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Century 170 T6a Operator's Manual



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OPERATORS MANUAL
80N4/11 OT4 -120N6/170T6
 MARINE 01     L ENGINES




                PUBLICATION NO. 045139
                    FIRST EDITION
                      JULY 2000




          WESTERBEKE CORPORATION
          MYLES STANDISH INDUSTRIAL PARK
          150 JOHN HANCOCK ROAD, TAUNTON, MA 02780-7319
       AIIT'-AIITAIIT
      NMMA         Member National Marine Manufacturers Association
      .. UWW
                      A    WARNING
Exhaust gasses contain Carbon Monoxide. an odorless and
colorless gas. Carbon Monoxide is poisonous and can cause
unconsciousness and death. Symptoms of Carbon Monoxide
exposure can include:
- Dizziness                  - Throbbing in Temples
-Nausea                      - Muscular Twitching
-Headache                    - Vomiting
- Weakness and Sleepiness - Inability to Think Coherently

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


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

INTRODUCTION                                                       PREVENT BURNS - FIRE
Read this safety manual carefully. Most accidents are caused
by failure to follow fundamental rules and precautions.
Know when dangerous conditions exist and talre the                  A WARNING:          Fire can cause injury or death!
necessary precautions to protect yourself, your personnel,
and your machinery.                                                 Prevent flash fires. Do not smoke or permit flames or
The following safety instructions are in compliance with the         sparks to occur near the carburetor, fuel line, filter, fuel
American Boat and Yacht Council (ABYC) standards.                    pump, or other potential sources of spilled fuel or fuel
                                                                     vapors. Use a suitable container to catch all fuel when
PREVENT 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 cleaner/silencer 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 engine/gener-
  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 vessel's AC
  circuits, except through a ship-to-shore double throw             Follow re-fueling safety instructions. Keep the vessel's
  transfer switch. Damage to vessel's AC generator may               hatches closed when fueling. Open and ventilate cabin
  result if this procedure is not followed.                          after fueling. Check below for fumes/vapor 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 when
PREVENT BURNS - HOT ENGINE                                           handling and storing fuels. Store fuel in a well-ventilated
                                                                     area away from spark-producing equipment and out of the
                                                                     reach of children.
  A WARNING: Do not touch hot engine parts or                       Do not fill the fuel tank(s) 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 INSTRUCTIONS

ACCIDENTAL 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 boat
BATTERY EXPLOSION                                                      builder or dealer for instaIlation of approved detectors.
                                                                         For additional information refer to ABYC T-22 (educa-
 A WARNING:         Battery explosion can cause injury                    tional information on Carbon Monoxide).
 or death!
                                                                         A    WARNING: Carbon monoxide (CO) is an invisible
 Do not smoke or aIlow an open flame near the battery                   odorless gas. Inhalation produces flu-like 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 exhaust/water 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 twitching
BATTERY 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 engine/generator 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 engine/generator.
 Do not check fluid levels or the drive belts' tension while         ABYC (American Boat and Yacht Council)
  the engine/generator 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 Solomon's Island Rd.
                                                                        Edgewater, MD 21037
HAZARDOUS 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.              P.O. Box 9101
                                                                        Quincy, MA 02269-9101
 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:
                                                                        U.S. Government Printing Office
                                                                      . Washington, D.C. 20404
 A WARNING: 00 not work on machinery when you
 are mentally or physically incapaCitated by fatigue!

OPERATORS MANUAL
Many of the preceding safety tips and warnings are repeated
in your Operators Manual along with other cautions and
notes to highlight critical information. Read your manual
carefully. maintain your equipment, and follow all safety
procedures.
GASOLINE ENGINE AND GENERATOR
INSTALLATIONS
Preparations to install a gasoline engine or generator should
begin with a thorough examination of the American Boat and
Yacht Council's (ABYC) standards. These standards are from
a combination of sources including the USCG and the NFPA.
Sections of the ABYC standards of particular interest are:
H-2 Ventilation
H-24 Gasoline fuel systems
P-l Exhaust systems
P-4 Inboard engines
E-9 DC Electrical systems
All installations must comply with the Federal Code of
Regulations (FCR).




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

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

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

EXHAUST SYSTEM
The exhaust hose must be certified for marine use. The system must be designed to
prevent water from entering the exhaust under any sea conditions and at any angle
of 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 CONTENTS
Parts Identification ................................................2              "" 0"
                                                                                  WIFing   lagrams ................ ;...............................27
Introduction .............................................................3       Engine Troubleshooting ... .................................. 29
 Warranty Procedures ........................................ .3                  Tachometer ........................................................31
  Serial Number Location ................................. ..4                    Engine Adjustments ... ..........................................32
Admiral Control Panel ........................................ .5                   Drive Belt Adjustment .................................... 32
Fuel, Engine Oil and Coolant ..............................6                        Fuel Injectors ................................................. 32
  Oil Pressure ...................................................... 6             Testing Engine Compression .......................... 33
Preparations for Initial Start-Up .........................7                        Testing Oil Pressure ........................................ 33
                                                                                    Valve Clearance Adjustment ......................... .34
Starting/Stopping Procedure ............................... 8
                                                                                    Injection Timing ............................................ 34
Warning Lights, Alarms and Circuit Breaker ...... 9                               Hurth Transmissions ..........................................36
Engine Break-In Procedure ...................... ......... 10                       Changing Fluid ............................................... 37
The Daily Routine ............................................. .11                 Maintenance .................................................. 37
  Starting the Engine ......................................... 11                  Cable Connections .......................................... 38
Maintenance Schedule .. ................................... 12                      Shaft Couplings .............................................. 38
Cooling System ................................................. .14              Borg Warner Transmission ..... ........................... 39
  Thermostat ...................................................... 15              Changing Fluid .............................................. .40
  Raw Water Pump ............................................ 16                    Maintenance .................................................. 41
  Heat Exchanger .............................................. 17                Transmission Troubleshooting ......................... .42
  Air Intake Filter .............................................. 18             Lay-up and Recommissioning .......................... .44
Fuel System ...................................................... .19            Metric Conversions ......................................... .46
  Fuel Lift Pump ................................................ 19              Specifications 80N4 ........................................ ..48
  Fuel Filters ...................................................... 19
  Fuel PumplFuel Bleeding ............................... 20
                                                                                  Specifications 11 OT4........................................ .49
Engine Lubricating Oil ....................................... 21                 Specifications 120N6 ........................................50
  Oil Change .................... :................................. 21           Specifications 170T6 ......................................... 51
  Remote Oil Filter ............................................ 22               Suggested Spares .............................................52
Water Heater .....................................................23
DC Electrical System ...........................................24
   Alternator Troubleshooting ............................ 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 FILL

CONNECTION
SIPHON 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
                                                    INTRODUCTION
These high perfonnance marine engines are products of                PRODUCT SOFTWARE
WESTERBEKE's long years of experience and advanced                   Product software, (technical data, parts lists, manuals,
technology. We take great pride in the superior durability and       brochures and catalogs), provided from sources other than
dependable perfonnance of our engines and generators.                WESTERBEKE are not within WESTERBEKE's control.
Thank you for selecting WESTERBEKE.
                                                                     WESTERBEKE CANNOT BE RESPONSIBLE FOR THE
In order to get the full use and benefit from your generator,        CONTENT OF SUCH SOFTWARE, MAKES NO WAR-
it is important that you operate and maintain it correctly.          RANTIES OR REPRESENTATIONS WITH RESPECT
This manual is designed to help you do this. Please read this        THERETO, INCLUDING ACCURACY, TIMELINESS OR
manual carefully and observe all the safety precautions              COMPLETENESS THEREOF AND WILL IN NO EVENT
throughout. Should your engine require servicing, contact            BE LIABLE FOR ANY TYPE OF DAMAGE OR INJURY
your nearest WESTERBEKE dealer for assistance.                       INCURRED IN CONNECTION WITH OR ARISING OUT
This is your operators manual. A parts catalog is also               OF THE FURNISHING OR USE OF SUCH SOFTWARE.
provided and a technical manual is available from your               WESTERBEKE customers should keep in mind the time
WESTERBEKE dealer. If you are planning to install this               span between printings of WESTERBEKE product software
equipment, contact your WESTERBEKE dealer for                        and the unavoidable existence of earlier WESTERBEKE
WESTERBEKE'S installation manual.                                    product software. The product software provided with            .
                                                                     WESTERBEKE products, whether from WESTERBEKE or
WARRANTY PROCEDURES                                                  other suppliers, must not and cannot be relied upon exclu-
Your WESTERBEKE Warranty is included in a separate                   sively as the definitive authority on the respective product. It
folder. If. after 60 days of submitting the Warranty Registry        not only makes good sense but is imperative that appropriate
fonn you have not received a customer identification card            representatives of WESTERBEKE or the supplier in question
registering your warranty, please contact the factory in             be consulted to detennine the accuracy and currentness of the
writing with model infonnation, including the unit's                 product software being consulted by the customer.
serial number and commission date.
                                                                     NOTES, CAUTIONS AND WARNINGS
Customer Identification Card                                         As this manual takes you through the operating procedures.
                                                                     maintenance schedules, and troubleshooting of your marine
    l"WV"JWESTERBEKE                                                 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. #UOOOO-E702                                   your engine.
 Expires 2151200 I

                                                                      A WARNING: Procedures which, if not properly
                                                                      followed, can result in personal injury or loss of life.
The WESTERBEKE serial number is an alphanumeric
number that can assist in detennining the date of manufacture
of your WESTERBEKE engine or generator. The manufac-
turer's date code is placed at the end of the engine serial
number and consists of a character followed by three num-
bers. The character indicates the decade (A=1960s, B=1970s,
C=1980s, D=1990s E=2000s), the first number represents the
year in the decade: and the second and third numbers repre-
sent the month of manufacture.




                                                          Engines & Generators

                                                                 3
                                                    INTRODUCTION
SERIAL NUMBER LOCATION                                                ORDERING PARTS
The engine's model number and serial number are located on            Whenever replacement parts are needed, always provide the
a nameplate mounted on the side of the engine's manifold.             engine model number and serial number as they appear on
The engine's serial number is stamped into the engine block           the silver and black nameplate located on the manifold. You
(left side) behind the alternator, below the manifold Take the        must provide us with this information so we may properly
time to enter this information on the illustration of the name-       identify your engine. In addition, include a complete part
plate shown below, as this will provide a quick reference when        description and part number for each part needed (see the
seeking technical information and/or ordering repair parts.           separately furnished Parts List). Insist upon WESTERBEKE

~~~~~~~~~
                                                                      packaged parts because will fit or generic parts are frequently


~1fii4il:1B3=t
                                                                      not made to the same specifications as original equipment.
                                                                      SPARES AND ACCESSORIES
o    MODEL
              0  SPEC         AVO_ MA USA      SER.NO..
                                                                      Certain spares will be needed to support and maintain your
                                                                      WESTERBEKE engine. Your local WESTE.RBEKE dealer
                                                                      will a'ssist you in preparing an inventory of spare parts. See
                                                                      the SPARE PARTS page in this manual. For engine acces-
                                                                      sories, see WESTERBEKE's ACCESSORIES brochure.
UNDERSTANDING THE DIESEL ENGINE
The diesel engine closely resembles the gasoline engine,
since the mechanism is essentially the same. The cylinders
are arranged above a closed crankcase. The crankshaft is the
same general type as a gasoline engine, and the diesel engine
has the same type of valves, camshaft, pistons, connecting
rods and lubricating system.
Therefore, to a great extent, a diesel engine requires the same
preventive maintenance as a gasoline engine. The most
important factors are proper ventilation and proper mamte-
nance of the fuel, lubricating and cooling systems. Fuel and
lubricating filter elements must be replaced at the time peri-
ods specified, and frequent checking for contaminants (water,
sediment, etc.) in the fuel system is also essential. Another
important factor is the consistent use of the same brand of
high detergent diesel lubrication oil designed specifically for
diesel engines.
The diesel engine' does differ from the gasoline engine,
however, in its method of handling and firing of fuel. The
carburetor and ignition systems are replaced by a single
component - the fuel injection pump - which performs the
function of both.




                                                           Engines & Generators

                                                                  4
                                                ADMIRAL CONTROL PANEL
 DESCRIPTION                                                                    When the engine is shut down with the key switch turned off,
                                                                                the water temperature gauge will continue to register the last
 This manually-operated control panel is equipped with a
                                                                                temperature reading indicated by the gauge before electrical
 KEY switch and RPM gauge with an ELAPSED TIME
                                                                                power was turned off The oil pressure gauge will fall to zero
 meter which measures the engine's running time in hours and
                                                                                when the key switch is turned off The temperature gauge
 in III 0 hours. The panel also includes a WATER TEMPER-
                                                                                will once again register the engine's true temperature when
 ATURE gauge which indicates water temperature in degrees
                                                                                electrical power is restored to the gauge.
 Fahrenheit, an OIL PRESSURE gauge which measures the
 engine's oil pressure in pounds per square inch, and a DC                      A separate 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-
 tem's voltage. All gauges are illuminated when the key                         necting the buzzer to the four-pin connection on the engine's
 switch is turned on and remain illuminated while the engine                    electrical harness. The installer is also responsib,le for installing
 is in operation. The panel also contains two rubber-booted                     the buzzer in a location where it will be dry and where it will
 pushbuttons, one for PREHEAT and 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
                                                                                engine's oil pressure rises above 15 psi (1.1 kg/cm2).

                                                                                                        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 ENGINE'S NORMAL OPERATING OIL
                               TURNED ON. THE ENGINE'S NORMAL OPERATING                                 PRESSURE RANGES BETWEEN 40 - 85 pSi.
                               TEMPERATURE IS 170 -190 F(n - SSC).

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



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




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




                                                                   Engines & Generators

                                                                            5
                       DIESEL FUEL, ENGINE OIL AND ENGINE COOLANT
DIESEL FUEL                                                                          OIL PRESSURE
Use fuel that meets the requirements or specification of Class                       The engine's oil pressure, during operation, is indicated
2-D (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 and
Care Of The Fuel Supply                                                              85 psi.
Use only clean diesel fuel! The clearance of the components                          NOTE: A newly staned, cold engine can have an oil pressure
in your fuel injection pump is very critical; invisible dirt
                                                                                     reading up to 85 psi. A warmed engine can have an oil pres-
particles which might pass through the filter can damage                             sure reading as low as 25 psi. These readings will vary
these finely finished parts. It is important to buy clean fuel,                      depending upon the temperature of the engine, the load
and keep it clean. The best fuel can be rendered unsatisfac-                         placed on the engine, and the RPM's.
tory by careless handling or improper storage facilities. To
assure that the fuel going into the tank for your engine's daily                     ENGINE COOLANT
use is clean and pure, the following practice is advisable:
                                                                                     WESTERBEKE recommends a mixture of 50% antifreeze
Purchase a well-known brand of fuel.                                                 and 50% distilled water. Distilled water is free from the
Install and regularly service a good, visual-type fuel                               chemicals that can corrode internal engine surfaces.
filter/water separator between the fuel tank and the engine.                         The antifreeze performs double duty. It allows the engine to
The 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 cooling
ENGINE OIL                                                                           circuit from rust and corrosion. Look for a good quality
                                                                                     antifreeze that contains Supplemental Cooling Additives
80N41120N6          API Grade CF or CG-4                                             (SCAs) that keep the antifreeze chemically balanced, crucial
l1OT41170T6         API Grade CG-4                                                   to long term protection.
Use the heavy duty engine oils as specified above. Change                            The distilled water and antifreeze should be premixed before
the engine oil after an initial 50 hour break-in period and                          being poured into the cooling circuit.
every 100 hours of operation thereafter.
                                                                                     NOTE: Look for the new environmentally-friendly long lasting
Engine oil viscosity largely affects engine startability, perfor-                    antifreeze that is now available.
mance, oil consumption, speed of wearing and occurrence of
seizure, etc. Using lubricants whose viscosity is selected                           Antifreeze mixtures will protect against an unexpected freeze
according to the atmospheric temperature is important.                               and they are beneficial to the engine's 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.   40.501
                                                                                     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 engine's manifold.




                                                                                                                        \\
                                                                                                                         ",

                                                                  Engines & Generators

                                                                                 6
                                PREPARATIONS FOR INITIAL START-UP
PRESTART INSPECTION
Before starting your engine for the first time or after a pro-
longed layoff, check the following items:
D Check the engine oil level. Add oil to maintain the level
   at the high mark on the dipstick.                                                                                                DIPSTICK
                                                                                                                                    PUSH IN TIGHT
D Turn on the fuel supply, then check the fuel supply and
  examine the fuel filter/water separator bowl for contami-
  nants.
D Check the transmission fluid leveL
   NOTE: Refer to the previous page for fuel, oil and
   transmission fluid.
D Check the DC electrical system. Inspect wire connections
   and battery cable connections. Make certain the positive
   (+) battery cable is connected to the starter solenoid and
  the negative (-) cable is connected to the engine ground
  stud (this location is tagged).
D Check the coolant level in both the plastic recovery tank
  and at the manifold.

    NOTE: If the engine has not yet been filled with coolant,
    refer to the COOLING SYSTEM section of this manual.
D Visually examine the engine. Look for loose or missing
  parts, disconnected wires, and unattached hoses. Check
  the threaded connections and engine attachments.
D Make certain there is proper ventilation around the
  engine. An ample supply is necessary for proper engine
  performance.
D Make sure the mounting installation is secure.
                                                                                                                                             '"

                                                                                                                                                  'II


                                                                                                                                                    \~

D Ensure the propeller shaft is securely attached to the
  transmission.                                              ~
D Open the through-hull and make certain raw water is     ~~ ""-..',
  primed to the raw water strainer                       ~ ~
                                                       ~/" ~                   "/',,---- .,,,1:'      ;,\\1''--   '~I
                                                  ~              ~,-~   ..'"                       ,,\)1                I
                                                                                             ",'\l'l/             .     i /


                                                                                                   j ?CcC"r~                     COOLANT PRESSURE CAP




                                                                                                                                                        .'"   )




                                                                                                                      MANIFOLD




                                                            Engines & Generators

                                                                    7
                                   STARTING/STOPPING PROCEDURE
THE STARTING SYSTEM                                                        5. Should the engine not start when the START button is
                                                                              depressed for 10 to 20 seconds, release both buttons and
These marine diesel engine have l2V DC electric starters. The
                                                                              wait 30 seconds; repeat the procedure above and preheat
start circuitry is designed so that the PREHEAT button must
                                                                              longer. Never run the starter for more than 30 seconds.
be depressed for the time specified in the preheat chart. Then,
while keeping the PREHEAT button engaged, the START
button is depressed to crank the engine.                                    A CAUTION: Prolonged cranking Intervals wfthout
Starting Procedure                                                          the engine starting can result in the engine exhaust
1. 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 engine's 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
                                                                            through-hull shutoff, draining the exhaust muffler, and
      vessels nearby.
                                                                            correcting the cause of the excessive engine cranking.
2. Turn the KEY SWITCH to the ON position (2 o'clock).                      Engine damage resulting from raw water entry is not a
                                                                            warrantable issue; the owner/operator should keep this
3. 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
                       TemperatureJPreheat                                    oil pressure and battery charging voltage.
                                                                               NOTE: Never attempt to engage the starter while the
     Atmospheric Temperature                Preheating TIme                    engine is running.
        41F(5C) or higher                Approx. 5 seconds
      41F(5C) to 23F (-5C)             Approx. 10 seconds              Starting Under Cold Conditions
        23F(-5C) 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 CG-4,
NOTE: The START button will not energize unless the PRE-                   SAE 30. lOW-30, or 15W-40, or 20W-40.
HEAT button is depressed. Depressing the PREHEAT button                    The battery should be fully charged to minimize voltage drop.
activates the glow plugs in the cylinder head so use the PRE-              Use a sufficient amount of preheat to aid in starting. See the
HEAT intem!ittently to avoid overheating the glow plugs.                   Temperature/Preheat chart elsewhere in this section.
4. 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 o'clock). If the key switch is left ON, the battery will
                                      12            I    14                discharge. An engine alarm buzzer is provided to warn the
NOTE: When starting:             ~6                                        operator of this condition (key switch ON). The best method
                                                                           of preventing the battery from discharging is to remove the
A voltage drop will occur
when the preheat button           ~
                                       \    ",
                                             'I,
                                                                           key from the key switch after stopping the engine.
is depressed.                     L....J           \: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
                                                                           coolant's operating temperature reaches approximately 210F
                                                                           (99C).




                                                                 Engines & Generators

                                                                       8
                    WARNING LIGHTS, ALARMS & CIRCUIT BREAKER
ALTERNATOR WARNINGS                                             LOW OIL PRESSURE ALARM SWITCH
The Admiral Control Panel uses a voltmeter to monitor the       A low oil pressure alarm switch is located off the engine's
performance of the alternator.                                  oil gallery. This switch's sensor monitors the engine's oil
                                                                pressure. Should the engine's oil pressure fall to 5 - IO psi
COOLANT TEMPERATURE SWITCH                                      (0.4 - 0.7 kg/cm2), this switch will activate a pulsating alarm.
A coolant temperature switch is located on the thermostat
housing. This switch will activate a continuous alarm if the    ENGINE CIRCUIT BREAKER
coolant's operating temperature reaches approximately 2IOOF     The DC harness on the engine is protected by an engine-
(99C).                                                         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 the
COOLANT TEMPERATURE                                             breaker to trip. In this event most engines will shut down
SENDOR                                                          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 BREAK-IN PROCEDURE
DESCRIPTION                                                         3. While using the vessel, run the engine at various engine
                                                                       speeds for the first 25 hours. Avoid prolonged periods of
Although your engine has experienced a minimum of one
                                                                       idling.
hour of test operations at the factory to make sure accurate
assembly procedures were followed and that the engine oper-         4. Avoid rapid acceleration, especially with a cold engine.
ated properly, a break-in time is required. The service life of     5. Use caution not to overload the engine. The presence of a
your engine is dependent upon how the engine is operated               grey or black exhaust and the inability of the engine to
and serviced during its initial 50 hours of use.                       reach its full rated speed are signs of an overload.
Breaking-in a new engine basically involves seating the pis-        6. During the next 25 hours, the engine may be operated at
ton rings to the cylinder walls. Excessive oil consumption             varying engine speeds, with short runs at full rated rpm.
and smoky operation indicate that the cylinder walls are               Avoid prolonged idling during this break-in period.
scored, which is caused by overloading the engine during the
break-in period.                                                    CHECK LIST
Your new engine requires approximately 50 hours of initial          o   Monitor the control panel gauges.
conditioning operation to break in each moving part in order        o   Check for leaks of fuel and engine oil.
to maximize the performance and service life of the engine.         o   Check for abnormal noise such as knocking, friction.
Perform this conditioning carefully, keeping in mind the fol-           vibration and blow-back sounds.
lowing:
                                                                    o   Confirm exhaust smoke:
1. Start the engine according to the STARTING PROCE-                    When the engine is cold - white smoke.
   DURE section. Run the engine at fast idle while checking             When the engine is warm - almost smokeless.
   that all systems (raw water pump, oil pressure, battery              When the engine is overloaded - some black smoke and soot.
   charging) are functioning.
                                                                    NOTE: See the TRANSMISSION section of this manualfor
2. Allow the engine to warm up (preferably by running at
                                                                    break-in information on your transmission.
   fast idle) until the water temperature gauge moves into
   the 130 - 140F (55 - 60C) range.




                                                           Engines & Generators

                                                                  10
                                                 THE DAILY ROUTINE
CHECK LIST                                                           STARTING THE ENGINE
Each day before starting your engine, take a few moments to          NOTE: See STARTING/STOPPING PROCEDURE in this
run this check list:                                                 manual for more detailed instructions.
o   Visually inspect the engine for fuel, oil, or water leaks.
                                                                     1. Put the transmission in neutral, throttle advanced.
o   Check the oil level.
o   Check the transmission fluid level.                                  NOTE: Hydraulically operated transmissions have a
                                                                         neutral safety switch through which the starter solenoid
o   Check for loose wires at the alternator.                             energizing circuit passes. This switch is open when the
o   Check the starting batteries (weekly).                               transmission is in gear so the starter solenoid will not
o   Check drive belts for wear and proper tension (weekly).              energize.
o   Log your engine running time. These hours relate to              2. Tum the KEY to the ON position (2 o'clock).
    scheduled maintenance.                                           3. Depress PREHEAT (5 seconds).
o   Check fuel supply; always keep fuel tank(s) as full as           4. While pressing PREHEAT, push START. As the engine
    possible.                                                           fires, release START and PREHEAT.
o   Look for clean fuel in the fueVwater separator bowl.
                                                                         NOTE: Some unstable running may occur in a cold
o   Check the coolant level in the plastic recovery tank.                engine. This condition should abate as normal operating
NOTE: Excessive loss of coolant indicates a cooling system               temperature is reached and loads are applied.
leak. Check the entire system. If necessary, use a cooling sys-          NOTE: Should the engine fail to start, wait 30 seconds,
tem pres'sure tester to pressurize the cooling system to locate         then repeat the above procedure, and PREHEAT longer.
the area of leakage. III cases of excessive coolant loss, refill
                                                                     5. Allow a few minutes for the engine to warm at a com-
the svstem as outlined in the ENGINE COOLANT CIRCUIT
                                                                        fortable rpm (approximately 1200 rpm), then reduce the
secti~n 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 transmission/damper plate.




                                                             Engines & Generators

                                                                   11
                                             MAINTENANCE SCHEDULE
In order to use this Maintenance Schedule, it will be neces-
sary to log your engine hours. Use your engine hounneter or                  A WARNING: Never attempt to perform any service
record your engine hours by running time.                                     while the engine is running. Wear the proper safety
NOTE: Many a/the/allowing maintenance procedures are                          equipment such as goggles and gloves, and use the
simple but others are more difficult and may require the                      correct tools for each job. Disconnect the battery
expert knowledge 0/ a service mechanic.                                       terminals when servicing any of the engine's DC
                                                                              electrical equipment.


        SCHEDULED              CHECK                 HOURS OF OPERATION                                  MAINTENANCE DESCRIPTION
       MAINTENANCE              EACH
                                 DAY    50     100     250    500     750 1000 1250
 Fuel Supply                    0                                                             Diesel No.2 rating of 45 cetane or higher.
 Fuel/Water Separator           0                                                             Check for water and dirt in fuel (drain/replace 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 (3/8" to 1/2" 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 engine's 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.
  Fuel/Water 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 anti-siphon valve opera-
                                                                                              tion. Check the exhaust elbow for carbon and/or
                                                                                              corrosion buildup on inside passages; clean and
                                                                                              replace as necessary. Check that all connections are
                                                                                              tight. Check casting integrity.
  Engine Hoses                                   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 WD-40 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 anti-seize
                                                                                    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
                                                                                    bearings.

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




                                                             Engines & Generators

                                                                   13
                                                 COOLING SYSTEM

DESCRIPTION                                                        NOTE: Periodically check the condition of the manifold pres-
Westerbeke marine diesel engines are designed and equipped         sure cap. Ensure that the upper and lower rubber seals are ill
for fresh water cooling. Heat produced in the engine by            good condition and check that the vacuum valve opens and
combustion and friction is transferred to fresh water coolant      closes tightly. Carry a spare cap.
which circulates throughout the engine. This circulating fresh
water coolant cools the engine block, its internal moving
parts, and the engine oil. The heat is transferred externally
from the fresh water coolant to raw water by means of a heat
exchanger, similar in function to an automotive radiator. Raw
water flows through the tubes of the heat exchanger while
fresh water coolant flows around the tubes; engine heat
transferred to the fresh water coolant is conducted through
the tube walls to the raw water which is then pumped into the
exhaust system where finally it is discharged overboard. In        CHANGING COOLANT
other words, the engine is cooled by fresh water coolant, this     The engine's coolant must be changed according to the
coolant is cooled by raw water, and the raw water carries the      MAINTENANCE SCHEDULE. If the coolant is allowed to
transferred heat overboard through the exhaust system. The         become contaminated, it can lead to overheating problems.
fresh water coolant and raw water circuits are independent of
each other. Using only fresh water coolant within the engine
.allows 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 fai/ures can be
                                                                        traced back to cooling system corrosion.
FRESH WATER COOLING CIRCUIT
NOTE: Refer to the ENGINE COOLANT section for the rec-                 Drain the engine coolant by loosening the drain plug on the
ommended antifreeze and water mixture to be used as the                engine block and opening the manifold pressure cap. Flush
fresh water coolant.                                                   the system with fresh water, then start the refill process.
Fresh water coolant is pumped through the engine by a
circulating pump, absorbing heat from the engine. The
coolant then passes through the thermostat into the manifold,
                                                                        A WARNING: Beware of the hot engine coolant.
to the heat exchanger where it is cooled, and returned to the            Wear protective gloves.
engine block via the suction side of the circulating pump.
When the engine is started cold, external coolant flow is
prevented by the closed thermostat (although some coolant
flow is bypassed around the thermostat to prevent,. the exhaust
manifold from overheating). As the engine warms up, the
thermostat gradually opens, allowing full flow of the engine's
coolant to flow unrestricted to the external portion of the
cooling system.
Coolant Recovery Tank
A coolant recovery tank allows for engine coolant expansion
and contraction during engine operation, without any
significant loss of coolant and without introducing air into
the cooling system. This tank should be located at or above
the 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 SYSTEM
Refilling the Coolant                                                  Replacing the Thermostat
After closing the engine block drain, pour clean, premixed             Remove the cap screws and disassemble the thermostat hous-
coolant into the manifold and when the coolant is visible in           ing as shown. When installing the new thermostat and gasket,
the manifold, start the engine and run it at slow idle. Open           apply a thin coat of sealant on both sides of the gasket before
the air bleed petcocks on the manifold and the thermostat              pressing it into place. Do not over-tighten the cap screws.
housing.                                                               Run the engine and check for normal temperatures and that
Monitor the coolant in the manifold and add as needed. Fill            there are no leaks at the thermostat housing.
the manifold to the filler neck and when the coolant flowing
from the petcock is free of air bubbles, close the petcock and
install the pressure cap.
Remove the cap on the coolant recovery tank and fill with
coolant mix to halfway between LOW and MAX and replace
the cap. Run the engine and observe the coolant expansion
flow into the recovery tank. When the petcock on the
thermostat housing is free of air bubbles, close that petcock.
After checking for leaks, stop the engine and allow it to cool.
Coolant should draw back into the cooling system as the
engine cools down. Add coolant to the recovery tank if
needed. Clean up any spilled coolant. . /
           ..---'     "\                      /
    ~'              AIR BLEED        ~.,.                                                                                  TEMPERATURE
                    PETCOCK, y--..        Q



                                .~,               _<\11'
             ~~~0:r~:1!~             "'\j~\}~"

                                 '.ij,j
                                     //
                                                                   THE GASKET IS GROOVED
                                                                   FITS AROUND THE OUTER


                                 ~~/-
                                                                   EDGE OF THE THERMOSTAT




THERMOSTAT
                                 I'
A thennostat, located near the manifold at the front of the
engine, controls the coolant temperature as the coolant
continuously flows through the closed cooling circuit.
When the engine is first started, the closed thermostat pre-
vents coolant from flowing (some coolant is by-passed
through a hole in the thermostat to prevent the exhaust
manifold from overheating). As the engine warms up, the
thermostat gradually opens. The thermostat is accessible
and can be checked, cleaned, or replaced easily. Carry a                               CHANGING THE THERMOSTAT
spare thermostat and gasket.




                                                              Engines & Generators

                                                                   15
                                                COOLING SYSTEM
RAW WATER COOLING CIRCUIT                                              Changing the Raw Water Pump Impeller
The raw water flow is created by a positive displacement               Close the raw water intake valve. Remove the pump cover
impeller pump. This pump draws water directly from the raw             and, with the aid of an impeller puller, carefully pry the
water source (ocean, lake, or river) through a hose to the             impeller out of the pump. Install the new impeller and gasket.
water strainer. The raw water passes from the strainer                 Move the blades to conform to the curved cam plate and
through the raw water pump to the heat exchanger (through              push the impeller into the pump's housing. When assem-
the heat exchanger tubes) where it cools the engine circulat-          bling, apply a thin coating of lubricant to the impeller and
ing fresh water coolant. The raw water is then discharged              gasket. Open the raw water intake valve.
into the water-injected exhaust elbow, mixing with and cool-           To be certain the pump is operating properly, run the engine
ing the exhaust gasses. This mixture of exhaust gas and raw            and check the following:
water is discharged overboard by the engine's exhaust gas
discharge pressure.
                                                                       o Inspect the raw water pump for leaks.
                                                                       o After warm up, monitor the temperature gauge. It should
Raw Water Pump                                                             indicate a normal engine temperature.
The raw water pump is a self-priming, rotary pump with a               o   Check aft. There should be a steady flow of water from
non-ferrous housing and a neoprene impeller. The impeller                  the stem tube.
has flexible vanes which wipe against a curved cam plate
within the impeller housing, producing the pumping action.
On no account should this pump be run dry as water acts as a             A CAUTION: If any of the vanes have broken off the
lubricant for the impeller. There should always be a spare               impeller, they must be found to prevent blockage in the
impeller and impeller cover gasket (an impeller kit) aboard.             cooling circuit. They onen can be found in the heat
Raw water pump impeller failures occur when lubricant (raw               exchanger.
water) is not present during engine operation. Such failures
are not warrantable, and operators are cautioned to make sure
raw water flow is present at start-up.                                 Impeller Puller
NOTE: Should a failure occur with the pump's internal parts            WESTERBEKE recommends using an impeller puller to
(seals and bearings). it may be more cost efficient to pur-            remove the impeller, this will prevent damage to the blades
chase 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.                                                                                ~~~ft-*""---HOUSING




                                           THE O-RING GASKET                        RAW WATER PUMP
                                           ONLY NEEDS TO BE        .
                                           REPLACED IF IT SHOWS ..
                                           SIGNS OF WEAR.




                                                          Engines & Generators

                                                                 16
                                                   COOLING SYSTEM
HEAT EXCHANGER
The heat exchanger is a copper cylinder which encloses a
large number of small copper tubes. Raw water is pumped
through the small copper tubes and the fresh water coolant                        ZINC ANODES
from the engine is circulated around the copper tubes. The
raw water removes heat from the fresh water coolant.

Heat Exchanger Service
After approximately 1000 hours of operation, remove, clean
and pressure test the engine's heat exchanger. (A local auto-
motive radiator shop should be able to clean and test the heat
exchanger.)                                                               NEW                   REPLACE              CLEAN & REUSE

NOTE: Operating in silty and/or tropical waters may require            If the zinc anodes need replacement, hold the hex boss into
that a heat exchanger cleaning be perfonned more often than            which the zinc anode is threaded with a wrench while loos-
every 1000 hours.                                                      ening the anode with another wrench. This prevents the hex
                                                                       boss from possibly tearing off the exchanger shell. After
Zinc Anode                                                             removing the zinc, note the condition of it. If the zinc is in
A zinc anode, or pencil, is located in the raw water cooling           poor condition, there are probably a lot of zinc flakes within
circuit within the heat exchanger. The purpose of having               the exchanger. Remove the end of the heat exchanger and
zinc anodes is to sacrifice them to electrolysis action taking         clean the inside of all zinc debris. Always have a spare heat
place in the raw water cooling circuit, thereby reducing the           exchanger end gasket in case the present one becomes dam-
effects of electrolysis on other components of the system.             aged when removing the end cover. Replace the gasket (refer
The condition of the zinc anode should be checked monthly              to your engine model's heat exchanger end gasket part num-
and the anode cleaned or replaced as required. Spare anodes            ber), O-ring and cover, and install a new zinc anode.
should be carried on board.                                            NOTE: The threads of the zinc anodes are pipe threads and
NOTE: Electrolysis action is the result of each particular             do not require sealant. Sealant should not be used as it may
installation 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 SYSTEM
Raw Water Intake Strainer                                              NOTE: Also follow the above procedure after having run hard
                                                                       aground.
NOTE: Always install the strainer at or below the waterline so
the strainer will always be self-priming.                              If the engine temperature gauge ever shows a higher than
                                                                       normal reading, the cause may be that silt, leaves or grass
A clean raw water intake strainer is a vital component of the          may have been caught up in the strainer, slowing the flow of
engine's cooling system. Include a visual inspection of this           raw water through the cooling system.
strainer when making your periodic engine check. The water
in the glass should be clear.
Perform the following maintenance after every 100 hours of
operation:
1. Close the raw water seacock.
2. Remove and clean the strainer filter.
                                                                   WASHER
3. Clean the glass.
4. Replace the washer if necessary.
5. Reassemble and install the strainer.
6. Open the seacock.
7. Run the engine and check for leaks.
                                                                   STRAINER
                                                                   FILTER




                                                                                TYPICAL RAW WATER INTAKE STRAINER
                                                                                            tOwner Installed]


                                                 AIR INTAKE FILTER
                                                                                           ........--CONNECTS TO ROCKER
DESCRIPTION                                                                                            ARM COVER
A marine diesel engine will typically consume as much as
6,000 cubic feet of air per hour. Not only must the engine
room be well ventilated, the air flow into the engine must be
unrestricted. The air intake filter/cleaner should be inspected
every 100 operating hours. Clean/replace when needed.




               AIR INTAKE FILTER




                                                          Engines & Generators

                                                                  18
                                                          FUEL SYSTEM
DIESEL FUEL                                                                FUEL FILTERS
Use No.2 diesel fuel with a cetane rating of 45 or higher. Do not          The fuel injection pump and the fuel injectors are precisely
use 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 fuel
FUEL WATER SEPARATOR                                                       must pass through at least two fuel filters. a fuel/water sepa-
A primary fuel filter of the water separating type must be                 rator and the engine's spin-on fuel filter. Visually inspect,
installed between the fuel tank and the engine to remove                   clean. and change these filters according to the maintenance
water and other contaminants from the fuel before they can                 schedule in this manual.
be carried to the fuel system on the engine.
 Most installers include a type of filter/water 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 filter/water 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 engine-mounted fuel system, any water in the fuel
 will affect the fuel pump, engine filter, and injection
 equipment. The owner/operator is responsible for making
 certain the fuel reaching the engine's injection equipment is
 free of impurities. This process is accomplished by installing
 and maintaining a proper filtration/separation system.

FUEL FILTER!
WATER SEPARATOR
[Owner 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 counterclockwise 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 bench-tested and the                      bracket so the new filter can be seated properly.
 owner-operator is cautioned not to attempt to service it. If it           4. Lightly oil the sealing O-ring on the new filter. To rein-
 requires servicing, remove it and take it to an authorized fuel              stall, turn the filter assembly counterclockwise carefully
 injection pump service facility. Do not attempt to disassemble               until the O-ring contacts the sealing surface of the housing
 and repair it.                                                               bracket. Turn 2/3 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 SYSTEM
FUEL FEED PUMP STRAINER                                            BLEEDING (PRIMING) THE FUEL SYSTEM
An additional fuel screen is located in the feed pump. This        1. Loosen the bleeding screw on the fuel injection pump.
screen (strainer) is removed for cleaning by releasing the         2. Tum the feed pump knob counterclockwise until the pump
banjo bolt at the bottom. This screen should be cleaned every         knob is forced up by the spring.
250 operating hours. Use compressed air and/or clean with
kerosene.                                                          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 manufacturer's
                                                                   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.


                       1.4---   BANJO
                                BOLT



After changing the fuel filter and cleaning the fuel feed pump
strainer, WESTERBEKE recommends the following proce-
dure for ensuring there is no air trapped in the fuel system.




                                                           Engines & Generators

                                                                  20
                                            ENGINE LUBRICATING OIL
DESCRIPTION
The lubricating system is a pressure feeding system using an                NOTE: Generic filters are not recommended. as the mater-
oil pump. The engine oil is drawn from the oil sump by the              ial standards or diameters of important items on generic
oil pump, which drives the oil, under pressure, through the             parts might be entirely different from genuine parts.
oil filter, oil cooler and various lubricating points in the .          Immediately after an oil filter change and oil fill. run the
engine. The oil then returns to the oil sump to repeat the              engine to make sure the oil pressure is normal and that
continuous cycle. When the oil pressure exceeds the                     there are no oil leaks around the new oilfilter.
specified pressure, the oil pushes open the relief valve in the      3. Filling the Oil Sump. Add new oil through the oil filler
oil pump and returns to the oil sump, keeping the oil pressure          cap on the top of the engine. After refilling, run the
within its specified range.                                             engine for a few moments while checking the oil
                                                                        pressure. Make sure there is no leakage around the new
Oil Pressure                                                            oil filter or from the oil drain system, and stop the engine.
The engine's oil pressure, during operation, is indicated               Then check the quantity of oil with the lube oil dipstick.
by the oil pressure gauge on the instrument panel. During               Fill to, but not over the high mark on the dipstick, should
normal operation, the oil pressure will range between 25 and            the engine require additional oil.
85 psi.
ENGINE OIL CHANGE
1. 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
                                                            1/4" NPT                                          O-RING. THEN TIGHTEN
                                                                                                              2/3 OF A TURN.
               SUMP
               DRAIN                                                                                         O-RING
               HOSE-_ _~                                                                                     APPLY CLEAN
                                                          6"0.0.                                             ENGINE OIL
                                                                                                             WHEN INSTALLING


   Always observe the used oil as it is removed. A
   yellow/gray emulsion indicates the presence of water in
   the oil. Although this condition is rare, it does require
   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 and/or 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 anti-siphon valve, its                                                    CUSTOMER OPTION
   poor location or lack of maintenance.                                                                       THIS WIRE CAN BE
                                                                                                               USED TO ATTACH A
2. 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
    filter's O-ring gasket's sealing surface free of oil and                                                   WIRING HARNESS.
    apply a thin coat of clean engine oil to the rubber O-ring
    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 (OPTIONAL)
INSTALLATION                                                              To install, simply remove the engine oil filter and thread on
                                                                          WESTERBEKE's remote oil filter kit as shown. Always
This popular accessory is used to relocate the engine's oil fil-          install this kit with the oil filter facing down as illustrated.
ter from the engine to a more convenient location such as an
engine room bulkhead.                                                     Contact your WESTERBEKE dealer for more information.

NOTE: Refer to ENGINE OIL CHANGE in this manualfor                        NOTE: Westerbeke is not responsible for engine failure due to
instructiollS on removing the oil filter.                                 incorrect installation of the Remote Oil Filter.


  A CAUTION: It Is Ifltal to Install the oill/nes
  correctly. If the 011 flows In themvelSB dlmctlon, the
  by-pass 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 O-RING WHEN                                        FILTER CONTACTS THE BASE, TIGHTEN IT AN
 INSTALLING THIS KIT. THREAD THE KIT ON, THEN HAND                                       ADDITIONAL 3/4 TURN.
 TIGHTEN AN ADDITIONAL 3/4 TURN AFTER THE O-RING
 CONTACTS THE BASE.




                                                              Engines & Generators

                                                                     22
                            WATER HEATER CONNECTION (OPTIONAL)
As an accessory, WESTERBEKE wiJI provide a connector               The water heater shouKl be mounted in a convenient location
that directs the engines hot water (coolant) flow to heat the      either in a high or low position in relation to the engine, so
fresh 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
                                                                    engine's 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 tank's location and
ENGINE                                                              the other back to the engine's return. Install the remote
FRONT                                                               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 (lC's), the             a. If the voltage is increasing toward 14 volts, the alterna-
  electronic voltage regulator is very compact and is mounted                  tor is working; omit Steps 3 through 8 and go directly
  internally or on the back of the alternator.                                 to "Checking the Service Battery" on the next page.
                                                                            h.If the voltage remains around 12 volts, a problem
                                                                               exists with either the alternator or the charging circuit;
     #14 GRAy==#=w__......                                                     continue with Steps 3 through 8.

                                                                                                           CIDJ
#14 PINK ~~~~~~~fiC--
#14 BLUE=
                                          (9)~~=#14 BROWN                             MULTIMETER
                                                                                                          o
                                                                                                          COM




                                    iB@lillili==== #10 REO

                                              SEE WIRING DIAGRAM
              ENGINE                          FOR WIRE CONNECTIONS
              GROUND     ,':1                 TO OPTIONAL ALTERNATORS.

  ALTERNATOR TROUBLESHOOTING                                                  TESTING THE STARTING
                                                                              BATTERYIALTERNATOR
                                                                              (ENGINE RUNNING)
   A    WARNING: A failed alternator can become very
   hot. 00 not touch until the alternator has cooled down.                                             -= GROUND
  Use this troubleshooting 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 battery's 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.
                                                                                                            ~W---MULTIMETER
   A     WARNING: When testing with a multimeter:
    DC and AC circuits are often mixed together in marine
    applications. Always disconnect a shore power cord,
    iso/ate 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 know/edge of AC circuits.                      (IGNITION ON - ENGINE OFF)



                                                               Engines & Generators                     -= GROUND
                                                                       24
                                             DC ELECTRICAL SYSTEM
7. Now check the voltage between the alternator output ter-                 Checking the Service Battery
   minal (B+) and ground. If the circuit is good, the voltage at
                                                                            Check the voltage of the service battery. This battery should
   the alternator will be the same as the battery, or if an isola-
                                                                            have a voltage between 13 and 14 volts when the engine is
   tor is in the circuit the alternator voltage will be zero. If
                                                                            running. If not, there is a problem in the service battery
   neither of the above is true, a problem exists in the circuit
                                                                            charging circuit. Troubleshoot the service battery charging
   between the alternator and the battery. Check all the
                                                                            circuit by checking the wiring and connections, the solenoid,
   connections - look for an opening in the charging circuit.
                                                                            isolator, battery switch, and the battery itself.
                                           MULTIMETER   CI2ID

                                            WITCH
                                                        0
                                                        COM
                                                                                    MumMETER    i
                                                                                                COM


                                             ~~a+"      I'   "\..



        TESTING THE STARTING
        BATTERYIALTERNATOR
        (ENGINE RUNNING)                    I
8. 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 13.5 and 14.5 volts. If your alternator                          GROUND                     TESTING THE SERVICE
   is over- or under-charging, have it repaired at a reliable
                                                                                                                 BATTERY (ENGINE RUNNING)
   service facility.
    NOTE: Before removing the alternator for repair; use a
    voltmeter to ensure that 12 volts DC excitation is present
    at the EXC terminal if the previous test showed only bat-                  A    CAUTI,ON: To avoid damaging the alternator diodes,
    tery voltage at the B output terminal.                                     do not use a high voltage tester (i.e. 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 connections.

12 VOLT DC CONTROL CIRCUIT                                                    Battery Care
The engine has a 12 volt DC electrical control circuit that is                Review the manufacturer's recommendations and then
shown on the wiring diagrams that follow. Refer to these                      establish a systematic maintenance schedule for your
diagrams when troubleshooting or when servicing the DC                        engine's starting batteries and house batteries.
electrical system.                                                            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
  engine's electrical circuit.
                                                                              o    Make certain that battery cable connections are clean and
                                                                                   tight to the battery posts (and to your engine).

BAnERY                                                                        o    Keep your batteries clean and free of corrosion.

The minimum recommended capacity of the battery used in
the engine's 12 volt DC control circuit is 600 - 900 Cold
Cranking Amps (CCA).
                                                                                  A   WARNING: Sulfuric acid in lead batteries can
                                                                                  cause severe bums on skin and damage clothing. Wear
                                                                                  protective gear.



                                                                    Engines & Generators

                                                                         25
                                                       GLOW PLUGS
  DESCRIPTION                                                       Re-install 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 don't heat up quickly, check for a short
  When PREHEAT is pressed at the control panel this solenoid
                                                                    circuit. When reinstalling the glow plugs, use anti-seize 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 plug's tip and threads with a
  soft brush and cleaning solution to remove all the carbon and     Glow Plug Tightening Torque   19.5 H-Ib (2.7 m-kg)
  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 plug's 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 0.4 - 0.6 ohm resistance. This method can be                       WITH AN OHMMETER
  used with the plug in or out of the engine. You can also use                           KEYIPREHEAT-QPi
  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 PREHEAT
TERMINAL
                                                                                                                           +




                                                           Engines & Generators

                                                                  26
                                          WIRING SCHEMATIC
                                          MARINE ENGINES #44781

             +   ~
                  . -______________~8~AT~T~E~RT~I~2~2~.~V~O~C~________________
                                                                              

                                  START
                                  SOl.            STARTER




     IZV (       24V
    20A          lOA
    C.B          C.B


                                                                                        OPTIONAL ALTERNATORS
                  e:       '"
                           u
                           ....

                  ....
                  c        .;
                   ~
                   ~
                   '"'



                                                                                         PRESlOLllE 12 AMP          ALl


                                                             TACHOMETER
                  KEY                                          $
                  SW.




                                                              VOLTMETER


ADMIRAL
PANEL

                                                                                  PRESlOLllE\LEECE-NEVILLE 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




                                       I----~~~~~t-w_----_rt_------t_--J_--~


                 "'~" ,~
                                       I
                                       I

                                +~
                                  ~-===-                                (USED
                                                                                aNEUTRAL
                                                                                   WI
                                                                                     rTY
                                                                                           H
                                                                                                  DELSI

                                  BATTERY
                                 12-21 VDC

NOTES:
    'NIS 'IOOUCI IS '.onenD IT " 1iI.. IiIUAL !tun ClIltUIl .RUln LOCATED IIUI TME
     ITAnn. [attallV[ CUIIUT Will UUS[ Ttll .ltUl.lII TO nIP AIID THE [II&III( Will
                                                                                                      SI
     SMUT DOI'IiI. 'HE IUILO[l/o.III[l MUST Sf SUII[ THU THE .IISTIUIiIUT p"ln, W.IIIIG. ,toIO
     IIG'I AlE ,.STALUD TO "II(VUT COII"CT en.EU [lECTlICAL OUlets AIID sUlun
2. 'II all-orr SWITCH I!tOULD IE IUTALUI IU.ElI THE I"HUr .. I' STAUn TO
   DISCOI"I[(T THE ,aTTU' UI ,.. (MUGUel "liD ,,"II LlAWl1IG TME 10AT ... SWnCM
   WITH A COITIIIUGUS IU"IG or 115 Allrs AT 12 "DC WILL I[lV[ THIS rUIICTlOI. IMIS
   $1. TeM 'MOULD lOT IE uUD TO MAil 01 .I[AI THE C !leUIT .
                                                                                                      PI
J. THE "11' 1.1It[ AT 'LUG Z IS .Iusn ".D SHOULD IE U'SULATED. CAPU'I               "un   OIlU




                                                                                                           II                          ADMIRAL
..   TME ,  .,. II.I[ AT '"UG 1 IS   u.usn .... 0   SMOULD liE IIilSULun, ADlIIIAL ' u n Gell'
5 co. . lcr rill CIICUIl IIURU ".0 USIUOt .'I[ ro '"l "," rUII''''L rOt 12 WOlf
  nSTUS OIU. FOt Z4 VOLT nSTtMs I[MOVI rill Clleulr IIUIII' "10 co.l[er rill
  IUISTOI .,lIl ro rill .. 4 LT ILU WillS "ID rill. GlOUID rll[ .," rUM .."l                                                           PANEL



                                                                                                                                  -,
                                                                       I
                                                                       I
                                                                       I
                                                                       I
                                                                       I
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                                                                        I
                                                                        I
                                                                        I
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                                                                        L   __
                                                                                                             110 REO




                                                                                                           Engines & Generators
                                                                                                                28
                                             ENGINE TROUBLESHOOTING
The following troubleshooting table describes certain problems                   NOTE: The engine's electrical system is protected by a 20
relating to engine service, the probable causes of these prob-                   ampere manual reset circuit breaker located on a bracket at
lems, and the recommendations to overcome these problems.                        the back of the engine. The preheat solenoid is mounted on
                                                                                 the same bracket.

               Problem                              Probable Cause                                        VerificationJRemedy
 No panel indications; fuel solenoid       1. Battery switch not on.                     1. Check switch and/or battery connections.
 or fuel pump is not working (key switch
 is on and PREHEAT button is depressed).   2. 20-amp circuit breaker tripped.            2. Reset breaker; if breaker trips again. check preheat solenoid
                                                                                            circuit and check circuit for shorts to ground.
                                           3. 10-amp 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 res~t.
                                           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 can't be stopped.                 1. Disconnect fuel shut-off cable.            1. Check connection at shut-off 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 SYSTEM/ALTERNATOR.
  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 tank(s); change filters and
                                                                                             bleed fuel system.
                                            5. Air intake obstruction.                    5. Check air intake filter cartridge.

                                                                                                                                                 (continued)


                                                                     Engines & Generators

                                                                             29
                                         ENGINE TROUBLESHOOTING
              Problem                          Probable Cause                                        Verification/Remedy
 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 - tighten/replace.
                                                                                   2d. Air leak in system; run engine and open the pressure cap to
                                                                                       bleed air. Add coolant as needed.
 Engine alarm sound pulsates.         1. Loss of oil.                              1. Check dipstick, look for oil leaks at oil filter and at
                                                                                      oil drain hose connection.
                                      2. Oil pressure switch.                      2. Replace oil pressure switch.
 Engine alarm sounds continuously.    1. Engine coolant.                           1. Check engine coolant level.
                                      2. High temperature switch opens at .        2. Check for satisfactory operation with switch bypassed,
                                         too Iowa temperature.                        check with ohmmeter, replace if faulty.
 Exhaust smoke problems               1. Blue smoke.                               1. Incorrect grade of engine oil.
                                                                                   1a. Crankcase is overfilled with engine oil (oil is blowing out
                                                                                       through the exhaust).
                                       2. White smoke.                             2. Engine is running cold.
                                                                                   2a. Faulty injector or incorrect injector timing.
                                       3. Black smoke.                             3. Improper grade of fuel.
                                                                                   3a. Fuel burn incomplete due to high back-pressure in exhaust or
                                                                                       insufficient air for proper combustion (check for restrictions in
                                                                                       exhaust system; check air intake).
                                                                                   3b. Improperly timed injectors or valves, or poor compression.
                                                                                   3c. Lack of air - check air intake and air filter. Check for proper
                                                                                       ventilation.
                                                                                   3d. Overload.




                        TROUBLESHOOTING COOLANT TEMPERATURE AND OIL PRESSURE GAUGES
If the gauge reading is other than what is nonnally indicated              If both of the above gauge tests are positive, the gauge is
by the gauge when the instrument panel is energized, the first             undoubtedly OK and the problem lies either with the
step is to check for 12 volts DC between the ignition (B+)                 conductor from the sender to the gauge or with the sender.
and the Negative (B-) tenninals of the gauge.                              If either of the above gauge tests are negative, the gauge is
Assuming that there is 12 volts as required, leave the                     probably defective and should be replaced.
instrument panel energized and perfonn the following steps:                Assuming the gauge is OK, check the conductor from the
1. Disconnect the sender wire at the gauge and see if the                  sender to the sender 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 the
2. 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
                                                      TACHOMETER
TACHOMETER/HOUR METER                                                 NOTE: Current model tachometers use a coarse adjustment
The tachometerlhour meter used in propulsion engine instru-           dial to set the tachometer to the crankshaft pulley rpms. The
ment panels contains two separate electrical circuits with a          calibrating screw is then used for fine tuning.
common ground. One circuit operates the hour meter and the
other the tachometer. The hour meter circuit operates on 12
volts alternator charging voltage supplied to the (+) terminal
on the back of the instrument.
The tachometer circuit operates on AC voltage 6-8 volts, fed
from one of the diodes in the alternator and supplied to the
tachometer input terminal while the engine is running, and
the alternator producing battery charging voltage 13.0-14.8                                                                        TERMINAL
volts DC.
The following are procedures to follow when troubleshooting
                                                                   COARSE
a fault in either of the two circuits in a tachometerlhour         ADJUSTMENT
meter.
                                                                                                                      TACH INP
Hour meter Inoperative                                                                                                AC VOLTAGE
Check for the proper DC voltage between (+) and (-)
terminals.                                                            TACHOMETER CHECK (New Installation)
1. 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 the
2. Voltage not present - trace (+) and (-) electrical con-
                                                                      engine's 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 temperature.
Tachometer Inoperative                                                    Remove any specks on the crankshaft pulley with a clean
Check for the proper AC voltage between tachometer input                  cloth and place a piece of suitable reflecting tape on the
terminal and (-) terminal with the engine running.                        pulley to facilitate use of a photoelectric type tachometer.
1. 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 to
2. 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 by
3. Check for AC voltage at tach terminal on alternator to                using the instrument coarse adjustment to calibrate the
   ground.                                                               instrument reading to the closest R.P.M. that the photo tach
                                                                         is showing. Then use the fine calibration adjustment to
4. Check electrical connections from tachometer input ter-               bring the instrument to the exact reading as the photo tach.
   minal to alternator connection.
Tachometer Sticking
1. Check for proper AC voltage between "tach inp."
   terminal and (-) terminal.
2. Check for good ground connection between meter (-)
   terminal and alternator.
3. Check that alternator is well grounded to engine block at
   alternator pivot bolt.
Tachometer Inaccurate
a. With a hand-held tach on the front of the crankshaft
   pulley retaining nut or with a strobe-type tach, read the
   front crankshaft pulley rpm at idle.
b. Adjust the tachometer with a small Phillips type screw-
   driver through the calibration access hole in the rear of
   the tachometer. Zero the tach and bring it to the rpm
   indicated by the strobe or hand tach. (Verify the rpm at
   idle and at high speed and adjust the tach as needed).




                                                           Engines & Generators

                                                                 31
                                              ENGINE ADJUSTMENTS
DRIVE BELT ADJUSTMENT
Proper inspection, service and maintenance of the drive belts
is important for the efficient operation of your engine (see
Drive Belts under MAINTENANCE SCHEDULE).                                    FUEL INJECTOR
Drive belts must be properly tensioned. Loose drive belts win
not provide proper alternator charging and will eventually
damage the alternator. Drive belts that are too tight will pun
                                                                        HOLOOWN NUTS
the alternator out of alignment and/or cause the alternator to
wear out prematurely. Excessive drive belt tension can also
cause rapid wear of the belt and reduce the service life of the
coolant pump's bearing. A slack belt or the presence of oil on
the belt can cause belt slipping, resulting in high operating
temperatures and tachometer variations.                             FUEL INJECTORS
The drive belt is properly adjusted if the belt can be deflected    In case of severe vibrations and detonation noise, have the
no less than 3/8 inch (lOmm) and no more than 112 inch              injectors checked and overhauled by an authorized fuel
(12mm) as the belt is depressed with the thumb at the mid-          injection service center. Poor fuel quality, contaminants and
point between the two pulleys on the longest span of the belt.      loss of positive fuel pressure to the injection pump can result
A 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 belt's 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 lift
Adjusting Belt Tension                                              out easily and is held in by carbon build-up or the like, work
1. Loosen the alternator adjusting strap bolt and the base          the injector side-to-side with the aid of the socket wrench to
   mounting bolt.                                                   free it, and then lift it out.
2. 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 and
3. 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 operating
4. Tighten the base mounting bolt and the adjusting strap               hours.
   bolt.                                                                INJECTION STARTING PRESSURE  2630 psi (18.1 Mpa) (185 Kg/em')
5. Run the engine for about 5 minutes, then shut down and               INJECTION HOLDDOWN NUTS TORQUE 13.7  1.5 It-Ib (1.9  0.2 Kg-m)
   recheck the belt tensions.
STARTER AND ALTERNATOR SERVICE
The starter and the alternator should be serviced every 1200
operating hours.
Starter commentator cleaning.
Alternator slip ring cleaning.
Carbon brushes and the brush contact check.
Refer 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 mechanic.

TESTING ENGINE COMPRESSION                                           OIL PRESSURE
Make certain the oil level (dipstick) is at the correct level        The engine's oil pressure, during operation, is indicated
and the air intake filter is clean. The battery and starter motor    by the oil pressure gauge on the instrument panel. During
must also be in good condition.                                      normal operation, the oil pressure will range between 40 and
1. Warm the engine to normal operating teITiperature.                85 psi.
2. 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 vary
3. Remove all the glow plugs from the engine and install                 depending upon the temperature of the engine, the load
   the compression gauge/adapter combination to the                      placed on the engine, and the RPM's.
   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 TROUBLESHOOTING 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 it's 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 n-Ib (1.2 - 1.8 m - Kg).




                                                                                                             PREHEAT SOLENOID
4. Close the raw water seacock (thru-hull).
5. Crank the engine and allow the gauge to reach a
   maximum reading, then record that reading.
6. Repeat this process for each cylinder.                                                                                          20A BREAKER
    COMPRESSION PRESSURE 441 psi (31.0 Kg/em') at 200 rpm.
    ALLOWABLE LIMIT    370psi (26.0 Kg/em').
    MAXIMUM PERMISSIBLE DIFFERENCE BETWEEN CYLINDERS
    28.44 psi (2.0 Kg/em')
NOTE: Jfthe readings are below the limit, the engine needs an
   overhaul.
7. Re-install the glow plugs and reset the fuel shut-off to the
   run position.
S. Open the raw water seacock (thru-hull).
Low Compression
When low compression is found, determine the cause by
applying a small amount of oil in the cylinder thru the glow
plug hole. Allow the oil to settle.
Install the pressure gauge and repeat the above test. If the
compression reading rises dramatically, the fault is with the
rings. If the compression valve does not rise, the problem is                                                OIL PRESSURE
with the valves.                                                                                             SWITCH
A slight rise in compression would indicate a problem with
both 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 mechanic.
VALVE CLEARANCE ADJUSTMENT                                                          3. After adjusting the valves with piston No. I at IDC,
The valve clearance must be adjusted every 200 operating                               rotate the crankshaft 3600 again aligning the TDC mark
hours. or whenever the valve rocker is abnormally noisy.                               and the pulley mark. This brings piston No.6 or No.4 to
Valve adjustment should only be done when engine is cold.                              TDC, then adjust the remaining valves.
Cold engine valve clearance is 0.0157 in (0.40 mm).
                                                                                    INJECTION TIMING CHECK/ADJUSTMENT
                                                                                    Improper injection timing can cause engine failure. In normal


                                                  ~..J ~D.D1571N
                                                                                    servicing, this check and adjustment in unnecessary, however,
                                                                                    it might be necessary in conjunction with other related work
                                                                   'D.4DMMI         such as an engine overhaul.



                                      ~VE
                                                                                                                                            TIMING MARKS


                                      ~ ~~EARANCE                                                                     .........   '~::7'l'---TDC   MARK

NOTE: The            head bolts have been tightened with the
"Angular Tightening Method". Therefore, it is not necessary
to retighten the cylinder head bolts before adjusting the valve                                                                              PULLEY MARK
clearances.

ADJUSTMENT PROCEDURE                                                          CRANKSHAFT PUllEY
Chart 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 No.1 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 No.6 cylinder is
      at TOC in the com-                    @@              @@         @@            stroke. Turn the crankshaft pulley c1ockwi~e (viewed at
      pression stroke                                                                engine front) and align the mark on the crankshaft pulley
                                                                                     with the IDC mark.
1. In order to bring No. I or No.6 piston (six cyl.) No.4                            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 timing
2. 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 No.6 piston                          turning the crankshaft pulley one more tum to repeat the
   (six cyl.) No.4 piston (four cyl.)is on IDC in the                                 procedure to make sure that it is in alignment.
   compression stroke.
Chart shows four cylinder model                                                           INJECTION
                                                                                          PUMP
      Cylinder No.                1         2      3       4                              MARKS
      Valve arrangement       I       E I       E I E I E
I-    When No.1 cylinder
Z
=
a::
II.
      is at TDC in the com-
      pression stroke
                              O0 0                     0

      When No.4 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 mechanic.
Check the crankshaft position for the start of fuel injection.       5. Notice which injection timing mark is aligned with the
1. Turn the crankshaft pulley counterclockwise 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 injection
2. Remove No. I high pressure injection line.
                                                                        The degrees before TDC differs depending on the engine


                           e
                           1'1~DELIVERY    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
                                                                        angle.
3. 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 - 4.5 Kg-m!28.9 - 32.5 ft-Ib)                          the delivery valve, spring and the valve holder.
                                                                        DELIVERY VALVE HOLDER TIGHTENING TORQUE:
4. Slowly turn the crankshaft pulley clockwise and at the               39 - 44 Nm (4 - 4.5 Kg-m!28.9 - 32.5 ft-Ib)
   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 tut;ning 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 TRANSMISSIONS
SHIPMENT                                                                     INITIAL OPERATION
For safety reasons, the transmission is not filled with trans-               Set the shifting lever to neutral position (N). Start the engine
mission fluid during shipment and the selector lever is tem-                 and let it run long enough in idle to fill the cooler and hoses
porarily attached to the actuating shaft.                                    with transmission fluid. Shift into gear, forward and reverse;
Before leaving the WESTERBEKE plant, each transmission                       shifting should be smooth and positive. Direct changes from
undergoes a test run, with Dextron III ATF transmission fluid.               forward to reverse are permissible since the mUltiple disc
The residual fluid remaining in the transmission after drain-                clutch permits changing at high rpm including sudden revers-
ing acts as a preservative and provides protection against cor-              ing at high speeds in the event of danger.
rosion 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
                                        ~;;iJ#N~k--AIR VENT
                                                                              LOCKING THE PROPELLER
                                                                              Locking of the propeller shaft by an additional brake is not
                                                                              required: use the gear shift lever position opposite your direc-
                                                                              tion of travel for this purpose. Never put the gear shift in the
                                                                              position corresponding to the direction of travel of the boat.
                                        ~~IJt,........~.JJ-- FLUID
                                                                FIlTER
                                 \l:I....e3IN
                                                                              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 transmission.

OIL COOLER                                                                     NOTE: When the boat is being sailed (engine stopped), the
                                                                               gear shift must be in the neutral position. The propeller is at
The oil cooler, mounted above the transmission, provides
                                                                               idle and can free-wheel.
continuous cooling for the transmission fluid. Raw water
passes through the tubes of the cooler and discharges over-                    DAILY OPERATION
board. The transmission fluid is cooled as it flows around the
tubes 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 not
TRANSMISSION FLUID                                                             exceed 176F (80C) under normal continous running. A
Fill the transmission with Dextron l/l ATF. The fluid level                    connection for a temperature probe is provided. At maximum
should be up to the mark on the dipstick. After checking the                   output of the engine, the fluid may reach 220F (l04C).
level, press the dipstick into the case and turn it to tighten.
During the first 25 operating hours, inspect the bell housing,
output shaft and transmission cooler for leakage. The fluid                     A CAUTION: If the transmission fluid temperature is
should be changed after the first 25 hours and every 300                        too high, stop the engine immediately and check the
hours thereafter.                                                               transmission fluid.
NEUTRAL SWITCH
These transmissions are equipped with a neutral safety
switch. This is to prevent the engine fr<,Jrn starting in gear.
Unless the transmission selector lever is perfectly aligned in
neutral, 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 -        2.12 quarts (2.0 Liters)
                                                                                     HURTH 63 - 3.2 quarts (3.0 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.


                         O-RINGS                                        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).

                                                                        Lay-upJWinterize
Filter Element                                                          Storage requires special care. Follow these procedures:
The Hurth transmission has a filter element located opposite            D Drain water from the transmission oil cooler and replace
the dipstick. This filter must be replaced whenever the fluid is            with a proper mixture of antifreeze coolant.
changed.                                                                    NOTE: This operation will normally occur when the
Remove the filter by loosening the screw on the cover using a               engine raw water cooling system is properly winterized.
6mm Allen wrench.
                                                                        D Clean up the transmission and touch up unpainted areas
Twist and pull out the filter and remove the element. Place                 (use heat resistant paint).
the new filter onto the cover and lock it into place by turning
it clockwise. Check the O-rings for damage and replace if
                                                                        D   Fill the transmission with Dextron 1Il ATF fluid to pre-
                                                                            vent internal corrosion (extended storage only, twelve
necessary. Replacement filters can be obtained from your
                                                                            months or more).
local WESTERBEKE dealer or ZF (Hurth dealer).
                                                                        D   Loosen attaching hardware from the transmission output
Removing the Fluid                                                          flange and propeller shaft coupling flange before remov-
Push a suction pump hose down through the pipe hole (under                  ing the boat from the water. Separate the flanges and
the filter) to the bottom of the housing and suck out the fluid.            spray with lubricant.
Remove the oil return line from the cooler and allow the oil            D   Inspect the gear shift cable, linkage, and attachments.
to drain into a container, then reconnect the oil return line.              Look for corrosion of the end fittings, cracks or cuts in
                                                                            the conduit, and bending of the actuator rods. Lubricate
Wipe down the transmission and properly dispose of the used                 all moving parts.
fluid.
                                                                            NOTE: If the transmission is to be stored for a 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 0.02in(0.5mm).            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.                                                           turer's instructions.
 Shifting Positions:                                                     Even with the engine solidly mounted,the 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- 0.021n
                                                      r(0.5mm)
                                  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
 TROUBLESHOarING)                                                                 Fort Lauderdale, FL 33312
                                                                                  Tel.: (954) 581-4040
 NOTE: Check for proper actuating lever travel at least each
                                                                                  Fax: (954) 581-4077
 season.

   A CAUTION: The position of the mechanism behind
   the actuating lever Is factory-adjusted to ensure equal
   shift lever travel from neutral position to A and B. If
   this mechanism Is In any way tampered with. the
   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 minutes.
SHIPMENT
For safety reasons, the transmission is not filled with trans-         Neutral
mission fluid during shipment and the selector lever is tem-           Move the gear shift lever to the middle position. You should
porarily attached to the actuating shaft.                              feel the detent. This centers the actuating lever on the trans-
Before leaving the WESTERBEKE plant, each transmission                 mission. With the control in this position, hydraulic power is
undergoes a test run, with Dextron III ATF transmission fluid.         completely interrupted and the output shaft of the transmis-
The residual fluid remaining in the transmission after drain-          sion does not tum.
ing acts as a preservative and provides protection against
                                                                       NOTE: Some transmissions are equipped with a neutral safety
corrosion for at least one year if properly stored.                    switch. Unless the transmission actuating lever is perfectly
TRANSMISSION FLUID                                                     aligned in neutral, the engine starter will not activate.
Check the transmission fluid level on the dipstick. If the
transmission has not been filled, fill with Dextron III and            Forward
continue to use this fluid. During the first 25 hours of opera-        Move the gear shift lever to the forward position. You should
tion, keep a lookout for any leakage at the bell housing, out-         feel the detent. The actuating lever on the transmission is in
put shaft and transmission cooler. This fluid should be                the forward position. The output shaft and the propeller shaft
changed after the first 25 hours and approximately every 300           move the boat in a forward direction.
operating hours thereafter and/or at winter lay-up.
                                                                       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 finger-tight.)
                                                                         D   Run the engine, shutdown and recheck the fluid level.

FORWARD                    NEUTRAL
           TRANSMISSION AC11JATING LEVER POSITIONS
                                                     REVERSE
                                                                          A   WARNING: Never pull out the dipstick while the
                                                                          engine Is running. Hot nuld will splash from the dipstick
DAILY OPERATION                                                           hole. This could cause severs bums.
o    Check the transmission fluid.
o    Visually check the gear shift linkage and transmission.             Oil Capacity
o    Start the engine in neutral. Allow a few minutes at idle            Approximately 2.5 quarts (2.36 liters) will fill most transmis-
     for the fluid to 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.

 INSPECTION
o    Visually check for oil leaks at the hydraulic connections.
     Check for wear on the hydraulic lines and replace if
     worn.
o    Lubricate the detent ball and shift cable attachments.
o    Inspect the shift linkage.
o    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 haul-out. 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 Ib-in2 (6.7 - 8.4 kg-cm 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 cap/dipstick hole.



                                                               EngInes & Generators

                                                                    40
                        BORG WARNER VELVET DRIVE TRANSMISSION
MAINTENANCE                                                             WARRANTY NOTES
Transmission maintenance is minimal. Keep the exterior                  Service manuals are available from your BORG WARNER
housing clean, check the fluid level as part of your regular            dealer.
routine, and change the fluid every 300 operating hours.                For assistance, contact:
Periodically inspect the transmission and the cooler for leaks                BORG WARNER
and corrosion. Make certain the air vent is clear and when                    200 Theodory Rice Blvd.
checking the fluid level look for signs of water contamination                New Bedford, MA 02745
(fluid will appear as strawberry cream).                                      Tel.: (508) 979-4881
Lay-up/Winterize                                                        BORG WARNER is aware of the shock loads that can be
                                                                        placed on its gears as the result of mechanical propeller oper-
Storage requires special care. Follow these procedures:
                                                                        ation or fully reversing of the propeller blades while shiftIng.
o   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 winterized.
o   Clean up the transmission and touch-up unpainted areas               A CAUTION: System-related noises or vibrations can
    (use heat resistant paint).                                          occur at low engine speeds which can cause gear rattle
o   Fill the transmission with Dextron III ATF fluid to pre-             resulting In damage to the engine and/or transmission.
    vent internal corrosion.                                             BORG WARNER Is not responsible for total system-
o   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 TROUBLESHOOTING in this manual.
o   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 TROUBLESHOOTING
CONTROL CABLES                                                                     OIL COOLERS
The majority of transmission difficulties arise as a result of                     The continued flow of raw water through the cooler will, in
improper clutch adjustments (manual transmissions) or prob-                        time, erode the inside of the cooler causing cross leaks to
lems with control cables (hydraulic transmissions) rather than                     occur. These internal cooler leaks will cause one of the fol-
from problems with the transmission itself.                                        lowing two problems:
HURTH clutches, in particular, are very sensitive to improper                          1. Transmission fluid will leak into the flow of raw water
cable adjustments.                                                                        and be discharged overboard through the engine exhaust.
If you experience operating problems with the transmission,                               A loss of transmission fluid will cause the transmission to
shut the engine down. First check the transmission-oil level,                             fail.
then have a helper move the cockpit shift lever through the                        2. The raw water will leak into the transmission fluid caus-
full range - from neutral to full forward, back to neutral,                           ing an increase in transmission fluid. This contaminated
into full reverse, and back to neutral - while you observe                            fluid will appear as strawberry cream. The transmission
the actuating lever on the transmission. If the remote is stiff                       will eventually fail.
to operate, break the cable loose at the transmission and try                      Either case requires an immediate response:
again. If it is still stiff, check the cable for kinks or exces-
sively tight bends, and check any linkage for binding. A new                           1. Install a new oil cooler.
cable and perhaps a new linkage mechanism may be needed.                           2. Refill the transmission with DEXTRON III ATF.
While the cable is loose, shift the transmission in and out of                         If water has contaminated the fluid, the transmission fluid
gear using the lever on the side of the transmission to make                           needs to be cleaned out and replaced with fresh fluid. It will
sure there's no binding inside the case.                                               take several fluid changes to get rid of the contamination.
If the transmission passes these tests, crank the engine and                           Check your dipstick each time until it appears as pure trans-
have a helper put it in forward and reverse while you observe                          mission fluid. Change the transmission filter and clean out
the propeller shaft; if the shaft isn't turning, the transmission                      the fluid lines that connect to the cooler.
needs professional attention. If it does tum but there's no                            If the transmission fails to shift properly, it will most likely
thrust, check to see you still have a propeller on the end of                          need the attention of a qualified transmission service facility.
the shaft or, if you have a folding or feathering propeller, that                      A transmission cooler may last ten years or more but, in
it isn't 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                                            VerlflcatlonJRemedy
  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 1/1 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 TROUBLESHOOTING
               Problem                           Probable Cause                                         VerlficatlonJRemedy
 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" position.

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




                                                                  Engines & Generators

                                                                          43
                                       LAY-UP & RECOMMISSIONING
GENERAL                                                                Fuel System [Gasoline]
Many owners rely on their boatyards to prepare their craft,            Top off your fuel tanks with unleaded gasoline of 89 octane
including engines and generators, for lay-up during the off-           of higher. A fuel conditioner such as STABIL gasoline
season or for long periods of inactivity. Others prefer to             stabilizer should be added. Change the element in your
accomplish lay-up preparation themselves.                              gasoline/water separator and clean the metal bowl.
The procedures which follow will allow you to perform your             Re-install and make certain there are no leaks. Clean
own lay-up and recommissioning, or you may use them as a               up any spilled fuel.
check list if others do the procedures.                                Fuel System [Diesel]
These procedures should afford your engine protection                  Top off your fuel tanks with No.2 diesel fuel. Fuel additiyes
during a lay-up and also help familiarize you with the                 such as BlOB OR and STABIL should be added at this time to
maintenance needs of your engine.                                      control algae and condition the fuel. Care should be taken
If you have any questions regarding lay-up procedures, call            that the additives used are compatible with the primary fuel
your local servicing dealer; he will be more than willing to           filter/water separator used in the system. Change the element
provide assistance.                                                    in your primary fuel filter/water separator, if the fuel system
                                                                       has one, and clean the separator sediment bowl.
Propeller Shaft Coupling [Propulsion Engine]
                                                                       Change the fuel filter elements on the engine and bleed the
The transmission and propeller half couplings should always
                                                                       fuel system, as needed. Start the engine and allow it to run
be opened up and the bolts removed when the boat is hauled
                                                                       for 5 - 10 minutes to make sure no air is left in the fuel
out of the water or moved from land to water, and during
                                                                       system. Check for any leaks that may have been created in
storage in the cradle. The flexibility of the boat often puts a
                                                                       the fuel system during this servicing, correcting them as
severe strain on the propeller shaft or coupling or both, while
                                                                       needed. Operating the engine for 5 - 10 minutes will help
the boat is taken out or put in the water. In some cases, the
                                                                       allow movement of the treated fuel through the injection
shaft has actually been bent by these strains. This does not
                                                                       equipment on the engine.
apply to small boats that are hauled out of the water when
not in use, unless they have been dry for a considerable               Raw Water Cooling Circuit
period of time.                                                        Close the through-hull seacock. Remove the raw water intake
Fresh 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 engine,
A 50-50 solution of antifreeze and distilled water is
                                                                       check the zinc anode found in the primary heat exchanger on
recommended for use in the coolant system at all times.
                                                                       the engine and clean or replace it as required, and also clean
This solution may require a higher concentration of
                                                                       any zinc debris from inside the heat exchanger where the
antifreeze, depending on the area's winter climate. Check the
                                                                       zinc anode is located. Clean the raw water strainer.
solution to make sure the antifreeze protection is adequate.
                                                                       Start the engine and allow the raw water pump to draw the
Should more antifreeze be needed, drain an appropriate
                                                                       fresh water through the system. When the bucket is empty,
amount from the engine block and add a more concentrated
                                                                       stop the engine and refill the bucket with an antifreeze
mixture. Operate the engine to ensure a complete circulation
                                                                       solution slightly stronger than needed for winter freeze
and mixture of the antifreeze concentration throughout the
                                                                       protection in your area.
cooling system. Now recheck the antifreeze solution's strength.
                                                                       Start the engine and allow all of this mixture to be drawn
Lubrication System                                                     through the raw water system. Once the bucket is empty, stop
With the engine warm, drain all the engine oil from the oil            the engine. This antifreeze mixture should protect the raw
sump. Remove and replace the oil filter and fill the sump              water circuit from freezing during the winter lay-up, as well
with new oil. Use the correct grade of oil. Refer to the               as providing corrosion protection.
ENGINE LUBRICATING OIL pages in this manual for the                    Remove the impeller from your raw water pump (some
oil changing procedure. Run the engine and check for proper            antifreeze mixture will accompany it, so catch it in a bucket).
oil 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 recommissioning, but replace the cover and gasket.
  A CAUTION: Do not leave the engine's old engine                      Cylinder Lubrication [Gasoline]
  oil in the sump over the lay-up 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 engine's
                                                                       out the engine as it coats the valves, cylinders and spark
  internal parts.                                                      plugs for winter protection.




                                                          Engines & Generators

                                                                  44
                                       LAY-UP &RECOMMISSIONING

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




                                                          Engines & Generators

                                                                   45
                               METRIC CONVERSIONS
              INCHES TO MILLIMETERS                                MILLIMETERS TO INCHES
Inches           mm           Inches          mm             mm           Inches     mm        Inches
  1             25.40           15        381.00              1           0.0394     15       0.5906
  2             50.80           20        508.00              2           0.0787     20       0.7874
  3             76.20           25        635.00              3           0.1181     25       0.9843
  4            101.60           30        762.00              4           0.1575     30       1.1811
  5            127.00           35        889.00              5           0.1969     35       1.3780
 10            254.00           40       1016.00             10           0.3937     40       1.5748
   10 MILLIMETERS = 1 CENTIMETER, 100 CENTIMETERS = 1 METER = 39.37 INCHES (3.3 FEET)

                  INCHES TO METERS                                      METERS TO INCHES
Inches          Meters        Inches         Meters         Meters        Inches    Meters     Inches
  1             0.0254           7           0.1778          0.1           3.937     0.7       27.559
  2             0.0508           8           0.2032          0.2           7.874     0.8       31.496
  3             0.0762           9           0.2286          0.3          11.811     0.9       35.433
  4             0.1016          10           0.2540          0.4          15.748     1.0       39.370
  5             0.1270          11           0.2794          0.5          19.685     1.1       43.307
  6             0.1524          12           0.3048          0.6          23.622     1.2       47.244
      TO CONVERT METERS TO CENTIMETERS, MOVE DECIMAL POINT TWO PLACES TO THE RIGHT

                    YARDS TO METERS                                     METERS TO YARDS
Yards           Meters        Yards          Meters         Meters        Yards     Meters     Yards
  1             0.91440         6            5.48640          1           1.09361     6       6.56168
  2             1.82880         7            6.40080          2           2.18723     7       7.65529
  3             2.74320         8            7.31520          3           3.28084     8       8.74891
  4             3.65760         9            8.22960          4           4.37445     9       9.84252
  5             4.57200        10            9.14400          5           5.46807    10      10.93614
            MOVE DECIMAL POINT FOR HIGHER VALUES - e.g. 6,000 METERS = 6,561.68 YARDS

               POUNDS TO KILOGRAMS                                 KILOGRAMS TO POUNDS
  Ib             kg      Ib     kg                            kg         Ib      kg              Ib
   1             0.454            6           2.722            1            2.205     6        13.228
   2             0.907            7           3.175            2            4.409     7        15.432
   3             1.361            8           3.629            3            6.614     8        17.637
   4             1.814            9           4.082            4            8.818     9        19.842
   5             2.268           10           4.536            5           11.023    10        22.046
                 GALLONS TO LITERS                                      LITERS TO GALLONS
Gallons          Liters       Gallons         Liters        Liters        Gallons   Liters     Gallons
   1             3.79           10            37.86            1           0.26      60        15.66
   2             7.57           20            75.71            2           0.53      90        23.77
   3            11.36           30           113.57            5           1.32     120        31.32
   4            15.14           40           151.42           10           2.64     150        39.62
   5            18.93           50           189.28           20           5.28     180        47.54

                     PINTS TO LITERS                                     LITERS TO PINTS
 Pints           Liters        Pints          Liters        Liters         Pints    Liters      Pints
   1             0.47            6             2.84           1             2.11       6       12.68
   2             0.95            7             3.31           2             4.23       7       14.79
   3             1.42            8             3.79           3             6.34       8       16.91
   4             1.89            9             4.26           4             8.45       9       19.02
   5             2.37           10             4.73           5            10.57      10       21.13

                                             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

                                                       46
STANDARD AND METRIC CONVERSION DATA

LENGTH-DISTANCE
  Inches (in) x 25.4 = Millimeters (mm) x .0394 = Inches
  Feet (ft) x .305 = Meters (m) x 3.281 = Feet
  Miles x 1.609 = Kilometers (km) x .0621 = Miles

VOLUME
  Cubic Inches (inJ) x 16.387 = Cubic Centimeters x .061 =in 3
  Imperial Pints (IMP pt) x .568 = Liters (L) x 1.76 = IMP pt
  Imperial Quarts (IMP qt) x 1.137 = Liters (L) x.88 = IMP qt
  Imperial Gallons (IMP gal) x 4.546 = Liters (L) x .22 = IMP gal
  Imperial Quarts (IMP qt) x 1.201 = US Quarts (US qt) x .833 = IMP qt
  Imperial Gallons (IMP gal) x 1.201 = US Gallons (US gal) x .833 = IMP gal
  Fluid Ounces x 29.573 = Milliliters x .034 = Ounces
  US Pints (US pt) x .473 = Liters(L) x 2.113 = Pints
  US Quarts (US qt) x .946 = Liters (L) x 1.057 = Quarts
  US Gallons (US gal) x 3.785 = Liters (L) x .264 = Gallons

MASS-WEIGHT
   Ounces (oz) x 28.35 = Grams (g) x .035 = Ounces
   Pounds (Ib) x .454 = Kilograms (kg) x 2.205 = Pounds

PRESSURE
   Pounds Per Sq In (psi) x 6.895 = Kilopascals (kPa) x .145 = psi
   Inches of Mercury (Hg) x .4912 = psi x 2.036 = Hg
   Inches of Mercury (Hg) x 3.377 = Kilopascals (kPa) x .2961 = Hg
   Inches of Water (H20) x .07355 = Inches of Mercury x 13.783 = H20
   Inches of Water (H20) x .03613 = psi x 27.684 = H20
   Inches of Water (H20) x .248 = Kilopascals (kPa) x 4.026 = H20

TORQUE
   Pounds-Force Inches (in-Ib) x .113 = Newton Meters (Nm) x 8.85 =in-Ib
   Pounds-Force Feet (ft-Ib) x 1.356 = Newton Meters (Nm) x .738 = ft-Ib

VELOCITY
   Miles Per Hour (MPH) x 1.609 = Kilometers Per Hour (KPH) x .621 = MPH

POWER
   Horsepower (Hp) x .745 = Kilowatts (Kw) x 1.34 = MPH

FUEL CONSUMPTION
   Miles Per Hour IMP (MPG) x .354 = Kilometers Per Liter (Km/L)
   Kilometers Per Liter (Km/L) x 2.352 = IMP MPG
   Miles Per Gallons US (MPG) x .425 = Kilometers Per Liter (Km/L)
   Kilometers Per Liter (Km/L) x 2.352 = US MPG

TEMPERATURE
   Degree Fahrenheit (OF) = (OC X 1.8) + 32
   Degree Celsius (OC) = (OF - 32) x .56




                              Engines & Generators

                                      47
                                                           80N4 SPECIFICATIONS
                              GENERAL                                                                            FUEL SYSTEM
Engine Type                 Diesel, four cylinder, four-cycle, marine engine.        General                      Closed system with bleed points.
                            Vertical in-line overhead valve, water cooled
                            direct injection, 80 hp @ 2500 rpm.                      Fuel                         No.2 diesel oil (cetane rating of 45 or higher).

                            Naturally aspirated.                                     Fuel Injection Pump          BOSCH Model A type (In-line).
Aspiration
                            Integral with injection pump.                            Fuel Injection Timing        WBTDC
Govemor
                                                                                     Nozzle                       Multi-hole
Bore & Stroke               4.02 x 4.65 inches (102.0 x 118.0 mm).
                                                                                     Fuel Filter                  Full flow replaceable.
Piston Displacement         262 cubic inches (4.3 liter).
                                                                                     (on engine)
Firing Order                1-3-4-2.
                                                                                     Air cleaner                  Replaceable paper element.
Direction of Rotation       Clockwise, when viewed from the front.
                                                                                     AirFlow                      150 efm.
Engine Torque               210 ft-Ib @ 1500 rpm.                                    (engine combustion)
Compression Ratio           17:1                                                     Fuel Consumption             4.7 U.S. gph (17.8 Iph).
Dimensions - inches (mm) Height              32.0 inches    (813 mm)
w/out transmission       Width:              25.2 inches    (645mm)                                           ELECTRICAL SYSTEM
                         Length:             47.2 inches    (1168 mm)
                                                                                     Starting Battery             12 Volt, (-) negative ground.
Weight (dry)                971 Ibs (440.8 kgs).
                                                                                     Battery Capacity             750 - 900 Cold Cranking Amps (CCA).

                    TUNE-UP SPECIFICATIONS                                           DC Charging A1temator        51 Amp rated, belt-driven.
                                                                                     Starting Aid                 Glow plugs.
Compression Pressure        441 psi (31 kg/cm') at 200 rpm
(Limit of difference        Not to exceed 28.44 psi (20.0 kg/cm').                   Starter                      12 Volt, 3 KW.
Injector Pressure            2133 psi (150 kf/cm').                                  DC No-load Current            2% of rated amps.
Valve Seat Angle             Intake 45 ..                                           DC Cranking Current          400 CCA.
                             Exhaust 45.
Valve Clearance              Intake and exhaust.                                                              LUBRICATION SYSTEM
(engine cold)                0.Q16 inches (0.40 mm).
                                                                                     General                      Gear type/pressure circulation.
Engine Speed                 Idle: 600 - 900 rpm.
                             Cruise: 1800 - 2200 rpm.                                Oil Filter                   Full flow, paper element, spin-on type.
                             Max: 2400 -2500 rpm.                                    Sump Capacity                14.5 U.S. QIs (13.8 liters).
                                                                                     (not including filter)
                        COOLING SYSTEM                                               Operating Oil Pressu re      25-85 psi.
General                      Fresh water-cooled block. thermostatically-             (engine hot)
                             controlled with heat exchanger.                         Oil Grade                    API Specification CF or CG-4,
Operating Temperature        170 -190 F (77 - 88 C).                                                            SAE 30, 10W-30, 15W-40.

Fresh Water Pump             Centrifugal type, metal impeller, belt-driven.
                                                                                                                TRANSMISSION
Raw Water Pump               Positive displacement, rubber impeller,
                             engine-driven.                                          General                       (HURTH Standard Transmission) Case-hardened
                                                                                                                   helical gears, hydraulically operated multiple disc
Coolant (Fresh Water)                                                                                              clutch.
System Capacity              17 US Qts (16.1 liters).
                                                                                     Gear Ratio (Standard)         2:00:1 (Hurth 45A) or (Hurth 63A)
                        EXHAUST SYSTEM                                               Propeller Shaft               Right handed-standard transmission.

Exhaust Elbow                45 elbow                                                Propeller Recommendations 22x16 P-2 blade or 22x14 P-3 blade
                                                                                      (using standard           propeller should allow the engine to reach its full
 Exhaust Hose Size           4" I.D. (101.6 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            2.13 US qts (2.0 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 SYSTEM
Engine Type                Diesel, four cylinder, four-cycle, turbocharged         General                     Closed system with bleed pOints.
                           marine engine. Vertical in-line overhead valve,
                           water cooled direct injection, 110 hp @ 2400            Fuel                        No.2 diesel oil (cetane rating of 45 or higher).
                           rpm.                                                    Fuel Injection Pump          BOSCH Model A type (In-line).
Aspiration                 Turbo charged.                                          Fuel Injection liming        12 BTDC.
Govemor                     Integral with injection pump.                          Nozzle                       Multi-hole.
Bore & Stroke              4.02 x 4.65 inches (102.0 x 118.0 mm).                  Fuel Filter                  Full flow replaceable.
Piston Displacement         202 cubic inches (4.3 liter).                          (on engine)

Firing Order                1 - 3 - 4 - 2.                                         Air cleaner                  Replaceable paper element.

Direction of Rotation       Clockwise, when viewed from the front.                 Air Flow                     230 cfm.
                                                                                   (engine combustion)
Engine Torque (max.)        280 ft-Ib @ 1500 rpm.
                                                                                   Fuel Consumption             6.1 U.S. gph (23.1 Iph).
Compression Ratio           17:1.
Dimensions - inches (mm) Height:             32.0 inches    (813 mm)                                        ELECTRICAL SYSTEM
w/out transmission       Width:              28.3 inches    (719 mm)
                         Length:             47.2 inches    (1168 mm)              Starting Battery             12 Volt, (-) negative ground

Weight (dry)                987 Ibs (448.0 kgs).                                   Battery Capacity             750 - 900 Cold Cranking Amps (CCA)
                                                                                   DC Charging Altemator        51 Amp rated, belt-driven
                   TUNE-UP SPECIFICATIONS                                          Starting Aid                 Glow plugs
Compression Pressure        441 psi (31 kg/cm') at 200 rpm                         Starter                      12 Volt, 3 KW
(Limit of difference        Not to exceed 28.44 psi (20.0 kg/cm').
                                                                                   DC No-load Current            2% of rated amps
Injector Pressure           2133 psi (150 kf/cm').
                                                                                   DC Cranking Current          400 CCA.
Valve Seat Angle            Intake 45
                            Exhaust 45
                                                                                                            LUBRICATION SYSTEM
Valve Clearance             Intake and exhaust
(engine cold)               0.016 inches (0.40 mm).                                General                      Gear type/pressure circulation
Engine Speed                Idle: 600 - 900 rpm.                                   Oil Filter                   Full flow, paper element, spin-on type.
                            Cruise: 1800 - 2200 rpm.                               Sump Capacity                14.5 U.S. Qts (13.8 liters)
                            Max: 2300 -2400 rpm.                                   (not including filter)
                                                                                   Operating Oil Pressure       25-85 psi
                        COOLING SYSTEM                                             (engine hot)
General                     Fresh water-cooled block, thermostatically-            Oil Grade                    API Specification CF or CG-4,
                            controlled with heat exchanger.                                                     SAE 30, 10W-30, 15W-40
Operating Temperature       180 -190 F(77 - 88 C)
Fresh Water Pump            Centrifugal type, metal impeller, belt-driven.
Raw Water Pump              Positive displacement, rubber impeller,                                           TRANSMISSION
                            engine-driven.                                         General                      (HURTH Standard Transmission) Case-hardened
Coolant (Fresh Water)                                                                                           helical gears, hydraulically operated multiple disc
System Capacity             17 US Qts (16.1 liters)                                                             clutch.
                                                                                   Gear Ratio (Standard)        2:00:1 (Hurth 45A) or (Hurth 63A)
                        EXHAUST SYSTEM                                             Propeller Shaft              Right handed-standard transmission.
Exhaust Elbow'              45 elbow                                              Propeller Recommendations 24x18 P-2 blade or 24x16 P-3 blade
Exhaust Hose Size           4" 1.0. (101.6 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           2.13 US Qts (2.0 liters) approximate.


Combustion Air              230 cfm
Note: The pressure differential between the outside of the engine compart-
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

                                                                              49
                                                        120N6 SPECIFICATIONS
                             GENERAL                                                                              FUEL SYSTEM
Engine Type                Diesel, six cylinder, four-cycle, Vertical in-line,        General                     Closed system with bleed pOints.
                           overhead valve, fresh water cooled direct
                           injection, marine engine. 120 hp @2500 rpm.                Fuel                        No.2 diesel oil (cetane rating of 45 or higher).

Aspiration                 Naturally aspirated.                                       Fuel Injection Pump         BOSCH Model A type (In-line).

                           Integral with injection pump.                              Fuel Injection TIming       WBTDC
Governor
                           4.13 x 4.92 inches (105.0 x 125.0 mm)                      Nozzle                      Multi-hole
Bore & Stroke
Piston Displacement        296 cubic inches (6.5 liter)                               Fuel Filter                 Full flow replaceable.
                                                                                      (on engine)
Firing Order               1-5-3-6-2-4
                                                                                      Air cleaner                 Replaceable paper element.
Direction of Rotation      Clockwise, when viewed from the front.
                                                                                      Air Flow                    240 cfm
Engine Torque               298 ft-Ib @1500 rpm.                                      (engine combustion)
Compression Ratio           17:1                                                      Fuel Consumption            6.5 U.S. gph (24.6Iph).
Dimensions - inches (mm) Height:          32.5 inches       (823mm)
w/out transmission       Width:           25.2 inches       (645mm)                                            ELECTRICAL SYSTEM
                         Length:          56.4 inches       (1410 mm)
                                                                                      Starting Battery            12 Volt, (-) negative ground
Weight(dry)                 1175 Ibs (534.1 kgs).
                                                                                      Battery Capacity            750 - 900 Cold Cranking Amps (CCA)

                   TUNE-UP SPECIFICATIONS                                             DC Charging Alternator      51 Amp rated, belt-driven
                                                                                      Starting Aid                 Glow plugs
Compression Pressure        441 psi (31 kg/cm') at 200 rpm
(Limit of difference        Not to exceed 28.44 psi (20.0 kg/cm').                    Starter                      12 Volt, 3 I

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