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Century 170 T6a 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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