Century 120 T4a Operator's Manual
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OPERATORS MANUAL80N411 OT4 120N6170T6 MARINE 01 L ENGINES PUBLICATION NO 045139 FIRST EDITION JULY 2000 WESTERBEKE CORPORATION MYLES STANDISH INDUSTRIAL PARK 150 JOHN HANCOCK ROAD TAUNTON MA 027807319 AIITAIITAIIT NMMA Member National Marine Manufacturers Association UWW A WARNINGExhaust gasses contain Carbon Monoxide an odorless andcolorless gas Carbon Monoxide is poisonous and can and death Symptoms of Carbon can include Dizziness Throbbing in TemplesNausea Muscular 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 restartuntil it has been inspected and repaired A WARNING DECAL is provided by WESTERBEKE and should be fixed to a bulkhead near your engine or generator WESTERBEKE also recommends installing CARBON MONOXIDE DETECTORS in the livingsleeping quarters of your vessel They are inexpensive and easily obtainable at your local marine store 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 SAFETY PREVENT BURNS FIRERead this safety manual carefully Most accidents are causedby failure to follow fundamental rules and when dangerous conditions exist and talre the A 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 the sparks to occur near the carburetor fuel line filter fuelAmerican 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 arrester removed Backfire can cause severe injury or A WARNING Do not touch AC electrical connections 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 enginegener enclosures and covers in place ator 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 bum 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 A 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 before start Electrical shock results from handling a charged capacitor ing 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 reach of children A WARNING Do not touch hot engine parts or Do not fill the fuel tanks while the engine is running exhaust system components A running engine gets Shut off the fuel service valve at the engine when servicing very 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 servicing recovery tank Ensure proper ventilation exists when servicing the fuel system A 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 Engines Generators SAFETY STARTING TOXIC EXHAUST GASES A WARNING Accidental starting can cause injury A WARNING Carbon monoxide CO is a deadly gas or death Ensure that the exhaust system is adequate to expel gases Disconnect the battery cables before servicing the engine discharged from the engine Check the exhaust system generator Remove the negative lead first and reconnect regularly for leaks and make sure the exhaust manifolds it last are securely attached and no warping exists Pay close attention to the manifold water injection elbow and Make certain all personnel are clear of the engine before exhaust pipe nipple starting Be sure the unit and its surroundings are weIl ventilated Make certain all covers guards and hatches are re instaIled before starting the engine In addition to routine inspection of the exhaust system instaIl a carbon monoxide detector Consult your boatBATTERY EXPLOSION builder or dealer for instaIlation of approved detectors For additional information refer to ABYC T22 educa A WARNING Battery explosion can cause injury tional information on Carbon Monoxide or death A WARNING Carbon monoxide CO is an invisible Do not smoke or aIlow an open flame near the battery odorless gas Inhalation produces flulike symptoms being serviced Lead acid batteries emit hydrogen a nausea or death highly explosive gas which can be ignited by electrical arcing or by lit tobacco products Shut off all electrical Do not use copper tubing in diesel exhaust systems Diesel equipment in the vicinity to prevent electrical arcing during fumes can rapidly destroy copper tubing in exhaust sys servicing tems Exhaust sulfur causes rapid deterioration of copper Never connect the negative battery cable to the positive tubing resulting in exhaustwater leakage connection terminal of the starter solenoid Do not test Do not instaIl exhaust outlet where exhaust can be drawn the battery condition by shorting the terminals together through portholes vents or air conditioners If the engine Sparks could ignite battery gases or fuel vapors Ventilate exhaust discharge outlet is near the waterline water could any compartment containing batteries to prevent accumu enter the exhaust discharge outlet and close or restrict the lation of explosive gases To avoid sparks do not disturb flow of exhaust Avoid overloading the craft the battery charger connections while the battery is being charged Although diesel engine exhaust gases are not as toxic as exhaust fumes from gasoline engines carbon monoxide Avoid contacting the terminals with tools etc to prevent gas is present in diesel exhaust fumes Some of the symp burns or sparks that could cause an explosion Remove toms or signs of carbon monoxide inhalation or poisoning wristwatch rings and any other jewelry before handling are the battery Vomiting Always turn the battery charger off before disconnecting the battery connections Remove the negative lead first Dizziness and reconnect it last when servicing the battery Throbbing in temples Muscular ACID Intense headache A WARNING Sulphuric acid in batteries can cause Weakness and sleepiness severe injury or death AVOID MOVING PARTS When servicing the battery or checking the electrolyte level wear rubber gloves a rubber apron and eye protec A WARNING Rotating parts can cause injury tion Batteries contain sulfuric acid which is destructive If or death it comes in contact with your skin wash it off at once with water Acid may splash on the skin or into the eyes Do not service the while it is running If a inadvertently when removing electrolyte caps situation arises in which it is absolutely necessary to make Engines Generators 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 GASOLINE AND DIESEL ENGINES AND moving parts GENERATORS Make sure all attaching hardware is properly tightened Read the following ABYC NFPA and USCG publications Keep protective shields and guards in their respective for safety codes and standards Follow their recommenda places at all times tions when installing your WESTERBEKE Do not check fluid levels or the drive belts tension while ABYC American Boat and Yacht Council the is operating Safety Standards for Small Craft Stay clear of the drive shaft and the transmission coupling Order From when the engine is running hair and clothing can easily ABYC be caught in these rotating parts 3069 Solomons Island Rd Edgewater MD 21037HAZARDOUS NOISE NFPA National Fire Protection Association Fire Protection Standard for Motor Craft A WARNING High noise levels can cause hearing Order From loss NFPA 1 Batterymarch Park Never operate a generator without its muffler installed PO Box 9101 Quincy MA 022699101 Do not run an engine with the air intake silencer removed USCG United States Coast Guard USCG 33CFR183 Do not run engines or generators for long periods with their enclosures open Order From US Government Printing Office Washington DC 20404 A WARNING 00 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 to install a gasoline engine or generator shouldbegin with a thorough examination of the American Boat andYacht Councils ABYC standards These standards are froma combination of sources including the USCG and the NFPASections of the ABYC standards of particular interest areH2 VentilationH24 Gasoline fuel systemsPl Exhaust systemsP4 Inboard enginesE9 DC Electrical systemsAll installations must comply with the Federal Code ofRegulations FCR Engines Generators iii installing WESTERBEKE engines and generators it is important that be paid to the following AND regulations ABYC guidelines and safety codes must be complied with wheninstalling 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 instaU A siphonbreak requires periodic inspection and cleaning to ensure Failure to properly maintain a siphonbreak can result in damage Consult the siphonbreak manufacturer for proper 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 angleof the vessels hull A detailed 40 page Marine Installation Manual covering gasoline and diesel engines and generators is available from your WESTERBEKE dealer Engines Generators iv TABLE OF CONTENTSParts Identification 2 0 WIFing lagrams 27Introduction 3 Engine 29 Warranty Procedures 3 Tachometer 31 Serial Number Location 4 Engine Adjustments 32Admiral Control Panel 5 Drive Belt Adjustment 32Fuel Engine Oil and Coolant 6 Fuel Injectors 32 Oil Pressure 6 Testing Engine Compression 33Preparations for Initial StartUp 7 Testing Oil Pressure 33 Valve Clearance Adjustment Procedure 8 Injection Timing 34Warning Lights Alarms and Circuit Breaker 9 Hurth Transmissions 36Engine BreakIn Procedure 10 Changing Fluid 37The Daily Routine 11 Maintenance 37 Starting the Engine 11 Cable Connections 38Maintenance Schedule 12 Shaft Couplings 38Cooling System 14 Borg Warner Transmission 39 Thermostat 15 Changing Fluid 40 Raw Water Pump 16 Maintenance 41 Heat Exchanger 17 Transmission 42 Air Intake Filter 18 Layup and 44Fuel System 19 Metric Conversions 46 Fuel Lift Pump 19 Specifications 80N4 48 Fuel Filters 19 Fuel PumplFuel Bleeding 20 Specifications 11 OT4 49Engine Lubricating Oil 21 Specifications 120N6 50 Oil Change 21 Specifications 170T6 51 Remote Oil Filter 22 Suggested Spares 52Water Heater 23DC Electrical System 24 Alternator 24 Battery 25 Glow Plugs 26 Engines Generators 1 PARTS IDENTIFICATION DC ALTERNATOR ID NAME PLATE EXHAUST ELBOW MODEL 110T4 ILLUSTRATED MANIFOLD HEAT COVER I EXCHANGER FRONT TRANSMISSION FLUID DIPSTICK RAW WATER STARTER MOTOR OIL DRAIN HOSE LEFT SIDE THERMOSTAT OIL FILL ASSEMBLY MANIFOLD PRESSURE CAP COOLANT BREAK FUEL FILTER TURBOCHARGER INJECTION PUMP FUEL PRIMING PUMP AIR INTAKE FILTER TRANSMISSION OIL COOLER BLE MOUNT OIL DIPSTICK REAR RIGHT SIDE OIL GALLERY OIL FILTER Engines Generators 2 high perfonnance marine engines are products of PRODUCT long years of experience and advanced Product software technical data parts lists We take great pride in the superior durability and brochures and catalogs provided from sources other thandependable perfonnance of our engines and generators WESTERBEKE are not within WESTERBEKEs controlThank you for selecting WESTERBEKE WESTERBEKE CANNOT BE RESPONSIBLE FOR THEIn order to get the full use and benefit from your generator CONTENT OF SUCH SOFTWARE MAKES NO WARit is important that you operate and maintain it correctly RANTIES OR WITH RESPECTThis manual is designed to help you do this Please read this THERETO INCLUDING ACCURACY TIMELINESS ORmanual carefully and observe all the safety precautions COMPLETENESS THEREOF AND WILL IN NO Should your engine require servicing contact BE LIABLE FOR ANY TYPE OF DAMAGE OR INJURYyour nearest WESTERBEKE dealer for assistance INCURRED IN CONNECTION WITH OR ARISING OUTThis is your operators manual A parts catalog is also OF THE FURNISHING OR USE OF SUCH and a technical manual is available from your WESTERBEKE customers should keep in mind the timeWESTERBEKE dealer If you are planning to install this span between printings of WESTERBEKE product contact your WESTERBEKE dealer for and the unavoidable existence of earlier installation manual product software The product software provided with WESTERBEKE products whether from WESTERBEKE orWARRANTY PROCEDURES other suppliers must not and cannot be relied upon excluYour WESTERBEKE Warranty is included in a separate sively as the definitive authority on the respective product Itfolder If after 60 days of submitting the Warranty Registry not only makes good sense but is imperative that you have not received a customer identification card of WESTERBEKE or the supplier in your warranty please contact the factory in be consulted to detennine the accuracy and currentness of thewriting with model infonnation including the units product software being consulted by the customerserial number and commission date NOTES CAUTIONS AND Identification Card As this manual takes you through the operating procedures maintenance schedules and of your marine lWVJWESTERBEKE engine critical infonnation will be highlighted by NOTES CAUTIONS and WARNINGS An explanation follows I NOTE An operating procedure essential to note Customer Identification MR WESTERBEKE OWNER MAIN STREET A CAUTION Procedures which if not strictly HOMETOWN USA observed can result in the damage or destruction of Model80N4 Ser UOOOOE702 your engine Expires 2151200 I A WARNING Procedures which if not properly followed can result in personal injury or loss of lifeThe WESTERBEKE serial number is an that can assist in detennining the date of manufactureof your WESTERBEKE engine or generator The manufacturers date code is placed at the end of the engine serialnumber and consists of a character followed by three numbers The character indicates the decade A1960s B1970sC1980s D1990s E2000s the first number represents theyear in the decade and the second and third numbers represent the month of manufacture Engines Generators 3 NUMBER LOCATION ORDERING PARTSThe engines model number and serial number are located on Whenever replacement parts are needed always provide thea nameplate mounted on the side of the engines manifold engine model number and serial number as they appear onThe engines serial number is stamped into the engine block the silver and black nameplate located on the manifold Youleft side behind the alternator below the manifold Take the must provide us with this information so we may properlytime to enter this information on the illustration of the name identify your engine In addition include a complete partplate shown below as this will provide a quick reference when description and part number for each part needed see theseeking technical information andor ordering repair parts separately furnished Parts List Insist upon WESTERBEKE packaged parts because will fit or generic parts are not made to the same specifications as original equipment SPARES AND ACCESSORIESo MODEL 0 SPEC AVO MA USA SERNO Certain spares will be needed to support and maintain your WESTERBEKE engine Your local WESTERBEKE dealer will assist you in preparing an inventory of spare parts See the SPARE PARTS page in this manual For engine acces sories see WESTERBEKEs ACCESSORIES THE DIESEL ENGINEThe diesel engine closely resembles the gasoline enginesince the mechanism is essentially the same The cylindersare arranged above a closed crankcase The crankshaft is thesame general type as a gasoline engine and the diesel enginehas the same type of valves camshaft pistons connectingrods and lubricating to a great extent a diesel engine requires the samepreventive maintenance as a gasoline engine The mostimportant factors are proper ventilation and proper mamtenance of the fuel lubricating and cooling systems Fuel andlubricating filter elements must be replaced at the time periods specified and frequent checking for contaminants watersediment etc in the fuel system is also essential factor is the consistent use of the same brand ofhigh detergent diesel lubrication oil designed specifically fordiesel enginesThe diesel engine does differ from the gasoline enginehowever in its method of handling and firing of fuel Thecarburetor and ignition systems are replaced by a the fuel injection pump which performs thefunction of both Engines Generators 4 ADMIRAL CONTROL PANEL DESCRIPTION When the engine is shut down with the key switch turned off the water temperature gauge will continue to register the last This control panel is equipped with a temperature reading indicated by the gauge before electrical KEY switch and RPM gauge with an ELAPSED TIME power was turned off The oil pressure gauge will fall to zero meter which measures the engines running time in hours and when the key switch is turned off The temperature gauge in III 0 hours The panel also includes a WATER TEMPER will once again register the engines true temperature when ATURE gauge which indicates water temperature in degrees electrical power is restored to the gauge Fahrenheit an OIL PRESSURE gauge which measures the engines oil pressure in pounds per square inch and a DC A separate alarm buzzer with harness is supplied with every control circuit VOLTAGE gauge which measures the sys Admiral Panel The installer is responsible for electrically con tems voltage All gauges are illuminated when the key necting the buzzer to the fourpin connection on the engines switch is turned on and remain illuminated while the engine electrical harness The installer is also responsible for installing is in operation The panel also contains two rubberbooted the buzzer in a location where it will be dry and where it will pushbuttons one for PREHEAT and on for START be audible to the operator should it sound while the engine is running The buzzer will sound when the ignition key is turned on and should silence when the engine has started and the engines oil pressure rises above 15 psi 11 kgcm2 OIL PRESSURE GAUGE THIS GAUGE IS GRADUATED WATER TEMPERATURE GAUGE THIS GAUGE IS IN POUNDS PER SQUARE INCH PSI AND IS GRADUATED IN DEGREES FAHRENHEIT AND IS ILLUMINATED WHILE THE KEY SWITCH IS TURNED ILLUMINATED WHILE THE KEY SWITCH IS ON THE ENGINES NORMAL OPERATING OIL TURNED ON THE ENGINES NORMAL OPERATING PRESSURE RANGES BETWEEN 40 85 pSi TEMPERATURE IS 170 190 Fn SSCRPM GAUGE REGISTERS REVOLUTIONSPER MINUTE OF THEENGINE AND CAN BERECALIBRATED FORACCURACY FROM THEREAR OF THE PANELHOURMETER SWITCH ELAPSED POWER ONLY TO THETIME AND SHOULD BE INSTRUMENT PANELUSED AS A GUIDE FOR CLUSTERTHE DC VOLTMETER INDICATES THE AMOUNT THE BATTERY IS BEING CHARGEDPREHEAT PRESSED ENERGIZES THE SHOULb SHOW 13V TO 14VALTERNATORS EXCITER THE FUEL LIFT PUMP THE AUTOMATIC ALARM SYSTEMFUEL SOLENOID ON THE INJECTION PUMP AND THEENGINES GLOW PLUGS IT BYPASSES THE ENGINESOIL PRESSURE ALARM SWITCH IN ADDITION THIS I SUPPLIED WITH THE INSTRUMENT PANEL IF THE ENGINES COOLANTBUTTON ENERGIZES THE START BUTTON REACHES 210 F 99C THIS SWITCH WILL CLOSE SOUNDING THE ALARM WHICH WILL EMIT A CONTINUOUS SIGNALSTART BUTTON WHEN PRESSED ENERGIZES THESTARTERS SOLENOID WHICH CRANKS THE ENGINE OIL PRESSURE ALARM AN OIL PRESSURE ALARM SWITCH ISTHIS BUTTON WILL NOT OPERATE ELECTRICALLY LOCATED OFF THE ENGINES OIL GALLERY THIS SWITCH MONITORSUNLESS THE PREHEAT BUTTON IS PRESSED AND HELD THE ENGINES OIL PRESSURE SHOULD THE ENGINES OIL PRESSUREAT THE SAME TIME FALL TO 5 10 psi 04 07 kgem THE SWITCH WILL CLOSE SOUND ING THE ALARM IN THIS EVENT THE ALARM WILL EMIT A PULSATING SIGNAL Engines Generators 5 DIESEL FUEL ENGINE OIL AND ENGINE COOLANTDIESEL FUEL OIL PRESSUREUse fuel that meets the requirements or specification of Class The engines oil pressure during operation is indicated2D ASTM and has a cetane rating of 45 or better by the oil pressure gauge on the instrument panel During normal operation the oil pressure will range between 25 andCare Of The Fuel Supply 85 psiUse only clean diesel fuel The clearance of the components NOTE A newly staned cold engine can have an oil pressurein your fuel injection pump is very critical invisible dirt reading up to 85 psi A warmed engine can have an oil presparticles which might pass through the filter can damage sure reading as low as 25 psi These readings will varythese finely finished parts It is important to buy clean fuel depending upon the temperature of the engine the loadand keep it clean The best fuel can be rendered unsatisfac placed on the engine and the RPMstory by careless handling or improper storage facilities Toassure that the fuel going into the tank for your engines daily ENGINE COOLANTuse is clean and pure the following practice is advisable WESTERBEKE recommends a mixture of 50 a wellknown brand of fuel and 50 distilled water Distilled water is free from theInstall and regularly service a good visualtype fuel chemicals that can corrode internal engine separator between the fuel tank and the engine The antifreeze performs double duty It allows the engine toThe Raycor 445 or larger is a good example of such a filter run at proper temperatures by transferring heat away from the engine to the coolant and lubricates and protects the coolingENGINE OIL circuit from rust and corrosion Look for a good quality antifreeze that contains Supplemental Cooling API Grade CF or CG4 SCAs that keep the antifreeze chemically balanced API Grade CG4 to long term protectionUse the heavy duty engine oils as specified above Change The distilled water and antifreeze should be premixed beforethe engine oil after an initial 50 hour breakin period and being poured into the cooling circuitevery 100 hours of operation thereafter NOTE Look for the new long lastingEngine oil viscosity largely affects engine startability perfor antifreeze that is now availablemance oil consumption speed of wearing and occurrence ofseizure etc Using lubricants whose viscosity is selected Antifreeze mixtures will protect against an unexpected to the atmospheric temperature is important and they are beneficial to the engines cooling system They retard rust and add to the life of the circulating pump seal ENGINE OIL VISCOSITY CHART ENGINE OIL VISCOSITY GRADE AMBIENT TEMPERATURE ANTIFREEZE PROTECTION I SAE 2020W SA 40501 Antifreeze Concentration 23 30 35 50 I I SAE lOW 1 SAE 30 I Freezing Temperature 14F 8F 10C 13C COOLANT RECOVERY TANK A coolant recovery tank kit is supplied with each WESTERBEKE diesel engine The purpose of this recovery tank is to allow for engine coolant expansion and contraction during engine operation without the loss of coolant and A CAUTION Do not allow two or more brands of without introducing air into the cooling system This kit is engine oil to mix Each brand contains its own additives provided and must be installed before operating the engine additives of different brands could react in the mixture NOTE This tank with its short run of plastic hose must be to produce properties harmful to your engine located above the level of the engines manifold Engines Generators 6 PREPARATIONS FOR INITIAL starting your engine for the first time or after a prolonged layoff check the following itemsD Check the engine oil level Add oil to maintain the level at the high mark on the dipstick DIPSTICK PUSH IN TIGHTD Turn on the fuel supply then check the fuel supply and examine the fuel filterwater separator bowl for contami nantsD Check the transmission fluid leveL NOTE Refer to the previous page for fuel oil and transmission fluidD Check the DC electrical system Inspect wire connections and battery cable connections Make certain the positive battery cable is connected to the starter solenoid and the negative cable is connected to the engine ground stud this location is taggedD Check the coolant level in both the plastic recovery tank and at the manifold NOTE If the engine has not yet been filled with coolant refer to the COOLING SYSTEM section of this manualD Visually examine the engine Look for loose or missing parts disconnected wires and unattached hoses Check the threaded connections and engine attachmentsD Make certain there is proper ventilation around the engine An ample supply is necessary for proper engine performanceD Make sure the mounting installation is secure II D Ensure the propeller shaft is securely attached to the transmission D Open the throughhull and make certain raw water is primed to the raw water strainer 1 1 I 1 I ll i j CcCr COOLANT PRESSURE CAP MANIFOLD Engines Generators 7 PROCEDURETHE STARTING SYSTEM 5 Should the engine not start when the START button is depressed for 10 to 20 seconds release both buttons andThese marine diesel engine have l2V DC electric starters The wait 30 seconds repeat the procedure above and preheatstart circuitry is designed so that the PREHEAT button must longer Never run the starter for more than 30 secondsbe depressed for the time specified in the preheat chart Thenwhile keeping the PREHEAT button engaged the STARTbutton is depressed to crank the engine A CAUTION Prolonged cranking Intervals Procedure the engine starting can result in the engine exhaust1 Place the transmission in neutral and advance the throttle system filling wfth raw water This may happen because control to slightly open the pump Is pumping raw water through the raw water cooling system during cranking This raw water can enter the engines cylinders by way of the exhaust A CAUTION Make certain the transmission is manifold once the exhaust system fills Prevent this in neutral Starting in gear could result in serious from happening by closing the raw water supply damage to your transmission your boat and throughhull shutoff draining the exhaust muffler and vessels nearby correcting the cause of the excessive engine cranking2 Turn the KEY SWITCH to the ON position 2 oclock Engine damage resulting from raw water entry is not a warrantable issue the owneroperator should keep this3 Depress the PREHEAT switch The voltmeter panel lights gauges meters and fuel solenoid will be activated in mind The PREHEAT switch should be depressed in accordance with the following chart 6 Once the engine starts check the instruments for proper oil pressure and battery charging voltage NOTE Never attempt to engage the starter while the Atmospheric Temperature Preheating TIme engine is running 41F5C or higher Approx 5 seconds 41F5C to 23F 5C Approx 10 seconds Starting Under Cold Conditions 23F5C or lower Approx 15 seconds Make sure the lubricating oil is appropriate for the prevailing temperature Use oil with an API Specification of CF or CG4NOTE The START button will not energize unless the PRE SAE 30 lOW30 or 15W40 or 20W40HEAT button is depressed Depressing the PREHEAT button The battery should be fully charged to minimize voltage dropactivates the glow plugs in the cylinder head so use the PRE Use a sufficient amount of preheat to aid in starting See theHEAT intemittently to avoid overheating the glow plugs chart elsewhere in this section4 While still depressing the PREHEAT switch depress the START switch This will engage the starter solenoid Stopping Procedure Upon engine starting release the START switch and To stop the engine bring the throttle to an idle position and release the PREHEAT switch place the transmission in neutral Allow the engine to idle for a few moments to stabilize temperatures Turn the engine off using the stop control cable NOTE Make certain this key switch is in the OFF position 12 oclock If the key switch is left ON the battery will 12 I 14 discharge An engine alarm buzzer is provided to warn theNOTE When starting 6 operator of this condition key switch ON The best method of preventing the battery from discharging is to remove theA voltage drop will occurwhen the preheat button I key from the key switch after stopping the engineis depressed LJ i VOLTS ALTERNATOR WARNINGS The Admiral Control Panel uses a voltmeter to monitor the performance of the alternator COOLANT TEMPERATURE SWITCH A coolant temperature switch is located on the thermostat housing This switch will activate a continuous alarm if the coolants operating temperature reaches approximately 210F 99C Engines Generators 8 WARNING LIGHTS ALARMS CIRCUIT WARNINGS LOW OIL PRESSURE ALARM SWITCHThe Admiral Control Panel uses a voltmeter to monitor the A low oil pressure alarm switch is located off the of the alternator oil gallery This switchs sensor monitors the engines oil pressure Should the engines oil pressure fall to 5 IO psiCOOLANT TEMPERATURE SWITCH 04 07 kgcm2 this switch will activate a pulsating alarmA coolant temperature switch is located on the This switch will activate a continuous alarm if the ENGINE CIRCUIT operating temperature reaches approximately 2IOOF The DC harness on the engine is protected by an engine99C mounted manual reset circuit breaker 20 amps DC AIR BLEED Excessive current draw or electrical overload anywhere in the PETCOCK instrument panel wiring or engine wiring will cause theCOOLANT TEMPERATURE breaker to trip In this event most engines will shut downSENDOR because the opened breaker disconnects the fuel supply If this should occur check and repair the source of the problem After repairing the fault reset the breaker and restart the engine OIL PRESSURE SWITCH NORMALLY OPEN I THERMOSTAT HOUSING OIL PRESSURE SEND OR FROM ENGINE BLOCK Engines Generators 9 ENGINE BREAKIN 3 While using the vessel run the engine at various engine speeds for the first 25 hours Avoid prolonged periods ofAlthough your engine has experienced a minimum of one idlinghour of test operations at the factory to make sure procedures were followed and that the engine oper 4 Avoid rapid acceleration especially with a cold engineated properly a breakin time is required The service life of 5 Use caution not to overload the engine The presence of ayour engine is dependent upon how the engine is operated grey or black exhaust and the inability of the engine toand serviced during its initial 50 hours of use reach its full rated speed are signs of an a new engine basically involves seating the pis 6 During the next 25 hours the engine may be operated atton rings to the cylinder walls Excessive oil consumption varying engine speeds with short runs at full rated rpmand smoky operation indicate that the cylinder walls are Avoid prolonged idling during this breakin periodscored which is caused by overloading the engine during thebreakin period CHECK LISTYour new engine requires approximately 50 hours of initial o Monitor the control panel operation to break in each moving part in order o Check for leaks of fuel and engine oilto maximize the performance and service life of the engine o Check for abnormal noise such as knocking this conditioning carefully keeping in mind the fol vibration and blowback soundslowing o Confirm exhaust smoke1 Start the engine according to the STARTING PROCE When the engine is cold white smoke DURE section Run the engine at fast idle while checking When the engine is warm almost smokeless that all systems raw water pump oil pressure battery When the engine is overloaded some black smoke and soot charging are functioning NOTE See the TRANSMISSION section of this manualfor2 Allow the engine to warm up preferably by running at breakin information on your transmission fast idle until the water temperature gauge moves into the 130 140F 55 60C range Engines Generators 10 THE DAILY ROUTINECHECK LIST STARTING THE ENGINEEach day before starting your engine take a few moments to NOTE See PROCEDURE in thisrun this check list manual for more detailed instructionso Visually inspect the engine for fuel oil or water leaks 1 Put the transmission in neutral throttle advancedo Check the oil levelo Check the transmission fluid level NOTE Hydraulically operated transmissions have a neutral safety switch through which the starter solenoido Check for loose wires at the alternator energizing circuit passes This switch is open when theo Check the starting batteries weekly transmission is in gear so the starter solenoid will noto Check drive belts for wear and proper tension weekly energizeo Log your engine running time These hours relate to 2 Tum the KEY to the ON position 2 oclock scheduled maintenance 3 Depress PREHEAT 5 secondso Check fuel supply always keep fuel tanks as full as 4 While pressing PREHEAT push START As the engine possible fires release START and PREHEATo Look for clean fuel in the fueVwater separator bowl NOTE Some unstable running may occur in a coldo Check the coolant level in the plastic recovery tank engine This condition should abate as normal operatingNOTE Excessive loss of coolant indicates a cooling system temperature is reached and loads are appliedleak Check the entire system If necessary use a cooling sys NOTE Should the engine fail to start wait 30 secondstem pressure tester to pressurize the cooling system to locate then repeat the above procedure and PREHEAT longerthe area of leakage III cases of excessive coolant loss refill 5 Allow a few minutes for the engine to warm at a comthe svstem as outlined in the ENGINE COOLANT CIRCUIT fortable rpm approximately 1200 rpm then reduce thesectin of this manual rpm and get underway A CAUTION When shifting the transmission always reduce the engine rpm to idle then shift the transmis sion firmly from one direction to another A slight pauSe in neutral will allow the propeller to slow Shifting at high rpm will damage the plate Engines Generators 11 MAINTENANCE SCHEDULEIn order to use this Maintenance Schedule it will be necessary to log your engine hours Use your engine hounneter or A WARNING Never attempt to perform any servicerecord your engine hours by running time while the engine is running Wear the proper safetyNOTE Many atheallowing maintenance procedures are equipment such as goggles and gloves and use thesimple but others are more difficult and may require the correct tools for each job Disconnect the batteryexpert knowledge 0 a service mechanic terminals when servicing any of the engines DC electrical equipment SCHEDULED CHECK HOURS OF OPERATION MAINTENANCE DESCRIPTION MAINTENANCE EACH DAY 50 100 250 500 750 1000 1250 Fuel Supply 0 Diesel No2 rating of 45 cetane or higher FuelWater Separator 0 Check for water and dirt in fuel drainreplace filter if necessary Engine Oil Level 0 Oil level should indicate between MAX and LOW on dipstick Coolant Level 0 Check at recovery tank if empty check at manifold Add coolant if needed Transmission Fluid Level 0 Fluid level should indicate between MAX and LOW on dipstick Drive Belts 0 Inspect for proper tension 38 to 12 deflection weekly and adjust if needed Check belt edges for wear Visual Inspection of Engine 0 NOTE Keep engine surface clean Dirt and Check for fuel oil and water leaks Inspect wiring oil will inhibit the engines ability to remain and electrical connections Keep bolts nuts tight cool Check for loose belt tension Fuel Filter 0 0 0 0 0 0 Change at 50 hours then every 250 hours Starting Batteries 0 Check electrolyte levels every 50 operating hours and House Batteries weekly and make sure connections are very tight Clean off excessive corrosion Engine Oil and Filter 0 0 0 0 0 0 0 Initial engine oil filter change at 50 hours then change both every 100 hours Heat Exchanger Zinc Anode 0 0 0 0 0 0 0 Inspect zinc anode replace if needed Clear the heat exchanger end of zinc anode debris FuelWater Separator 0 0 0 0 0 0 Change filter every 200 hours Exhaust System 0 0 0 0 Initial check at 50 hours then every 250 hours Inspect for leaks Check antisiphon valve opera tion Check the exhaust elbow for carbon andor corrosion buildup on inside passages clean and replace as necessary Check that all connections are tight Check casting integrity Engine Hoses 0 0 0 0 0 0 Hose should be hard tight Replace if soft or spongy Check and tighten all hose clamps Throttle and Transmission 0 0 0 0 Check for loose fittings cotter pins etc Control Cable Lubricate with WD40 or equivalent Raw Water Pump 0 0 0 Remove the pump cover and inspect the impeller gasket cam and cover for wear Check the bearings and seals the shaft can turn but not wobble Lubricate when reassembling continued Engines Generators 12 MAINTENANCE SCHEDULE NOTE Use the engine hourmeter gauge to log your engine hours or record your engine hours by running time SCHEDULED CHECK HOURS OF OPERATION MAINTENANCE EACH MAINTENANCE DESCRIPTION DAY 50 100 250 500 750 1000 1250 Coolant System 0 0 Drain flush and refill cooling system with appropriate antifreeze mix DC Alternator 0 0 0 Check DC charge from alternator Check mounting bracket tighten electrical connections Transmission Oil Cooler 0 Remove have professionally cleaned and pressure tested Engine Transmission 0 Chattering at idle and low rpms is an indication Damper Plate of damper plate wear Remove and replace Fuellnjectors 0 Check and adjust injection opening pressure and spray condition Refer to your service manual Starter Motor 0 0 Check solenoid and motor for corrosion Remove and lubricate Clean and lubricate the starter motor pinion drive Preheat Circuit 0 0 Check operation of preheat solenoid Remove and clean glow plugs Reinstall with antiseize compound on threads Engine Cylinder 0 0 Check compression pressure and timing Compression see ENGINE ADJUSTMENTS Adjust the Valve Clearances 0 0 0 Adjust Valve Clearances see ENGINE ADJUSTMENTS Heat Exchanger 0 Remove have professionally cleaned and pressure tested Lubricate Panel Key Switch 0 0 0 0 0 0 At first 100 hours then each year at winterizing with Lockeze Transmission 0 0 0 0 0 0 Initial fluid change at 25 hours then every Fluid and Filter 300 hours or at winterizing Replace the filter at each fluid change Feed Pump Strainer 0 0 0 0 0 Clean every 250 operating hours Turbocharger 0 0 Initial 50 hour check inspect all connections for oil and exhaust leaks Check mounting bolts for tightness Check for air leakage Inspect the radial and axil play of the rotor shaft Lubricate the shaft recommends this service be performed by an authorized mechanic Engines Generators 13 COOLING NOTE Periodically check the condition of the manifold presWesterbeke marine diesel engines are designed and equipped sure cap Ensure that the upper and lower rubber seals are illfor fresh water cooling Heat produced in the engine by good condition and check that the vacuum valve opens andcombustion and friction is transferred to fresh water coolant closes tightly Carry a spare capwhich circulates throughout the engine This circulating freshwater coolant cools the engine block its internal movingparts and the engine oil The heat is transferred externallyfrom the fresh water coolant to raw water by means of a heatexchanger similar in function to an automotive radiator Rawwater flows through the tubes of the heat exchanger whilefresh water coolant flows around the tubes engine to the fresh water coolant is conducted throughthe tube walls to the raw water which is then pumped into theexhaust system where finally it is discharged overboard In CHANGING COOLANTother words the engine is cooled by fresh water coolant this The engines coolant must be changed according to thecoolant is cooled by raw water and the raw water carries the MAINTENANCE SCHEDULE If the coolant is allowed totransferred heat overboard through the exhaust system The become contaminated it can lead to overheating problemsfresh water coolant and raw water circuits are independent ofeach other Using only fresh water coolant within the engineallows the cooling water passages to stay clean and free from A CAUTION Proper cooling system maintenance is harmful deposits critical a substantial number of engine faiures can be traced back to cooling system corrosionFRESH WATER COOLING CIRCUITNOTE Refer to the ENGINE COOLANT section for the rec Drain the engine coolant by loosening the drain plug on theommended antifreeze and water mixture to be used as the engine block and opening the manifold pressure cap Flushfresh water coolant the system with fresh water then start the refill processFresh water coolant is pumped through the engine by acirculating pump absorbing heat from the engine Thecoolant then passes through the thermostat into the manifold A WARNING Beware of the hot engine coolantto the heat exchanger where it is cooled and returned to the Wear protective glovesengine block via the suction side of the circulating pumpWhen the engine is started cold external coolant flow isprevented by the closed thermostat although some coolantflow is bypassed around the thermostat to prevent the from overheating As the engine warms up thethermostat gradually opens allowing full flow of the enginescoolant to flow unrestricted to the external portion of thecooling systemCoolant Recovery TankA coolant recovery tank allows for engine coolant expansionand contraction during engine operation without anysignificant loss of coolant and without introducing air intothe cooling system This tank should be located at or abovethe engine manifold level and should be easily accessible TO COOLANT RECOVERY DRAIN PLUG TANK I DRAIN PETCOCK COOLANT RETRACTION COOLANT EXPANSION I SOME ENGINE MODELS ARE EQUIPPED WITH A PETCOCK THAT ALLOWS FOR Engines Generators A HOSE TO BE ATTACHED 14 COOLING the Coolant Replacing the closing the engine block drain pour clean premixed Remove the cap screws and disassemble the thermostat houscoolant into the manifold and when the coolant is visible in ing as shown When installing the new thermostat and gasketthe manifold start the engine and run it at slow idle Open apply a thin coat of sealant on both sides of the gasket beforethe air bleed petcocks on the manifold and the thermostat pressing it into place Do not overtighten the cap screwshousing Run the engine and check for normal temperatures and thatMonitor the coolant in the manifold and add as needed Fill there are no leaks at the thermostat housingthe manifold to the filler neck and when the coolant flowingfrom the petcock is free of air bubbles close the petcock andinstall the pressure capRemove the cap on the coolant recovery tank and fill withcoolant mix to halfway between LOW and MAX and replacethe cap Run the engine and observe the coolant expansionflow into the recovery tank When the petcock on thethermostat housing is free of air bubbles close that petcockAfter checking for leaks stop the engine and allow it to coolCoolant should draw back into the cooling system as theengine cools down Add coolant to the recovery tank ifneeded Clean up any spilled coolant AIR BLEED TEMPERATURE PETCOCK y Q 11 0r1 j ijj THE GASKET IS GROOVED FITS AROUND THE OUTER EDGE OF THE IA thennostat located near the manifold at the front of theengine controls the coolant temperature as the flows through the closed cooling circuitWhen the engine is first started the closed thermostat prevents coolant from flowing some coolant is a hole in the thermostat to prevent the from overheating As the engine warms up thethermostat gradually opens The thermostat is accessibleand can be checked cleaned or replaced easily Carry a CHANGING THE thermostat and gasket Engines Generators 15 COOLING SYSTEMRAW WATER COOLING CIRCUIT Changing the Raw Water Pump ImpellerThe raw water flow is created by a positive displacement Close the raw water intake valve Remove the pump coverimpeller pump This pump draws water directly from the raw and with the aid of an impeller puller carefully pry thewater source ocean lake or river through a hose to the impeller out of the pump Install the new impeller and gasketwater strainer The raw water passes from the strainer Move the blades to conform to the curved cam plate andthrough the raw water pump to the heat exchanger through push the impeller into the pumps housing When assemthe heat exchanger tubes where it cools the engine circulat bling apply a thin coating of lubricant to the impeller anding fresh water coolant The raw water is then discharged gasket Open the raw water intake valveinto the waterinjected exhaust elbow mixing with and cool To be certain the pump is operating properly run the engineing the exhaust gasses This mixture of exhaust gas and raw and check the followingwater is discharged overboard by the engines exhaust gasdischarge pressure o Inspect the raw water pump for leaks o After warm up monitor the temperature gauge It shouldRaw Water Pump indicate a normal engine temperatureThe raw water pump is a selfpriming rotary pump with a o Check aft There should be a steady flow of water fromnonferrous housing and a neoprene impeller The impeller the stem tubehas flexible vanes which wipe against a curved cam platewithin the impeller housing producing the pumping actionOn no account should this pump be run dry as water acts as a A CAUTION If any of the vanes have broken off thelubricant for the impeller There should always be a spare impeller they must be found to prevent blockage in theimpeller and impeller cover gasket an impeller kit aboard cooling circuit They onen can be found in the heatRaw water pump impeller failures occur when lubricant raw exchangerwater is not present during engine operation Such failuresare not warrantable and operators are cautioned to make sureraw water flow is present at startup Impeller PullerNOTE Should a failure occur with the pumps internal parts WESTERBEKE recommends using an impeller puller toseals and bearings it may be more cost efficient to pur remove the impeller this will prevent damage to the bladeschase a new pump and rebuild the original pump as a spare and to the edges of the pump housing IMPELLER INSPECTION CHECK AT THE BASE OF EACH BLAOE BY BENDING VIGOROUSLY REPLACE THE IMPELLER IF THERE ARE ANY CRACKS WATER LEAKING HERE WOULD WHEN INSTALLING TAKE CARE TO ALIGN INDICATE THE PUMP SEAL HAS THE IMPELLER KEYWAY WITH THE SHAFT FAILED AND THE PUMP NEEDS KEY FOLD THE IMPELLER BLADES IN IMMEDIATE SERVICE EITHER DIRECTION THEY WILL TURN IN THE CORRECT POSITION WHEN THE PUMP STARTS GREASE THE BLADES AND THE PUMP CHAMBER WITH PETROLEUM JELLY TO PROVIDE LUBRICATION FOR THE FEW SECONDS THE PUMP HAS TO RUN DRY THE GREASE IMPROVES THE SEAL OF THE BLADES AND MAKES INSTALLATION EASIER ftHOUSING THE ORING GASKET RAW WATER PUMP ONLY NEEDS TO BE REPLACED IF IT SHOWS SIGNS OF WEAR Engines Generators 16 COOLING SYSTEMHEAT EXCHANGERThe heat exchanger is a copper cylinder which encloses alarge number of small copper tubes Raw water is pumpedthrough the small copper tubes and the fresh water coolant ZINC ANODESfrom the engine is circulated around the copper tubes Theraw water removes heat from the fresh water coolantHeat Exchanger ServiceAfter approximately 1000 hours of operation remove cleanand pressure test the engines heat exchanger A local automotive radiator shop should be able to clean and test the heatexchanger NEW REPLACE CLEAN REUSENOTE Operating in silty andor tropical waters may require If the zinc anodes need replacement hold the hex boss intothat a heat exchanger cleaning be perfonned more often than which the zinc anode is threaded with a wrench while loosevery 1000 hours ening the anode with another wrench This prevents the hex boss from possibly tearing off the exchanger shell AfterZinc Anode removing the zinc note the condition of it If the zinc is inA zinc anode or pencil is located in the raw water cooling poor condition there are probably a lot of zinc flakes withincircuit within the heat exchanger The purpose of having the exchanger Remove the end of the heat exchanger andzinc anodes is to sacrifice them to electrolysis action taking clean the inside of all zinc debris Always have a spare heatplace in the raw water cooling circuit thereby reducing the exchanger end gasket in case the present one becomes dameffects of electrolysis on other components of the system aged when removing the end cover Replace the gasket referThe condition of the zinc anode should be checked monthly to your engine models heat exchanger end gasket part numand the anode cleaned or replaced as required Spare anodes ber Oring and cover and install a new zinc anodeshould be carried on board NOTE The threads of the zinc anodes are pipe threads andNOTE Electrolysis action is the result of each particular do not require sealant Sealant should not be used as it and vessel location not that of the engine insulate the zinc from the metal of the heat exchanger hou ing preventing electrolysis action on the zinc CLEAN OUT ACCUMULATED DEBRIS CLEAN OUT BOTH ENDS ZINC ANODE ALSO SERVES AS A DRAIN FOR THE RAW WATER SYSTEM HEAT EXCHANGER GASKET TO REMOVE HEAT EXCHANGER 17 COOLING SYSTEMRaw Water Intake Strainer NOTE Also follow the above procedure after having run hard agroundNOTE Always install the strainer at or below the waterline sothe strainer will always be selfpriming If the engine temperature gauge ever shows a higher than normal reading the cause may be that silt leaves or grassA clean raw water intake strainer is a vital component of the may have been caught up in the strainer slowing the flow ofengines cooling system Include a visual inspection of this raw water through the cooling systemstrainer when making your periodic engine check The waterin the glass should be clearPerform the following maintenance after every 100 hours ofoperation1 Close the raw water seacock2 Remove and clean the strainer filter WASHER3 Clean the glass4 Replace the washer if necessary5 Reassemble and install the strainer6 Open the seacock7 Run the engine and check for leaks STRAINER FILTER TYPICAL RAW WATER INTAKE STRAINER tOwner Installed AIR INTAKE FILTER CONNECTS TO ARM COVERA marine diesel engine will typically consume as much as6000 cubic feet of air per hour Not only must the engineroom be well ventilated the air flow into the engine must beunrestricted The air intake filtercleaner should be inspectedevery 100 operating hours Cleanreplace when needed AIR INTAKE FILTER Engines Generators 18 FUEL SYSTEMDIESEL FUEL FUEL FILTERSUse No2 diesel fuel with a cetane rating of 45 or higher Do not The fuel injection pump and the fuel injectors are preciselyuse kerosene or home heating fuel manufactured and they must receive clean diesel fuel free from water and dirt To ensure this flow of clean fuel the fuelFUEL WATER SEPARATOR must pass through at least two fuel filters a fuelwater sepaA primary fuel filter of the water separating type must be rator and the engines spinon fuel filter Visually between the fuel tank and the engine to remove clean and change these filters according to the and other contaminants from the fuel before they can schedule in this manualbe carried to the fuel system on the engine Most installers include a type of filterwater separator with the installation package as they are aware of the problems A WARNING Shut off the fuel valve at the tank that contaminants in the fuel can cause when servicing the fuel system Take care in catching any fuel that may spill DO NOT allow any smoking A typical fuel filterwater separator is iIIustrated below This open flames or other sources of fire near the fuel is the Raycor Model 445 Keep in mind that if a water system when servicing Ensure proper ventilation exists separator type filter is not installed between the fuel supply when servicing the fuel system tank and enginemounted fuel system any water in the fuel will affect the fuel pump engine filter and injection equipment The owneroperator is responsible for making certain the fuel reaching the engines injection equipment is free of impurities This process is accomplished by installing and maintaining a proper systemFUEL FILTERWATER SEPARATOROwner Installed LIGHTLY WIPE WITH CLEAN FUEL TO LlFTPUMP AND INCOMING FUEL TO INJECTION PUMP Changing the Fuel Filter 1 Shut the fuel supply off 2 Loosen the fuel filter turning with a FUEL INJECTION PUMP filter wrench Place the used filter in a container for proper disposal The fuel injection pump is a very important component of the diesel engine requiring the utmost care in handling The fuel 3 Using a rag wipe clean the sealing face on the housing injection pump has been thoroughly benchtested and the bracket so the new filter can be seated properly owneroperator is cautioned not to attempt to service it If it 4 Lightly oil the sealing Oring on the new filter To rein requires servicing remove it and take it to an authorized fuel stall turn the filter assembly carefully injection pump service facility Do not attempt to disassemble until the Oring contacts the sealing surface of the housing and repair it bracket Turn 23 further with the filter wrench The only adjustment the servicing mechanic should make to the NOTE The cartridge contains fuel Take care not to spill it fuel injection pump is the adjustment for engine idle speed during disassembly FUEL LIFT PUMP The fuel lift pump is an integral part of the fuel injection pump Engines Generators 19 FUEL SYSTEMFUEL FEED PUMP STRAINER BLEEDING PRIMING THE FUEL SYSTEMAn additional fuel screen is located in the feed pump This 1 Loosen the bleeding screw on the fuel injection pumpscreen strainer is removed for cleaning by releasing the 2 Tum the feed pump knob until the pumpbanjo bolt at the bottom This screen should be cleaned every knob is forced up by the spring250 operating hours Use compressed air andor clean withkerosene 3 Depressing the pump knob will cause it to drain out the air mixed fuel from the loosened bleeding screws TO FUEL FILTER 4 Repeat the pumping action until no bubbles are visible in the flowing fuel 5 Tighten the bleed screw and the feed pump knob FUEL ADDITIVES If fungus or bacteria is causing fuel problems you should have INJECTION PUMP BLEED SCREW an authorized dealer correct these problems Then use a diesel fuel biocide to sterilize the fuel follow the manufacturers instructions SPARE PARTS FEED PUMP While the likelihood of having to service the system at sea is slim the possibility does exist Therefore we recommend that banjo washers injector seat washers and a fuel filter be carried on board at all times Purchase needed spare parts from your local FUEL FEED PUMP WESTERBEKE dealer or distributor If a leak should develop at a banjo washer that cannot be corrected by a simple tightening of the fitting replace the sealing washer with a replacement found in the hardware kit for your model 14 BANJO BOLTAfter changing the fuel filter and cleaning the fuel feed pumpstrainer WESTERBEKE recommends the following procedure for ensuring there is no air trapped in the fuel system Engines Generators 20 ENGINE LUBRICATING lubricating system is a pressure feeding system using an NOTE Generic filters are not recommended as the materoil pump The engine oil is drawn from the oil sump by the ial standards or diameters of important items on genericoil pump which drives the oil under pressure through the parts might be entirely different from genuine partsoil filter oil cooler and various lubricating points in the Immediately after an oil filter change and oil fill run theengine The oil then returns to the oil sump to repeat the engine to make sure the oil pressure is normal and thatcontinuous cycle When the oil pressure exceeds the there are no oil leaks around the new pressure the oil pushes open the relief valve in the 3 Filling the Oil Sump Add new oil through the oil filleroil pump and returns to the oil sump keeping the oil pressure cap on the top of the engine After refilling run thewithin its specified range engine for a few moments while checking the oil pressure Make sure there is no leakage around the newOil Pressure oil filter or from the oil drain system and stop the engineThe engines oil pressure during operation is indicated Then check the quantity of oil with the lube oil dipstickby the oil pressure gauge on the instrument panel During Fill to but not over the high mark on the dipstick shouldnormal operation the oil pressure will range between 25 and the engine require additional oil85 psiENGINE OIL CHANGE1 Draining the Oil Sump Discharge the used oil through the sump drain hose attached to the front of the engine while the engine is wann Drain the used oil completely replace the hose in its bracket and replace the end cap SPIN ON 1 OIL FILTER urely FOR EXTENSION TURN HAND TIGHT AGAINST 14 NPT ORING THEN TIGHTEN 23 OF A TURN SUMP DRAIN ORING HOSE APPLY CLEAN 600 ENGINE OIL WHEN INSTALLING Always observe the used oil as it is removed A yellowgray emulsion indicates the presence of water in the oil Although this condition is rare it does require prompt attention to prevent serious damage Call a qualified mechanic should water be present in the oil Raw water present in the oil can be the result of a fault in the exhaust system attached to the engine andor a siphoning of raw water through the raw water cooling circuit into the exhaust filling the engine This problem is often caused by the absence of an antisiphon valve its CUSTOMER OPTION poor location or lack of maintenance THIS WIRE CAN BE USED TO ATTACH A2 Draining the Oil Filter Back off the drain plug until oil GAUGE OR ALARM flows from the drain into an appropriate container After OEVICE TO MONITOR draining remove the filter and wipe off any excess oil THE CONDITION OF Tighten the drain plug THE OIL FILTER THE WIRE IS CURRENTLY When installing the new oil filter element wipe the BUNDLED INTO THE filters Oring gaskets sealing surface free of oil and WIRING HARNESS apply a thin coat of clean engine oil to the rubber Oring on the new oil filter Screw the filter onto the threaded oil filter nipple on the oil filter bracket and then tighten the CHANGING THE ENGINE OIL filter firmly by hand Engines Generators 21 REMOTE OIL FILTER To install simply remove the engine oil filter and thread on WESTERBEKEs remote oil filter kit as shown AlwaysThis popular accessory is used to relocate the engines oil fil install this kit with the oil filter facing down as illustratedter from the engine to a more convenient location such as anengine room bulkhead Contact your WESTERBEKE dealer for more Refer to ENGINE OIL CHANGE in this manualfor NOTE Westerbeke is not responsible for engine failure due on removing the oil filter incorrect installation of the Remote Oil Filter A CAUTION It Is Ifltal to Install the oillnes correctly If the 011 flows In themvelSB dlmctlon the bypass valve In the filter assembly will prevent the 011 FASTEN SECURelY TO A BULKHEAD from reaching the engine causing an Intemal engine SCREWS ARE OWNER SUPPLIED failure If there Is no 011 pmssuTB reading shutdown immediately and check the hose connections NOTE THE IN AND OUT MARKINGS ON THE ADAPTER WHEN THE HOSES ARE REMOVED FOR INSTALLATION SO THEY WILL BE RECONNECTED CORRECTLY I APPLY A THIN COAT OF CLEAN OIL TO THE FIL TER GASKET WHEN INSTALLING AFTER THE APPLY A COAT OF CLEAN OIL TO THE ORING WHEN FILTER CONTACTS THE BASE TIGHTEN IT AN INSTALLING THIS KIT THREAD THE KIT ON THEN HAND ADDITIONAL 34 TURN TIGHTEN AN ADDITIONAL 34 TURN AFTER THE ORING CONTACTS THE BASE Engines Generators 22 WATER HEATER CONNECTION OPTIONALAs an accessory WESTERBEKE wiJI provide a connector The water heater shouKl be mounted in a convenient locationthat directs the engines hot water coolant flow to heat the either in a high or low position in relation to the engine sofresh water in the ships hot water tank that the connecting hoses from the heater to the engine can run in a reasonably direct line without any loops which might trap air Hoses should rise continuously from their low point at the ROCKER COVER heater to the engine so that air will rise naturally from the heater to the engine If trapped air is able to rise to the heater then an air bleed petcock must be installed at the higher fitting on the heater for bleeding air while filling the system NOTE If any portion of the heating circuit rises above the engines closed cooling system pressure cap then a pressur ized aluminum remote expansion tank Kit 024177 must be installed in the circuit to become the highest point Tee the remote expansion tank into the heater circuit choosing the higher of the two connections for the return Tee at the heater and plumb a single line up to the tanks location andENGINE the other back to the engines return Install the remoteFRONT expansion tank in a convenient location so the fresh water coolant level can easily be checked The remote expansion tank will now serve as a check and system fill point The plastic coolant recovery tank is not used when the remote HOSES expansion tank kit is installed since this tank serves the CONNECT TO same function THE HOT WATER TANK EITHER CONNECTION CUT THE DISCARDED MOLDED HOSE TO PROVIDE THE TWO HOSE CONNECTIONS THAT REMOTE EXPANSION ARE NEEDED TO ATTACH TANK THE CONNECTOR TO THE ENGINE WATER WATER HEATER HEATER Engines Generators 23 DC ELECTRICAL SYSTEM ALTERNATOR 1 Start the engine The charging system consists of a DC belt driven alternator 2 After the engine has run for a few minutes measure the with a voltage regulator an engine DC wiring harness a starting battery voltage at the battery terminals using a mounted DC circuit breaker and a battery with connecting multimeter set on DC volts cables Because of the use of integrated circuits lCs the a If the voltage is increasing toward 14 volts the alterna electronic voltage regulator is very compact and is mounted tor is working omit Steps 3 through 8 and go directly internally or on the back of the alternator to Checking the Service Battery on the next page hIf the voltage remains around 12 volts a problem exists with either the alternator or the charging circuit 14 GRAyw continue with Steps 3 through 8 CIDJ14 PINK fiC14 BLUE 914 BROWN MULTIMETER o COM iBlillili 10 REO SEE WIRING DIAGRAM ENGINE FOR WIRE CONNECTIONS GROUND 1 TO OPTIONAL ALTERNATORS ALTERNATOR TESTING THE STARTING ENGINE RUNNING A WARNING A failed alternator can become very hot 00 not touch until the alternator has cooled down GROUND Use this section to determine if a problem 3 Turn off the engine Inspect all wiring and connections exists with the charging circuit or with the alternator If it is Ensure that the battery terminals and the engine ground determined that the alternator or voltage regulator is faulty connections are tight and clean have a qualified technician check it The alternator charging circuit charges the starting battery A CAUTION To avoid damage to the battery and the service battery An isolator with a diode a solenoid charging circuit never shut off the engine battery or a battery selector switch is usually mounted in the circuit switch when the engine is running to isolate the batteries so the starting battery is not discharged along with the service battery If the alternator is charging the 4 If a battery selector switch is in the charging circuit starting battery but not the service battery the problem is in ensure that it is on the correct setting the service batterys charging circuit and not with the alterna S Turn on the ignition switch but do not start the engine tor 6 Check the battery voltage If the battery is in good condi Testing the Alternator tion the reading should be 12 to 13 volts Cl2ID A CAUTION Before starting the engine make certain that everyone is clear of moving parts Keep away from sheaves and belts during test procedures WMULTIMETER A WARNING When testing with a multimeter DC and AC circuits are often mixed together in marine applications Always disconnect a shore power cord isoate DC and AC converters and shut down the engine TESTING THE before performing DC testing No AC tests should be ALTERNATOR VOLTAGE made without a proper knowedge of AC circuits IGNITION ON ENGINE OFF Engines Generators GROUND 24 DC ELECTRICAL SYSTEM7 Now check the voltage between the alternator output ter Checking the Service Battery minal B and ground If the circuit is good the voltage at Check the voltage of the service battery This battery should the alternator will be the same as the battery or if an isola have a voltage between 13 and 14 volts when the engine is tor is in the circuit the alternator voltage will be zero If running If not there is a problem in the service battery neither of the above is true a problem exists in the circuit charging circuit Troubleshoot the service battery charging between the alternator and the battery Check all the circuit by checking the wiring and connections the solenoid connections look for an opening in the charging circuit isolator battery switch and the battery itself MULTIMETER CI2ID WITCH 0 COM MumMETER i COM a I TESTING THE STARTING ENGINE RUNNING I8 Start the engine again Check the voltage between the ENGIN E GROUND alternator output and ground SERVICE BATTERY The voltage reading for a properly operating alternator should be between 135 and 145 volts If your alternator GROUND TESTING THE SERVICE is over or undercharging have it repaired at a reliable BATTERY ENGINE RUNNING service facility NOTE Before removing the alternator for repair use a voltmeter to ensure that 12 volts DC excitation is present at the EXC terminal if the previous test showed only bat A CAUTION To avoid damaging the alternator diodes tery voltage at the B output terminal do not use a high voltage tester ie a megger when performing tests on the alternator charging circuit If 12 volts is not present at the EXC terminal trace the wiring and look for breaks and poor connections12 VOLT DC CONTROL CIRCUIT Battery CareThe engine has a 12 volt DC electrical control circuit that is Review the manufacturers and thenshown on the wiring diagrams that follow Refer to these establish a systematic maintenance schedule for yourdiagrams when or when servicing the DC engines starting batteries and house system o Monitor your voltmeter for proper charging during engine operation A CAUTION To avoid damage to the battery charging o Check the electrolyte level and specific gravity with a hydrometer circuit never shut off the engine battery switch while the engine is running Shut off the engine battery SWitch o Use only distilled water to bring electrolytes to a proper level however to avoid electrical shorts when working on the engines electrical circuit o Make certain that battery cable connections are clean and tight to the battery posts and to your engineBAnERY o Keep your batteries clean and free of corrosionThe minimum recommended capacity of the battery used inthe engines 12 volt DC control circuit is 600 900 ColdCranking Amps CCA A WARNING Sulfuric acid in lead batteries can cause severe bums on skin and damage clothing Wear protective gear Engines Generators 25 GLOW PLUGS DESCRIPTION Reinstall the plugs in the engine and test them again The plugs should get very hot at the terminal end within 7 to 15 The glow plugs are wired through the preheat solenoid seconds If the plugs dont heat up quickly check for a short When PREHEAT is pressed at the control panel this solenoid circuit When reinstalling the glow plugs use antiseize com should click on and the glow plug should begin to get hot pound on the threads INSPECTION To inspect the plug remove the electrical terminal connec A WARNING Do not keep a glow plug on for more tions then unscrew or unclamp each plug from the cylinder than 30 seconds head Thoroughly clean each plugs tip and threads with a soft brush and cleaning solution to remove all the carbon and Glow Plug Tightening Torque 195 HIb 27 mkg oil deposits While cleaning examine the tip for wear and burn erosion if it has eroded too much replace the plug IC TERMINAL END TESTING An accurate way to test glow plugs is with an ohmmeter Touch one prod to the glow plugs wire connection and the other to the body of the glow plug as shown A good glow TESTING A GLOW PLUG plug will have a 04 06 ohm resistance This method can be WITH AN OHMMETER used with the plug in or out of the engine You can also use KEYIPREHEATQPi an ammeter to test the power drain 5 6 amps per plug A WARNING These glow plugs will become very hot TIP to the touch Be careful not to burn your fingers when testing the plugs TESTING A GLOW PLUG GLOW PLUGS USING A TEST LIGHT FROM Engines Generators 26 WIRING SCHEMATIC MARINE ENGINES 44781 8ATTERTI22VOC START SOl STARTER IZV 24V 20A lOA CB CB OPTIONAL ALTERNATORS e u c PRESlOLllE 12 AMP ALl TACHOMETER KEY SW 90 AMP ALl PREHEAT SWITCH DISCONNECT JUMPER fOR USE WITH TWO BATTERIES LESTEK 135 160 190 AMP ALT l ZUlli Engines Generators 27 WIRING DIAGRAM MARINE ENGINES 44781 ALTERNATOR 21Y 12A ItwrttJ I I USED aNEUTRAL WI rTY H DELSI BATTERY 1221 VDCNOTES NIS IOOUCI IS onenD IT 1iI IiIUAL tun ClIltUIl RUln LOCATED IIUI TME ITAnn attallV CUIIUT Will UUS Ttll ltUllII TO nIP AIID THE IIIII Will SI SMUT DOIIiI HE IUILOloIIIl MUST Sf SUII THU THE IISTIUIiIUT pln WIIIIG toIO IIGI AlE STALUD TO IIVUT COIICT enEU lECTlICAL OUlets AIID sUlun2 II allorr SWITCH ItOULD IE IUTALUI IUElI THE IHUr I STAUn TO DISCOIIT THE aTTU UI MUGUel liD II LlAWl1IG TME 10AT SWnCM WITH A COITIIIUGUS IUIG or 115 Allrs AT 12 DC WILL IlV THIS rUIICTlOI IMIS 1 TeM MOULD lOT IE uUD TO MAil 01 IAI THE C leUIT PIJ THE 11 11It AT LUG Z IS Iusn D SHOULD IE USULATED CAPUI un OIlU II ADMIRAL TME III AT UG 1 IS uusn 0 SMOULD liE IIilSULun ADlIIIAL u n Gell5 co lcr rill CIICUIl IIURU 0 USIUOt I ro l rUIIL rOt 12 WOlf nSTUS OIU FOt Z4 VOLT nSTtMs IMOVI rill Clleulr IIUIII 10 coler rill IUISTOI lIl ro rill 4 LT ILU WillS ID rill GlOUID rll rUM l PANEL I I I I I I I I I I I I I L 110 REO Engines Generators 28 ENGINE following table describes certain problems NOTE The engines electrical system is protected by a 20relating to engine service the probable causes of these prob ampere manual reset circuit breaker located on a bracket atlems and the to overcome these problems the back of the engine The preheat solenoid is mounted on the same bracket Problem Probable Cause No panel indications fuel solenoid 1 Battery switch not on 1 Check switch andor battery connections or fuel pump is not working key switch is on and PREHEAT button is depressed 2 20amp circuit breaker tripped 2 Reset breaker if breaker trips again check preheat solenoid circuit and check circuit for shorts to ground 3 10amp breaker tripped on 3 Check the voltage both at and after the breaker on the preheat solenoid preheat solenoid wait for it to cool then rest 4 Loose battery connections 4 Check connection to starter solenoid and connection to engine ground stud Check battery cable connections 5 Preheat solenoid not operating 5 Check solenoid S terminal for voltage START button is depressed no starter 1 Connection to solenoid faulty 1 Check connection engagement 2 Gear shift not in neutral 2 Gear shift must be in neutral see NEUTRAL SWITCH under HURTH TRANSMISSIONS 3 Faulty switch 3 Check switch with ohmmeter 4 Faulty solenoid 4 Check that 12 volts are present at the solenoid connection 5 Loose battery connections 5 Check battery connections 6 Low battery 6 Check battery charge state Engine cranks but does not 1 Faulty fueling system 1 Check that fuel valves are open start 1a Check for air in fuel system Bleed air from fuel system 1b Fuel filters clogged Replace filters and bleed air from fuel system 2 Preheat solenoid faulty 2 Check solenoid 3 Low battery power 3 Switch to combine house and start batteries 3a Replace batteries Engine cant be stopped 1 Disconnect fuel shutoff cable 1 Check connection at shutoff lever Pull lever back to close off the fuel Battery runs down 1 Oil pressure switch 1 Observe if gauges and panel lights are activated when engine is not running Test the oil pressure switch 2 High resistance leak to ground 2 Check wiring Insert sensitive 0 25 amp meter in battery lines Do not start engine Remove connections and replace after short is located 3 Low resistance leak 3 Check all wires for temperature rise to locate the fault 4 Poor battery connections 4 Check cable connections at battery for loose connections corrosion 5 DC alternator not charging 5 Check connections check belt tension test alternator See tachometer not operating DC ELECTRICAL Battery not charging 1 Alternator drive 1 Check drive belt tension alternator should turn freely Check for loose connections Check output with voltmeter Ensure 12 volts are present at the Exc terminal Engine slows and stops 1 Fuel starvation 1 Check fuel supply fuel valves fuel lift pump 2 20 Amp circuit breaker tripping 2 Check for high DC amperage draw during operation Ensure breaker is not overly sensitive to heat which would cause tripping Push button to reset 3 Exhaust system is restricted 3 Check for blockage collapsed hose carbon buildup at exhaust elbow 4 Water in fuel 4 Pump water from fuel tanks change filters and bleed fuel system 5 Air intake obstruction 5 Check air intake filter cartridge continued Engines Generators 29 ENGINE Problem Probable Cause Engine overheats 1 Raw water not circulating 1 Raw water pump failure Check impeller replace 2 Coolant not circulating 2 Obstruction at raw water intake or raw water filter 2a Thermostat remove and test in hot water Replace thermostat 2b Loss of coolant check hoses hose clamps drain plug etc lor leaks 2c Broken or loose belts tightenreplace 2d Air leak in system run engine and open the pressure cap to bleed air Add coolant as needed Engine alarm sound pulsates 1 Loss of oil 1 Check dipstick look for oil leaks at oil filter and at oil drain hose connection 2 Oil pressure switch 2 Replace oil pressure switch Engine alarm sounds continuously 1 Engine coolant 1 Check engine coolant level 2 High temperature switch opens at 2 Check for satisfactory operation with switch bypassed too Iowa temperature check with ohmmeter replace if faulty Exhaust smoke problems 1 Blue smoke 1 Incorrect grade of engine oil 1a Crankcase is overfilled with engine oil oil is blowing out through the exhaust 2 White smoke 2 Engine is running cold 2a Faulty injector or incorrect injector timing 3 Black smoke 3 Improper grade of fuel 3a Fuel burn incomplete due to high backpressure in exhaust or insufficient air for proper combustion check for restrictions in exhaust system check air intake 3b Improperly timed injectors or valves or poor compression 3c Lack of air check air intake and air filter Check for proper ventilation 3d Overload COOLANT TEMPERATURE AND OIL PRESSURE GAUGESIf the gauge reading is other than what is nonnally indicated If both of the above gauge tests are positive the gauge isby the gauge when the instrument panel is energized the first undoubtedly OK and the problem lies either with thestep is to check for 12 volts DC between the ignition B conductor from the sender to the gauge or with the senderand the Negative B tenninals of the gauge If either of the above gauge tests are negative the gauge isAssuming that there is 12 volts as required leave the probably defective and should be panel energized and perfonn the following steps Assuming the gauge is OK check the conductor from the1 Disconnect the sender wire at the gauge and see if the sender to the sender tenninal at the gauge for continuity gauge reads zero which is the nonnal reading for this Check that the engine block is connected to the ground situation Some starters have isolated ground tenninals and if the2 Remove the wire attached to the sender tenninal at the battery is connected to the starter both plus and minus sender and connect it to ground See if the gauge reads tenninals the ground side will not necessarily be connected full scale which is the nonnal reading for this situation to the block Engines Generators 30 METER NOTE Current model tachometers use a coarse adjustmentThe meter used in propulsion engine instru dial to set the tachometer to the crankshaft pulley rpms Thement panels contains two separate electrical circuits with a calibrating screw is then used for fine tuningcommon ground One circuit operates the hour meter and theother the tachometer The hour meter circuit operates on 12volts alternator charging voltage supplied to the terminalon the back of the instrumentThe tachometer circuit operates on AC voltage 68 volts fedfrom one of the diodes in the alternator and supplied to thetachometer input terminal while the engine is running andthe alternator producing battery charging voltage 130148 TERMINALvolts DCThe following are procedures to follow when COARSEa fault in either of the two circuits in a TACH INPHour meter Inoperative AC VOLTAGECheck for the proper DC voltage between and terminals TACHOMETER CHECK New Installation1 Voltage present meter is defective repair or replace NOTE In a new installation having new instrument panels the tachometer may not always be correctly calibrated to the2 Voltage not present trace and electrical con engines rpm This calibration should be checked in all new nections for fault Jump 12 volts DC to meter installations terminal to verify the operation 1 Warm up the engine to normal operating Inoperative Remove any specks on the crankshaft pulley with a cleanCheck for the proper AC voltage between tachometer input cloth and place a piece of suitable reflecting tape on theterminal and terminal with the engine running pulley to facilitate use of a photoelectric type tachometer1 Voltage present attempt adjusting meter through calibra 2 Start and idle the engine tion access hole No results repair or replace meter 3 Aim the light of the tachometer onto the reflecting tape to2 AC voltage not present check for proper alternator DC confirm the engine speed Check the instrument panel output voltage tachometer reading Adjust the tachometer in the panel by3 Check for AC voltage at tach terminal on alternator to using the instrument coarse adjustment to calibrate the ground instrument reading to the closest RPM that the photo tach is showing Then use the fine calibration adjustment to4 Check electrical connections from tachometer input ter bring the instrument to the exact reading as the photo tach minal to alternator Sticking1 Check for proper AC voltage between tach inp terminal and terminal2 Check for good ground connection between meter terminal and alternator3 Check that alternator is well grounded to engine block at alternator pivot boltTachometer Inaccuratea With a handheld tach on the front of the crankshaft pulley retaining nut or with a strobetype tach read the front crankshaft pulley rpm at idleb Adjust the tachometer with a small Phillips type screw driver through the calibration access hole in the rear of the tachometer Zero the tach and bring it to the rpm indicated by the strobe or hand tach Verify the rpm at idle and at high speed and adjust the tach as needed Engines Generators 31 ENGINE BELT inspection service and maintenance of the drive beltsis important for the efficient operation of your engine seeDrive Belts under MAINTENANCE SCHEDULE FUEL INJECTORDrive belts must be properly tensioned Loose drive belts winnot provide proper alternator charging and will the alternator Drive belts that are too tight will pun HOLOOWN NUTSthe alternator out of alignment andor cause the alternator towear out prematurely Excessive drive belt tension can alsocause rapid wear of the belt and reduce the service life of thecoolant pumps bearing A slack belt or the presence of oil onthe belt can cause belt slipping resulting in high and tachometer variations FUEL INJECTORSThe drive belt is properly adjusted if the belt can be deflected In case of severe vibrations and detonation noise have theno less than 38 inch lOmm and no more than 112 inch injectors checked and overhauled by an authorized fuel12mm as the belt is depressed with the thumb at the mid injection service center Poor fuel quality contaminants andpoint between the two pulleys on the longest span of the belt loss of positive fuel pressure to the injection pump can resultA spare belt or belts should always be carried on board in injector faults Since fuel injectors must be serviced in a clean room environment it is best to carry at least one extra A WARNING Never attempt to check Dr adjust the injector as a spare should a problem occur drive belts tension while the engine is in operation Before removing the old injector clean the area around the base of the injector to help prevent any rust or debris from falling down into the injector hole If the injector will not liftAdjusting Belt Tension out easily and is held in by carbon buildup or the like work1 Loosen the alternator adjusting strap bolt and the base the injector sidetoside with the aid of the socket wrench to mounting bolt free it and then lift it out2 With the belt loose inspect for wear cracks and frayed The injector seats in the cylinder head on a copper sealing edges washer This washer should be removed with the injector and3 Pivot the alternator on the base mounting bolt to the left replaced with a new washer when the new injector is installed or right as required to loosen or tighten The fuel injectors should be pressure tested after 750 operating4 Tighten the base mounting bolt and the adjusting strap hours bolt INJECTION STARTING PRESSURE 2630 psi 181 Mpa 185 Kgem5 Run the engine for about 5 minutes then shut down and INJECTION HOLDDOWN NUTS TORQUE 137 15 ItIb 19 02 Kgm recheck the belt AND ALTERNATOR SERVICEThe starter and the alternator should be serviced every 1200operating hoursStarter commentator slip ring cleaningCarbon brushes and the brush contact checkRefer to your WESTERBEKE SERVICE MANUAL Engines Generators 32 ENGINE ADJUSTMENTS NOTE WESTERBEKE recommends that the following engine adjust ments be performed by a competent engine mechanic The information below is provided to assist the ENGINE COMPRESSION OIL PRESSUREMake certain the oil level dipstick is at the correct level The engines oil pressure during operation is indicatedand the air intake filter is clean The battery and starter motor by the oil pressure gauge on the instrument panel Duringmust also be in good condition normal operation the oil pressure will range between 40 and1 Warm the engine to normal operating teITiperature 85 psi2 Move the control lever to a position for shutting off the NOTE A newly started cold engine can have an oil pressure fuel Disconnect the wires if a fuel shutdown solenoid reading up to 85 psi A warmed engine can have an oil is used pressure reading as low as 40 psi These readings will vary3 Remove all the glow plugs from the engine and install depending upon the temperature of the engine the load the compression gaugeadapter combination to the placed on the engine and the RPMs cylinder on which the compression is to be measured Low Oil Pressure The specified safe minimum oil pressure is 5 10 psi A gradual loss of oil pressure usually indicates worn bearings For additional information on low oil pressure readings see the ENGINE chart MEASURING Testing Oil Pressure COMPRESSION To test the oil pressure remove the oil pressure sender then DIAL GAUGE install a mechanical oil pressure gauge in its place After warming up the engine set the engine speed at idle and read the oil pressure gauge OIL PRESSURE 15 20 psi at idle speed SENDER AND SWITCH TORQUE 9 13 nIb 12 18 m Kg PREHEAT SOLENOID4 Close the raw water seacock thruhull5 Crank the engine and allow the gauge to reach a maximum reading then record that reading6 Repeat this process for each cylinder 20A BREAKER COMPRESSION PRESSURE 441 psi 310 Kgem at 200 rpm ALLOWABLE LIMIT 370psi 260 Kgem MAXIMUM PERMISSIBLE DIFFERENCE BETWEEN CYLINDERS 2844 psi 20 KgemNOTE Jfthe readings are below the limit the engine needs an overhaul7 Reinstall the glow plugs and reset the fuel shutoff to the run positionS Open the raw water seacock thruhullLow low compression is found determine the cause byapplying a small amount of oil in the cylinder thru the glowplug hole Allow the oil to settleInstall the pressure gauge and repeat the above test If thecompression reading rises dramatically the fault is with therings If the compression valve does not rise the problem is OIL PRESSUREwith the valves SWITCHA slight rise in compression would indicate a problem withboth the rings and the valves Engines Generators 33 ENGINE ADJUSTMENTS NOTE WESTERBEKE recommends that the following engine adjust ments be performed by a competent engine mechanic The information below is provided to assist the mechanicVALVE CLEARANCE ADJUSTMENT 3 After adjusting the valves with piston No I at IDCThe valve clearance must be adjusted every 200 operating rotate the crankshaft 3600 again aligning the TDC markhours or whenever the valve rocker is abnormally noisy and the pulley mark This brings piston No6 or No4 toValve adjustment should only be done when engine is cold TDC then adjust the remaining valvesCold engine valve clearance is 00157 in 040 mm INJECTION TIMING Improper injection timing can cause engine failure In normal J DD1571N servicing this check and adjustment in unnecessary however it might be necessary in conjunction with other related work D4DMMI such as an engine overhaul VE TIMING MARKS EARANCE 7lTDC MARKNOTE The head bolts have been tightened with theAngular Tightening Method Therefore it is not necessaryto retighten the cylinder head bolts before adjusting the valve PULLEY PROCEDURE CRANKSHAFT PUllEYChart shows six cylinder model Cylinder No 1 2 3 4 5 6 Valve arrangement I E I E I E I E I E I E When No1 cylinder is at TOC in the com O0 0 0 0 0 CHECK PROCEDURE pression stroke Bring No 1 piston to the top dead center on the compression When No6 cylinder is at TOC in the com stroke Turn the crankshaft pulley c1ockwie viewed at pression stroke engine front and align the mark on the crankshaft pulley with the IDC mark1 In order to bring No I or No6 piston six cyl No4 Remove the access cover at the front of the injection pump piston four cyl to the top dead center in the compression and check the alignment between the pointer A on the stroke align the TDC mark and the crank shaft pulley injection pump gear lock plate and the projected pointer B on mark the timing gear case If A and B are in alignment the timing2 Do the adjustment on the circle marked valves in the is set correctly above table where No I piston is in the IDC in the If they are in alignment No 1 cylinder is at the TDC on compression stroke After these steps do the adjustment the compression stroke If it is in misalignment recheck by on the double circle marked valves where the No6 piston turning the crankshaft pulley one more tum to repeat the six cyl No4 piston four cylis on IDC in the procedure to make sure that it is in alignment compression strokeChart shows four cylinder model INJECTION PUMP Cylinder No 1 2 3 4 MARKS Valve arrangement I E I E I E I EI When No1 cylinderZaII is at TDC in the com pression stroke O0 0 0 When No4 cylinder is at TOC in the com pression stroke Engines Generators 34 ENGINE ADJUSTMENTS NOTE WESTERBEKE recommends that the following engine adjust ments be peiformed by a competent engine mechanic The information below is provided to assist the mechanicCheck the crankshaft position for the start of fuel injection 5 Notice which injection timing mark is aligned with the1 Turn the crankshaft pulley viewed from pulley mark The timing mark in alignment with the the engine front about 30 pulley mark indicates the degrees before IDC the start of fuel injection2 Remove No I high pressure injection line The degrees before TDC differs depending on the engine e 11DELIVERY HOLDER VALVE model Refer to the specifications on the injection timing for the respective model engine If the timing is incorrect do the following adjustment ADJUSTMENT PROCEDURES 1 Align the pulley mark and the specified timing mark Refer to the injection timing specifications 2 Loosen the four injection pump attachment nuts 3 To advance the timing pivot the injection pump at the DELIVERY pump drive shaft away from the engine VALVE To retard the timing pivot the injection pump at the pump drive shaft toward the engine NOTE The 1mm misalignment between the timing marks on the crankshaft pulley correspond to about r in crank angle3 Remove the injection pump No I delivery valve holder 4 Recheck the timing following procedures I through 5 delivery valve and spring and reinstall the delivery valve 5 Tighten the four injection pump attachment nuts holder back into the pump 6 Again remove No I delivery valve holder and reinstall DELIVERY VALVE HOLDER TIGHTENING TORQUE 39 44 Nm 4 45 Kgm289 325 ftIb the delivery valve spring and the valve holder DELIVERY VALVE HOLDER TIGHTENING TORQUE4 Slowly turn the crankshaft pulley clockwise and at the 39 44 Nm 4 45 Kgm289 325 ftIb same time feed fuel to the injuection pump by slowly 7 Reinstall the No I high pressure injection line pumping the feed pump When the fuel stops to flow out from No I delivery valve holder stop tutning the crank shaft pulley and pumping This is th beginning of fuel injection LOOSEN FOUR NUTS 80TH SIDES PULLEY MARK TIMING GEAR CASE Engines Generators 35 HURTH INITIAL OPERATIONFor safety reasons the transmission is not filled with trans Set the shifting lever to neutral position N Start the enginemission fluid during shipment and the selector lever is tem and let it run long enough in idle to fill the cooler and hosesporarily attached to the actuating shaft with transmission fluid Shift into gear forward and reverseBefore leaving the WESTERBEKE plant each transmission shifting should be smooth and positive Direct changes fromundergoes a test run with Dextron III ATF transmission fluid forward to reverse are permissible since the mUltiple discThe residual fluid remaining in the transmission after drain clutch permits changing at high rpm including sudden reversing acts as a preservative and provides protection against cor ing at high speeds in the event of dangerrosion for at least one year if properly stored After initial operation make a visual inspection of the output coupling oil cooler and hoses and the cable connections to the transmission DIPSTICK iJNkAIR VENT LOCKING THE PROPELLER Locking of the propeller shaft by an additional brake is not required use the gear shift lever position opposite your direc tion of travel for this purpose Never put the gear shift in the position corresponding to the direction of travel of the boat IJtJJ FLUID FIlTER lIe3IN WHEN UNDER SAIL OR BEING TOWED Rotation of the propeller without a load such as when the boat is being sailed being towed or anchored in a river as OUTPUT well as operation of the engine with the propeller stopped COUPLING for charging the battery will have no detrimental effects on MODEL 630 the COOLER NOTE When the boat is being sailed engine stopped the gear shift must be in the neutral position The propeller is atThe oil cooler mounted above the transmission provides idle and can cooling for the transmission fluid Raw waterpasses through the tubes of the cooler and discharges over DAILY OPERATIONboard The transmission fluid is cooled as it flows around thetubes and back into the transmission o Check the transmission fluid o Visually check the gear shift linkage and transmission WESTERBEKE RECOMMENDS CARRYING RAW WATER CONNECTION o Start the engine in neutral allowing a few minutes at idle ASPARE OIL COOLER ABOARD to warm the fluid o Shift into gear NOTE Too Iowan idle speed will produce a chattering noise from the transmission gear and damper plate In such cases the idle speed should be increased RAW WATER CONNECTION TRANSMISSION OIL COOLER Operating Temperature The operating temperature of the transmission should FLUID exceed 176F 80C under normal continous running AFill the transmission with Dextron ll ATF The fluid level connection for a temperature probe is provided At maximumshould be up to the mark on the dipstick After checking the output of the engine the fluid may reach 220F l04Clevel press the dipstick into the case and turn it to tightenDuring the first 25 operating hours inspect the bell housingoutput shaft and transmission cooler for leakage The fluid A CAUTION If the transmission fluid temperature isshould be changed after the first 25 hours and every 300 too high stop the engine immediately and check thehours thereafter transmission fluidNEUTRAL SWITCHThese transmissions are equipped with a neutral safetyswitch This is to prevent the engine frJrn starting in gearUnless the transmission selector lever is perfectly aligned inneutral the engine starter will not activate Engines Generators 36 HURTH TRANSMISSIONS CHANGING THE TRANSMISSION FLUID Replacing the Fluid Pour in new Dextron 1Il ATF fluid and check the quantity with the dipstick Transmission fluid quantities will vary with the use of cool ers length of hoses and the angle of the transmission Approximate Quantities HURTH 45 212 quarts 20 Liters HURTH 63 32 quarts 30 Liters Reinsert the filter assembly into the housing Press it in place and tighten the Allen screw ACTUATING LEVER NOTE Some transmissions use a T handle in place of a screw on their filter assemblies 16mm 8 SCREW After running the engine shut down and recheck the fluid level A WARNING Neller pull out the dipstick while the engine Is ronnlng Hot nuld will splash from the dipstick hole This could cause sellere bums ORINGS MAINTENANCE MODEL 450 Transmission maintenance is minimal Keep the exterior housing clean check the fluid level as part of your regular routine and change the fluid every 300 operating hours Periodically inspect the transmission and the cooler for leaks FILTER ELEMENT and corrosion Make certain the air vent is clear and when checking the fluid level look for signs of water contamination fluid will appear as strawberry cream Element Storage requires special care Follow these proceduresThe Hurth transmission has a filter element located opposite D Drain water from the transmission oil cooler and replacethe dipstick This filter must be replaced whenever the fluid is with a proper mixture of antifreeze coolantchanged NOTE This operation will normally occur when theRemove the filter by loosening the screw on the cover using a engine raw water cooling system is properly winterized6mm Allen wrench D Clean up the transmission and touch up unpainted areasTwist and pull out the filter and remove the element Place use heat resistant paintthe new filter onto the cover and lock it into place by turningit clockwise Check the Orings for damage and replace if D Fill the transmission with Dextron 1Il ATF fluid to pre vent internal corrosion extended storage only Replacement filters can be obtained from your months or morelocal WESTERBEKE dealer or ZF Hurth dealer D Loosen attaching hardware from the transmission outputRemoving the Fluid flange and propeller shaft coupling flange before removPush a suction pump hose down through the pipe hole under ing the boat from the water Separate the flanges andthe filter to the bottom of the housing and suck out the fluid spray with the oil return line from the cooler and allow the oil D Inspect the gear shift cable linkage and attachmentsto drain into a container then reconnect the oil return line Look for corrosion of the end fittings cracks or cuts in the conduit and bending of the actuator rods LubricateWipe down the transmission and properly dispose of the used all moving partsfluid NOTE If the transmission is to be stored for a 10llg time twelve months or more it should be topped off with fluid to prevent internal corrosion Reduce the fluid level before putting the engine back into service Engines Generators 37 HURTH TRANSMISSIONS CABLE CONNECTIONS SHAn COUPLINGS The transmission is suitable for a single lever gear shift WESTERBEKE recommends a flexible connection between Upon loosening the retaining screw the actuating lever see the transmission and the propeller shaft if the engine is flexi illustration can be moved to any position required for the bly mounted in order to compensate for angular deflections control elements cable or rod linkage Make certain that the The installation of a special propeller thrust bearing is not actuating lever does not contact the lever hub the minimum required since the propeller thrust will be absorbed by the distance between the lever and hub should be 002in05mm transmission bearing provided the value specified under The control cable or rod should be arranged at a right angle SPECIFICATIONS is not exceeded However the output to the actuating lever when in the neutral position The neu shaft should be protected from additional loads Special care tral position of the gear shift lever on the control console should be taken to prevent torsional vibration When using a should coincide with the neutral position of the lever on the universal joint shaft make certain to observe the manufac transmission turers instructions Shifting Positions Even with the engine solidly mountedthe use of a flexible A Propeller rotation opposite of engine rotation coupling or DRIVESAVER will reduce stress in the gearbox N Neutral position bearings caused by hull distortions especially in wooden B Propeller rotation same as engine rotation boats or where the distance between the transmission output coupling and stern gland is less than about 800mm NOTE When shifting to A or B positions make sure the shift lever travel is sufficient for the actuating lever to contact NOTE When installing the transmission make certain that its stop CABLE N shifting is not impeded by restricted movability of the cable BRACKET or rod linkage by unsuitably positioned guide sheaves too small a bending radius or other restrictions In order to mount a support for shift control cable connections use the two threaded holes located on the cable bracket mounted 011 the gear housing Refer to the WESTERBEKE parts list GEAR SHIFT LEVER 8 ACTUATING LEVER LEVER HUB ACTUATING 1 0021n r05mm LEVER TYPICAL STEERING STATION A greater amount of actuating lever travel is in no way detrimental and is recommended However if the lever travel is shorter proper clutch engagement might be impeded For additional information contact which in turn would mean premature wear excessive heat HURTH MARINE GEAR generation and clutch plate failure This would be indicated ZF Industries by slow clutch engagement or no engagement at all see Marine US Headquarters CONTROL CABLES under TRANSMISSION 3131 SW 42nd Street Fort Lauderdale FL 33312 Tel 954 5814040 NOTE Check for proper actuating lever travel at least each Fax 954 5814077 season A CAUTION The position of the mechanism behind the actuating lever Is to ensure equal shift lever travel from neutral position to A and B If this mechanism Is In any way tampered with the transmlsslDn wananty will be vDld Engines Generators 38 BORG WARNER VELVET DRIVE TRANSMISSION SHIFT LEVER POSITION OIL COOLER The gear shift control mechanism and linkage must position the actuating lever on the transmission exactly in Forward F Neutral N and Reverse R shifting positions A detent ball located behind the transmission lever must work freely to center the lever in each position The gear shift positions at the helm must be coordinated with those of the Velvet Drive actuating lever through shift mechanism adjustments An improperly adjusted shift mechanism can cause damage to the transmission The shifting mechanism and transmission actuating lever should be free of dirt and well lubricated to ensure proper operation Shifting Into Gear Place the gear shift in Neutral before starting the engine Shifting from one selector position to another selector posi tion may be made at any time below 1000 rpm and in any order Shifts should be made at the lowest practical engine speed Start the engine and set the throttle at idle speed allow the transmission fluid to warm up for a few safety reasons the transmission is not filled with trans Neutralmission fluid during shipment and the selector lever is tem Move the gear shift lever to the middle position You shouldporarily attached to the actuating shaft feel the detent This centers the actuating lever on the transBefore leaving the WESTERBEKE plant each transmission mission With the control in this position hydraulic power isundergoes a test run with Dextron III ATF transmission fluid completely interrupted and the output shaft of the transmisThe residual fluid remaining in the transmission after drain sion does not tuming acts as a preservative and provides protection against NOTE Some transmissions are equipped with a neutral for at least one year if properly stored switch Unless the transmission actuating lever is FLUID aligned in neutral the engine starter will not activateCheck the transmission fluid level on the dipstick If has not been filled fill with Dextron III and to use this fluid During the first 25 hours of opera Move the gear shift lever to the forward position You shouldtion keep a lookout for any leakage at the bell housing out feel the detent The actuating lever on the transmission is input shaft and transmission cooler This fluid should be the forward position The output shaft and the propeller shaftchanged after the first 25 hours and approximately every 300 move the boat in a forward hours thereafter andor at winter layup Reverse Move the gear shift lever to the reverse position You should A CAUTION Be ceffaln the transmission Is filled feel the detent The actuating lever on the transmission is in the reverse position The output shaft and the propeller and the correct slzs cooler Is properly Installed before should move the boat in a reverse direction astern staffing the engine NOTE Moving the transmission actuating lever from Neutral Position to Forward is always toward the engine Reverse is always away from the engine If boat moves backwards with the gear shift control in the forward position shut off the engine This problem may be a result of incorrect movement of the actuating lever by the gear shift lever Engines Generators 39 BORG WARNER VELVET DRIVE TRANSMISSION o Clean off the transmission and properly dispose of the used fluid o Refill the transmission with DEXTRON II ATF The quantity will vary depending on the transmission model and the installation angle Fill through the dipstick hole D Check the dipstick for the proper fluid level D Replace the oil filler cap and dipstick Press the dipstick into place and tum clockwise until fingertight D Run the engine shutdown and recheck the fluid levelFORWARD NEUTRAL TRANSMISSION AC11JATING LEVER POSITIONS REVERSE A WARNING Never pull out the dipstick while the engine Is running Hot nuld will splash from the dipstickDAILY OPERATION hole This could cause severs bumso Check the transmission fluido Visually check the gear shift linkage and transmission Oil Capacityo Start the engine in neutral Allow a few minutes at idle Approximately 25 quarts 236 liters will fill most transmis for the fluid to warm sions to the oil level fill mark on the dipstick Many variables NOTE Too Iowan idle speed will produce a chattering have a direct relationship to the oil capacity Additional oil noise from the transmission gear and damper plate In will be required to fill the oil cooler and the cooler lines The such cases the idle speed should be increased angle of installation will make a difference in the quantity of oil required to fill the transmission o Shift into gear A CAUTION Shifting gears above 1000 rpm can Make certain the rubber seal Is screwed tight to the handle cause damage to the engine damper plate Pulling the throttle back to Idle when shifting gears will save wear on the transmission and the damper plate INSPECTIONo Visually check for oil leaks at the hydraulic connections Check for wear on the hydraulic lines and replace if worno Lubricate the detent ball and shift cable attachmentso Inspect the shift linkageo Inspect the transmission bolts retorque if necessary A CAUTION Clutch fallurs will occur If the transmis OILDIPsnCK sion shift lellSr does not fully engage the detent ball Oil Temperature plISltlons A maximum oil temperature of 1900 P 88C is recom mended Discontinue operation anytime sump oil tempera CHANGING THE TRANSMISSION FLUID ture exceeds 230 0 P 1lO D C After the initial 50 hour change the transmission fluid should PRESSURE GAUGE be changed at every 300 operating hours thereafter or at win ter haulout However the fluid must be changed whenever it An optional mechanical pressure gauge can be installed at becomes contaminated changes color or smells rancid the control panel to constantly monitor the pressure of the transmission fluid A normal reading at 2000 rpm in forward o Remove the oil filler cap and dipstick gear should indicate 95 120 Ibin2 67 84 kgcm 2 and be o Remove the oil cooler return line and allow the oil to constant drain into a container o Reconnect the oil cooler return line D Use a suction pump to remove the transmission oil through the filler capdipstick hole EngInes Generators 40 BORG WARNER VELVET DRIVE WARRANTY maintenance is minimal Keep the exterior Service manuals are available from your BORG WARNERhousing clean check the fluid level as part of your regular dealerroutine and change the fluid every 300 operating hours For assistance inspect the transmission and the cooler for leaks BORG WARNERand corrosion Make certain the air vent is clear and when 200 Theodory Rice Blvdchecking the fluid level look for signs of water contamination New Bedford MA 02745fluid will appear as strawberry cream Tel 508 BORG WARNER is aware of the shock loads that can be placed on its gears as the result of mechanical propeller operStorage requires special care Follow these procedures ation or fully reversing of the propeller blades while shiftIngo Drain the water from the transmission oil cooler and Therefore torque loads and directional changes should be replace it with a proper mixture of antifreeze coolant made at low engine speeds If it is found that a failure was NOTE This operation will usually occur when the engine caused by a shock load any warranty claim wiJI be denied raw water cooling system is properly winterizedo Clean up the transmission and touchup unpainted areas A CAUTION Systemrelated noises or vibrations can use heat resistant paint occur at low engine speeds which can cause gear rattleo Fill the transmission with Dextron III ATF fluid to pre resulting In damage to the engine andor transmission vent internal corrosion BORG WARNER Is not responsible for total systemo Loosen attaching hardware from the transmission related torsional vibration of this type output flange and propeller shaft coupling flange before removing the boat from the water Separate the flanges If any problems occur with the transmission see and spray with lubricant TRANSMISSION in this manualo Inspect the gear shift cable linkage and attachments Look for corrosion of the end fittings cracks or cuts in the conduit and bending of the actuator rods Lubricate all moving parts NOTE If the transmission is to be stored for a long time twelve months or more it should be topped off with fluid to prevent internal corrosion Reduce the fluid level before putting the engine back into service Engines Generators 41 TRANSMISSION CABLES OIL COOLERSThe majority of transmission difficulties arise as a result of The continued flow of raw water through the cooler will inimproper clutch adjustments manual transmissions or prob time erode the inside of the cooler causing cross leaks tolems with control cables hydraulic transmissions rather than occur These internal cooler leaks will cause one of the folfrom problems with the transmission itself lowing two problemsHURTH clutches in particular are very sensitive to improper 1 Transmission fluid will leak into the flow of raw watercable adjustments and be discharged overboard through the engine exhaustIf you experience operating problems with the transmission A loss of transmission fluid will cause the transmission toshut the engine down First check the level failthen have a helper move the cockpit shift lever through the 2 The raw water will leak into the transmission fluid causfull range from neutral to full forward back to neutral ing an increase in transmission fluid This full reverse and back to neutral while you observe fluid will appear as strawberry cream The actuating lever on the transmission If the remote is stiff will eventually failto operate break the cable loose at the transmission and try Either case requires an immediate responseagain If it is still stiff check the cable for kinks or excessively tight bends and check any linkage for binding A new 1 Install a new oil coolercable and perhaps a new linkage mechanism may be needed 2 Refill the transmission with DEXTRON III ATFWhile the cable is loose shift the transmission in and out of If water has contaminated the fluid the transmission fluidgear using the lever on the side of the transmission to make needs to be cleaned out and replaced with fresh fluid It willsure theres no binding inside the case take several fluid changes to get rid of the the transmission passes these tests crank the engine and Check your dipstick each time until it appears as pure transhave a helper put it in forward and reverse while you observe mission fluid Change the transmission filter and clean outthe propeller shaft if the shaft isnt turning the transmission the fluid lines that connect to the coolerneeds professional attention If it does tum but theres no If the transmission fails to shift properly it will most likelythrust check to see you still have a propeller on the end of need the attention of a qualified transmission service facilitythe shaft or if you have a folding or feathering propeller that A transmission cooler may last ten years or more but init isnt stuck in the no pitch position some circumstances depending on operating hours tropical waters maintenance etc it might only last half that time WESTERBEKE recommends having a spare cooler aboard Problem Probable Cause Transmission gears cannot be shifted 1 Shifting lever is loose 1 TIghten damping bolt on shifting lever 2 Shifting cable is broken bent or 2 Check the cable reattach or replace unattached 3 Loss of transmission fluid 3 Check for leaks at transmission seal and output shaft Tighten gear case bolts Check all oil hoses for leaks Oil cooler leak see OIL COOLER 4 Water in transmission fluid 4 Replace oil cooler see OIL COOLER High water in engine compartment remedy cause Shifting pressure too low see item 2 Shifting pressure too low 1 Improper fluid 1 Replace with DEXTRON 11 ATF 2 Filter is dirty if applicable 2 Replace filter 3 Water in transmission fluid 3 Replace oil cooler see OIL COOLER 4 Transmission fluid too low 4 Add fluid 5 Air vent is clogged 5 Remove painVdirt from vent Transmission noise becomes louder 1 Fluid level too low 1 Top up with fluid to marking on dipstick so that pump sucks in air 2 Damage starting on flexible coupling due 2 Replace flexible coupling Check alignment between engine to wear or fatigue possibly due to misalign and transmission ment between engine and transmission 3 Beginning damage of bearings in trans 3 Transmission needs professional attention mission due to torsional vibrations running without fluid overload wrong alignment of transmiSSion or excessive engine output continued Engines Generators 42 TRANSMISSION Problem Probable Cause Chattering transmission noise 1 The engine or propeller generates torsional 1 Mount a flexible coupling with another stiffness factor mainly at low engine speed vibrations in the drive unit which produces between the engine and transmission a coupling with a chattering noise in the transmission a higher stiffness factor might be sufficient Transmission shifts into gear but 1 Output coupling Is not tuming 1 Transmission needs professional attention fails to propel the boat 2 Propeller shaft is not turning 2 The coupling bolts are sheared or the coupling is slipping Output coupling is tuming on the propeller shaft Tighten or replace set screws keys pins and coupling bolts as necessary 3 Output coupling and 3 Inspect the propeller it may be missing or damaged propeller shaft are turning A folding propeller may be jammed Variable pitch propeller may be in no pitch positionNOTE If you suspect a major problem in your contact your WESTERBEKE dealer or anauthorized marine transmission facility Engines Generators 43 LAYUP Fuel System GasolineMany owners rely on their boatyards to prepare their craft Top off your fuel tanks with unleaded gasoline of 89 engines and generators for layup during the off of higher A fuel conditioner such as STABIL gasolineseason or for long periods of inactivity Others prefer to stabilizer should be added Change the element in youraccomplish layup preparation themselves gasolinewater separator and clean the metal bowlThe procedures which follow will allow you to perform your Reinstall and make certain there are no leaks Cleanown layup and or you may use them as a up any spilled fuelcheck list if others do the procedures Fuel System DieselThese procedures should afford your engine protection Top off your fuel tanks with No2 diesel fuel Fuel a layup and also help familiarize you with the such as BlOB OR and STABIL should be added at this time tomaintenance needs of your engine control algae and condition the fuel Care should be takenIf you have any questions regarding layup procedures call that the additives used are compatible with the primary fuelyour local servicing dealer he will be more than willing to filterwater separator used in the system Change the elementprovide assistance in your primary fuel filterwater separator if the fuel system has one and clean the separator sediment bowlPropeller Shaft Coupling Propulsion Engine Change the fuel filter elements on the engine and bleed theThe transmission and propeller half couplings should always fuel system as needed Start the engine and allow it to runbe opened up and the bolts removed when the boat is hauled for 5 10 minutes to make sure no air is left in the fuelout of the water or moved from land to water and during system Check for any leaks that may have been created instorage in the cradle The flexibility of the boat often puts a the fuel system during this servicing correcting them assevere strain on the propeller shaft or coupling or both while needed Operating the engine for 5 10 minutes will helpthe boat is taken out or put in the water In some cases the allow movement of the treated fuel through the injectionshaft has actually been bent by these strains This does not equipment on the engineapply to small boats that are hauled out of the water whennot in use unless they have been dry for a considerable Raw Water Cooling Circuitperiod of time Close the throughhull seacock Remove the raw water intakeFresh Water Cooling Circuit hose from the seacock Place the end of this hose into a five gallon bucket of clean fresh water Before starting the engineA 5050 solution of antifreeze and distilled water is check the zinc anode found in the primary heat exchanger onrecommended for use in the coolant system at all times the engine and clean or replace it as required and also cleanThis solution may require a higher concentration of any zinc debris from inside the heat exchanger where theantifreeze depending on the areas winter climate Check the zinc anode is located Clean the raw water to make sure the antifreeze protection is adequate Start the engine and allow the raw water pump to draw theShould more antifreeze be needed drain an appropriate fresh water through the system When the bucket is emptyamount from the engine block and add a more concentrated stop the engine and refill the bucket with an Operate the engine to ensure a complete circulation solution slightly stronger than needed for winter freezeand mixture of the antifreeze concentration throughout the protection in your areacooling system Now recheck the antifreeze solutions strength Start the engine and allow all of this mixture to be System through the raw water system Once the bucket is empty stopWith the engine warm drain all the engine oil from the oil the engine This antifreeze mixture should protect the rawsump Remove and replace the oil filter and fill the sump water circuit from freezing during the winter layup as wellwith new oil Use the correct grade of oil Refer to the as providing corrosion LUBRICATING OIL pages in this manual for the Remove the impeller from your raw water pump someoil changing procedure Run the engine and check for proper antifreeze mixture will accompany it so catch it in a bucketoil pressure and make sure there are no leaks Examine the impeller Acquire a replacement if needed and a cover gasket Do not replace the impeller into the pump until but replace the cover and gasket A CAUTION Do not leave the engines old engine Cylinder Lubrication Gasoline oil in the sump over the layup period Engine oil and combustion deposits combine to produce harmful With the engine running remove the flame arrester and spray fogging oil into the open air intake The fogging oil will stall chemicals which can reduce the life of your engines out the engine as it coats the valves cylinders and spark internal parts plugs for winter protection Engines Generators 44 LAYUP Motor SPARE and cleaning of the starter drive pinion is advis Layup time provides a good opportunity to inspect yourable if access to the starter permits its easy removal Make WESTERBEKE engine to see if external items such as drivesure the battery connections are shut off before attempting to belts or coolant hoses need replacement Check your basicremove the starter Take care in properly replacing any elec spares kit and order items not on hand or replace those itemstrical connections removed from the starter used during the layup such as filters and zinc anodes Refer to the SPARE PARTS section of this manualCylinder Lubrication DieselIf you anticipate a long layup period 12 months or more recommends removing the glow plugs or The of your WESTERBEKE engine after afuel injectors for access to the cylinders Squirt light seasonal layup generally follows the same procedures aslubricating oil into the cylinders to prevent the piston rings those described in the PREPARATIONS FOR STARTINGfrom sticking to the cylinder walls Rotate the engine by hand section regarding preparation for starting and normal startstwo revolutions then replace the glow plugs or injectors However some of the layup procedures will need to beMake sure you have a replacement if removing the injector counteracted before starting the enginesealing washer for the injector and fuel line return 1 Remove any rags that were placed in the exhaust intake manifold or flame arresterNOTE If engine storage is going to be a lengthy one 12months or beyond it is wise to rotate the engine by hand two 2 Remove the raw water pump cover and gasket and turns every additional 4 months to allow the injec the old gasket Install the raw water pump impellertion pump components to move This will help prevent their removed during layup or a replacement if during extended storage periods Install the raw water pump cover with a new cover gasket 3 Reinstall the batteries that were removed during the layIntake Manifold and ThruHull ExhaustDiesel up and reconnect the battery cables making sure thePlace a clean cloth lightly soaked in lubricating oil in the terminals are clean and that the connections are tightopening of the intake manifold to block the opening Do not Check to make sure that the batteries are fully chargedshove the cloth out of sight If it is not visible at 4 Remove the spark plugs wipe clean regap and and an attempt is made to start the engine to proper tightness Gasolineyou may need the assistance of a servicing dealer Make a 5 Check the condition of the zinc anode in the raw waternote to remove the cloth prior to startup The throughhull circuit and clean or replace the anode as needed Noteexhaust port can be blocked in the same manner that it is not necessary to flush the waterIntake Manifold Gasoline solution from the raw water coolant system When the engine is put into operation the system will selfflush inClean the filter screen in the flame arrester and place a clean a short period of time with no adverse affects Also opencloth lightly soaked in lube oil around the flame arrester to up the heat exchanger ends and clear out any accumublock any opening Also place an oilsoaked cloth in the lated exhaust port Make a note to remove cloths priorto startup 6 Check the transmission fluid if it had been topped off during the layup lower the level of the fluid to Propulsion Engine Propulsion EngineCheck or change fluid in the transmission as required If the 7 Make certain all electrical connections and switches areengine is to be layed up 12 months or more fill the transmis in the correct position and there are noloads on thesion to the very top to prevent corrosion Lower the fluid to generator at start up Generatorits nonnaI at Wipe off grime and grease 8 Start the engine in accordance with the proceduresand touch up unpainted areas Protect coupling and output described in the PREPARATIONS FOR STARTINGflange with an anticorrosion coating Refer to the section of this SECTION in this manual for batteries are to be left on board during the layup periodmake sure they are fully charged and will remain that wayto prevent them from freezing If there exists any doubt thatthe batteries will not remain fully charged or that they willbe subjected to severe environmental conditions removethe batteries and store them in a warmer more Engines Generators 45 METRIC CONVERSIONS INCHES TO MILLIMETERS MILLIMETERS TO INCHESInches mm Inches mm mm Inches mm Inches 1 2540 15 38100 1 00394 15 05906 2 5080 20 50800 2 00787 20 07874 3 7620 25 63500 3 01181 25 09843 4 10160 30 76200 4 01575 30 11811 5 12700 35 88900 5 01969 35 13780 10 25400 40 101600 10 03937 40 15748 10 MILLIMETERS 1 CENTIMETER 100 CENTIMETERS 1 METER 3937 INCHES 33 FEET INCHES TO METERS METERS TO INCHESInches Meters Inches Meters Meters Inches Meters Inches 1 00254 7 01778 01 3937 07 27559 2 00508 8 02032 02 7874 08 31496 3 00762 9 02286 03 11811 09 35433 4 01016 10 02540 04 15748 10 39370 5 01270 11 02794 05 19685 11 43307 6 01524 12 03048 06 23622 12 47244 TO CONVERT METERS TO CENTIMETERS MOVE DECIMAL POINT TWO PLACES TO THE RIGHT YARDS TO METERS METERS TO YARDSYards Meters Yards Meters Meters Yards Meters Yards 1 091440 6 548640 1 109361 6 656168 2 182880 7 640080 2 218723 7 765529 3 274320 8 731520 3 328084 8 874891 4 365760 9 822960 4 437445 9 984252 5 457200 10 914400 5 546807 10 1093614 MOVE DECIMAL POINT FOR HIGHER VALUES eg 6000 METERS 656168 YARDS POUNDS TO KILOGRAMS KILOGRAMS TO POUNDS Ib kg Ib kg kg Ib kg Ib 1 0454 6 2722 1 2205 6 13228 2 0907 7 3175 2 4409 7 15432 3 1361 8 3629 3 6614 8 17637 4 1814 9 4082 4 8818 9 19842 5 2268 10 4536 5 11023 10 22046 GALLONS TO LITERS LITERS TO GALLONSGallons Liters Gallons Liters Liters Gallons Liters Gallons 1 379 10 3786 1 026 60 1566 2 757 20 7571 2 053 90 2377 3 1136 30 11357 5 132 120 3132 4 1514 40 15142 10 264 150 3962 5 1893 50 18928 20 528 180 4754 PINTS TO LITERS LITERS TO PINTS Pints Liters Pints Liters Liters Pints Liters Pints 1 047 6 284 1 211 6 1268 2 095 7 331 2 423 7 1479 3 142 8 379 3 634 8 1691 4 189 9 426 4 845 9 1902 5 237 10 473 5 1057 10 2113 TEMPERATURE 32 40 50 60 70 75 85 95 105 140 175 212 OF I I I I I I I I I I I I I I I I I I I I I I I I 0 5 10 15 20 25 30 35 40 60 80 100 C Engines Generators 46STANDARD AND METRIC CONVERSION Inches in x 254 Millimeters mm x 0394 Inches Feet ft x 305 Meters m x 3281 Feet Miles x 1609 Kilometers km x 0621 MilesVOLUME Cubic Inches inJ x 16387 Cubic Centimeters x 061 in 3 Imperial Pints IMP pt x 568 Liters L x 176 IMP pt Imperial Quarts IMP qt x 1137 Liters L x88 IMP qt Imperial Gallons IMP gal x 4546 Liters L x 22 IMP gal Imperial Quarts IMP qt x 1201 US Quarts US qt x 833 IMP qt Imperial Gallons IMP gal x 1201 US Gallons US gal x 833 IMP gal Fluid Ounces x 29573 Milliliters x 034 Ounces US Pints US pt x 473 LitersL x 2113 Pints US Quarts US qt x 946 Liters L x 1057 Quarts US Gallons US gal x 3785 Liters L x 264 Ounces oz x 2835 Grams g x 035 Ounces Pounds Ib x 454 Kilograms kg x 2205 PoundsPRESSURE Pounds Per Sq In psi x 6895 Kilopascals kPa x 145 psi Inches of Mercury Hg x 4912 psi x 2036 Hg Inches of Mercury Hg x 3377 Kilopascals kPa x 2961 Hg Inches of Water H20 x 07355 Inches of Mercury x 13783 H20 Inches of Water H20 x 03613 psi x 27684 H20 Inches of Water H20 x 248 Kilopascals kPa x 4026 H20TORQUE PoundsForce Inches inIb x 113 Newton Meters Nm x 885 inIb PoundsForce Feet ftIb x 1356 Newton Meters Nm x 738 ftIbVELOCITY Miles Per Hour MPH x 1609 Kilometers Per Hour KPH x 621 MPHPOWER Horsepower Hp x 745 Kilowatts Kw x 134 MPHFUEL CONSUMPTION Miles Per Hour IMP MPG x 354 Kilometers Per Liter KmL Kilometers Per Liter KmL x 2352 IMP MPG Miles Per Gallons US MPG x 425 Kilometers Per Liter KmL Kilometers Per Liter KmL x 2352 US MPGTEMPERATURE Degree Fahrenheit OF OC X 18 32 Degree Celsius OC OF 32 x 56 Engines Generators 47 80N4 SPECIFICATIONS GENERAL FUEL SYSTEMEngine Type Diesel four cylinder fourcycle marine engine General Closed system with bleed points Vertical inline overhead valve water cooled direct injection 80 hp 2500 rpm Fuel No2 diesel oil cetane rating of 45 or higher Naturally aspirated Fuel Injection Pump BOSCH Model A type Integral with injection pump Fuel Injection Timing WBTDCGovemor Nozzle MultiholeBore Stroke 402 x 465 inches 1020 x 1180 mm Fuel Filter Full flow Displacement 262 cubic inches 43 liter on engineFiring Order 1342 Air cleaner Replaceable paper of Rotation Clockwise when viewed from the front AirFlow 150 efmEngine Torque 210 ftIb 1500 rpm engine Ratio 171 Fuel Consumption 47 US gph 178 IphDimensions inches mm Height 320 inches 813 mmwout transmission Width 252 inches 645mm ELECTRICAL SYSTEM Length 472 inches 1168 mm Starting Battery 12 Volt negative groundWeight dry 971 Ibs 4408 kgs Battery Capacity 750 900 Cold Cranking Amps CCA TUNEUP SPECIFICATIONS DC Charging A1temator 51 Amp rated beltdriven Starting Aid Glow Pressure 441 psi 31 kgcm at 200 rpmLimit of difference Not to exceed 2844 psi 200 kgcm Starter 12 Volt 3 KWInjector Pressure 2133 psi 150 kfcm DC Noload Current 2 of rated ampsValve Seat Angle Intake 45 DC Cranking Current 400 CCA Exhaust 45Valve Clearance Intake and exhaust LUBRICATION SYSTEMengine cold 0Q16 inches 040 mm General Gear typepressure Speed Idle 600 900 rpm Cruise 1800 2200 rpm Oil Filter Full flow paper element spinon type Max 2400 2500 rpm Sump Capacity 145 US QIs 138 liters not including filter COOLING SYSTEM Operating Oil Pressu re 2585 psiGeneral Fresh watercooled block engine hot controlled with heat exchanger Oil Grade API Specification CF or CG4Operating Temperature 170 190 F 77 88 C SAE 30 10W30 15W40Fresh Water Pump Centrifugal type metal impeller beltdriven Water Pump Positive displacement rubber impeller enginedriven General HURTH Standard Transmission Casehardened helical gears hydraulically operated multiple discCoolant Fresh Water clutchSystem Capacity 17 US Qts 161 liters Gear Ratio Standard 2001 Hurth 45A or Hurth 63A EXHAUST SYSTEM Propeller Shaft Right handedstandard Elbow 45 elbow Propeller 22x16 P2 blade or 22x14 P3 blade using standard propeller should allow the engine to reach its full Exhaust Hose Size 4 ID 1016 mm hose transmission rated rpm 2500 000 100 at full open throttle while underway in forward gear ENGINE AIR REQUIREMENTS Lubricating Fluid Dextron III Combustion Air 150 cfm Transmission Sump Note The pressure differential between the outside of the engine compart Capacity Hurth 45 213 US qts 20 liters approximate ment versus the inside of the engine compartment should not exceed 2 inches of water 51 mm at full open throttle measure with a manometer Engines Generators 48 110T4 SPECIFICATIONS GENERAL FUEL SYSTEMEngine Type Diesel four cylinder fourcycle turbocharged General Closed system with bleed pOints marine engine Vertical inline overhead valve water cooled direct injection 110 hp 2400 Fuel No2 diesel oil cetane rating of 45 or higher rpm Fuel Injection Pump BOSCH Model A type Turbo charged Fuel Injection liming 12 BTDCGovemor Integral with injection pump Nozzle MultiholeBore Stroke 402 x 465 inches 1020 x 1180 mm Fuel Filter Full flow Displacement 202 cubic inches 43 liter on engineFiring Order 1 3 4 2 Air cleaner Replaceable paper of Rotation Clockwise when viewed from the front Air Flow 230 cfm engine Torque max 280 ftIb 1500 rpm Fuel Consumption 61 US gph 231 IphCompression Ratio 171Dimensions inches mm Height 320 inches 813 mm ELECTRICAL SYSTEMwout transmission Width 283 inches 719 mm Length 472 inches 1168 mm Starting Battery 12 Volt negative groundWeight dry 987 Ibs 4480 kgs Battery Capacity 750 900 Cold Cranking Amps CCA DC Charging Altemator 51 Amp rated beltdriven TUNEUP SPECIFICATIONS Starting Aid Glow Pressure 441 psi 31 kgcm at 200 rpm Starter 12 Volt 3 KWLimit of difference Not to exceed 2844 psi 200 kgcm DC Noload Current 2 of rated ampsInjector Pressure 2133 psi 150 kfcm DC Cranking Current 400 CCAValve Seat Angle Intake 45 Exhaust 45 LUBRICATION SYSTEMValve Clearance Intake and exhaustengine cold 0016 inches 040 mm General Gear typepressure Speed Idle 600 900 rpm Oil Filter Full flow paper element spinon type Cruise 1800 2200 rpm Sump Capacity 145 US Qts 138 liters Max 2300 2400 rpm not including filter Operating Oil Pressure 2585 psi COOLING SYSTEM engine hotGeneral Fresh watercooled block Oil Grade API Specification CF or CG4 controlled with heat exchanger SAE 30 10W30 15W40Operating Temperature 180 190 F77 88 CFresh Water Pump Centrifugal type metal impeller beltdrivenRaw Water Pump Positive displacement rubber impeller TRANSMISSION enginedriven General HURTH Standard Transmission Fresh Water helical gears hydraulically operated multiple discSystem Capacity 17 US Qts 161 liters clutch Gear Ratio Standard 2001 Hurth 45A or Hurth 63A EXHAUST SYSTEM Propeller Shaft Right handedstandard Elbow 45 elbow Propeller 24x18 P2 blade or 24x16 P3 bladeExhaust Hose Size 4 10 1016 mm hose using standard propeller should allow the engine to reach its full transmission rated rpm 2400 000 100 at full open throttle while underway in forward gear Lubricating Fluid Dextron III Transmission Sump Capacity Hurth 45A 213 US Qts 20 liters Air 230 cfmNote The pressure differential between the outside of the engine compartment versus the inside of the engine compartment should not exceed 2inches of water 51 mm at full open throttle measure with a manometer Engines Generators 49 120N6 SPECIFICATIONS GENERAL FUEL SYSTEMEngine Type Diesel six cylinder fourcycle Vertical inline General Closed system with bleed pOints overhead valve fresh water cooled direct injection marine engine 120 hp 2500 rpm Fuel No2 diesel oil cetane rating of 45 or Naturally aspirated Fuel Injection Pump BOSCH Model A type Inline Integral with injection pump Fuel Injection TIming WBTDCGovernor 413 x 492 inches 1050 x 1250 mm Nozzle MultiholeBore StrokePiston Displacement 296 cubic inches 65 liter Fuel Filter Full flow replaceable on engineFiring Order 153624 Air cleaner Replaceable paper of Rotation Clockwise when viewed from the front Air Flow 240 cfmEngine Torque 298 ftIb 1500 rpm engine Ratio 171 Fuel Consumption 65 US gph inches mm Height 325 inches 823mmwout transmission Width 252 inches 645mm ELECTRICAL SYSTEM Length 564 inches 1410 mm Starting Battery 12 Volt negative 1175 Ibs 5341 kgs Battery Capacity 750 900 Cold Cranking Amps CCA TUNEUP SPECIFICATIONS DC Charging Alternator 51 Amp rated beltdriven Starting Aid Glow Pressure 441 psi 31 kgcm at 200 rpmLimit of difference Not to exceed 2844 psi 200 kgcm Starter 12 Volt 3 IN actuated shiftInjector Pressure 2631 psi 180 kfcm DC Noload Current 2 of rated ampsValve Seat Angle Intake 45 DC Cranking Current 400 CCA Exhaust 45Valve Clearance Intake and exhaust LUBRICATION SYSTEMengine cold 0016 inches 040 mm General Gear typepressure Speed Idle 600 900 rpm Cruise 1800 2200 rpm Oil Filter Full flow paper element spinon type Max 2400 2500 rpm Sump Capacity 22 US qts 208 liters not including filter COOLING SYSTEM Operating Oil Pressure 25 85 psi 35 42 kgcmGeneral Fresh watercooled block engine hot controlled with heat exchanger Oil Grade API Specification CF or CG4Operating Temperature 180 1900 F 77 880 C SAE 30 1OW3 15W40Fresh Water Pump Centrifugal type metal impeller beltdriven Water Pump Positive displacement rubber impeller enginedriven General HURTH Standard Transmission Casehardened helical gears hydraulically operated multiple discCoolant Fresh Water clutchSystem Capacity 25 US qts 237 liters Gear Ratio Standard 2001 Hurth 45A or Hurth 63A EXHAUST SYSTEM Propeller Shaft Right handedstandard Elbow 45 elbow Propeller 22x16 P2 blade or 22x14 P3 blade using standard propeller should allow the engine to reach itsExhaust Hose Size 4 ID 1016 mm hose transmission full rated rpm 2500 000 100 at full open throttle while underway in forward gear ENGINE AIR REQUIREMENTS Lubricating Fluid Dextran 11Combustion Air 240cfm Transmission Sump Capacity Hurth 45 213 US qts 20 liters The pressure differential between the outside of the engine compart Hurth 63 42 US qts 40 liters versus the inside of the engine compartment should not exceed 2inches of water 51 mm at full open throttle measure with a manometer Engines Generators 50 170T6 SPECIFICATIONS GENERAL FUEL SYSTEMEngine Type Diesel six cylinder fourcycle turbocharged General Closed system with bleed points marine engine Vertical inline overhead valve fresh water cooled direct injection 170 hp Fuel No2 diesel oil cetane rating of 45 or higher 2500 rpm Fuel Injection Pump BOSCH Model A type Turbocharged Fuel Injection TIming 12 BTDCGovemor Integral with injection pump Nozzle MultiholeBore Stroke 413 x 492 inches 1050 x 1250 mm Fuel Filter Full flow Displacement 423 cubic inches 65 liter on engineFiring Order 153624 Air cleaner Replaceable paper of Rotation Clockwise when viewed from the front Air Flow 365 cfm engine Torque max 423 ftIb 1800 rpm Fuel Consumption 93 US gph 352 IphCompression Ratio 171Dimensions inches mm Height 335 inches 823 mm ELECTRICAL SYSTEMwout transmission Width 280 inches 711 mm Length 575 inches 1410mm Starting Battery 12 Volt negative groundWeight dry 12451bs 56523 kgs Battery Capacity 750 900 Cold Cranking Amps CCA DC Charging Alternator 51 Amp rated beltdriven TUNEUP SPECIFICATIONS Starting Aid Glow Pressure 441 psi 31 kgcm at 200 rpm Starter 12 Volt 3 ImLimit of difference Not to exceed 2844 psi 200 kgcm DC Noload Current 2 of rated ampsInjector Pressure 2631 psi 185 kfcm DC Cranking Current 400 CCAValve Seat Angle Intake 45 Exhaust 45 LUBRICATION SYSTEMValve Clearance Intake and exhaustengine cold 0016 inches 040 mm General Gear typepressure Speed Idle 600 900 rpm Oil Filter Full flow paper element spinon type Cruise 1800 2200 rpm Sump Capacity 22 US qts 208 liters Max 2400 2500 rpm not including filter Operating Oil Pressure 2585 psi COOLING SYSTEM engine hotGeneral Fresh watercooled block Oil Grade API Specification CF or CG4 controlled with heat exchanger SAE 30 10W30 15W40Operating Temperature 180 190 F 77 88 CFresh Water Pump Centrifugal type metal impeller beltdriven Water Pump Positive displacement rubber impeller General HURTH Standard Transmission Casehard enginedriven ened helical gears hydraulically operated multiple disc clutchCoolant Fresh WaterSystem Capacity 25 US qts 237 liters Gear Ratio Standard 2001 Hurth 45A or Hurth 63A Propeller Shaft Right handedstandard transmission EXHAUST SYSTEM Propeller 24x18 P2 blade or 24x16 P3 bladeExhaust Elbow 45 elbow using standard propeller should allow the engine to reach its transmission full rated rpm 2500 000 100 at full openExhaust Hose Size 4 10 1016 mm hose throttle while underway in forward gear Lubricating Fluid Dextran III Transmission Sump Capacity Hurth 63 42 US qts 40 liters Air 365 cfmNote The pressure differential between the outside of the engine compartment versus the inside of the engine compartment should not exceed 2inches of water 51 mm at full open throttle measure with a manometer Engines Generators 51 SUGGESTED SPARE PARTS WESTERBEKE MARINE DIESEL ENGINES CONTACT YOUR WESTERBEKE DEALER FOR ADDITIONAL SUGGESTIONS AND INFORMATION TRANSMISSION i FILTERFUEL FILTERS OIL FILTERS I FUEL STRAINER HARDWARE KIT THERMOSTATS JP AND GASKETS SPARE PARTS KITS WESTERBEKE offers Spare Parts Kits in two versions each packaged in a canvas duffel bag Kit A has the basic spares Kit B is for more complete for offshore cruising Kit A KitB Impeller Impeller Heat Exchanger Gasket Heat Exchanger Gasket Fuel Filter Fuel Filter Oil Filter Oil Filter Drive Belts Drive Belts Zincs Zincs Thermostat Thermostat The red and black duffel bag is Complete Gasket Kit 18 long with a full zipper dual Injector handles and a carrying strap Air Filter separate Engines Generators Transmission Filter 52 Engines
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