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Westerbeke Diesel 63d Four Operator's Manual



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 OPERATORS MANUAL
MARINE DIESEL ENGINES
           64 F




                    PUBLICATION NO.49112
                       FIRST EDITION
                      DECEMBER 2003




         member     WESTERBEKE CORPORATION· MYLES STANDISH INDUSTRIAL PARK
     -             150 JOHN HANCOCK ROAD, TAUNTON, MA 02780-7319 U.S.A.
    ~             TEL: (508)823-7877. FAX: (508)884-9688· WEBSITE: www.WESTERBEKE.COM
                      A    WARNING
Exhaust gasses contain carbon Monoxide, an odorless and
colorless gas. carbon Monoxide is poisonous and can cause
unconsciousness and death. Symptoms of Carbon Monoxide
exposure can include:
-Dizziness                   - Throbbing in Temples
-Nausea                      - Muscular Twitching
-Headache                    - Vomiting
- Weakness and Sleepiness -Inability to Think Coherently

IF YOU OR ANYONE ELSE EXPERIENCE ANY OF THESE SYMPTOMS,
GET OUT INTO THE FRESH AIR IMMEDIATELY. If symptoms persist,
seek medical attention. Shut down the unit and do not restart
until it has been inspected and repaired.


                         A WARNING DECAL is provided by
                         WESTERBEKE and should be fixed to a
                         bulkhead near your engine or generator.
                         WESTERBEKE also recommends installing
                         CARBON MONOXIDE DETECTORS in the




                    CALIFORNIA
               PROPOSITION 65 WARNING
             Marine diesel and gasoline engine
            exhaust and some of its constituents
            are known to the State of California
              to cause cancer, birth defects,
               and other reproductive harm.
                                             SAFETY INSTRUCTIONS
INTRODUCTION                                                          PREVENT BURNS - FIRE
Read this safety manual carefully. Most accidents are
caused by failure to follow fundomental rules and precau-                 A WARNING: Fire can cause-;njury or death!
tions. Know when dangerous conditions exist and take the
necessary precautions to protect yourself, your personne~             ·     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 fuellme, carburetor, or fuel filters.
PREVENT ELECTRIC SHOCK                                                ·     Do not operate with a Coast Guard Approved flame
                                                                            arrester removed. Backfire can cause severe injury or
                                                                            death.
    A WARNING: Do not touch AC electrical connections                 ·     Do not operate with the air cleaner/silencer removed.
    while engine is running, or when connected to shore                     Backfire can cause severe injury or death.
    power. Lethal voltage is present at these connections!            ·     Do not smoke or permit flames or sparks to occur near
                                                                            the fuel system. Keep the compartment and the
·    Do not operate this machinery without electrical                       engine/generator clean and free of debris to minimize the
     enclosures and covers in place.                                        chances of fire. Wipe up all spilled fuel and engine oil.
·    Shut off electrical power before accessing electrical            ·     Be aware - diesel fuel will burn.
     equipment.
·    Use insulated mats whenever working on electrical                PREVENT BURNS - EXPLOSION
     equipment.
·    Make sure your clothing and skin are dry, not damp
     (particularly shoes) when handling electrical equipment.
                                                                          A WARNING: Explosions from fuel vapors can cause
                                                                          injury or death!
·    Remove wristwatch and all jewelry when working on
     electrical equipment.                                            · Follow re-fueling safety instructions. Keep the vessel's
·    Do not connect utility shore power to vessel's AC                  hatches closed when fueling. Open and ventilate cabin
     circuits, except through a ship-to-shore double throw              after fueling. Check below for fumes/vapor before run-
     transfer switch. Damage to vessel's AC generator may               ning the blower. Run the blower for four minutes before
     result if this procedure is not followed.                          starting your engine.
·    Electrical shock results from handling a charged capaci-         · All fuel vapors are highly explosive. Use extreme care
     tor. Discharge capacitor by shorting terminals together.           when handling and storing fuels. Store fuel in a well-ven-
                                                                        tilated area away from spark-producing equipment and
PREVENT BURNS - HOT ENGINE                                              out of the reach of children.
                                                                      · Do not fill the fuel tank(s) while the engine is running.
    A WARNING: Do not touch hot engine parts or                       · Shut off the fuel service valve at the engine when servicing
                                                                        the fuel system. Take care in catching any fuel that might
    exhaust system components. Arunning engine gets                     spill. DO NOT allow any smoking, open flames, or other
    very hot!                                                           sources of fire near the fuel system or engine when servic-
                                                                        ing. Ensure proper ventilation exists when servicing the
·     Always check the engine coolant level at the coolant              fuel system.
      recovery tank.
                                                                      · Do not alter or modify the fuel system.
                                                                      · Be sure all fuel supplies have a positive shutoff valve.
    A WARNING: Steam can cause injury or death!                       · Be certain fuel line fittings are adequately tightened and
                                                                        free of leaks.
· In case of an engine overheat, allow the engine to cool             · Make sure a fire extinguisher is installed nearby and is
  before touching the engine or checking the coolant.                   properly maintained. Be familiar with its proper use.
                                                                        Extinguishers rated ABC by the NFPA are appropriate
                                                                        for all applications encountered in this environment.




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




                                                        Engines & Generators

                                                                ii
                                              SAFETY INSTRUCTIONS
· Do not wear loose clothing or jewelry when servicing                  ABYC, NFPA AND USCG PUBLICATIONS FOR
  equipment; tie back long hair and avoid wearing loose
  jackets, shirts, sleeves, rings, necklaces or bracelets that          INSTALLING DIESEL ENGINES
  could be caught in moving parts.                                      Read the following ABYC, NFPA and USCG publications
                                                                        for safety codes and standards. Follow their recommenda-
· Make sure all attaching hardware is properly tightened.
  Keep protective shields and guards in their respective                tions when installing your engine.
  places at all times.                                                  ABYC (American Boat and Yacht Council)
                                                                        "Safety Standards for Small Craft"
· Do not check fluid levels or the drive belt's tension while
  the engine is operating.                                              Order from:
· Stay clear of the drive shaft and the transmission coupling              ABYC
  when the engine is running; hair and clothing can easily                  15 East 26th Street
  be caught in these rotating parts.                                       New York, NY 10010
                                                                        NFPA (National Fire Protection Association)
HAZARDOUS NOISE                                                         "Fire Protection Standard for Motor Craft"
                                                                        Order from:
    A WARNING: High noise levels can cause hearing                          National Fire Protection Association
    loss!                                                                   11 Tracy Drive
                                                                           Avon Industrial Park
·     Never operate an engine without its muffler installed.               Avon, MA 02322
·     Do not run an engine with the air intake (silencer)               USCG (United States Coast Guard)
      removed.                                                          "USCG 33CFR183"
·     Do not run engines for long periods with their enclosures         Order from:
      open.
                                                                            U.S. Government Printing Office
                                                                           Washington, D.C. 20404
    A WARNING: Do not wotlc on machinery when you are
    mentally or physically incapacitated by fatigue!

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




                                                          Engines & Generators

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

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

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

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


        Adetailed 40 page Marine Installation Manual covering gasoline and
        diesel, engines and generators, is available from your WESTERBEKE
        dealer.




                                             Engines & Generators

                                                   iv
                                                        TABLE OF CONTENTS
Parts Identification ................................................2            Glow Plugs .........................................................26
Introduction .............................................................3       W""
                                                                                    iring 0"
                                                                                           lagram .. ................................................27
  Warranty Procedures ........................................ .3                 Wiring Schematic ..............................................28
  Serial Number Location .................................. .4                    Starter Motor .....................................................29
Admiral Control Panel .........................................5                  Dual Output Alternators ................................... .31
Captain Control Panel .........................................6                    Troubleshooting ............................................. .32
Fuel, Engine Oil and Coolant ..............................7                      Engine Troubleshobting .....................................33
Preparations for Initial Start-Up .........................8                      Engine Adjustments .............................................35
Starting/Stopping Procedure ...............................9                        Belt Adjustment .............................................. 35
                                                                                    Fuel Injectors ................................................. 35
Warning Lights, Alarms and Circuit Breaker .... l0                                  11estmg
                                                                                         . Engme . CompresslOn          . .......................... 36
Engine Break-In Procedure ............................... 11                        Valve Clearance Adjustment .......................... 36
The Daily Operation ........................................... 12                  Idling Speed .................................................... 37
Maintenance Schedule ..................................... 13                       Stop Solenoid.................................................. 37
                                                                                    Oil Pressure .................................................... 38
Fuel System ....................................................... 15
  FuellWater Separator ...................................... 15                  Hurth HSW Transmissions .................................39
  Fuel Filters ...................................................... 15            Specification ...................................................40
                                                                                    Fluid Change ............................................ .40,41
Cooling System .................................................. 16                Shipment .........................................................41
  Changing Coolant ........................................... 16
                                                                                    Transmission Fluid ........................................ .41
  Thermostat ...................................................... 17
                                                                                    Changing Filter .............................................. .42
  Raw Water Intake Strainer.............................. 17
                                                                                    Cable Connections ........... ;............................. .43
  Raw Water Cooling Circuit ............................ 18
                                                                                    Couplings .... :...................................................43
  Raw Water Intake Strainer.............................. 18
                                                                                    Transmission Coolers ................................... .43
  Raw Water Pump ............................................ 18
                                                                                    Maintenance....................................................44
  Heat Exchanger .............................................. 19
  Zinc Anode ..................................................... 19             Borg Warner Transmission ................................47
                                                                                    Maintenance..................................................... 48
Engine Lubricating 0i1 ....................................... 20                   Oil Coolers ............................................... ~ .......49
. Changing the Oil Filter................................... 20
  Changing the Oil ........................................... 20                 Lay-up an d Recommlsslonmg " " " ...........................5,0
Remote Oil Filter (Optional) ..............................21                     Metric Conversions Oata ...................................51
Water Heater .....................................................22              Engine Specifications .......................................52
Tachometer ........................................................23             Suggested ~pare Parts .....................................53
DC Electrical System ...........................................24
  Alternator Troubleshooting ............................ 24
  Battery Care .................................................... 25




                                                                     Engines & Generators

                                                                              1
                                      PARTS IDENTIFICATION

                                                                            WATER INJECTED
                                                                                    ELBOW
                                                                           _EXlrlAU!~T




                                                                                    REAR
    DC CHARGING




                                                                                               TRANSMISSION
  FUEL LIFT PUMP



 RAW WATER

                                                                           .jk.~~~~"", ENGINE BLOCK
                                                                                       DRAIN PLUG




                 FRONT                                     LEFT SIDE

                                         20 AMP
                                         CIRCUIT
                                                                           FILL
          AIR INTAKE/AIR FILTER
                 SILENCER     .

  PREHEAT IiULltNUIU,


              ZINC
              ANODE                                                          =......--MANIFOLD
                                                                                        I.D. PLATE

                                                                                         ALTERNATOR
HEAT EXr::HA~IGEFI---




REAR
                                                                                                     FRONT
    HBW
    HURTH                                                        MOTOR    OIL DRAIN HOSE'
    TRANSMISSION-Q."-'''''''''"III!
                                                           AND SOLENOID

                                                               BELL HOUSING/FLYWHEEL
                                                               ASSEMBLY
          TRANSMISSION
          SHIFT LEVER
                                           FLEXIBLE
                                           MOUNT
                                                              RIGHT SIDE


                                              Engines & Generators

                                                      2
                                                     INTRODUCTION
This WESTERBEKE Diesel Engine is a product of                          PRODUCT SOFTWARE
WESTERBEKE's long years of experience and advanced                     Product software, (technical data, parts lists, manuals,
technology. We take great pride in the superior durability and         brochures and catalogs), provided from sources other than
dependable performance of our engines and generators.                  WESTERBEKE are not within WESTERBEKE's control.
Thank you for selecting WESTERBEKE.
                                                                       WESTERBEKE CANNOT BE RESPONSIBLE FOR THE
In order to get the full use and benefit from your engine, it is       CONTENT OF SUCH SOFTWARE, MAKES NO
important that you operate and maintain it correctly. This             WARRANTIES OR REPRESENTATIONS WITH RESPECT
manual is designed to help you do this. Please read this               THERETO, INCLUDING ACCURACY, TIMEUNESS OR
manual carefully and observe all the safety precautions                COMPLETENESS THEREOF AND WILL IN NO EVENT
throughout. Should your engine require servicing, contact              BE LIABLE FOR ANY TYPE OF DAMAGE OR INJURY
your nearest WESTERBEKE dealer for assistance.                         INCURRED IN CONNECTION WITH OR ARISING OUT
This is your operators manual. A parts catalog is also                 OF THE FURNISHING OR USE OF SUCH SOFTWARE.
provided and a technical manual is available from your                 WESTERBEKE customers should keep in mind the time
WESTERBEKE dealer. If you are planning to install this                 span between printings of WESTERBEKE product software
equipment, contact your WESTERBEKE dealer for                          and the unavoidable existence of earlier WESTERBEKE
WESTERBEKE'S installation manual.                                      product software. The product software provided with
                                                                       WESTERBEKE products, whether from WESTERBEKE or
WARRANTY PROCEDURES                                                    other suppliers, must not and cannot be relied upon
Your WESTERBEKE Warranty is included in a separate                     exclusively as the definitive authority on the respective
folder. If, after 60 days of submitting the Warranty Registry          product. It not only makes good sense but is imperative that
form you have not received a customer identification card              appropriate representatives ofWESTERBEKE or the sup-
registering your warranty, please contact the factory in               plier in question be consulted to determine the accuracy and
writing with model information, including the engine's                 currentness of the product software being consulted by the
serial number and commission date.                                     customer.
Customer Identification Card                                           NOTES, CAUTIONS AND WARNINGS
                                                                       As this manual takes you through the operating procedures,
                                                                       maintenance schedules, and troubleshooting of your marine
                                                                       engine, critical information will be highlighted by NOTES,
                                                                       CAUTIONS, and WARNINGS. An explanation follows:
 Customer Identification
                                                                       NOTE: An operating procedure essential to note.
 MR. ENGINE OWNER
 MAIN STREET
 HOMETOWN, USA                                                          A CAUTION: Procedures which. if not strictly
                                  Serial Number
                                                                        observed. can result in the damage or destruction of
 Model 64A FOUR
                                                                        your engine.
 Expires 3/20/04

                                                                        A WARNING: Procedures which. if not properly
                                                                        followed. can result in personal injury or loss of life.




                                                            Engines & Generators

                                                                   3
                                                                     INTRODUCTION
           SERIAL NUMBER LOCATION                                                   ORDERING PARTS
           The engine's model number and serial number are located on               Whenever replacement parts are needed, always provide the
           the nameplate mounted on the side of the engine's manifold.              engine model number and serial number as they appear on
           The engine's serial number is stamped into the engine block              the silver and black nameplate located on the manifold. You
           on a flat swface directly above the injection pump. Take the             must provide us with this infor:mation so we may properly
           time to enter this information on the illustration of the name-          identify your engine. In addition, include a complete part
           plate shown below, as this will provide a quick reference                description and part number for each part needed (see the
           when seeking technical information and/or ordering parts.                separately furnished Parts List). Insist upon WES1ERBEKE
                                                                                    packaged parts because will fit or generic parts are frequently
                                                                                    not made to the same specifications as original equipment.
                                                                                    SPARES AND ACCESSORIES
                                                                                    Certain spares will be needed to support and maintain your
                                                                                    WES1ERBEKE engine. Your local WES1ERBEKE dealer
                                                                                    will assist you in preparing an inventory of spare parts. See
           Fill in the infol71lationforyour reference. ~                            the SPARE PARTS page in this manual. For engine acces-
                                                                                    sories, see WES1ERBEKE'S ACCESSORIES brochure.
           UNDERSTANDING THE DIESEL ENGINE
           The diesel engine closely resembles the gasoline engine, since
           the mechanism is essentially the same. The cylinders are
           arranged above a closed crankcase. The crankshaft is the same
           general type as a gasoline engine, and the diesel engine has the
           same type of valves, camshaft, pistons, connecting rods and
           lubricating system.
           Therefore, to a great extent, a diesel engine requires the same
           preventive maintenance as a gasoline engine. The most impor-
           tant factors are proper ventilation and proper maintenance of
           the fuel, lubricating and cooling systems. Fuel and lubricating
           filter elements must be replaced at the time periods specified,
           and frequent checking for contaminants (water, sediment, etc.)
           in the fuel system is also essential. Another important factor is
           the consistent use of the same brand of high detergent diesel
           lubrication oil designed specifically for diesel engines.
           The diesel engine does differ from the gasoline engine,
           however, in its method of handling and firing of fuel. The
           carburetor and ignition systems are replaced by a single
           component - the fuel injection pump - which performs the
           function of both.

               GLOW PLUG·
ENERGIZED BY THE PREHEAT BIlTTON:.e5115'




                                       17"1:a------„A---IJI~SEL   FUEL SPRAY

   PRE·COMBUSTION   CHAMBER-2~~~~~




                                                                          Engines & Generators

                                                                                4
                                                ADMIRAL CONTROL PANEL
  DESCRIPTION                                                                   When the engine is shut down with the key switch turned off,
                                                                                the water temperature gauge will continue to register the last
   This manually-operated control panel is equipped with a
                                                                                temperature reading indicated by the gauge before electrical
   KEY switch and RPM gauge with an ELAPSED TIME
                                                                                power was turned off. The oil pressure gauge will fall to zero
   meter which measures the engine's running time in hours and
                                                                                when the key switch is turned off. The temperature gauge
   in 1/10 hours. The panel also includes a WATER TEMPER-
                                                                                will once again register the engine's true temperature when
   ATURE gauge which indicates water temperature in degrees
                                                                                electrical power is restored to the gauge.
   Fahrenheit, an OIL PRESSURE gauge which measures the
   engine's oil pressure in pounds per square inch, and a DC                    A separate alann buzzer with harness is supplied with every
 . control circuit VOLTAGE gauge which measures the sys-                        Admiral Panel. TIle installer is responsible for electrically con-
   tem's voltage. All gauges are illuminated when the key                       necting the buzzer to the four-pin connection on the engine's
   switch is turned on and remain illuminated while the engine                  electrical harness. The installer is also responsible for installing
   is in operation. The panel also contains two rubber-booted                   the buzzer in a location where it will be dry and where it will
  pushbuttons, one for PREHEAT and one for START.                               be audible to the operator should it sound while the engine is
                                                                                running. The buzzer will sound when the ignition key is turned
                                                                                on and should silence when the engine has started and the
                                                                                engine's oil pressure rises above 15 psi (1.1 kg/cm2).

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

RPM GAUGE: REGIS·
TERS REVOLUTIONS
PER MINUTE OF THE
ENGINE AND CAN BE
RECALiBRATED FOR
ACCURACY FROM THE
REAR OF THE PANEL.



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




                                                                       ~
                                                                                                        ~                          DC VOLTMETER:
                                                                                                                                   INDICATES THE AMOUNT THE
                                                                                                                                   BATTERY IS BEING CHARGED.
PREHEAT                PRESSED, ENERGIZES THE                                    ~                                                 SHOULb SHOW 13V TO 14V.
ALTERNATOR'S EXCITER, THE FUEL liFT PUMP. THE                               "        AUTOMATIC ALARM SYSTEM
FUEL SOLENOID ON THE INJECTION PUMP, AND THE
ENGINE'S GLOW PLUGS. IT BYPASSES THE ENGINE'S                   .           "        COOLANT TEMPERATURE ALARM: AN ALARM BUZZER HAS BEEN
                                                           ,
OIL PRESSURE ALARM SWITCH. IN ADDITION, THIS                   !~.:                  SUPPliED WITH THE INSTRUMENT PANEL. IF THE ENGINE'S COOLANT
BUTTON ENERGIZES THE START BUTTON.                             '.;;,,/               REACHES 210· F (99·C), THIS SWITCH WILL CLOSE SOUNDING THE
                                                                   '-..              ALARM WHICH WILL EMIT A CONTINUOUS SIGNAL.
START BUTTON: WHEN PRESSED, ENERGIZES THE
STARTER'S SOLENOID WHICH CRANKS THE ENGINE.                                          OIL PRESSURE ALARM: AN 01 L PRESSURE ALARM SWITCH IS
THIS BUTTON WILL NOT OPERATE ELECTRICALLY                                            LOCATED OFF THE ENGINE'S OIL GALLERY. THIS SWITCH MONITORS
UNLESS THE PREHEAT BUTTON IS PRESSED AND HELD                                        THE ENGINE'S OIL PRESSURE. SHOULD THE ENGINE'S OIL PRESSURE
AT THE SAME TIME.                                                                    FALL TO 5 -10 psi (0.4 - 0.7 kg/em'), THE SWITCH WILL CLOSE SOUND·
                                                                                     ING THE·ALARM. IN THIS EVENT, THE ALARM WILL EMIT A PULSATING
                                                                                     SIGNAL.




                                                                    Engines & Generators

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




                                                                          ALARM: THE ALARM WILL SOUND IF THE ENGINE'S OIL PRESSURE FALLS
                                                                          BELOW 5 -10 psi (0.4 - 0.7 kg/cm'). 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                                          210°F (99°C). IN THIS EVENT, THE ALARM WILL EMIT A CONTINUOUS SIGNAL.
PER MINUTE OF THE ENGINE AND CAN BE                                       NOTE: THE ALARM WILL SOUND WHEN THE KEY SWITCH IS TURNED ON. THIS
RECALIBRATED FOR ACCURACY FROM                                            SOUNDING IS NORMAL. ONCE THE ENGINE STARTS AND THE ENGINE'S OIL
THE REAR OFTHE PANEL.                                                     PRESSURE REACHES 15 psi (1.1 kg/cm'), THE ALARM WILL SILENCE.

                                         OIL PRESSURE   ALTERNATOR
                                         ALARM LIGHT    AlARM LIGHT


                                                                                                                           TEST BunON: WHEN
                                                                                                                           PRESSED, TESTS THE
                                                                                                                           ALTERNATOR, THE OIL
                                                                                                                           PRESSURE, AND THE
                                                                                                                           COOLANT TEMPERA-
                                                                                                                           TURE CONTROL CIR-
                                                                                                                           CUITS. WHEN PRESSED,
                                                                                                                           TH£ 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 TEMPERATURE
                                      ALARM LIGHT



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




                                                               Engines & Generators

                                                                      6
                       DIESEL FUEL, ENGINE OIL AND ENGINE COOLANT
DIESEL FUEL                                                             ENGINE COOLANT
Use fuel that meets the requirements or specification of Class          WESTERBEKE reco~ends a mixture of 50% antifreeze
2-D (ASTM), and has a cetane rating of #45 or better.                   and 50% distilled water. Distilled water is free from the
                                                                        chemicals that can corrode internal engine surfaces.
Care Of The Fuel Supply                                                 The antifreeze performs double duty. It allows the engine to
Use only clean diesel fuel! The clearance of the components             run at proper temperatures by transferring heat away from
in your fuel injection pump is very critical; invisible dirt par-       the engine to the coolant, and lubricates and protects the
ticles which might pass through the filter can damage these             cooling circuit from rust and corrosion. Look for a good
finely finished parts. It is important to buy clean fuel, and           quality antifreeze that contains Supplemental Cooling
keep it clean. The best fuel can be rendered unsatisfactory by          Additives (SCAs) that keep the antifreeze chemically
careless handling or improper storage facilities. To assure             balanced, crucial to long term protection.
that the fuel going into the tank for your engine's daily use is        The distilled water and antifreeze should be premixed before
clean and pure, the following practice is advisable:                    being poured into the cooling circuit.              .
Purchase a well-known brand of fuel.
                                                                        NOTE: Look for the new environmentally-friendly long lasting
Install and regularly service a good, visual-type fuel                  antifreeze that is now available.
filter/water separator between the fuel tank and the engine.
The Raycor 500 FG or 900 FG are good examples of such                   The recommended 50/50 mixture will protect the engine
filters.                                                                against the most extreme temperatures. The antifreeze
                                                                        mixture will also retard rust within the engine and add to the
ENGINE OIL                                                              life of the circulating pump impeller and seals.
Use a heavy duty engine oil with an API classification of CF
or CG-4 or better. Change the engine oil after an initial 50            Coolant Recovery Tank
hours of break-in operation, and every 100 hours of operation           A coolant recovery tank kit is supplied with each
thereafter. For recommended oil viscosity, see the following            WESTERBEKE diesel engine. The purpose of this recovery
chart:                                                                  tank is to allow for engine coolant expansion and contraction
       Operating Temperature            Oil Viscosity
                                                                        during engine operation, without the loss of coolant and
                                                                        without introducing air into the cooling system. This kit is
         Above 68°F (20°C)       SAE 30, 10W-30 or 15W-40               provided and must be installed before operating the engine.
        41° - 68°F (5 - 20°C)    SAE 20, 10W-30 or 15W-40               NOTE: This tank, with its short run ofplastic hose, is best
                                                                        located at or above the level of the engine's manifold, but it
          Below 41°F (5°C)        SAE 10W-30 or 15W-40
                                                                        can be located below the level of the engine's manifold if the
                                                                        particular installation makes this necessary.
 A    CAUTION: 00 not allow two or more brands of
 engine oil to mix. Each brand contains its own additives;
 additives of different brands could react in the mixture
 to produce properties harmful to your engine.

Oil Pressure
The engine's oil pressure, during operation, is indicated
by the oil pressure gauge on the instrument panel. During
normal operation, the oil pressure will range between 35 and
55 psi (2.5 and 3.9 kglcm2).
NOTE: A newly started, cold engine can have an oil pressure
reading up to 60 psi (4.2 kglcm 2). A warmed engine can have
an oil pressure reading as low as 25 psi (1.8 kglcm2 ). These
readings will vary depending upon the temperature of the
engine and the load placed on the engine.




                                                             Engines & Generators

                                                                    7
                               PREPARATIONS FOR INITIAL START-UP
PRESTARTINSPECTION
Before starting your engine for the first time or after a
prolonged layoff, check the following items:
                                                                                  COOLANT
D Check the engine oil level. Add oil to maintain the level                       RECOVERY
    at the high mark on the dipstick.                                             TANK
D Turn on the fuel supply, then check the fuel supply and
    examine the fuel filter/water separator bowl for
    contaminants.
D Check the transmission fluid level.
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).
D Check the coolant level in both the plastic recovery tank
    and at the manifold.
    NOTE: If the engine has not yet been filled with coolant,
    refer to the COOUNG 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.
o Make certain there is proper ventilation around the
  engine. An ample supply is necessary for proper engine
  performance.
o Make sure the mounting installation is secure.
D Ensure the propeller shaft is securely attached to the
  transmission.
D Open the thru-hull and make certain raw water is primed
  to the raw water strainer.                                                                 I~_-     OIL DIPSTICK
                                                                                                    , PRESS IN TIGHT




                                                           Engines & Generators

                                                                 8
                                 STARTING · STOPPING PROCEDURE
STARTING PROCEDURE                                                   STOPPING PROCEDURE
1. Place the transmission in neutral and advance the throttle        To stop the engine, bring the throttle to an idle position and
   control to slightly open.                                         place the transmission in neutral. Allow the engine to idle for
2. Thrn the KEY SWITCH to the ON position (2 o'clock).               a few moments to stabilize temperatures, then shut the
   (If the panel is energized, the gauges are on.)                   engine down by turning off the key switch.
3. Press the PREHEAT BUTION, and hold for 5 seconds.                 NOTE: Make certain this key switch is in the OFF position
   (The fuel lift pump is priming the engine.)                       (12 o'clock). If the key switch is left ON, the energized
                                                                     instrument panel will put a drain on the battery.
4. Release the PRESTART BUTION and press the START
   BUTION. (The starter motor is cranking the engine).               Starting Under Cold Conditions
5. Release the START BUTION as the engine starts.                    Make certain the lubricating oil is appropriate for the
6. With the engine running, check the instruments for                prevailing temperature. Use oil with an API Specification
   proper oil pressure and battery charging voltage. The             of CF or CG-4, SAE 30, lOW-30, or 15W-40.
   water temperature will rise slowly and then stabilize
   when the thermostat opens.                                        FAILURE TO START
   NOTE: Never attempt to engage the starter while the               If the engine fails to start when the start button is pressed for
   engine is running.                                                5 seconds, wait for at least 30 seconds and repeat the starting
                                                                     procedure. Make certain the transmission control is in the
   It is important to closely monitor the panel gauges.              neutral position as some engines have a neutral safety switch
   Become aware of the normal engine readings and take               to prevent starting in gear.
   immediate action if these readings start to vary.                 Never run the starter for more then 30 seconds. If the engine
                                                                     fails to start, refer to the TROUBLESHOOTING CHART in
                      Temperature/Preheat                            this manual.
     Atmospheric Temperature           Preheating Time
        41°F(5°C) or higher           Approx. 10 seconds
     41°F(5°C) to 23°F (-5°C)         Approx. 15 seconds              A CAUTION: Prolonged cranking intervals without
       23°F(-5°C) or lower            Approx. 20 seconds              the engine starting can result in the engine exhaust
      Limit of continuous use      30 seconds before cranking         system filling with raw water. This may happen because
                                                                      the pump is pumping raw water through the raw water
NOTE: The START button will not energize unless the                   cooling system during cranking. This raw water can
PREHEAT button is depressed. Depressing the PREHEAT
button activates the glow plugs in the cylinder head so use           enter the engine's cylinders by way of the exhaust
the PREHEAT intermittently to avoid overheating the glow              manifold once the exhaust system fills. Prevent this
plugs.                                                                from happening by closing the raw water supply
                                                                      through-hull shutoff, draining the exhaust muffler, and
                                                                      correcting the cause of the excessive engine cranking.
                                                                      Engine damage resulting from raw water entry is not a
NOTE: When starting:                                                  warrantable issue; the owner/operator should keep this
A voltage drop will occur                                             in mind.
when the preheat button
is depressed.




                                                            Engines & Generators

                                                                 9
                           WARNING LIGHTS, ALARMS & CIRCUIT BREAKER
      ALTERNATOR WARNINGS                                                 LOW OIL PRESSURE ALARM SWITCH
      The Captain Control Panel indicates alternator low discharge        A low oil pressure alarm switch is located off the engine's
      with a red warning light.                                           oil gallery. This switch's sensor monitors the engine's oil
      The Admiral Control Panel uses a voltmeter to monitor the           pressure. Should the engine's oil pressure fall to 5 - 10 psi
      performance of the alternator.                                      (0.4 - 0.7 kg/cm2), this switch will activate a pulsating alarm.

      COOLANT TEMPERATURE SWITCH                                          ENGINE CIRCUIT BREAKER
      A coolant temperature switch is located on the thermostat           The DC harness on the engine is protected by an engine-
      housing. This switch will activate a continuous alarm if the        mounted manual reset circuit breaker (20 amps DC).
      coolant's operating temperature reaches approximately               Excessive current draw or electrical overload anywhere in
      210 0 P (99°C).                                                     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

                                                                                                                              2DACIRCUIT
                                                                                                                              BREAKER




COOLANT
SENOOR




          THERMOSTAT
          ASSEMBLY
                                                                     OIL GALLERY




                                                                Engines & Generators

                                                                     10
                                      ENGINE BREAK-IN PROCEDURE
DESCRIPTION                                                         3. While using the vessel, run the engine at various engine
                                                                       speeds for the first 25 hours. Avoid prolonged periods of
Although your engine has experienced a minimum of one
                                                                       idling.
hour of test operations at the factory to make sure accurate
assembly procedures were followed and that the engine oper-         4. Avoid rapid acceleration, especially with a cold engine.
ated properly, a break-in time is required. The service life of     5. Use caution not to overload the engine. The presence of a
your engine is dependent upon how the engine is operated               grey or black exhaust and the inability of the engine to
and serviced during its initial 50 hours of use.                       reach its full rated speed are signs of an overload.
Breaking-in a new engine basically involves seating the pis-       \6. During the next 25 hours, the engine may be operated at
ton rings to the cylinder walls. Excessive oil consumption             varying engine speeds, with short runs at full rated rpm.
and smoky operation indicate that the cylinder walls are               Avoid prolonged idling during this break-in period.
scored, which is caused by overloading the engine during the
break-in period.                                       .               CHECKLIST
Your new engine requires approximately 50 hours of initial             D Monitor the control panel gauges.
conditioning operation to break in each moving part in order           D . Check for leaks of fuel and engine oil.
to maximize the performance and service life of the engine.            D Check for abnormal noise such as knocking, friction,
Perform this conditioning carefully, keeping in mind the fol-            vibration and blow-back sounds.
lowing:                                                                D Confirm exhaust smoke:
1. Start the engine according to the STARTING PROCE-                     When the engine is cold - white smoke.
    DURE section. Run the engine at fast idle while checking             When the engine is warm - almost smokeless.
    that all systems (raw water pump, oil pressure, battery              When the engine is overloaded - some black smoke and soot
    charging) are functioning.
                                                                       NOTE: See the TRANSMISSION section of this manualfor
2. Allow the engine to warm up (preferably by running at
                                                                       break-in information on your transmission.
    fast idle) until the water temperature gauge moves into
    the 130 - 1400 P (55 - 60°C) range.




                                                         Engines. & Generators

                                                                  11
                                             THE DAILY OPERATION
CHECK LIST                                                           FAILURE TO START
Follow this check list each day before starting your en~ine.         If the engine fails to start when the start button is pressed for
D VIsually inspect the engine for fuel, oil, or water leaks.         5 seconds, wait for at least 30 seconds and repeat the starting
D Check the oil level (dipstick).                                    procedure. Make certain the transmission control is in the
                                                                     neutral position as some engines have a neutral safety switch
D Check the coolant level in the coolant recovery tank.              to prevent starting in gear.
    Periodically check the manifold coolant level.
                                                                     Never run the starter for more than 30 seconds. If the engine
D   Check the transmission fluid level.                              fails to start, refer to the TROUBLESHOOTING CHART in
D   Check your fuel supply.                                          this manual.
D   Look for clean fuel in the fuel filter/water separator
    transparent bowl.
D   Check for loose wires at the alternator and make sure its         A CAUTION: Prolonged cranking intervals without the
    mounting is secure.                                               engine starting can result in the engine exhaust system
D   Check the starting batteries (weekly).                            filling with raw water. This may happen because the
                                                                      pump is pumping raw water through the raw water
D   Check drive belts for wear and proper tension (weekly).           cooling system during cranking. This raw water can
D   VIsually inspect the raw water pump for leakage.                  enter the engine's cylinders by way of the exhaust
                                                                      manifold once the exhaust sytem fills. Prevent this
STARTING THE ENGINE                                                   from happening by closing the raw water supply
NOTE: See STARTINGISTOPPING PROCEDURE in thi,;,'                      through-hull shutoff, draining the exhaust muffler, and
manual for more detailed instructions.                                correcting the cause of the excessive engine cranking.
                                                                      Engine damage resulting from raw water entry is not a
1. Put the transmission in neutral, throttle advanced.                warrantable issue; the owner/operator should keep this
    NOTE: Hydraulically operated transmissions have a                 in mind.
    neutral safety switch through which the starter solenoid
    energizing circuit passes. This switch is open when the
    transmission is in gear so the starler solenoid will not
    energize.                                                        Stopping Procedure
                                                                     To stop the engine, bring the throttle to an idle position and
2. Tum the KEY SWITCH to the ON position (2 0' clock).
                                                                     place the transmission in neutral. Allow the engine to idle for
   [The panel is energized, gauges are lite}.
                                                                     a few moments to stabilize temperatures. Then shut the
3. Depress the PRESTART BUITON, hold for 5 seconds.                  engine down by turning off the key switch.
   [The fuel lift pump is priming the engine}.
4. Release the PRESTARr BUITON and press the START
                                                                     NOTE: Make certain this key switch is in the OFF
                                                                     position(120'clock}. 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 temperaturewill rise slowly until the thermostat
   opens.
    NOTE: Never attempt to engage the starter while the
    engine is running.
It is important to closely monitor the panel gauges. Become
aware of the normal engine readings and take immediate
action if these readings start to vary.




                                                          Engines. & Generators

                                                                12
                                            MAINTENANCE SCHEDULE
In order to use this Maintenance Schedule, it will be neces-
sary to log your engine hours. Use your engine hounneter or                  A WARNING: Never attempt to perform any service
record your engine hours by running time.                                    while the engine is running. Wear the proper safety
NOTE: M0J7.Y of the following maintenance procedures are                     equipment such as goggles and gloves, and use the
simple but others are more difficult 0J7.d may require the                   co"ect tools for each job. Disconnect the battery
expert knowledge of a service mech0J7.ic.                                    terminals when servicing any of the engine's DC
                                                                             elecuicalequipment


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



                                                             Engines & Generators

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


       SCHEDULED                CHECK             HOURS OF OPERATION
      MAINTENANCE               EACH                                                         MAINTENANCE DESCRIPTION
                                 DAY    50    100 250 500 750 1000 1250
 Coolant System                                           0                   0   Drain, flush, and refill cooling system with
                                                                                  appropriate antifreeze mix.
 Air Cleaner/Silencer                   0     0     0     0     0      0      0   Every 100 hours, inspect, clean, replace as needed.
 DC Alternator                                      0           0             0   Check DC charge from alternator. Check mounting
                                                                                  bracket; tighten electrical connections.
 Transmission Oil Cooler                                               0          Remove; have professionally cleaned and pressure
                                                                                  tested.
 Engine Transmission                                                   0          Chattering at idle and low rpms is an indication
 Damper Plate                                                                     of damper plate wear. Remove and replace.
 *Fuellnjectors                                                 0                 Check and adjust injection opening pressure and
                                                                                  spray condition (see ENGINE ADJUSTMENTS).
 *Starter Motor                                           0                   0   Check solenoid and motor for corrosion. Remove
                                                                                  and lubricate. Clean and lubricate the starter motor
                                                                                  pinion drive.
 *Preheat Circuit                                         0                   0   Check operation of preheat solenoid. Remove and
                                                                                  clean glow plugs, check resistance value of heater
                                                                                  element (X-X ohms). Reinstall with anti-seize
                                                                                  compound on threads.
 *Engine Cylinder                                         0                   0   Check compression pressure and timing (see Engine
  Compression                                                                     Adjustments).
 *Adjust the Valve Clearances           0                 0            0          Adjust Valve Clearances (see ENGINE
                                                                                  ADJUSTMENTS).
 *Heat Exchanger                                                       0          Remove, have professionally cleaned and pressure
                                                                                  tested.
 Lubricate Panel Key Switch                   0      0    0     0      0      0   At first 100 hours, then each year at winterizing.
 with "Lockeze"
 Transmission                           0            0    0     0      0      0   Initial fluid change at 25 hours, then every
 Fluid                                                                            300 hours or at winterizing.



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




                                                          Engines & Generators

                                                               14
                                                       FUEL SYSTEM
FUEL FILTERJWATER SEPARATOR                                             FUEL FILTERS
A primary fuel filter of the water separating type must be              The fuel injection pump and the fuel injectors are precisely
installed between the fuel tank and the engine to remove                manufactured and they must receive clean diesel fuel, free
water and other contaminants from the fuel before they can              from water and dirt. To ensure this flow of clean fuel, the fuel
be carried to the fuel system on the engine.                            must pass through at least two fuel filters, a fuel filter/water
Most installers include a fuel filter/water separator with the          separator and the engine's spin-on fuel filter. Visually inspect,
installation package as they are aware of the problems that             clean, and change these filters according to the maintenance
contaminants in the fuel can cause.                                     schedule in this manual.clean, and change these filters
                                                                        according to the maintenance schedule in this manual.
A typical fuel filter/water separator is illustrated below. This
is the Rayeor Model 500 MA. Keep in mind that if a water
separator type filter is not installed between the fuel supply
tank and engine-mounted fuel system, any water in the fuel
                                                                          A WARNING: Shut off the fuel valve at the tank
                                                                          when servicing the fuel system. Take care in catching
will affect the fuel pump, engine filter, and injection                   any fuel that may spill.   . .
equipment. The owner/operator is responsible for making
certain the fuel reaching the engine's injection equipment is
free of impurities. This process is accomplished by installing
and maintaining a proper fuel filter/water separator.




                                                                                                                                 "'-~U;l\L.11111   GASKET


  FUEL FILTER!
  WATER SEPARATOR
  [Owner Installed]                                                                     LIGHTLY WIPE
                                                                                        WITH CLEAN FUEL


                                                                        Changing the Fuel Filter
FUEL LIFT PUMP                                                          1. Shut off the fuel supply.
Periodically check the fuel connections to and out of the               2. Loosen the fuel filter, turning counterclockwise with a
pump and make sure that no leakage is present and that the                  filter wrench. Place the used filter in a container for
fittings are tight and secure. The DC ground connection at                  proper disposal.
one of the pump's mounting bolts should be clean and well
secured by the mounting bolt to ensure proper pump                      3. Using a rag, wipe clean the sealing face on the housing
operations.                                                                 bracket so the new filter can be seated properly.
When energized thru the preheat circuit, the fuel lift pump             4. Lightly oil the sealing gasket on the new filter. To
will purge air from the fuel system and provide a continuous                reinstall, tum the filter assembly counterclockwise care-
flow of fuel as the engine is running.                                      fully until the gasket contacts the sealing surface of the
                                                                            housing bracket. Turn 213 further with the filter wrench.
                                                                        5. .Twn on the fuel supply and start the engine. The normal
                                                TO FUEL FILTER              preheat function should quickly prime the system and the
                                                                            engine should start.
                                                                        FUEL INJECTION PUMP
                                                                        The fuel injection pump is a very important component of the
                                                                        diesel engine, requiring the utmost care in handling. The fuel
                                                                        injection pump has been thoroughly bench-tested and the
                                                                        owner-operator is cautioned not to attempt to service it. If it
                                                                        requires servicing, remove it and take it to an authorized fuel
                                                                        injection pump service facility. Do not attempt to
                                                                        disassemble and repair it.
                                                                        The only adjustment the servicing mechanic should make to
                                                                        the fuel injection pump is the adjustment for engine idle
                                                                        speed (see IDLE SPEED ADJUSTMENT under ENGINE
                                                                        ADJUSTMENTS.


                                                            Engines & Generators

                                                                   15
                                                 COOLING SYSTEM

DESCRIPTION                                                             CHANGING COOLANT
Westerbeke marine engines are designed and equipped for                 The engine's coolant must be changed according to the
fresh water cooling. Heat produced in the engine by combus-             MAINTENANCE SCHEDULE. If the coolant is allowed to
tion and friction is transferred to fresh water coolant which           become contaminated, it can lead to overheating problems.
circulates throughout the engine. This circulating fresh water
coolant cools the engine block, its internal moving parts, and
the engine oil. The heat is transferred externally from the              A CAUTION: Proper cooling system maintenance is
fresh water coolant to raw water by means of a heat                      criticalj a substantial number of engine failures can be
exchanger, similar in function to an automotive radiator. Raw            traced back to cooling system corrosion.
water flows through the tubes of the heat exchanger while
fresh water coolant flows around the tubes; engine heat trans-          Drain the engine coolant by loosening the drain plug on the
ferred to the fresh water coolant is conducted through the              engine block and opening the manifold pressure cap. Flush
tube walls to the raw water which is then pumped into the               the system with fresh water, then start the refill process.
exhaust system where finally it is discharged overboard. In             NOTE: The drain petcock on the heat exchanger should also
other words, the engine is cooled by fresh water coolant, this          be used to help drain engine coolant.
coolant is cooled by raw water, and the raw water carries the
transferred heat overboard through the exhaust system. The
fresh water coolant and raw water circuits are independent of            A WARNING: Beware of the hot engine coolant.
each other. Using only fresh water coolant within the engine             Wear protective gloves.
allows the cooling water passages to stay clean and free from
harmful deposits.
FRESH WATER COOLING CIRCUIT
                                                                        Refilling the Coolant
                                                                        After replacing the engine block drain plug, close the heat
NOTE: Refer to the ENGINE COOlANT section for the                       exchanger's coolant petcock. Then run the engine at idle and
 recommended antifreeze and water mixture to be used as the             slowly pour clean, premixed coolant into the manifold.
fresh water coolant.
                                                                        NOTE: Open the air-bleed petcock on the heat exchanger.
Fresh water coolant is pumped through the engine by a circu-            When a steady flow of coolant appears at the petcock, close
lating pump, absorbing heat from the engine. The coolant                the petcock and fill the system until the manifold remains full.
tIlen paSses through the thermostat into the manifold, to the
heat exchanger where it is cooled, and returned to the engine           Monitor the coolant in the manifold and add as needed. Fill
block via the suction side of the circulating pump. When the            the manifold to the filler neck and install the manifold pres-
engine is started cold, external coolant flow is prevented by           sure cap.
the closed thermostat (although some coolant flow is                    Remove the cap on the coolant recovery tank and fill with
bypassed around the thermostat to prevent the exhaust mani-             coolant mix to halfway between LOW and MAX and replace
fold from overheating). As the engine warms up, the thermo-             the cap. Run the engine and observe the coolant expansion
stat gradually opens, allowing full flow of the engine's                flow into the recovery tank.
coolant to flow unrestricted to the external portion of the             After checking for leaks, stop the engine and allow it to cool.
cooling system.                                                         Coolant should draw back into the cooling system as the
                                                                        engine cools down. Add coolant to the recovery tank if
Coolant Recovery Tank                                                   needed. Clean up any spilled coolant.
A coolant recovery tank allows for engine coolant expansion
and contraction during engine operation, without any signifi-                 mCOOLANT                   KEEP THE
cant loss of coolant and without introducing air into the cool-            RECOVERY TANK                 COOLANT PASSAGE
ing system. This tank should be located at or above the                                                  CLEAR
engine manifold level and should be easily accessible.
NOTE: Periodically check the condition of the manifold pres-
sure cap. Ensure that the upper and lower rubber seals are in
good condition and check that the vacuum valve opens and
closes tightly. Carry a spare cap.                                         FROM COOLANT
                                                                           RECOVERY TANK                                   PRESSURE
                                                                                                                         /CAP


                                                                  THE ENGINE COOLANT DRAIN
                                                                  IS LOCATED ON THE ENGINE
                                                                  BLOCK JUST TO THE RIGHT              COOLANT RETRACTION
                                                                  OF THE OIL FILTER


                                                 j"""'WESTERBEKE
                                                        , Enain~s ~ Generatars

                                                                   16
                                                     COOLING SYSTEM
   THERMOSTAT                                                            RAW WATER INTAKE STRAINER
   A thennostat, located near the manifold at the front of the           NOTE: Always install the strainer at or below the waterline so
   engine, controls the coolant temperature as the coolant               the strainer will always be self-priming.
   continuously flows through the closed cooling circuit. When
   the engine is first started, the closed thennostat prevents           A clean raw water intake strainer is a vital component of the
   coolant from flowing (some coolant is by-passed through a             engine's cooling system. Include a visual inspection of this
   hole in the thennostat to prevent the exhaust manifold from           strainer when making your periodic engine check. The water
   overheating). As the engine warms up, the thennostat                  in the glass should be clear.
   gradually opens. The thennostat is accessible and can be              Perfonn the following maintenance after every 100 hours of
   checked, cleaned, or replaced easily. Carry a spare thennostat        operation:
   and gasket                                                            1. Close the raw water seacock.
   Replacing the Thermostat                                              2. Remove and clean the strainer filter.
   Remove the cap screws and disassemble the thennostat                  3. Clean the glass.
   housing as shown. When installing the new thennostat and              4. Replace the washer if necessary.
   gasket, apply a thin coat of sealant on both sides of the             5. Reassemble and install the strainer.
   gasket before pressing it into place. Do not over-tighten the
   cap screws.                                                           6. Open the seacock.
   Run the engine and check for nonnal temperatures and that             7. Run the engine and check for leaks.
   there are no leaks at the tbennostat housing.                         NOTE: Also follow the above procedure after having run hard
                                                                         aground.
                                                                         If the engine temperature gauge ever shows a higher than
                                                                         nonnal reading, the cause may be that silt, leaves or grass
                                                                         may have been caught up in the strainer, slowing the flow of
                                                                         raw water through the cooling system.




                                                                           GASKET .




                                                                          STRAINER.
                                                                          FILTER




mo:{
TEMPERATURE
SENDER
                                                                                      TYPICAL RAW WATER INTAKE STRAINER
                                                                                                {Owner Installed]




                                                             Engines & Generators

                                                                    17
                                                  COOLING SYSTEM
RAW WATER COOLING CIRCUIT                                               ChangiWJ the Raw Water Pump Impeller
The raw water flow is created by a positive displacement                Close the raw water intake valve. Remove the pump cover
impeller pump. This pump draws water directly from the raw              and, with the aid of two small screwdrivers, carefully pry the
water source (ocean,lake, or river) through a hose to the               impeller out of the pump. Install the new impeller and gasket.
water strainer. The raw water passes from the strainer                  Move the blades to conform to the curved cam plate and
through the raw water pump to the heat exchanger (through               push the impeller into the pump's housing. When
the heat exchanger tubes) where it cools the engine circulat-           assembling, apply a thin coating of lubricant to the impeller
ing fresh water coolant. The raw water is then discharged               and gasket. Open the raw water intake valve.
into the water-injected exhaust elbow, mixing with and cool-
ing the exhaust gases. This mixture of exhaust gas and raw
water is discharged overboard by the engine's exhaust gas
discharge pressure.
                                                                         A CAUTION: If any of the vanes bave broken off the
                                                                         impeller, they must be located to prevent blockage in
RAW WATER PUMP                                                           the cooling circuit. They often can be found in the heat
The raw water pump is a self-priming, rotary pump with a                 exchanger.
non-ferrous housing and a Neoprene impeller. The impeller
has flexible blades which wipe against a curved cam plate
within the impeller housing, producing the pumping action.
On no account should this pump be run dry. There should                                   RAW WATER PUMP
always be a spare impeller and impeller cover gasket aboard
(an impeller kit). Raw water pump impeller failures occur
when lubricant (raw water) is not present during engine
operation. Such failures are not warrantable, and operators                       ALIGN WITH THE
are cautioned to make sure raw water flow is present at start-                    SLOT IN THE SHAFT
up. The raw water pump should be inspected periodically for
broken or tom impeller blades. See MAINTENANCE
SCHEDULE.
NOTE: Should a failure occur with the pump:SO internal parts
(seals and bearings), it may be more cost efficient to
purchase a new pump and rebuild the original pump as a
spare.

AIR INTAKE FILTERISILENCER
The replaceable canister contains a paper element that should
be inspected often. Dirt in the element can be shaken off or
cleaned with compressed air, however, if the element is
greasy or black with dirt, the canister must be replaced, carry                                        /
                                                                                                           l '.'   INSPECTION: CHECK AT THE BASE OF
                                                                                                                   EACH BLADE BY BENDING VIGOROUSLY.
a spare.                                                                                           /               REPLACE THE IMPELLER IF THERE
                                                                                    RAW WATER IN                   ARE ANY CRACKS.
NOTE: To operate efficiently a diesel engine must intake a                                WHEN INSTALLING: TAKE CARE TO ALIGN
continuous. volume of clear air. Hard starting, an erratic idle,                          THE IMPELLER KEYWAY WITH THE SHAFT
and black e:fhaust smoke are all symptoms of a restricted air                             KEY. FOLD THE IMPELLER BLADES IN
intake.                                                                                   EITHER DIRECTION (THEY WILL TURN IN
                                                                                          THE CORRECT POSITION WHEN THE
                                                                                          PUMP STARTS).     APPLY LIQUID SOAP
                                                                                                               AT ASSEMBLY




               AIR INTAKE FILTERJSILENCER



                                                           Engines & Generators

                                                                   18
                                                  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 engine model's heat exchanger end gasket part num-
                                                                      ber), O-ring and cover, and install a new zinc anode.
                                                                      NOTE: The threads of the zinc anodes are pipe threads and
                                                                      do .not require sealant. Sealant should not be used as it may
                                                                      insulate the zinc from the metal of the heat exchanger hous-
                                                                      ing preventing electrolysis action on the zinc.

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

                                                                                                 ~IR   BLEED
                                   ZINC ANODE                                           ~PETCOCK
                                   DO NOT USE SEALANT
                                   ON THE THREADS                                     ?-I;~




            COVER
            SECURING
            BOLT

                       INSPECT
                       BOTH ENDS

                                                         HEAT EXCHANGER
                                     NOTE: When installing the heat exchanger end covers. Be
                                     sure that the end cover securing bolt's sealing a-ring is
                                     installed. Failure to install this sealing a-ring can result in
                                     end plate failure/sea water leakage.




                                                         Engines & Generators

                                                                19
                                                    ENGINE LUBRICATING OIL
        ENGINE OIL CHANGE                                                           When installing the new oil filter element, wipe the filter
        1. Draining the Oil Sump. Discharge the used oil through                    gasket's sealing surface on the bracket free of oil and
           the sump drain hose (attached to the front of the engine)                apply a thin coat of clean engine oil to the rubber gasket
           while the engine is warm. Drain the used oil completely,                 on the new oil filter. Screw the filter onto the threaded oil
           replace the hose in its bracket, and replace the end cap                 filter nipple on the oil filter bracket, and then tighten the
                                                                                    filter firmly by hand.
           securely.
           NOTE: Thread size for the lube oil drain hose capped end                 NOTE: The engine oil is c.ooled by engine coolant flowing
           is 114 NPT.                                                              through passages in the oil filter bracket housing assembly.
           Always observe the used oil as it is removed. A
           yellow/gray emulsion indicates the presence of water in
           the oil. Although this condition is rare, it does require              A WARNING: Used engine oil contains harmful
           prompt attention to prevent serious damage.·Call a                     contaminants. Avoid prolonged skin contact. Clean skin
           qualified mechanic should water be present in the oil.                 and nails thoroughly using soap and water. Launder or
           Raw water present in the oil can be the result of a fault in           discard clothing or rags containing used oil. Discard
           the exhaust system attached to the engine and/or a                     used oil properly.
           siphoning of raw water through the raw water cooling
           circuit into the exhaust, filling the engine. This problem
           is often caused by the absence of an anti-siphon valve, its              NOTE: Generic filters are not recommended, as the
           poor location or lack of maintenance.                                    material standards or diameters of important items on
        2. Replacing the Oil Filter. When removing the used oil                     generic parts might be entirely different from genuine
           filter, you may find it helpful and cleaner to punch a hole              parts. Immediately after an oil filter change and oil fill,
           in the upper and lower portion of the old filter to drain                run the engine to make sure the oil pressure is normal
           the oil from it into a container before removing it. This                and that there are no oil leaks around the new oil filter.
           helps to lessen spillage. A small automotive filter wrench
           should be helpful in removing the old oil filter.                     3. Filling the Oil Sump. Add new oil through the oil filler
                                                                                    cap on the top of the engine or through the side oil fill.
           NOTE: Do not punch this hole without first loosening the
                                                                                    After refilling, run the engine for a few moments while
           filter to make certain it can be removed.
                                                                                    checking the oil pressure. Make sure there is no leakage
           Place some paper towels and a plastic bag around the                     around the new oil filter or from the oil drain system, and
           filter when unscrewing it to catch any oil left in the filter.           stop the engine. Then check the quantity of oil with the
            (Oil or any other fluid on the engine reduces the engine's              lube oil dipstick. Fill to, but not over the high mark on
           cooling ability. Keep your engine clean.) Inspect the old                the dipstick, should the engine require additional oil.
           oil filter as it is removed to make sure that the rubber
            sealing gasket comes off with the old oil filter. If this
           rubber sealing gasket remains sealed against the filter                                ~              II\~
           bracket, gently remove it.                                                                         O~
                                                                                                              ~~               ".,
                                                                                              ,
                                                                                                     ~   /.     0))1r~
                                                                                               ~                                A~
REMOVE  USING ANOR
                 BMM  (77/76') SOCKET   ~~I~~i::t~~                                                      ·"·~d""
TO DRAIN THE OIL   PUMP   THE WARMED                                 ~bi~_
OIL UP THRU THE HOSE.
                    OIL DRAIN HOSE


                        11/16"0.D.

                                                                                                                                     SPIN ON FILTER
                                                                                 OIL FILTER ASSEMBLY                                 APPLY CLEAN ENGINE OIL
                                                                                                                                     WHEN INSTALLING
                                                                                                                                     TURN ON HAND TIGHT




                                                                    Engines & Generators

                                                                            20
                                        REMOTE OIL FILTER (OPTIONAL)
INSTALLATION                                                                   NOTE: Westerbeke is not responsible for engine failure due to
This popular accessory is used to relocate the engine's oil fil-               incorrect installation of the Remote Oil Filter.
ter from the engine to a more convenient location such as an
engine room bulkhead.                                     .
NOTE: Refer to ENGINE OIL CHANGE in this manualfor                               A CAUTION: It is vital to install the oil lines cor-
instructions on removing the oil filter.                                         rectly. If the oil flows in the reverse direction, the by-
To install, simply remove the engine oil fllter and thread on                    pass valve in the filter assembly will prevent the oil
WESTERBEKE's remote oil fllter kit as shown. Always                              from reaching the engine causing an intemal engine
install this kit with the oil filter facing down as illustrated.                 failure. If there is no oil pressure reading, shutdown.
Contact your WESTERBEKE dealer for more information.                             immediately and check the hose conlnelJ:tiolIS.


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



                                                    THE IN CONNECTION HOSE
                                                    MUST ATTACH TO THE OUT
                                                    CONNECTION AT THE
                                       J;:;p~~---AI:Mn'TI: OIL FILTER.




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




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




                                                                 Engines & Generators

                                                                          21
                                        WATER HEATER CONNECTIONS
WESTERBEKE provides easy access for connecting to an                       NOTE: An air bleed petcock is located on the engine:SO heat
on-board hot water system. These connections allow for the                 exchanger and on the thermostat housing. Open these
engines hot water (coolant) to flow to the ships hot water                 petcocks when filling the engine:SO coolant system to allow air
tank, heating the fresh water and then cycling back to the                 to escape. Close both tightly after all the air is removed.
engine.
The water heater should be mounted in a convenient location                NOTE: If any portion of the heating circuit rises above the
either in a high or low position in relation to the engine, so             engine:SO closed cooling system pressure cap, then a
that the connecting hoses from the heater to the engine can                pressurized (aluminum) remote expansion tank (Kit #024177)
run in a reasonably direct line without any loops which might              must be installed in the circuit to become the highest point.
trap air.                                                                  Tee the remote expansion tank into the heater circuit, choos-
                                                                           ing the higher of the two connections for the return Tee at
Hoses should rise continuously from their low point at the                 the heater; and plumb a single line up to the tanks location
heater to the engine so that air will rise naturally from the              and the other back to the engine:SO return. Install the remote
heater to the engine. If trapped air is able to rise to the heater,        expansion tank in a convenient location so the fresh water
then an air bleed petcock must be installed at the higher                  coolant level can easily be checked. The remote expansion
fitting on the heater for bleeding air while filling the system.           tank will now serve as a check and system fill point. The
                                                                           plastic coolant recovery tank is not used when the remote
                                                                           expansion tank kit is installed, since this tank serves the
                                                                           same function.



                                                                                         ':~

                          TO CONNECT TO THE WATER HEATER
                                                                             DISCONNECT THE EXISTING HOSE
                                                                             AND ATTACH THE HEATER HOSE AT
                                                                             THIS COUPLING

                                                                            REMOVE THE EXISTING BY-PASS HOSE




                                                                                                    DISCONNECT THE EXISTING HOSE
                                                                                                    AND ATTACH THE HEATER HOSE
                                                                                                    TO THIS FITTING.




                                                              Engines & Generators

                                                                      22
                                                      TACHOMETER
TACHOMETER/HOUR METER                                                  NOTE: Current model tachometers use a coarse adjustment
The tachometerlhour meter used in propulsion engine instru-            dial to set the tachometer to the crankshaft pulley rpms. The
ment panels contains two separate electrical circuits with a           calibrating screw is then used for fine tuning.
common ground. One circuit operates the hour meter and the
other the tachometer. The hour meter circuit operates on 12
volts alternator charging voltage supplied to ·the (+) terminal
on the back of the instrument.
The tachometer circuit operates on AC voltage 6-8 volts, fed
from one of the diodes in the alternator and supplied to the
tachometer input terminal while the engine is running, and
the alternator producing battery charging voltage 13.0-14.8
volts DC.
The following are procedures to follow when troubleshooting
a fault in either of the two circuits in a tachometerlhour
meter.
Hour meter Inoperative
Check for the proper DC voltage between (+) and (-)
terminals.                                                             IDLE SPEED ADJUSTMENT
1. Voltage present - meter is defective - repair or replace.
                                                                       &TACHOMETER CHECK (New Installation)
2. Voltage not present - trace (+) and (-) electrical con-
    nections for fault. (Jump 12 volts DC to meter (+)                 Checking the idle speed
    terminal to verify the operation.) ,                               NOTE: In a new installation having new instrument panels,
                                                                       the tachometer may not always be correctly calibrated to the
Tachometer Inoperative                                                 engine:S- rpm This calibration should be checked in all new
Check for the proper AC voltage between tachometer input               installations.
terminal and (-) terminal with the engine running.                     1. Warm up the engine to normal operating temperature.
1. Voltage present - attempt adjusting meter through calibra-              Remove any specks on the crankshaft pulley with a clean
    tion access hole. No results, repair or replace meter.                 cloth and place a piece of suitable reflecting tape on the
2. AC voltage not present - check for proper alternator DC                 pulley to facilitate use of a photoelectric type tachometer.
    output voltage.                                                    2. Start and idle the engine.
3. Check for AC voltage at tach terminal on alternator to              3. Aim the light of the tachometer onto the reflecting tape to
    ground.                                                                confirm the engine speed. Check the instrument panel
4. Check electrical connections from tachometer input ter-                 tachometer reading. Adjust the tachometer in the panel by
    minal to alternator connection.                                        using the instrument calibration pod as needed to bring
                                                                           the instrument panel tachometer into the same rpm
Tachometer Sticking                                                        reading as the engine.
1. Check for proper AC voltage between ''tach inp." termi-             4. Adjust the idle speed if the engine speed is not within the
   nal and (-) terminal.                                                   specified value.
2. Check for good ground connection between meter (-) ter-                 Normal idle speed is 690-950 RPM.
   minal and alternator.
3. Check that alternator is well grounded to engine block at
   alternator pivot bolt
Tachometer Inaccurate
a. With a hand-held tach on the front of the crankshaft
   pulley retaining nut or with a strobe-type tach, read the
   front crankshaft pulley rpm at idle.
b. Adjust the tachometer with a small Phillips type screw-
   driver through the calibration access hole in the rear of
   the tachometer. Zero the tach and bring it to the rpm
   indicated by the strobe or hand tach. (Verify the rpm at
   idle and at high speed,




                                                         Engines & Generators
                                                                  23
                                                DC ELECTRICAL SYSTEM
   ALTERNATOR                                                               1. Start the engine.
  The charging system consists of a DC belt driven alternator               2. After the engine has run for a few minutes, measure the
  with a voltage regulator, an engine DC wiring harness, a                     starting battery voltage at the"battery terminals using a
  mounted DC circuit breaker and a battery with connecting                     multimeter set on DC volts.
  cables. Because of the use of integrated circuits (IC's), the                a. If the voltage is increasing toward 14 volts, the alterna-
  electronic voltage regulator is very compact and is mounted                     tor is working; omit Steps 3 through 8 and go directly
  internally or on the back of the alternator.                                    to "Checking the Service Battery" on the next page.
                                                                               b. If the voltage remains around 12 volts, a problem
                                                                                  exists with either the alternator or the charging circuit;
    114GRAY==~=~-_                                                                continue with Steps 3 through 8.



                                                                                                                o
                                                                                                                CKQ)
                                                                                         MULTIMETER
#14 PINK ~~~~~~~Eii~
'14 BLUE=
                                                                                                                COM




                                    iie@J~fI-~=110 RED

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

  ALTERNATOR TROUBLESHOOTING                                                    TESTING THE STARTING
                                                                                BATTERY/ALTERNATOR
   A WARNING: A failed altemator can become very                                (ENGINE RUNNING)
   hot. Do not touch until the altemator has cooled down.
  Use this troubleshooting section to determine if a problem                3. Tum off the engine. Inspect all wiring and connections.
  exists with the charging circuit or with the alternator. If it is            Ensure that the battery terminals and the engine ground
  determined that the alternator or voltage regulator is faulty,               connections are tight and clean ..
  have a qualified technician check it.
  The alternator charging circuit charges the starting battery                   A    CAUTION: To avoid damage to the battery
  and the service battery. An isolator with a diode, a solenoid                  charging circuit, never shut off the engine battery
  or a battery selector switch is usually mounted in the circuit                 switch when the engine is running!
  to isolate the batteries so the starting battery is not discharged
  along with the service battery. If the alternator is charging the         4. If a battery selector switch is in the charging circuit,
  starting battery but not the service battery, the problem is in              ensure that it is on the correct setting.
  the service battery's charging circuit and not with the alterna-          5. Tum on the ignition switch, but do not start the engine.
  tor.
                                                                            6. Check the battery voltage. If the battery is in good condi-
  Testing the Alternator                                                       tion, the reading should be 12 to 13 volts.

   A CAUTION: Before starting the engine make certain                                                           ~
   that everyone is clear of moving parts! Keep away from
   sheaves and belts during test procedures.                                                                   0..,...--MULTIMETER
                                                                                                               coM



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



                                                              Engines &·Generators                       -=-   GROUND
                                                                       24
                                             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.
                                          MULTIMETER. (]Z5J


                                                       G
                                                       COM




        TESTING THE STARTING
        BATTERY/ALTERNATOR                                  ENGINE
        (ENGINE RUNNING)                    -1..=o-c=::.--I GROUND
                                            -
s.   Start the engine again. Check the voltage between the
     alternator output and ground.                                                                            ,SERVICE BATTERY
     The voltage reading for a properly operating alternator
     should be between 13.5 and 14.5 volts. If your alternator                                              TESTING THE SERVICE
     is over- or under-charging, have it repaired at a reliable                                             BATTERY (ENGINE RUNNING)
     service facility.
     NOTE: Before removing the alternator for repair, use a
     voltmeter to ensure that 12 volts DC excitation is present
     at the EKC terminal if the previous test showed only bat-             A    CAUTION: To avoid damaging the altemator dlodesl
     tery voltage at the B output terminal.                                do not use a high voltage tester (i.e. a megger) when
                                                                           perfonnlng tests on the altemator charging circuit.
     If 12 volts is not present at the EXC terminal, trace the
     wiring and look for breaks and poor connections.

12 VOLT 01; CONTROL CIRCUIT                                               Battery Care
The engine has a 12 volt DC electrical control circuit that is            Rev.iew the manufacturer's recommendations and then
shown on the· wiring diagrams that follow. Refer to these                 establish a systematic maintenance schedule for your
diagrams when troubleshooting or when servicing the DC                    engine's starting batteries and house batteries.
electrical system.                                                        D Monitor your voltmeter for proper chargip,g during
                                                                              engine operation.
 A CAUTION: To avoid damage to the battery charging                       D Check the electrolyte level and specific gravity with a .
                                                                              hydrometer.
 clrcultl never shut off the engine battery switch while
 the engine Is running. Shut off the engine battery swltchl               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
 englnets electrical circuit.                                                 tight to the battery posts (and to your engine).
                                                                          D Keep your batteries clean and free of corrosion.
BATTERY
The minimum recommended capacity of the battery used in
the engine's 12 volt DC control circuit is 600 - 900 Cold.
Cranking Amps (CCA).
                                                                            A WARNING: Sulfuric acid In lead batteries can
                                                                            cause severe bums on skin and damage clothing. Wear
                                                                            protective gear.



                                                             Engines.& Generators

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


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


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




                                                       Engines & Generators

                                                                26
                                                                                                                      WIRING SCHEMATIC
                      +     12   vee                  START
                                                   SOL.                         STARTER                                     -
                                                  r-,
                                                                                  M
                                                  I
                                                  I
                                                       _
                                                  .... ...I
                                                              I
                                                                                ------------                                    ------,
                                                                                                                                                        I           NOTES:
                                                                                                                                                                    I. THIS PRODUCT IS PROTECTED SY A MANUAL RESET CIRCUIT BREAKER LOCAHD NEAR THE
                                                                      PREHEAT                                                                           I              STARTER.  EXCESSIVE CURRENT WILL CAUSE THE SREAKER TO TRIP AND THE ENGINE Will
                                                          r--,SOL.
                                                                                                                                                        I                 ~~~r N~O:~t I~~~Af~~5D~g 1~:~~:N~U~bN~~C'U:~T~~~~ H~c ~=f~:~Ng~~ It:~E~ND W~:~:i tE~ro
                                                  ~
                                                                      I                   GlOWPLUGS
                                                                                                                                                        I           2.    AN ON-Orr SWITCH SHOULD BE         IHSTALlED BETWEEN THE BATTER" AND STARTER TO
                                                         I
                                                   L.._.J
                                                                                                                                                        I                 ~: f~O~N~~~T T~~O~~Tn~1 N~ NO~N I i~E:~~~~Y ~~D I ;H~~C L~~~~ N;E~~~ ~~~i' F UN~T f~~ ~CH TH I ~
                                                                                  ALTERNATOR                                                            I                 SWITCH SHOULD NOT BE USED TO MAI'IE OR BREAK THE CIRCUIT.
                                                                                                                                                        I           3. THE PINK WIRE AT PLUG 2 IS UNUSED AND SHOULD 8E INSULATED, CAPTAIN PANEL ONLY.


                                                                                    ~
                                                                                                                                                        I           .c.   THE GRAY WIRE AT PLUG     Z IS UNUSED AND SHOULD BE INSULATED. ADMIRAL PANEL ONLY.


                     ~ ,
                      ~ C.B..                 (   ~,'OA
                                                      C.B.
                                                                                                                                 ,   TO At T.      :
                                                                                                                                                        I
                                                                                                                                            . . . . . . . J..
                                                                                                     L 1FT PUMP



                                                                                                  F'UEL.
                                                                                                             P
                                                                                                                    IWHEH
                                                                                                                                 '"'"TJt
                                                                                                                                 l'
                                                                                                                                 ,
                                                                                                                                                ~ L.~~w~CuimFTl::::==:-:---,
                                                                                                                                                'H'oi:'D ··
                               =                                                                    -
                                                                                                  SOl'e-USEDI
                                                                                                                     -- .....
                                                                                                                                 Il2c


                               II
                                                                                              s~N~iR ~
                                                  ~
                                                                                                                                         298

                                         .:
                                         .;                                                    ".T.        'XJ
                                                                                              SENDER       0..                                                                      PRESTOLITE\LEECE-NEYILLE
                                                  ~
                                                                                                           \!J
                                                                                               W. T.
                                                                                              SWITCH




                                                                                       1                                l~

                         BAT
                                                                                                                                ADMIRAL
                                                                                               TACHOMETER
                            KEY                                                                  S    GNO
                                                                                                                                PANEL
                            SW.
                         IGN
                                                                                                                                                                                                     ALT
                                                                                               VOL. TMETER
                                                                                               +        GNO
                                                                  o   ALARM
                                                                                                                                                                                                                                NOTE;
                                                                  +                                                                                                                                                             WIRE FOR BATTERY ATTATCHMENT WILL NEED
                                                                                                                                                                                                                                TO BE UPGRADED TO AN      .a   GAUGE F ROM 10 GAUGE
                                                                                                           w. T.
                                                                                                           GAUGE                                                                                     '14 8RN
                                                                                                           GND




                                                                                                                                                                # 14 GRA

                                                                                                                                                                                                                                 # 14 BRN          UN I VERSAL PROPULS I ON
                                                                                                                                                                                                                                                 PRESTOL LIE SIAMP AU
                                                                                                                                                                ®    PRESTOL!TE 71 AMP              AL T ,
                                                                                                                                                                                                                                #14 GRA
                     PH           PI-' PH PI·T               P2·UP2·1I PH             P2'12                            PH
                                                                                                                                                                                                    #14 LT. BLU

                                                                                                        NO
                                                                                                                                                    'N~~\~~~,l(                                  <      #14 PINK

                            KEY
                            S,.
                                                                                                                            CAPTAIN
                                                                                                                            PANEL
                                                                                                             LAMP
                                                                                                                                                                                                                                #14 PINK
                                                                                                             TEST
                                                                                                              SW.
                                         ~                                                                                                               I I 0 RED
                                                                                                      T4
                                                                                                                                                                                                                             #14 LT.       BL
                                         j
                                                                                                                                                                                       LESTEK 100 AMP. ALT.            CD       .14 LT, BLU         .14 PINK
                                                                                                                                                                           MALE CONNECTOR
                                                                                                                                                                             ON THIS SIDE
                           PREHEAT                    ALARM
                                                                                                                                                                                                  WHT
                           SWI TCH                                                                                                                                                                                    RED
                                                  +




                                                                      WIRING SCHEMATIC #39144                                                                                                                                 BLK


       IroIALE CONNECTOR
            ON THIS SIDE
                                                                                                                                                                                                                                    BLK

______~.~I.~BRN      ~~~~OIR~N::~:::::::::::::::::::::::;"l
         IT.6.CHl~""';                 RED

                                                              BLU
                                                                                                                                                                                                                               51         AMP.    ALTERNATOR
          II 4 GSA                                                                                                                                                                                                             STANDARD ALTERNATOR ON THE
         CNOT USEDl   ~X                                                                                                                                                                                                       63B IJl. 63C IJl. 71B IJl. 62B IJl.
                                                                                                                                                                                                                               108B n. & ID8C n .
           · 4 REO




                           OPTIONAL ALTERNATORS®
                           13:'.iA. 160A. 190A, LESTEK ALTERNATORS
   AVAILA81.E ON THE I.ISOB e3l3:IV 6ICIV 'IJ!:IV 8ZB:IV IOEVI                                &. lOst:: VI                       Engines & Generators
                      ®
                                                                                                                                           27
                                                                     WIRING DIAGRAM, ~'/iwm~                                    o
                                                                                                    '1<


                                                                 "   .10 R D




                                                                                                                      .14 PNK




                                                                                              BlU

                                                                                       114   T.




              r----
              1
          1"6'                                                                                                             11

          I~
SEE NOTE 21

          1 .J
           1
           1
           1
        +A£l                                                                                                                        LIFT PUMP

          ~~
          aAI..I.E.B.l
NOTE: An on-off switch
should be installed in this·
circuit.to disconnect the                     SI

starter from the battery in,
an emergency and when
                                              PI
leaving the.bdat. Twelve
volt engine starters
typically draw 200 to 300                                                                             ADM I RAL
amps when cranking. A                                                                                 PANEL
switch with a continuous
rating of 175 amps at 12 .
VDC will normally serve
this function, but a switch'   --------
                               QI~   PRESS.          w"i1iR TBi-:- -   --------                                                 WIRING DIAGRAM #39144
must never be used to            OAUGII!                 GAUGE
"make" the starter circuit.          o                       o




                                                                                                    PI


                                                                                                                                                             CAPTAIN
                                                   liD RED                                                                               .      ~


                                                                                                                                                =   ~
                                                                                                                                                    z        PANEL
                                                                                                                 ;
                                                                                                                                         ..
                                                                                                                                          :
                                                                                                                                            .
                                                                                                                                                        RN
                                                             r--                                                                                    "
                                                                                                    o
                                                                                                    .180RN
                                                                                                                                 ALT.
                                                                                                                                lAM"




                                                                                                                                                               TACHOMETER

                                                                                                                                 DP.
                                                                                                                                lAM"




                                                                          ICEYSWlTCH



                                                                                                          '18 eLK
                                                                                                          .18 SLit
                                                                                                          .18 8l1'1
                                                                                                          .18 BlK




                                                                         Engines & Generators

                                                                                 28
                                                         STARTER MOTOR
 DESCRIPTION
 TIle starting system includes the battery, starter motor, solenoid,
 and starter button.
 When the starter button on the instrument panel is depressed,
 current flows and energizes the starter's solenoid coil. The
                                                                                                                      ~~--"""\(M)            TERMINAL
 energized coil becomes an electromagnet, which pulls the plunger
 into the coil, and closes a set of contacts which allow high current
                                                                                IGNITION
 to reach the starter motor. At the same time, the plunger also                 TERMINAL
 serves to push that starter pinion to mesh with the teeth on the               TO CONTROL
 flywheel.                                                                      PANEL
 To prevent damage to the starter motor when the engine starts, the
 pnuon gear incorporates an over-running (one-way) clutch which
 is splnled to the starter armature shaft. The rotation of the running
 engine may speed the rotation of the'pinion but not the starter
 motor itself
  Once the started button is released, the current flow ceases, stop-
  ping the activation of the solenoid. TIle plunger is pulled out of
                                                                                                              In
                                                                              To test the ignition circuit, locate the ignition(s) terminal (it is one
                                                                              of the small tem1inaJ studs and is wired to the ignition circuit).
                                                                              Use a screwdriver, don't touch the blade, to jump from that
  contact with the battery-to-start cables by a coil spring, and the          ignition teID1inaI to the positive battery connection teIDlinal on
  flow of electricity is interrupted to the starter. This weakens the         the solenoid.
. magnetic fields and the starter ceases its rotation. As the solenoid
                                                                              Iftbe starter cranks, the fault lies with the ignition circuit
  plunger is released, its movement also pulls the starter drive gear
  from its engagement with the engine flywheel.                               If tbe solenoid clicks but nothing else happens, the starter
                                                                              motor is probably faulty.




MOTOR ---t':~-+-


                                                                                                                                       -(+) POSITIVE
    TYPICAL                                                                                                                                TERMINAL
    STARTER MOTOR
                                                                                   IGNITION
                                                                                   TERMINAL
 TROUBLESHOOTING                                                                   TO CONTROL
                                                                                   PANEL
 Prior to testing, make certain the slups batteries are at full charge
 and that the starting system wiring connections (termiI1als) are
 clean and tight. Pay particular attention to the ground wiI'e                                                                     ~
 connections on the engine block.                                             If nothing at all happens the solenoid isn't getting current·
 To check the wiring, try cranking the starter for a few seconds,             Check the battery isolation switch and inspect the wiring
 never more than 10 seconds at a tinle, then run your hand along              connections. It is also possible that the solenoid is defective.
 the wires and tenninals looking for warm spots that indicate
 resistance. Repair or replace any trouble spots.
 Using a l11Ultinleter, test the voltage between the positive terminal          A WARNING: There will be arching and sparks will
 stud on the start solenoid and the engine block (ground).                      fly when jumping terminals. Be certain the engine
 If you read 12 volts, tbe starter is faulty.                                   space is free of potentially explosive fumes, especially
                                                                                gasoline.




                                                      /"""WESTERBEKE
                                                              I EnQines & Generators
                                                                         29
                                                       STARTER MOTOR
                                                                            SERVICE
                                                                            Westerbeke uses a standard marine starter motor which can be
                                        (+) POSITIVE                        serviced or rebuilt at any starter motor automotive service center.
                                  ~---.- TERMINAL                           Ifreplacing the starter motor, make certain the new motor is
                                                                            certified for marine use. Automotive starters do not meet USCG
                                                                            standards. If in doubt, contact your WESTERBEKE dealer.
                                 ~...,....---(M)   TERMINAL
                 .. r':'~~
                                                                            TO REMOVE FOR SERVICE

~i~OL(:jfJ""~__,
                                                                            1. Disconnect the negative battery cable.
                                                                            2. If necessary, remove any components to gain full access to the
                                                                               starter motor.
Test again by jumping the two large terminal studs. Hold the                3. Label and disconnect the wiring from the starter. (Do not allow
screwdriver blade firnlly between the studs. Do not allow the                  wires to touch, tape over the tenninals).
screwdriver blade to touch the solenoid or starter casing, this             4. Remove the starter mounting bolts.
would cause a short.
                                                                            5. Remove the starter from the engine. In some cases the starter
                                                                               will have to be turned to a different angle to clear obstructions.
  A WARNING: There will be arching as the full
  starting current should be flowing thru the blade of the
  screwdriver.


If the starter spins, the solenoid is faulty.
If the starter fails to spin, the motor is probably faulty.
If no arching occurred. There is po juice reaching the solenoid.
NOTE: Starter motors are either inertia type or pre-engaged. In
the pre-engaged model, the solenoid also maves .an ann that
engages the starter motor to the flywheel ofthe engine. Using a
screwdriver to bypass the solenoid on such a starter will run the
motor without engaging the flywheel. Tum the starter switch on to
provide the power to the solenoid. HopefUlly it will create enough
magnetic field for the ann to mave even though the contacts inside
the solenoid are bad.




                                                                  Engines & Generators

                                                                       30
                                          DUAL OUTPUT ALTERNATORS
                                                                                                            SPACER TO MOUNTING
                                                                                                            BRACKET

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

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

S. Make certain that the batteries negative post ground
   cable to the engine block is the same heavy gauge as
   the positive cable.
6. Mount the regulator to a flat surface in a cool dry
   location.
   a. Connect the black wire to the ground terminal on the
      alternator.                                          TO


  A CAUTION: Do not connect any power source with-
  out first grounding the regulator.


    b. Plug the 2-pin connector into the alternator, make
       certain it is firmly seated.
    c. The red "battery sense" wire should be connected to
                                                                                  ~:;::;--   "BATIERY SENSE"
       the batteries positive [+] post [or the positive cable].                              TO BATTERY POSITIVE POST
    d. The brown wire "keyed ignition" is the key circuit
       which actuates the regulator, this wire must connect                              yCONNECTS TO PINK AND
       to a switched [+] 12 volt source. Refer to the                                       BLUE LEADS. THE PINK
                                                                                                  CONNECTS TO THE
      WESTERBEKE WIRING DIAGRAM for the proper                                             ALARM BUZZER. THE BLUE
      connection.                                                                           WIRE CONNECTS TO TNE
                                                                                            OIL PRESSURE SWITeN.
Dual Pulleys
A variety of accessory pulleys for high powered and dual                                DUAL OUTPUT ALTERNATOR
charging alternators are available from your                                            [CHARGING TWO BATTERIES]
dealer.


                                                           Engines & Generators

                                                                  31
                                        DUAL OUTPUT ALTERNATORS
TROUBLESHOOTING                                                        Alternator Testing
NOTE: Before troubleshooting, make certain that the drive              The regulator is functioning properly and the batteries
belts are tight and the batteries are in good condition.               are in good condition.
Regulator Testing                                                      1. Test the voltage at the alternator plug with the engine
                                                                           off-key on. The voltage at the alternator terminal F and
The red "battery sensing" wire A connects to the battery, it               the voltage in the plug [blue wire F] from the regulator
must always read battery voltage. If battery voltage is not                should read the same.
present, trace the wire for a bad connection.
                                                                       2. Hold a screw driver close [1/2"] to the alternator puJley.
The orange wire S should read 0 volts with the key off, 12                 If voltage is present you should feel the magnetic field. If
volts [approximately] with the key on. If the readings are                 not, the problem may be the brushes [worn] or the rotor
incorrect, trace the wire for a bad connection.                            [open circuit].
The blue wire F supplies current to the alternator fields, its         3. Start the engine, at fast idle the output terminals should
voltaO"e will vary depending on the battery charge or actual               indicate 14.2 volts [no load]. A reading of 12.6 would
loadl;'m. 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 electJ.ic bilge pump, the voltage
KEY ON - NO VOLTAGE     REGULATOR IS DEFECTIVE                             should maintain at least 13.8 volts. 13 volts or less
KEY OFF - BATTERY VOLTAGE   REGULATOR IS DEFECTIVE                         indicates the alternator is faulty.
REGULATOR TEST POINTS AND PROPER VOLTAGE
               Ignition Off Ignition On    Engine Running
                                                                       NOTES:
Terminal/Color
                                                                       When the engine is first started, it takes a few moments for
 I Brown       ovolts       2 -12 volts    14.2 volts
                                                                       the alternator to "kick in" andtake.the load. A noticeable
 A Red         12.6 volts   12 volts       14.2 volts                  change in the sound of the engine will occur.
 S Orange       ovolts      ovolts         6 - 8 volts
 F Blue         ovolts      10-11 volts    4 - 12 volts                There will be a slight wine from the alternator when the load
 Alt. Output   12.6 volts   12 volts       14.2 volts                  is normal.
                                                                       When the alternator is producing high amperage, it can
                                                                       become quite hot.
                                                                       When replacing the alternator drive belts, always purchase
                                                                       and replace dual belts in matched pairs.




                                                            Engines & Generators

                                                                 32
                                              ENGINE TROUBLESHOOTING
The following troubleshooting table describes certain problems                     NOTE: The engine's electrical system is protected by a 20
relating to engine service, the probable causes of these prob-                     ampere manual reset circuit breaker located on. a bracket at
lems, and the recommendations to overcome these problems.                          the back of the engine. The preheat solenoid is mounted on
                                                                                   the same bracket.
               Problem                               Probable Cause                                         VerificationJRemedy
 No panel indications; fuel solenoid       1. Battery switch not on.                       1. Check switch and/or battery connections.
 or fuel pump is not working (key switch
 is on and PREHEAT button is depressed).   2. 20-amp Circuit breaker tripped.              2. Reset breaker; if breaker trips again, check preheat solenoid
                                                                                              circuit and check circuit for shorts to ground.
                                           3. 1O-amp breaker tripped on                    3. Check the voltage both at and after the breaker on the
                                              preheat solenoid                                preheat solenoid.
                                           4. Loose battery connections.                   4. Check (+) connection to starter solenoid and (-) connection to
                                                                                              engine ground stud. Check battery cable connections.
                                           5. Preheat solenoid not operating.              5. Check solenoid "S" terminal for voltage.
 START button is depressed, no starter     1. Connection to solenoid faulty.               1. Check connection.
 engagement.
                                           2. Gear shift not in neutral.                   2. Gear shift must be in neutral (see NEUTRAL SWITCH under
                                                                                              HURTH HSW TRANSMISSIONS).
                                           3. Faulty switch.                               3. Check switch with ohmmeter.
                                           4. Faulty solenoid.                             4. Check that 12 volts are present at the solenoid connection.
                                           5. Loose battery connections.                   5. Check battery connections.
                                           6. Low battery.                                 6. Check battery charge state.
 START button is depressed; panel          1. Poor connections to fuel solenoid.           1. Check connections.
 indications OK; starter solenoid OK;
 fuel solenoid not functioning.            2. Defective fuel solenoid.                     2. Check that 12 volts are present at the (+) connection on the
                                                                                              fuel run solenoid.
 Engine cranks, but does not               1. Faulty fueling system.                       1. Check that fuel valves are open.
 start, fuel solenoid energized.
                                                                                           1a. Check for air in fuel system. Bleed air from fuel system.
                                                                                           1b. Fuel filters clogged. Replace fiHers and bleed air from
                                                                                               fuel system.
                                           2. Preheat solenoid faulty.                     2. Check solenoid.
                                           3. Low battery power.                           3. Switch to combine house and start batteries.
                                                                                           3a. Replace batteries.
 Engine can't be stopped.                  1. Faulty DC altemator.                         1. Remove Exc. connection at alternator; repair alternator.
                                           2. Disconnect fuel shut-off cable.              2. Check connection at shut-off lever. Pull lever back to close
                                                                                              offthe fuel
                                           3. Fuel run solenoid will not de-energize.      3. Manually disconnect the 12 volt connection to the fuel run
                                                                                              solenoid at the injection pump.
 Battery runs down.                        1. Oil pressu re switch.                        1. Observe if gauges and panel lights are activated when engine
                                                                                              is not running. Test the oil pressure switc~.
                                           2. High resistance leak to ground.              2. Check wiring. Insert sensitive (0 - .25 amp) meter in battery
                                                                                              lines. (Do not start engine.) Remove connections and replace
                                                                                              after short is located.
                                           3. Low resistance leak.                         3. Check all wires for temperature rise to locate the fault.
                                           4. Poor battery connections.                    4. Check cable connections at battery for loose connections,
                                                                                              corrosion
                                           5. DC altemator not cHarging                    5. Check connections, check belt tension, test altemator. See
                                              (tachometer not operating).                     DC ELECTRICAL SYSTEM/ALTERNATOR.
 Battery not charging                      1. DC charge circuit faulty.                    1. Perform DC voltage check of generator charging circuit. See
                                                                                              Testing the Battery Charging Circuit.
                                           2. Altemator drive.                             2. Check drive belt tenSion; altemator should tum freely. Check
                                                                                              for loose connections. Check output with voltmeter. Ensure 12
                                                                                              volts are present at the Exc. terminal.


                                                                                                                                                  (continued)


                                                                   Engines & Generators

                                                                            33
                                          ENGINE TROUBLESHOOTING
              Problem                            Probable Cause                                        Verificalion/Remedy
 Engine slows and stops.               1. Fuel lift pump failure.                    1. Fuel lift pump should make a distinct ticking sound. Replace
                                                                                         pump with spare.
                                       2. Switches and/or wiring loose               2. Inspect wiring for short circuits and loose connections.
                                          or disconnected.                              Inspect switches for proper operation.
                                       3. Fuel starvation.                           3. Check fuel supply, fuel valves, fuel lift pump.
                                       4. 20 Amp circuit breaker tripping.           4. Check for high DC amperage draw during operation.
                                                                                         Ensure breaker is not overly sensitive to heat which would
                                                                                         cause tripping.
                                       5. Exhaust system is restricted.              5. Check for blockage, collapsed hose, carbon buildup at
                                                                                         exhaust elbow.
                                       6. Water in fuel.                             6. Pump water from fuel tank(s); change filters and
                                                                                         bleed fuel system.
                                       7. Air intake obstruction.                    7. Check air intake filter cartridge.
 Engine overheats/shuts down.          1. Raw water not circulating.                 1. Raw water pump failure. Check impeller - replace.
                                       2. Coolant not circulating.                   2. Obstruction at raw water intake or raw water filter.
                                                                                     2a. Thermostat - remove and test in hot water.
                                                                                         Replace thermostat
                                                                                     2b. Loss of coolant - check hoses, hose clamps, drain plug, etc.
                                                                                         for leaks.
                                                                                     2c. Broken or loose belts - tighten/replace.
                                                                                     2d. Air leak in system; run engine and open the pressure cap to
                                                                                         bleed air. Add coolant as needed.
 Engine alarm sound pulsates.          1. Loss of oil.                               1. Check dipstick, look for oil leaks at oil filter and at
                                                                                         oil drain hose connection.
                                       2. Oil pressure switch.                       2. Replace oil pressure switch.
 Engine alarm sounds continuously.     1. Engine coolant.                            1. Check engine coolant level.
                                       2. High temperature switch opens at .         2. Check for satisfactory operation with switch bypassed,
                                          too Iowa temperature.                         check with ohmmeter, replace if faulty.
 Exhaust smoke problems                1. Blue smoke.                                1. Incorrect grade of engine oil.
                                                                                     1a. Crankcase is overfilled with engine oil (oil is blowing out
                                                                                         through the exhaust).
                                       2. White smoke.                               2. Engine is running cold.
                                                                                     2a. Faulty injector or incorrect injector timing.
                                       3. Black smoke.                               3. Improper grade of fuel.
                                                                                     3a. Fuel bum incomplete due to high back-pressure in exhaust or
                                                                                         insufficient air for proper combustion (check for restrictions in
                                                                                         exhaust system; check air intake).
                                                                                     3b. Improperly timed injectors or vaives, or poor compression.
                                                                                     3c. Lack of air - check air intake and air filter. Check for proper
                                                                                         ventilation.
                                                                                     3d. Overload.

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

                                                                       34
                                              ENGINE ADJUSTMENTS
                                NOTE: WESTERBEKE recommends that the following engine adjust-
                                ments be performed by a competent engine mechanic. The information
                                below is provided to assist the mechanic.

DRIVE BELT ADJUSTMENT                                                   FUEL INJECTORS
Proper inspection, service and maintenance of the drive belts           In case of severe vibrations and detonation noise, have the
is important for the efficient operation of your engine (see            injectors checked and overhauled by an authorized fuel
Drive Belts under MAINTENANCE SCHEDULE).                                injection service center. Poor fuel quality, contaminants and
Drive belts must be properly tensioned. Loose drive belts               loss of positive fuel pressure to the injection pump can result
will not provide proper alternator charging and will eventu-            in injector faults. Since fuel injectors must be serviced in a
ally damage the alternator. Drive belts that are too tight will         clean room environment, it is best to carry at least one extra
pull the alternator out of alignment and/or cause the alterna-          injector as a spare should a problem occur.
tor to wear out prematurely. Excessive drive belt tension can           Before removing the old injector, clean the area around the
also cause rapid wear of the belt and reduce the service life           base of the injector to help prevent any rust or debris from
of the coolant pump's bearing. A slack belt or the presence of          falling down into the injector hole. If the injector will not lift
oil on the belt can cause belt slipping, resulting in high              out easily and is held in by carbon build-up or the like, work
operating temperatures and tachometer variations.                       the injector side-to-side with the aid of the socket wrench to
The drive belt is properly adjusted if the belt can be deflected        free it, and then lift it out.
no less than 3/8 inch (lOmm) and no more than 112 inch                  The injector seats in the cylinder head on a copper sealing
(12mm) as the belt is depressed with the thumb at the                   washer. This washer should be removed with the injector and
midpoint between the two pulleys on the longest span of the             replaced with a new washer when the new injector is
belt. A spare belt or belts should always be carried on board.          installed.
                                                                        INJECTOR TO CYLINDER HEAD TIGHTENING TORQUE
 A    WARNING: Never attempt to cbeck or adjust the                     43-51 fI-lb (6.0-7.0 mka)
 drive belt's tension while the engine is in operation.

Adjusting Belt Tension
1. Loosen the alternator adjusting strap bolt and the base
   mounting bolt.                                                                     FUEL INJECTOR
2. With the belt loose, inspect for wear, cracks and frayed
   edges.
3. Pivot the alternator on the base mounting bolt to the left
   or right as required, to loosen or tighten.
4. Tighten the base mounting bolt and the adjusting strap
   bolt.
5. Run the engine for about 5 minutes, then shut down and
   recheck the belt tensions.
RAW WATER PUMP BELT
The tension of the raw water pump belt is adjusted by
releasing the pumps fasteners and sliding the pump back
and forth. The water pump belt should be firmly tight and
checked often.
STARTER AND ALTERNATOR SERVICE
Refer to the engine troubleshooting chart in this manual. Also
included in this manual are basic troubleshooting and test
procedures for both the starter motor and the alternator. Note
also that there are automotive shops that specialize in the
repair and rebuilding of starter motors and alternators.




                                                           Engines & Generators

                                                                   35
                                                            ENGINE ADJUSTMENTS
                                            NOTE: WESTERBEKE recommends that the following engine adjust-
                                            ments be performed by a competent engine mechanic. The information
                                            below is provided to assist the mechanic.
  VALVE CLEARANCE ADJUSTMENT                                                                8. Adjust each valve's clearance by inserting a 0.012in
                                                                                               (0.03mm) feeler gauge between the rocker ann and the
  1. Wann 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
     position each cylinder for valve adjustment.
     Valves are adjusted with the piston in the cylinder being
     adjusted at TOC of its compression stroke.
  NOTE: Retorque the cylinder head bolts before adjusting the
  engine s valves.
  4. Loosen the head bolts in the reverse order of tightening.




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


                                                                                             ENGINE COMPRESSION
            13       9       5          1         4     8     12
                                                                                            Check the compression pressure. To do this, wann the
  5. Tighten the head bolts in the order shown. Torque at                                   engine, remove all fuel injectors, or glow plugs, disconnect
       85 90 ft -Ib (11.8 -12.5 m-kg)
                                                                                            the fuel shut-off solenoid wire, and install a compression
                                                                                            adapter in the injector hole or glow plug hole. Connect a
   6. Set the piston of No.1 cylinder to TOC (compression)                                  compression tester on the adapter and crank the engine with
      and check the valve clearance at each position indicated.                             the starter motor until the pressure reaches a maximum value.
      If the clearance is incorrect, adjust to specifications:                              Repeat this process for each cylinder. Look for cylinders with
      Intake - No.1 and No.2 cylinders; and                                                 dramatically (at least 20%) lower compression than the
      Exhaust - No. 1 and No.3 cylinders.                                                   average of the others. Compression pressure should not differ
   7. Turn the crankshaft once, setting the piston of No. 4                                 by more than 42.7 psi (3.0 kglcm2) at 200 rpm.
      cylinder at TOC (compression) and adjust to the
      following specifications:
      Intake - No.3 and No.4 cylinders; and
      Exhaust - No.2 and No.4 cylinders.

      I
4 EXHAUST
          WHEN NO.4 CYLINDER IS AT TOP DEAD CENTER
          41NTAKE 31NTAKE
                             EXHAUST 2
                                                                                       COMPRESSION GAUGE  I
                                                                                                               ~
                                                                                             COMPRESSION PRESSURE STANDARD 427 PSI al200 RPM (30.0 Kg/em')
                                                                                             COMPRESSION PRESSURE LIMIT    384 PSI al200 RPM (27.0 Kg/em')
                                                                                             LIMIT BETWEEN CYLINDERS       42.7 PSI (3.0 Kg/em')
                                                                                             If a weak cylinder is flanked by healthy cylinder, the problem
                                                                                             is either valve or piston related. Check the valve clearances
                                                                                             for the weak cylinder, adjust as needed and test again.
                                                                                             If the cylinder is still low, apply a small amount of oil into
                                            2 INTAKE        NTAKE1                           the cylinder to seal the rings and repeat the test.
                    f EXHAUST                 I        ~ EXHfUST                             If compression comes up - the rings are faulty.
      WHEN NO. 1 CYLINDER IS AT TOP DEAD CENTER               I"!!""'!.""!""!""~

                                                                                   Engines & Generators

                                                                                       36
                                             ENGINE ADJUSTMENTS
                               NOTE: WESTERBEKE recommends that the following engine adjust-
                               ments be performed by a competent engine mechanic. The information
                               below is provided to assist the mechanic.

ENGINE IDLING SPEED                                                 INJECTION PUMP SERVICE
The engine idling speed is pre-set at the factory but once the      For disassembly, inspection, reassembly and internal
boat is operating in the water other variables such as              adjustments of the injection pump, it is recommended the
propeller size, shaft length, and the transmission can affect       pump be taken to a qualified injection service shop
the idle speed.                                                     authorized to service Diesel KiKi or Zexel injection
The normal idle speed for this engine is 650-950 RPM,               equipment.
however, simply put the idle speed should feel comfortable.
It should be quiet and smooth, not racing but not so low that       ENGINE STOP SOLENOID
it causes chugging and transmission rattle.                         This solenoid is installed on the top rear of the injection
                                                                    pump and is activated by 12 VDC electrical current.
SETTING THE IDLING SPEED
To adjust the engine idle speed (engine running), loosen the
                                                                    Troubleshooting
locknut of the idle adjustment bolt and turn the bolt                  1. The solenoid does not operate when
clockwise to increase idle speed and counterclockwise to                  the keyswitch is turned "ON".
reduce. Once the speed is set to your satisfaction, tighten the           a. Are the engine batteries turned "ON"?
locknut.                                                                  h. Is the 20 amp circuit breaker set?
                                                                          c. Is 12 VDC present at the solenoid
                                                                             connection?
                                                                       2. The solenoid does not stop the engine when
                                                                          the keyswitch is switched "OFF'.
                                                                                                                         J:=      SPRING

                                                                          a. Check to see if 12 VDC is still present              PLUNGER
                                                                             at the solenoid electrical lead with the
                                                                             key off.
                                                                          h. Remove solenoid from injection
                                                                             pump and ensure plunger and spring
                            , THROTTLE STOP BOLT (FACTORY SET)
                                                                             in the solenoid are not sticking.

          FUEL INJECTION PUMP (TOP)




                                                           Engines & Generators

                                                                  37
                                              ENGINE ADJUSTMENTS
                                NOTE: WESTERBEKE recommends that the following engine adjust-
                                ments be performed by a competent engine mechanic. The information
                                below is provided to assist the mechanic.

 TESTING OIL PRESSURE                                                  LOW OIL PRESSURE
 The lubricating system is a pressure feeding system using an          The specified safe minimum oil pressure is 4.3 + 1.4 psi (0.3
 oil pump. The engine oil is drawn from the oil sump by the            + 0.1 kglcm2). A gradual loss of oil pressure usually indi-
 oil pump, which drives the oil, under pressure, through the           cates a worn bearings. For additional information on low oil
 oil filter, oil cooler and various lubricating points in the          pressure readings, see the ENGINE TROUBLESHOOTING
 engine. The oil then returns to the oil sump to repeat the            chart.
 continuous cycle. When the oil pressure exceeds the specified
 pressure, the oil pushes open the relief valve in the oil pump        OIL PRESSURE SWITCH/SENDER
 and returns to the oil sump, keeping the oil pressure within
 its specified range.                                                  Occasionally a faulty oil pressure sender will give a false
                                                                       reading. When installing a new sender, apply teflon sealant to
 To test the oil pressure, remove the oil pressure sender, then        the threaded ends being careful not to close off the oil hole in
 install a mechanical oil pressure gauge in it's place. After          the sender.
 warming up the engine, set the engine speed at approx.
                                                                       OIL PRESSURE SENDER AND SWITCH TORQUE
 2600 rpm and read the oil pressure gauge.
                                                                       9 -13 fHb (1.2 -1.8 m-Kg).

                                                                                        OIL PRESSURE
                                                                                        SWITCH

                                   INJECTION PUMP
                                                                                                          CONNECTION TO
                                                                                                          ENGINE BLOCK

 OIL PRESSURE GAUGE
 WITH ADAPTER
THIS MECHANICAL TEST GAUGE CAN BE
INSTALLED WHERE THE OIL HOSE ENTERS
THE ENGINE BLOCK OR IN PLACE OF THE
OIL PRESSURE SENDER

                                                                                                          OIL GALLERY




                                                            Engines &. Generators

                                                                  38
                                              HURTH TRANSMISSIONS
 DESCRIPTION                                                              NOTE: When installing the transmission, make certain that
 The information below is specific to the HBW                             shifting is not impeded by restricted movability of the
 Transmissions, the TRANSMISSION TROUBLESHOOTING                          Bowden cable or rod linkage, by unsuitably positioned guide
 SECTION applies to all models.                                           sheaves, too small a bending radius, etc. In order to mount a
                                                                          support for shift control cable connections, use the two
 CONNECTION OF GEAR BOX WITH PROPELLER                                    threaded holes located above the shift cover on top of the
 HBW recommend a flexible connection between the trans-                   gear housing. Refer to the WESTERBEKE parts list.
 mission gearbox and the propeller shaft if the engine is                 CONTROL CABLES
 flexibly mounted, in order to compensate for angular
 deflections. The installation of a special propeller thrust bear-        The transmission is suitable for single lever remote control.
 ing is not required, since the propeller thrust will be taken by         Upon loosening the retaining screw, the actuating lever can
 the transmission bearing, provided the value specified under             be moved to any position required for the shift control
 SPECIFICATIONS is not exceeded. However, the output                      elements (cable or rod linkage). Make certain that the
 shaft should be protected from additional loads. Special                 actuating lever does not contact the actuating lever cover
 care should be taken to prevent torsional vibration. When                plate: the minimum distance between lever and cover should
 using a universal joint shaft, make certain to observe the               be'O.5mm.
 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 ,*PRIVESAVER" 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
                                                                          positions A and B should be at least 35mm for the outer pivot
                                                                          point and 3Dmm for the inner pivot point.
                                               HURTHHBW                   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
                                                                                           FORWARD
                                                                                             ..B.
                                                                      CHECK FOR EQUAL TRAVEL
                                                                      FROM NEUTRAL THRU
                                                                      FORWARD AND REVERSE.




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

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


                                                            Engines & Generators                      0.02 in (0.5mm)
                                                                                                      MINIMUM CLEARANCE
                                                                     39
                                         HURTH HBW TRANSMISSIONS
 INITIAL OPERATION                                                       OPERATING TEMPERATURE
 All HBW marine transmissions are test-run on a test stand           The maximum permissible ATF temperature should not exceed
 with the engine at the factory prior to delivery. For safety        2300 (110°). This temperature can only be reached for a short
 reasons the fluid is drained before shipment.                       time.
 Fill the gearbox with Automatic Transmission Fluid
 (Dm{TRON ill). 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 pUIpose. 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
   CHECKING     I'                                                   charging the battery), will have no detrimental effects on the
   FLUID                                                             transmission
   LEVEL        i
                                                                     DAILY OPERATION

            'nm~1
                                       FLUID                         o       Check the transmission fluid.
                                                                     o       Visually check the gear shift level linkage and
                                                                             transmission.
. FLUID DRAIN   ~~
                 I
                                                                     o       Start the engine in neutral, allowing a few minutes at
                                                                             idle to warm the fluid.
 FLUID CHANGE                                                        o       Shift into gear.
 Change the fluid for the first time after about 25 hours of             NOTE: Too low an idle speed will produce a chattering noise
 operation, then every 300 operating hours or at least once a        from the transmission gear and damper plate. In such cases
 year or at winterizing.                                             the idle speed should be increased
 Removing the fluid                                                  For additional infonnation refer to the following text in this
 Push a suction pump hose down through the dipstick hole to          Transmission Section: SHAFT COUPLINGS, MAINTE-
 the bottom of the housing and suck out the fluid. (If space         NANCEAND TRANSMISSION TROUBLESHOOTING.
 allows, use the transmission drain). Remove the drain plug
 from the bottom of the transmission and allow the fluid to                    HBW TRANSMISSIONS SPECIFICATIONS
                                                                                               - - -             -----       --      -
 drain into a container, then reinstall the plug with its sealing
                                                                          ~---             ~




 washer. Wipe down the transmission and properly dispose of               General                 (Hurth Standard Transmission) Case-
 the used fluid. After running the engine, shut down and                                          hardened helical gears, with a servo-
 recheck the fluid level.                                                                         operated multiple disc' clutch.
                                                                          Gear ratio (optional)   2.63 : 1 (HBW 150A - 3R)
 DRAIN PLUG TORQUE 20 - 25 fI/Ibs
                                                                                                  2.99 : 1 (HBW 150v - 3R)
                                                                                                  2.74: 1 (HBW 250 - 3R)
 NOTE: When changing the fluid, take care not to lose the
 drain plug sealing washer. The drain plug will leak without              Lubricating Fluid       ATF - type A or Dextran - /I or III
 this sealing washer.                                                     Transmission Sump       HBW 150A 0.59 U.S. qts (0.561 liters)
                                                                          Capacity                HBW 150V 1.11·U.S. qts (1.05 liters)
                                                                                                  HBW 250       0.75 U.S. qts (0.79 liters)
   A    WARNING: Never pull out the dipstick while the                    Propeller Shaft         Right hand - standard
   engine is running. Hot fluid will splash from the dip-                 Direction of Rotation   transmission
   stick hole. This could cause severe bums.




                                                            Engines.& generators

                                                                    40
                                              HURTH TRANSMISSIONS
 Operating Temperature                                                      MAINTENANCE
                                                                            Transmission maintenance is minimal. Keep the exterior
   A CAUTION: If the transmission guid 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 guid.                                                       and corrosion. Lubricate the cable connections.

 Normal operating temperature of the transmission fluid
                                                                            Lay-up/Winterize
 should be in the range of 122°F (50°C) to 212°F (l00°C). A                 Storage requires special care. Follow these procedures:
 maximum temperature of 266°F (l30°C) 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                   o   Inspect the gear shift cable, linkage, and attachments.
 some circumstances, depending on operating hours, tropical                     Look for corrosion of the end fittings, cracks or cuts in
 waters, maintenance, etc. it might only last half that time.                   the conduit, and bending of the cable rods. Lubricate all
                                                                                moving parts.
                                                                                NOTE: If the transmission is to be stored for a long time
                                                                                (twelve months or more), it should be topped offwith
                                                                                fluid to prevent internal corrosion. Reduce the fluid level
                                                                                before putting the engine back into service
                                                                            For additional information contact:
                                                                                  HURTH MARINE GEAR
TRANSMISSION COOLER                                                               ZF Industries
                                                                                  3131 S.W. 42nd Street
                                            ""PE'RIO[,U{;ALLY INSPECT FOR
                                              EROSION AND LEAKAGE                 Fort Lauderdale, FL 33312
                           TRANSMISSION                                           Tel.: (954) 581-4040       .




                                                               Engines. & Generators

                                                                       41
                                           HURTH HSW TRANSMISSIONS
SHIPMENT                                                                          INITIAL OPERATION'
For safety reasons, the transmission is not filled with                           Set the shifting lever to neutral position (N). Start the engine
transmission fluid during shipment and the selector lever is                      and let it run long enough in idle to fill the cooler and hoses
temporarily attached to the actuating shaft.                                      with transmission fluid. Shift into gear, forward and reverse;
Before leaving the WESTERBEKE plant, each transmission                            shifting should be smooth and positive. Direct changes from
undergoes a test run, with Dextron III ATF transmission fluid.                    forward to reverse are permissible since the multiple disc
The residual fluid remaining in the transmission after                            clutch permits changing at high rpm including sudden
draining acts as a preservative and provides protection                           reversing at high speeds in the event of danger.
against corrosion for at least one year if properly stored.                       After initial operation, make a visual inspection of the output
                                                                                  coupling, oil cooler and hoses, and the cable connections to
                                                                                  the transmission.
                                   r!!f!!P:~r„II:,...-- AIR   VENT                LOCKING THE PROPELLER
                                                                                  Locking of the propeller shaft by an additional brake is not
                                                                                  required: use the gear shift lever position opposite your
                                                                                  direction of travel for this purpose. Never put the gear shift
                                                                                  in the position corresponding to the direction of travel of the
                                  S=~~~~JJ..- FLUID                               boat.
                                                               FILTER
                                                                                  WHEN UNDER SAIL OR BEING TOWED
                                                                                  Rotation of the propeller without a load, such as when the
     OUTPUT
                                                                                  boat is being sailed, being towed or anchored in a river, as
     COUPLING ~-....                                                              well as operation of the engine with the propeller stopped
                                                                                  (for charging the battery), will have no detrimental effects
                                                                                  on the transmission.
" OIL COOLER
                                                                                  NOTE: When the boat is being sailed (engine stopped), the
 The oil cooler, mounted above the transmission, provides                         gear shift must be in the neutral position. The propeller is at
 continuous cooling for the transmission fluid. Raw water                         idle and can free-wheel.
 passes through the tubes of the cooler and discharges over-
 board. The transmission fluid is cooled as it flows around the                   DAILY OPERATION
 tubes ·and back into the transmission.
                                                                                  o   Check the transmission fluid.
 WESTERBEKE RECOMMENDS CARRYING                                RAW WATER          o   Visually check the gear shift linkage and transmission.
 ASPARE OIL COOLER ABOARD
                                                               CONNECTION
                                                                                  o   Start the engine in neutral, allowing a few minutes at idle
                                                                                      to warm the fluid.
                                                                                  o   Shift into gear.
                                                                                  NOTE: Too low an idle speed will produce a chattering noise
                                                                                  from the transmission gear and damper plate. In such cases
  RAW WATER                                                                       the idle speed should be increased.
  CONNECTION              TRANSMISSION OIL COOLER
                                                                                  Operating Temperature
 TRANSMISSION FLUID                                                               The operating temperature of the transmission should not
 Fill the transmission with Dextron III ATF. The fluid level                      exceed 176°F (80°C). A connection for a temperature probe
 should be up to the mark on the dipstick. After checking the                     is provided. At maximum output of the engine, the fluid may
 level, press the dipstick into the case and turn it to tighten.                  reach 220°F (104°C).
 During the first 25 operating hours, inspect the bell housing,
 output shaft and transmission cooler for leakage. The fluid
 should be changed after the first 25 hours and every 300                          A CAUTION: If thl1 transmission fluid temperature is
 hours thereafter.                                                                  too high, stop the engine immediately and check the
                                                                                    transmission fluid.
 NEUTRAL SWITCH
 These transmissions are equipped with a "neutral safety
 switch. This is to prevent the engine from starting in gear.
 Unless the transmission selector lever is perfectly aligned in
 neutral, the engine starter will not activate.




                                                                        Engines & Generators

                                                                             42
                                         HURTH HSW TRANSMISSIONS
 CHANGING THE TRANSMISSION FLUID                                         Replacing the Fluid
                                                                         Pour in new Dextron III. ATF fluid and check the quantity
                                                                         with the dipstick.
                                                                         Transmission fluid quantities will vary with the use of
                                                                         coolers, length of hoses and the angle of the transmission.
                                                                                             Approximate Quantities
                                                                                      HSW450 - 2.12 quarts (2.0 Liters)
                                                                                      HSW630 - 3.2 quarts (3.0 Liters)
                                                                                      HSW630V - 4.2 quarts (4.0 Liters)
                                                                         Reinsert the filter assembly into the housing. Press it in place
   ACTUATING                                                             and tighten the Allen screw.
   LEVER
                                                                         NOTE: Some HSW transmissions use a "T" handle in place of
16mm (8") SCREW                                                          a screw on their filter assemblies.
                                                                         After running the engine, shut down and recheck the fluid level.


                                                                          A WARNING: Never pullout the dipstick while the
                                                                          engine is running. Hot "uid will splash from the dipstick
                                                                          hole. This could cause severe bums.

                                                                         MAINTENANCE
                                  HSW MODEL 450                          Transmission maintenance is minimal. Keep the exterior
                                                                         housing clean, check the fluid level as part of your regular
                                                                         routine, and change the fluid every 300 operating hours.
                                                                         Periodically inspect the transmission and the cooler for leaks
                      FILTER ELEMENT                                     and corrosion. Make certain the air vent is clear and when
                                                                         checking the fluid level look for signs of water contamination
                                                                         (fluid will appear as strawberry cream).
                                                                         Lay-up/Winterize
 Filter Element                                                          Storage requires special care. Follow these procedures:
 The Hurth HSW transmission has a filter element located                 D Drain water from the transmission oil cooler and replace
 opposite the dipstick. This filter must be replaced whenever                with a proper mixture of antifreeze coolant.
 the fluid is changed.                                                       NOTE: This operation will normally occur when the
 Remove the filter by loosening the screw on the cover using                 engine raw water cooling system is properly winterized.
 a 6mm Allen wrench.                                                     D Clean up the transmission and touch up unpainted areas
 Twist and pull out the filter and remove the element. Place                 (use heat resistant paint).
 the new filter onto the cover and lock it into place by turning         D Fill the transmission with Dextron III ATF fluid to pre-
 it clockwise. Check the O-rings for damage and replace if                 vent internal corrosion (extended storage only, twelve
 necessary. Replacement filters can be obtained from your                  months or more).
 local WESTERBEKE dealer or ZF (Hurth dealer).
                                                                         D Loosen attaching hardware from the transmission output
 Removing the Fluid                                                        flange and propeller shaft coupling flange before
 Push a suction pump hose down through the pipe hole (under                removing the boat from the water. Separate the flanges
 the filter) to the bottom of the housing and suck out the fluid.          and spray with lubricant.
 Remove the oil return line from the cooler and allow the oil            D Inspect the gear shift cable, linkage, and attachments.
 to drain into a container, then reconnect the oil return line.            Look for corrosion of the end fittings, cracks or cuts in
                                                                           the conduit, and bending of the actuator rods. Lubricate
 Wipe down the transmission and properly dispose of the used               all moving parts.
 fluid.
                                                                             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.


                                                            Engines & Generators

                                                                    43
                                       HURTH HSW TRANSMISSIONS
CABLE CONNECTIONS                                                 SHAFT COUPLINGS
The transmission is suitable for a single lever gear shift.       WESTERBEKE recommends a flexible connection between
Upon loosening the retaining screw, the actuating lever (see      the transmission and the propeller shaft if the engine is
illustration) can be moved to any position required for the       flexibly mounted, in order to compensate for angular
control elements (cable or rod linkage). Make certain that the    deflections. The installation of a special propeller thrust
actuating lever does not contact the lever hub: the minimum       bearing is not required, since the propeller thrust will be
distance between the lever and the hub should be O.02in           absorbed by the transmission bearing, provided the value
(O.5mm).                                                          specified under SPECIFICATIONS is not exceeded.
The control cable or rod should be arranged at a right angle      However, the output shaft should be protected from
to the actuating lever when in the neutral position. The neu-     additional loads. Special care should be taken to prevent
tral position of the gear shift lever on the control console      torsional vibration. When using a universal joint shaft, make
should coincide with the neutral position of the lever on the     certain to observe the manufacturer's instructions.
transmission.                                                     Even with the engine solidly mounted the use of a flexible
The shifting travel, as measured at the pivot point of the        coupling or "DRIVESAVER" will reduce stress in the gear-
actuating lever between the neutral position and end positions    box bearings caused by hull distortions, especially in wooden
A and B, should be at least 1-3/8in (35mm) for the outer and      boats or where the distance between the transmission output
 1-3/16in (3Omm) for the inner pivot point.                       coupling and stem gland is less than about 8oomm.
                                                                      NOTE: When installing the transmission, make certain that
                                              N                       shifting is not impeded by restricted movability of the cable
                                                                      or rod linkage, by unsuitably positioned guide sheaves, too
                                                                      small a bending radius or other restrictions. In order to
                                                                      mount a support for shift control cable connections, use the
                                                                      two threaded holes located on the cable bracket mounted on
                                                                      the gear housing. Refer'to the WESTERBEKE parts list.




                           ACTUATING
                             LEVER
                                                                                                            TYPICAL STEERING STATION

A greater amount of actuating lever travel is in no way
detrimental and is recommended. However, if the lever travel
                                                                      For additional information contact:
is shorter, proper clutch engagement might be impeded
which, in turn, would mean premature wear, excessive heat                   HURTH MARINE GEAR
generation and clutch plate failure. This would be indicated                ZF Industries
by slow clutch engagement or no engagement at all (see                      1018 Carolina Drive
CONTROL CABLES under TRANSMISSION                                           West Chicago, IT... 60185
TROUBLESHOOTING)                                                            Tel.: (874) 634-3500
NOTE: Checkfor proper actuating lever travel at least each
season.

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


                                                  '..".,./WESTERBEKE
                                                       I Enaines & Generators
                                                                 44
                                TRANSMISSION TROUBLESHOOTING [HURTH]
CONTROL CABLES                                                                            A new cable and perhaps a new linkage mechanism may be
The majority of transmission difficulties arise as a result of                            needed. While the cable is loose, shift the transmission in and
improper clutch adjustments (manual transmissions) or                                     out of gear using the lever on the side of the transmission to
problems with control cables (hydraulic transmissions)                                    make sure there's no binding inside the case.
rather than from problems with the transmission itself.                                   If the transmission passes these tests, crank the engine and
HURTH clutches, in particular, are very sensitive to improper                             have a helper put it in forward and reverse while you observe
cable adjustments.                                                                        the propeller shaft; if the shaft isn't turning, the transmission
                                                                                          needs professional attention. If it does tum but there's no
If you experience operating problems with the transmission,                               thrust, check to see you still have a propeller on the end of
shut the engine down. First check the transmission-fluid                                  the shaft or, if you have a folding or feathering propeller, that
level, then have a helper move the cockpit shift lever through                            it isn't stuck in the "no pitch" position.
the full range - from neutral to full forward, back to neu-
tral, into full reverse, and back to neutral - while you                                  NOTE: lfyou suspect a major problem in your transmission,
observe the actuating lever on the transmission. If the remote                            immediately contact your WESTERBEKE dealer or an
is stiff to operate, break the cable loose at the transmission                            authorized marine transmission facility.
and try again. If it is still stiff, check the cable for kinks or
excessively tight bends, and check any linkage for binding.
                                              ,

 Problem                                                    Probable Cause                                           Verification/Remedy
 Transmission gears cannot be shifted.            1. Actuating lever is loose.                        1. Tighten damping bolt on actuating lever.
 Fails to move into gear.
                                                  2. Shifting cable is broken, bent or                2. Check the cable, reattach or replace.
                                                     unattached. Cable radius is too severe.
                                                  3. Actuating lever is binding against the.          3. Detach the shift cable and operate the actuating lever by
                                                     cover plate.                                        hand. Clearance should beO.02 in (0.5mm).
 Transmission shifts into gear, but               1. Output coupling is not tuming.                   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 tuming.                          on the propeller shaft. Tighten or replace set screws, keys,
                                                                                                         pins and coupling bolts as necessary.
                                                  3. Output coupling and                              3. Inspect the propeller; it may be missing or damaged.
                                                     propeller shaft are tuming.                         Afolding propeller may be jammed. A variable pitch
                                                                                                         propeller may be in "no pitch" position.
 .Delay of gear engagement or engages             1. Actuating lever travel Nto B not.                1. Adjust cover plate until the lever is exact mid-position .
  only after an increase in speed.                    equal to Nto A.                                     See ACTUATING LEVER TEXT AND DIAGRAM.
                                                  2. Actuating lever travel is insufficient.          2. Check shift lever cable length. See ACTUATING LEVER
                                                                                                         DIAGRAM.
                                                  3. Actuating lever is binding against cover plate. 3. Check clearance, adjust if necessary.
 Transmission noise becomes louder.               1. Damage starting on flexible coupling due         1. Check alignment, inspect flexible coupling. If noise persists,
                                                      to wear or fatigue, possibly due to misalign-       inspect the damper plate between the transmission and the
                                                      ment 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.
                                                      Damage sealing ring.
                                                  2. Misalignment of output flanges.                  2. Check alignment. Must be within 0.003 in (O.OBmm).




                                                                           Engines. & Generators

                                                                                  45
                                      TRANSMISSION ·TROUBLESHOOTING
               Problem                          Probable Cause                                          Verification)Remedy
 Chattering transmission noise,         1. The engine or propeller generates torsional    1. Mount a flexible coupling with another stiffness factor
 mainly at low engine speed.                vibrations in the drive unit which produces      between the engine and transmission; a coupling with
                                            a "chattering" noise in the transmission.        a higher stiffness factor might be sufficient.
 Transmission shifts into gear, but     1. Output coupling is not turning.                1. Transmission needs professional attention.
 fails to propel the boat.
                                        2. Propeller shaft is not turning.                2. The coupling bolts are sheared or the coupling is slipping
                                           Output coupling is turning.                       on the propeller shaft. TIghten or replace set screws, keys,
                                                                                             pins and coupling bolts as necessary.
                                        3. Output coupling and                            3. Inspect the propeller; it may be missing or damaged.
                                           propeller shaft are turning.                      Afolding propeller may be jammed.
                                                                                             Variable pitch propeller may be in "no pitch" position.

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




                                                             Engines & Generators

                                                                     46
                       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
                                                     WARNER           order. Shifts should be made at the lowest practical engine
                                                VELVET DRIVE          speed. Start the engine and set the throttle at idle speed;
                                              , TRANSIV!ISSION.       allow the transmission fluid to warm up for a few minutes.
SHIPMENT
For safety reasons, the transmission is not filled with               Neutral
transmission fluid during shipment and the selector lever             Move the gear shift lever to the middle position. You should
is temporarily attached to the actuating shaft.                       feel the detent. This centers the actuating lever on the trans-
Before leaving the WESTERBEKE plant, each transmission                mission. With the control in this position, hydraulic power is
undergoes a test run, with Dextron III ATF transmission               completely interrupted and the output shaft of the transmis-
fluid. The residual fluid remaining in the transmission after         sion does not turn.
draining acts as a preservative and provides protection
against corrosion for at least one year if properly stored.
                                                                      NOTE: Some transmissions are equipped with a neutral safety
                                                                      switch. Unless the transmission actuating lever is perfectly
TRANSMISSION FLUID                                                    aligned in neutra~ the engine starter will not activate.
Check the transmission fluid level on the dipstick. If the
transmission has not been filled, fill with Dextron III and           Forward
continue to use this fluid. During the first 25 hours of.             Move the gear shift lever to the forward position. You should
operation, keep a lookout for any leakage at the bell housing,        feel the detent. The actuating lever· on the transmission is in
output shaft and transmission cooler. This fluid should be            the forward position. The output shaft and the propeller shaft
changed after the first 25 hours and approximately every              move the boat in a forward direction.
300 operating hours thereafter and/or at winter lay-up.
                                                                      Reverse
                                                                      Move the gear shift lever to the reverse position. You should
 A CAUTION: Be certain the transmission is filled                     feel the detent The actuating lever on the transmission is in
 and the correct size cooler is properly installed before             the reverse position. The output shaft and the propeller
 starting the engine.                                                 should move the boat in a reverse direction (astern).
                                                                      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

                                                                 47
                        BORG WARNER VELVET DRIVE TRANSMISSION
                                            o Clean off the transmission and properly dispose of the
                                                                           used fluid.
                                                                       o   Refill the transmission with DEXTRON III ATF. The
                                                                           quantity will vary depending on the transmission model
                                                                           and the installation angle. FilI through the dipstick hole.
                                                                       o   Check the dipstick for the proper fluid level.
                                                                       o   Replace the oil filler cap and dipstick. (Press the dipstick
                                                                           into place and turn clockwise until finger-tight.)
                                                                       o   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 Ruid will splash from the dipstick
DAILY OPERATION                                                         hole. This could cause severe bums.
o   Check the transmission fluid.
o   Visually check the gear shift linkage and transmission.            Oil Capacity
o   Start the engine in neutral. Allow a few minutes at idle           Approximately 2.5 quarts (2.36 liters) will fill most transmis-
    for the fluid to Waml.                                             sions to the oil level fill mark on the dipstick. Many variables
    NOTE: Too low an idle speed will produce a chattering              have a direct relationship to the oil capacity. Additional oil
    noise from the transmission gear and damper plate. In              will be required to fill the oil cooler and the cooler lines. The
    such cases the idle speed should be increased.                     angle of installation will make a difference in the quantity of .
                                                                       oil required to fill the transmission.
o   Shift into gear.

 A    CAUTION: Shifting gears above 1000 rpm can
 cause damage to the engine damper plate. Pulling the                  DIPSTICK _----r.
                                                                       MAKE CERTAIN THE
                                                                                                               FLUID LEVEL
 throttle back to idle when shifting gears will save wear
                                                                       RUBBER SEAL IS
 on the transmission and the damper plate;                             SCREWED                                 FULL
                                                                       TIGHTTOTHE
                                                                       HANDLE      .
INSPECTION
o   Visually check for oil leaks at the hydraulic connections.
    Check for wear on the hydraulic lines and replace if
    worn.
o   Lubricate the detent ball and shift cable attachments.
o   Inspect the shift linkage.
                                                                       Oil Temperature
o   Inspect the transmission bolts; retorque if necessary.
                                                                       A maximum oil temperature of 190°F (88°C) is recom-
                                                                       mended. Discontinue operation anytime sump oil tempera-
 A    CAUTION: Clutch failure will occur if the transmis-              ture exceeds 2300 P (1 10°C).
 sion shift lever does not fully engage the detent ball                PRESSURE GAUGE
 positions.                                                            An optional mechanical pressure gauge can be installed at
                                                                       the control panel to constantly monitor the pressure of the
CHANGING THE TRANSMISSION FLUID                                        transmission fluid. A normal reading at 2000 rpm in forward
After the initial 50 hour change, the transmission fluid should        gear should indicate 95 -120 Ib-in2 (6.7 - 8.4 kg-cm2) and be
be changed at every 300 operating hours thereafter or at win-          constant.
ter haul-out However, the fluid must be changed whenever it
becomes contaminated, changes color, or smells rancid.
o Remove the oil filler cap and dipstick.
o Remove the oil cooler return line and allow the oil to
    drain into a container.
o    Reconnect the oil cooler return line.
o    Use a suction pump to remove the transmission oil
     through the filler cap/dipstick hole.



                                                          Enl1ines & Generators
                                                                  48
                        BORG WARNER VELVET DRIVE TRANSMISSION
MAINTENANCE                                                            WARRANTY NOTES
Transmission maintenance is minimal. Keep the exterior                 Service manuals are available from your BORG WARNER
housing clean, check the fluid level as part of your regular           dealer.
routine, and change the fluid every 300 operating hours.               For assistance, contact:
Periodically inspect the transmission and the cooler for leaks                BORG WARNER
and corrosion. Make certain the air vent is clear and when                    200 Theodory Rice Blvd.
checking the fluid level look for signs of water contamination                New Bedford, MA02745
(fluid will appear as strawberry cream).                                     Tel.: (508) 979-4881
Lay-up/Winterize                                                       BORG WARNER is aware of the shock loads that can be
                                                                       placed on its gears as the result of mechanical propeller oper-
Storage requires special care. Follow these procedures:                ation or fully reversing of the propeller blades while shifting.
D 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
                                                                       ca~sed by a shock load, any warranty claim will be denied.
    NOTE: This operation will usually occur when the engine
    raw water cooling system is properly winterized.
D Clean up the transmission and touch-up unpainted areas                A CAUTION: System-related noises or vibrations can
  (use heat resistant paint).                                           occur at low engine speeds which can cause gear rattle
D Fill the transmission with Dextron III ATF fluid to                   resulting in damage to the engine and/or transmission.
  prevent internal corrosion. (Extended storage only,                   BORG WARNER is not responsible for total system-
  12 months or more).                                                   related torsional vibration of this type.
D 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 TROUIJLESHOOTING in this manual.
  and spray with lubricant.
D 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 offwith
   fluid to prevent internal corrosion. Reduce the fluid level
   before putting the engine back into service.


OIL COOLERS
The continued flow of raw water through the cooler will, in            If water has contaminated the fluid, the transmission fluid
time, erode the inside of the cooler causing cross leaks to            needs to be cleaned out and replaced with fresh fluid. It will
occur. These internal cooler leaks will cause one of the               take several fluid changes to get rid of the contamination.
following two problems:                                                Check your dipstick each time until it appears as pure trans-
                                                                       mission fluid. Change the transmission filter and clean out
1. Transmission fluid will leak into the flow of raw water             the fluid lines that connect to the cooler.
     and be discharged overboard through the engine exhaust.
    A loss of transmission fluid will cause the transmission to        If the transmission fails to shift properly, it will most likely
    fail.                                                              need the attention of a qualified transmission service facility.
2. The raw water will leak into the transmission fluid caus-           A transmission cooler may last ten years or more but, in
     ing an increase in transmission fluid. This contaminated          some circumstances, depending on operating hours, tropical
     fluid will appear as strawberry cream. The transmission           waters, maintenance, etc. it might only last half that time.
     will eventually fail.                                             WES1ERBEKE recommends having a spare cooler aboard.
Either case requires an immediate response:
1. Install a new oil cooler.
2. Refill the transmission with DEXTRON III ATF.




                                                         Engines & Generators

                                                                  49
                                       LAY-UP & RECOMMISSIONING
General                                                                Fuel System [Gasoline]
Many owners rely on their boatyards to prepare their craft,            Top off your fuel tanks with unleaded gasoline of 89 octane
including engines and generators, for lay-up during the off-           or higher. A fuel conditioner such as STABIL gasoline
season or for long periods of inactivity. Others prefer to             stabilizer should be added. Change the element in your
accomplish lay-up preparation themselves.                              gasoline/water separator and clean the metal bowl.
The procedures which follow will allow you to perform your             Re-install and make certain there are no leaks. Clean
own lay-up and recommissioning, or will serve as a checklist           up any spilled fuel.
if others do the procedures.                                           Fuel System      [Diese~
These procedures should provide protection for your                    Top off your fuel tanks with No.2 diesel fuel. Fuel additives
engine/generator during a lay-up and also help familiarize             such as BWBOR and STABIL should be added at this time to
you with its maintenance needs.                                        control algae and condition the fuel. Care should be taken
If you have any questions regarding lay-up procedures, call            that the additives used are compatible with the primary fuel
your local servicing dealer. He will be more than willing to           filter/water separator used in the system. Change the element
provide assistance.                                                    in your primary fuel filter/water separator, if the fuel system
                                                                       has one, and clean the separator sediment bowl.
Propeller Shaft Coupling [Propulsion Engine]
                                                                       Change the fuel filter elements on the engine and bleed the
The transmission and propeller half couplings should always
                                                                       fuel system, as needed. Start the engine and allow it to run
be opened up and the bolts removed when the boat is hauled
                                                                       for 5 - 10 minutes to make sure no air is left in the fuel
out of the water or moved from land to water, and during
                                                                       system. Check for any leaks that may have been created in
storage in the cradle. The flexibility of the boat often puts a        the fuel system during this servicing, correcting them as
severe strain on the propeller shaft or coupling or both, while        needed. Operating the engine for 5 - 10 minutes will help
the boat is taken out or put in the water. In some cases, the
                                                                       allow movement of the treated fuel through the injection
shaft has actually been bent by these strains. This does not           equipment on the engine.
apply to small boats that are hauled out of the water when
not in use, unless they have been dry for a considerable               Raw Water Cooling Circuit
period of time.                                                        Close the through-hull fitting. Remove the raw water intake
Fresh Water Cooling Circuit [Propulsion Engine]                        hose from the fitting. Place the end of this hose into a five
                                                                       gallon bucket of clean fresh water. Before starting the engine,
A 50-50 solution of antifreeze and distilled water is recom-
                                                                       check the zinc anode found in the primary heat exchanger on
mended for use in the fresh water cooling system at all times.
                                                                       the engine and clean or replace it as required and also clean
This solution may require a higher concentration of antifreeze,
                                                                       any zinc debris from inside the heat exchanger where the
depending on the area's winter climate. Check the solution to          zinc anode is located. Clean the raw water strainer.
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 amount          fresh water through the system. When the bucket is empty,
from the engine block and add a more concentrated mixture.             stop the engine and refill the bucket with an antifreeze
Operate the engine to ensure a complete circulation and mix-
                                                                       solution slightly stronger than needed for winter freeze
ture of the antifreeze concentration throughout the cooling            protection in your area.
system. Then recheck the antifreeze solution's strength.
                                                                       Start the engine and allow all of this mixture to be drawn
Lubrication System                                                     through the raw water system. Once the bucket is empty, stop
With the engine warm, drain all the engine oil from the oil            the engine. This antifreeze mixture should protect the raw
sump. Remove and replace the oil filter and fill the sump              water circuit from freezing during the winter lay-up, as well
with new oil. Use the correct grade of oil. Refer to the               as providing corrosion protection.
ENGINE LUBRICATING OIL pages in this manual for                        Remove the impeller from your raw water pump (some
"engine oil change".                                                   antifreeze mixture will accompany it, so catch it in a bucket).
Run the engine and check for proper oil pressure and make              Examine the impeller. Get a replacement, if needed, and a
sure there are no leaks.                                               cover gasket. Do not replace the impeller (into the pump)
                                                                       until recommissioning, but replace the cover and gasket.

 A CAUTION: Do not leave the engine's old engine                       Intake Manifold and Thru-Hull Exhaust
                                                                       Place a clean cloth, lightly soaked in lubricating oil, in the
  oil in the sump over the lay-up period. Engine oil and
                                                                       opening of the intake manifold to block the opening. Do not
  combustion deposits combine to produce harmful
                                                                       shove the cloth out of sight. (If it is not visible at
  chemicals which can reduce the life of your engine's                 recommissioning, and an attempt is made to start the engine,
  internal parts.                                                      you may need assistance of the servicing dealer). Make a
                                                                       note to remove the cloth prior to start-up. The thru-hull
                                                                       exhaust port can be blocked in the same manner.


                                                         Engines & Generators

                                                                  50
                                       LAY-UP & RECOMMISSIONING
Starter Motor                                                           SPARE PARTS
Lubrication and cleaning of the starter drive pinion is advis-          Lay-up time provides a good opportunity to inspect your
able, if access to the starter pennits its easy removal. Make           WESTERBEKE engine to see if external items such as drive
sure the battery connections are shut off before attempting to          belts or coolant hoses need replacement. Check your basic
remove the starter. Take care in properly replacing any elec-           spares kit and order items not on hand, or replace those items
trical connections removed from the starter.                            used during the lay-up, such as filters and zinc anodes. Refer
                                                                        to the SPARE PARTS section of this manual.
Cylinder Lubrication [Diesel]
If you anticipate a long lay-up period (12 months or more)              RECOMMISSIONING
WESTERBEKE recommends removing the glow plugs or                        The recommissioning of your WESTERBEKE engine after a
fuel injectors for access to the cylinders. Squirt light                seasonal lay-up generally follows the same procedures as
lubricating oil into the cylinders to prevent the piston rings          those described in the PREPARATIONS FOR STARTING
from sticking to the cylinder walls. Rotate the engine by hand          section regarding preparation for starting and nonnal starts.
two revolutions then replace the glow plugs or injectors.               However, some of the lay-up procedures will need to be
Make sure you have a replacement if removing the injector               counteracted before starting the engine.
sealing washer for the injector and fuel line return.                   1. Remove any rags that were placed in the exhaust, intake
                                                                           manifold, or flame arrester.
NOTE: If engine storage is going to be a lengthy one, 12
months or beyond, it is wise to rotate the engine by hand two           2. Remove the raw water pump cover and gasket and discard
complete turns every additional 4 months to allow the injec-               the old gasket. Install the raw water pump impeller
tion pump components to move. This will help prevent their                 removed during lay-up (or a replacement, if required).
sticking during extended storage periods.                                  Install the raw water pump cover with a new cover gasket.
                                                                        3. Reinstall the batteries that were removed during the lay-
Intake Manifold and Thru-Hull Exhaust[Diesel]                              up, and reconnect the battery cables, making sure the
Place a clean cloth, lightly soaked in lubricating oil, in the             tenninals are clean and that the connections are tight.
opening of the intake manifold to block the opening. Do not                Check to make sure that the batteries are fully charged.
shove the cloth out of sight. (If it is not visible at                  4. Remove the spark plugs, wipe clean, re-gap, and install
recommissioning, and an attempt is made to start the engine,               to proper tightness. [Gasoline]
you may need the assistance of a servicing dealer.) Make a              5. Check the condition of the zinc anode in the raw water
note to remove the cloth prior to start-up. The through-hull               circuit and clean or replace the anode as needed. Note
exhaust port can be blocked in the same manner.                            that it is not necessary to flush the antifreeze/fresh water
Intake Manifold [Gasoline]                                                 solution from the raw water coolant system. When the
                                                                           engine is put into operation, the system will self-flush in
Clean the filter screen in the flame arrester, and place a clean           a short period of time with no adverse affects. Also open
cloth lightly soaked in lube, oil around the flame arrester to             up the heat exchanger ends and clear out any accumu-
block any opening. Also place an oil-soaked cloth in the                   lated debris.
through-hull exhaust port, Make a note to remove cloths prior
to start-up!                                                            6. Check the transmission fluid, if it had been topped off
                                                                           during the lay-up, lower the level of the fluid to nonnal.
Transmission [Propulsion Engine]                                            [Propulsion Engine]
Check or change fluid in the transmission as required. If the           7. Make certain all electrical connections and switches are
engine is to be layed up 12 months or more, fill the transmis-             in the correct position and there are no-loads on the
sion to the very top to prevent corrosion. Lower the fluid to              generator at start up. [Generator]
its normal at recommissioning. Wipe off grime and grease                8. Start the engine in accordance with the procedures
and touch up unpainted areas. Protect coupling and output                  described in the PREPARATIONS FOR STARTING
flange with an anticorrosion coating, Refer to the                         section of this manual.
TRANSMISSION SECTION in this manual for additional
infonnation.
Batteries
If batteries are to be left on board during the lay-up period,
make sure they are fully charged, and will remain that way,
to prevent them from freezing. If there exists any doubt that
the batteries will not remain fully charged, or that they will
be subjected to severe environmental conditions, remove
the batteries and store them in a warmer, more compatible
environment.




                                                          Engines & Generators

                                                                   51
STANDARD AND METRIC CONVERSION DATA
LENGTH-DISTANCE
   Inches (in) x 25.4 = Millimeters (mm) x .0394 = Inches
   Feet (ft) x .305 = Meters (m) x 3.281 = Feet
   Miles x 1.609 = Kilometers (km) x .0621 = Miles
DISTANCE EQUIVALENTS
   1 Degree of Latitude = 60 Nm = 111.120 km
   1 Minute of Latitude = 1 Nm = 1.852 km
VOLUME
   Cubic Inches (in3) x 16.387 = Cubic Centimeters x .061 =in3
   Imperial Pints (IMP pt) x .568 = Liters (L) x 1.76 = IMP pt
   Imperial Quarts (IMP qt) x 1.137 = Liters (L) x.88 = IMP qt
   Imperial Gallons (IMP gal) x 4.546 = Liters (L) x .22 = IMP gal
   Imperial Quarts (IMP qt) x 1.201 = US Quarts, (US qt) x .833 = IMP qt
   Imperial Gallons (IMP gal) x 1.201 = US Gallons (US gal) x .833 = IMP gal
   Fluid Ounces x 29.573 = Milliliters x .034 = Ounces
   US Pints (US pt) x .473 = Liters(L) x 2.113 = Pints
   US Quarts (US qt) x .946 = Liters (L) x 1.057 = Quarts
   US Gallons (US gal) x 3.785 = Liters (L) x .264 = Gallons
MASS-WEIGHT
   Ounces (oz) x 28.35 = Grams (g) x .035 = Ounces
   Pounds (Ib) x .454 = Kilograms (kg) x 2.205 = Pounds
PRESSURE
   Pounds Per Sq In (psi) x 6.895 = Kilopascals (kPa) x .145 = psi
   Inches of Mercury (Hg) x .4912 = psi x 2.036 = Hg
   Inches of Mercury (Hg) x 3.377 = Kilopascals (kPa) x .2961 = Hg
   Inches of Water (H20) x .07355 = Inches of Mercury x 13.783 = H20
   Inches of Water (H20) x .03613 = psi x 27.684 = H20
   Inches of Water (H20) x .248 = Kilopascals (kPa) x 4.026 = H20

TORQUE
   Pounds-Force Inches (in-Ib) x .113 = Newton Meters (Nm) x 8.85 =in-Ib
   Pounds-Force Feet (ft-Ib) x 1.356 = Newton Meters (Nm) x .738 = ft-Ib
VELOCITY
   Miles Per Hour (MPH) x 1.609 = Kilometers Per Hour (KPH) x .621 = MPH

POWER
   Horsepower (Hp) x .745 = Kilowatts (Kw) x 1.34 = MPH
FUEL CONSUMPTION
   Miles Per Hour IMP (MPG) x .354 = Kilometers Pe~ Liter (Km/L)
   Kilometers Per Liter (KmlL) x 2.352 = IMP MPG
   Miles Per Gallons US (MPG) x .425 = Kilometers Per Liter (Km/L)
   Kilometers Per Liter (KmlL) x 2.352 = US MPG
TEMPERATURE
   Degree Fahrenheit (OF) = (OC X 1.8) + 32
   Degree Celsius (OC) = (OF - 32) x .56

LIQUID WEIGHTS
   Diesel Oil = 1 US gallon = 7.131bs
   Fresh Water = 1 US gallon = 8.33 Ibs
   Gasoline = 1 US gallon = 6.1 Ibs
   Salt Water = 1 US gallon = 8.56 Ibs



                                 Engines, & Generators

                                          52
                              SPECIFICATIONS-64A FOUR MARINE ENGINE
                        SPECIFICATIONS                                                                             FUEL SYSTEM
Engine Type                  Diesel, four-cycle, four-cylinder, fresh                  General                      Open flow, self priming-1 bleed point.
                             water-cooled, vertical in-line overhead valve
                             mechanism..                                               Fuel                         No.2 diesel oil (cetane rating of 45 or higher).

Aspiration                   Naturally aspirated.                                      Fuel Injection Pump          ZEXEL Model VE Distributor (Diesel KiKi)

Combustion Chamber         . Swirl type.                                               Fuel Injection liming        0° TOC (Top Dead Center).

Bore &Stroke                 3.74 x4.13 inches (95 x 105 mm)                           Nozzle                       Throttle type.

Piston Displacement          182 cubic inches (2.98 liters)                            Fuel Filter                  Spin-on type, full flow
                                                                                       (on engine)
Firing Order                 1 - 3 - 4-2
                                                                                       Air cleaner                  Paper element-cleanable
Direction of Rotation        Clockwise, when viewed from the front.
                                                                                       Airflow                      94.6 cfm (2.7 cmm) .
Compression Ratio            21:1                                                      (engine combustion)
Dimensions - inches (mm) Height: 27.3 inches (694.0 mm)
Engine Only              Width: 25.5 inches (647.7 mm)                                                           COOLING SYSTEM
                         Length: 38.8 inches (985.8 mm)
                                                                                       General                      Fresh water-cooled block, thermostatically-
Weight                       678 Ibs (307 kgs).                                                                     controlled with heat exchanger.
Inclination                  Continuous 15°                                            Operating Temperature        170-190° F(77 -88° C)
                             Temporary 25° (not to exceed 20 min.)
                                                                                       Fresh Water Pump             'Centrifugal type, metal impeller, belt-driven.
Generator Power Take Off     40 Hp (Maximum)
                                                                                       Raw Water Pump               Positive displacement, rubber impeller,
                                                                                                                    belt-driven.
                   TUNE-UP SPECIFICATIONS
                                                                                       Raw Water Flow               15.0 gpm (56.7 Ipm) (measured before
Compression Pressure         427 psi (30 kg/cm2) at 200 rpm                            at 2600 rpm                  discharging into exhaust elbow).
(Limit of difference
between cylinders)           47.2 psi (3.0 kg/cm2
                                                )                                      System Capacity              13.0 US qts (12.3 liters)
                                                                                       (coolant)
Valve liming                 Intake Opens 17" BTDC
                             Intake Closes 47" ABDC                                                             LUBRICATION SYSTEM
                             Exhaust Opens 51 ° BBDC
                             Exhaust Closes 13° ATDC                                   General                      Pressure fed system.
                                                                                       Oil Filter                   Full flow, paper element, spin-on type.
Valve Seat Angle             Intake 45°
                             Exhaust 30°                                               Sump Capacity                6.5 U.S. qts (6.15 liters)
Valve Clearance              Intake 0.012 inches (0.3 mm)                              (not including filter)       plus filter/cooler assembly
(engine cold)                Exhaust 0.012 inches (0.3 mm)                             Operating Oil Pressure       50 - 60 psi (3.5 - 4.2 kg/cm2
                                                                                                                                                )
Injector Pressure            1920 + 71 - 0 psi (135 + 5 - 0 kgf/cm2).                  (engine hot)

Engine liming                Static timed-drop valve method                            Oil Grade                    API Specification CF or CG-4,
                             0.205 ± .005 inches BTOC                                                               SAE 30, 10W-30, 15W-40


               EXHAUST EMISSIONS SYSTEMS                                                                        ELECTRICAL SYSTEM
Emission Control             Indirect Fuel Injection                                   Starting Battery             12 Volt, (-) negative ground
Systems                                                                                Battery Capacity             400 - 600 Cold Cranking Amps (CCA)
                                                                                       Starter                      12 Volt, reduction gear
                                                                                       Starting Aid                 'Glow plugs, sheathed type
                                                                                       Battery Charging             51 Amps
                                                                                       Alternator




                                                                             Engines & Generators

                                                                                  53
                                           SUGGESTED SPARE PARTS
                                                     'MARINE ENGINES
                    CONTACT YOUR WESTERBEKE DEALER EOR.SUGGESTIONS AND ADDITIONAL INFORMATION




                     WESTERBEKE RECOMMENDS CARRYING ENOUGH SPARE
                     ENGINE OIL (YOUR BRAND) FOR AN OIL CHANGE
                     AND A GALLON OF PREMIXED COOLANT.




FUEL LINE FILTERS                                                                               MOLDED
(OWNER INSTALLED)                                                                               HOSE KIT
                                                                                                (INA CANVAS
                                                                                                CARRYING BAG)



                                                  SPARE PARTS KITS
   WESTERBEKE also offers two Spare Parts Kits,                              KIT B
   each packaged in a rugged hinged toolbox.
   Kit "A" includes the basic spares.                                        DRIVE BELTS
   Kit "B" is more extensive
                                                                             OIL FILTER
                                                                             FUEL FILTER
           KIT A
                                                                             INJECTOR
          DRIVE BELTS                                                        OVERHAUL GASKET KIT
          OIL FILTER                                                         AIR FlltfR
          FUEL FILTER                                                        GLOW PLUG
          FUEL SYSTEM HARDWARE KIT                                           FUEL SYSTEM HARDWARE KIT
          FUEL PUMP INLET FILTER                                             FUEL PUMP INLET FILTER

                                                      Engines & Generators

                                                           54
               Engines & Generators




107412D3WMDW


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