE COOLANT
TEMPERATURE IN THE FRESHWATER COOLING CIRCUIT RISES TO
RPM GAUGE REGISTERS REVOLUTIONS 210F 99C IN THIS EVENT THE ALARM WILL EMIT A CONTINUOUS SIGNAL
PER MINUTE OF THE ENGINE AND CAN BE NOTE THE ALARM WILL SOUND WHEN THE KEY SWITCH IS TURNED ON FOR ACCURACY FROM
SOUNDING IS NORMAL ONCE THE ENGINE STARTS AND THE ENGINES OIL
THE REAR OF THE PANEL PRESSURE REACHES 15 psi 11 kgem THE ALARM WILL SILENCE
TEST BUTTON WHEN
PRESSED TESTS THE
ALTERNATOR THE OIL
PRESSURE AND THE
COOLANT TEMPERA
TURE CONTROL CIR
CUITS WHEN PRESSED
THE ALTERNATOR THE
OIL PRESSURE AND
THE WATER TEMPERA
TURE INDICATOR
LIGHTS ILLUMINATE IN
ADDITION TO SOUND
ING THE ALARM
BUZZER
KEY SWITCH PROVIDES
POWER ONLY TO THE
INSTRUMENT PANEL
CLUSTER
WATER ALARM LIGHT
START BUTTON WHEN PRESSED ENERGIZES THE
STARTERS SOLENOID WHICH CRANKS THE ENGINE THIS PREHEAT BUTTON WHEN PRESSED ENERGIZES THE
BUTTON WILL NOT OPERATE ELECTRICALLY UNLESS THE ALTERNATORS EXCITER THE FUEL LIFT PUMP THE FUEL
PREHEAT BUTTON IS PRESSED AND HELD AT THE SAME SOLENOID ON THE INJECTION PUMP AND THE ENGINES
TIME GLOW PLUGS AND BYPASSES THE ENGINES OIL PRES
SURE ALARM SWITCH IN ADDITION THIS BUTTON ENER
GIZES THE START BUTTON
Engines Generators
DIESEL FUEL ENGINE OIL AND ENGINE FUEL ENGINE COOLANT
Use fuel that meets the requirements or specification of Class WESTERBEKE recommends a mixture of 50 ASTM and has a cetane rating of 45 or
better and 50 distilled water Distilled water is free from the
chemicals that can corrode internal engine 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 by Additives SCAs that keep the antifreeze chemically bal
careless handling or improper storage facilities To assure anced crucial to long term the fuel going into the tank for your engines daily
use is
The distilled water and antifreeze should be premixed before
clean and pure the following practice is advisable
being poured into the cooling a wellknown brand of fuel
NOTE Look for the new long and regularly service a good visualtype fuel
antifreeze that is now 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
and they are beneficial to the engines cooling system They
retard rust and add to the life of the circulating pump seal
ENGINE OIL
Use a heavy duty engine oil with an API of CF
or CG4 or better Change the engine oil after an initial 50
ANTIFREEZE of breakin operation and every 100 hours of operation Antifreeze Concentration 23 30 35 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 10W30 or 15W40 Coolant Recovery Tank
41 6BoF 5 20C SAE 20 10W30 or 15W40 A coolant recovery tank kit is supplied with each
WESTERBEKE diesel engine The purpose of this recovery
Below 41F 5C SAE 10W30 or 15W40 tank is to allow for engine coolant expansion and contraction
during engine operation without the loss of coolant and
without introducing air into the cooling system This kit is
A CAUTION Do not allow two or more brands of provided and must be installed before operating the engine
engine oil to mix Each brand contains its own additives NOTE This tank with its short run of plastic hose is best
additives of different brands could react in the mixture located at or above the level of the engines manifold but it
to produce properties harmful to your engine can be located below the level of the engines manifold if the
particular installation makes this Pressure
The engines 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 25 and 39 A newly started cold engine can have an oil up to 60 psi 42 kgcm2 A warmed engine can have
an oil pressure reading as low as 25 psi 18 kgcm2 will vary depending upon the temperature of the
engine and the load placed on the engine
Engines Generators
PREPARATIONS FOR INITIAL starting your engine for the first time or after a pro
longed layoff check the following items
D Check the engine oil level Add oil to maintain the level
at the high mark on the dipstick
D Turn on the fuel supply then check the fuel supply and
examine the fuel filterwater separator bowl for contami
COOLANT
nants RECOVER
D Check the transmission fluid level TANK
CHECK COOLANT HERE
NOTE Refer to the 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 Good ventilation and an ample air supply are necessary
for proper engine Make sure the mounting installation is secure
D Ensure the propeller shaft is securely attached to the
Open the throughhull and prime the raw water intake
strainer Inspect the raw water supply
OIL MAKE CERTAIN
IT IS PUSHED ALL
THE WAY IN
Iiil LOW
Engines Generators
PROCEDURE
THE STARTING 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 nozzles 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 engines 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 throughhull 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 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 oclock 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
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
41F5C or higher Approx 5 seconds
discernible
41F5C to 23F 5C Approx 10 seconds
23F5C or lower Approx 15 seconds Starting Under Cold Conditions
Make sure the lubricating oil is appropriate for the The START button will not energize unless the PRE temperature Use oil with an API
Specification of CF or CG4
HEAT button is depressed Depressing the PREHEAT button SAE 30 lOW3 15W40 or the glow plugs in the cylinder head so use the PRE
The battery should be fully charged to minimize voltage drop
HEAT 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 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 deener
gizing the fuel solenoid on the injection pump 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
oclock 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
deenergized shutting off the flow offuel
Engines Generators
ENGINE BREAKIN 3 While using the vessel run the engine at various engine
speeds for the first 25 hours Avoid prolonged periods of
Although your engine has experienced a minimum of one
idling
hour of test operations at the factory to make sure procedures were followed and that the engine oper 4 Avoid rapid acceleration
especially with a cold engine
ated properly a breakin time is required The service life of 5 Use caution not to overload the engine The presence of a
your engine is dependent upon how the engine is operated grey or black exhaust and the inability of the engine to
and serviced during its initial 50 hours of use reach its full rated speed are signs of an a new engine basically involves
seating the pis 6 During the next 25 hours the engine may be operated at
ton rings to the cylinder walls Excessive oil consumption varying engine speeds with short runs at full rated rpm
and smoky operation indicate that the cylinder walls are Avoid prolonged idling during this breakin which is caused by overloading
the engine during the
breakin period CHECK LIST
Your new engine requires approximately 50 hours of initial o Monitor the control panel operation to break in each moving part in order
o Check for leaks of fuel and engine oil
to maximize the performance and service life of the this conditioning carefully keeping in mind the fol
o Check for abnormal noise such as knocking friction
vibration and blowback 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 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 breakin information on your the 130 140F 55 60C range
Engines Generators
THE DAILY 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 CHART in
D Check your fuel supply this manual
D Look for clean fuel in the fuel filterwater 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 engines 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 PROCEDURE in this throughhull 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 should keep this
NOTE Hydraulically operated transmissions have a inmnd
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 oclock
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 BUTION and press the START
If the key switch is left ON the
BUITON 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 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 if these readings start to vary
Engines Generators
WARNING liGHTS ALARMS CIRCUIT WARNINGS LOW OIL PRESSURE ALARM SWITCH
The Captain Control Panel indicates alternator low discharge A low oil pressure alarm switch is located off the engines
with a red warning light oil gallery This switchs sensor monitors the engines oil
The Admiral Control Panel uses a voltmeter to monitor the pressure Should the engines oil pressure fall to 5 10 of the alternator
04 07kgcm2 this switch will activate a pulsating TEMPERATURE SWITCH
A coolant temperature switch is located on the This switch will activate a continuous alarm if the
coolants operating temperature reaches approximately 210 0
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
MAINTENANCE SCHEDULE
In order to use this Maintenance Schedule it will be neces
sary to log your engine hours Use your engine hourrneter or A WARNING Never attempt to perform any your engine hours by running time
while the engine is running Wear the proper safety
NOTE Many of the following maintenance procedures are equipment such as goggles and gloves and use the
simple but others are more difficult and may require the correct tools for each job Disconnect the knowledge of a service
mechanic terminals when servicing any of the engines DC
electrical equipment
SCHEDULED CHECK HOURS OF OPERATION
EACH MAINTENANCE DESCRIPTION
MAINTENANCE
DAY 50 100 250 500 750 1000 1250
Fuel Supply D Diesel No2 rating of 45 cetane or higher
FuelWater Separator D Check for water and dirt in fuel 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 38 to 12 deflection
weekly and adjust if needed Check belt edges for wear
of Engine D NOTE Keep engine surface clean Dirt and Check for fuel oil and water leaks Inspect wiring
oil will inhibit the engines ability to remain and electrical connections Keep bolts nuts tight
cool Check for loose belt tension
Fuel Filter 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 changeat 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
FuelWater 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 antiSiphon valve
operation Check the exhaust elbow for carbon
andor corrosion buildup on inside passages
clean and replace as necessary Check that all
connections are 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 WD40 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
Engines Generators
MAINTENANCE SCHEDULE
NOTE Use the engine hourmeter gauge to log your engine hours or record your
engine hours by running time
SCHEDULED CHECK HOURS OF OPERATION
MAINTENANCE EACH MAINTENANCE DESCRIPTION
DAY 50 100 250 500 750 1000 1250
Coolant System D D Drain flush and refill cooling system with
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 cleaned and pressure
tested
Engine Transmission D Chattering at idle and low rpms is an indication
Damper Plate of damper plate wear Remove and replace
D Check and adjust injection opening pressure and
spray 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 XX ohms Reinstall with antiseize
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
Heat Exchanger D Remove have cleaned and pressure
tested
Lubricate Panel Key Switch D D D D D D At first 100 hours then each year at winterizing
with Lockeze
Transmission Fluid D D D D D D Initial fluid change at 25 hours then every
300 hours or at recommends this service be performed by an authorized Engines Generators
COOLING When the engine is started cold external coolant flow is pre
vented by the closed thermostat although some coolant marine diesel engines are designed and equipped
is bypassed around the thermostat to prevent the exhaust
for fresh water cooling Heat produced in the engine by com
manifold from overheating As the engine warms up the
bustion and friction is transferred to fresh water coolant
thermostat gradually opens allowing full flow of the circulates throughout the engine This circulating fresh
coolant to flow unrestricted to the external portion of the
water coolant cools the engine block its internal moving
cooling and the engine oil The heat is transferred the fresh water coolant to raw water by means of a heat Coolant Recovery similar in
function to an automotive radiator Raw
water flows through the tubes of the heat exchanger while A coolant recovery tank allows for engine coolant water coolant flows around
the tubes engine heat trans and contraction during engine operation without any to the fresh water coolant is conducted through the
cant loss of coolant and without introducing air into the cool
tube walls to the raw water which is then pumped into the ing system This tank should be located at or above the
exhaust system where finally it is discharged overboard In engine manifold level and should be easily words the engine is cooled by fresh
water coolant this CHANGING is cooled by raw water and the raw water carries the
The engines coolant must be changed according to heat overboard through the exhaust system The
MAINTENANCE SCHEDULE If the coolant is allowed to
fresh water coolant and raw water circuits are independent of
become contaminated it can lead to overheating other Using only fresh water coolant within the engine
allows the cooling water passages to stay clean and free from
harmful deposits A CAUTION Proper cooling system maintenance is
FRESH WATER COOLING CIRCUIT critical a substantial number of engine failures can be
traced back to cooling system Refer to the ENGINE COOLANT section for the rec
ommended antifreeze and water mixture to be used as the Drn 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 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
COOLING SYSTEM
Refilling the Coolant Replacing the Thermostat
After replacing the engine block drain plug close the heat Remove the cap screws and disassemble the thermostat hous
exchangers coolant petcock Then 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 overtighten the cap
NOTE Open the airbleed 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
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
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 exhaust elbow mixing with and cool
ing the exhaust gasses This mixture of exhaust gas and raw
water is discharged overboard by the engines exhaust gas
CHECKING
THE PRESSURE discharge pressure
Raw Water Pump
The raw water pump is a selfpriming rotary pump with a
nonferrous housing and a neoprene impeller The impeller
THERMOSTAT has flexible vanes which wipe against a curved cam plate
A thermostat located near the manifold at the front of the within the impeller housing producing the pumping action
engine controls the coolant temperature as the coolant contin On no account should this pump be run dry as water acts as a
uously flows through the 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 bypassed through a hole in the Raw water pump impeller failures occur when lubricant raw
thermostat to prevent the exhaust manifold from overheating water is not present during engine operation Such failures
As 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 startup
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
COOLING SYSTEM
Changing the Raw Water Pump Impeller NOTE Also follow the above procedure after having run hard
Close the raw water intake valve Remove the pump cover aground
and with the aid of two small screwdrivers carefully pry the If the engine temperature gauge ever shows a higher than
impeller out of the pump Install the new impeller and gasket normal reading the cause may be that silt leaves or grass
Move the blades to conform to the curved cam plate and may have been caught up in the strainer slowing the flow of
push the impeller into the pumps housing When assem raw water through the cooling system
bling apply a thin coating of lubricant to the impeller and
gasket Open the raw water intake valve INCOMING RAW
WATER
CHECK AT THE BASE OF
EACH BLADE BY BENDING THE IMPELLER IF
SEACOCK
ARE ANY CRACKS
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 selfpriming ZINC ANODE 11
A clean raw water intake strainer is a vital component of the
engines cooling system Include a visual inspection of this
strainer when making your periodic engine check The water 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
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 egine models heat exchanger end gasket part num
ber Onng 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 engines 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 andor tropical waters may require
NOTE Electrolysis action is the result of each particular that a heat exchanger cleaning be performed more often and vessel location not
that of the engine every 1000 hours
Engines Generators
FUEL SYSTEM
DIESEL FUEL TO FUEL FILTER
Use No2 diesel fuel with a cetane rating of 45 or higher Do
not use kerosene or home heating fuel GROUNO
FUEL FILTERWATER SEPARATOR
A primary fuel filter of the water separating type must be FUEL LIFT 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 filterwater separator with the
FUEL FILTERS package as they are aware of the problems that The fuel injection pump and the fuel
injectors are in the fuel can cause manufactured and they must receive clean diesel fuel free
from water and dirt To ensure this flow of clean fuel the fuel
A typical fuel filterwater separator is illustrated below This
must pass through at least two fuel filters a fuel the Rayeor Model 500 MA Keep in mind that if a water
separator and the engines spinon fuel filter Visually type filter is not installed between the fuel supply
clean and change these filters according to the and fuel system any water in the fuel
schedule in this manual
will affect the fuel pump engine filter and injection equip
ment The is responsible for making certain
the fuel reaching the engines injection equipment is free This process is accomplished by installing and
A WARNING Shut off the fuel valve at the a proper fuel filterwater separator when servicing the fuel system Take care in
catching
any fuel that may spill DO NOT allow any smoking
open flames or other sources of fire near the fuel sys
tem when servicing Ensure proper ventilation when servicing the fuel
LOOSEN FITTING l4
WHEN PRIMING Ul9
FILL FILTER
The fuel injection pump is a very important component of
the diesel engine requiring the utmost care in handling The
fuel injection pump has been thoroughly benchtested and is cautioned not to attempt to service it If it
requires servicing remove it and take it to an authorized 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 with a
speed see IDLE SPEED ADJUSTMENT under ENGINE
filter wrench Place the used filter in a container for LIFT PUMP
3 Using a rag wipe clean the sealing face on the check the fuel connections to and out of the
bracket so the new filter can be seated and make sure that no leakage is present and that the 4 Lightly oil the sealing Oring on
the new filter To are tight and secure The DC ground connection at stall tum the filter assembly carefully
one of the pumps mounting bolts should be clean and well until the oring contacts the sealing surface of the by the mounting bolt
to ensure proper pump opera bracket Tum 23 further with the filter
5 The keyon 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
GLOW Reinstall 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 dont heat up quickly check for a
When PREHEAT is pressed at the control panel this solenoid
short circuit When reinstalling the glow plugs use click on and the glow plug should begin to get hot
compound on the threads
Glow Plug Tightening Torque 7 11 IbH 10 15 inspect the plug remove the electrical terminal then unscrew or unclamp each plug from the cylinder
A WARNING 00 not keep a glow plug on for more
head Thoroughly clean each plugs 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 accurate way to test glow plugs is with an one prod to the glow plugs wire connection and
the other to the body of the glow plug as shown A good
glow plug will have a 10 to 15ohm resistance This Tightening can be used with the plug in or out of the engine
JO 15 mkg 7 llftlb
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
ENGINE OIL
ENGINE OIL CHANGE When installing the new oil filter element wipe the filter
gaskets 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
yellowgray emulsion indicates the presence of water in OIL FILTER PN35828
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 andor a siphoning
of raw water through the raw water cooling circuit into
the exhaust filling the engine This problem is often
caused by the absence of an antisiphon valve its poor
location or lack of PRESSURE SWITCH
OIL FILTER ASSEMBLY
NOTE Generic filters are not recommended as the mater
ial standords 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 engines 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
REMOTE OIL FILTER NOTE Westerbeke is not responsible for engine failure due to
lbis popular accessory is used to relocate the engines oil fil
incorrect installation of the Remote Oil Filter
ter from the engine to a more convenient location such as an
engine room Refer to ENGINE OIL CHANGE in this manual for A CAUTION It is vital to install the oil lines 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 remote oil filter
kit as shown Always from reaching the engine causing an intemal this kit with the oil filter facing down as illustrated
failure If there is no oil pressure reading your WESTERBEKE dealer for more information immediately and
check the APPLY A THIN COAT OF CLEAN OIL TO THE ORING WHEN
INSTALLING THIS KIT THREAD THE KIT ON THEN HAND
TIGHTEN AN ADDITIONAL 34 TURN AFTER THE ORING
CONTACTS THE BASE
THE IN CONNECTION HOSE
MUST ATTACH TO THE OUT
CONNECTION ATTHE
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 Engines Generators
METER NOTE Current model tachometers use a coarse meter used in propulsion engine instru
dial to set the tachometer to the crankshaft pulley rpms The
ment panels contains two separate electrical circuits with a calibrating screw is then usedfor fine 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 68 volts fed
from one of the diodes in the alternator and supplied to input terminal while the engine is running and
the alternator producing battery charging voltage 130148
The following are procedures to follow when fault in either of the two circuits in a
COARSE
ADJUSTMENT TACHINP
AC VOLTAGE
Hour meter Inoperative for the proper DC voltage between and
IDLE SPEED ADJUSTMENT
1 Voltage present meter is defective repair or replace
TACHOMETER CHECK New Voltage not present trace and electrical con
nections for fault Jump 12 volts DC to meter Checking the idle speed
terminal to verify the operation NOTE In a new installation having new instrument panels
the tachometer may not always be correctly calibrated to Inoperative engines rpm This calibration
should be checked in all new
Check for the proper AC voltage between tachometer input and terminal with the engine running 1 Warm up the engine
to normal operating Voltage present attempt adjusting meter through calibra Remove any specks on the crankshaft pulley with a clean
tion access hole No results repair or replace meter cloth and place a piece of suitable reflecting tape on the
2 AC voltage not present check for proper alternator DC pulley to facilitate use of a photoelectric type tachometer
output voltage 2 Start and idle the engine
3 Check for AC voltage at tach terminal on alternator to 3 Aim the light of the tachometer onto the reflecting tape to
ground confirm the engine speed Check the instrument panel
4 Check electrical connections from tachometer input ter tachometer reading Adjust the tachometer in the panel by
minal to alternator connection using the instrument calibration pod as needed to bring
the instrument panel tachometer into the same 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 Check that alternator is well grounded to engine block at
alternator pivot Inaccurate
a With a handheld tach on the front of the crankshaft
pulley retaining nut or with a strobetype tach read the
front crankshaft pulley rpm at idle
b Adjust the tachometer with a small Phillips type screw
driver through the calibration access hole in the rear of
the tachometer Zero the tach and bring it to the rpm
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
WATER HEATER
WATER HEATER INSTALLATIONS The pressure cap on the engines manifold should be
installed after the engines 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 onboard water heater
tank after the system is filled and is free of air and exhibits
The water heater should be mounted in a convenient location
good coolant circulation During engine operation in a high or low position in relation to the engine so
the engines coolant should be done at the remote tank and
that the connecting hoses from the heater to the engine can
not at the engine manifold cap The hose connection from the
run 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
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 engines
heat exchanger Open this petcock when filling the If any portion of the heating circuit rises above the coolant system to allow air in
the exchanger to own pressure cap then a pressurized aluminum
Close tightly after all the air is expansion tank Kit 024177 must be installed in the
circuit to become the highest point Tee the remote into the heater circuit choosing the higher of the for the return Tee at the heater and plumb a
single line up to the tanks location and the other back to the
engines return 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 Engines Generators
DC ELECTRICAL SYSTEM
ALTERNATOR 1 Start the engine
The charging system consists of a DC belt driven alternator 2 After the engine has run for a few minutes measure the
with a voltage regulator an engine DC wiring harness a starting battery voltage at thebattery 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 lCs 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 continue with Steps 3 through 8
BLUE
MULTIMETER
SEE WIRING DIAGRAM
ENGINE FOR WIRE CONNECTIONS
GROUND TO OPTIONAL ALTERNATOR TESTING THE STARTING
A WARNING A failed alternator can become very ENGINE RUNNING
hot Do not touch until the alternator has cooled down
Use this 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 batterys charging circuit and not with the alterna
S Turn on the ignition switch but do not start the engine
6 Check the battery voltage If the battery is in good condi
Testing the Alternator tion the reading should be 12 to 13 volts
A CAUTION Before starting the engine make certain G2ID
that everyone is clear of moving parts Keep away from
sheaves and belts during test procedures
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 eg
IGNITION ON ENGINE OFF
Engines Generators GROUND
DC ELECTRICAL SYSTEM
7 Now check the voltage between the alternator output ter Checking the Service Battery
minal B and ground If the circuit is good the voltage at
Check the voltage of the service battery This battery should
the alternator will be the same as the battery or if an isola
have a voltage between 13 and 14 volts when the engine is
tor is in the circuit the alternator voltage will be zero If
running If not there is a problem in the service battery
neither of the above is true a problem exists in the circuit
charging circuit Troubleshoot the service battery charging
between the alternator and the battery Check all the
circuit by checking the wiring and connections the solenoid
connections look for an opening in the charging circuit
isolator battery switch and the battery itself
MULTI METER Cl25J
TESTING THE STARTING
ENGINE
ENGINE RUNNING c GROUND
8 Start the engine again Check the voltage between the
alternator output and ground SERVICE BATTERY
The voltage reading for a properly operating alternator
should be between 135 and 145 volts If your alternator GROUND TESTING THE SERVICE
is over or have it repaired at a reliable BATTERY ENGINE RUNNING
service facility
NOTE Before removing the alternator for repair use a
voltmeter to ensure that 12 volts DC excitation is present
at the EXC terminal if the previous test showed only bat A CAUTION To avoid damaging the altemator diodes
tery voltage at the B output terminal do not use a high voltage tester ie a megger when
performing tests on the altemator charging circuit
If 12 volts is not present at the EXC terminal trace the
wiring and look for breaks and poor VOLT DC CONTROL CIRCUIT Battery Care
The engine has a 12 volt DC electrical control circuit that is Review the and then
shown on the wiring diagrams that follow Refer to these establish a systematic maintenance schedule for your
diagrams when or when servicing the DC engines starting batteries and house system
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
engines electrical circuit tight to the battery posts and to your engine
D Keep your batteries clean and free of minimum recommended capacity of the battery used in
the engines 12 volt DC control circuit is 600 900 Cold
Cranking Amps CCA
A WARNING Sulfuric acid in lead batteries can
cause severe bums on skin and damage clothing Wear
protective gear
Engines Generators
630 FOUR ENGINE
WIRING DIAGRAM 39144
sn HOTE
I J
An onoff 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 draw 200 to 300
ALARM
lutUIt
ADMIRAL
amps when cranking A PANEL
switch with a of 175 amps at 12
VDC will nonnally serve
this function but a switch
must never be used to
make n the starter circuit
tl Itn
CAPTAIN
PANEL
Engines Generators
630 FOUR ENGINE
WIRING SCHEMATIC 39144
f
12 vDe
nTEI NOTES
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 EII WILL
SIT THE II
EHIIE All IIUAU
I lIMIT I lUI TIIAT THE ITItUNUT PANEL WI AD
YIlT TACT IETlIEII ELECTICAI EVICES AID su n
Z AI 01 RITCI IE IIITALLED TftEM TI IAnElT AND STAiTEI TO
ECT TIlE I AI bII1ICl AD WIIEIf LEAYI THE 100T A awnCH
I COITI
WITIIA DICIT OF 115 AT 12 1DC WILL EIVE THII CTIOfi TU
DIED TO E 01 IIIAI TIE CIICUIT
I Til I WIlE AT LUI Z I UIUIE AI SHOULD IE INSULATE CATAI AlEL OILY
TIll IAY W AT tL Z II UIIUIID AID SHOULD IE NSULATED ADNIIAl AHEL OIU
10TE
WI 01 IAnEl AnATeMMEII WILLMEED
TO I UADED to All IAutE FlOil I 0 IAUI
MITSYBISHI 50 AHP ALI
LIFT UN
fUlL IWI
SUDlI
114 GRA
11 11 1 1111111 II PRESTOLI TELEECEHEV ILLE 90 AMP ALT
PIt 1 riII
iiiii Ii
Ar TAcNOIUUI
ADMIRAL
Il1 W PANEL
AC TAP
t l alII
Ull 114 LT BLU
114 PINK
110 RED
11 1 PRESTOl I IE 72 AMP
ALI
114 BRN
CAPTAIN
PANEL
LAP II 4 GRA
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
OPT IONAl AL IERNAIORS
1110 IUA 1t0A LESTEX ALTERNATORS
rMLJ jJ is rt lip if UP g 91P on I Rae i5 2Ml
Engines Generators
DUAL OUTPUT ALTERNATORS SPACER TO MOUNTING
output and high output alternators are available as
optional equipment on most WESTERBEKE engines can be installed during factory assembly or as
addon equipment at anytime
Dual alternators can be configured to charge two banks of
batteries at the same time or using a battery selector each set of batteries separately
an optional dual alternator has already been factory follow the WESTERBEKE wiring diagram and the
engine installation the new dual alternator is being added to an existing engine carefully follow the alternator below
1 Disconnect the alternators negative cable from the battery
2 Remove the alternator and disconnect or tape off the
output positive cable Do not reuse
3 Install the new Attach a new heavy gauge output cables from the
alternators output terminal s Using the cable sizes
indicated
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
A CAUTION Do not connect any power source TO
without first grounding the regulator
h Plug the 2pin 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 COWNECTS 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 Engines Generators
DUAL OUTPUT Alternator Testing
NOTE Before make certain that the drive The regulator is functioning properly and the are tight and the batteries are in good condition
are in good Testing 1 Test the voltage at the alternator plug with the engine
otTkey on The voltage at the alternator terminal F and
The red battery sensing wire A connects to the battery it the voltage in the plug blue wire F from the always read battery voltage If
battery voltage is not should read the trace the wire for a bad connection
2 Hold a screw driver close 112 to the alternator pulley
The orange wire S should read 0 volts with the key off 12 If voltage is present you should feel the magnetic field If
volts with the key on If the readings are not the problem may be the brushes worn or the trace the wire for a bad connection
open circuit
The blue wire F supplies current to the alternator fields its 3 Start the engine at fast idle the output terminals will vary depending on the
battery charge or actual indicate 142 volts no load A reading of 126 The readings can vary from 4 to 12 volts with the
indicate the alternator is not performing properly
key on 0 volts with the key off
Apply a load such as an electric bilge pump the voltage
KEY ON NO VOLTAGE REGULATOR IS DEFECTIVE should maintain at least 138 volts 13 volts or less
KEY OFF BATTERY VOLTAGE REGULATOR IS DEFECTIVE indicates the alternator is TEST POINTS AND PROPER VOLTAGE
Engine Running
Ignition Off IgnRion On
I Brown o volts 2 12 Yolts 142 yolts D When the engine is first started it takes a few moments
A Red 126 volts 12 volts 142 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 126 yolts 12 yolts 142 volts D A slight whine is normal when running with a full load
on the alternator
D When the alternator is producing high amperage it will
become very hot
D When replacing the alternator drive belts always
purchase and replace dual belts in matched pairs
Engines Generators
ENGINE following table describes certain problems NOTE The engines electrical system is protected by a 20
relating to engine service the probable causes of these prob ampere manual reset circuit breaker located on a bracket at
lems and the to overcome these problems the back of the engine The preheat solenoid is mounted on
the same bracket
Problem Probable Cause No panel indications fuel solenoid 1 Battery switch
not on 1 Check switch andor battery connections
or fuel pump is not working key switch
is on and PREHEAT button is depressed 2 20amp circuit breaker tripped 2 Reset breaker if breaker trips again check preheat solenoid
circuit and check circuit for shorts to ground
3 10amp breaker tripped on 3 Check the voltage both at and after the breaker on the
preheat solenoid preheat solenoid
4 Loose battery connections 4 Check connection to starter solenoid and connection to
engine ground stud Check battery cable connections
5 Preheat solenoid not operating 5 Check solenoid S terminal for voltage
START button is depressed no starter 1 Connection to solenoid faulty 1 Check connection
engagement
2 Gear shift not in neutral 2 Gear shift must be in neutral see NEUTRAL SWITCH under
HURTH HSW 3 Faulty switch 3 Check switch with ohmmeter
4 Faulty solenoid 4 Check that 12 volts are present at the solenoid connection
5 Loose battery connections 5 Check battery connections
6 Low battery 6 Check battery charge state
START button is depressed panel 1 Poor connections to fuel solenoid 1 Check connections
indications OK starter solenoid OK
fuel solenoid not functioning 2 Defective fuel solenoid 2 Check that 12 volts are present at the connection on the
fuel run solenoid
Engine cranks but does not 1 Faulty fueling system 1 Check that fuel valves are open
start fuel solenoid energized
1a Check for air in fuel system Bleed air from fuel system
1b Fuel filters clogged Replace filters and bleed air from
fuel system
2 Preheat solenoid faulty 2 Check solenoid
3 Low battery power 3 Switch to combine house and start batteries
3a Replace batteries
Engine cant be stopped 1 Faulty DC alternator 1 Remove Exc connection at alternator repair alternator
2 Disconnect fuel shutoff cable 2 Check connection at shutoff lever Pull lever back to close
offthe fuel
3 Fuel run solenoid will not deenergize 3 Manually disconnect the 12 volt connection to the fuel run
solenoid at the injection pump
Battery runs down 1 Oil 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 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
Engines Generators
ENGINE Problem Probable Cause Engine slows and stops 1
Fuel lift pump failure 1 Fuel lift pump should make a distinct ticking sound Replace
pump with spare
2 Switches andor wiring loose 2 Inspect wiring for short circuits and loose connections
or disconnected Inspect 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 tanks change filters and
bleed fuel system
7 Air intake obstruction 7 Check air intake filter cartridge
Engine down 1 Raw water not circulating 1 Raw water pump failure Check impeller replace
2 Coolant not circulating 2 Obstruction at raw water intake or raw water filter
2a Thermostat remove and test in hot water
Replace thermostat
2b Loss of coolant check hoses hose clamps drain plug etc
for leaks
2c Broken or loose belts 2d Air leak in system run engine and
open the pressure cap to
bleed air Add coolant as needed
Engine alarm sound pulsates 1 Loss of oil 1 Check dipstick look for oil leaks at oil filter and at
oil drain hose connection
2 Oil pressure switch 2 Replace oil pressure switch
Engine alarm sounds continuously 1 Engine coolant 1 Check engine coolant level
2 High temperature switch opens at 2 Check for satisfactory operation with switch bypassed
too Iowa temperature check with ohmmeter replace if faulty
Exhaust smoke problems 1 Blue smoke 1 Incorrect grade of engine oil
1a Crankcase is overfilled with engine oil oil is blowing out
through the exhaust
2 White smoke 2 Engine is running cold
2a Faulty injector or incorrect injector timing
3 Black smoke 3 Improper grade of fuel
3a Fuel bum incomplete due to high backpressure in exhaust or
insufficient air for proper combustion check for restrictions in
exhaust system check air intake
3b Improperly timed injectors or valves or poor compression
3c Lack of air check air intake and air filter Check for proper
ventilation
3d Overload
COOLANT TEMPERATURE AND OIL PRESSURE GAUGES
If the gauge reading is other than what is normally indicated If both of the above gauge tests are positive the gauge is
by the gauge when the instrument panel is energized the first undoubtedly OK and the problem lies either with the
step is to check for 12 volts DC between the ignition B conductor from the sender to the gauge or with the sender
and the Negative B terminals of the gauge If either of the above gauge tests are negative the gauge is
Assuming that there is 12 volts as required leave the probably defective and should be panel energized and perform the
following steps Assuming the gauge is OK check the conductor from the
1 Disconnect the sender wire at the gauge and see if the sender to the sender terminal at the gauge for continuity
gauge reads zero which is the normal reading for this Check that the engine block is connected to the ground
situation Some starters have isolated ground terminals and if the
2 Remove the wire attached to the sender terminal at the battery is connected to the starter both plus and minus
sender and connect it to ground See if the gauge reads terminals the ground side will not necessarily be connected
full scale which is the normal reading for this situation to the block
WESTERBEKE
Engnes Generators
HURTH HBW OPERATION OPERATING HBW marine transmissions are testrun on a test stand
The maximum permissible ATF temperature should not exceed
with the engine at the factory prior to delivery For safety 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 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
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 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 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 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
drain into a container then reinstall the plug with its 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 the fluid level
operated multiple disc clutch
Gear ratio optional 263 1 HBW 150A 3R
DRAIN PLUG TORQUE 20 25 ftIbs
299 1 HBW 150v 3R
274 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 059 US qts 0561 liters
Capacity HBW 150V 111 US qts 105 liters
HBW 250 075 US qts 079 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 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
the TRANSMISSION 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
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 OSmm
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
pOitions 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
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 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 is a product of Globe Marine Rockland
Engines Generators 002 in 05mm
MINIMUM CLEARANCE
HURTH 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 Normal operating temperature of the
transmission fluid
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 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 COOLER ZF Industries
3131 Sw 42nd Street
INSPECT FOR
EROSION AND LEAKAGE Fort Lauderdale FL 33312
TRANSMISSION Tel 954 5814040
Engines Generators
BORG WARNER VELVET DRIVE TRANSMISSION
OPTIONAL TRANSMISSION
SHIFT LEVER POSITION
The gear shift control mechanism and linkage must position
the actuating lever on the transmission exactly in Forward
F Neutral N and Reverse R shifting positions A 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 safety reasons the transmission is not filled with fluid during shipment and the
selector lever Move the gear shift lever to the middle position You should
is temporarily attached to the actuating shaft feel the detent This centers the actuating lever on the trans
Before leaving the 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 The residual fluid remaining
in the transmission after sion does not acts as a preservative and provides corrosion for at least one year if properly stored
NOTE Some transmissions are equipped with a neutral safety
switch Unless the transmission actuating lever is FLUID aligned in neutral the engine starter will
not the transmission fluid level on the dipstick If has not been filled fill with Dextron III and to use this fluid During the first 25
hours of Move the gear shift lever to the forward position You keep a lookout for any leakage at the bell housing feel the detent
The actuating lever on the transmission is in
output shaft and transmission cooler This fluid should be the forward position The output shaft and the propeller shaft
changed after the first 25 hours and approximately every move the boat in a forward operating hours thereafter andor at winter layup
Reverse
Move the gear shift lever to the reverse position You should
A CAUTION Be certain the transmission is filled feel the detent The actuating lever on the transmission is in
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
BORG WARNER VELVET DRIVE TRANSMISSION
D Clean off the transmission and properly dispose of the
used fluid
D Refill the transmission with DEXTRON III ATF The
quantity will vary depending on the transmission model
and the installation angle Fill through the dipstick hole
D Check the dipstick for the proper fluid level
D Replace the oil filler cap and dipstick Press the dipstick
into place and tum clockwise until D Run the engine shutdown and recheck the
fluid level
FORWARD NEUTRAl REVERSE
TRANSMISSION ACTUATING LEVER POSITIONS
A WARNING Never pullout the dipstick while the
engine is running Hot fluid will splash from the OPERATION hole This could cause severe burns
D Check the transmission fluid
D Visually check the gear shift linkage and transmission Oil Capacity
D Start the engine in neutral Allow a few minutes at idle Approximately 25 quarts 236 liters will fill most transmis
for the fluid to warm sions to the oil level fill mark on the dipstick Many variables
NOTE Too Iowan idle speed will produce a chattering have a direct relationship to the oil capacity Additional oil
noise from the transmission gear and damper plate In will be required to fill the oil cooler and the cooler lines The
such cases the idle speed should be increased angle of installation will make a difference in the quantity of
oil required to fill the Shift into gear
A CAUTION Shifting gears above 1000 rpm can
cause damage to the engine damper plate Pulling the FLUID LEVEL
throttle back to idle when shifting gears will save wear MAKE CERTAIN THE
RUBBER SEAL IS
on the transmission and the damper plate SCREWED FUU
TIGHT TO THE
Visually check for oil leaks at the hydraulic connections
Check for wear on the hydraulic lines and replace if
worn
D Lubricate the detent ball and shift cable Inspect the shift linkage
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 Ibin2 67 84 kgcm2 and be
be changed at every 300 operating hours thereafter or at win constant
ter haulout However the fluid must be changed whenever it
becomes contaminated changes color or smells rancid
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 capdipstick hole
Engines Generators
BORG WARNER VELVET DRIVE WARRANTY maintenance is minimal Keep the exterior
Service manuals are available from your BORG clean check the fluid level as part of your regular and change the fluid every 300 operating
hours For assistance inspect the transmission and the cooler for leaks BORG WARNER
and corrosion Make certain the air vent is clear and when 200 Theodory Rice the fluid level look for signs of water contamination
New Bedford MA 02745
fluid will appear as strawberry cream Tel 508 BORG WARNER
is aware of the shock loads that can be
placed on its gears as the result of mechanical propeller oper
Storage requires special care Follow these procedures
ation or fully reversing of the propeller blades while shifting
o Drain the water from the transmission oil cooler and Therefore torque loads and directional changes should be
replace it with a proper mixture of antifreeze coolant made at low engine speeds If it is found that a failure was
NOTE This operation will usually occur when the engine caused by a shock load any warranty claim will be denied
raw water cooling system is properly winterized
o Clean up the transmission and touchup unpainted areas A CAUTION noises or vibrations can
use heat resistant paint occur at low engine speeds which can cause gear rattle
o Fill the transmission with Dextron III ATF fluid to resulting in damage to the engine andor prevent internal corrosion
Extended storage only BORG WARNER is not responsible for total system
12 months or more related torsional vibration of this type
o Loosen attaching hardware 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 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 COOLERS
The continued flow of raw water through the cooler will in If water has contaminated the fluid the transmission fluid
time erode the inside of the cooler causing cross leaks to needs to be cleaned out and replaced with fresh fluid It will
occur These internal cooler leaks will cause one of the take several fluid changes to get rid of the two problems
Check your dipstick each time until it appears as pure trans
mission fluid Change the transmission filter and clean out
1 Transmission fluid will leak into the flow of raw water the fluid lines that connect to the cooler
and be discharged overboard through the engine exhaust
A loss of transmission fluid will cause 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 depending on operating hours tropical
fluid will appear as strawberry cream The transmission waters maintenance etc it might only last half that time
will eventually fail WESTERBEKE recommends having a spare cooler case requires an immediate response
1 Install a new oil cooler
2 Refill the transmission with DEXTRON III ATF
Engines Generators
TRANSMISSION 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 or
make sure theres no binding inside the with control cables hydraulic 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 isnt turning the adjustments
needs professional attention If it does tum but theres 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 the shaft or if you have a folding or feathering propeller that
level then have a helper move the cockpit shift lever through it isnt 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 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 tight bends and check any linkage for binding
Problem Probable Cause Transmission gears cannot be shifted
1 Actuating lever is loose 1 Tighten damping bolt on 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 beO02 in 05mm
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 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 0003 in
Engines Generators
TRANSMISSION Problem Probable Cause 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 If you suspect a major problem in your contact your WESTERBEKE dealer or an
authorized marine transmission Engines Generators
ENGINE BELT ADJUSTMENT FUEL 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 andor 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 pumps 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 buildup or the like work
in high operating temperatures and tachometer variations the injector sidetoside 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 38 inch lOmm and no more than 112 inch The injector seats in the cylinder head on a copper 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 HIb 55 05 kgfm
drive belts tension while the engine is in 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 Engines Generators
ENGINE ADJUSTMENTS
NOTE WESTERBEKE recommends that the following engine adjust
ments be performed by a competent engine mechanic The information
below is provided to assist the OIL PRESSURE LOW OIL PRESSURE
The lubricating system is a pressure feeding system using an The specified safe minimum oil pressure is 43 14 psi 03
oil pump The engine oil is drawn from the oil sump by the 01 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 oil cooler and various
lubricating points in the engine readings see the ENGINE chart
The oil then returns to the oil sump to repeat the When the oil pressure exceeds the specified pressure OIL PRESSURE 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 a mechanical oil pressure gauge in its place After OIL PRESSURE
SENDER AND SWITCH up the engine set the engine speed at approx 9 13 ttIb 12 18 mKg
3600 rpm and read the oil pressure PRESSURE 5404 Ibin 38 Kgem or more at
approx 3600 rpm
Engines Generators
ENGINE ADJUSTMENTS
NOTE WESTERBEKE recommends that the following engine adjust
ments be performed by a competent engine mechanic The information
below is provided to assist the CLEARANCE ADJUSTMENT 8 Adjust each valves clearance by inserting a
0012in
003mro 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
engines valves
4 Loosen the head bolts in the reverse order of tightening
3
9 Install the cylinder head cover
HEAD COVER BOLT TORQUE 2 3 It Ib 03 045 mkg
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 shutoff solenoid wire and install a HEAD BOLTTORQUE 80 85 It Ib 110 117 mkg
adapter in the injector hole or glow plug hole Connect a
6 Set the piston of No1 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 Repeat this process for each cylinder Look for cylinders with
Intake No1 and No2 cylinders and dramatically at least 20 lower compression than the aver
Exhaust No1 and No3 cylinders age of the others Compression pressure should not differ by
7 Turn the crankshaft once setting the piston of No4 more than 427 psi 30 kglcm2 at 200 rpm
cylinder at TDC compression and adjust to the follow
ing Intake No3 and No4 cylinders and
Exhaust No2 and No4 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 300 kgem
COMPRESSION PRESSURE LIMIT 384 psi al200 rpm 270 kgem
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
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
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 COMPRESSION INJECTION PUMP
When low compression is found determine the cause by For disassembly inspection reassembly and internal 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 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
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 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 reinstalling the glow plugs use antiseize compound
connection
2 The solenoid does not stop the THE IDLE SPEED PROPULSION ENGINE when the keyswitch is switched OFF SPRING
1 Warm the engine to normal operating 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 bRemove 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
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 to reduce
NOTE Should engine rpm be in question verify
as shown at the instrument panel
See THROTTLE STOP
SCREW
KEEP LINKAGE
WELL Engines Generators
LAYUP Fuel System owners rely on their boatyards to prepare their craft
Top off your fuel tanks with unleaded gasoline of 89 engines and generators for layup during the off of higher A fuel conditioner such as
STABIL or for long periods of inactivity Others prefer to stabilizer should be added Change the element in layup preparation themselves
separator and clean the metal bowl
The procedures which follow will allow you to perform your Reinstall and make certain there are no leaks Clean
own layup and or you may use them as a up any spilled fuel
check list if others do the procedures Fuel System procedures should afford your engine protection
Top off your fuel tanks with No2 diesel fuel Fuel a layup and also help familiarize you with the such as BIOBOR and STABIL should be
added at this time needs of your engine control algae and condition the fuel Care should be taken
If you have any questions regarding layup procedures call that the additives used are compatible with the primary fuel
your local servicing dealer he will be more than willing to filterwater separator used in the system Change the assistance
in your primary fuel filterwater separator if the fuel system
has one and clean the separator sediment Shaft Coupling Propulsion Engine
Change the fuel filter elements on the engine and bleed the
The transmission and propeller half couplings should always
fuel system as needed Start the engine and allow it to run
be opened up and the bolts removed when the boat is hauled
for 5 10 minutes to make sure no air is left in the fuel
out of the water or moved from land to water and during
system Check for any leaks that may have been created in
storage in the cradle The flexibility of the boat often puts a
the fuel system during this servicing correcting them as
severe strain on the propeller shaft or coupling or both while
needed Operating the engine for 5 10 minutes will help
the boat is taken out or put in the water In some cases the
allow movement of the treated fuel through the has actually been bent by these strains This does not
equipment on the engine
apply to small boats that are hauled out of the water when
not in use unless they have been dry for a considerable Raw Water COOling of time
Close the throughhull seacock Remove the raw water intake
Fresh Water Cooling Circuit hose from the seacock Place the end of this hose into a five
gallon bucket of clean fresh water Before starting the engine
A 5050 solution of antifreeze and distilled water is
check the zinc anode found in the primary heat exchanger for use in the coolant system at all times
the engine and clean or replace it as required and also clean
This solution may require a higher concentration of
any zinc debris from inside the heat exchanger where depending on the areas winter climate Check the
zinc anode is located Clean the raw water to make sure the antifreeze protection is adequate
Start the engine and allow the raw water pump to draw the
Should more antifreeze be needed drain an appropriate
fresh water through the system When the bucket is empty
amount from the engine block and add a more concentrated
stop the engine and refill the bucket with an 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 solutions strength
Start the engine and allow all of this mixture to be System through the raw water system Once the
bucket is empty stop
With the engine warm drain all the engine oil from the oil the engine This antifreeze mixture should protect the raw
sump Remove and replace the oil filter and fill the sump water circuit from freezing during the winter layup as well
with new oil Use the correct grade of oil Refer to the as providing corrosion LUBRICATING OIL pages in this manual for the
Remove the impeller from your raw water pump some
oil changing procedure Run the engine and check for proper antifreeze mixture will accompany it so catch it in a bucket
oil pressure and make sure there are no leaks Examine the impeller Acquire a replacement if needed and
a cover gasket Do not replace the impeller into the pump
until but replace the cover and gasket
A CAUTION 00 not leave the engines old engine Cylinder Lubrication Gasoline
oil in the sump over the layup 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 engines
out the engine as it coats the valves cylinders and spark
internal parts plugs for winter Engines
Generators
LAYUP Motor SPARE and cleaning of the starter drive pinion is advis Layup 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 layup such as filters and zinc anodes Refer
to the SPARE PARTS section of this Lubrication Diesel
If you anticipate a long layup period 12 months or more recommends removing the glow plugs or The of your
WESTERBEKE engine after a
fuel injectors for access to the cylinders Squirt light seasonal layup generally follows the same procedures 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 layup procedures will need to be
Make sure you have a replacement if removing the injector counteracted before starting the washer for the injector and fuel line
return 1 Remove any rags that were placed in the exhaust intake
manifold or flame 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 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 layup or a replacement if 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 ThruHull 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 of the intake manifold to
block the opening Do not Check to make sure that the batteries are fully the cloth out of sight If it is not visible at
4 Remove the spark plugs wipe clean regap and and an attempt is made to start the engine to proper tightness 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 startup The throughhull 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 water
Intake Manifold Gasoline solution from the raw water coolant system When the
engine is put into operation the system will selfflush 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 oilsoaked cloth in the lated exhaust port Make a note to remove cloths prior
to startup 6 Check the transmission fluid if it had been topped off
during the layup lower the level of the fluid to 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 noloads on the
sion to the very top to prevent corrosion Lower the fluid to generator at start up normal at Wipe off grime and grease
8 Start the engine in accordance with the touch up unpainted areas Protect coupling and output described in the PREPARATIONS FOR
with an anticorrosion coating Refer to the section of this SECTION in this manual for batteries are to be left on board
during the layup 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 conditioQS remove
the batteries and store them in a warmer more Engines Generators
METRIC CONVERSIONS
INCHES TO MILLIMETERS MILLIMETERS TO INCHES
Inches mm Inches mm mm Inches mm Inches
1 2540 15 38100 1 00394 15 05906
2 5080 20 50800 2 00787 20 07874
3 7620 25 63500 3 01181 25 09843
4 10160 30 76200 4 01575 30 11811
5 12700 35 88900 5 01969 35 13780
10 25400 40 101600 10 03937 40 15748
10 MILLIMETERS 1 CENTIMETER 100 CENTIMETERS 1 METER 3937 INCHES 33 FEET
INCHES TO METERS METERS TO INCHES
Inches Meters Inches Meters Meters Inches Meters Inches
1 00254 7 01778 01 3937 27559 07
2 00508 8 02032 02 7874 31496 08
3 00762 9 02286 03 11811 35433 09
4 01016 10 02540 04 15748 39370 10
5 01270 11 02794 05 19685 43307 11
6 01524 12 03048 06 23622 47244 12
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 091440 6 548640 1 109361 6 656168
2 182880 7 640080 2 218723 7 765529
3 274320 8 731520 3 328084 8 874891
4 365760 9 822960 4 437445 9 984252
5 457200 10 914400 5 546807 10 1093614
MOVE DECIMAL POINT FOR HIGHER VALUES eg 6000 METERS 656168 YARDS
POUNDS TO KILOGRAMS KILOGRAMS TO POUNDS
Ib kg Ib kg kg Ib kg Ib
1 0454 6 2722 1 2205 6 13228
2 0907 7 3175 2 4409 7 15432
3 1361 8 3629 3 6614 8 17637
4 1814 9 4082 4 8818 9 19842
5 2268 10 4536 5 11023 10 22046
GALLONS TO LITERS LITERS TO GALLONS
Gallons Liters Gallons Liters Liters Gallons Liters Gallons
1 379 10 3786 1 026 60 1566
2 757 20 7571 2 053 90 2377
3 1136 30 11357 5 132 120 3132
4 1514 40 15142 10 264 150 3962
5 1893 50 18928 20 528 180 4754
PINTS TO LITERS LITERS TO PINTS
Pints Liters Pints Liters Liters Pints Liters Pints
1 047 6 284 1 211 6 1268
2 095 7 331 2 423 7 1479
3 142 8 379 3 634 8 1691
4 189 9 426 4 845 9 1902
5 237 10 473 5 1057 10 2113
TEMPERATURE
32 40 50 60 70 75 85 95 105 140 175 212 of
I I I I I I I I I I I I
I I I I I I I I I I I I
0 5 10 15 20 25 30 35 40 60 80 100 C
Engines Generators
STANDARD AND METRIC CONVERSION Inches in x 254 Millimeters mm x 0394 Inches
Feet ft x 305 Meters m x 3281 Feet
Miles x 1609 Kilometers km x 0621 Cubic Inches in3 x 16387 Cubic Centimeters x 061 in 3
Imperial Pints IMP pt x 568 Liters L x 176 IMP pt
Imperial Quarts IMP qt x 1137 Liters L x88 IMP qt
Imperial Gallons IMP gal x 4546 Liters L x 22 IMP gal
Imperial Quarts IMP qt x 1201 US Quarts US qt x 833 IMP qt
Imperial Gallons IMP gal x 1201 US Gallons US gal x 833 IMP gal
Fluid Ounces x 29573 Milliliters x 034 Ounces
US Pints US pt x 473 LitersL x 2113 Pints
US Quarts US qt x 946 Liters L x 1057 Quarts
US Gallons US gal x 3785 Liters L x 264 Ounces oz x 2835 Grams g x 035 Ounces
Pounds Ib x 454 Kilograms kg x 2205 Pounds Per Sq In psi x 6895 Kilopascals kPa x 145 psi
Inches of Mercury Hg x 4912 psi x 2036 Hg
Inches of Mercury Hg x 3377 Kilopascals kPa x 2961 Hg
Inches of Water H20 x 07355 Inches of Mercury x 13783 H20
Inches of Water H20 x 03613 psi x 27684 H20
Inches of Water H20 x 248 Kilopascals kPa x 4026 H20
TORQUE
PoundsForce Inches inIb x 113 Newton Meters Nm x 885 inIb
PoundsForce Feet ftIb x 1356 Newton Meters Nm x 738 Miles Per Hour MPH x 1609 Kilometers Per Hour KPH x 621 MPH
POWER
Horsepower Hp x 745 Kilowatts Kw x 134 MPH
FUEL CONSUMPTION
Miles Per Hour IMP MPG x 354 Kilometers Per Liter KmL
Kilometers Per Liter KmL x 2352 IMP MPG
Miles Pe Gallons US MPG x 425 Kilometers Per Liter KmL
Kilometers Per Liter KmL x 2352 US Degree Fahrenheit OF OC X 18 32
Degree Celsius 0C OF 32 x 56
Engines Generators
SUGGESTED SPARE PARTS
WESTERBEKE MARINE DIESEL ENGINES
CONTACT YOUR WESTERBEKE DEALER FOR SUGGESTIONS AND ADDITIONAL HARDWARE KIT
MODEL HOSE KIT
HOSE KITDUFFEL BAG
Molded engine replacement j
hoses pack in a fII6IIIJ
rugged canvas
carrying bag
THERMOSTAT
GASKET
SPARE PARTS also offers two Spare Parts Kits
each packaged in a rugged hinged toolbox B Kit
Kit A includes the basic spares Impeller Kit
Kit B is for more extensive offshore cruising Water Pump Repair Kit
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
630 ENGINE
ENGINE FUEL SYSTEM
Engine Type Diesel fourcycle fresh General Open flow self priming one bleed point
watercooled vertical inline overhead valve Fuel No2 diesel oil cetane rating of 45 or higher
mechanism 63 hp at 4000 rpm maximum
Fuel Injection Pump Distributor Type VE Diesel KiKi 1348 cuin 221 liter
Fuel Injection Timing 0 TOC Top Dead Naturally aspirated
Nozzle Throttle type
Governor Centrifugal type
Fuel Filter Spinon Replaceable Chamber Swirl type
Air cleaner Metal screen type Stroke 362 x 351 inches 920 x 891 mm
AirFlow 700 cfm 19 cmm
Piston Displacement 1444 cubic inches 237 liters engine Order of Rotation Clockwise when viewed from the
front ELECTRICAL Ratio 21 1 Starting Battery
12Volt negative Height 2493 inches 6332 mm Battery Capacity 400 600 Cold Cranking Amps CCA
Width 2263 inches 5746 mm DC Charging Alternator 51 Amp rated belt driven
Length 3875 inches 9843 mm
Starter 12Volt reduction gear
Weight 614 Ibs 2787 kgs
Starting Aid Glow plugs sheathed type
Fuel Consumption 13 US gph 49Iph at 2500 rpm
DC NoLoad Current 2 of rated 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
TUNEUP General Fresh watercooled block
controlled with heat Pressure 427 psi 30 kgcm at 280 rpm limit
Minimum 384 psi 27 kgcm Operating Temperature 170 190 F77 88 C
Valve Timing Intake Opens 17 BTDC Fresh Water Pump Centrifugal type metal impeller bettdriven
Intake Closes 47 ABDC Raw Water Pump Positive displacement rubber impeller
Exhaust Opens 51 BBDC geardriven
Exhaust Closes 13 ATOC Raw Water Flow 60 US gpm 227 Ipm Timing Static 1915
at 3600 rpm before discharging into exhaust elbow
Valve Seat Angle Intake 45 System Capacity 100 qts 946 liters
Exhaust 45 fresh water
Engine Speed 1800 rpm 60 Hertz
1500 rpm 50 Hertz LUBRICATION SYSTEM
Valve Clearance Intake 0012 inches 030 mm General Pressure fed cold Exhaust 0012
inches 030 mm
Oil Filter Full flow paper element spinon type
Injector Pressure 1920 71 0 psi 135 5 0 kgcm2 PN 035828
Engine Timing Static timed drop valve method 0205 005 Sump Capacity 53 US qts 50 liters
in BTOC or 0 TOC 1 cylinder 1mm of cam lift not including filter plus filtercooler assembly
using measuring device for injection pump
Operating Oil Pressure 50 65 psi 35 457 kgcm2
engine hot
Oil Grade API Specification CF or CG4
SAE 30 10W30 15W40
Engines Generators
Engines

Ad by Google

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