Sunday, May28, 2017 L-36.com

Westerbeke Diesel 63d Four Operator's Manual




NOTE: DO NOT HIT REFRESH!!! These files are big and can take a long time to load. This file is 6.41 MB. Give it time.
If there is text in the file, you can scroll it while the image loads. Enjoy

View PDF

Image Preview



Ad by Google

PDF to Text

OPERATORS MANUAL
MARINE DIESEL ENGINES
64 F
PUBLICATION NO49112
FIRST EDITION
DECEMBER 2003
member WESTERBEKE CORPORATION MYLES STANDISH INDUSTRIAL PARK
150 JOHN HANCOCK ROAD TAUNTON MA 027807319 USA
TEL FAX WEBSITE A gasses contain carbon Monoxide an odorless and
colorless gas carbon Monoxide is poisonous and can and death Symptoms of Carbon can Throbbing in Muscular
Vomiting
Weakness and Sleepiness Inability to Think YOU OR ANYONE ELSE EXPERIENCE ANY OF THESE SYMPTOMS
GET OUT INTO THE FRESH AIR IMMEDIATELY If symptoms persist
seek medical attention Shut down the unit and do not restart
until it has been inspected and repaired
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 PREVENT BURNS FIRE
Read this safety manual carefully Most accidents are
caused by failure to follow fundomental rules and precau A WARNING Fire can causenjury 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 ELECTRIC SHOCK Do not operate with a Coast Guard Approved
flame
arrester removed Backfire can cause severe injury or
death
A WARNING Do not touch AC electrical connections Do not operate with the air removed
while engine is running or when connected to shore Backfire can cause severe injury or death
power Lethal voltage is present at these connections Do not smoke or permit flames or sparks to occur near
the fuel system Keep the compartment and the
Do not operate this machinery without electrical clean and free of debris to minimize the
enclosures and covers in place chances of fire Wipe up all spilled fuel and engine oil
Shut off electrical power before accessing electrical Be aware diesel fuel will 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 refueling safety instructions Keep the vessels
Do not connect utility shore power to vessels AC hatches closed when fueling Open and ventilate cabin
circuits except through a shiptoshore double throw after fueling Check below for fumesvapor before run
transfer switch Damage to vessels AC generator may ning the blower Run the blower for four minutes before
result if this procedure is not followed starting your engine
Electrical shock results from handling a charged capaci All fuel vapors are highly explosive Use extreme care
tor Discharge capacitor by shorting terminals together when handling and storing fuels Store fuel in a wellven
tilated area away from equipment and
PREVENT BURNS HOT ENGINE out of the reach of children
Do not fill the fuel tanks while the engine is running
A WARNING Do not touch hot engine parts or Shut off the fuel service valve at the engine when servicing
the fuel system Take care in catching any fuel that might
exhaust system components 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 Engines Generators
SAFETY STARTING TOXIC EXHAUST GASES
A WARNING Accidental starling can cause injury A WARNING Carbon monoxide CO is a deadly gas
or death
Disconnect the battery cables before servicing the engine Ensure that the exhaust system is adequate to expel gases
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 T22 educa
A WARNING Battery explosion can cause injury tional information on Carbon Monoxide
or death
Do not smoke or allow an open flame near the battery A WARNING Carbon monoxide CO is an invisible
being serviced Lead acid batteries emit hydrogen a odorless gas Inhalation produces flulike symptoms
highly explosive gas which can be ignited by electrical nausea or death
arcing or by lit tobacco products Shut off all electrical
equipment in the vicinity to prevent electrical arcing dur Do not use copper tubing in diesel exhaust systems Diesel
ing servicing fumes can rapidly destroy copper tubing in exhaust sys
Never connect the negative battery cable to the posi tems Exhaust sulfur causes rapid deterioration of copper
tive connection terminal of the starter solenoid Do tubing resulting in exhaustwater leakage
not test the battery condition by shorting the terminals Do not install exhaust outlet where exhaust can be drawn
together Sparks could ignite battery gases or fuel vapors through portholes vents or air conditioners If the engine
Ventilate any compartment containing batteries to prevent exhaust discharge outlet is near the waterline water could
accumulation of explosive gases To avoid sparks do not enter the exhaust discharge outlet and close or restrict the
disturb the battery charger connections while the battery flow of exhaust Avoid overloading the craft
is being charged
Although diesel engine exhaust gases are not as toxic as
Avoid contacting the terminals with tools etc to prevent exhaust fumes from gasoline engines carbon monoxide
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 ACID
AVOID MOVING PARTS
A WARNING Sulfuric acid in batteries can cause A WARNING Rotating parts can cause injury
severe injury or death
or death
When servicing the battery or checking the electrolyte
level wear rubber gloves a rubber apron and eye protec Do not service the engine while it is running If a situa
tion Batteries contain sulfuric acid which is destructive tion arises in which it is absolutely necessary to make
If it comes in contact with your skin wash it off at once operating adjustments use extreme care to avoid touching
with water Acid may splash on the skin or into the eyes moving parts and hot exhaust system components
inadvertently when removing electrolyte caps
Engines Generators
SAFETY Do not wear loose clothing or jewelry when servicing ABYC NFPA AND USCG PUBLICATIONS FOR
equipment tie back long hair and avoid wearing loose
jackets shirts sleeves rings necklaces or bracelets that INSTALLING DIESEL ENGINES
could be caught in moving parts Read the following ABYC NFPA and USCG 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 belts tension while
the engine is operating Order from
Stay clear of the drive shaft and the transmission coupling ABYC
when the engine is running hair and clothing can easily 15 East 26th Street
be caught in these rotating parts New York NY 10010
NFPA National Fire Protection 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
US Government Printing Office
Washington DC 20404
A WARNING Do not wotlc on machinery when you are
mentally or physically incapacitated by MANUAL
Many of the preceding safety tips and warnings are repeated
in your Operators Manual along with other cautions and
notes to highlight critical information Read your maintain your equipment and follow all to install an engine should begin with a thor
ough examination of the American Boat and Yacht standards These standards are a combination of
sources including the USCG and the of the ABYC standards of particular interest are
H2 Ventilation
Pl Exhaust systems
P4 Inboard engines
E9 DC Electrical systems
All installations must comply with the Federal Code FCR
Engines Generators
installing WESTERBEKE engines and generators it is important that be paid to the following AND federal regulations ABYC guidelines and safety codes
must be complied with
when installing engines and generators in a marine installations where the exhaust injected exhaust elbow is close to
or will be below the vessels waterline provisions must be made to install a siphon
break in the raw water supply hose to the exhaust elbow This hose must be looped a
minimum of 20 above the vessels waterline Failure to use a siphonbreak when
the exhaust injected exhaust elbow is near or below the loaded
water line of the vessel will result in raw water damage to the engine and of the vessel
If you have any doubt about the position of the exhaust elbow relative
to the vessels waterline under the vessels various operating conditions install
AVAILABLE FROM
YOUR WESTERBEKE
NOTE A siphonbreak requires periodic inspection and cleaning to ensure proper DEALER
operation Failure to properly maintain a siphonbreak can result in catastrophic
engine damage Consult the siphonbreak manufacturer for proper SYSTEM
The exhaust hose must be certified for marine use The system must be designed to
prevent water from entering the exhaust under any sea conditions and at any angle
Adetailed 40 page Marine Installation Manual covering gasoline and
diesel engines and generators is available from your WESTERBEKE
dealer
Engines Generators
TABLE OF Glow Plugs W
iring 0
lagram Warranty Procedures 3 Wiring Schematic Serial Number Location 4 Starter Motor Control Panel
Dual Output Alternators 31
Captain Control Panel 32
Fuel Engine Oil and Coolant Engine for Initial StartUp Engine Adjustments Procedure
Belt Adjustment 35
Fuel Injectors 35
Warning Lights Alarms and Circuit Breaker l0 11estmg
Engme CompresslOn 36
Engine BreakIn Procedure 11 Valve Clearance Adjustment 36
The Daily Operation 12 Idling Speed Schedule 13 Stop 37
Oil Pressure 38
Fuel System 15
FuellWater Separator 15 Hurth HSW Transmissions Fuel Filters 15 Specification
Fluid Change System 16 Shipment Changing Coolant 16
Transmission Fluid 41
Thermostat 17
Changing Filter 42
Raw Water Intake 17
Cable Connections 43
Raw Water Cooling Circuit 18
Couplings Raw Water Intake 18
Transmission Coolers 43
Raw Water Pump 18
Heat Exchanger 19
Zinc Anode 19 Borg Warner Transmission 48
Engine Lubricating 0i1 20 Oil Coolers 49
Changing the Oil 20
Changing the Oil 20 Layup an d Oil Filter Optional Metric Conversions Oata Heater Engine
Suggested pare Parts Electrical System Alternator 24
Battery Care 25
Engines Generators
PARTS WATER INJECTED
ELBOW
REAR
DC CHARGING
TRANSMISSION
FUEL LIFT PUMP
RAW WATER
jk ENGINE BLOCK
DRAIN PLUG
FRONT LEFT SIDE
20 AMP
CIRCUIT
FILL
AIR INTAKEAIR FILTER
SILENCER
PREHEAT ZINC
ANODE
ID PLATE
FRONT
HURTH MOTOR OIL DRAIN HOSE
AND SOLENOID
BELL ASSEMBLY
TRANSMISSION
SHIFT LEVER
FLEXIBLE
MOUNT
RIGHT SIDE
Engines Generators
WESTERBEKE Diesel Engine is a product of PRODUCT long years of experience and advanced Product software
technical data parts lists We take great pride in the superior durability and brochures and catalogs provided from sources other performance
of our engines and generators WESTERBEKE are not within WESTERBEKEs you for selecting WESTERBEKE
WESTERBEKE CANNOT BE RESPONSIBLE FOR THE
In order to get the full use and benefit from your engine it is CONTENT OF SUCH SOFTWARE MAKES NO
important that you operate and maintain it correctly This WARRANTIES OR WITH 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 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 and a technical manual is available from your
WESTERBEKE customers should keep in mind the dealer If you are planning to install this span between printings of
WESTERBEKE product contact your WESTERBEKE dealer for and the unavoidable existence of earlier installation manual
product software The product software provided with
WESTERBEKE products whether from WESTERBEKE or
WARRANTY PROCEDURES other suppliers must not and cannot be relied upon
Your WESTERBEKE Warranty is included in a separate exclusively as the definitive authority on the 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 card appropriate ofWESTERBEKE or the your warranty please contact the factory in
plier in question be consulted to determine the accuracy and
writing with model information including the engines currentness of the product software being consulted by the
serial number and commission date Card NOTES CAUTIONS AND WARNINGS
As this manual takes you through the operating procedures
maintenance schedules and of your marine
engine critical information will be highlighted by NOTES
CAUTIONS and WARNINGS An explanation follows
Customer 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 32004
A WARNING Procedures which if not properly
followed can result in personal injury or loss of life
Engines Generators
INTRODUCTION
SERIAL NUMBER LOCATION ORDERING PARTS
The engines model number and serial number are located on Whenever replacement parts are needed always provide the
the nameplate mounted on the side of the engines manifold engine model number and serial number as they appear on
The engines 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 information 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 andor ordering parts separately furnished Parts List Insist upon WES1ERBEKE
packaged parts because will fit or generic parts are frequently
not made to the same 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 reference the SPARE PARTS page in this manual For engine acces
sories see WES1ERBEKES 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 BY THE PREHEAT FUEL SPRAY
Engines Generators
ADMIRAL CONTROL PANEL
DESCRIPTION When the engine is shut down with the key switch turned off
the water temperature gauge will continue to register the last
This control panel is equipped with a
temperature reading indicated by the gauge before electrical
KEY switch and RPM gauge with an ELAPSED TIME
power was turned off The oil pressure gauge will fall to zero
meter which measures the engines running time in hours and
when the key switch is turned off The temperature gauge
in 110 hours The panel also includes a WATER TEMPER
will once again register the engines true temperature when
ATURE gauge which indicates water temperature in degrees
electrical power is restored to the gauge
Fahrenheit an OIL PRESSURE gauge which measures the
engines oil pressure in pounds per square inch and a DC A separate 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
tems voltage All gauges are illuminated when the key necting the buzzer to the fourpin connection on the engines
switch is turned on and remain illuminated while the engine electrical harness The installer is also responsible for installing
is in operation The panel also contains two rubberbooted the buzzer in a location where it will be dry and where it will
pushbuttons one for PREHEAT and one for START be audible to the operator should it sound while the engine is
running The buzzer will sound when the ignition key is turned
on and should silence when the engine has started and the
engines oil pressure rises above 15 psi 11 kgcm2
OIL PRESSURE GAUGE THIS GAUGE IS GRADU
ATED IN POUNDS PER SQUARE INCH PSI AND IS
WATER TEMPERATURE GAUGE THIS GAUGE IS ILLUMINATED WHILE THE KEY SWITCH IS TURNED
GRADUATED IN DEGREES FAHRENHEIT AND IS ON THE ENGINES NORMAL OPERATING OIL
ILLUMINATED WHILE THE KEY SWITCH IS PRESSURE RANGES BETWEEN 30 60 psi
TURNED ON THE ENGINES NORMAL OPERATING 21 42 kgem
TEMPERATURE IS 170 190 F 77 aac
RPM GAUGE REGIS
TERS MINUTE OF THE
ENGINE AND CAN FOR
ACCURACY FROM THE
REAR OF THE
SWITCH ELAPSED POWER ONLY TO THE
TIME AND SHOULD BE INSTRUMENT PANEL
USED AS A GUIDE FOR CLUSTER
THE
DC VOLTMETER
INDICATES THE AMOUNT THE
BATTERY IS BEING PRESSED ENERGIZES THE SHOULb SHOW
13V TO EXCITER THE FUEL liFT PUMP THE AUTOMATIC ALARM SYSTEM
FUEL SOLENOID ON THE INJECTION PUMP AND THE
ENGINES GLOW PLUGS IT BYPASSES THE ENGINES COOLANT TEMPERATURE ALARM AN ALARM BUZZER HAS BEEN
OIL PRESSURE ALARM SWITCH IN ADDITION THIS SUPPliED WITH THE INSTRUMENT PANEL IF THE ENGINES ENERGIZES THE START
BUTTON REACHES 210 F 99C THIS SWITCH WILL CLOSE SOUNDING THE
ALARM WHICH WILL EMIT A CONTINUOUS SIGNAL
START BUTTON WHEN PRESSED ENERGIZES THE
STARTERS SOLENOID WHICH CRANKS THE ENGINE OIL PRESSURE ALARM AN 01 L PRESSURE ALARM SWITCH IS
THIS BUTTON WILL NOT OPERATE ELECTRICALLY LOCATED OFF THE ENGINES OIL GALLERY THIS SWITCH THE PREHEAT
BUTTON IS PRESSED AND HELD THE ENGINES OIL PRESSURE SHOULD THE ENGINES OIL PRESSURE
AT THE SAME TIME FALL TO 5 10 psi 04 07 kgem THE SWITCH WILL CLOSE SOUND
ING THEALARM IN THIS EVENT THE ALARM WILL EMIT A PULSATING
SIGNAL
Engines Generators
CAPTAIN CONTROL The panel also includes an alann buzzer for low OIL
PRESSURE or high COOLANT TEMPERATURE The
This control panel is equipped with a RPM gauge is illuminated when the KEY switch is turned on
KEY switch an RPM gauge PREHEAT and START but and remains illuminated while the engine is in an INSTRUMENT TEST button and
three one for ALTERNATOR DISCHARGE one for low
OIL PRESSURE and one for high ENGINE ALARM THE ALARM WILL SOUND IF THE
ENGINES OIL PRESSURE FALLS
BELOW 5 10 psi 04 07 kgcm IN THIS EVENT THE ALARM WILL EMIT A
PULSATING SIGNAL THE ALARM WILL ALSO SOUND IF THE COOLANT
TEMPERATURE IN THE FRESHWATER COOLING CIRCUIT RISES TO
RPM GAUGE REGISTERS REVOLUTIONS 210F 99C IN THIS EVENT THE ALARM WILL EMIT A CONTINUOUS SIGNAL
PER MINUTE OF THE ENGINE AND CAN BE NOTE THE ALARM WILL SOUND WHEN THE KEY SWITCH IS TURNED ON FOR ACCURACY
FROM SOUNDING IS NORMAL ONCE THE ENGINE STARTS AND THE ENGINES OIL
THE REAR OFTHE PANEL PRESSURE REACHES 15 psi 11 kgcm 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
STARTERS SOLENOID WHICH CRANKS THE ENGINE THIS PREHEAT BUnON WHEN PRESSED ENERGIZES THE
BunON WILL NOT OPERATE ELECTRICALLY UNLESS THE ALTERNATORS EXCITER THE FUEL LIFT PUMP THE FUEL
PREHEAT BunON IS PRESSED AND HELD AT THE SAME SOLENOID ON THE INJECTION PUMp AND THE ENGINES
TIME GLOW PLUGS AND BYPASSES THE ENGINES OIL PRES
SURE ALARM SWITCH IN ADDITION THIS BUnON ENER
GIZES THE START BUnON
Engines Generators
DIESEL FUEL ENGINE OIL AND ENGINE FUEL ENGINE COOLANT
Use fuel that meets the requirements or specification of Class WESTERBEKE recoends a mixture of 50 ASTM and has a cetane rating of 45 or
better and 50 distilled water Distilled water is free from the
chemicals that can corrode internal engine Of The Fuel Supply The antifreeze performs double duty It
allows the engine to
Use only clean diesel fuel The clearance of the components run at proper temperatures by transferring heat away from
in your fuel injection pump is very critical invisible dirt par the engine to the coolant and lubricates and protects the
ticles which might pass through the filter can damage these cooling circuit from rust and corrosion Look for a good
finely finished parts It is important to buy clean fuel and quality antifreeze that contains Supplemental Cooling
keep it clean The best fuel can be rendered by Additives SCAs that keep the antifreeze handling or improper storage facilities To assure
balanced crucial to long term the fuel going into the tank for your engines daily use is The distilled water and antifreeze should be
premixed before
clean and pure the following practice is advisable being poured into the cooling circuit
Purchase a wellknown brand of fuel
NOTE Look for the new long and regularly service a good visualtype fuel antifreeze that is now separator between the fuel tank and
the engine
The Raycor 500 FG or 900 FG are good examples of such The recommended 5050 mixture will protect the
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 of CF
or CG4 or better Change the engine oil after an initial 50 Coolant Recovery Tank
hours of breakin operation and every 100 hours of operation A coolant recovery tank kit is supplied with For recommended oil viscosity see
the following WESTERBEKE diesel engine The purpose of this 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 68F 20C SAE 30 10W30 or 15W40 provided and must be installed before operating the engine
41 68F 5 20C SAE 20 10W30 or 15W40 NOTE This tank with its short run ofplastic hose is best
located at or above the level of the engines manifold but it
Below 41F 5C SAE 10W30 or 15W40
can be located below the level of the engines 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 engines oil pressure during operation is indicated
by the oil pressure gauge on the instrument panel During
normal operation the oil pressure will range between 35 and
55 psi 25 and 39 A newly started cold engine can have an oil up to 60 psi 42 kglcm 2 A warmed engine can have
an oil pressure reading as low as 25 psi 18 kglcm2 will vary depending upon the temperature of the
engine and the load placed on the engine
Engines Generators
PREPARATIONS FOR INITIAL starting your engine for the first time or after a
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 filterwater separator bowl for
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 Make certain there is proper ventilation around the
engine An ample supply is necessary for proper engine
Make sure the mounting installation is secure
D Ensure the propeller shaft is securely attached to the
Open the thruhull and make certain raw water is primed
to the raw water strainer I OIL DIPSTICK
PRESS IN TIGHT
Engines Generators
STARTING STOPPING 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 oclock 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 oclock 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 proper oil pressure and battery
charging voltage The of CF or CG4 SAE 30 lOW30 or 15W40
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 CHART in
this manual
Atmospheric Temperature Preheating Time
41F5C or higher Approx 10 seconds
41F5C to 23F 5C Approx 15 seconds A CAUTION Prolonged cranking intervals without
23F5C 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 activates the glow plugs in the cylinder head so use enter the engines cylinders by way of the
exhaust
the PREHEAT to avoid overheating the glow manifold once the exhaust system fills Prevent this
plugs from happening by closing the raw water supply
throughhull 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 should keep this
A voltage drop will occur in mind
when the preheat button
is Engines Generators
WARNING LIGHTS ALARMS CIRCUIT BREAKER
ALTERNATOR WARNINGS LOW OIL PRESSURE ALARM SWITCH
The Captain Control Panel indicates alternator low discharge A low oil pressure alarm switch is located off the engines
with a red warning light oil gallery This switchs sensor monitors the engines oil
The Admiral Control Panel uses a voltmeter to monitor the pressure Should the engines oil pressure fall to 5 10 psi
performance of the alternator 04 07 kgcm2 this switch will activate a pulsating alarm
COOLANT TEMPERATURE SWITCH 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
coolants operating temperature reaches approximately Excessive current draw or electrical overload anywhere in
210 0 P 99C 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
THERMOSTAT
ASSEMBLY
OIL GALLERY
Engines Generators
ENGINE BREAKIN 3 While using the vessel run the engine at various engine
speeds for the first 25 hours Avoid prolonged periods of
Although your engine has experienced a minimum of one
idling
hour of test operations at the factory to make sure procedures were followed and that the engine oper 4 Avoid rapid acceleration especially
with a cold engine
ated properly a breakin time is required The service life of 5 Use caution not to overload the engine The presence of a
your engine is dependent upon how the engine is operated grey or black exhaust and the inability of the engine to
and serviced during its initial 50 hours of use reach its full rated speed are signs of an a new engine basically involves
seating the pis 6 During the next 25 hours the engine may be operated at
ton rings to the cylinder walls Excessive oil consumption varying engine speeds with short runs at full rated rpm
and smoky operation indicate that the cylinder walls are Avoid prolonged idling during this breakin which is caused by overloading the
engine during the
breakin period new engine requires approximately 50 hours of initial D Monitor the
control panel 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 this conditioning carefully keeping
in mind the fol vibration and blowback 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
breakin information on your fast idle until the water temperature gauge moves into
the 130 1400 P 55 60C range
Engines Generators
THE DAILY LIST FAILURE TO START
Follow this check list each day before starting your enine If the engine fails to start when the start button is pressed for
D VIsually inspect the engine for fuel oil or water leaks 5 seconds wait for at least 30 seconds and repeat the starting
D Check the oil level dipstick procedure Make certain the transmission control is in the
neutral position as some engines have a neutral safety switch
D Check the coolant level in the coolant recovery tank to prevent starting in gear
Periodically check the manifold coolant level
Never run the starter for more than 30 seconds If the engine
D Check the transmission fluid level fails to start refer to the CHART in
D Check your fuel supply this manual
D Look for clean fuel in the fuel filterwater separator
transparent bowl
D Check for loose wires at the alternator and make sure its A CAUTION Prolonged cranking intervals without the
mounting is secure engine starting can result in the engine exhaust system
D Check the starting batteries weekly filling with raw water This may happen because the
pump is pumping raw water through the raw water
D Check drive belts for wear and proper tension weekly cooling system during cranking This raw water can
D VIsually inspect the raw water pump for leakage enter the engines 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 PROCEDURE in thi throughhull shutoff draining the exhaust muffler and
manual for more detailed instructions correcting the cause of the excessive engine cranking
Engine damage resulting from raw water entry is not a
1 Put the transmission in neutral throttle advanced warrantable issue the should keep this
NOTE Hydraulically operated transmissions have a 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
If the key switch is left ON the
BUITON The start motor is cranking the engine
energized instrument panel will put a drain on the battery
5 Release the START BUITON as the engine starts
6 With the engine running check the instruments for
proper oil pressure and battery charging voltage The
water rise slowly until the thermostat
opens
NOTE Never attempt to engage the starter while the
engine is running
It is important to closely monitor the panel gauges Become
aware of the normal engine readings and take if these readings start to vary
Engines Generators
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 your engine hours by running time
while the engine is running Wear the proper safety
NOTE M0J7Y of the following maintenance procedures are equipment such as goggles and gloves and use the
simple but others are more difficult 0J7d may require the coect tools for each job Disconnect the knowledge of a service mech0J7ic
terminals when servicing any of the engines DC
SCHEDULED CHECK HOURS OF OPERATION
EACH MAINTENANCE DESCRIPTION
MAINTENANCE
DAY 50 100 250 500 750 1000 1250
Fuel Supply D Diesel No2 rating of 45 cetane or higher
FuelWater Separator D Check for water and dirt in fuel filter if
necessary
Engine Oil Level D Oil level should indicate between MAX and lOW on
dipstick
Coolant Level D Check at recovery tank if empty check at manifold
Add coolant if needed
Transmission Fluid Level D Fluid level should indicate between MAX and LOW
on dipstick
Drive Belts D Inspect for proper tension 38 to 12 deflection
weekly and adjust if needed Check belt edges for wear
of Engine D NOTE Keep engine surface clean Dirt and Check for fuel oil and water leaks Inspect wiring
oil will inhibit the engines ability to remain and electrical connections Keep bolts nuts tight
cool Check for loose belt tension
Fuel Filter D D D D D D Clean with kerosene at 50 hours then clean every
100 hours Change at 500 hours
Starting Batteries D Check electrolyte levels every 50 operating hours
and House Batteries weekly and make sure connections are very tight Clean off
excessive corrosion
Engine Oil and Filter D D D D D D D Initial engine oil filter 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
FuelWater Separator D D D D D D Change filter every 200 hours
Exhaust System D D D D Initial check at 50 hours then every 250 hours
Inspect for leaks Check antisiphon valve
operation Check the exhaust elbow for carbon
andor corrosion buildup on inside passages
clean and replace as necessary Check that all
connections are tight Check casting integrity
Engine Hoses D D D D D D Hose should be hard tight Replace if soft or
spongy Check and tighten all hose clamps
Throttle and Transmission D D D D Check for loose fittings cotter pins etc
Control Cable Lubricate with WD40 or equivalent
Adjust Engine Idle Speed D Adjust to 750 1000 rpm
Raw Water Pump D D D Remove the pump cover and inspect the impeller
gasket cam and cover for wear Check the bearings
seals and shaft drive tang
Engines Generators
MAINTENANCE SCHEDULE
NOTE Use the engine hourmeter gauge to log your engine hours or record your
engine hours by running time
SCHEDULED CHECK HOURS OF OPERATION
MAINTENANCE EACH MAINTENANCE DESCRIPTION
DAY 50 100 250 500 750 1000 1250
Coolant System 0 0 Drain flush and refill cooling system with
appropriate antifreeze mix
Air 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 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
0 Check and adjust injection opening pressure and
spray condition see ENGINE 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 XX ohms Reinstall with antiseize
compound on threads
Engine Cylinder 0 0 Check compression pressure and timing see Engine
Compression Adjust the Valve Clearances 0 0
0 Adjust Valve Clearances see ENGINE
Heat Exchanger 0 Remove have 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 recommends this service be performed by an
authorized Engines Generators
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 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 installers include a fuel
filterwater separator with the separator and the engines spinon fuel filter Visually package as they are aware of the problems that
clean and change these filters according to the in the fuel can cause schedule in this manualclean and change
these filters
according to the maintenance schedule in this manual
A typical fuel filterwater separator is illustrated below This
is the Rayeor Model 500 MA Keep in mind that if a type filter is not installed between the fuel supply
tank and 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 is responsible for the fuel reaching the engines injection equipment is
free of impurities This process is accomplished by maintaining a proper fuel filterwater
GASKET
FUEL FILTER
WATER SEPARATOR
Owner Installed LIGHTLY WIPE
WITH CLEAN FUEL
Changing the Fuel Filter
FUEL LIFT PUMP 1 Shut off the fuel check the fuel connections to and out of the
2 Loosen the fuel filter turning 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 pumps 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
bracket so the new filter can be seated 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 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 benchtested and the
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
Engines Generators
COOLING CHANGING marine engines are designed and equipped for The
engines 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 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 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 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 is cooled by raw water and the raw water carries
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 the cooling water passages to stay clean and free from
harmful 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 exchangers 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 water coolant
NOTE Open the airbleed petcock on the heat 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 gradually opens allowing full flow
of the engines 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 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
THE ENGINE COOLANT DRAIN
IS LOCATED ON THE ENGINE
BLOCK JUST TO THE RIGHT COOLANT RETRACTION
OF THE OIL FILTER
Enains Generatars
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 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 bypassed through a engines 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 overtighten 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
TYPICAL RAW WATER INTAKE STRAINER
Owner Engines Generators
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 pump This pump draws water
directly from the raw and with the aid of two small screwdrivers carefully pry the
water source oceanlake 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 pumps 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 exhaust elbow mixing with and cool
ing the exhaust gases This mixture of exhaust gas and raw
water is discharged overboard by the engines 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 selfpriming rotary pump with a 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 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 Should a failure occur with the pumpSO 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 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 volume of clear air Hard
starting an erratic idle THE IMPELLER KEYWAY WITH THE SHAFT
and black efhaust 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 Engines Generators
COOLING SYSTEM
Zinc Anode If the zinc anodes need replacement hold the hex boss into
A zinc anode or pencil is located in the raw water cooling which the zinc anode is threaded with a wrench while loos
circuit within the heat exchanger The purpose of having the ening the anode with another wrench This prevents the hex
zinc anode is to sacrifice them to electrolysis action taking boss from possibly tearing off the exchanger shell After
place in the raw water cooling circuit thereby reducing the removing the zinc note the condition of it If the zinc is in
effects of electrolysis on other components of the system poor condition there are probably a lot of zinc flakes within
The condition of the zinc anode should be checked monthly the exchanger Remove the end of the heat exchanger and
and the anode cleaned or replaced as required Spare anodes clean the inside of all zinc debris Always have a spare heat
should be carried on board exchanger end gasket in case the present one becomes dam
aged when removing the end cover Replace the gasket refer
to your engine models heat exchanger end gasket part num
ber Oring and cover and install a new zinc anode
NOTE The threads of the zinc anodes are pipe threads and
do not require sealant Sealant should not be used as it may
insulate the zinc from the metal of the heat exchanger hous
ing preventing electrolysis action on the zinc
Heat Exchanger Service
After approximately 1000 hours of operation remove clean
NEW REPLACE REPLACE CLEAN AND and pressure test the engines heat exchanger A local auto
REUSE
motive radiator shop should be able to clean and test the heat
ZINC ANODES exchanger
NOTE Operating in silty andor tropical waters may require
NOTE Electrolysis action is the result of each particular that a heat exchanger cleaning be peiformed more often 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 bolts sealing aring is
installed Failure to install this sealing aring can result in
end plate failuresea water leakage
Engines Generators
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 gaskets 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 cooled 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
yellowgray 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 damageCall 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 andor 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 antisiphon 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 engines 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
REMOVE USING ANOR
BMM 7776 SOCKET Iit d
TO DRAIN THE OIL PUMP THE WARMED bi
OIL UP THRU THE HOSE
OIL DRAIN HOSE
11160D
SPIN ON FILTER
OIL FILTER ASSEMBLY APPLY CLEAN ENGINE OIL
WHEN INSTALLING
TURN ON HAND TIGHT
Engines Generators
REMOTE OIL FILTER NOTE Westerbeke is not responsible for engine failure due to
This popular accessory is used to relocate the engines oil fil incorrect installation of the Remote Oil Filter
ter from the engine to a more convenient location such as an
engine room bulkhead
NOTE Refer to ENGINE OIL CHANGE in this manualfor A CAUTION It is vital to install the oil lines on removing the oil
filter rectly If the oil flows in the reverse direction the by
To install simply remove the engine oil fllter and thread on pass valve in the filter assembly will prevent the remote oil fllter
kit as shown Always from reaching the engine causing an intemal this kit with the oil filter facing down as illustrated
failure If there is no oil pressure reading your WESTERBEKE dealer for more information immediately and
check the hose APPLY A THIN COAT OF CLEAN OIL TO THE ORING WHEN
INSTALLING THIS KIT THREAD THE KIT ON THEN HAND
TIGHTEN AN ADDITIONAL 34 TURN AFTER THE ORING
CONTACTS THE BASE
THE IN CONNECTION HOSE
MUST ATTACH TO THE OUT
CONNECTION AT THE
OIL FILTER
THE OUT CONNECTION HOSE
MUST ATTACH TO THE IN
CONNECTION AT THE
REMOTE OIL FILTER
APPLY A THIN COAT OF CLEAN OIL TO THE FILTER
GASKET WHEN INSTAlLING AFTER THE FILTER
CONTACTS THE BASE TIGHTEN IT AN Engines Generators
WATER HEATER provides easy access for connecting to an NOTE An air bleed petcock is located on the engineSO heat
onboard 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 engineSO 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 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 engineSO 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 to the engine so that
air will rise naturally from the and the other back to the engineSO 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 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 BYPASS HOSE
DISCONNECT THE EXISTING HOSE
AND ATTACH THE HEATER HOSE
TO THIS FITTING
Engines Generators
METER NOTE Current model tachometers use a coarse meter used in propulsion engine instru
dial to set the tachometer to the crankshaft pulley rpms The
ment panels contains two separate electrical circuits with a calibrating screw is then used for fine ground One circuit operates the hour
meter and the
other the tachometer The hour meter circuit operates on 12
volts alternator charging voltage supplied to the terminal
on the back of the tachometer circuit operates on AC voltage 68 volts fed
from one of the diodes in the alternator and supplied to input terminal while the engine is running and
the alternator producing battery charging voltage DC
The following are procedures to follow when fault in either of the two circuits in a meter for the proper DC voltage between and
IDLE SPEED ADJUSTMENT
1 Voltage present meter is defective repair or replace
TACHOMETER CHECK New Voltage not present trace and electrical con
nections for fault Jump 12 volts DC to meter Checking the idle speed
terminal to verify the operation NOTE In a new installation having new instrument panels
the tachometer may not always be correctly calibrated to Inoperative engineS rpm This calibration
should be checked in all new
Check for the proper AC voltage between tachometer input and terminal with the engine running 1 Warm up the engine
to normal operating Voltage present attempt adjusting meter through calibra Remove any specks on the crankshaft pulley with a clean
tion access hole No results repair or replace meter cloth and place a piece of suitable reflecting tape on the
2 AC voltage not present check for proper alternator DC pulley to facilitate use of a photoelectric type tachometer
output voltage 2 Start and idle the engine
3 Check for AC voltage at tach terminal on alternator to 3 Aim the light of the tachometer onto the reflecting tape to
ground confirm the engine speed Check the instrument panel
4 Check electrical connections from tachometer input ter tachometer reading Adjust the tachometer in the panel by
minal to alternator connection using the instrument calibration pod as needed to bring
the instrument panel tachometer into the same Sticking reading as the engine
1 Check for proper AC voltage between tach inp termi 4 Adjust the idle speed if the engine speed is not within the
nal and terminal specified value
2 Check for good ground connection between meter ter Normal idle speed is 690950 RPM
minal and Check that alternator is well grounded to engine block at
alternator pivot Inaccurate
a With a handheld tach on the front of the crankshaft
pulley retaining nut or with a strobetype tach read the
front crankshaft pulley rpm at idle
b Adjust the tachometer with a small Phillips type screw
driver through the calibration access hole in the rear of
the tachometer Zero the tach and bring it to the rpm
indicated by the strobe or hand tach Verify the rpm at
idle and at high speed
Engines Generators
DC ELECTRICAL SYSTEM
ALTERNATOR 1 Start the engine
The charging system consists of a DC belt driven alternator 2 After the engine has run for a few minutes measure the
with a voltage regulator an engine DC wiring harness a starting battery voltage at thebattery terminals using a
mounted DC circuit breaker and a battery with connecting multimeter set on DC volts
cables Because of the use of integrated circuits ICs 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
continue with Steps 3 through 8
PINK BLUE
SEE WIRING DIAGRAM
ENGINE FOR WIRE CONNECTIONS
GROUND TO OPTIONAL ALTERNATOR TESTING THE STARTING
A WARNING A failed altemator can become very ENGINE RUNNING
hot Do not touch until the altemator has cooled down
Use this section to determine if a problem 3 Tum off the engine Inspect all wiring and connections
exists with the charging circuit or with the alternator If it is Ensure that the battery terminals and the engine ground
determined that the alternator or voltage regulator is faulty connections are tight and clean
have a qualified technician check it
The alternator charging circuit charges the starting battery A CAUTION To avoid damage to the battery
and the service battery An isolator with a diode a solenoid charging circuit never shut off the engine battery
or a battery selector switch is usually mounted in the circuit switch when the engine is running
to isolate the batteries so the starting battery is not discharged
along with the service battery If the alternator is charging the 4 If a battery selector switch is in the charging circuit
starting battery but not the service battery the problem is in ensure that it is on the correct setting
the service batterys charging circuit and not with the alterna 5 Tum on the ignition switch but do not start the engine
6 Check the battery voltage If the battery is in good condi
Testing the Alternator tion the reading should be 12 to 13 volts
A CAUTION Before starting the engine make certain
that everyone is clear of moving parts Keep away from
sheaves and belts during test procedures
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
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
TESTING THE STARTING
ENGINE
ENGINE RUNNING 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 135 and 145 volts If your alternator TESTING THE SERVICE
is over or have it repaired at a reliable BATTERY ENGINE RUNNING
service facility
NOTE Before removing the alternator for repair use a
voltmeter to ensure that 12 volts DC excitation is present
at the 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 ie 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 VOLT 01 CONTROL CIRCUIT Battery Care
The engine has a 12 volt DC electrical control circuit that is Review the and then
shown on the wiring diagrams that follow Refer to these establish a systematic maintenance schedule for your
diagrams when or when servicing the DC engines starting batteries and house system
D Monitor your voltmeter for proper chargipg 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 minimum recommended capacity of the battery used in
the engines 12 volt DC control circuit is 600 900 Amps CCA
A WARNING Sulfuric acid In lead batteries can
cause severe bums on skin and damage clothing Wear
protective gear
Engines Generators
GLOW ReinstaII the plugs in the engine and test them again The
plugs should get very hot at the terminal end within 20 to
The glow plugs are wired through the preheat solenoid
25 seconds If the plugs dont heat up quickly check for a
When PREHEAT is pressed at the control panel this solenoid
short circuit When reinstalling the glow plugs use click on and the glow plug should begin to get hot
compound Qn the threads
Glow Plug Tightening Torque 7 11Ibfl 10 15 inspect the plug remove the electrical terminal then unscrew or unclamp each plug from the cylinder
A WARNING Do not keep a glow plug on for more
head Thoroughly clean each plugs tip and threads with a than 30 seconds
soft brush and cleaning solution to remove all the carbon and
oil deposits While cleaning examine the tip for wear and
TERMINAL END
burn erosion if it has eroded too much replace the accurate way to test glow plugs is with an one prod to the glow plugs wire connection and
the other to the body of the glow plug as shown A good
glow plug wiII have a 10 to 15ohm resistance This Tightening can be used with the plug in or out of the engine
10 15 mkg 7 llftlb
You can also use an ammeter to test the power drain
8 to 9 amps per plug
A WARNING These glow plugs will become very hot TIP
to the touch Be careful not to burn your fingers when
testing the plugs
GLOW PLUG
THE OHMMETER TEST
Engines Generators
WIRING SCHEMATIC
12 vee START
SOL STARTER
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
rSOL
I r NOt IAf5Dg Hc fNg ItEND Wi tEro
I GlOWPLUGS
I 2 AN ONOrr SWITCH SHOULD BE IHSTALlED BETWEEN THE BATTER AND STARTER TO
I fONT TOTn1 N NON I iEY D I HC L NE i F UNT f CH TH I
ALTERNATOR I SWITCH SHOULD NOT BE USED TO MAIIE 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
CB OA
TO At T
L 1FT PUMP
FUEL
IWHEH
HoiD
SOleUSEDI
Il2c
sNiR
T XJ
SENDER 0
SWITCH
1 l
ADMIRAL
TACHOMETER
KEY S GNO
PANEL
VOL TMETER
o ALARM
NOTE
WIRE FOR BATTERY ATTATCHMENT WILL NEED
TO BE UPGRADED TO AN a GAUGE F ROM 10 GAUGE
GAUGE 14 8RN
14 GRA
14 BRN UN I VERSAL PROPULS I ON
PRESTOL LIE SIAMP AU
PRESTOLTE 71 AMP AL T
14 GRA
PH PI PH PIT P2UP21I PH P212 PH
14 LT BLU
Nl 14 PINK
CAPTAIN
PANEL
LAMP
14 PINK
TEST
I I 0 RED
14 LT BL
LESTEK 100 AMP ALT CD 14 LT BLU 14 PINK
MALE CONNECTOR
ON THIS SIDE
PREHEAT ALARM
SWI TCH
RED
WIRING SCHEMATIC 39144
IroIALE CONNECTOR
ON THIS SIDE
IT6CHl RED
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
13iA 160A 190A LESTEK ALTERNATORS
AVAILA81E ON THE IISOB e3l3IV 6ICIV IJIV 8ZBIV IOEVI lOst VI Engines Generators
WIRING DIAGRAM iwm o
10 R D
14 PNK
114 T
16 11
SEE NOTE 21
Al LIFT PUMP
An onoff switch
should be installed in disconnect the SI
starter from the battery in
an emergency and when
leaving thebdat Twelve
volt engine draw 200 to 300 ADM I RAL
amps when cranking A PANEL
switch with a of 175 amps at 12
VDC will normally serve
this function but a switch
QI PRESS wi1iR TBi WIRING DIAGRAM 39144
must never be used to OAUGII GAUGE
make the starter circuit o o
CAPTAIN
liD RED
z PANEL
r
180RN
TACHOMETER
18 eLK
18 SLit
18 8l11
18 BlK
Engines Generators
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 starters solenoid coil The
M TERMINAL
energized coil becomes an 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 overrunning oneway clutch which
is splnled to the starter armature shaft The rotation of the running
engine may speed the rotation of thepinion 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
To test the ignition circuit locate the ignitions terminal it is one
of the small tem1inaJ studs and is wired to the ignition circuit
Use a screwdriver dont touch the blade to jump from that
contact with the 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 t
POSITIVE
TYPICAL TERMINAL
STARTER MOTOR
IGNITION
TERMINAL
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 wiIe
connections on the engine block If nothing at all happens the solenoid isnt 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 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
I EnQines Generators
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
TERMINAL
TO REMOVE FOR 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 blade firnlly
between the studs Do not allow the wires to touch tape over the 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 A WARNING There will be arching as the full
starting current should be flowing thru the blade of the
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 Starter motors are either inertia type or preengaged In
the preengaged 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 field for the ann to mave even though the contacts inside
the solenoid are bad
Engines Generators
DUAL OUTPUT ALTERNATORS
SPACER TO MOUNTING
output and high output alternators are available as
optional equipment on most WESTERBEKE engines can be installed during factory assembly or as
addon equipment at anytime
Dual alternators can be configured to charge two banks of
batteries at the same time or using a battery selector each set of batteries separately an optional dual alternator has already
been factory installed
simply follow the WESTERBEKE wiring diagram and the
engine installation the new dual alternator is being added to an existing engine carefully follow the alternator below
1 Disconnect the alternators negative cable from the
battery
2 Remove the alternator and disconnect or tape off the
output positive cable Do not reuse
3 Install the new Attach a new heavy gauge output cables from the
alternators output terminal s Using the cable sizes
indicated
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 2pin 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 alternators are available from your
CHARGING TWO Engines Generators
DUAL OUTPUT Alternator Testing
NOTE Before make certain that the drive The regulator is functioning properly and the are tight and the batteries are in good condition
are in good Testing 1 Test the voltage at the alternator plug with the engine
offkey on The voltage at the alternator terminal F and
The red battery sensing wire A connects to the battery it the voltage in the plug blue wire F from the always read battery voltage If
battery voltage is not should read the trace the wire for a bad connection
2 Hold a screw driver close 12 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 with the key on If the readings are not the problem may be the brushes worn or the trace the wire for a bad connection
open circuit
The blue wire F supplies current to the alternator fields its 3 Start the engine at fast idle the output terminals will vary depending on the
battery charge or actual indicate 142 volts no load A reading of 126 The readings can vary from 4 to 12 volts with the
indicate the alternator is not performing properly
key on 0 volts with the key off
Apply a load such as an electJic bilge pump the voltage
KEY ON NO VOLTAGE REGULATOR IS DEFECTIVE should maintain at least 138 volts 13 volts or less
KEY OFF BATTERY VOLTAGE REGULATOR IS DEFECTIVE indicates the alternator is TEST POINTS AND PROPER VOLTAGE
Ignition Off Ignition On Engine Running
When the engine is first started it takes a few moments for
I Brown ovolts 2 12 volts 142 volts
the alternator to kick in andtakethe load A noticeable
A Red 126 volts 12 volts 142 volts change in the sound of the engine will occur
S Orange ovolts ovolts 6 8 volts
F Blue ovolts 1011 volts 4 12 volts There will be a slight wine from the alternator when the load
Alt Output 126 volts 12 volts 142 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
ENGINE following table describes certain problems NOTE The engines electrical system is protected by a 20
relating to engine service the probable causes of these prob ampere manual reset circuit breaker located on a bracket at
lems and the to overcome these problems the back of the engine The preheat solenoid is mounted on
the same bracket
Problem Probable Cause No panel indications fuel solenoid 1 Battery
switch not on 1 Check switch andor battery connections
or fuel pump is not working key switch
is on and PREHEAT button is depressed 2 20amp Circuit breaker tripped 2 Reset breaker if breaker trips again check preheat solenoid
circuit and check circuit for shorts to ground
3 1Oamp breaker tripped on 3 Check the voltage both at and after the breaker on the
preheat solenoid preheat solenoid
4 Loose battery connections 4 Check connection to starter solenoid and connection to
engine ground stud Check battery cable connections
5 Preheat solenoid not operating 5 Check solenoid S terminal for voltage
START button is depressed no starter 1 Connection to solenoid faulty 1 Check connection
engagement
2 Gear shift not in neutral 2 Gear shift must be in neutral see NEUTRAL SWITCH under
HURTH HSW 3 Faulty switch 3 Check switch with ohmmeter
4 Faulty solenoid 4 Check that 12 volts are present at the solenoid connection
5 Loose battery connections 5 Check battery connections
6 Low battery 6 Check battery charge state
START button is depressed panel 1 Poor connections to fuel solenoid 1 Check connections
indications OK starter solenoid OK
fuel solenoid not functioning 2 Defective fuel solenoid 2 Check that 12 volts are present at the connection on the
fuel run solenoid
Engine cranks but does not 1 Faulty fueling system 1 Check that fuel valves are open
start fuel solenoid energized
1a Check for air in fuel system Bleed air from fuel system
1b Fuel filters clogged Replace 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 cant be stopped 1 Faulty DC altemator 1 Remove Exc connection at alternator repair alternator
2 Disconnect fuel shutoff cable 2 Check connection at shutoff lever Pull lever back to close
offthe fuel
3 Fuel run solenoid will not deenergize 3 Manually disconnect the 12 volt connection to the fuel run
solenoid at the injection pump
Battery runs down 1 Oil 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 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
Engines Generators
ENGINE Problem Probable Cause Engine slows and stops 1
Fuel lift pump failure 1 Fuel lift pump should make a distinct ticking sound Replace
pump with spare
2 Switches andor wiring loose 2 Inspect wiring for short circuits and loose connections
or disconnected Inspect switches for proper operation
3 Fuel starvation 3 Check fuel supply fuel valves fuel lift pump
4 20 Amp circuit breaker tripping 4 Check for high DC amperage draw during operation
Ensure breaker is not overly sensitive to heat which would
cause tripping
5 Exhaust system is restricted 5 Check for blockage collapsed hose carbon buildup at
exhaust elbow
6 Water in fuel 6 Pump water from fuel tanks change filters and
bleed fuel system
7 Air intake obstruction 7 Check air intake filter cartridge
Engine down 1 Raw water not circulating 1 Raw water pump failure Check impeller replace
2 Coolant not circulating 2 Obstruction at raw water intake or raw water filter
2a Thermostat remove and test in hot water
Replace thermostat
2b Loss of coolant check hoses hose clamps drain plug etc
for leaks
2c Broken or loose belts 2d Air leak in system run engine and
open the pressure cap to
bleed air Add coolant as needed
Engine alarm sound pulsates 1 Loss of oil 1 Check dipstick look for oil leaks at oil filter and at
oil drain hose connection
2 Oil pressure switch 2 Replace oil pressure switch
Engine alarm sounds continuously 1 Engine coolant 1 Check engine coolant level
2 High temperature switch opens at 2 Check for satisfactory operation with switch bypassed
too Iowa temperature check with ohmmeter replace if faulty
Exhaust smoke problems 1 Blue smoke 1 Incorrect grade of engine oil
1a Crankcase is overfilled with engine oil oil is blowing out
through the exhaust
2 White smoke 2 Engine is running cold
2a Faulty injector or incorrect injector timing
3 Black smoke 3 Improper grade of fuel
3a Fuel bum incomplete due to high backpressure in exhaust or
insufficient air for proper combustion check for restrictions in
exhaust system check air intake
3b Improperly timed injectors or vaives or poor compression
3c Lack of air check air intake and air filter Check for proper
ventilation
3d Overload
COOLANT TEMPERATURE AND OIL PRESSURE GAUGES
If the gauge reading is other than what is normally indicated If both of the above gauge tests are positive the gauge is
by the gauge when the instrument panel is energized the first undoubtedly OK and the problem lies either with the
step is to check for 12 volts DC between the ignition B conductor from the sender to the gauge or with the sender
and the Negative B terminals of the gauge If either of the above gauge tests are negative the gauge is
Assuming that there is 12 volts as required leave the probably defective and should be panel energized and perform the
following steps Assuming the gauge is OK check the conductor from the
1 Disconnect the sender wire at the gauge and see if the sender to the sender terminal at the gauge for continuity
gauge reads zero which is the normal reading for this Check that the engine block is connected to the ground
situation Some starters have isolated ground terminals and if the
2 Remove the wire attached to the sender terminal at the battery is connected to the starter both plus and minus
sender and connect it to ground See if the gauge reads terminals the ground side will not necessarily be connected
full scale which is the normal reading for this situation to the block
WESTERBEKE
Engines Generators
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 BELT ADJUSTMENT FUEL inspection service and maintenance of the
drive belts In case of severe vibrations and detonation noise have the
is important for the efficient operation of your engine see injectors checked and overhauled by an authorized fuel
Drive Belts under MAINTENANCE SCHEDULE injection service center Poor fuel quality contaminants and
Drive belts must be properly tensioned Loose drive belts loss of positive fuel pressure to the injection pump can result
will not provide proper alternator charging and will 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 andor 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 pumps 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 buildup or the like temperatures and
tachometer variations the injector sidetoside with the aid of the socket wrench to
The drive belt is properly adjusted if the belt can be deflected free it and then lift it out
no less than 38 inch lOmm and no more than 112 inch The injector seats in the cylinder head on a copper as the belt is depressed
with the thumb at the 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 4351 fIlb 6070 mka
drive belts tension while the engine is in 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 AND ALTERNATOR SERVICE
Refer to the engine chart in this manual Also
included in this manual are basic and 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 Engines Generators
ENGINE ADJUSTMENTS
NOTE WESTERBEKE recommends that the following engine adjust
ments be performed by a competent engine mechanic The information
below is provided to assist the mechanic
VALVE CLEARANCE ADJUSTMENT 8 Adjust each valves clearance by inserting a 0012in
003mm 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 9 Install
the cylinder head cover
HEAD COVER BOLT TORQUE 2 3 ft Ib 03 045 mkg
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 118 125 mkg
the fuel shutoff solenoid wire and install a compression
adapter in the injector hole or glow plug hole Connect a
6 Set the piston of No1 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 Repeat this process for each cylinder Look for cylinders with
Intake No1 and No2 cylinders and dramatically at least 20 lower compression than the
Exhaust No 1 and No3 cylinders average of the others Compression pressure should not differ
7 Turn the crankshaft once setting the piston of No 4 by more than 427 psi 30 kglcm2 at 200 rpm
cylinder at TOC compression and adjust to the
following Intake No3 and No4 cylinders and
Exhaust No2 and No4 cylinders
4 EXHAUST
WHEN NO4 CYLINDER IS AT TOP DEAD CENTER
41NTAKE 31NTAKE
EXHAUST 2
COMPRESSION GAUGE I
COMPRESSION PRESSURE STANDARD 427 PSI al200 RPM 300 Kgem
COMPRESSION PRESSURE LIMIT 384 PSI al200 RPM 270 Kgem
LIMIT BETWEEN CYLINDERS 427 PSI 30 Kgem
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 Engines
Generators
ENGINE ADJUSTMENTS
NOTE WESTERBEKE recommends that the following engine adjust
ments be performed by a competent engine mechanic The information
below is provided to assist the IDLING SPEED INJECTION PUMP SERVICE
The engine idling speed is preset 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 650950 RPM simply put the idle speed should feel 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 THE IDLING SPEED
To adjust the engine idle speed engine running loosen the
of the idle adjustment bolt and turn the bolt 1 The solenoid does not operate to increase idle speed and to the
keyswitch is turned ON
reduce Once the speed is set to your satisfaction tighten the a Are the engine batteries turned
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
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 43 14 psi 03
oil pump The engine oil is drawn from the oil sump by the 01 kglcm2 A gradual loss of oil pressure usually 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 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 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 its 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 12 18 mKg
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
HURTH 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
the TRANSMISSION Bowden cable or rod linkage by unsuitably positioned guide
SECTION applies to all models sheaves too small a bending radius etc In order to mount a
support for shift control cable connections use the two
CONNECTION OF GEAR BOX WITH PROPELLER threaded holes located above the shift cover on top of the
HBW recommend a flexible connection between the trans gear housing Refer to the WESTERBEKE parts list
mission gearbox and the propeller shaft if the engine is CONTROL CABLES
flexibly mounted in order to compensate for angular
deflections The installation of a special propeller thrust bear The transmission is suitable for single lever remote control
ing is not required since the propeller thrust will be taken by Upon loosening the retaining screw the actuating lever can
the transmission bearing provided the value specified under be moved to any position required for the shift control
is not exceeded However the output elements cable or rod linkage Make certain that the
shaft should be protected from additional loads Special actuating lever does not contact the actuating lever cover
care should be taken to prevent torsional vibration When plate the minimum distance between lever and cover should
using a universal joint shaft make certain to observe the beO5mm
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
CHECK FOR EQUAL TRAVEL
FROM NEUTRAL THRU
FORWARD AND REVERSE
A CAUTION The pOSition of the mechanism behind
the actuating lever is to ensure equal
shift lever travel from neutral position A and B If ACTUATING
LEVER
this mechanism is in any way tampered with the
transmission warranty will be void is a product of Globe Marine Rockland
Engines Generators 002 in 05mm
MINIMUM CLEARANCE
HURTH HBW INITIAL OPERATION OPERATING TEMPERATURE
All HBW marine transmissions are testrun on a test stand The maximum permissible ATF temperature should not exceed
with the engine at the factory prior to delivery For safety 2300 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
DmTRON 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
FLUID o Check the transmission fluid
o Visually check the gear shift level linkage and
FLUID DRAIN
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 allows use the transmission drain Remove the drain plug
from the bottom of the transmission and allow the fluid to HBW TRANSMISSIONS

drain into a container then reinstall the plug with its 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 263 1 HBW 150A 3R
DRAIN PLUG TORQUE 20 25 fIIbs
299 1 HBW 150v 3R
274 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 059 US qts 0561 liters
Capacity HBW 150V 111US qts 105 liters
HBW 250 075 US qts 079 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
HURTH 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 Normal operating temperature of the
transmission fluid
should be in the range of 122F 50C to 212F l00C A Storage requires special care Follow these procedures
maximum temperature of 266F l30C 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 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 COOLER ZF Industries
3131 SW 42nd Street
INSPECT FOR
EROSION AND LEAKAGE Fort Lauderdale FL 33312
TRANSMISSION Tel 954 5814040
Engines Generators
HURTH HSW INITIAL safety reasons the transmission is not filled with
Set the shifting lever to neutral position N Start the fluid during shipment and the selector lever is and
let it run long enough in idle to fill the cooler and attached to the actuating shaft with transmission fluid
Shift into gear forward and leaving the WESTERBEKE plant each transmission shifting should be smooth and positive Direct
changes 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 acts as a
preservative and provides protection reversing at high speeds in the event of 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 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
SJJ 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 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 freewheel
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 o Check the transmission fluid
WESTERBEKE RECOMMENDS CARRYING RAW WATER o Visually check the gear shift linkage and 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 176F 80C 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 220F 104C
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 Engines Generators
HURTH HSW 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 Approximate
Quantities
HSW450 212 quarts 20 Liters
HSW630 32 quarts 30 Liters
HSW630V 42 quarts 40 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 fluid will appear as
strawberry cream
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 Orings 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
HURTH HSW 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 can be moved to any position
required for the flexibly mounted in order to compensate for elements cable or rod linkage Make certain that the deflections The
installation of a special propeller 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 O02in absorbed by the transmission bearing provided the
specified under 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 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 lever between the neutral position
and end positions box bearings caused by hull distortions especially in wooden
A and B should be at least 138in 35mm for the outer and boats or where the distance between the transmission output
1316in 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 Referto the WESTERBEKE parts list
ACTUATING
LEVER
TYPICAL STEERING STATION
A greater amount of actuating lever travel is in no and is recommended However if the lever travel
For additional information contact
is shorter proper clutch engagement might be in turn would mean premature wear excessive heat HURTH MARINE 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
Tel 874 Checkfor proper actuating lever travel at least A CAUTION The position of the mechanism behind
the actuating lever is 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
I Enaines Generators
TRANSMISSION CABLES A new cable and perhaps a new linkage mechanism may
The majority of transmission difficulties arise as a result of needed While the cable is loose shift the transmission in
improper clutch adjustments manual or out of gear using the lever on the side of the transmission to
problems with control cables hydraulic make sure theres 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 isnt turning the
transmission
needs professional attention If it does tum but theres no
If you experience operating problems with the transmission thrust check to see you still have a propeller on the end of
shut the engine down First check the the shaft or if you have a folding or feathering propeller that
level then have a helper move the cockpit shift lever through it isnt stuck in the no pitch position
the full range from neutral to full forward back to neu
tral into full reverse and back to neutral while you NOTE lfyou suspect a major problem in your the actuating lever
on the transmission If the remote immediately contact your WESTERBEKE dealer or an
is stiff to operate break the cable loose at the transmission authorized marine transmission facility
and try again If it is still stiff check the cable for kinks tight bends and check any linkage for binding
Problem Probable Cause Transmission gears cannot be
shifted 1 Actuating lever is loose 1 Tighten damping bolt on actuating lever
Fails to move into gear
2 Shifting cable is broken bent or 2 Check the cable reattach or replace
unattached Cable radius is too severe
3 Actuating lever is binding against the 3 Detach the shift cable and operate the actuating lever by
cover plate hand Clearance should beO02 in 05mm
Transmission shifts into gear but 1 Output coupling is not tuming 1 Transmission needs professional attention
failsto 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
midposition
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 0003 in
Engines Generators
TRANSMISSION Problem Probable Cause Chattering transmission noise
1 The engine or propeller generates torsional 1 Mount a flexible coupling with another stiffness factor
mainly at low engine speed vibrations in the drive unit which produces between the engine and transmission a coupling with
a chattering noise in the transmission a higher stiffness factor might be sufficient
Transmission shifts into gear but 1 Output coupling is not turning 1 Transmission needs professional attention
fails to propel the boat
2 Propeller shaft is not turning 2 The coupling bolts are sheared or the coupling is slipping
Output coupling is turning on the propeller shaft TIghten or replace set screws keys
pins and coupling bolts as necessary
3 Output coupling and 3 Inspect the propeller it may be missing or damaged
propeller shaft are turning Afolding propeller may be jammed
Variable pitch propeller may be in no pitch lfyou suspect a major problem in your contact your WESTERBEKE dealer or an
authorized marine transmission Engines Generators
BORG WARNER VELVET DRIVE TRANSMISSION
OPTIONAL TRANSMISSION
SHIFT LEVER POSITION
The gear shift control mechanism and linkage must position
the actuating lever on the transmission exactly in Forward
F Neutral N and Reverse R shifting positions A detent
ball located behind the transmission lever must work freely
to center the lever in each position The gear shift positions at
the helm must be coordinated with those of the Velvet Drive
actuating lever through shift mechanism adjustments An
improperly adjusted shift mechanism can cause damage to
the transmission The shifting mechanism and transmission
actuating lever should be free of dirt and well lubricated to
ensure proper operation
Shifting Into Gear
Place the gear shift in Neutral before starting the engine
Shifting from one selector position to another selector posi
tion may be made at any time below 1000 rpm and in any
WARNER order Shifts should be made at the lowest practical engine
VELVET DRIVE speed Start the engine and set the throttle at idle speed
allow the transmission fluid to warm up for a few safety reasons the transmission is not filled with fluid during shipment and the
selector lever Move the gear shift lever to the middle position You should
is temporarily attached to the actuating shaft feel the detent This centers the actuating lever on the trans
Before leaving the WESTERBEKE plant each transmission mission With the control in this position hydraulic power is
undergoes a test run with Dextron III ATF transmission completely interrupted and the output shaft of the The residual fluid remaining
in the transmission after sion does not acts as a preservative and provides corrosion for at least one year if properly stored
NOTE Some transmissions are equipped with a neutral safety
switch Unless the transmission actuating lever is FLUID aligned in neutra the engine starter will
not the transmission fluid level on the dipstick If has not been filled fill with Dextron III and to use this fluid During the first 25
hours of Move the gear shift lever to the forward position You keep a lookout for any leakage at the bell housing feel the detent
The actuating lever on the transmission is in
output shaft and transmission cooler This fluid should be the forward position The output shaft and the propeller shaft
changed after the first 25 hours and approximately every move the boat in a forward operating hours thereafter andor at winter layup
Reverse
Move the gear shift lever to the reverse position You should
A CAUTION Be certain the transmission is filled feel the detent The actuating lever on the transmission is in
and the correct size cooler is properly installed before the reverse position The output shaft and the propeller
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
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 o Run the engine shutdown and recheck the
fluid NEUTRAL REVERSE
TRANSMISSION ACTUATING LEVER POSITIONS
A WARNING Never pullout the dipstick while the
engine is running Hot Ruid will splash from the 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 25 quarts 236 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 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 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 Inspect the shift linkage
Oil Temperature
o Inspect the transmission bolts retorque if necessary
A maximum oil temperature of 190F 88C is recom
mended Discontinue operation anytime sump oil tempera
A CAUTION Clutch failure will occur if the transmis ture exceeds 2300 P 1 10C
sion shift lever does not fully engage the detent ball PRESSURE GAUGE
positions An optional mechanical pressure gauge can be installed at
the control panel to constantly monitor the pressure of the
CHANGING THE TRANSMISSION FLUID transmission fluid A normal reading at 2000 rpm in forward
After the initial 50 hour change the transmission fluid should gear should indicate 95 120 Ibin2 67 84 kgcm2 and be
be changed at every 300 operating hours thereafter or at win constant
ter haulout However the fluid must be changed whenever it
becomes contaminated changes color or smells rancid
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 capdipstick hole
Enl1ines Generators
BORG WARNER VELVET DRIVE WARRANTY maintenance is minimal Keep the exterior
Service manuals are available from your BORG clean check the fluid level as part of your regular and change the fluid every 300 operating
hours For assistance inspect the transmission and the cooler for leaks BORG WARNER
and corrosion Make certain the air vent is clear and when 200 Theodory Rice the fluid level look for signs of water contamination
New Bedford will appear as strawberry cream Tel 508
BORG WARNER is aware of the shock loads that can be
placed on its gears as the result of mechanical propeller oper
Storage requires special care Follow these procedures ation or fully reversing of the propeller blades while shifting
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
cased 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 touchup unpainted areas A CAUTION 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 andor prevent internal corrosion Extended
storage only BORG WARNER is not responsible for total system
12 months or more related torsional vibration of this type
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 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 COOLERS
The continued flow of raw water through the cooler will in If water has contaminated the fluid the transmission fluid
time erode the inside of the cooler causing cross leaks to needs to be cleaned out and replaced with fresh fluid It will
occur These internal cooler leaks will cause one of the take several fluid changes to get rid of the two problems
Check your dipstick each time until it appears as pure trans
mission fluid Change the transmission filter and clean out
1 Transmission fluid will leak into the flow of raw water the fluid lines that connect to the cooler
and be discharged overboard through the engine exhaust
A loss of transmission fluid will cause the transmission to If the transmission fails to shift properly it will most likely
fail need the attention of a qualified transmission service facility
2 The raw water will leak into the transmission fluid caus A transmission cooler may last ten years or more but in
ing an increase in transmission fluid This contaminated some depending on operating hours tropical
fluid will appear as strawberry cream The transmission waters maintenance etc it might only last half that time
will eventually fail WES1ERBEKE recommends having a spare cooler case requires an immediate response
1 Install a new oil cooler
2 Refill the transmission with DEXTRON III ATF
Engines Generators
LAYUP Fuel System owners rely on their boatyards to prepare their craft
Top off your fuel tanks with unleaded gasoline of 89 engines and generators for layup during the off or higher A fuel conditioner such as
STABIL or for long periods of inactivity Others prefer to stabilizer should be added Change the element in layup preparation themselves
separator and clean the metal bowl
The procedures which follow will allow you to perform your Reinstall and make certain there are no leaks Clean
own layup and or will serve as a checklist up any spilled fuel
if others do the procedures Fuel System Diese
These procedures should provide protection for your Top off your fuel tanks with No2 diesel fuel Fuel during a layup and also help
familiarize such as 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 layup procedures call that the additives used are compatible with the primary fuel
your local servicing dealer He will be more than willing to filterwater separator used in the system Change the assistance
in your primary fuel filterwater separator if the fuel system
has one and clean the separator sediment Shaft Coupling Propulsion Engine
Change the fuel filter elements on the engine and bleed the
The transmission and propeller half couplings should always
fuel system as needed Start the engine and allow it to run
be opened up and the bolts removed when the boat is hauled
for 5 10 minutes to make sure no air is left in the fuel
out of the water or moved from land to water and during
system Check for any leaks that may have been created in
storage in the cradle The flexibility of the boat often puts a the fuel system during this servicing correcting them as
severe strain on the propeller shaft or coupling or both while needed Operating the engine for 5 10 minutes will help
the boat is taken out or put in the water In some cases the
allow movement of the treated fuel through the has actually been bent by these strains This does not equipment on the engine
apply to small boats that are hauled out of the water when
not in use unless they have been dry for a considerable Raw Water Cooling of time
Close the throughhull 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 5050 solution of antifreeze and distilled water is recom
check the zinc anode found in the primary heat exchanger on
mended for use in the fresh water cooling system at all times
the engine and clean or replace it as required and also clean
This solution may require a higher concentration of antifreeze
any zinc debris from inside the heat exchanger where the
depending on the areas winter climate Check the solution to zinc anode is located Clean the raw water sure the antifreeze protection is
adequate
Start the engine and allow the raw water pump to draw the
Should more antifreeze be needed drain an appropriate amount fresh water through the system When the bucket is empty
from the engine block and add a more concentrated mixture stop the engine and refill the bucket with an the engine to ensure a complete
circulation and mix
solution slightly stronger than needed for winter freeze
ture of the antifreeze concentration throughout the cooling protection in your area
system Then recheck the antifreeze solutions strength
Start the engine and allow all of this mixture to be System through the raw water system Once the
bucket is empty stop
With the engine warm drain all the engine oil from the oil the engine This antifreeze mixture should protect the raw
sump Remove and replace the oil filter and fill the sump water circuit from freezing during the winter layup as well
with new oil Use the correct grade of oil Refer to the as providing corrosion LUBRICATING OIL pages in this manual for
Remove the impeller from your raw water pump some
engine oil change antifreeze mixture will accompany it so catch it in a bucket
Run the engine and check for proper oil pressure and make Examine the impeller Get a replacement if needed and a
sure there are no leaks cover gasket Do not replace the impeller into the pump
until but replace the cover and gasket
A CAUTION Do not leave the engines old engine Intake Manifold and ThruHull Exhaust
Place a clean cloth lightly soaked in lubricating oil in the
oil in the sump over the layup period Engine oil and
opening of the intake manifold to block the opening Do not
combustion deposits combine to produce harmful
shove the cloth out of sight If it is not visible at
chemicals which can reduce the life of your engines and an attempt is made to start the engine
internal parts you may need assistance of the servicing dealer Make a
note to remove the cloth prior to startup The thruhull
exhaust port can be blocked in the same manner
Engines Generators
LAYUP Motor SPARE and cleaning of the starter drive pinion is advis Layup 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 layup such as filters and zinc anodes Refer
to the SPARE PARTS section of this Lubrication Diesel
If you anticipate a long layup period 12 months or more recommends removing the glow plugs or The of your
WESTERBEKE engine after a
fuel injectors for access to the cylinders Squirt light seasonal layup generally follows the same procedures oil into the cylinders to
prevent the piston rings those described in the PREPARATIONS FOR STARTING
from sticking to the cylinder walls Rotate the engine by hand section regarding preparation for starting and nonnal starts
two revolutions then replace the glow plugs or injectors However some of the layup procedures will need to be
Make sure you have a replacement if removing the injector counteracted before starting the washer for the injector and fuel line return
1 Remove any rags that were placed in the exhaust intake
manifold or flame If engine storage is going to be a lengthy one 12
months or beyond it is wise to rotate the engine by hand two 2 Remove the raw water pump cover and gasket and turns every additional 4
months to allow the injec the old gasket Install the raw water pump impeller
tion pump components to move This will help prevent their removed during layup or a replacement if during extended storage periods
Install the raw water pump cover with a new cover gasket
3 Reinstall the batteries that were removed during the lay
Intake Manifold and ThruHull up and reconnect the battery cables making sure the
Place a clean cloth lightly soaked in lubricating oil in the tenninals are clean and that the connections are of the intake manifold to
block the opening Do not Check to make sure that the batteries are fully the cloth out of sight If it is not visible at
4 Remove the spark plugs wipe clean regap and and an attempt is made to start the engine to proper tightness may need the assistance
of a servicing dealer Make a 5 Check the condition of the zinc anode in the raw water
note to remove the cloth prior to startup The throughhull circuit and clean or replace the anode as needed Note
exhaust port can be blocked in the same manner that it is not necessary to flush the water
Intake Manifold Gasoline solution from the raw water coolant system When the
engine is put into operation the system will selfflush in
Clean the filter screen in the flame arrester and place a clean a short period of time with no adverse affects Also open
cloth lightly soaked in lube oil around the flame arrester to up the heat exchanger ends and clear out any accumu
block any opening Also place an oilsoaked cloth in the lated exhaust port Make a note to remove cloths prior
to startup 6 Check the transmission fluid if it had been topped off
during the layup lower the level of the fluid to Propulsion Engine Propulsion Engine
Check or change fluid in the transmission as required If the 7 Make certain all electrical connections and switches are
engine is to be layed up 12 months or more fill the transmis in the correct position and there are noloads on the
sion to the very top to prevent corrosion Lower the fluid to generator at start up normal at Wipe off grime and grease 8
Start the engine in accordance with the touch up unpainted areas Protect coupling and output described in the PREPARATIONS FOR with
an anticorrosion coating Refer to the section of this SECTION in this manual for batteries are to be left on board during
the layup period
make sure they are fully charged and will remain that way
to prevent them from freezing If there exists any doubt that
the batteries will not remain fully charged or that they will
be subjected to severe environmental conditions remove
the batteries and store them in a warmer more Engines Generators
STANDARD AND METRIC CONVERSION Inches in x 254 Millimeters mm x 0394 Inches
Feet ft x 305 Meters m x 3281 Feet
Miles x 1609 Kilometers km x 0621 EQUIVALENTS
1 Degree of Latitude 60 Nm 111120 km
1 Minute of Latitude 1 Nm 1852 km
VOLUME
Cubic Inches in3 x 16387 Cubic Centimeters x 061 in3
Imperial Pints IMP pt x 568 Liters L x 176 IMP pt
Imperial Quarts IMP qt x 1137 Liters L x88 IMP qt
Imperial Gallons IMP gal x 4546 Liters L x 22 IMP gal
Imperial Quarts IMP qt x 1201 US Quarts US qt x 833 IMP qt
Imperial Gallons IMP gal x 1201 US Gallons US gal x 833 IMP gal
Fluid Ounces x 29573 Milliliters x 034 Ounces
US Pints US pt x 473 LitersL x 2113 Pints
US Quarts US qt x 946 Liters L x 1057 Quarts
US Gallons US gal x 3785 Liters L x 264 Ounces oz x 2835 Grams g x 035 Ounces
Pounds Ib x 454 Kilograms kg x 2205 Pounds Per Sq In psi x 6895 Kilopascals kPa x 145 psi
Inches of Mercury Hg x 4912 psi x 2036 Hg
Inches of Mercury Hg x 3377 Kilopascals kPa x 2961 Hg
Inches of Water H20 x 07355 Inches of Mercury x 13783 H20
Inches of Water H20 x 03613 psi x 27684 H20
Inches of Water H20 x 248 Kilopascals kPa x 4026 H20
TORQUE
PoundsForce Inches inIb x 113 Newton Meters Nm x 885 inIb
PoundsForce Feet ftIb x 1356 Newton Meters Nm x 738 Miles Per Hour MPH x 1609 Kilometers Per Hour KPH x 621 MPH
POWER
Horsepower Hp x 745 Kilowatts Kw x 134 MPH
FUEL CONSUMPTION
Miles Per Hour IMP MPG x 354 Kilometers Pe Liter KmL
Kilometers Per Liter KmlL x 2352 IMP MPG
Miles Per Gallons US MPG x 425 Kilometers Per Liter KmL
Kilometers Per Liter KmlL x 2352 US Degree Fahrenheit OF OC X 18 32
Degree Celsius OC OF 32 x 56
LIQUID WEIGHTS
Diesel Oil 1 US gallon 7131bs
Fresh Water 1 US gallon 833 Ibs
Gasoline 1 US gallon 61 Ibs
Salt Water 1 US gallon 856 Ibs
Engines Generators
FOUR MARINE ENGINE
FUEL SYSTEM
Engine Type Diesel fourcycle fresh General Open flow self priming1 bleed point
watercooled vertical inline overhead valve
mechanism Fuel No2 diesel oil cetane rating of 45 or
Naturally aspirated Fuel Injection Pump ZEXEL Model VE Distributor Diesel Chamber Swirl type
Fuel Injection liming 0 TOC Top Dead Stroke 374 x413 inches 95 x 105 mm
Nozzle Throttle type
Piston Displacement 182 cubic inches 298 liters Fuel Filter Spinon type full flow
on Order 1 3 42
Air cleaner Paper of Rotation Clockwise when viewed from the front
Airflow 946 cfm 27 cmm
Compression Ratio 211 engine inches mm Height 273 inches 6940 mm
Engine Only Width 255 inches 6477 mm COOLING SYSTEM
Length 388 inches 9858 mm
General Fresh watercooled block 678 Ibs 307 kgs
controlled with heat Continuous 15 Operating Temperature 170190 F77 88 C
Temporary 25 not to exceed 20 min
Fresh Water Pump Centrifugal type metal impeller Power Take Off 40 Hp Maximum
Raw Water Pump Positive displacement rubber impeller
beltdriven
TUNEUP Raw Water Flow 150 gpm 567 Ipm measured
Pressure 427 psi 30 kgcm2 at 200 rpm at 2600 rpm discharging into exhaust of cylinders
472 psi 30 kgcm2
System Capacity 130 US qts 123 liters
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 spinon type
Valve Seat Angle Intake 45
Exhaust 30 Sump Capacity 65 US qts 615 liters
Valve Clearance Intake 0012 inches 03 mm not including filter plus filtercooler cold
Exhaust 0012 inches 03 mm Operating Oil Pressure 50 60 psi 35 42 kgcm2
Injector Pressure 1920 71 0 psi 135 5 0 kgfcm2 engine hot
Engine liming Static timeddrop valve method Oil Grade API Specification CF or CG4
0205 005 inches BTOC SAE 30 10W30 15W40
EXHAUST EMISSIONS SYSTEMS ELECTRICAL Control Indirect Fuel
Injection Starting Battery 12 Volt negative
Battery Capacity 400 600 Cold Cranking Amps CCA
Starter 12 Volt reduction gear
Starting Aid Glow plugs sheathed type
Battery Charging 51 Amps
Engines Generators
SUGGESTED SPARE PARTS
MARINE ENGINES
CONTACT YOUR WESTERBEKE DEALER AND ADDITIONAL WESTERBEKE RECOMMENDS CARRYING ENOUGH SPARE
ENGINE OIL YOUR BRAND FOR AN OIL CHANGE
AND A GALLON OF PREMIXED 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
Engines

Ad by Google

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