' Westerbeke Marine Engine Installation Manual'

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INSTALLATION MANUALMARINE DIESEL AND GASOLINE PUBLICATION 43268 2nd Edition May 2004 CALIFORNIA PROPOSITION 65 WARNING Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer birth defects and other reproductive harm n WARNINGExhaust gasses contain Carbon Monoxide an odorless andcolorless gas Carbon Monoxide is poisonous and can and death Symptoms of Carbon Monoxide exposure can include Dizziness Throbbing in Temples Nausea Muscular Twitching Headache Vomiting Weakness and Sleepiness Inability to Think CoherentlyIF YOU OR ANYONE ELSE EXPERIENCE ANY OF THESE SYMPTOMSGET OUT INTO THE FRESH AIR IMMEDIATELY If symptoms persistseek medical attention Shut down the unit and do not restart untilit 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 livingsleeping quarters of your vessel They are inexpensive and easily obtainable at your local marine store SAFETY PREVENT BURNS FIRERead this safety manual carefully Most accidents are causedby failure to follow fundamental rules and when dangerous conditions exist and take the WARNING Fire can cause injury or deathnecessary precautions to protect yourself your personneland your machinery Prevent flash fires Do not smoke or permit flames orThe following safety instructions are in compliance with sparks to occur near the carburetor fuel line filter fuelthe American Boat and Yacht Council ABYC standards pump or other potential sources of spilled fuel or fuel vapors Use a suitable container to catch all fuel whenPREVENT ELECTRIC SHOCK removing the fuel line carburetor or fuel filters Do not operate with a Coast Guard Approved flame WARNING Do not touch AC electrical connections arrester removed Backfire can cause severe injury or death while engine is running or when connected to shore Do not operate with the air removed power Lethal voltage is present at these connections Backfire can cause severe injury or death Do not smoke or permit flames or sparks to occur near the Do not operate this machinery without electrical fuel system Keep the compartment and the enginegenera enclosures and covers in place tor clean and free of debris to minimize the chances of Shut off electrical power before accessing electrical fire Wipe up all spilled fuel and engine oil equipment Be aware diesel fuel will burn Use insulated mats whenever working on electrical equipment PREVENT BURNS EXPLOSION Make sure your clothing and skin are dry not damp particularly shoes when handling electrical equipment Remove wristwatch and all jewelry when working on WARNING Explosions from fuel vapors can cause injury or death electrical equipment Do not connect utility shore power to vessels AC circuits except through a shiptoshore double throw Follow refueling safety instructions Keep the vessels transfer switch Damage to vessels AC generator may hatches closed when fueling Open and ventilate cabin result if this procedure is not followed after fueling Check below for fumesvapor before running the blower Run the blower for four minutes Electrical shock results from handling a charged capacitor before starting your engine Discharge capacitor by shorting terminals together All fuel vapors are highly explosive Use extreme care whenPREVENT BURNS HOT ENGINE handling and storing fuels Store fuel in a wellventilated area away from sparkproducing equipment and out of the WARNING Do not touch hot engine parts or reach of children Do not fill the fuel tanks while the engine is running exhaust system components A running engine gets very Shut off the fuel service valve at the engine when servicing hot the fuel system Take care in catching any fuel that might spill DO NOT allow any smoking open flames or other Always check the engine coolant level at the coolant sources of fire near the fuel system or engine when recovery tank servicing Ensure proper ventilation exists when servicing the fuel system WARNING Steam can cause injury or death Do not alter or modify the fuel system Be sure all fuel supplies have a positive shutoff valve In case of an engine overheat allow the engine to cool Be certain fuel line fittings are adequately tightened and before touching the engine or checking the coolant free of leaks Make sure a fire extinguisher is installed nearby and is properly maintained Be familiar with its proper use Extinguishers rated ABC by the NFPA are appropriate for all applications encountered in this environment i SAFETY STARTING TOXIC EXHAUST GASES WARNING Accidental starting can cause injury WARNING Carbon monoxide CO is a deadly gas or death Ensure that the exhaust system is adequate to expel gases Disconnect the battery cables before servicing the engine discharged from the engine Check the exhaust system generator Remove the negative lead first and reconnect regularly for leaks and make sure the exhaust it last elbow is securely attached Make certain all personnel are clear of the engine before Be sure the unit and its surroundings are well ventilated starting Run blowers when running the generator set or engine Make certain all covers guards and hatches are re Do not run the generator set or engine unless the boat is installed before starting the engine equipped with a functioning marine carbon monoxide detector that complies with ABYCA24 Consult your boatBATTERY EXPLOSION builder or dealer for installation of approved detectors WARNING Battery explosion can cause injury For additional information refer to ABYC T22 or death educational information on Carbon Monoxide Do not smoke or allow an open flame near the battery 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 Do not use copper tubing in diesel exhaust systems Diesel during servicing fumes can rapidly destroy copper tubing in exhaust systems Never connect the negative battery cable to the Exhaust sulfur causes rapid deterioration of copper tubing positive connection terminal of the starter solenoid resulting in exhaustwater leakage Do not test the battery condition by shorting the terminals Do not install exhaust outlet where exhaust can be drawn together Sparks could ignite battery gases or fuel vapors through portholes vents or air conditioners If the engine Ventilate any compartment containing batteries to prevent exhaust discharge outlet is near the waterline water could accumulation of explosive gases To avoid sparks do not enter the exhaust discharge outlet and close or restrict the disturb the battery charger connections while the battery flow of exhaust Avoid overloading the craft is being charged Although diesel engine exhaust gases are not as toxic as Avoid contacting the terminals with tools etc to prevent exhaust fumes from gasoline engines carbon monoxide burns or sparks that could cause an explosion Remove gas is present in diesel exhaust fumes Some of the wristwatch rings and any other jewelry before handling symptoms or signs of carbon monoxide inhalation or the battery poisoning are Always turn the battery charger off before disconnecting Vomiting Inability to think coherently the battery connections Remove the negative lead first and reconnect it last when servicing the battery Dizziness Throbbing in temples Headache Muscular ACID Nausea Weakness and sleepiness WARNING Sulphuric acid in batteries can cause AVOID MOVING PARTS severe injury or death When servicing the battery or checking the electrolyte WARNING Rotating parts can cause injury or death level wear rubber gloves a rubber apron and eye protec tion Batteries contain sulfuric acid which is destructive If Do not service the engine while it is running If a it comes in contact with your skin wash it off at once with situation arises in which it is absolutely necessary to make water Acid may splash on the skin or into the eyes inad operating adjustments use extreme care to avoid touching vertently when removing electrolyte caps moving parts and hot exhaust system components ii SAFETY INSTRUCTIONS Do not wear loose clothing or jewelry when servicing ABYC NFPA AND USCG PUBLICATIONS FOR equipment avoid wearing loose jackets shirts sleeves rings necklaces or bracelets that could be caught in INSTALLING DIESEL ENGINES moving parts Read the following ABYC NFPA and USCG publications for safety codes and standards Follow their Make sure all attaching hardware is properly tightened when installing your engine Keep protective shields and guards in their respective 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 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 be 3069 Solomons Island Rd caught in these rotating parts Edgewater MD 21037 NFPA National Fire Protection NOISE Fire Protection Standard for Motor Craft Order from WARNING High noise levels can cause hearing NFPA loss 11 Tracy Drive Avon Industrial Park Never operate a generator 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 or generators for long periods with Order from their enclosures open US Government Printing Office Washington DC 20404 WARNING Do not work on machinery when you are mentally or physically incapacitated by MANUALMany of the preceding safety tips and warnings are repeatedin your Operators Manual along with other cautions andnotes to highlight critical information Read your maintain your equipment and follow all ENGINE AND GENERATOR to install an engine should begin with athorough examination of the American Boat and YachtCouncils ABYC standards These standards are acombination of sources including the USCG and the NFPASections of the ABYC standards of particular interest are H2 Ventilation P1 Exhaust Systems P4 Inboard Engines E9 DC Electrical SystemsAll installations must comply with the Federal Code ofRegulations FCR iii 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 withwhen installing engines and generators in a marine installations where the exhaust manifoldwater injected exhaust elbow is close toor will be below the vessels waterline provisions must be made to install a siphonbreak in the raw water supply hose to the exhaust elbow This hose must be looped aminimum of 20 above the vessels waterline Failure to use a siphonbreak whenthe exhaust manifold injection port is at or below the load waterline will result inraw water damage to the engine and possible flooding of the boatIf you have any doubt about the position of the waterinjected exhaust elbow relativeto the vessels waterline under the vessels various operating conditions install A siphonbreak requires periodic inspection and cleaning to ensure Failure to properly maintain a siphonbreak can result in damage Consult the siphonbreak manufacturer for proper SYSTEMThe exhaust hose must be certified for marine use The system must be designed toprevent water from entering the exhaust under any sea conditions and at any angle AVAILABLE FROMof the vessels hull YOUR WESTERBEKE DEALER A detailed 40 page Marine Installation Manual covering gasoline and diesel engines and generators is available from your WESTERBEKE dealer TABLE OF 2 Fuel System 24 Installation Codes and Safety Standards2 Fuel Tanks General 24 Recommended Reading 2 Fuel Tanks Gasoline24 Product Software 3 Fuel Tanks Located Above The 25 Notes Cautions and Warnings 3 Fuel Tanks Located Below The 25 Inspection of Shipment 3 Gasoline Engine Fuel Tanks25Engine Location and Mounting 4 Diesel Fuel System AntiSiphon Devices 25 Engine Location 4 Dual Purpose Fuel Tank 26 Engine Bed 4 Fuel Lines26 SSB Grounding 4 Rigid Fuel Lines 26 Engine Mounting5 Flexible Fuel Lines 26 ShutOff Valves 27Generator Location and Mounting 6 Fuel Filters 27 Generator Location6 Fuel27 Generator Mounting 6 SOUND GUARD7 Cooling System 28 Raw Water Intake 28Rigging and Lifting 8 Raw Water Outlet 28Propeller Shaft Alignment 9 Fittings28 Propeller Shaft Coupling Engines 9 Coolant Recovery Tank29 Flexible Couplings 9 Coolant 29 Alignment10 Engine Oil 30Propeller Selection 11 Oil Specifications 30Exhaust System 12 Oil Drain Hose 30 Recommended Guidelines 12 Oil Dipstick 30 Water Separator Exhaust Systems15 Pressure Sensing Devices30 Dry Stack Exhaust Systems 15 Relocating Engine Parts 30 Exhaust Back Pressure 15 Remote Oil Filter 31 Exhaust Hose16 Installation 31 Exhaust Elbow 17 Precautions 18 Ventilation 32Electrical System 19 Water Heater Connections33 Installation 33 DC Electrical Connections 19 Control Panels for Propulsion Engines 19 Transmission 34 Diesel Generator Instrument Panels19 Transmission 34 Optional Instrument Panel Gasoline Generators19 Shipment34 Optional Remote StartStop Panel Fluid 34 Diesel and Gasoline Generators 19 Control Cables ZF 34 Control Wiring 20 Borg Warner Velvet Drive35 AC Wiring Generators20 Installation Final Check 36 Batteries20 Wire Sizing Chart 37 Grounding20 Metric Conversion Chart 38 Admiral Control Panel 22 Captain Control Panel 23 1 marine Installation Manual covers all WESTERBEKE Within the CFRs are the detailed requirements and Generator models both diesel and gasoline The to boats with gasoline engines The majority of of this manual is to provide boatyards and installers pertinent to recreational vessels are contained in 33 CFRwho are already familiar with installation procedures addi Part 183tional detailed installation instructions to ensure the safestand most efficient operating conditions These instructions Subpart IElectrical Systems vary due to the many WESTERBEKE Engines and Subpart JFuel Systems available and the diversity of boat designs Subpart KVentilation location and installation of the engine or generator in Standards for marine carburetors and the requirements for thethe vessel are of prime importance Factors in the installation backfire flame arrester are contained in 46 CFR Subpartsthat must be considered are 2535 and 5810 Also within Subpart 5810 are the exhaust manifold and exhaust system requirements for both gasoline1 Ventilation to provide air for engine combustion and and diesel engine installations Several publications that to remove heat produced by the while address these federal mandates making compliance easier operating include2 Exhaust System to properly discharge cooling water The USCG Fuel System Electrical System and quiet the exhaust and expel exhaust gas Install a Ventilation Compliance Guidelines siphonbreak The USCG Safety Standards for Backyard Boat Builders3 Cooling Water Supply to cool the engine with a continuous flow of filtered raw water The National Fire Prevention Association NFPA302 Fire Protection Standard for Pleasure and Commercial4 Fuel System to provide an unrestricted fuel supply and Motor Craft properly filtered fuel to the fuel pump The ABYC Standards and Recommended Practices for5 Electrical Connections both AC and DC and proper Small Craft grounding The ABYC Standards Manual is the most comprehensive and6 Transmission Propeller Connections Engines only widely used reference ABYC constantly revises and updatesPlease read this manual carefully and observe the safety its projects as it calls each topic section The manual isprecautions Should your engine or generator require easy to read and quite detailed Adherence with theseservicing contact your WESTERBEKE dealer For Serial standards will put the recreational boater in compliance withNumber location Decal information or Parts Ordering federal mandates Anyone considering installing an refer to your WESTERBEKE Operators or generator should start with a thorough review of theseManual standards H2Ventilation of Boats Using CODES AND SAFETY STANDARDS H24Gasoline Fuel publications concerning Safety Codes and P1Installation of Exhaust are listed in this safety section Following is a P4Marine Inboard Enginessummary of what these standards include Both the US E9DC Electrical Systems Under 50 VoltsCode USC which are the laws passed by Congress and the USCG inspected vessels especially those carryingCode of Federal Regulations CFR which are agency passengers for hire are required to meet even more rules contain pertinent information standards than those discussed above A very thoroughTitle 46 Chapter 43 of the USC applies specifically to review of the applicable CFRs is necessary before the vessels It gives the Secretary of Transportation Guard arrives for their inspectionthe authority to set the standards for boats that and operated in the United States It also spells Recommended Readingout the penalties for violation of the standards For added information on installing Marine Engines andAccording to Title 46 USC 4307 a person may not Generators WESTERBEKE recommends the construct assemble offer for sale introduce booksinto interstate commerce or import into the United States Elements of Yacht Design Skeneany recreational vessel that does not comply with the federal Marine Engines Any associated equipment or component used on The Propeller Handbook Gerrone of these vessels must also be in compliance Further aperson is prohibited from operating any vessel that does notcomply with the regulations 2 SOFTWARE INSPECTION OF software tech data parts lists manuals brochures The is shipped from the factory securelyand catalogs provided from sources other than mounted and properly crated Accessory equipment isWESTERBEKE are not within WESTERBEKEs control shipped in a separate small box usually packed within the engines CANNOT BE RESPONSIBLE FOR THECONTENT OF SUCH SOFTWARE MAKES NO Before accepting shipment of the engine from theWARRANTIES OR WITH RESPECT transportation company the crate should be opened and theTHERETO INCLUDING ACCURACY TIMELINESS OR contents inspected for damage If there is either visible orCOMPLETENESS THEREOF AND WILL IN NO EVENT concealed damages you should require the delivery agent toBE LIABLE FOR ANY TYPE OF DAMAGE OR INJURY write Received in damaged condition on the IN CONNECTION WITH OR ARISING OUT receipt Also compare the contents of the shipment againstOF THE FURNISHING OR USE OF SUCH SOFTWARE the packing list and make sure that any discrepancies are properly noted This is your protection against loss orWESTERBEKE customers should also keep in mind the damage Claims concerning loss or damage must be made totime span between printings of WESTERBEKE product the carrier not to WESTERBEKE and the unavoidable existence of manuals In summation product software NOTE For safety reasons the engine is NOT filled withprovided with WESTERBEKE products whether from lubricating oil for shipment Before leaving the or other suppliers must not and cannot be however each is thoroughly tested with oilrelied upon exclusively as the definitive authority on the in its engine This testing among other things provides allrespective product It not only makes good sense but is internal parts with a coating of oil This oil acts as aimperative that appropriate of preservative providing reliable protection against or the supplier in question be consulted to for at least one year if the is the accuracy and currentness of the product storedsoftware being consulted by the customerNOTES CAUTIONS AND WARNINGSAs this manual takes you through the installation proceduresfor your critical information will be highlighted by NOTES CAUTIONS and WARNINGS Anexplanation followsNOTE An operating procedure essential to note CAUTION Procedures which if not strictly observed can result in the damage or destruction of your engine WARNING Procedures which if not properly fol lowed can result in personal injury or loss of life 3 ENGINE LOCATION AND MOUNTINGENGINE LOCATION Many boat manufacturers are now providing preformed fiberglass mounting beds for their engine installations TheseThe overall layout of the engine room should be planned for beds when used should be of sufficient thickness for propereasy inspection servicing and handling of the engine support and should be wellglassed to the hull when study all the equipment to be installed and makea paper plan to provide optimum engine room space Avoid the temptation to install the engine on a pair of angleConsider the following irons glassed in place Such a construction will allow1 Ventilation Since an increase in engine room vibration to pass through to the hull Flexible engine temperature causes a reduction in the intake air and thus a mounts require a firm foundation drop in engine output ventilation inside the engine room must be ample See your Operators Manual for the ventilation requirements for your a Dimension and capacity with a ventilator installed b Dimension and capacity with an intake duct installed2 Engine Room Height For engines having a top oil fill the distance from the oil cap at the top of the rocker cover to the overhead must be enough that oil can easily be added3 Space to move the propeller shaft flange Allow approximately 3 4 in 77 100 cm of space to move the flange toward the stern for changing the transmission etc4 Exhaust System Make sure there is adequate space for all exhaust system components including the exhaust silencer See the BASIC EXHAUST SYSTEMS section in this manualENGINE BEDA strong mounting bed contributes to the and operating of the engine The bed must berigidly constructed and neither deflect nor twist when it issubjected to the engines weight or to the pressures that theboat may experience while operating in rough seas The bedmust be strong enough to keep the engines alignment withinone or two thousands of an inch at all times The bed has towithstand the forward push of the propeller shaft It is alsocritical that the beds are parallel to one another and to theline of the propeller shaft when viewed from above Theyalso must be offset an equal distance from the line of thepropeller shaftIn fiberglass hulls we recommend that solid wooden similar to those in wooden hulls be formed andfitted then glassed securely to the hull This will allow thehanger bolts to be installed firmly in the wood noise and transmitted vibration When preparing the engine load also plan out and build an engine drip pan To simplify cleaning up after oil changesThe stringers must be as wide or wider than the engine consider a separate drip pan for use under the oil and fuelmounting isolator Avoid excessive height Isolator overhang filtersandor rounded stringer surfaces are detrimental to theflexible mounts ability to retain between the bed stringers and supports extending at SSB GROUNDINGright angles from the stringers to the hull may be required for If your boat needs a ground plane for a radio and otherproper strength and to aid in the absorption of vibrations electronic gear this is the ideal time to bond a substantialThe engine bed must be constructed so that a wrench can be area of copper mesh into the base of the engine space whileset at the engine base to retighten the engine mounting bolts it is accessibleat the mounting feet 4 ENGINE LOCATION AND MOUNTINGENGINE MOUNTING The engines mounting angle cannot exceed 15L from the horizontal plane Refer to the specification section in yourBronze or stainless steel hanger bolts of appropriate size are operating manual for the angle limit of your for use through the engines flexible mountsLess preferred are lag screws because their hold on the wood NOTE There are various transmissions that provide downis weakened every time they are moved whereas hanger angle output flanges to help in positioning the engine on abolts stay in position If the nut on top of the hanger bolt is more level planeremoved to allow the engine to be lifted the hanger boltitself remains in place as a stud Consequently the bondbetween the hanger bolt and the wood is not weakened bythe removal of the nut or the engineTo screw a hanger bolt onto a stringer thread two nuts ontothe hanger bolt jam them together then turn the hanger boltinto the stringer using a wrench on the uppermost nut 5 GENERATOR LOCATION AND LOCATION GENERATOR MOUNTINGA solid level mounting platform is very important for the Generator mounting rails have numerous predrilled boltproper operation of your generator Select a location that will holes to ensure that the generator is properly positioned andallow adequate space on all sides for ventilation and secured to its mounting preferably on and parallel with the keel or vesselcenter line Keep the generator away from living quartersand away from bilge splash and vaporsMake sure there is room to access the following servicepoints Negative and positive battery connections Fuel inlet and outlet connections Oil fill and oil drain hose Raw water inlet and outlet Location of the owner supplied fuelwater fuel filterA generator will rock on its mounts in rough seas is necessary on all sides Larger generators requireup to a threeinch 76mm clearanceAvoid supporting the generator from bulkheads which cancreate drumming effects and transmit noise and the boatGenerator location is preferable in the same room orcompartment as the propulsion engine as this is usually awell ventilated area insulated close to the fuel supply andthe center of the electrical load distribution However agenerator cannot be installed in the propulsion unless specific conditions are metUSCG regulation 33CFR183 pertains to gasoline fuelsystems and requires a generator operating in a gasoline to be ignition protected This means agenerator capable of operating in an explosive igniting that environment Properly installed andoperated a WESTERBEKE gasoline generator can operatein an explosive environment WARNING Gasoline fire or explosion can result in severe personal injury or death Do not install a gasoline generator in the same room or compartment as a diesel engine or generator The diesel unit may not be ignition protected and may ignite gasoline fumes Be sure a gasoline generator is installed in its own room or compartment on a diesel powered boat Do not install a diesel generator in the same room or compartment as a gasoline engine 6 SOUND ENCLOSUREThere are custom designed sound enclosures for each modelof WESTERBEKE generators The Sound Guard is a easy to clean enclosure that reduces the generatornoise to a pleasant hum The enclosure can be in close quartersQuick action fittings allow for easy access for inspection orroutine maintenance of the generator If major repairs areneeded all the panels can be disassembled in a few minutesNo tools requiredSound Guard is prepackaged with the skirt and baseassembled to assure a safe arrival and easy provides the necessary fittings andconnecting hoses for water exhaust fuel and a quiet dependable sound enclosure contact yourWESTERBEKE dealer 7 RIGGING AND LIFTINGThe is fitted with lifting eyes Attach wire If it becomes necessary to hoist the or chain slings capable of supporting the engine frontend pulleydrive belt end upwards or rearend flygenerators weight to the eyes and lift the by wheelgenerator end upwards the attachment of liftingmeans of tackle attached to these slings The lifting eyes have slings must be done carefully to avoid damaging the parts onbeen designed to carry the full weight auxiliary slings are which the weight of the slings may bearnot necessary NOTE Rigging work is best done by someone experienced and competent in handling heavy machinery WARNING Sings must NOT be so short as to place stress on the lifting eyes A sling must be long enough so that its angle to the vertical plane does not exceed 10 The general rule in moving an is to ensurethat all equipment used is adequately strong and firmly fixedin place Move the a little at a time andmake sure it is firmly supported Eliminate the possibility ofaccidents by avoiding haste Do not lift by the WARNING Make certain all personnel stand clear during lifting and lowering operationsIn certain situations it may be necessary to lift in positions other than the Certain situations require it to be lowered endwisethrough a small hatchway which cannot be made larger Ifthe opening of the hatchway is extremely small it is possibleto reduce the outside dimensions of the byremoving external components such as the cooling systempiping the heat exchanger certain filters the mounting railson generators and other obstructive components Theseshould be removed by a competent mechanic and specialcare should be taken to avoid damage to any exposed partsBe careful not to allow dirt to enter any openings created bythe removal of equipment Reinstall the components in theiroriginal positions after the engine is in its installation areaReplace gaskets as needed for the parts that were removed 8 PROPELLER SHAFT SHAFT COUPLING EnginesA propeller shaft halfcoupling is available for all enginemodels It is bored to shaft size for the specific order and haseither a keyway with set screws and two locking bolts or isof the clamping type with a keywayThis coupling is carefully machined to allow a onto the shaft and to make an accurate matingsurface between the coupling and the output flange of forward end of the propeller shaft has a long straightkeyway Any burrs should be removed from the shafts endThe coupling should be a light drive fit onto the shaft andthe shaft should not have to be scraped down or filed in orderto get a fit It is important that the key be properly fitted toboth the shaft and to the coupling The key should fit the sideof the keyway closely but should not touch the top of thekeyway in the hub of the couplingIf driving the coupling over the shaft is difficult the couplingcan be expanded by heating it in a pail of boiling water Theface of the propeller coupling must be exactly the center line axis of the propeller shaft Have amachine shop fit the coupling and face the coupling so thatthe mating surface of the flange is at a perfect right angle tothe propeller shaftAfter driving the coupling over the shaft remove the twolocking bolts from the coupling and countersink the shaftbelow each locking bolt hole Insert and tighten the twobolts then wire the two bolt heads together with stainlesswire This will secure the coupling to the shaft Foradditional security a stainless hose clamp can be the coupling shoulder and over the two bolt heads These illustrations show typical propeller shaft installations with variations on stuffing boxes and stern tubes The propeller shaft on the boat with the spade rudder is supported by the stern tube An external strut supports the shaft on the other boatFLEXIBLE COUPLINGSA flexible coupling or a drive saver can be the WESTERBEKE shaft coupling and coupling to reduce vibration and absorb thrustand torque This is an important consideration when usingflexible engine mounts Follow the and instructions 9 PROPELLER SHAFT engine must be exactly aligned with the propeller shaftNo matter what material is used to build a boat the materialwill be flexible to some extent The boats hull will changeits shape to a greater extent than is usually realized when theboat is launched and operated in the water Therefore itbecomes extremely important to check the at frequent intervals and to correct any errorswhen they between the engine and the propeller shaft The alignment is correct when the propeller shaft can beoften creates serious problems which are often blamed on easily slipped backward and forward into the areas suspected of causing the trouble Misalignment and when a feeler gauge indicates that the flanges comewill cause excessive bearing wear rapid shaft wear and will together at all points The alignment between the propellerin many cases reduce the life of the boats hull by loosening shaft halfcoupling and the transmisson halfcoupling canthe hulls fastenings A bent propeller shaft will produce these contain an error no greater than 001in 25 mm per inch ofsame effects therefore a perfectly straight propeller shaft is the coupling diameter For example if your propeller necessary One result of misalignment may be halfcoupling is 3 76mm in diameter the maximum errorleakage of transmission oil through the transmissions rear oil that can be allowed in the alignment is 003 in 076mmseal If oil should leak from this seal check and make surethat the alignment is within the limits attempt a final alignment when the boat is on landThe boat should be in the water and have had an opportunityto assume its final water form The propeller coupling alignment is best performed with thefuel and water tanks about half full with all the usualequipment on board and on sailboats after the mainmasthas been stepped and the final rigging has been installedTake sufficient time to make this alignment dont besatisfied with less than perfect results In making the final check for alignment the transmisson halfcoupling should be held in one position and the align ment with the propeller shaft halfcoupling tested with the propeller shaft halfcoupling in each of four positions A while rotated 90 between each position This test will also check whether the propeller shaft halfcoupling is in exact alignment on its shaft Then keeping the propeller shaft halfcoupling in one position the alignment should be checked by rotating the transmission halfcoupling in 90L increments checking dimension A while in each 90L position until it has been rotated fullcircle The engines alignment should be rechecked after the boat has been in service for one to three weeks and if necessary the alignment performed again Usually it will be found that the engine is no longer in alignment This does not mean that the first alignment has been done improperly rather it means that the boat has taken some time to take its final shape and that the engines bed and stringers have probably absorbed some moisture It may even be necessary to realign the coupling halves again at a later time 10 PROPELLER SELECTIONThe type and size of propeller varies with the gear ratio andmust be selected to fit the application based upon boat testsTo utilize the full power of the engine and to achieve idealloading conditions use a propeller which will permit theengine to reach its full rated rpm at full throttle while under anormal load and while the boat is moving forward throughthe waterThe following information is needed to calculate and match amarine propeller to a boat a The engine output in hp b The maximum rpm of the engine c The reduction of the transmission d The maximum hull speed of the boat e The type of boat and its displacement f The waterline length LWLMost propeller shops now have computer programs that willanalyze all this data and select the propeller choices innumber of blades diameter and pitch Inwater testinghowever is always the final answerFor more information on propellers read The by Gerr published by International 11 EXHAUST SYSTEM GUIDELINES Sea Water Intrusion Through The Exhaust OutletThese guidelines dated February 2004 supercede all The diagram above illustrates a below waterline guidelines published by Westerbeke of an engine or genset The letters A through H are theCorporation for all types of exhaust systems Water important dimensions that are discussed in detail in theintrusion is not covered by warranty because it is not following textcaused by a product defect Please study these before planning your exhaust system installation Lets start with A the difference between the highest underside of the boat deck near the and theThroughout these guidelines our use of the word engine is high point of the exhaust run from the water lift muffler togeneric it refers equally to either a propulsion engine or to the the exhaust outlet A should be minimized There is everyengine driving a generator set sea water and raw water are the reason to attach the high point of the exhaust hose directly tosame the underside of the deck There is no reason to fail to takeBeyond conveying exhaust gases and cooling system sea full advantage of this maximum available height because itwater out of the boat the other purpose of the exhaust system forms the primary barrier to water intrusionis to prevent sea water intrusion into the engine at the exhaust We need to define the water line for exhaust under all conceivable conditions of boat trim boat purposes By water line we mean the highest point the wateroperation sea conditions and heel angle while not exceeding level can reach at the location of the exhaust through hullthe manufacturers back pressure Seawater fitting from all conceivable causes other than is usually catastrophic to catalytic converters and waves of a duration of not more than a second or two Thisengines The enginegenset supplier is not in a position to worst case water level could be caused by any of thejudge what installation will prevent water following backing down aggressively turning in all conceivable circumstances That judgment is coming up onto a plane decelerating off a plane extremethe responsibility of the engine installer What we as the boat trim high seas wallowing in following seas can do is advise the best practice as we see it etc Hereafter these instructions will refer exclusively to thisleaving final judgments to the installer worst case water level as the relevant water level to plan a good installation 12 EXHAUST SYSTEM leads to B the amount by which the spill over point of G is the length of exhaust hose leading from the water liftthe exhaust outlet is above the worst case water level B muffler to the high point The shorter this length the lowershould be maximized and certainly always positive Then the back pressure and the greater will be the reserve capacitythe exhaust loop height C from the high point spill over inside a given water lift muffler The shorter the better but itpoint to the through hull fitting spillover point becomes a is much more important to minimize A than to minimize Gback up to B for preventing water intrusion rather than being The water lift muffler should be sized to hold multiples ofthe primary defense as becomes the case whenever the the volume of water that spills back from the exhaust highexhaust outlet spillover point dips beneath the water level point when the shuts off The actual amount of normal spill back at shut down is a function of length G the exhaust hose inside diameter E and the sea water pump flow rate The larger the muffler the better Remember when all else fails and water comes pouring over the high point only reserve capacity in the muffler can contain it and prevent it from entering the H is the height of the engines water injected exhaust elbow outlet above the top of the water lift muffler This should be maximized This length of hose is additional reserve capacity to contain both intruding water and splashing inside the water lift muffler J is the total height engine exhaust gas pressure must move water up hill from the bottom of the muffler to the spillover point at the exhaust run high point J is driven by other installation dimensions It results from a conservative installation rather than being a driving factor In most installations J would not exceed 4 12m this height should produce adequate exhaust system back pressure levelBut the height of C is also important The only defenseagainst momentary passing waves when they immerse theexhaust outlet is the exhaust loop height C If A has beenminimized C will probably be in excess of a couple of feetThe higher the better Maximize this height C because it isyour only defense against a passing wave rogue verticality D of the hose run from the high point to theexhaust outlet is also important When a momentarily risingwater level immerses the exhaust outlet and is accompaniedby water velocity towards that through hull fitting it is easierfor the intruding water to rise along a sloping hose towardsthe high point than to rise vertically towards that high pointMinimize D and keep this part of the exhaust hose as verticalas it is desirable that angle N be a 90 degree anglewith the exhaust hose rising vertically This will water intrusion especially when backing downturning or otherwise experiencing sea water the exhaust outletE is the inside diameter of the exhaust hose This should beno less than F the outside diameter of the generators waterinjected exhaust elbow E should only exceed F if exhaustsystem back pressure requirements are not metNOTE When the length of G is more than 20 ft increase thehose diameter E by 12 in to relieve back pressure WARNING Use extreme care during installation to ensure a tight exhaust system Exhaust gases are deadly 13 EXHAUST SYSTEM water Intrusion Through The Intake Seacock GeneratorNot in Operation Water means of water intrusion is though the sea water Boat operators may be accustomed to seeing a seacock This can occur when any part of the sea engine exhaust outlet dip beneath the water frequently whenwater system or exhaust system are below the worst case underway and think this is acceptable for a generator exhaustwater level other than the seacock itself which is already outlet as well Not so When the boat is underway exhaustbelow the water level of course What happens is that upon pressure keeps water out of the propulsion engine exhaustengine shutdown sea water siphons from the intake seacock But when the generator is not running there is no exhaustup through the sea water cooling circuit containing the sea pressure to keep water out of its exhaust outlet The exhaustwater pump heat exchanger and water injected exhaust outlet of engines which may not be operating when theelbow into the water lift muffler This seawater will siphon vessel is underway sailboat engines and generators mustpast the impeller of the sea water pump and fill the muffler be well above the worst case water leveland all hoses attached to the muffler until the outside waterlevel is reached If the engine exhaust manifold is below the Cumulative water level seawater will simply pour into the Water intrusion between operations of the engine is acylinders destroying the engine cumulative process If just a little bit of water spills over the high point but it happens many times it will fill the mufflerThis form of water intrusion is avoided by the proper and endanger the engine This could easily be the case for ainstallation of an anti siphon valve in the sea water circuit power boat not using its generator or for a sailboat not usingbetween the sea water pump outlet and the water injected its engine If you suspect that water is intruding run theexhaust elbow inlet Refer again to the generic drawing of a engine frequently until the suspected problem is confirmedbelow water line installation utilizing a and fixedwater lift muffler NOTE Running the engine or Genset will normally preclude water intrusion as the exhaust flow under pressure prevents water from entering the exhaust outlet Cranking the Starter Draining the Muffler Prolonged cranking of the starter may cause excessive sea water to build up between the engine and the high point Each time cranking is interrupted additional water may spill back into the muffler In time this cumulative spill back can flood the engine Unusual cranking andor cranking interruptions must be monitored and the muffler drained before excessive water buildup occurs This may be made more convenient by installing a suitable noncorrosive valve at the muffler drain fittingK is the difference between the highest underside of the boatdeck near the and the anti siphon valve Kshould be minimized There is every reason to attach theantisiphon valve directly to the underside of the deck Thereis no reason to fail to take full advantage of this height because it forms the only barrier to waterintrusion by siphoning The anti siphon valve must be wellabove the worst case water level under all conceivable conditions of boat trim boat operation sea conditions and heelangle The antisiphon break and the exhaust hose pointshould be located as near to the boats centerline as on sailboats due to large and steady healing Thesiphon must be accessible for maintenance 14 EXHAUST SYSTEM Valves Dry Stack Exhaust SystemsVarious types of check valves are available and suitable for Commonly seen on commercial fishing boats dry stackexhaust runs Examples are inline check valves offered by exhausts can also be used on trawler style pleasure boats Asome exhaust component manufacturers and flapper valves dry stack exhaust directs the exhaust gas straight from theon exhaust outlets None of these may be considered as an generator or engine without obstructions A dry stack to a good installation They can leak they can becomes very hot when the engine is operating and shouldfoul and they can open intermittently Think of them as an not be close to any combustible materials wood means to keep out that rogue wave or extreme etc unless it is properly shielded or sea Never rely on them to stay closed for morethan a second or two Read again CUMULATIVE Make certain the exhaust and muffler are of on the previous page diameter to clear the exhaust gasses and prevent excessive back pressure Provisions must also be made for Separators Exhaust Systems the raw cooling waterWater separators are the latest innovation in exhaust systems After final assembly test run the generator and check allThe separator uses gravity and centrifugal force to separate connections and elbows for exhaust leaks A cooling water from the exhaust gas and then discharges test should also be performed at this time Back pressurethen separately under the vessels hull This makes for a quiet should not exceed 15 psi 011 kgcm2and efficient system that reduces back pressure and prevents Regulations require that the exhaust muffler be constructedsea water intrusion by wave action of aluminized steel or other corrosion resistant material and be of welded or crimped construction An approved spark arrestor must be installed with the muffler in gasoline installations NOTE Liability for damage or injury and warranty expenses becomes the responsibility of the person installing an exhaust system Contact WESTERBEKE or your WESTERBEKE dealer regarding any exhaust system separator must be securely mounted as high as possiblepoint A in the previous diagrams above the water liftmuffler and well above the vessels waterline in all attitudesof operationThe discharge drain hose for the separated cooling watermust go directly and vertically down from the separator to athru hull fitting on the hull below the waterline Thisprovides a very quiet exhaustThe discharge drain hose for the exhaust gas must also godirectly and vertically down to a thru hull fitting under thehull just above the waterline This gas discharge hose willstill contain some water to prevent this water from becoming Exhaust Back and impeding the flow of gases make certain the After the installation is operational exhaust back pressurehose leads down hill without any loops or dips must be measured at the outlet of the water injected exhaust elbow Measure with an appropriate gauge or manometerWater separators are manufactured by Operate a propulsion engine underway at cruising RPMHalyard Limited Centek Industries Inc Operate a generator at rated load As the Business Park 116 Plantation Oak Drive operates it continuously pushes the exhaust gases and Road PO Box 3028 water thru the exhaust system up hill and overboard thru theWhadden Salisbury SP53HF Thomasville GA Kingdom exhaust outlet This causes significant back Excessive back pressure reduces engine power higher temperatures and cab reduce the life of the engine 15 EXHAUST SYSTEM Back Pressure cont Exhaust HoseBack pressure should not exceed 15 psi or 41 WC To ensure that vibration doesnt transmit toExcessive back pressure can be reduced by increasing E the hull most installations use flexible rubber exhaust hoseincreasing the size of the water lift muffler reducing J and for the water cooled section of the exhaust line because ofreducing G However A C and B should not be compromised the ease of installation and flexibility This exhaust hose mustto relieve back pressure be marine certified Provide adequate support for the rubber hose to prevent sagging bending and formation of waterBack pressure should not exceed the following pockets Always use corrosion resistant carriers and 3 inches of mercury For dry or custom pipe exhaust systems use a flexible 41 inches of water in the water column section preferably of stainless steel no less than 12 30 cm 15 psi 01 kgcm2 overall threaded at each end and installed as close to the engine as possible This flexible section should be installed with no bends and covered with insulating material The exhaust line should be properly supported by brackets to eliminate any strain on the manifold flange studs WARNING Do not install rubber hose with sharp bends as this will reduce efficiency Do not use rubber hose on dry type exhaust applications Doing so may cause hose failure and leakage of deadly exhaust gas Make sure that the water discharge into the rubber hose section is behind a riser elbow or sufficiently below the exhaust flange so that water cannot possibly flow back into the engine Also in custom systems make sure that entering raw water cannot spray directly against the inside of the exhaust piping Otherwise excessive erosion will occur Dry components of the exhaust system between the exhaust manifold and the water injected exhaust elbow must be properly insulated to hold in the heat prior to the cooling water being injectedSea TrialA sea trial must be conducted to confirm that no waterintrusion takes place either via the exhaust outlet or via thesea water intake seacock Do not operate the engine duringthe trial Disconnect the exhaust hose at the muffler outletand place it in an empty bucket bucket 1 Disconnect thesea water hose entering the exhaust elbow and place it into asecond empty bucket bucket 2Select the worst sea conditions available Operate the boat asaggressively as possible putting it through as large a variety ScoopType Intakeof operating situations as you would ever encounter Operate Where generators are installed in very high speed vesselsthe boat in this way for as long as possible 5060 knots it has been necessary to use a scooptype verify that no water enters either bucket Any water intake to insure an adequate supply of cooling water towater in bucket 1 is water intrusion via the exhaust outlet the generator Generally this is not recommended but if itAny water in bucket 2 is water intrusion via the sea water needs to be done the generator must be mounted highintake seacock Either instance of water intrusion shows that enough so that the exhaust piping has a continuousthe installation is not adequate since you will someday downward pitch from the muffler to the exhaust outlet in theexperience conditions worse than the sea trial hull The pitch should be adequate so that the muffler will continuously drain and no water can backup into the engine see illustration 16 EXHAUST SYSTEMEXHAUST ELBOW elbows are standard on generators optional onengines For installation on your we offer450 700 and 900 exhaust elbowsNOTE Fabricated exhaust elbows or risers attached to theexhaust manifold shall not exceed 8 lbs when unsupported1 Coat only one side of the exhaust gasket with High Tack manufactured by Permatex Company Brooklyn NY adhesive sealant Place this coated surface against the exhaust manifolds exhaust port flange the gasket should stick to the flange without falling off2 Place the clamp over the elbows flange Place your exhaust elbow against the exhaust manifolds flange so the exhaust manifolds flange rests snug against the exhaust elbows flange with the gasket centered between the two Now slip the exhaust clamp over both flanges3 Tighten the clamp just enough so the exhaust elbow can remain attached to the manifold and still be rotated The exhaust elbow discharge must be directed downward so the mixture of raw water and exhaust gases will flowfall downward into the exhaust muffler which must be posi tioned below the exhaust elbow There should be no loops or rises in the exhaust hose connected between the exhaust elbow and the muffler as these would trap water and possibly allow water to flow back into the engine dur ing starting or at shutdown4 Adjust the elbow by rotating it until the desired alignment with the exhaust piping is acquired5 Carefully tighten the clamp between 8 to 10 lbft or 24 to 35 lbin or 027 to 041 kgm CAUTION 10 lbft 14 kgm Torque Limit approach the 10 lbft 14 kgm torque limit with caution The clamps threads will break if more than 10 lbft 14 kgm is applied to the clamp6 When the engine is started for the first time with the new elbow check this exhaust manifoldelbow connection for leaks If a leak exists correct it immediately 17 EXHAUST SYSTEMEXHAUST SYSTEM PRECAUTIONS Raw Water Erosion When the engines raw water is fed into an exhaust system soCarbon Monoxide that the full stream of this water strikes a surface erosionThe best protection against carbon monoxide poisoning is a takes place This erosion may cause premature failures Thedaily inspection of the complete exhaust system Check for proper design of either a waterjacketed or around manifolds gaskets and welds Make sure wet exhaust system to prevent this problem requires thatexhaust lines are not heating surrounding areas excessively the raw water inlet be positioned so that the entering streamIf excessive heat is present correct the situation immediately of raw water does not directly strike a surface In additionIf you notice a change in the sound or appearance of the the velocity of the entering raw water stream should be asexhaust system shut down the unit immediately and have the low as possible which can be achieved by having inlet fitsystem inspected and repaired at once by a qualified tings as big in diameter as Excessive Weight WARNING Carbon Monoxide Gas is Deadly Make sure there are no unnecessary objects suspended from any portion of the exhaust lines Exhaust risers installed off Carbon monoxide is a dangerous gas that can cause the exhaust manifold should not exceed 8 lbs in total weight and is potentially lethal Some of the when rigidly constructed Excessive weight could cause symptoms or signs of carbon monoxide inhalation or poi deflection or distortion of the manifold resulting in damage andor internal leaks soning are Dizziness Throbbing in Temples Insulation Nausea Muscular Twitching Inspect insulated portions of the exhaust system to ensure Headache Vomiting there is no deterioration of the insulation Weakness and Inability to Think Overcranking Sleepiness Coherently If you experience any of the above symptoms get out Prolonged cranking intervals without the engine starting can result in filling the enginemounted exhaust system with raw into fresh air immediately water coolant This may happen because the raw water pump is pumping raw water through the raw water cooling systemA carbon monoxide warning decal has been provided by during cranking This raw water can enter the engines Display this decal near your engine or generator ders by the way of the exhaust manifold once the exhauston your cabin bulkhead or in some other nearby location system fills To prevent this from happening close the raw water supply throughhull shutoff drain the exhaust mufflerNOTE It is extremely important that a carbon monoxide and correct the cause for the excessive engine be installed in your boats living quarters Make needed to obtain a start Engine damage resulting form thissure it is manufactured for the marine industry They are type of raw water entry is not a warrantable and easily available at your marine supplier 18 ELECTRICAL SYSTEMDC ELECTRICAL CONNECTIONS The panel can also be remote mounted by using optional plugin extension harnesses which are available in 15 ftWESTERBEKE engines and generators are supplied 46 m increments A maximum of two harnesses 30 ftprewired and with plugin connectors Never make or break 92 m can be connected For longer distances hard while the engine is running Carefully follow all can be used as shown in the Operators Manual An on the wiring diagram supplied especially those cover plate is available to cover the face of the panel boxrelating to fusecircuit breaker requirements Wiring diagrams when the instrument panel is remote mounted An optionalare included in your Operators Manual plate with preheat and start and stop switches is alsoNOTE WESTERBEKE manufactures marine engines and available for mounting in place of the instrument panel forgenerators using components that meet very rigid safety operation at the unitstandards If a component on the engine or generator is The 5776 BTD comes standard with an instrument panelreplaced with one that is noncompliant then the safety of for remote mounting see illustration and one 15 ft 46 mthe boat is jeopardized Make certain that any engine extension harness Preheat and start and stop switches arecomponent you replace is a genuine WESTERBEKE provided on the partCONTROL PANELS FOR PROPULSION ENGINESTwo optional control panels forpropulsion engines are available from are the ADMIRAL CONTROL PANEL and theCAPTAIN CONTROL PANEl Both panels come with 15 ft46 m of connecting harness The features of these twopanels are described in detail at the end of this sectionDIESEL GENERATOR INSTRUMENT PANELSAll WESTERBEKE diesel generators come with a standardengine instrument panel see illustration With the exceptionof the 5776 BTD they are mounted in a panel box attachedto the AC alternator The panel faces the service side of the Two instrument panels can be installed using the and can be rotated to suit particular installations dual gauge sender kit This second panel must be hardwired by the installer OPTIONAL INSTRUMENT PANEL GASOLINE GENERATORS An optional instrument panel is available supplied with an engine oil pressure gauge water temperature gauge engine mounted alternator voltage gauge engine operating hourmeter and control switches This panel must be wired into the terminal strip in the main control panel on the and must be mounted in a remote location where the instruments can be monitored and the switches activated NOTE This panel must not be located in an engine or generator compartment because it is not ignition protected and has not been Coast Guard approved OPTIONAL REMOTE STARTSTOP PANEL DIESEL AND GASOLINE GENERATORS An optional remote StartStop panel is available containing three switches and a run indicator light green This panel must be wired into the terminal strip in the main control panel on the and must be mounted in a remote location such as the vessels wheelhouse NOTE This panel must not be located in an engine or gener ator compartment because it is not ignition protected and has not been Coast Guard approved 19 ELECTRICAL SYSTEMCONTROL WIRING Starter batteries must be of a type which permits a high rate of dischargeFor control wiring see the DC WIRE SIZING page in thismanual See your Operators Manual specifications for cold cranking ampere hours requirements Most marine batteries on theNOTE All wiring should be tied down with clamps or plastic market today have large cranking capacities The batteryties and spaced at intervals close enough to prevent chafing compartment must be well ventilated to preventfrom vibration Check to make sure all the harness connec accumulation of explosive battery gasestions are tight and that they are made to the Mount the battery in an acidresistant tray on a platform above the floor It must be secured to prevent shifting If CAUTION The electrical code will not allow DC mounted in an engine compartment always install a nonmetallic cover to prevent battery damage and arcing wiring to be routed together with AC wiring from accidentally dropped tools Be sure the battery connections are clean and tight then cover the batteryRefer to the wire size chart DC in this manual when terminals with a dielectric grease to retard the wire size to be used between the engine control US Coast Guard regulations and Marine Insurancepanel and remote startstop panel Use color codes to comply Companies require that the ships batteries have a fixed coverwith ABYC Standards See your WESTERBEKE Operators or holdown straps to keep the batteries in place should aManual for the remote panel wiring schematic rollover occurNOTE Generator AC load connections shore power Carefully follow the recommended wire sizes voltage adjustments and all the necessary in WESTERBEKES wiring diagrams for the batterywiring diagrams are included in your WESTERBEKE Manual BATTERY CABLE REQUIREMENTSAC WIRING GENERATORS Maximum Length of One CableVarious AC output voltages and frequencies are available for Cable Size 2 1 0 00 000 0000your generator For these specifications and for information Length ft 4 5 7 9 11 14about AC wiring connections and adjustments refer to yourOperators Manual Length m 12 15 21 27 34 43The generators data plate gives the voltage current and frequency rating of the generator A diagram of the various ACvoltage connections is provided on the AC wiring decal that WARNING Do not connect the starting batteryis affixed to the inside of the louvered cover at the generator until installation is complete Accidental starting of theend of the unit engine or generator could cause serious personal publications concerning electrical and safety codes are listed in the section of this manual Make sure that all connections tests and adjustments are performedby a qualified electrician Generators and propulsion engines must be grounded in accordance with USCG regulation 33CFR183415 TheBATTERIES regulation requires that a common ground conductor be connected between the generator and the vessels mainStarter batteries should be located as close to the engine or propulsion engines grounded cranking motor as possible to avoid voltage drop through longleads Install a battery disconnect switch in the B cable so The engine or generator must be bonded to the vesselsthe battery can be disconnected when the is common bonding conductor with a bonding strap If aserviced It is bad practice to use the starter batteries for other metallic fuel line is installed between the fuel tank and theservices unless they require low amperage or are intermittent shutoff valve it too must be bonded to theIn cases where there are substantial loads from lights same vessel common radios depth sounders etc it is essential to This conductor prevents accidental passage of crankinghave a complete separate system and to provide charging current through the fuel systems and smaller for this by means of a second alternator dual output conductors common to engines and generators This canalternator or alternator output splitter The output splitter is a happen if a cranking motor ground circuit becomes marine accessory It comes with complete or opens from corrosion vibration a bad cable on how it can be integrated with an 20 ELECTRICAL SYSTEM WARNING An improper ground can cause severe personal injury or death from fire or explosion Be sure to install a common ground conductor between all on board cranking circuitsA common ground for negative DC is located at thebellhousing of the next to the starter in theform of a threaded grounding stud This location is tagged Itis recommended that the battery ground be connected hereFailure to do so can cause arcing or resistance in the WARNING The ignition of gasoline fuel or fumes can result in severe personal injury or death Connect the battery ground lead only at the location shownConnect battery positive to the starter solenoid terminaltagged for this connectionThe DC power source for the generator can be obtained fromthe main engines starting battery A battery disconnect switchshould be installed in the B battery cable to the generator 21 ADMIRAL CONTROL When the engine is shut down with the key switch turned off the water temperature gauge will continue to register the lastThis control panel is equipped with a temperature reading indicated by the gauge before electricalKEY switch and RPM gauge with an ELAPSED TIME power was turned off The oil pressure gauge will fall to zerometer which measures the engines running time in hours and when the key switch is turned off The temperature gaugein 110 hours The panel also includes a WATER TEMPER will once again register the engines true temperature whenATURE gauge which indicates water temperature in degrees electrical power is restored to the an OIL PRESSURE gauge which measures theengines oil pressure in pounds per square inch and a DC A separate alarm buzzer with harness is supplied with everycontrol circuit VOLTAGE gauge which measures the sys Admiral Panel The installer is responsible for electrically contems voltage All gauges are illuminated when the key necting the buzzer to the fourpin connection on the enginesswitch is turned on and remain illuminated while the engine electrical harness The installer is also responsible for installingis in operation The panel also contains two rubberbooted the buzzer in a location where it will be dry and where it 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 22 CAPTAIN CONTROL The panel also includes an alarm buzzer for low OILThis control panel is equipped with a PRESSURE or high COOLANT TEMPERATURE TheKEY switch an RPM gauge PREHEAT and START but RPM gauge is illuminated when the KEY switch is turned ontons an INSTRUMENT TEST button and three indicator and remains illuminated while the engine is in operationlamps one for ALTERNATOR DISCHARGE one for lowOIL PRESSURE and one for high ENGINE 23 FUEL SYSTEMFUEL TANKSGENERAL Mount the fuel tank and secure it into position The NFPA recommends that the bottom tanks be installed on slattedIt is very important that the design construction and wooden platforms to help prevent moisture of all fuel system components meet the highest Cylindrical tanks should be set in chocks or cradles andpossible standards Use only products specified for marine securely all wood or metal surfaces the tank surface with a nonabrasive and tanks for diesel engines and generators may be made of aluminum or stainless Fuel tanks for and generators may be made of only fiberglass or FUEL stainless is not appropriate for gasoline because Tanks must be labeled with the manufacturers name tankimproper welding can remove carbon leaving only steel material and capacity They also must be marked that theywhich will rust and then leak have been pressure tested to the requirements of Title 33If the tank is made of fiberglass be certain that the interior is CFR sub part J If either the fuelfill fitting or the tank isgelcoated to prevent fibers from contaminating the fuel sys metallic it will need to be grounded A 10gauge or largertem Copper or galvanized fuel tanks should not be used The stranded copper wire must be fastened from the metal comnominal thickness of a fuel tank depends on the material ponents to the boats groundused Any fitting or opening must be at the top of the tank A Design the fuel tank vent line so that gasoline cannot spilldrain plug at the bottom of the tank is not acceptable onto the boat A loop in the vent line from the top of the tankAvoid the use of fittings made of copperbased alloys such as to the underside of the deck and then to the throughhull fitbrass as they will deteriorate the aluminum fittings ting will prevent this The line should drain back to the tankFastenings for an aluminum tank should be 300 series stain with no traps The vent line should be no less than 9160 IDless steel The throughhull vent fittings must be equipped with a flameIt is not necessary to mount the tank above the engine level arrestoras the fuel lift pump provided will raise the fuel from the Fuel Tanks Located Above the The amount of lift should be kept to a minimum 6 feetbeing maximum If a tank is already installed above engine A carburetor float valve cannot be trusted to hold back fuel inlevel it can be utilized in this position an installation having a fuel tank located at or above the fuel system This type of system and care are especially important when the fuel some or all of the fuel supply line to the carburetor routedtank is installed because any dirt left in the tank will cause below the level of the fuel tanks top requires a shutofffouling when the engine is started for the first time valve to shut off the fuel supply to the engine or generator when the engine isnt running CAUTION Make sure the fuel tank filler is properly sealed to prevent water reentry should it become awash The fuel tanks vent should be routed so as to prevent water entry as wellThe fuel tanks fuel pickup tube should be clear and unobstructed without screens or gauze strainers Make sure thatall fittings are sufficiently tightened to prevent leakingFuel tanks that are located below the engines fuel systemlevel must have their fuel return connection at the tankextending down into the tank in the same manner as thepickup tube otherwise air will replace fuel siphoning out ofthe engines fuel system through the returnThe fuel tanks vent should be located so that its dischargeroute cannot allow water to enter through to the fuel tanksMoisture must not be allowed to accumulate in the vents line 24 FUEL TANKS FUEL SYSTEMThis shutoff valve is necessary to guard against the possibil GASOLINE ENGINEFUEL TANKSity of gasoline siphoning through the supply line to the carburetor and into the engine in case the carburetor float valvedoesnt close the carburetor needle valve doesnt or the fuel line ruptures between the engine and thefuel tank at a point below the fuel level The shutoff valvecan be installed at the tank withdrawal fitting or at a locationwhere the line from the fuel tank will no longer remainabove the fuel tank top level It can be electrically with manual override to open when theengine starts and close when it shuts down A manually operated valve can also be used operated either from theStartStop panel area or from the vessels deck The shutoffvalve should be of the fuel oil type and it is important thatall joints be free of pressure leaksNOTE The use of mechanical springtype check valvesinstead of a solenoid shutoff valve is not recommended sincethese may tax the fuel lift pumps ability to draw fuel througha check valve A check valve can trap debris under its seatwhich inhibits the valves ability to close In addition if acheck valves cracking pressure is too high it can contributeto vapor lock Should a mechanicaltype springloaded checkvalve be used it should be an adjustable type such as aWeatherhead 43 x 6 This adjustable type valve should beadjusted to have a cracking pressure that will when the engine or generator is not operating butnot so excessive as to prevent the fuel lift pump from drawingfuel through the valveFuel Tanks Located Below the installation having a fuel tank located below the engine orgenerators fuel system with the fuel supply line to the carburetor routed above the level of the fuel tanks top does notrequire an antisiphon shutoff valve but does require service shutoff valves one located atthe fuel connection to the tank and another located at thefuel connection to the DIESEL FUEL SYSTEM ANTISIPHON DEVICES Fuel system antisiphon devices should not be used with a diesel It is not necessary and in addition introduces air into the fuel which may cause erratic operation The fuel system should include one or more fuel shutoff valves 25 FUEL SYSTEMDUAL PURPOSE FUEL TANK Run fuel lines at the top level of the fuel tank to a point as close to the engine or generator as possible to reduce theIf youre running both a generator and a propulsion engine danger of fuel siphoning out of the tank if the line shouldand they use the same fuel you can use the same fuel tank breakHowever before that decision is made the following factorsmust be considered Fuel piping should always be routed and securely anchored to prevent leaks from vibration and chafing Fuel piping is 4 There must be adequate fuel capacity for both usually secured by copper straps every 1214 in 3036 cm engines refer to the specifications section of Use as few connections as possible and install the lines so your owners manual for fuel consumption figures they are accessible and protected Avoid lockedin torsional stresses 4 In diesel installations the fuel returning to the tank is warm To obtain maximum engine efficiency fuel RIGID FUEL LINES delivered to the injectors must be cooled The fuel tank volume must be adequate to cool the returned For installations with rigid fuel lines Westerbeke recom fuel mends using copper tubing with suitable flated fittings both for the supply line and the return line Use seamless annealedIf a fuel tank is shared a fuel line tee should not be used A double flared fuel lines that are approved for marine installatee can cause erratic genset operation due to fuel starvation tions Run the tubing in the longest pieces obtainable toThe gensets fuel pump does not have the capacity to avoid the use of unnecessary fittings and connectors Theovercome the draw of the propulsion engines fuel pump minimum size of the fuel supply line and fuel return line isThis is true also of the return lines Pressure from one engine 14 inch inside diametercould be higher than the other and force return fuel back into When a copper fuel line is used electrically bond the fuelthe lowerpressure engine injector The return line should line to the vessels common bonding conductor with aenter the tank as far as possible from the supply lines suitable strap or 10 gauge wire FLEXIBLE FUEL LINES If a rigid metallic fuel line is run into the compartment a length of flexible hose must be installed to absorb vibration from the Install a nonorganic flexible hose without metal reinforcement between the rigid fuel line and the to absorb the vibration This line must be long enough to prevent binding or stretching because of movement A flexible fuel line may also be installed between the fuel yank and the for both the supply line and the return line For the supply line flexible hose may beFUEL LINES installed from the fuel tank outlet to the fuel filterwaterThe proper installation of fuel lines is very important All separator and from the fuel filterwater separator to thefuel line materials must be approved for marine installations enginemounted fuel pump inletand meet the requirements of both the USCG and the ABYC Use suitable end fittings and install all the hose in theThe fuel system should be installed in such a manner as to longest runs possible to avoid the use of unnecessary fittingsallow the enginemounted fuel lift pump to maintain a and connectors There must not be an electrical inlet pressure to the injection pump under all between the hose end fittings as a bad ground in the conditions As the fuel lift pump has a capacity in circuit will cause a wirereinforced hose to become chargedexcess of that required by the injection pump the overflow is and ignite the fuel during crankingpiped to the fuel tank and should be connected at the top ofthe tankGreat care should be taken to ensure that the fuel system is WARNING Ignition of fuel can cause fire andcorrectly installed so that airlocks are eliminated and severe personal injury or death Be sure any flexible taken against dirt and water entering the fuel line used between the fuel tank and the engineNOTE The fuel supply line to the should be generator meets ABYC and USCG its own pickup in the fuel tank and NOT teed off thesupply line to another the fuel lines as far as possible from the exhaust pipeand hot engine areas this is to keep the fuel at a to reduce the chance of vapor lock in 26 FUEL SYSTEMSHUTOFF VALVES FUELMake sure your fuel system has positive shutoff valves To insure satisfactory operation an engine or generator mustknow their locations and how they operate have a dependable supply of clean fuelNOTE See the US Coast Guard publication Fuel System Diesel Fuel use No 2 oil with a cetane rating of 45 orCompliance Guideline for basic fuel system layouts and highershutoff valve locations Gasoline use unleaded 89 octane or higherFUEL FILTERSA primary fuelwater separator should be installed in the fuel WARNING Gasoline leakage in or around thesupply line between the fuel tank and the to compartment is a potential for firehelp remove contaminants in the fuel before the fuel reaches andor explosions Repair leaks promptly and ensure thatthe engine mounted fuel lift pump It should be mounted in the compartment is properly ventilatedan accessible location for ease in monitoring for water and for servicing Such contaminants cancause the failure of components and such failures are not Make sure there is a installed near thewarrantable A recommended type of fuelwater separator is and that it is properly maintained Be familavailable from the list of accessories A secondary fuel filter iar with its use An extinguisher with the NFPA rating ofis mounted on the and it has a replacement ABC is appropriate for all elementAfter installation test the fuel system for tightness per Fuel filters for gasoline installations must use metalbowls to meet Coast Guard regulations 27 COOLING SYSTEMRAW WATER INTAKE A throughhull fitting that is completely flush with the surface of the boats hull and without an external strainerRaw water should be supplied to the raw water pump may be necessary for the generator raw water intake on verythrough a standardtype throughhull fitting located on the highspeed boats The protrusion of a standard type throughhull so as to be below the waterline during all angles of boat hull fitting and a strainer can cause a venturi effect on theoperation intake of a high speed boat creating a suction which works against the raw water pump causing an inadequate supply of CAUTION Do not use a high speed scooptype cooling water to the engine throughhull fitting for the raw water supply for generators and auxiliary sailboat engines as it will tend to encourage siphoning Water pressure against this type CAUTION On some extremely highspeed boats the use of a sea scoop type strainer may be necessary to of fitting while the vessel is underway with the provide an adequate supply of cooling to the generator generator off or when sailing can push water past the when the boat is underway If this is necessary the raw water pump impeller and into the exhaust system exhaust piping from the generator must have a filling it and the engine as well continuous downward pitch to the outlet at the transom so that no water can be trapped and backup into theThe raw water should be directed from the through a seacock to a visualtype raw water strainer engine A solenoid operated shutoff valve can also beand then delivered to the pump The strainer should be of the installed in the raw water supply to the raw water pumptype that may be withdrawn for cleaning while the vessel is and wired to close when the generator is not inunderway and should be mounted below the waterline to selfpriming Seacocks and strainers should be at leastone size greater than the inlet thread of the raw water pumpHoses routed from the throughhull fitting to the strainer andto the raw water pump should be wirereinforced to prevent CAUTION Water intrusion into the engine throughthe hose from collapsing during the the exhaust system is not covered by suction from the pump may collapse anonreinforced hose If a generator set is located above the waterline of the boat it is good practice to provide a loop or loops above the inlet of the raw water pump in the raw water supply hose from the raw water strainer The loops provide a head of water on the raw water pump which on startup lubricates the pump impeller until the pump starts drawing water from the intake RAW WATER OUTLET Wirereinforced flexible hose should be used between the raw water outlet on the heat exchanger and the exhaust system This reduces vibration and permits the engine to be moved slightly when its being realigned FITTINGSMake sure this system is in proper order Check that the hull All pipe and fittings should be of bronze Use sealinginlet seacock and strainer are unobstructed Inspect the raw compound or tape at all connections to prevent air leaks Thewater lines to make sure there are no collapsed sections neoprene impeller in the raw water pump should never bewhich would restrict water flow Make sure there are no air run dry All hose joints should be double clamped withleaks at any of the connections use double clamps on hose 304306 stainlesssteel hose clamps Tbolt clamps are below the waterline better but must be 304306 stainlessBe sure that the raw water intake is clear of any by the propellers CAUTION The use of common street elbows isThe raw water intake to the engine or generator should be not recommended in plumbing the raw water and not combined with any other inlet for the main These generally have a very restrictive inside or air conditioners The use of sea chest intakesis permissible but they must be engineered to provide an The use of machinetype fittings is supply of water for all equipment connected tothem 28 COOLING SYSTEMCOOLANT RECOVERY TANKA coolant recovery tank kit is supplied with eachWESTERBEKE The purpose of thisrecovery tank is to allow for engine coolant expansion andcontraction during engine operation without the loss ofcoolant and without introducing air into the cooling systemThis coolant recovery tank should be installed at or aboveengine manifold level in a location where it can be A wire mounting bracket is supplied with eachkit along with a 30 in 76 cm length of clear plastic hoseand clamps to connect the hose between the fitting and the hose spud on the base of therecovery recommends a mixture of 50 antifreezegood quality and compatible with aluminum componentsand 50 distilled water 29 ENGINE OILOIL SPECIFICATIONS When additional sensing devices such as switches or sensors need to be installed that function on engine oil pressure theseRefer to your Westerbeke Operators Manual for the oil devices must be and connected to the for your sump using an appropriate grade of lubricating oil hose Any fittings used to connect the hose to the gallery must be ofOIL DRAIN HOSE steel or malleable iron composition Brass must not be usedAn oil sump drain hose is located at the front or side of the for this Oil may be drained from this hose by removing thecap and the discharge end of the hose from its mounting RELOCATING ENGINE PARTSbracket and lowering the hose into a container The hose cap Any reassembly or relocation of engine parts such as fuelfitting is 14 NPT and it can be extended or have a pump filters dipstick senders and switches to accommodate aadded for easier removal of the old oil restricted engine space must be authorized by theWhen installing the engine make certain that this drain hose WESTERBEKE Corporation and the work must beis accessible and that the drain hose fitting at the bottom of performed by a WESTERBEKE approved mechanic or thethe engine oil pan is well clear of the boats oil pan engines warranty will be void The oil filter can be relocated to a convenient bulkhead location by using aOIL DIPSTICK WESTERBEKE Remote Oil Filter kitIf the engine is going to be mounted at an angle instead oflevel its a good idea to add the proper amount of lube oil tothe engine and check the dipstick before installation with theengine level After installation check the dipstick to seewhere the oil now rests and mark the dipstick at this pointfor future SENSING DEVICESOil pressure sensing devices such as senders and switchesmust not be connected to an engines oil sump with the useof extended nipples or tees The reason is simply thatcontinued engine vibration causes fatigue of the fittings usedto make such a connection If these fittings fail during lubricating oil will be lost and internal enginedamage will resultNOTE Oil filter assemblies vary with each engine modelswitches senderscoolers etc are shown in detail in allOperators Manuals 30 REMOTE OIL Always install this kit with the oil filter facing down as popular accessory is used to relocate the engines oilfilter from the engine to a more convenient location such as Contact your WESTERBEKE dealer for more informationan engine room bulkhead NOTE WESTERBEKE is not responsible for engine failureTo install simply remove the engine oil filter and thread on due to incorrect installation of the Remote Oil Remote Oil Filter kit as shown 31 VENTILATIONThe ventilation requirements of the engine or the following combustion air is required for theengines cylinders and cooling air is required for the engineand generator electrical end and also for removing the heatproduced during operation WARNING Ventilating air is required to clear the bilges as well as the compartment in which the engine or generator is located of potentially toxic and flammable vaporsKeep in mind that hot air rises so heated air should beremoved from the upper area of the engine or and cool fresh air should be directed to thelower areas of the compartment Ventilation should beaccomplished with the aid of power ventilation especiallywhen the vessel is not underwayPower ventilation incorporates a powered exhaust blower todraw air from the compartment and discharge to theatmosphere The exhaust blower must meet a rating based on compartment volume The graphbelow is used to calculate the required capacity NOTE See your Operators Manual for the ventilation requirements of your generator Refer to the ABYC standards and US Coast Guard regulations for ventilation require ments on both engines and generators 32 WATER HEATER REMOTE EXPANSION TANKWater heater hose connections vary from one engine to The pressure cap on the engines manifold should beanother Refer to your WESTERBEKE Operators Manual for installed after the engines cooling system is filled withyour engines water heater connections coolant Finish filling the cooling system from the remote tank after the system is filled and is free of air and exhibitsNOTE Water heater connections are not standard on marine good coolant circulation During engine operation products the engines coolant should be done at the remote tank andWESTERBEKE marine engines are equipped with not at the engine manifold cap The hose connection from theconnections for the plumbing of engine coolant to heat an heater to the remote expansion tank should be routed andonboard water heater The water heater should be mounted supported so it rises continuously from the heater to the tankin a convenient location either in a high or low position in enabling any air in the system to rise up to the tank and outrelation to the engine so that the connecting hoses from the of the systemheater to the engine can run in a reasonably direct line with NOTE Air bleed petcocks are located on the engines heatout any loops which might trap air exchanger and on the thermostat housing Open these petHoses should rise continuously from their low point at the cocks when filling the engines fresh water system to allowheater to the engine so that air will rise naturally from the air in the coolant circuit to escape Close tightly after all theheater to the engine If trapped air is able to rise to the air is removedheater then an air bleed petcock must be installed at thehigher fitting on the heater for bleeding air while fillingthe systemNOTE If any portion of the heating circuit rises above theengines closed cooling system pressure cap then apressurized aluminum remote expansion tank must beinstalled in the circuit to become the highest point Tee theremote expansion tank into the heater circuit choosing thehigher of the two connections for the return Tee at theheater and plumb a single line up to the tanks location andthe other back to the engines return Install the tank in a convenient location so the fresh watercoolant level can easily be checked The remote expansiontank will now serve as a check and system fill point Theplas ticc oo lantr ecov ery tank is not used when theremote expa nsion ta n kk itisi nstalledsin cet his tankserves the same function The remote expansion tank hasan overflow fitting that should be directed by a hose to anarea where any overflow will not cause damage 33 CONTROL CABLESFor safety reasons the transmission is not filled with NOTE When installing the transmission make certain fluid during shipment and the selector lever is shifting is not impeded by restricted movability of thetemporarily attached to the actuating shaft Bowden cable or rod linkage by unsuitably positioned guideBefore leaving the WESTERBEKE plant each transmission sheaves too small a bending radius etc In order to mount aundergoes a test run with Dextron III ATF transmission fluid support for shift control cable connections use the twoThe residual fluid remaining in the transmission after threaded holes located above the shift cover on top of thedraining acts as a preservative and provides protection gear housing Refer to the WESTERBEKE parts listagainst corrosion for at least one year if properly stored CONTROL CABLES The transmission is suitable for single lever remote control Upon loosening the retaining screw the actuating lever can be moved to any position required for the control elements cable or rod linkage Make certain that the shift lever does not contact the actuating lever cover plate the minimum distance between lever and cover should be 05mm The control cable or rod should be arranged at right angle to the actuating shift lever when in the neutral position The neutral position of the operating lever on the control console should coincide with the neutral position of this lever The shifting travel as measured at the pivot point of the actuating lever between the neutral position and end positions A and B should be at least 35mm for the outer and 30mm for the inner pivot FLUID A greater amount of shift lever travel is in no way detrimental and is recommended However if the leverFill the transmission with Dextron III ATF The fluid level travel is shorter proper clutch engagement might be impededshould be up to the mark on the dipstick After checking the which in turn would mean premature wear excessive heatlevel press the dipstick into the case and turn it to tighten generation and clutch plate failure This would be the first 25 operating hours inspect the bell housingoutput shaft and transmission cooler for leakage The fluid by slow clutch engagement or no engagement at allshould be changed after the first 25 hours and every 300 NOTE Check for proper lever travel at least each seasonhours SWITCHThese transmissions are equipped with a neutral safetyswitch This is to prevent the engine from starting in gearUnless the transmission selector lever is perfectly aligned inneutral the engine starter will not OF GEAR BOX WITH PROPELLERUse a flexible connection between the transmission gearboxand the propeller shaft if the engine is flexibly mounted inorder to compensate for angular deflections The installationof a special propeller thrust bearing is not required since thepropeller thrust will be taken by the transmission the value specified under SPECIFICATIONS is notexceeded However the output shaft should be protectedfrom additional loads Special care should be taken to vibration When using a universal joint shaft makecertain to observe the manufacturers instructions For additional information contactEven with the engine solidly mounted the use of flexible ZF or DRIVESAVER will reduce stress in the Marine US bearings caused by hull distortions especially in 3131 SW 42nd Streetwooden boats or where the distance between transmission Fort Lauderdale FL 33312output flange and stern gland is less than about 800mm Tel 954 is a product of Globe Marine Rockland MA Fax 954 5814077 WWWZFMARINECOM 34 WARNER VELVET DRIVE Shifting Into GearCheck the transmission fluid level on the dipstick If the Place the transmission selector control in Neutral has not been filled fill with Dextron III and starting the engine Shifting from one selector position tocontinue to use this fluid During the first 50 hours of another selector position may be made at any time belowoperation keep a lookout for any leakage at the bell housing 1000 rpm and in any order Shifts should be made at theoutput shaft and transmission cooler This fluid should be lowest practical engine speed Start the engine and set thechanged after the first 50 hours and approximately every throttle at idle speed allow the transmission fluid to warm up1000 operating hours or at winter layup for a few minutesNOTE Some transmissions are equipped with a neutral Neutralsafety switch Unless the transmission shift lever is in neutral the engine starter will not activate Move the shift control handle to the middle position You should feel the detent Center the shift lever on theShift Lever Position transmission through the linkage to the selector lever WithThe shift control handle and linkage must position the shift the control in this position hydraulic power is on the transmission exactly in Forward F Neutral N interrupted and the output shaft of the transmission does notand Reverse R shifting positions A detent ball located turnbehind the transmission shift lever must work freely to center Forwardthe lever in each position The shift control positions at thehelms must be coordinated with those of the Velvet Drive Move the shift control handle to the forward position Youshift lever through shift mechanism adjustments An should feel the detent The shift lever on the transmission isimproperly adjusted shift mechanism can cause damage to in the forward position The output shaft and the propellerthe transmission The shifting mechanism and transmission shaft move the boat in a forward directionshift lever should be free of dirt to ensure proper operation ReverseNOTE Do not remove the detent ball Move the shift control handle to the reverse position YouNOTE If the boat moves backwards with the selector control should feel the detent The shift lever on the transmission isin the forward position shut off the engine This problem in the reverse position The output shaft and the propellermay be the result of incorrect movement of the shift lever by should move the boat in a reverse direction asternthe shift control NOTE Moving the transmission shift lever from Neutral Position to Forward is always towards the engine Reverse is always away from the engine NOTE Be aware of any unusual noises or vibrations and investigate to determine the cause NOTE Low engine idle rpm can produce damper plate and gear box chatterrattle This is the result of unstable rotation through the damper plate and the gear box Increase the idle rpm until this chatterrattle is eliminated Refer to your transmission manufacturers operators manual for more detailed information on installation and operation For additional information on throttle and shift controls contact Edson International New Bedford Massachusetts 35 FINAL INSTALLATION CHECKSNOTE Also refer to PREPARATIONS FOR INITIAL STARTUP in your Operators ManualBefore starting the engine or generator complete the follow With the engine or generator running check the followinging checklist Make certain that water is flowing from the exhaust Is there fuel in the tanks and are the fuel valves open Check the instrument gauges for proper readings Has lube oil been added to the engine Inspect the engine for fuel water coolant and oil Is there transmission fluid in the transmission leaks Has the proper coolant mix been added Listen for unusual sounds and vibrations Are the battery cables properly connected Will the engine shift in and out of gear Is the exhaust system secure and all connections tight Can you throttle up to the recommended rpms Is the Is the transmission linkage positioned correctly Is the throttle action smooth gear in Neutral Apply a load to the generator check the output fre Is the raw water petcock open Is the raw water pump quency primed NOTE See your operators manual for the output Are the AC and load connection wires securely adjustment connected to the circuit breaker After shutdown check the engine or generator carefully inspect all fluid levels check hose clamps fuel lines etc 36ENGLISH TO METRIC CONVERSION CHART 37WIRE SIZING 38DECIMAL TO METRIC EQUIVALENT CHART 39604WMDW1082

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