Westerbeke Diesel W 40 Technical Manual
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OPERATORS MANUAL WESTERBEKE 40NA MARINE DIESEL ENGINE Publication 37169 Edition One February 1988 WESTERBEKE WESTERBEKE CORPORATION AVON INDUSTRIAL PARK AVON MA 02322 TEL 617 5887700 SAFETY PRECAUTIONSThe following symbols appear in this manual to call attention Use Extreme Care When Handling Engine Fuelto and emphasize conditions potentially dangerous to theoperator A constant danger of explOSion or fire exists 00 not fill fuel tanks while the engine is running IIWARNINGI Do not smoke or use an open flame near the engine or the fuel tankThe above symbol is used in the manual to warn of personal injury or loss of life Do Not Alter or Modify the Fuel System Be sure all fuel supplies have a positive shutoff valve CAUTION Be certain fuel line fittings are adequately tightened andThe above symbol is used in the manual to caution personnel free of leaksof possible damage to equipment Make sure a fire extinguisher is installed nearby and isRead the manual carefully and thoroughly before attempting properly maintained Be familiar with its proper use exto operate the equipment Know when dangerous conditions tinguishers rated ABC by the NFPA are appropriate for allcan exist and take necessary precautions to protect personnel applications encountered in this environmentand equipmentFuels exhaust gases batteries electrical equipment andmoving and hot parts are potential hazards that could result in Use Extreme Care When Servicing personal injury or death Follow recommended procedures carefully Wear rubber gloves a rubber apron and eye protection when servicing operate bilge blowers for at least five minutes beforestarting a gasolinefueled engine ensure no gasoline fumes are Lead acid batteries emit hydrogen a gaspresent before starting which can be ignited by electrical arcing or by a lighted cigarette cigar or pipe Do not smoke or allow an open flame near the battery being serviced Shut off all electri Preyent Electric Shock cal equipment in the vicinity to prevent electrical arcing during servicing Shut off electric power before accessing electrical equip ment Use insulated mats whenever working on electrical equip Avoid Moving parts ment 00 not service the unit while the unit is running if a situa Make sure your clothing is dry not damp particularly tion arises in which it is absolutely necessary to make shoes and keep your skin surfaces dry when handling operating adjustments use extreme care to avoid moving electrical equipment parts and hot exhaust system components Remove wristwatch and jewelry when working on electri Do not wear loose clothing or jewelry when servicing cal equipment equipment avoid wearing loose jackets shirts or sleeves rings necklaces O bracelets that might be caught in Do not connect utility shore power to vessels AC circuits moving parts except through a shiptoshore doublethrow transfer switch Damage to vessels AC generator may result if this Make sure aU attaching hardware is properly tightened is not done Keep protective shields and guards in their respective place at all times Be extremely careful when working on electrical com ponents High voltage can cause injury or death Do not check fluid levels or the drivebelts tension while the unit is operating Do not work on the equipment when mentally or physical Exhaust Gases Are Toxic ly incapacitated by fatigue Ensure that the exhaust system Is adequate to expel gases discharged from the engine Check exhaust system regularly for leaks and make sure the exhaust manifolds are securely attached and no warping exists Be sure the unit and its surroundings are wellventilated IMPORTANT PRODUCT SOFTWARE software of all kinds such as brochures drawings technical data operators and workshop manualsparts lists and parts price lists and other related information instructions and specifications provided fromsources other than Westerbeke is not within Westerbekes control and accordingly is provided to Westerbeke customers only asa courtesy and service WESTERBEKE CANNOT BE RESPONSIBLE FOR THE CONTENT OF SUCH SOFTWARE MAKES NO WARRANTIES OR WITH RESPECTTHERETO INCLUDING THE ACCURACY TIMELINESS OR COMPLETENESS THEREOF AND WILL IN NOEVENT BE LIABLE FOR ANY TYPE OF DAMAGES OR INJURY INCURRED IN CONNECTION WITH ORARISING OUT OF THE FURNISHING OR USE OF SUCH SOFTWAREFor example components and SUbassemblies incorporated into Westerbekes products and supplied byothers such as engine blocks fuel systems and components transmissions electrical components pumpsand other products are generally supported by their manufacturers with their own software and Westerbekemust depend on such software for the design of Westerbekes own product software Such may be outdated and no longer accurate Routine changes made by Westerbekes suppliers ofwhich Westerbeke rarely has notice in advance are frequently not reflected in the suppliers sofivare untilafter such changes take place Westerbeke customers should also keep in mind the time span between printings of Westerbeke and the unavoidable existence of earlier noncurrent Westerbeke software editions In the field Additionally most Westerbeke products include special features that frequently do not Include complete summation product software provided with Westerbeke products whether from Westerbeke or other suppliers must not and cannot be relied upon exclusively as the definitive authority on the respective productIt not only makes good sense but is imperative that appropriate of Westerbeke or the supplier in question be consulted to determine the accuracy and currency of the product software being consulted by the customer 1 Westerbeke Diesel Engines INSTALLATION the crafts In which Westerbeke engines are installed vary in design installation procedures will varyaccording to your crafts specific design It is not the intent of this section to advise boatyards or installerson procedures and wellunderstood However it is important that the there are details of the installation which require periodic checks to ensure the best operating conditions for the equipment and safe operating conditions for the personnel on board Proper location and installation of the diesel engine in the vessel are of prime in the installation that must be considered are ventilation to aid in cooling and to provide air for engine combustion exhaust system to properly discharge raw cooling water quiet the exhaust and expel exhaust gas cooling water supply fuel supply and electrical connections CAUTION For safety reasons the engine and transmission are NOT filled with lubricating oil for ship ment Before leaving the factory however each engine with transmission is thoroughly tested with oil in it This testing among other things provides all internal parts with a coating of 011 This oil acts as a preservative providing reliable protection against corrosion for at least one year if the engine and transmission are properly location should be such that it is dry and in an area where bilge water or water from above cannot splashon the engine The engine should be properly ventilated and accessible for minor servicing and repairs access for major repairs should be given consideration as well The location must be properly ventilated toprovide fresh air for engine combustion The engines lubrication oil sump dipstick the fresh water and oilfills and the transmissions dipstick and transmission or oil fill port must be accessible FILL CAoP COOLANT RECOVERY COCKPIT TANK ALTRNT MOUN11NO STRAP POSITIONS CABIN INSTALLATION ANGLE MUST HOT EXCEED l Please note that the engines installation angle cannot exceed 17 from the horizontal Diesel Engines 10Rigging and LiftingThe engine is fitted with lifting eyes Rope or chain slings capable of supporting the engines weight shouldbe attached to the eyes and the engine lifted by means of tackle attached to these slings The lifting eyeshave been designed to carry the full weight of the engine therefore auxiliary slings are not required or desired CAUTION Slings must not be so short as to place signaicant sheer stress on the engines lifting eyes Strain placed on the engines lifting eyes by the lifting sling must not be in excess of 10 from the vertical plain 10 SLXNG LIFTJNG ANGLE IoiUST NOT EXCEED 10 LIFTING EYE ENGINEThe general rule in moving engines is to see that all of the equipment used is amply strong and firmly fixedin place Move the engine a little at a time and see that tt is firmly supported Eliminate the possibility of accidents by avoiding haste Do not lift the engine by tts propeller coupling or pry against this coupling witha crowbar because excessive pressure of this type may distort the couplingIn certain situations it may be necessary to lift the engine in positions other than the horizontal position Certain situations exist by which the engine must be lowered endwise through a small hatchway which cannotbe made larger Under these conditions if the opening of the hatchway is extremely narrow tt is possibleto reduce to some extent the outside dimensions of the engine by removing external components such asthe alternator the cooling systems piping the heat exchanger certain filters the mounting lugs and equipment This accessory equipment should be removed by a competent mechanic and special care should be taken to avoid damaging any exposed parts In addition be careful not to allow dirt fromentering any opening created by the removal of equipment Parts removed should be returned to their respective position as soon as the engine has cleared the hatchwayIn case it becomes necessary to hoist the engine either frontend upwards or upwards theattachment of slings must be done carefully to avoid the possibility of damaging the parts on which the weightmay bear Special rigging work is best done by someone experienced and competent in handling heavymachinery 11 Westerbeke Diesel EnginesEngine BoltsBronze or stainless steel hanger bolts of appropriate size are recommended for use through the mounts Less preferred are lag screws because their hold on the Wood is weakened every time theyare moved whereas the hanger bolts stay in position If the nut on top of the hanger bolt is removed to allowthe engine to be lifted from s resting place the hanger bolt self remains in place as a stud Consequently the bond between the hanger bolt and the wood is not weakened by the removal of the nut or the for the EngineA good engine bed contributes much toward the satisfactory operation of the engine The engines bedmust be rigidly constructed and neither deflect nor twist when it is subjected to the engines weight or to thepressures that the boat may experience while operating in rough seas The bed must keep the within one or two thousandths of an inch of this position at all times The bed has to withstandthe forward push of the propeller shaft which pushes against the thrust washer bearing which finally pushesagainst the engines bolts and bedIn fiberglass hulls we recommend that similar wooden stringers as in wooden hulls be formed fitted andthen glassed securely to the hull This allows the hanger bolts to be installed firmly in the wood noise and transmitted vibrationThe engine support stringers must be as wide or wider than the engine mounting isolator Isolator overhangandor rounded stringer surfaces are detrimental to the isolators ability to retain fiberglass engine beds when used should be of sufficient thickness to properly support the engine and should be wellglassed to the hull temptation to Install the engine on a pair offiberglass angle Irons must be resisted will allow engine vibration to passthrough to the hull Flexible mounts require a firmfoundation against which they must act ifthey areto perform their function When possible followbed design A and avoid bed design B refer tothe illustration ASupports between the bed stringers and extending from the stringers to the hull may be requiredfor proper support and to aid in the absorption ofvibrations BAD B Note Avoid excessive height use solid stringer construction A Westerbeke Diesel Engines 12Propeller Shaft CouplingThe propeller shaft coupling fitted to the transmissions output flange must transmit not only the power of theengine to turn the propeller shaft and propeller but must also transmit the thrust of the ahead or asternThe coupling bore should be carefully machined for a slight forced fit onto the shaft and an accurate matingsurface for the coupling to the output flange of the W 40NA engine is equipped with a Federal Flexible Coupling The Federal Flexible Coupling consists ofa metal hub and a flange The hub Is accurately bored to accept the rubber bushings and the face of theflange Is machined to match the engines coupling The neoprene rubber bushings have a bonded innerbrass sleeve and the entire bushing is pressed into the flange using the correct compression pressure Alloysteel spider pins screw through the bushings into the hub which are locked into posttion The rubber bushings are ample to absorb vibration from the propeller and to allow a slight angular misalignment The is not designed to do the work of a universal joint The engine must be properly aligned before theFlexible Coupling is installed Afterthe coupling has been installed the coupling will compensate for misalign ments caused by hull distortion and from engine movement The Federal Flexible Coupling will absorb boththrust and torsional loads The pins and rubber bushings are replaceable in case of damageWhen ordering replacement parts refer to the Parts List at the back of this type and size of propeller varies with the gear ratio and must be selected to Itt the application basedupon boattests To utilize the full power olthe engine and to achieve ideal loading conditions use a propellerwhich will permit the engine to reach tts full rated RPM at full throttle while under a normal load and while itis moving the boat forward through the waterAlignment of the EngineThe engine must be exactly aligned with the propeller shaft using a solid coupling before installing the No matter what material is used to build a boat the material will be found to be flexible to some extent hence the boats hull will change its shape to a greater extent than is usually realized when the boat islaunched and operated in the water Therefore it becomes extremely important to check the engines alignment at frequent intervals and to correct any errors when they between the engine and the propeller shaft often creates serious problems which are oftenblamed on other areas suspected of causing the trouble Misalignment will cause excessive bearing wearrapid shaft wear and will in many cases reduce the life of the boats hull by loosening the hulls fasteningsA bent propeller shaft will have the exact effect as those just stated therefore a perfectly straight propellershaft is absolutely necessary One particularly annoying result of misalignment may be leakage of transmission oil through the transmissions rear oil sealNever attempt a final alignment with the boat on land The boat should be in the water and have had an opportunity to assume its final water form The best time to perform the propeller is with the fuel and water tanks about half full and all the usual equipment on board and after themain mast has been stepped and the final rigging has been accomplished 13 Westerbeke Diesel EnginesTake plenty of time in making this alignment and donot be satisfied wtth anything less than perfect resultsThe alignment is correct when the shaft can be easily 093 FEELER GAGEslipped backward and forward into the counterboreand when a feeler gauge indicates that the flangescome together at all points The alignment between PROPELLER SHAFTthe propeller shaft coupling and the engines couplingcan contain an error no greater than one thousandthof an inch per Inch of the coupling diameter For example if your propeller shaft coupling is three inchesin diameter the maximum error that can be allowed inthe alignment is three thousandths of an inch 003In making the final check for alignment theengines half coupling should be held in oneposition and the alignment with the tested wtth the propeller coupling ineach offour positions A while rotated 90 between each position This test will also checkwhether the propellers halfcoupling is in exactalignment on its shaft Then keeping thepropeller coupling in one position the alignment should be checked by rotating theengines halfcoupling in 90 increments checking dimension A while in each 90 position until the halfcoupling has been rotated full circle The engines alignment should be recheckedafter the boat has been in service for one tothree weeks and if necessary perform thealignment again Usually tt will be found thatthe engine is no longer in alignment This doesnot mean that the work has been done improperly at first rather tt means that the boathas taken some time to take its final shape andthat the engines bed and stringers haveprobably absorbed some moisture It may even be necessary to realign the coupling halves again at a later time Westerbeke Diesel Engines 14Exhaust SystemThe exhaust system provides an outlet line to vent engine exhaust gases out of and away from the vesselThe system also discharges sea water which has passed through the engines sea water circuit by mixing itwith hot exhaust gases This mixing helps cool the exhaust gases and exhaust elbow and plumbing The exhaust system and the sea water supply to the exhaust must be configured to prevent the siphoning of seawater into the exhaust through the sea water cooling circuit and to prevent the entry of sea water into the exhaust through the circutts throughhull discharge port If not prevented sea water entering through the discharge port can fill the exhaust system muffler and enter the engines cylinders This will prevent properstarting and possibly cause damage to internal engine componentsThe sea water supply hose to the exhaust system water injection elbow should be routed looped at least12 inches above the vessel water line An antisiphon break should be installed when needed at the top ofthis loop The top of the loop should be placed high enough above the vessels water line so as to remainabove the water line when the vessel is underway no matter what the angle of heel or roll may be 74 or 1 It LD hose NOTE The engines heat exchanger outlet will determme the Ik or 1 ff dimenSion lor the vented loop 48 max Installation with exhaust J elbow at a minimum of 6 above vessel water line HydrOHush Waterline Insulate 48 mal CAUTION Vented loop must be in a location where it will remain above the water line during all aHitudes of the vessels operation installation with exhaust HydroHush elbow at or below vessel water lineThe sea water supply throughhull sea cock fittings must be of the flushhull type Highspeed scoop typeof fittings should not be used as they tend to encourage siphoningThe exhaust discharge from the water lift muffler should be routed well above the water line then downwardto the throughhull discharge This routing will prevent sea water entry if the throughhull discharge fittingbecomes submerged when the vessel heels or rolls while under way or is subjected to following sea conditions Refer to the figures shown above for recommended exhaust system installations 15 Westerbeke Diesel EnginesExhaust exhaust discharge hose must be of adequate size andminimal run to prevent excessive exhaust backpressure should be checked before the engineis put into service Refer to the illustration Excessive backpressure will affect the engines performanceTo measure for backpressure use a mercury manometer apressure gauge or a water column A boatyard or marine should have a manometer or a pressure gauge ElbowMeasure backpressure at the exhaust elbow when the en gine is running at 3000 rpm Backpressure as measured by Exhausta manometer a pressure gauge or water column should not be over the following specifications I Mercury Manometer NOTE Other pressure gauges may be available to test for exhaust backpressure Check with a competent mechanicRefer to the pressure specifications belowA water column can be made by taking a clear plastic tubeand taping one end of the tube along a yardstick and fittingthe other end of the tube with a 14 inch NPT National PipeTap pipe fittingMeasure backpressure at the exhaust elbow when the engine is running at 3600 rpmDimension A cannot exceed 39 inches of waterBack pressure as measured by a gauge instrument shouldnot exceed the following specifications 3 inches of mercury 0104 kgcm 2 39 inches of water in a water column 099 kgcm2 at 4 C 22 ounces psi 1 12 psiExcessive backpressure can be caused by a small diameter exhaust hose a small muffler sharp bends inthe exhaust hose improper fittings water pockets and a high volume of water in the exhaust system dueto the length of the exhaust discharge hose The use of elbows and fittings in the exhaust discharge hosesrouting should be limited since these will create flow restrictions and contribute to exhaust engines exhaust system must be separate from any other engines exhaust system Dry portions of theexhaust system between the engines exhaust manifold and the water injected exhaust elbow must be insulated to hold in the heatWesterbeke Diesel Engines 16Exhaust System FailuresWhen the engines sea water is fed into an exhaust system so that the full stream of this water strikes a surface erosion takes place This erosion may cause premature failures The proper design of either a waterjacketed or water injected wet exhaust system to prevent this problem requires that the sea water inlet bepositioned so that the entering stream of sea water does not directly strike a surface In addition the velocityof the entering sea water stream should be as low as possible which can be achieved by having inlet fittingsas big in diameter as possibleThe best protection against exhaust system leaks is to routinely inspect the complete exhaust system Checkfor leaks around manifolds gaskets and welds Make sure exhaust lines are not heating surrounding If excessive heat is present correct the situation immediately If you notice a change in thesound or appearance of the exhaust system inspect the exhaust system and correct the causeExhaust risers installed off the exhaust mannold should not exceed 8 Ibs in total weight wen rigidly connected Excessive weight and vibration can result in a manifold failure andor the fracturing of the riser fromthe manifold at tts attachment Dry portions of the exhaust connected to the manifold which lay before thewater Injected exhaust system MUST be properly insulated to retain the exhaust heat wtthin the exhaustpipe iWARNINGI Although diesel engine exhaust gases are not as toxic as exhaust fumes from gasoline en gines carbon monoxide is present in diesel exhaust fumes in less concentration Carbon monoxide is a dangerous gas that can cause and is potentially lethal Some of the symptoms or signs of carbon monoxide inhalation or pOisoning are as follows a Dizziness a Vomiting a Intense Headache a Muscular Twitching a Weakness and Sleepiness a Throbbing in Temples If you experience any of the above symptoms get out into fresh air sure there are no unnecessary objects suspended from any portion of the exhaust lines could cause deflection or distortion of the lines resulting in damage or leaks Inspect insulated portions of the exhaust system to ensure there is no deterioration of the insulationOil Drain HoseAn oil sump drain hose is located at the lower front of the engine Oil may be drained from this hose byremoving the cap and the discharge end of the hose from the support bracket and lowering the hose into acontainer The hose cap fitting is 14 inch NPT National Pipe Tap and can be extended or have a pumpadded for easier removal of the old oil if desired 17 Westerbeke Diesel Pressure Sensing Devices to Oil GalleriesOil pressure sensing devices such as senders and switches must not be connected to an engines oil gallery with the use of extended nipples or tees The reason is simply that continued engine vibration causesfatigue of the fittings used to make such a connection If these fittings fail the engine loses its oil pressureand quickly seizesWhen additional sensing devices such as switches or sensors need to be installed that function on engineoil pressure these devices must be and connected to the oil gallery using an of lubricating oil hose Any fittings used to connect the hose to the gallery must be of steel or malleable iron composition Brass must not be used for this Alarm System High Water Temperature AlarmA high water temperature alarm buzzer has been supplied with the instrument panel If the engines freshwater coolant reaches 2100 F 988 C a water temperature switch on the engine closes causing the alarmto emit a continuous signal Refer to the DESCRIPTION OF INSTRUMENT PANEL section of this manualfor the location of the alarm in your engine panel page 24 Low Oil Pressure AlarmA low oil pressure alarm switch is located off the engines oil gallery This switch monitors the engines oilpressure Should the engines oil pressure fall to 10 15 psi the switch will close sounding this same alarmIn this event the alarm will emit a pulsating signal Refer to the DESCRIPTION OF INSTRUMENT PANELsection of this manual for the location of the alarm in your engine panel page 24Cooling SystemThe engine is fresh water cooled by an enginemounted heat exchanger Sea water is used as the heatexchangers cooling medium Sea water is pumped into the exchanger by a sea water pump where it coolsthe fresh water that circulates through the engine block and is then injected into the exhaust elbow carrying with it the heat removed from the engines fresh water cooling systemSea water should be supplied to the sea water pump through a flushtype hull fitting using a between the throughhull fitting and the sea water pump The sea water should be directed through avisualtype sea water strainer which will trap debris before it reaches the sea water pump and the heat exchanger and then be delivered to the pump Hoses routed from the throughhull fitting to the strainer andto the sea water pump should be wirereinforced to prevent the hose from collapsing while the engine is running suction from the pump may collapse a nonreinforced hose The sea water strainer should be mountedat or below the water line to make sure the sea water line remains Diesel Engines 18 CAUTION DO NOT use a scooptype throughhull fitting as a means of supplying sea water to the en gine Water pressure against this type of fitting while the vessel is under sail can push sea water past the sea water pumps impeller into the engines exhaust system filling it and the engine as well Flushtype clear throughhull fittings are recommended and should be lo cated on the hull so as to be below the waterline during all angles of boat operation The use of commontype street elbows is not recommended for plumbing the sea water cir cuit These generally have very restrictive inside diameters Machine fittings are preferred To Fresh Water Circulating Pump Inlel on Engine Block iI rJ r Fresh Water Pressure Fill Cap Y W Coolant Recovery Tank FRESH WATER Thermostat f Incoming Sea Water I Exhaust Manifold J Sea Water Impeller Pump To Transmission Oil Cooler 111ustrated above is the cooling system for the W 40NA engine 19 Westerbeke Diesel EnginesSea Water Intake SystemMake sure the intake system sea water cooling system is in proper order Check that the throughhull inletsea cock and strainer are unobstructed Sea cocks and strainers should be at least one size greater thanthe inlet thread of the sea water pump The strainer should be of the type that may be withdrawn for cleaning while the vessel is at sea and should be mounted below the water line to ensure selfpriming Inspectthe sea water lines to ensure there are no collapsed sections which would restrict water flow Make surethere are no air leaks at any of the connections Placing double clamps at the sea water plumbing connection located below the water line is strongly SystemThe fuel system should be installed in such a manner as to allow the enginemounted mechanical fuel liftpump to maintain a positive inlet pressure to the fuel injection pump under all operating conditions Theminimum size of the fuel supply line and fuel return line is 14 inch inside diameter and there should be aprimary fuel filter installed between the fuel tank and the fuel lift pump Only one fuel filter is installed on theengine between the mechanical fuel lift pump and the injection pump this filter has a replaceable filter elementThe fuel tanks fuel pickup tube should be clear and unobstructed No screen or gauze strainers should beincorporated in the fuel pickup tubeMake sure that the fuel supply and return lines are securely anchored to prevent chafing and that all fillingsare sufficiently tightened to prevent leaking Also make sure your fuel system has a positive shutoff valveknow its location and how it operates NOTE DO NOT use springloaded check valves in the fuel supply line in lieu of mechanical shutoff valves This type of valve can create fuel starvation problems for the engines fuel sys temFuel tanks that are located below the engines fuel system level must have its fuel return at the tank extending down into the tank in the same manner as a pickup tube otherwise fuel siphoning out of the enginesfuel system through the return will take placeEnsure that the fuel tank filler is properly sealed to prevent water entry should tt become awash The fueltanks vent should be routed so as to prevent water entry as wellBe sure there is a fire extinguisher Installed near the unit and that it is properly maintained Be familiar withits use An extinguisher with the NFPA rating of ABC is appropriate for all applications in this environment Westerbeke Diesel Engines 20Electrical SystemThe electrical system should be checked to ensure that all wiring harnesses are tied down properly withclamps or plastic ties spaced at intervals close enough to prevent chafing from vibration Check to ensurethat all the engines harness connections are tight and that they are connected to the appropriate terminals WARNINGI Do not smoke or allow an open flame near batteries Lead acid batteries emit hydrogen a gas Turn off the emergency switch in the positive line of batteryMake sure the positive battery connection is connected to the battery connection of the starting solenoidThe negative battery connection should be connected to the system ground the engine block IWARNINGI When servicing the battery or checking the electrolyte level wear rubber gloves a rUbber apron and eye protection Battery acid may splash on the skin or into the eyes inadvertent ly when removing electrolyte capsCheck level and specific gravity of battery electrolyte to ensure maximum engine starting efficiency Makesure terminals are clean and ventilation requirements of the engine include the following combustion air is required for the and ventilating air is required to clear the bilges below the engine as well as the compartment inwhich the engine is located of engine heat and potentially toxic and flammable diesel fumes Refer to section of this manual for airflow requirements page 8 21 Westerbeke Diesel Engines PREPARATION FOR STARTINGThis section of the manual provides the operator with preparation initial starting breakin starting cold orwarm and stopping procedures Follow the procedures as presented for the conditions indicated andyour Westerbeke engine set will give you reliable performance and long service lifeFill the engine with 011 by pouring engine oil through theoil filler cap Fill the engine up to or near the upper limijon the dipstick the installation angle may have an effecton the dipstick reading Select readily available Oil Filler Caplubricating oil with an API specification of CC or CD andan SAE number suitable for the temperature in your Rocker Coveroperating area see page 47 For the quantity of oilneeded in this engine refer to the SYSTEM SPECIFICATION section of this manual page 8Fill the transmission to the FULL mark on the dipstick Oil Dipstickwith the correct lubricant Refer to the section of this manual page 9 Upper LimitEach unit is supplied with a coolant recovery kit Normal LevelloI24977 as standard equipment to which the follow ing applies Lower Limit Oil A Remove the pressure cap from the engines ex Crankcase haust manifold and slowly fill the engines cooling system with a mixture of water and antifreeze suitable for your temperature zone See the COOLING SYSTEM section of this manual page 42 Operate the engine and observe the coolant level in the manifold Maintain this level to the base of the filler neck Once the engine reaches its operat ing temperature 170 190 F ensure that there is coolant flow to the domestic water heaters when in stalled Top off the cooling system and install the pressure cap B Make sure the plastic recovery tank is properly mounted near the unit with the bracket provided in a location where it can be monitored and filled easily The recovery tank should be mounted at manifold level or above In these installations that require ij the plastic recovery tank can be mounted below the exhaust manifolds level C Add coolant to the plastiC tank after the engine has been started and operating temperature has been reached to ensure that all air is expelled from the manifold and the engines cooling system With the manifold filled and the pressure cap Installed fill the plastic recovery tank half full Monitor daily and add coolant as neededFill the fuel tank with a good grade of No2 diesel fuel and prime the fuel system up to the engine see page32 When returning fuel is free of air the engines fuel system is bled and the engine is ready to startEnsure that the Installation Checks have been made in accordance with those specified in the INSTALLATION CHECKS section of this manual refer to page 10Westerbeke Diesel Engines 22Starting SystemThe W 40NA diesel engine uses an electric starter for both normal and cold weather starting A cold start aidsystem is furnished on the W 40NA engine as standard equipment part 36258 Both the thermostart deviceand the cold start aid are located on the air intake manifold side of the engine The PREHEAT button energizes the thermostart device assists in vaporizing the fuel at the intake manifold inlet The vaporized dieselfuel is drawn into the cylinder during cranking and allows for easy combustion during compression Thisprocess allows the engine to start rapidly and reduces wear on the starter Air I ntake Screen Stand Pipe Thermostart Cold Start AidThe W 40NA engines electrical system is designed so that the PREHEAT button must be depressed for thetime specified in the Preheat chart shown on page 26 While keeping the PREHEAT button depressed theSTART button must be pressed to crank the engine NOTE The START button will not crank the engine unless the PREHEAT button is depressed atthe same time When the PREHEAT button is depressed the thermostart device is activated USE THE PREHEAT BUnON ONLY AS NECESSARY Overuse of the PREHEAT button will overheat the thermostart deviceRefer to the STARTING PROCEDURE section of this manual for starting instructions page 26 23 Westerbeke Diesel Engines STOPPING PROCEDURESIn the cockpit of the boat there Is a tee handle or a knobtype shutof control When this control is pulledOUTWARD the control will STOP the engine The other end of the shutoff control is attached to a lever onthe top of the fuel Injection pump Pushing the shutoff control fully inward will place the engine in the RESTART RUN positionWhen the engine is stopped turn the Circuit Breaker located in the vessel to the OFF position If the CircuitBreaker is left ON the battery will discharge CAUTION DO NOT attempt to shutdown the engine by turning the Circu Breaker OFF The Circuit Breaker only provides power to the instrument panel and to the DC alternator the engine will continue running even if the Circuit Breaker is turned OFF Stop the engine by pulling the shutoff control fully OUTWARDEngine BreakIn your engine has experienced a minimum of one hour of test operations to ensure accurate assembly and proper operation of all systems breakin time is required The service life of your engine is dependent upon how the engine is operated and serviced during s initial hours of useYour new engine requires approximately 50 hours of Inial conditioning operation to break In each movingpart in order to maximize the performance and service life of the engine Perform this conditioning carefully keeping in mind the following 1 Start the engine according to the STARTING PROCEDURE section found on page 26 run the engine at fast idle while checking that all systems sea water pump oil pressure battery charging are function ing 2 Allow the engine to warm up preferably by running at fast idle until the gauge moves into the t 30140 F range 3 While using the vessel under power vary the engines rpm cruise settings during the engines initial 25 hours of operation 4 Avoid rapid acceleration especially with a cold engine 5 Use caution not to overload the engine The presence of a gray or black exhaust and the inability of the engine to reach its full rated speed are signs of an overload that is a propeller that is too large 6 During the next 25 hours the engine may be operated at varying engine speeds with short runs at full rated rpm Avoid idling the engine for prolonged periods of timeBreakingin a new engine basically involves seating the piston rings to the cylinder walls This cannot be accomplished by long periods of running at Idle nor by early running at full speedIdle running may glaze the cylinder walls resulting in excessive oil consumption and smoky operation Excessive speed or heavy overloading especially with a cold engine may cause scoring of the cylinder wallsproducing similar Diesel Engines 28As indicated above operate the engine in moderation during the 50hour breakin period On one handdont baby the engine but on the other hand however dont abuse itStarting Under Normal the procedure below for normal starting of the engine 1 Check the engine and transmission lubricant levels and fill if necessary 2 Make sure there is sufficient fuel on board Keep fuel tanks as full as possible Check the fuel filters and water separators for the presence of contaminants andor water Drain and clean them as needed 3 Check the coolant level in the plastic recovery tank Add coolant solu1ion as needed NOTE Excessive loss of coolant from the plastic recovery tank indicates a cooling system leak Check the entire cooling system and the recovery tank and s connections at the ex haust manifold and pressurize the system to locate the leak In cases of excessive coolant loss the system must be refilled as outlined under the PREPARATION FOR STARTING sec tion of this manual page 22 4 Check for oil and fuel leaks particularly if signs of such leaks are found on the bottom of the engine or below the engine 5 When checking your engines coolant and oil levels check the engine for any noticeable abnormalities such as loose or missing bolts loose brackets and mounts loose hose clamps chafed wires or any other components that exhibit wear or are looseStart the engine in accordance with the STARTING PROCEDURE instructions found on page 26 and allowthe engines operating temperature to reach 140 150 F before operating the engine underway 29 Westerbeke Diesel Under Cold extremely cold temperatures the following conditions can occur Follow the instructions listed belowwhen operating your engine in cold OIL TURNS VISCOUS Make certain that the lubricating oil used conforms with the ratingsfor the prevailing atmospheric temperature Refer to the LUBRICATION SYSTEM section of this manualpage 47 for an atmosphericoil viscosity specification tableVOLTAGE ACROSS THE BATTERY TERMINALS DROPS Make certain that the battery is fully charged tominimize voltage drop across the battery terminalsTHE TEMPERATURE OF THE INTAKE AIR IS LOW AND THE COMPRESSION TEMPERATURE DOES NOTRISE ENOUGH Allow the thermostart device to operate sufficiently to aid In starting during the preheatperiod whenever the temperature of the intake air is low and when the compression temperature within thecylinders will not rise quickly during cranking Refer to the Preheat chart found in the STARTING PROCEDURE section of this manual page 26Westerbeke Diesel Engines 30 FUEL SYSTEMDiesel FuelUse No2 diesel fuel with a cetane rating of 45 or higher Never use kerosene or home heating oil since thesefuels do not have the same lubricating properties as No2 diesel fuelIn cold weather particular1y water vapor is produced by condensation when air is present in the fuel tankKeep fuel tanks full and completely free of dirt and waterFuel FiltersA primary fuel filter of the type must be installed between the fuel tank and the engine A XN5TALLATXON fuel filter shown here is avail HOSE FITTING 1 aau SDIIIUTIIITEI TIIM SCUREL TO All MCESI1L snucrul SII from your local Westerbeke rep IHAr IfCETIClE II tille HlUAU UI IE nKO 111101 Itresentative or your boatbuilder This 2 If FOn IS rl IE 111 1111 emufilter adapted for boatbuilder use II tullO lllIlH 11K IUtl IU FUIIILEI PlBUIK II SUI fIE 1111111 PlaTIcomes complete with fittings for either 1 UCII 111108111 TIE FUllUl BFOIIEhose or metal tubing Mount it in an mllrtllllC 111 MItaccessible place inspect it often and 3 IF TIn XI fa I 10 nH IIU utIdrain off water accumulation fre TIlE n 111118 SHIU rIm AID SNEll IUPPUtl IE cuun INU m HlIIt SELEtTUquently MU IUllaDl 18111 IIIUIlED lTD CUIII DI 111E IAaI TIlIT IT IB MEOUIIE LUEt AlII Hill IT II UKI IPOUEDIf a water trap type filter is not installed 4 If IlitEi 11 IEUII III HIE FUEl 11 tILLbetween the fuel tank and the engine COLLECT SlOlU II Til IDTUII OF Til SOUUIER llIEl THE lEI flOAT IIImounted fuel system any water in the IUCIlES THE DIAU LUI 01 TilE Lum BOWL LOast TIlE SOTTOII IUU lua UMnLfuel system will tend to lay in the bot ALL ITEI RUd OUTtom of the electric lift pump Internal S 118111 DUll LUI IEtUIElf II 110 u UIImetal parts of the lift pump will rust NUl THE luruParticles will pass on to filters and EMElGIl TIlE FaEl PUIIP TD HILL Til Boneventually to the injection pump andinjectors with damaging results andthe possibility of expensive water damage to the fuelsystem is not covered under theWesterbeke warrantyIn addition any gasoline In the fuel system will damage the engines fuel injection pump assembly and injectors as gasoline does not have the same lubricating qualities as diesel fuelAlthough most boatbuilders supply a water trapfilter some do not Westerbeke offers a as an optional extra at moderate cost The filter is supplied with fittings for either hose or metaltubing fuel lines 31 Weslerbeke Diesel EnginesPriming and Bleeding the Fuel SystemThe W 40NA engine has only one replaceable fuel filter located on the enginemounted fuel system Thisfuel filter is located just after the discharge side of the mechanical fuel lift pump Gust below the fuel filterThe manualbleeding design of the fuel system allows the fuel filter to be easily serviced To replace the fuelfilter remove and replace filter elements as described in the Replacing Filter Elements section of thismanual page 35 Be careful to catch any fuel that may spill from within this fuel filter assembly NOTE Any primary fuel filterWater separator installed between the fuel tank and the engines fuel lift pump that is a Raycor Dahl or other similar filters should be manually filled before an attempt to bleed the fuel system between the fuel tank and the engine is madeTo bleed remaining air from that portion of the fuel system which runs between the fuel tank and the engineonce the primary fuel filter has been manually filled move the mechanical fuel lift pumps priming lever upand down using steady even strokes one stroke per second for a period of one minute For this no fittings should be open Refer to the illustration of the fuel system when following the procedure described above page 33 Fuel Supply IN Manual Priming Lever Mechanical Fuel Lift PumpRefer to the illustration on the next page when following the procedures described below1 After all air has been bled from between the fuel tank and the engine proceed to either one of the two bleed points 1 located on top of the fuel filter see the next page Choose the one that is easily asses sable Loosen the banjo bolt on top of the filter or the plug on the side of the filter housing one to two turns DO NOT remove the bolt or the plug2 Move the priming lever up and down as described on the previous page to purge the air out of the secon dary fuel filter through the open banjo bolt or plugWesterbeke Diesel Engines 32 NOTE As a safety precaution place a small plastic trash bag containing a few cloth rags around and under the secondary filterto catch any fuel that may spill from within the filter when it is removed Also note that when working the manual priming lever on the fuel lift pump move the lever up and down using long even strokes DO NOT operate the lever using rapid jerks In some rare instances the fuel lift pump may be at or near its internal maximum pump stroke In this situation no pumping action will be accomplished using the external manual priming lever In this case turn the engine over one or two turns do not attempt to start the engine to reposition the pumps internal pumping lever Now attempt to bleed the fuel system using the manual priming leverOnce the fuel system is bled which is indicated by a flow of bUbblefree fuel from bleed point 1 the banjo bolt or the plug and proceed to point 23 Using either a 516 box wrench or a 14 drive 516 socket wrench open the 516 2 bleed screw lo cated on the side of the fuel injection pump onehalf to one turn only DO NOT remove this special bleed screw Once again move the manual priming lever up and down to purge all of the air from this area of the fuel Injection pump When the fuel flows bubblefree from the 2 bleed screw retighten the bleed screw and proceed to point 3 Refer to the illustration below Return Fuel ToFuel Ta 81eedscrew 1 Bleedscrew 1t1 tl Fuel Supply IN Mechanical Lift Pump High pressure Injectors Fuel Line IN ifiF Sleedscrew 3 81eedscrew 2 Fuel Injection Pump Fuel System 33 Westerbeke Diesel Engines4 Using the 516 box wrench or the 14 drive 516 socket wrench open the 3 bleed screw and bleed this portion of the fuel Injection pump in the same manner as described in step 3 Proceed to step 5 NOTE Make sure that the throttle Is fully open and the engines shutoff lever is in its RUN poslon before proceeding to step 55 Using a 58 open end wrench loosen all four high pressure injector line nuts 4 located at the base of each injector one to two turns Using the starter motor crank the engine over to bleed any air in the high pressure lines between the fuel Injection pump and the injectors Crank the engine until fuel spurts from between the injector nut and the high pressure injector line NOTE Only spurts of fuel should come from this bleed point not a steady flow of fuel DO NOT crank the engine for long periods of time Excessive cranking will cause the starter to overheat and will flood the exhaust system with sea waterRetighten ali four high pressure injector line nuts with the 58 open end wrench NOTE Excessive torque is not required to properly tighten the injector line nuts to the base of the high pressure injectors6 The engine is now primed and ready to start Leaving the throttle in the FULL OPEN posion make sure that the engines STOP lever is in the RUN posion and that the transmission is in NEUTRAL At this point proceed to start the engine Use the PREHEAT button as required and crank the engine using the starter Once the engine fires return then throttle to its IDLE position Check to make sure that the engines In struments indicate the proper oil pressure reading and that sea water is discharged with the exhaust Allow the engine to idle between 1000 to 1200 rpm for five minutes to make sure that all air in the fuel system has been bledIf the engine fails to start reprime the fuel system and try to start the engine once again CAUTION Prolonged cranking intervals without the engine starting can result in filling the engine mounted exhaust system with sea water coolant This may happen because the sea water pump is pumping sea water through the sea water cooling system during crank ing This sea water can enter the engines cylinders by way of the exhaust manifold once the exhaust system fills Prevent this from happening by closing the sea water supply throughhull shutoff drain the exhaust muffler and correct the cause for the excessive engine cranking needed to obtain a start Engine damage resulting from this type of sea water entry is not a warrantable issue the owneroperator should keep this in mind NOTE When the secondary onengine fuel filter has been serviced the 1 and 2 bleed points should only be bleed to make sure that ali air has been removed from the fuel system No other bleed points need to be opened at this time may find daubing white paint on each of the bleed points helpful If an un expected problem occurs in which the fuel system needs bleeding these points will be clear Diesel Engines 34While the likelihood of having to service the fuel system at sea is small the possibility does exist Thereforewe recommend that a replacement fuel filter be carried on board at all times Each fuel filter comes with twoOring gaskets Select the part numbers for this fuel filter from your Parts List and purchase spares from yourlocal Westerbeke Dealer or DistributorIf a leak should develop at a banjo or sealing washer that cannot be corrected by a simple tightening of thefitting replace the leaking washer A Fuel Hardware Kit is available for this engine which contains all the sealing washers used in the fuel system except those noted in the fuel filter replacement cartridge below Replacing the Fuel Filter ElementsAfter the first 50 hours of operation remove filter cup 9 by unscrewing bolt 3 and drawing down on the6 element Be careful to catch any fuel that may spill from within this fuel filter cup Discard the old 6filter element and the old 5 7 and 8 Orings Clean the 9 filter cup and install the new 6 filter element along with new 5 7 and 8 Orings 2 7 5 6 8 NOTE Replacement element part number 14776 contains items 5 6 7 and 8 9 Fuel FilterAfter the first 50hour change the change period may be increased to 200 hours or once per season 35 Westerbeke Diesel EnginesFuel Injection PumpThe fuel injection pump is one of the most important components of the diesel engine and therefore callsfor the utmost caution in handling Furthermore the fuel injection pump has been thoroughly benchtestedand should not be tampered withIdle speed and timing adjustment are the only adjustments the servicing dealer can perform on the Injectionpump Other types of adjustments or repairs must be performed by a qualified injection service shopTo obtain long and satisfactory service from the injection pump always use fuel which is free from impuritiesand maintain a good filtration and water separation system between the fuel tank and the engine Servicethis system regularly the Injection pump it saves may be your ownBelt Drive SystemThe illustration below shows the complete belt drive system for the W 40NA engine A compressor bracketand mounting bracket are provided for the installation of a Grunnert refrigeration compressorTwo alternators are mounted on the W 40NA engine The second alternator charges the ships service batterys Two oil pressure cutout switches for the fields on the alternators are mounted on a bracket at therear of the engine These switches will prevent any load on the engine upon the engines Inttlal startup Westerbeke Diesel Engines 36 ELECTRICAL SYSTEMEngine 12Volt DC Control CircuitThe Westerbeke 40NA propulsion engine has a 12Volt DC electrical control circuit as shown on the wiringdiagrams which follow on pages 40 and 41 Refer to these diagrams when or components on the engine CAUTION To avoid damage to the battery charging circuit never shut off the engine battery switch while the engine is running When the engine Is not running shut OFF the engines battery switch to avoid when working on the engine electrical circuit Prereat SolenoidNote that the engines controlsystem electrical System isprotected by a 20Ampere DC Circuit Breakermanual reset circuit breaker located on the rear lifting bracketBattery minimum recommended capacity of the battery used in the engines 12Volt DC control circuit is 125 150 Amperehours minimum CAUTION When quickcharging the battery with an external charger be sure to disconnect the battery cables from the battery Leaving the charging circuit connected while quickcharging will damage the alternators diodes 37 Westerbeke Diesel CAUTION When testing the alternator circuit charging circuit do not use a highvoltage tester such as a megger damaged diodes could result During highspeed operation of the engine do not disconnect the positive terminal of the bat tery from the B terminal of the alternator nor disconnect the negative terminal of the battery from the ground Damage to the alternators diodes will result When cleaning the engine with a steam cleaner be careful to keep steam away from the al ternator Always connect the batterys cables to the correct terminals Reversing the connections will damage the DC charging alternator To connect the battery connect the Positive lead Hot first and then connect the Negative lead Ground last To disconnect the battery disconnect the Negative lead Ground first and then disconnect the Positive lead Hot lastRefer to pages 40 and 41 for the electrical system wiring schematic for the W 40NAWesterbeke Diesel Engines 38The charging system consists of two alternators with external voltage regulators an enginemounted circuitbreaker a battery and connecting wiresBecause of the use of ICs integrated circuits the electronic voltage regulator is very compact and ismounted on the rear bracket of the Voltage TestIf you suspect that the alternator is not producing enough voltage to charge the engines battery performthe following voltage test 14 L T BLUE 2T o 0 4 19 10 RED 14 GREEN ALTERNATOR 51 A for Charging Voltage Test1 Using a voltOhms meter make sure that 12 Volts are at the EXC connection while the engine is running and the oil pressure EXC switches are closed2 Using a voltmeter connect the voltmeters red wire clip to the B output terminal on the alternator Refer to the schematic shown above3 Connect the other wire clip to a ground on the engine4 Start the engine and increase the engines speed to 2000 rpm Now record the reading given by the voltmeterThe voltage reading for a properly operating alternator should be between 135 to 145 volts If your alternator is over or under charging have tt replaced or rebuilt by a reliable service shop NOTE Disconnect all battery power to the engine before attempting to disconnect or remove the alternators for repair 39 Westerbeke Diesel Engines W 40NA DC Control Circuit Wiring Diagram 37248 page 1 of 2 WIPING DIAGPAM s W y rt b I b 0 I w CD D lO I o os UELWesterbeke Diesel Engines 40 W 40NA DC Control Circuit Wiring Diagram 37248 page 2 of 2SCHEMATIC OIAGRAI1 A l 0 L j 40110 IRING ODIFICATIOS ANDPARTS SUPPLIED BY HANSEN MARINE EIIGINEERING 01945 41 Westerbeke Diesel Engines COOLING marine diesel engines are designed and equipped for fresh water cooling Heat produced inthe engine by combustion and friction is transferred to fresh water which circulates throughout the engineThis circulating fresh water cools the engine block and s internal moving parts The heat is transferred externally from the fresh water to sea water by means of a heat exchanger similar in function to an automotive radiator Sea water flows through the tubes of the heat exchanger while fresh water flows around thetubes engine heat transferred to the fresh water is conducted through the tube walls to the sea water whichis then pumped into the exhaust system where finally is discharged overboard In other words the engineis cooled by fresh water the fresh water is cooled by sea water and the sea water carries the over the side through the exhaust system The fresh water and sea water circus are independent ofeach other Using only fresh water whin the engine allows the cooling water passages to stay clean andfree from harmful deposs The two independent circuits and their components are discussed in the following Water Circuit NOTE Refer to paragraphs A and B in this section for the recommended antifreeze and water mixture to be used as the fresh water coolant and for information on filling the fresh water below is a typical Westerbeke engines cooling system Both fresh water and sea water flowthrough their independent COOling circus To Fresh Water Circulating Pump Inlet on Engine Block b Incoming Sea Water Sea Water Impeller Pump To Transmission Oil Diesel Engines 42Electrical SystemThe electrical system should be checked to ensure that all wiring harnesses are tied down properly withclamps or plastic ties spaced at intervals close enough to prevent chafing from vibration Check to ensurethat all the engines harness connections are tight and that they are connected to the appropriate terminals IWARNINGI Do not smoke or allow an open flame near batteries Lead acid batteries emit hydrogen a gas Turn off the emergency switch in the positive line of batteryMake sure the positive battery connection is connected to the battery connection of the starting solenoidThe negative battery connection should be connected to the system ground the engine block WARNINGI When servicing the battery or checking the electrolyte level wear rUbber gloves a rubber apron and eye protection Battery acid may splash on the skin or into the eyes inadvertent ly when removing electrolyte capsCheck level and specific gravity of battery electrolyte to ensure maximum engine starting efficiency Makesure terminals are clean and ventilation requirements of the engine include the following combustion air Is required for the and ventilating air is required to clear the bilges below the engine as well as the compartment inwhich the engine is located of engine heat and potentially toxic and flammable diesel fumes Refer to section of this manual for airflow requirements page 8 21 Westerbeke Diesel Engines PREPARATION FOR STARTINGThis section of the manual provides the operator with preparation initial starting breakin starting cold orwarm and stopping procedures Follow the procedures as presented for the conditions indicated andyour Westerbeke engine set will give you reliable performance and long service lifeFill the engine with oil by pouring engine oil through theoil filler cap Fill the engine up to or near the upper limiton the dipstick the installation angle may have an effecton the dipstick reading Select readily available Oil Filler Caplubricating oil with an API specification of CC or CD andan SAE number suitable for the temperature in youroperating area see page 47 For the quantity of oilneeded in this engine refer to the SYSTEM SPECIFICATION section of this manual page 8Fill the transmission to the FULL mark on the dipstick Oil Dipstickwith the correct lubricant Refer to the section of this manual page 9 Upper LimitEach unit is supplied with a coolant recovery kit Normal Levelhf124977 as standard equipment to which the follow Oiling applies Lower Limit A Remove the pressure cap from the engines ex Crankcase haust manifold and slowly fill the engines cooling system with a mixture of water and antifreeze suitable for your temperature zone See the COOLING SYSTEM section of this manual page 42 Operate the engine and observe the coolant level in the manifold Maintain this level to the base of the filler neck Once the engine reaches its operat ing temperature 170 190 F ensure that there is coolant flow to the domestic water heaters when in stalled Top off the cooling system and install the pressure cap B Make sure the plastic recovery tank is property mounted near the unit with the bracket provided in a location where it can be monitored and filled easily The recovery tank should be mounted at manifold level or above In these installations that require it the plastic recovery tank can be mounted below the exhaust manifolds level C Add coolant to the plastic tank after the engine has been started and operating temperature has been reached to ensure that all air is expelled from the manifold and the engines cooling system With the manifold filled and the pressure cap installed fill the plastic recovery tank half full Monitor daily and add coolant as neededFill the fuel tank with a good grade of No2 diesel fuel and prime the fuel system up to the engine see page32 When returning fuel is free of air the engines fuel system is bled and the engine is ready to startEnsure that the Installation Checks have been made in accordance with those specified in the INSTALLATION CHECKS section of this manual refer to page 10Westerbeke Diesel Engines 22Starting SystemThe W 40NA diesel engine uses an electric starter for both normal and cold weather starting A cold start aidsystem is furnished on the W 40NA engine as standard equipment part 36258 Both the thermostart deviceand the cold start aid are located on the air intake manifold side of the engine The PREHEAT button energizes the thermostart device assists in vaporizing the fuel at the intake manifold Inlet The vaporized dieselfuel is drawn into the cylinder during cranking and allows for easy combustion during compression Thisprocess allows the engine to start rapidly and reduces wear on the starter Air Intake Screen Stand Pipe Thermostart Cold Start AidThe W 40NA engines electrical system is designed so that the PREHEAT button must be depressed for thetime specified in the Preheat chart shown on page 26 While keeping the PREHEAT button depressed theSTART button must be pressed to crank the engine NOTE The START button will not crank the engine unless the PREHEAT button is depressed at the same time When the PREHEAT button is depressed the thermostart device is activated USE THE PREHEAT BUTTON ONLY AS NECESSARY Overuse of the PREHEAT button will overheat the thermostart device Refer to the STARTING PROCEDURE section of this manual for starting instructions page 26 23 Westerbeke Diesel Engines DESCRIPTION OF INSTRUMENT 40NA engines are supplied with instrument panels Read the following instruction operating the engine RPM Gauge Water Temperature Gauge Oil Pressure Gauge Ammeter Voage panel is equipped with an RPM gauge with an ELAPSED TIME meter which measuresthe engines running time in HOURS and in 110 hours The panel also includes a water temperature gaugewhich indicates in degrees Fahrenheit WATER 0 F an oil pressure gauge which measuresthe engines oil pressure in pounds per square inch OIL PSI a DC control circuit voltage gauge whichmeasures the systems DC voltage VOLTS and a DC Ammeter which allows the operator to in the DC charging circuit All gauges are illuminated when the circuit breaker is turned ON andremain illuminated while the engine is in operation The panel also contains two rubberbooted push buttons one for PREHEAT and one for START 1 Circuit Breaker Not Shown The Circuit Breaker positioned somewhere in the vessel so it may be easily reached provides power only to the instrument cluster Refer to the STOPPING PROCEDURE section of this manual page 28 2 PREHEAT The PREHEAT button energizes the alternators EXC terminal and the intake manifolds thermostart device This button also energizes the START button 3 SIABI The START button when pressed energizes the starters solenoid which cranks the engine This button will not operate electrically unless the PREHEAT button is pressed and held at the same timeWesterbeke Diesel Engines 244 Ammeter Gauge An Ammeter gauge is provided by the Dealer and is located in the lower right hand corner of the instrument panel The Ammeter is not shown in the photograph on the preceding page NOTE An alarm buzzer is supplied with every panel The installer is responsible for electrical ly connecting the buzzer to the fourpin connection on the engines electrical harness The in staller is also responsible for installing the buzzer in a dry location so that will be audible to the operator should sound while the engine is running The buzzer will sound when the eir cui Breaker is turned ON and should silence when the engine has started and when the engines oil pressure rises above 15 psi5 Water Temperature Gauge This gauge is graduated in degrees Fahrenhe and is illuminated while the main engine circuit breaker is turned ON The engines normal operating temperature is 170 190 F 77 88C6 Oil Pressure Gauge This gauge is graduated in pounds per square inch PSI and Is illuminated while the main engine circuit breaker is turned ON The engines normal operating oil pressure ranges be tween 30 60 PSI NOTE When the engine is manually shut down and the engines circuit breaker Is turned OFF the water temperature gauge will continue to register the last temperature reading indicated by the gauge before electrical power was turned OFF The temperature gauge will once again register the engines true temperature once electrical power is restored to the gauge 25 Westerbeke Diesel Engines STARTING PROCEDURE1 Place the transmission in the NEUTRAL position and advance the throttle to its full open position for a cold engine and partially open for a warm engine2 Turn the Circuit Breaker to the ON position Make sure the pushpull stop lever has been returned to the RUN position3 Depress and hold the PREHEAT switch Preheat according to the following chart Atmospheric Temperature Preheating Time 41 F 5 C or higher Approx 10 sec 41F 5Cto 23F5C Approx 20 sec 23 F 5 C or lower Approx 30 sec Limit of continuous use 1 minuteThe Instrument panel includes a DC control circuitvoltage gauge A properly operating is indicated when the voltmeter registers a volt Voltage Dropage drop when the PREHEAT button is depressedThis voltage drop will be slight but noticeable If thevoltmeter indicates no voltage drop at the time thePREHEAT button is depressed then the could be defective or the preheat circuit is faulty check for any loose holding the PREHEAT button depressed 13 15depress the START button The starter motor will run thereby cranking the engine As soon as the engineruns release the START button and PREHEAT buttonShould the engine not start when the START button isdepressed for 10 to 12 seconds release both buttonsand wait 30 seconds repeat the previous procedure DC Control Circuit Voltage GaugeNever run the starter motor for more than 30 secondsat a time CAUTION Prolonged cranking intervals without the engine starting can result In filling the engine mounted exhaust system with sea water coolant This may happen because the sea water pump is pumping sea water through the sea water cooling system during crank ing This sea water can enter the engines cylinders by way of the exhaust manifold once the exhaust system fills Prevent this from happening by closing the sea water supply throughhull shutoff drain the exhaust muffler and correct the cause for the excessive engine cranking needed to obtain a start Engine damage resulting from this type of sea water entry is not a warrantable issue the owneroperator should keep this in mindWesterbeke Diesel Engines 26Once the engine starts move the throttle into a fast idle position 1000 1200 rpm Check your for proper engine operation Make sure that sea water discharges along with the exhaust discharge NOTE Some unstable running may occur in a cold engine but this condition should smooth out as the operating temperature of 170 190 F 77 88 C is ShiftingTo shift the transmission use the remote control shifting lever located in the cockptt This remote lever rotates the shifting lever on the side of the standard transmission Rotating the shifting lever ina direction places the transmission In FORWARD gear To shift the transmission inREVERSE gear rotate the shifting lever in a clockwise direction through NEUTRAL into FORWARD GEAR Rotate the lever REVERSE GEAR Rotate the lever CLOCKWISE through NEUTRAL into REVERSEFor a more detailed description of the HBW transmissions operation refer to the HBW of this manual page 50 Remote Control Shifting Cable Neutral o Reverse A B Soljl o 0 Or Counter Clockwise Clockwise Transmission Cover Plate 0 0 r Shifting Lever Transmission Shifting Positions 27 Westerbeke Diesel Engines STOPPING PROCEDURESIn the cockpit of the boat there is a tee handle or a knobtype shutof control When this control is pulledOUTWARD the control will STOP the engine The other end of the shutoff control is attached to a lever onthe top of the fuel Injection pump Pushing the shutoff control fully inward will place the engine in the RESTART RUN posttionWhen the engine is stopped turn the Circuit Breaker located in the vessel to the OFF position If the CircuitBreaker is left ON the battery will discharge CAUTION DO NOT attempt to shutdown the engine by turning the Circutt Breaker OFF The Circutt Breaker only provides power to the instrument panel and to the DC alternator the engine will continue running even H the Circuit Breaker is turned OFF Stop the engine by pulling the shutoff control fully OUTWARDEngine BreakIn your engine has experienced a minimum of one hour of test operations to ensure accurate assembly and proper operation of all systems breakin time is required The service life of your engine is dependent upon how the engine is operated and serviced during its initial hours of useYour new engine requires approximately 50 hours of initial conditioning operation to break In each movingpart in order to maximize the performance and service life of the engine Perform this conditioning carefully keeping in mind the following 1 Start the engine according to the STARTING PROCEDURE section found on page 26 run the engine at fast idle while checking that all systems sea water pump oil pressure battery charging are function ing 2 Allow the engine to warm up preferably by running at fast idle until the water temperature gauge moves into the 130140 F range 3 While using the vessel under power vary the engines rpm cruise settings during the engines initial 25 hours of operation 4 Avoid rapid acceleration especially with a cold engine 5 Use caution not to overload the engine The presence of a gray or black exhaust and the inability of the engine to reach its full rated speed are signs of an overload that is a propeller that is too large 6 During the next 25 hours the engine may be operated at varying engine speeds with short runs at full rated rpm Avoid idling the engine for prolonged periods of timeBreakingin a new engine basically involves seating the piston rings to the cylinder walls This cannot be accomplished by long periods of running at Idle nor by early running at full speedIdle running may glaze the cylinder walls resulting in excessive oil consumption and smoky operation Excessive speed or heavy overloading especially with a cold engine may cause scoring of the cylinder wallsproducing similar Diesel Engines 28As indicated above operate the engine in moderation during the 50hour breakin period On one handdont baby the engine but on the other hand however dont abuse itStarting Under Normal the procedure below for normal starting of the engine 1 Check the engine and transmission lubricant levels and fill if necessary 2 Make sure there is sufficient fuel on board Keep fuel tanks as full as possible Check the fuel filters and water separators for the presence of contaminants andor water Drain and clean them as needed 3 Check the coolant level in the plastic recovery tank Add coolant solution as needed NOTE Excessive loss of coolant from the plastic recovery tank indicates a cooling system leak Check the entire cooling system and the recovery tank and its connections at the ex haust manifold and pressurize the system to locate the leak In cases of excessive coolant loss the system must be refilled as outlined under the PREPARATION FOR STARTING sec tion of this manual page 22 4 Check for all and fuel leaks particularly if signs of such leaks are found on the bottom of the engine or below the engine 5 When checking your engines coolant and all levels check the engine for any noticeable abnormalities such as loose or missing bolts loose brackets and mounts loose hose clamps chafed wires or any other components that exhibit wear or are looseStart the engine in accordance with the STARTING PROCEDURE instructions found on page 26 and allowthe engines operating temperature to reach 140 150 F before operating the engine underway 29 Westerbeke Diesel Under Cold extremely cold temperatures the following conditions can occur Follow the instructions listed belowwhen operating your engine in cold OIL TURNS VISCOUS Make certain that the lubricating oil used conforms with the ratingsfor the prevailing atmospheric temperature Refer to the LUBRICATION SYSTEM section of this manualpage 47 for an atmosphericoil viscosity specification tableVOLTAGE ACROSS THE BATIERY TERMINALS DROPS Make certain that the battery is fully charged tominimize voltage drop across the battery terminalsTHE TEMPERATURE OF THE INTAKE AIR IS LOW AND THE COMPRESSION TEMPERATURE DOES NOTRISE ENOUGH Allow the thermostart device to operate sufficiently to aid in starting during the preheatperiod whenever the temperature of the intake air is low and when the compression temperature within thecylinders will not rise quickly during cranking Refer to the Preheat chart found in the STARTING PROCEDURE section of this manual page 26 Westerbeke Diesel Engines 30Fresh water is pumped through the engine by a beltdriven fresh water circulating pump absorbing heat fromthe engine The fresh water coolant circulates through the engines block absorbing heat then passesthrough the thermostat into the exhaust manifold to the heat exchanger where it is cooled and then isreturned to the engine block through the suction side of the fresh water circulating pump When the engineis started cold external fresh water flow is prevented by the closed thermostat although some fresh waterflow Is bypassed around the thermostat to prevent the exhaust manifold from overheating As the enginewarms up the thermostat gradually opens allowing full flow of the engines fresh water coolant to flow unrestricted to the external portion of the cooling system A Fresh Water Coolant Antifreeze MixtureA freshwater and antifreeze mixture should be used yearround in the fresh water cooling system Waterwhen it freezes expands sufficiently to split the heat eXChanger and crack the engine block A mixture of proper concentration will prevent freezing see below for an mixture chartUse soft water with few Impurities such as tap water potable water or rainwater Never use hard or foulwater Use of hard water or water containing Impurities will lead to the collection of scale in the engine andheat exchanger which will reduce the cooling systems of poor quality or without rust inhibitors will cause corrosion within the COOling system Jwaysuse antifreeze which is compatible with aluminum cooling system components and is made by a Never mix different brands of antifreezeMake sure that the cooling system of the engine is well cleaned before adding antifreeze Recommended antifreeze for year round use is ZEREX or PRESTONE with rust inhibitorsIn order to control the concentration of the mixture mix the antifreeze and freshwater thoroughly before adding it to the cooling system ANTIFREEZE CONCENTRATION DATA Antifreeze Concentration 13 23 30 35 45 50 60 Freezing F 23 14 5 4 22 40 58 Temperature C 5 10 15 20 30 40 50 NOTE An antifreeze concentration should be selected on the basis of a temperature which is about 10 F 5 C lower than the actual atmospheric temperature expected B Filling the Fresh Water SystemA coolant recovery tank kit is supplied with each Westerbeke diesel engine The purpose of this recoverytank is to allow for engine coolant expansion and contraction during engine operation without the loss ofcoolant and without introducing air into the cooling systemThis coolant recovery tank should be installed at or above engine manifold level in a location where it canbe easily monitored and where coolant can be easily added if needed see the figure below A stainlesssteel mounting bracket is supplied with each kit along with a 3Dinch length of clear plastic hose and clampsto connect the hose between the engines manifold fitting to the hose spud on the base of the recovery tank 43 Westerbeke Diesel Engines COOANT RECOVERY TANK PIISSURE CAP Coolant Recovery Tank Recommended from the engine when heated during engine operation will expand lifting the springloaded cap and enter the coolant recovery tank by way of the hose connecting the recovery tank to theexhaust mannoldWhen the engine is shut down and cools a small check valve in the pressure cap is opened by the contraction of the engine coolant allowing some of the coolant in the recovery tank to be drawn back Into theengines cooling system free of air and without loss FUNCTION OF MANIFOLD PRESSURE CAP COOLANT RETRACTION to Coolant Tlnk COOLANT Diesel Engines thermostats are of two types One is simply a choking device which opens and closes as theengines temperature rises and falls The second type has a bypass mechanism Usually this is a disc onthe bottom olthe thermostat which moves downward to close off an internal bypass passage within the headSince 1980 each type of thermostat has a hole punched through it The hole is a bypass to prevent the exhaust manifold from overheating during the engines warmup Replacement thermostats must have thisdesign Water CircuitThe sea water flow is created by a geardriven positive displacement neoprene impeller pump The pumpdraws sea water directly from the ocean through the sea cock and sea water strainer and passes the waterto the heat exchangers sea water inlet The sea water passes through the heat exchangers tubes fromwhich heat from the fresh water system is absorbed and then the sea water is discharged from the coolingsystem overboard through the waterinjected wet exhaust systemA zinc anode or pencil is located in the seawater cooling circuit within the heat exchanger The purpose of the zinc anode isto sacrifice itself to electrolysis actiontaking place in the sea water cooling circuit thereby reducing the effects of electrolysison other components of the system Thecondition of the zinc anode should bechecked monthly and the anode cleanedor replaced as required Spare anodesshould be carried on board Be sure toclean zinc debris from the area inside of the CLEAN NEW ORheat exchanger where the zinc anode is AHODE REPLACE REPLACE REPLACE positioned Zinc Anode ConditionsSea Water PumpThe sea water pump is a selfpriming geardriven rotary pump with a nonferrous housing and a The impeller has flexible vanes Which wipe against a curved cam plate within the impeller the pumping action On no account should this pump be run dry There should always be a spareimpeller and impeller cover gasket aboard an impeller kit Sea water failures occur when lubricant seawater Is not present Such failures are not warrantable and the operators are cautioned to ensure that seawater flow is present at startup 45 Westerbeke Diesel and Water Pump Drive 8elt Tension iWARNINGI Never attempt to adjust the drive belts tension while the engine is in operation CAUTION Excessive alternator and water pump drive belt tension can cause rapid wear of the belt and reduce the service life of the fresh water pump and alternator shaft bearings Excessive slack or the presence of oil on the belt can cause belt slipping resulting in high operating tempera ture as well as insufficient alternator outputThe alternator and water pump drive belts isare properly adjusted if the belt can be deflected no less than38 inch and no more than 12 Inch 10 mm 12 mm as the belt is depressed with the thumb at the the two pulleys on the longest span of the belt See the figure below A spare drive belts shouldbe carried on board Alternator and Water Pump Belt Diesel Engines 46 LUBRICATION SYSTEMEngine OilFor engine lubrication use lubricating oil designated for diesel service These oils are classified accordingto the AFI specifications Into service grades CA CB CC and CD The use of CC or higher CD grades madeby wellknown manufacturers is recommended The oil selected should be used Oil Viscosity SAE NumberUse an oil having a viscosity best suited to the atmospheric temperature Use of an allseason oil SAE 10W30 with minimum viscosity change under different temperatures is suggested Atmospheric Temperature Viscosity 68 F 20 C or higher SAE 30 or 1OW3 41 F 5 C 68 F 20 C SAE 20 or 1OW3 41 F5 C or lower SAE 10W30 NOTE Do not usean engine lubricating oil with an SAE number greater than 30 in the engineOil PressureThe engines oil pressure during operation is indicated by the oil pressure gauge on the instrument panelsee page 24During normal operation the oil pressure will range between 30 and 60 psi At idle speed the oil pressurewill range between 20 and 35 psi At the time of cranking the oil pressure will rise with speed NOTE A newly started cold engine can have an oil pressure reading upwards of 60 psi A warmed engine can have an oil pressure reading as low as 35 psi These readings will vary depending upon the speed at which the engine is running 47 Westerbeke Diesel EnginesEngine Oil Change to include filter1 Draining the Oil Sump IIIIIIIIIII I 111 1 11 I ilill IP 1 Remove the oil drain hose from s attachment bracket and lower the end of the hose into a container to allow the oil to drain or attach a pump to the drain hose andpump the oil out Make sure the oil drain hose isproperly secured in its holder after all of the old oil hasbeen removedAlways observe the old oil as it is removed A yellowgray emulsion indicates the presence of water inthe oil Although this condition is rare it does requireprompt attention to prevent serious damage Call acompetent mechanic should water be present in the oilSea water present In the oil can be the result of a faultin the exhaust system attached to the engine andor asiphoning through the sea water cooling circuit into theexhaust filling it up into the engine refer to the installation illustrations on page 152 Replacement of the Oil FilterWhen removing the used oil filter you may find ithelpful and cleaner to punch a hole in the upper Oil Filter Part Number 16655and lower portion of the old filter to drain the oilfrom It Into a container before removing it Thishelps to lessen spillage A small style wrench should be helpful in removing the oldoil filter Place some paper towels and a plasticbag around the filter when unscrewing it to catchany oil left In the filter Oil or any other fluid onthe engine reduces the engines cooling abilityPlease keep your engine clean Inspect the oldoil filter as it is removed to make sure that the rubber sealing gasket came off with the old oil filter Oil Filter BracketIf this rubber sealing gasket remains sealedagainst the engine block gently remove it Thereplaceable cartridgetype oil filter requires nocleaning inside so it may be properly disposed of Oil FilterWhen Installing the new oil filter element wipe thefilter gaskets sealing surface on the engine block free of oil and apply a thin coat of clean engine oil to therubber gasket on the oil filter Screw the filter onto the threaded oil filter stub and then tighten the filter firmly by hand See the TORQUE SPECIFICATIONS section of this manual for the proper oil filter page 61Westerbeke Diesel Engines 483 Filling the Oil SumpAdd fresh oil through the oil filler cap on the valvecover refer to the photographs on pages 5 and 6 Oil Filler Capfor the location of the oil filler cap and lube oildipstick After refilling the oil run the engine for afew moments while checking the engines oil pressure Ensure there is no leakage around the newoil filter or from the oil drain system and then stopthe engine Then check the quantity of oil wtth thelube oil dipstick Fill to but not over the high mark Oil Dipstickon the dipstick should the engine require additlonaloil r Oil NOTE Immediately after an oil filter change Lower Limit 0 and oil fill run the engine to ensure that the oil pressure is normal and that there are no Crankcase oil leaks around the new oil filter Check the oil pressure by observing the oil pressure gauge in your instrument panel STARBOARD To Fresh Water Circulating Pump Inlet on Engine Block From Heat Exchanger Exhaust Manifold PORT Oil Cooler Assembly 49 Westerbeke Diesel Engines THE HBW 150 HBW 150 transmission Is equipped with a helical gearing system The servooperated multlpledisc clutch requires only a minimum effort to change drives This featuremakes the transmission suitable for a singlelever remote control with a rod linkage such as a Morse or Bowden cable For safety reasons the transmission is NOT filled with transmission fluid for shipment Beforeleaving the factory however each transmission is thoroughly tested with fluid in the transmission This testing among other things provides all internal parts with a coating of transmission fluid This fluid acts as apreservative providing reliable protection against corrosion for at least one year if the transmission is proper1y stored DIPSTICK AND FIll HBW 150 transmission is an type Fill the transmission up to or near the top ofthe machined notch cut on the dipstick with approximately 060 US quarts 056 liters of automatic transmission fluid ATF The HBW 150 has its own dipstick and oil sumpChange the transmission fluid after the first 30 hours of engine operation and thereafter every 250 hours oronce per year minimum The HBW 150 transmission has a drain plug for draining the old transmission fluidTo ensure that most of the old fluid is drained from the transmission run the engine in NEUTRAL for approximately 10 to 15 minutes so the transmission fluid may warm and flow better from the transmission fluid may also be removed by inserting a small tube through the dipstick opening where fluid is added and attaching a pump onto the tube so the old fluid may be sucked out NOTE When removing the dipstick or drain plug make sure the thin aluminum sealing washer located under the plug is not lost Leakage will result if the sealing washer is not Diesel Engines 50 NOTE To check the transmission fluid level remove the dipstick and wipe off all transmission fluid on the dipstick and place the dipstick back in the hole where it was removed making sure that the base of the dipsticks threaded portion rests on the transmission housing Now remove the dipstick and see where the fluid measures on the dipstick If the transmissions fluid level lies below the notch add enough transmission fluid to raise the level back up to the notch Do not overtill the transmission DO NOT screw the dipstick into this hole to check the transmission fluid level Screw the dipstick into this hole only after an accurate reading of the fluids level has been taken Make sure that the dipstick is screwed in before and while the engine is operating Ensure that the sealing washer is present and that the dipstick Is not crossthreaded or overtightened TO CHECK OIL LEVEL TRANSMISSION IN OPERATION b FLUID LEVEL DAAINPLUGThe Transmission drain plug is located directly below the dipstick and is the same size hex head as thedipstick This drain plug also has a sealing washer Maximum tightening torque for the Drain Plug and Dipstick 25 Ibft 345 between the transmissions coupling and the propeller shafts coupling can create Ensure that the alignment procedures outlined in the Propeller Coupling the Propeller andthe Alignment of the Engine sections of this manual are followed pages 13 and 14 51 Westerbeke Diesel only controls required to operate the transmission is a single lever remote control cable using a 33Ccable The cable should be attached at right angles to the gear box lever using the cable bracket suppliedwith the unit Both the gear box lever and the remote control lever must be in the NEUTRAL position whenthe cable is attached to the gear box lever This allows the remote cable an equal throw distance to shift thegear box into FORWARD or into REVERSE from the NEUTRAL position without running out of cable 118 inches 1 316 minimum of cable throw from the NEUTRAL position on the box lever to the each of the two drive positions NOTE If the throw distance Remote Control Shifting Cable or travel of the remote cable is too short the gear box lever Cable Bracket Neutral cannot fully engage the trans Forward 0 Reverse mission Into FORWARD A or REVERSE 8 In this situa C f d tion the transmissions clutch plates will wear prematurely 0X Or and the transmission will Counter Clockwise I Clockwise eventually fail Transmission Cover Plate NOTE Excessive throw dis tance in the remote control lever is not detrimental to the Cover Plate Hub Shifting Lever HUb transmission Note that the position of the remote control lever should align with the NEUTRAL marking on its bracket when the transmis 05 mm Clearance sion is really in NEUTRAL Transmission Shifting shift the transmission from NEUTRAL into FORWARD exert a heavy push to the remote control lever Agentle throw may not carry enough force to actually shift the transmissions internal gears A gentle throwis signalled by the transmission not engaging into the desired drive Make sure the remote control lever islubricated at lease once each operating season Shift the transmission while the engine is running at 1200rpm or below The clutch pack within the transmission makes an audible clunk when engaging into gear CAUTION NEVER remove or loosen the fourbolt gear box lever COVElr from the transmission The posi tion of this plate and the actuating lever inside of the transmission has been finely adjusted at the factory to ensure equal throw distance of internal mechanisms Loosening of this covers capscrews voids the transmissions Diesel Engines 52ServiceIf any seal on the transmission shows signs of leaking have the transmission looked at by a qualified HurthServicing Dealer This problem especially concerning the rear seal is often contributed to an improper alignment of the transmissions coupling and the propeller shafts coupling Refer to the Alignment of the Engine section of this manual page 13 NOTE A leaking rear seal can also be the result of a blocked vent hole in the head of the dipstick Propeller Size Propeller 18 D x 10 P 2 blade or 18 D x 8 P 3 blade using HBW 150 transmission Propeller should allow the engine to reach 1881 reduction its full rated RPM 3000 000 100 at full open throttle while underway 53 Westerbeke Diesel Engines ENGINE tables which follow Indicate procedures based upon certain problem indicators theprobable causes of the problems and the to overcome these problemsNote that the engines control system electrical system is protected by a 20Ampere manual reset circuitbreaker located on the rear lifting bracketproblem probable Cause button is de Battery switch or Check the swttch Breaker andpressed no panel in Circuit Breaker or the battery is not ON 20Amp circutt Reset breaker Hthe breaker breaker has tripped trips again check the preheat solenoid circutt and circuit for shortsSTART button is de Must PREHEAT first PREHEAT button must bepressed no starter depressed to activate theengagement START button Connection to the Check the connection solenoid is faulty FaUlty START switch Check the switch with an ohmmeter Faulty solenoid Check that 12 Volts is present at the solenoid connection on the Diesel Engines 54Problem Probable Cause switch Is de Loose battery Check batterypressed no starter connection Low battery Check voltage present at voltage the solenoid S terminal when the START button is depressedNo ignition engine Shutoff lever Return shutoff lever tocranks but does not the RUN positionstart Faulty fueling system 1 Check for fuel to the engine 2 Check for air in the fuel system Bleed the fuel system 3 Fuel lift pump is faulty 4 Filters are clogged Replace filters and bleed the fuel systemFailure to stop Shutoff linkage is Stop engine by manually disconnected moving the RUN linkage to STOP That failing shut off fuel and air Loosen high pressure lines to the stops Fuel starvation RPM fluctuation before stopping Check for fuel blockage clogged filters or air in the fuel system Fuel contamination Suddenly stops Fuel contamination damaging the fuel injection pump Clean the filter and bleed the fuel system Check fuel delivery to the injectors 55 Westerbeke Diesel EnginesProblem Probable Cause stops Transmission failure Check the fluid level in thecontinued transmission Transmission seizure will stop the engine Engine will not turn over by engaging the starterBattery is not Alternator drive Check drive belt Be sure the alternator turns freely Check for loose connections Check output with a voltmeter Ensure that 12 Volts are present at the EXC connection Check the alternator as described on page 39Battery runs down Circuit Breaker Observe if the gauges and panel lights are activated when the engine is not running Test the Circuit Breaker High resistance leak Check wiring Insert a to the ground sensitive 025 Amp Amp meter in the battery lines Do not start the engine Remove connections and replace after the short Is located Low resistance leak Check all wires for to ground temperature rise to locate the fault Alternator Disconnect the alternator at the output after a good battery charging If the leakage stops remove the alternator and bench test Repair or replace the unn Preheat solenoid Test the preheat solenoid with a voltmeter on the lead to the thermostart Diesel Engines 56 MAINTENANCE AND section contains a scheduled preventive maintenance program and several adjustment procedures can periorm without the benefit of sophisticated and expensive tools and the preventive maintenance in accordance with the schedules listed in the following to these schedules will ensure the equipment Is maintained in the best possible condition andthat tt will periorm to expectations Those ttems marked by an asterisk are recommended to be periormedby an authorized dealer or before each use 1 Check the 011 sump level Maintain the 011 level at or near upper level mark on dipstick 2 Check the coolant level in the plastic recovery tank Maintain this level at or above the level marked ADD 3 Check the transmissions lubricant level and add additional lubricant as needed 4 Visually inspect the engine check for loose belts chafed or broken wires loose brackets and fmings damaged hoses loose clamps and other equipment not properly secured This check should Include the propeller shaft coupling to the transmissions output flange 5 Visually Inspect the sea water strainer 6 Check the fuel supply Fill tanks with a good grade of No2 diesel fuel if required Fuel additives are recommended to prevent algae growth 7 Check the primary filterWater separator Drain and service as required A primary fllterWater separator is optional but strongly recommended 8 Check the engines gauges or lights for proper 011 pressure operating temperature and starting battery charging voltage once the engine is operating 9 Check each alternators output gauge if installed for proper DC the condttion of the zinc anode in the heat exchangers sea water circuit Clean or replace the anodeas required Keep the area inside the heat exchanger clean of zinc anode debris The rapid deterioration ofthe zinc anode may be an indication of electrolysis action caused by an electrical fault adjacent to the vessel or from an electrical fault on the vessel 57 Westerbeke Diesel After Initial 50 Hours of Operation 1 Change the engines lubrication oil and oil filter 2 Replace the fuel filter element as described on page 35 Clean and replace the filter element and bowl of the primary fuel filterWater separator if one has been installed 3 Torque the cylinder head nuts 4 Adjust valve clearances 5 Adjust the alternator water pump and compressor drive belt tension if required 6 Lubricate the throttle the RUN linkage cable and the transmissions remote control cable 7 Clean the air intake screen 8 Adjust the engines idle as needed 9 Change the transmissions transmission fluidServicing After Every 100 Hours of Operation 1 Change the engines lubrication oil and oil fnter 2 Adjust the alternator and water pump drive belt tension if required 3 Check the transmission fluid or oil levelServicing After Every 250 Hours of Operation 1 Replace the onengine fuel filter element and service the primary fuel filterwater separator as needed Check the sea water pumps impeller 2 Change the transmissions transmission fluidServicing After Every 500 Hours of Operation 1 Torque the cylinder head nuts 2 Adjust the valve clearances 3 Drain flush and refill the fresh water cooling system 4 Check the condition of the starter motor drive pinion lubricate the pinion 5 Check the sea water pump for any internal wear Check the pumps cover cam and impeller Replace those parts that are excessively wornWesterbeke Diesel Engines 58 6 Check the condition of all hoses and drive belts Replace those that are badly worn NOTE Items highlighted by an asterisk should be performed by a competent After Every 800 Hours of Operation 1 Remove and check fuel injectors Injector spray setting pressure 2200 psi 155 kglcm 2 Minimum working pressure POOR 2000 psi 140 kglcm 2Eliminate undesirable injection conditions Refer to the illustration to the right fef em lIiilii GOOD 2 Check the engines compression pressure Remove each glow plug and check each cylinders compression pressure The engines cranking speed is between 250 and 300 rpm Standard Minimum 450 psi 350 psi 316 kglcm 2 246 kglcm 2 Maximum difference between cylinders 25 psi 17 kglcm 2 3 Check the alternator for proper operation 4 Check the tightness of bolts nuts and After Every 1000 Hours of Operation 1 Remove clean and pressure test the primary heat exchanger A local automotive radiator shop should be able to clean and test the heat exchanger NOTE Operating in silty andor tropical waters may require that a heat exchanger cleaning be performed more often than every 1000 hours 2 Check the fuel Injection pumps timing 59 Westerbeke Diesel Engines VALVE CLEARANCE ADJUSTMENT CAUTION The cylinder head nuts must be retightened after the first 50hours of breakin operation and before adjusting the valves Make sure the engine is cold when retightening the cylinder head nuts Refer to the TORQUE SPECIFICATION section of this manual for proper tightening specifications page 61If the engine needs to be timed refer to the TIMING ADJUSTMENT section in the Technical Manual Engine timing should be performed by a competent diesel mechanicFollow the procedure described below when tightening cylinder head nuts and when adjusting valves1 Loosen the hose clamp on the air breather pipe and remove the hose clamp and the air breather from the rocker cover Remove the rocker cover bolts and remove the rocker cover2 Tighten the cylinder head nuts according to the sequence shown in the illustration shown below Make sure the engine is cold when this is done Loosen one head nut onehalf turn and then tighten it to either 60 Ibft 83 kgm or to 81 Nm Then proceed to the next head nut in the sequence numbering shown3 Torque the rocker shaft bracket securing nuts evenly between 12 to 15 Ibft or 17 to 2 kgm4 Adjust the valve clearances according to the procedures described in steps AD Adjust all valve clearances to 0012 inches 030 mm while the engine is cold A While facing the front of the engine turn the engines crankshaft clockwise so that the No 1 cylinders valves are in their Valve overlap position that is the period between the opening of the inlet valve and the closing of the exhaust valve B In this pOSition adjust the clearances of the No4 cylinders valves Turn the crankshaft as described in step A so that the valves of the No3 cylinder are in their overlap position and then adjust the NO2 cylinders valves C Turn the crankshaft again so that the valves of the No4 cylinder are in their overlap position and ad just the No1 cylinders valves D Turn the crankshaft so that the valves of the NO2 cylinder are in their overlap position and adjust the No3 cylinders Diesel Engines 60 TORQUE following torque tensions apply when the components are lightly oiled before assembly Lbft Kgm NmCylinder Head Nuts 60 83 81Connecting Rod Cap Bolts 42 58 57 Main Bearing Cap Bolts 85 1175 115Flywheel Bolts 60 83 81Idle Gear Hub Bolts 36 50 49Crankshaft Pulley Bolt 150 207 203Injector Securing Nuts 12 17 16Fuel High Pressure Pipe Nuts 15 21 20Alternator Pulley Nut 30 41 41Thermostat Housing 10 138 13Thermostat I nsulating Adapter 10 138 13 The tab and shim washers may be discarded where they were once used on earlier models but the boltsmust be tightened to the torque specification indicatedAll threads used except those used to manufacture the basic engine are of the Unified Series and AmericanPipe Series The crankshaft and the pulley retaining bolts are threaded 58 inch Unified National Fine UNF18 threads per inch 61 Westerbeke Diesel Engines GENERAL TORQUE TIGHTENING CHART 1bftUNLESS OTHERWISE INDICATEDGrade 6T 6mm boltnut 07 10 5 7 8mm boltnut 16 23 12 17 10mm boltnut 32 47 23 24 12mm boltnut 56 82 41 59 14mm boltnutGrade 8T and 88 77 105 56 76 6mm boltnut 8 12 6 9 8mm boltnut 18 27 13 20 10mm boltnut 37 55 27 40 12mm boltnut 14mm boltnut 64 95 104 140 46 69 75 101Grade 5 capscrew 14 UNC 12 18 15 9 11 14 UNF 15 28 11 13 516 UNC 25 32 18 20 516 UNF 29 21 23 38 UNe 37 46 28 33 38 UNF 41 48 30 35 716 UNe 61 68 44 49 716 UNF 69 76 50 55 12 UNe 94 101 68 73 12 UNF 101 111 73 80 Westerbeke Diesel Engines 62 LAYUP AND owners rely on their boatyards to prepare their craft including engines and generators for layup duringthe offseason or for long periods of inactivity Others prefer to accomplish layup preparation themselvesThe procedures which follOW will allow you to perform your own layup and or to use asa check list others do the procedures should afford your engine protection during a layup and also help familiarize you with themaintenance needs of your engineIf you have any questions regarding layup procedures call your local servicing dealer he will be more thanwilling to provide CouplingThe transmission and propeller half couplings should always be opened up and the bolts removed wheneverthe boat Is hauled out of the water or moved from land to water and during storage in a cradle The flexibilityof the boat often puts a severe strain on the propeller shaft or coupling or both while the boat Is taken outor put in the water I n some cases the shaft has actually been bent by these strains This does not apply tosmall boats that are hauled out of the water when not in use unless they have been dry for a of timeFresh Water Cooling SystemA 5050 solution of antifreeze and fresh water is recommended for use in the fresh water cooling system atall times This solution may require a higher concentration of antifreeze depending on the areas winterclimate Check the solution to ensure that the antifreeze protection is adequateShould more antifreeze be needed drain an appropriate amount from the engine block and add a more concentrated mixture Operate the engine to ensure a complete circulation and mixture of the antifreeze concentration throughout the cooling system Now recheck the antifreeze solutions SystemWith the engine warm drain all the lubricating oil from the oil sump Remove and replace the oil filter Placesome paper towels and a plastic bag around the filter to catch the oil during its removalWhen installing the new oil filter be sure to apply a small amount of oil on the rubber sealing gasket at thebase of the filter Fill the sump with the correct amount of oil for your engine Refer to section of this manual page 8 Use an oil with an API specicatlon of CC or CD Runthe engine and check for proper oil pressure and ensure that there are no leaks 63 Westerbeke Diesel Engines CAUTION Do not leave the engines old lubricating oil in the sump over the layup period Lubricating oil and combustion deposits combine to produce harmful chemicals which can reduce the life of your engines internal partsFuel SystemTop off your fuel tanks with No2 diesel fuel Fuel additives should be added at this time to control algaeand condition the fuel Care should be taken that the additives used are compatible with the primary filterwater separator used in the system Change the element in your primary fuel filterWater separator if thefuel system contains one and clean the separator sediment bowlChange the fuel filter elements on the engine and bleed the fuel system as needed Start the engine andallow it to run for 5 10 minutes to ensure that no air is left In the fuel system Check for any leaks that mayhave been created in the fuel system during this servicing correcting them as neededSea Water CircuitClose the throughhull sea cock Remove the sea water intake hose from the sea cock Place the end ofthis hose into a 5gallon bucket of clean fresh water Before starting the engine check the zinc anode foundin the primary heat exchanger on the engine and clean or replace it as required Clean the sea strainer one is installed in the inside of the hullStart the engine and allow the sea water pump to draw fresh water through the system When the bucket Isempty stop the engine and refill the bucket with an antifreeze solution slightly stronger than needed for winterfreeze protection in your areaStart the engine and allow all of this mixture to be drawn through the sea water system Once the bucket Isempty stop the engine This antifreeze mixture should protect the sea water circuit from freezing during thewinter layup as well as providing corrosion the Impeller from your sea water pump some antifreeze mixture will accompany it so catch it in abUCket Examine the impeller Acquire a replacement needed along with a cover gasket Do not replacethe impeller into the pump until but replace the cover and gasketIntake Manifold and ThroughHull ExhaustPlace a clean cloth lightly soaked In lubricating oil in the opening of the intake manifold to block the opening Do not shove the cloth out of sight If it is not visible at and an attempt is made tostart the engine you may need the assistance of a servicing dealer Make a note to remove the cloth priorto startup The throughhull exhaust part can be blocked in the same mannerStarter and cleaning of the starter drive pinion is advisable if access to the starter permits its easyremoval Ensure that the battery connections are shut off before attempting to remove the starter Take carein properly replacing any electrical connections removed from the Diesel Engines 64Cylinder LubricationIt is not necessary to remove the fuel injectors from the cylinder head to squirt light lubricating oil into thecylinders for the few months of normal layup However if you anticipate a longer layup period 12 monthsormore we recommended that this procedure be performed The light oil in the cylinders will prevent thepistons rings from sticking to the cylinder walls Make sure you have replacements for the injector and returnline sealing time provides a good opportunity to inspect your Westerbeke engine to see if external ITems such asdrive belts or coolant hoses need replacement Check your basic spares kit and order items not on handor replace those items used during the layup such as filters and zinc batteries are to be left on board during the layup period make sure they are fully charged and that theywill remain that way to prevent them from freezing If there exists any doubtthat the batteries will not remainfully charged or that they will be subjected to severe environmental condITions remove the batteries andstore them In a warmer more compatible of your Westerbeke engine after a seasonal layup generally follows the same procedures as those presented in the PREPARATIONS FOR STARTING section page 22 regarding preparationfor starting and normal starts However some of the layup procedures will need to be counteracted beforestarting the engine1 Remove the oilsoaked cloths from the intake manifold and from the throughhull exhaust port2 Remove the sea water pump cover and gasket and discard the old gasket Install the sea water pump im peller removed during layup or a replacement if required Install the sea water pump cover WITh a new cover gasket Wear rubber gloves a rubber apron and eye protection when servicing batteries Lead acid batteries emit hydrogen a gas which can be ignited by electrical arcing or a lighted cigarette cigar or pipe Do not smoke or allow an open flame near the bat tery while someone is servicing it Shut off all electrical equipment in the vicinity to prevent electrical arCing during servicing3 Reinstall the batteries that were removed during the layup and reconnect the battery cables making sure the terminals are clean and that the connections are tight Check to ensure that the batteries are fully charged 65 Westerbeke Diesel Engines4 Check the condition of the zinc anode in the sea water circuit and clean or replace the anode as needed Note that it is not necessary to flush the water solution from the sea water coolant sys tem When the engine is put into operation the system will selfflush in a short period of time with no ad verse affects5 Start the engine In accordance with procedures in the PREPARATIONS FOR STARTING section of this manual page 22 Westerbeke Diesel Engines 66 INDEX AADJUSTMENTS MAINTENANCE AND 57ADJUSTMENT VALVE CLEARANCE 60Alignment The HBW 150 Transmission 51Alignment of the Engine Installation Checks 13Alternator and Water Pump Drive Belt Tension 46ANTIFREEZE CONCENTRATION DATA 43Assembly Oil Cooler Illustration 49Automatic Alarm System Installation Checks 18 BBackPressure Exhaust Installation Checks 15Batteries Layup and 65Battery Specification 37Belt Drive System 36Belt Tension Alternator and Water Pump Drive 46Bleeding the Fuel System Priming and 32Bolts Engine Installation Checks 12BreakIn Procedures Engine 28 C CAUTIONS ENGINE SHIPPED WITHOUT OIL 10 LIFTING SLINGS 11 THROUGHHULL FITTINGS 19 PROLONGED CRANKING 26 SHUTTING OFF THE ENGINE WITHOUT THE CIRCUIT BREAKER 28 PROLONGED CRANKING 32 BATTERY CHARGING CiRCUiT 37 QUICKCHARGING THE BATTERy 37 TESTING THE ALTERNATOR 38 EXCESSIVE BELT TENSION 46 GEAR BOX LEVER COVER 52 TIGHTENING CYLINDER HEAD NUTS 60 LEAVING OLD OIL IN THE SUMP 64Change Engine Oil to include filter 48Charging Voltage Test 39CHART GENERAL TORQUE TIGHTENING 62Circuit Fresh Water 42Circuit Sea Water 45Cold Conditions Starting Under 30CONTENTS TABLE OF 3Control Circutt Engine 12Volt DC 37Control Circuit Wiring Diagram 37248 DC 40 and 41 67 Westerbeke Diesel The HBW 150 Transmission 52Connecting Pressure Sensing Devices to Oil Galleries Installation Checks 18Cooler Oil Assembly Illustration 49Cooling System Installation Checks 18COOUNG SYSTEM 42Coupling Propeller Layup and 63Coupling Propeller Shaft Installation Checks 13Cylinder Lubrication Layup and 65 DDC Control Circuit Engine 12Volt 37DC Control Circuit Wiring Diagram 37248 40 and 41DESCRIPTION OF INSTRUMENT PANEL 24Diesel Engine Understanding the 4Diesel Fuel 31DISCLAIMER PRODUCT SOFTWARE 1Drain Hose Oil Installation Checks 17Drive System Bell 36 EElectrical System Installation Checks 21ELECTRICAL SYSTEM 37Engine 12Volt DC Control Alignment of the Installation Checks 13Engine Bolts Installation Checks 12Engine BreakIn Procedures 28Engine Diesel Understanding the 4Engine Foundation for the Installation Checks 12Engine 011 47Engine 011 Change to Include filter 48Engine Oil Viscosity SAE Number 47ENGINE 54Equipment Inspection of 2Exhaust BackPressure Installation Checks 16Exhaust System Installation Checks 15Exhaust System Failures Installation Checks 17 F Failures Exhaust System Installation Checks 17 FORWARD2 Foundation for the Engine Installation Checks 12 Fresh Water Circuit 42 Fresh Water Cooling System Layup and 63 Fuel Diesel 31 Fuel Filters 31 Fuel Filter Elements Replacing the 35 Westerbeke Diesel Engines 68Fuel Injection Pump 36Fuel System Installation Checks 20FUEL SYSTEM 31Fuel System Layup and 64Fuel System Priming and Bleeding 32 GGENERAL 4GENERAL SPECIFICATIONS 7GENERAL TORQUE TIGHTENING CHART 62 HHBW 150 TRANSMISSION THE 50Hose Oil Drain Installation Checks 17INDEX 67Injection Pump Fuel 36Inspection of Equipment 2INSTALLATION CHECKS 10INSTRUMENT PANEL DESCRIPTION OF 24Intake Manifold and ThroughHull Exhaust Layup and 64 LLAYUP AND 63Lifting Rigging and Installation Checks 11LIST PARTS 99Location Installation Checks 10Lubrication The HBW 150 Transmission 50Lubrication Cylinder Layup and 65LUBRICATION SYSTEM 47Lubrication System Layup and 63 MMAINTENANCE AND ADJUSTMENTS 57Motor Starter Layup and 64 N Normal Conditions Starting Under 29 69 Westerbeke Diesel Engines aOil Change Engine to Include filter 48Oil Cooler Assembly illustration 49all Drain Hose Installation Checks 17Oil Engine 47Oil Engine Viscosity SAE Number 47Oil Galleries Connecting Pressure Sensing Devises to Installation Checks 18Oil Pressure 47Ordering Parts4 pPANEL DESCRIPTION OF INSTRUMENT 24PARTS LIST 99Parts Ordering 4Priming and Bleeding the Fuel System 32PRECAUTIONS SAFETY Inside front FOR STARTING 22Pressure Oil 47Pressure Sensing Devices to Oil Galleries Connecting Installation Checks 18Procedures Engine BreakIn 28PROCEDURE STARTING 26PROCEDURES STOPPING 28PRODUCT SOFTWARE DISCLAIMER 1Propeller Installation Checks 13Propeller Coupling Layup and 63Propeller Shaft Coupling Installation Checks 13Propeller Size Recommended The HBW 150 Transmission 53Pump Fuel Injection 36Pump Sea Water 45 RRecommended Propeller Size The HBW 150 Transmission Layup and 65Replacing the Fuel Filter and Lifting Installation Checks 11 sSAFETY PRECAUTIONS Inside front coverSea Water Circuit 45Sea Water Circuit Layup and 64Sea Water Intake System Installation Checks 20Sea Water Pump 45Service The HBW 150 Transmission 53Shaft Coupling Propeller Installation Checks 13Shifting The HBW 150 Transmission 52 Westerbeke Diesel Engines 70Shifting Transmission 27SOFTWARE DISCLAIMER PRODUCT 1Spares Layup and GENERAL 7 SYSTEM 8 Battery 37 TORQUE 61STOPPING PROCEDURES 28Starter Motor Layup and 64STARTING PREPARATION FOR 22STARTING PROCEDURE 26Starting Under Cold Conditions 30Starting Under Normal Conditions 29SYSTEM Exhaust Installation Checks 15 Failures Exhaust Installation Checks 17 Automatic Alarm Installation Checks 18 Cooling Installation Checks 18 Fuel Installation Checks 20 Electrical Installation Checks 21 Starting 23 FUEL 31 Belt Drive 36 ELECTRICAL 37 COOLING 42 TTABLE OF CONTENTS 3Tension Alternator and Water Pump Drive Belt Tension 46Test Charging Voltage 39THE HBW 150 TRANSMISSION 50Thermostat 45ThroughHull Exhaust Intake Manifold and Layup and 64TORQUE SPECiFiCATIONS 61TORQUE TIGHTENING CHART GENERAL 62Transmission Shifting 27TRANSMISSION THE HBW 150 ENGINE 54 uUnder Cold Conditions Starting 30Under Normal Conditions Starting the Diesel Engine 4 71 Westerbeke Diesel Engines vVALVE CLEARANCE ADJUSTMENT 60Ventilation Installation Checks 21Viscosity Engine Oil SEA Number 47Voltage Test Charging 39 W iWARNINGsl DIESEL FUMES 17 SMOKING NEAR BATTERIES 21 SERVICING BATTERIES 21 ADJUSTING DRIVE BELT TENSiON 48 BATTERY ACiD 85Water Clrcu Fresh 42Water Clrcu Sea 45Water Intake System Sea Installation Checks 20Water Pump SeaWiring Diagram 37248 DC Control Circu 40 and 41 Westerbeke Diesel Engines 72 PARTS LISTCylinder Block 100Cylinder Head and Valves 102Crankshaft and Pistons 104Timing System and Camshaft 106Rocker Shaft and Cover 108Intake Manifold 110Lube Oil Sump and Oil Pump 112Cooling System 114Fresh Water Pump and WaterInjected Exhaust Elbow 118Sea Water Pump 120Fuel System 122Back End Transmission Mounting System 126HBW Bracket 130Standard Alternator Oil manifold 132Electrical Harness 134Instrument Panel 136Alternators and System 138 99 Westerbeke Diesel Engines 17 416 15 14100 ESTERBEKE 40A CYLINDER BLOCKREF PN NAME REMARKS QUAN 1 1 030870 ENGINE BLOCK HEAD ASSEMBLY 1 12 011487 ENGINE ASSEMBLY 1 2 019990 LINER 4 4 012452 PLUG 1 5 012458 PLUG REAR CAMSHAFT CHAMBER 1 6 012334 HOUSING 1 7 012356 BOLT 2 8 031758 LOCKIASHER 516 2 9 012475 CAPSCREIJ 516NF X 138 FULLY THREADED 6 10 031758 LOCKIJASHER 516 6 11 012661 GASKET 1 12 011993 SEAL 2 13 013341 PLUG BLOCK DRAIN 1 14 012454 PLUG EXPANSION 5 15 019992 PLUG OIL GALLERY 2 16 012469 BOLT MAIN BEARING CAP 6 17 012623 SHIM 6 18 012380 DOIJEL 6 19 012456 PLUG EXPANSION FRONT REAR 220 031758 LOCKIJASHER 516 421 012473 CAPSCREIJ 516NF X 34 422 012656 PLATE TIMING COVER MOUNT 123 012406 GASKET 124 012371 CONNECTOR FRESH IJATER HOSE 125 012464 PLUG ALTERNATE DIPSTICK POSITION 126 012484 SHAFT TACHOMETER DRIVE 127 014686 BEARING TACHOMETER DRIVE 128 012485 SLEEVE TACHOMETER DRIVE 129 012363 SNAPRING TACHOMETER DRIVE 1301 012620 CAP PLASTIC 1302 019994 CAP METAL 131 012619 IJASHER TACHOMETER DRIVE 132 012666 GASKET SIDE COVER TO BLOCK 133 020029 COVER SIDE 134 012652 STIFFENER 1035 031758 LOCKIJASHER 5116 1036 012473 CAPSCREIJ 516NF X 34 237 031760 NUT 516NF 838 012498 STUD 840 020020 GASKET HEAD 141 019965 STUD 1842 013341 PLUG BLOCK DRAIN 1 1 01 WESTERBEKE 40A CYLINDER HEAD AND VALVES 24 21 20 18 25 1 2 11 r1915 iil 2814 102 jESTERBEKE 40A CYLINDER HEAD AND VALVESREF PN NAME REMARKS QUAN 1 019939 HEAD ASSEMBLY 1 2 019979 PLUG TOP 3 3 023143 PLUG TOP 4 4 012452 PLUG SIDE 1 5 012454 PLUG REAR 1 6 012455 PLUG REAR 1 7 012629 GUIDE INTAKE VALVE 4 8 012628 GUIDE EXHAUST VALVE 4 9 012546 EYE REAR LIFTING 110 031764 LOCKWASHER 38 211 031628 CAPSCREW 38NF X 34 212 019999 SEAT INTAKE VALVE 413 019997 SEAT EXHAUST VALVE 414 012509 VALVE INTAKE 415 012635 DEFLECTOR INTAKE VALVE 816 01251 0 VALVE EXHAUST 418 019960 SPRING VALVE 819 012536 SEAT VALVE SPRINGLOWER 820 012360 SEAT VALVE SPRINGUPPER 821 012378 COTTER VALVEPAIR 822 012682 INSERT COMBUSTION CHAMBER 423 012542 WASHER WELSH 425 014445 NUT HEADSHORT 1226 020005 NUT HEADLONG 627 014443 WASHER HEAD STUDS 1828 031760 NUT 516NF 4291 031758 LOCKWASHER 516 4292 031759 WASHER FLAT 516 430 011653 GASKET HEAD TO EXHAUST MANIFOLD 231 014810 STUD EXHAUST MANIFOLD TO HEAD 4 103 WESTERBEKE 40A CR AND PISTONS ANKSHAFT 21 20 19 1 8 104 WESTERBEKE 40A CRANKSHAFT AND PISTONSREF PN NAME REMARKS QUAN 1 023105 CRANKSHAFT ASSEMBLY 1 21 012343 BEARING SETCONNECTING ROD STD 1 22 012414 BEARING SETCONNECTING ROD o 01 0 1 23 012423 BEARING SETCONNECTING ROD 0020 1 24 012519 BEARING SETCONNECTING ROD 0030 1 31 012342 BEARING SETMAIN STD 1 32 012349 BEARING SETMAIN 0010 1 33 012370 BEARING SETMAIN 0020 1 34 012373 BEARING SETMAIN 0030 1 41 014707 WASHER THRUST STD 2 42 019969 WASHER THRUST 0007 AR 51 012537 WASHER THRUST STD 1 52 019968 WASHER THRUST 0007 AR 6 014719 GEAR CRANKSHAFT 1 7 012383 SLINGER 1 8 012633 ADAPTER CRANKSHAFT PULLEY 1 9 011857 WASHER CRANKSHAFT PULLEY 110 012613 BOLT PULLEY RETAINING 11 1 1 012595 PULLEY CRANKSHAFT STD 1112 023526 PULLEY OPTIONAL 6 IN 6 GR 1113 016356 PULLEY OPTIONAL 5 IN 4 GR 4 IN 2 GR 1114 012038 PULLEY OPTIONAL 7 IN 2 GR 1115 036428 PULLEY OPTIONAL 6 IN 4 GR 1116 012020 PULLEY ACCESSORY 5 IN 2 GR 111 7 012039 PULLEY ACCESSORY 6 IN 2 GR 112 031752 LOCKWASHER 14 413 CAPSCREW 14NF X 118 STD PULLEY 414 012408 KEY 215 019935 ROD CONNECTING ASSEMBLY 416 012348 BOLT CONNECTING ROD 817 012622 WASHER FLAT 818 019986 BUSHING CONNECTING ROD 419 019938 PISTON ASSEMBLY 420 019984 SNAPRING PISTON PIN 821 019937 RING SET STD 4 105 ESTERBEKE 40A TIMING SYSTEM AND CAMSHAFT 3 l 1 8ab 7 s12I 9 10 20 17 16 23 30 31 22 106 WESTERBEKE 40A TIMING SYSTEM AND CAMSHAFTREF PN NAME REMARKS QUAN 1 012605 CAMSHAFT 1 2 012460 PUSHROD FUEL LI FT PUMP 1 3 012654 PLATE CAMSHAFT THRUST 2 4 012440 DOWEL 1 5 012597 GEAR CAMSHAFT 1 6 012625 PLATE 1 7 031758 LOCKWASHER 516 3 8 012474 CAPSCREW 516NF X 78 3 9 012481 CAPSCREW IDLER GEAR 2 10 012541 TABWASHER 1 11 012551 PLATE IDLER GEAR 1 12 012689 GEAR IDLER WITH BUSHING 1 13 014685 BUSHING IDLER GEAR 1 14 012388 HUB IDLER GEAR 1 15 012658 GASKET TIMING COVER 1 16 012652 STIFFENER 8 17 031758 LOCKWASHER 516 10 18 012474 CAPSCREW 516NF X 78 9 19 012493 STUD 1 20 031760 NUT 516NF 1 21 012466 SEAL TIMING COVER 1 22 012678 COVER TIMING 1 23 031760 NUT 516NF 4 24 031758 LOCKWASHER 516 4 25 012471 CAPSCREW 14NF X 58 4 26 013536 STIFFENER 3 27 031752 LOCKWASHER 14 4 28 031754 NUT 14NF 4 29 012636 GASKET PLATE TO TIMING COVER 1 30 012500 STUD SEA WATER PUMP MOUNT 4 31 012626 PLATE SUPPORT SEA WATER PUMP 1 107a 0 0 21 0 I 2 I 0 WESTERBEKE lOA ROCKER SHAFT AND COVERREF PN NAME REMARKS QUAN 1 012681 COVER ROCKER 2 012404 GASKET ROCKER COVER 1 3 012429 NUT 2 4 012535 WASHER 2 5 012467 SEAL 2 6 012567 CAP OIL FILLER INCL GASKET 1 7 032184 GASKET OIL FILLER CAP 1 8 012607 PUSHROD 8 9 012606 TAPPET 8 10 012434 NUT LOCKING 8 11 031759 WASHER FLAT 516 8 12 012499 STUD SHORT 358 6 13 012494 STUD LONG 412 2 14 012336 SHAFT COMPLETE ASSEMBLY 1 15 012335 SHAFT ROCKER WITH PLUGS 1 16 012446 PLUG 2 17 012362 SNAPRING 2 18 012525 WASHER 4 19 012539 WASHER 2 20 012333 ROCKER WITH BUSHING 8 21 012488 SPRING 3 22 012358 BRACKET 4 23 012462 SCREW ROCKER ADJUSTING 8 24 012433 NUT 8 25 012372 CONNECTOR OIL FEED TO ROCKER SHAFT 1 26 012413 FERRULE 2 27 012419 NUT 2 28 012637 LINE HEAD TO ROCKER SHAFT 1 29 012331 BUSHING ROCKER 8 109 WESTERBEKE 40A INTAKE MANIFOLD 121 10 11 0 WESTERBEKE 40A INTAKE MANIFOLDREF PN NAME REMARKS QUAN 1 012683 COVER AIR INTAKE 1 2 012556 FILTER AIR INTAKE 1 3 011411 CLAMP HOSE 32 1 4 020021 GASKET INTAKE MANIFOLD TO HEAD 1 51 022841 ADAPTER MANIFOLD TO 78UNF 1 52 024881 PLUG 78UNFWHEN HEATER NOT INSTALLED 1 53 013392 BUSHING 78UNF TO 18NPT 1 61 011 688 START AID ETHER TYPE 1 62 011615 PLUG 18NPT 1 7 031758 LOCKWASHER 516 7 81 031582 CAPSCREW 516NF X 112 4 82 031581 CAPSCREW 516NF X 114 2 91 012688 MANIFOLD AIR INTAKE 1 92 019382 MANIFOLD AIR INTAKEACCEPTS LUBCEL 1 10 031588 CAPSCREW 516NF X 3 1 11 012639 ELBOW BREATHER HOSE 1 12 01 134 1 CLAMP HOSE 8 2 13 011530 HEATER MANIFOLD 12 VDC 1 11 1 ESTERBEKE 40A LUBE OIL SUMP AND OIL PUMP27 26 19 a 18 17 1 112 WESTERBEKE 40A LUBE OIL SUMP AND OIL PUMPREF PN NAME REMARKS QUAN 1 035304 SUMP OIL 1 2 035305 PLUG SUMP DRAIN 3416UNF 1 3 035306 WASHER SUMP DRAIN PLUG 1 4 012473 CAPSCREW 516NF X 34 8 5 031758 LOCKIJASHER 516 8 6 012652 STIFFENER SUMP SIDE 8 7 012547 STIFFENER 1 8 031758 LOCKIJASHER 516 8 9 012474 CAPSCREIJ 516NF X 78 8 10 012407 GASKET 2 11 012550 STIFFENER 1 12 012659 GASKET SET SUMPLEFT AND RIGHT 1 13 012549 STIFFENER 1 14 012548 STIFFENER 1 15 012612 DIPSTICK 1 16 014816 IJASHER 1 17 012686 STRAINER OIL PICKUP 1 18 012491 SPRING OIL PICKUP 1 19 012651 LINE OIL STRAINER TO PUMP 120 012473 CAPSCREIJ 516NF X 34 121 031758 LOCKIJASHER 516 122 031759 IJASHER FLAT 516 123 020006 NUT SUCTION LINE 124 019950 FERRULE SUCTION LINE 125 012692 PUMP LUBE OIL 126 020017 TABIJASHER OIL PUMP RETAINING CAPSCREIJ 127 CAPSCREIJ 516NF X 1116 128 019951 FERRULE LUBE OIL DELIVERY LINE 221 019952 NUT LUBE OIL DELIVERY LINE 230 012442 LINE LUBE OIL DELIVERY TO BLOCK 131 036088 IJASHER SUMP DRAIN HOSE TO SUMP 132 036392 HOSE SUMP DRAIN 133 036087 TABIJASHER SUMP DRAIN 134 036085 BOLT BANJOSUMP DRAIN 135 024922 BRACKET SUMP DRAIN HOSE 136 024905 CAP SUMP DRAIN HOSE 1 113 3 2 9j10 53 52 1 11 131O 51C S It 55 r l J n 50 54 Jy r 14 15 cr 0 E III f i III u 16 tD III III 41 B o l 40 j n 34 a a r 49 z on f f i III 3 20 nv21 28 47 J 7 48 tZ 2 W 23 22 26 WESTERBEKE 40A COOLING SYSTEMREF PN NAME REMARKS QUAN 1 015564 MANIFOLD EXHAUST 1 2 019334 PLUG EXPANSION 1 3 024306 CAP PRESSURE 15 PSI 1 4 011653 GASKET MANIFOLD TO HEAD 2 5 019324 PLUG 1 5NPT 1 6 024907 ELBOW MANIFOLD TO COOLANT RECOVERY TANK HOSE 1 7 021878 CLAMP HOSE 20 2 8 011652 HOSE THERMOSTAT TO MANIFOLD 1 9 031923 CAPSCREW 38NF X 2 SOCKET HEAD 1 10 031764 LOCKWASHER 38 2 11 031922 CAPSCREW 38NF X 1 SOCKET HEAD 1 12 012009 HOUSING THERMOSTAT 1 13 012663 GASKET THERMOSTAT HOUSING 1 14 024688 THERMOSTAT 1 15 011 951 FILTER LUBE OIL 1 16 013610 NIPPLE OIL FILTER TO ADAPTER 117 036379 ADAPTER LUBE OIL FILTER WITHOUT OIL COOLER 118 012669 GASKET LUBE OIL FILTER ADAPTER TO BLOCK 119 011143 GASKET SEA WATER PUMP MOUNTING 120 016423 PUMP SEA WATER 121 036366 ELBOW 12NPT 45 DEGREE STREET 122 032230 NIPPLE 12NPT TO 78 HOSE 123 011386 CLAMP HOSE 12 224 030166 HOSE SEA WATER PUMP TO EXCHANGER 125 011885 ZINC 126 011471 PET COCK 227 036896 EXCHANGER HEAT 1281 013619 CAPSCREW M 8 X 30 DIN 933 2282 031786 LOCKWASHER M 8 DIN 127 2283 031787 WASHER M 8 DIN 125 2291 036838 NIPPLE 34NPT TO 78 HOSE 1292 036622 NIPPLE 34NPT TO 1 HOSE 130 021878 CLAMP HOSE 20 231 024304 HOSE MANIFOLD TO EXCHANGER 1321 031506 CAPSCREW 14NC X 114 2322 031752 LOCKWASHER 14 2323 031753 WASHER FLAT 14 233 021878 CLAMP HOSE 20 434 036325 HOSE 135 036456 TUBE WHEN OIL COOLER NOT USED 136 036324 HOSE 137 022851 GASKET EXCHANGER END 238 019321 ORING 239 022850 COVER EXCHANGER END 240 022852 CAPSCREW 38NC X 12 BRASS 2 115 91r 10 tIl Jt11 12 13 10 fl tf5p Ci I 14 m 15 b UJ i m 0 II m J m J o 41 n o o 34 r z UJ UJ i m 3 20 df11 1trX 45 33 1 36 47 48 22 26 WESTERBEKE 40A COOLING SYSTEMREF PN NAME REMARKS QUAN 41 036260 KIT OIL COOLER EXCLUDING REF 153334 36 42 0344134 COOLER LUBE OIL 1 43 0351131 CLAMP OIL COOLER MOUNT 1 441 031506 CAPSCREU 14NC X 114 1 442 031752 LOCKUASHER 14 1 443 031753 UASHER FLAT 14 1 451 013334 CONNECTOR INCLUDING NUT AND FERRULE 4 452 013333 FERRULE AR 461 0316130 CAPSCREU 716NF X 1 1 462 031770 LOCKUASHER 716 1 47 0363132 LINE ADAPTER TO OIL COOLER 1 413 0363131 LINE OIL COOLER TO ADAPTER 1 49 0113972 ADAPTER LUBE OIL FILTER UITH OIL COOLER 1 50 024977 KIT COOLANT RECOVERY TANK 1 51 0247136 STRAP COOLANT RECOVERY TANK MOUNT 1 52 024704 TANK COOLANT RECOVERY 1 53 024858 CAP COOLANT RECOVERY TANK 1 54 024637 TUBING MANIFOLD TO RECOVERY TANKINCHES REQD 30 55 024906 CLAMP HOSE 2 56 0316131 CAPSCREU 716NF X 114 2 57 031770 LOCKUASHER 716 2 117WESTERBEKE 40A FRESH WATER PUMP AND WATER INJECTED EXHAUST ELBOW 118 WESTERBEKE 40A FRESH WATER PUMP AND WATER INJECTED EXHAUST ELBOWREF PN NAME REMARKS QUAN 1 1 020035 PUMP FRESH WATER 1 12 019933 KIT WATER PUMP REPAIR 1 2 031758 LOCKWASHER 515 4 3 031584 CAPSCREW 515NF X 2 2 4 019987 PULLEY FRESH WATER PUMP 1 5 031750 NUT 516NF 1 5 031583 CAPSCREW 516NF X 134 1 7 035388 STUD 516NF X 218 8 012673 GASKET WATER PUMP TO PLATE 1 9 012655 PLATE FRESH WATER PUMP TO BLOCK 1 10 012674 GASKET PLATE TO BLOCK 1 11 036259 KIT WATER INJECTED EXHAUST ELBOW 1 12 020439 NIPPLE 1 5NPT CLOSE 1 13 034486 ELBOW WATER INJECTED EXHAUST 45 DEGREE 1 141 030183 ELBOW 12NPT TO 78 HOSE 1 142 035616 ELBOW 12NPT TO 1 HOSE 1 15 035747 PLUG 12NPT 1 1 19 IESTERBEKE 40A SEA lATER PUMP o N1 o V 120 WESTERBEKE 40A SEA WATER PUMPREF PN NAME REMARKS QUAN 1 011143 GASKET SEA WATER PUMP MOUNTING 1 21 016423 PUMP SEA WATER 1 22 018169 HOUSING SEA WATER PUMP BODY 1 23 018172 KIT PUMP MAJOR REPAIR 1 3 018160 SCREW BRASSPUMP HOUSING TO CAM 1 4 018152 CAM 1 5 015153 GASKET IMPELLER COVER 1 G 018171 COVER IMPELLER 1 7 032183 LOCKWASHER 4 8 018151 SCREW BRASSIMPELLER COVER 4 9 033104 KIT IMPELLER AND COVER GASKET 1 10 018159 SEAL 1 11 018170 BEARING 2 12 018176 SHAFT 1 13 018148 KEY IMPELLER TO SHAFT 1 121 5 t1 4 Q 2 G f 56 I 753 rn 45 60 J 50 i rn 46 0 m rn QP7 53 76 VkII 9 rn 0 43 J 25ruru c rn r J J i rn 3 38 32 WESTERBEKE lOA FUEL SYSTEMREF PN NAME REMARKS QUAN 1 023909 HOSE FUEL SUPPLY 1 2 031062 VALVE CHECK 1 3 031061 WASHER SEALING 1 4 016245 GASKET LIFT PUMP MOUNT 1 51 016443 PUMP FUEL LIFT 1 52 035125 KIT FUEL LIFT PUMP REPAIR 1 6 034857 HOSE FUEL RETURN 1 7 032974 FILTER TRAPOPTIONAL 1 8 031756 NUT 516NC 4 9 019509 FILTER FUEL 1 10 ORING FUEL FILTERSEE REF 12 1 11 GASKET SET FUEL FILTERSEE REF 12 1 12 014776 ELEMENT FUEL FILTER INCL REF 1011 1 13 011936 BANJO FUEL RETURN 1 14 011944 WASHER BANJO 2 15 012351 BOLT BANJO 1 161 019505 PLUG UNUSED FILTER PORT 1 162 019507 WASHER FUEL FILTER PLUG 1 17 012522 WASHER BANJO 4 18 011941 BANJO FILTER TO INJECTION PUMP LINES e 19 012350 BOLT BANJO e20 01951 1 LINE LIFT PUMP TO FILTER 121 014814 LINE INJECTION PUMP TO FILTER 122 014813 LINE FILTER TO INJECTION PUMP 123 014678 PUMP FUEL INJECTION 124 016034 LEVER THROTTLE 125 016033 BRACKET IDLE SCREW 126 016539 SCREW IDLE ADJUSTING 127 011934 FERRULE 228 019364 BALL JOINT THROTTLE CABLE 129 031760 NUT 516NF 230 031758 LOCKWASHER 516 331 031759 WASHER FLAT 516 332 012497 STUD e33 012561 CAPSCREW 516NF X 114 SOCKET HEAD FULL THREAD 134 019261 WASHER 135 019204 SCREW BLEED ASSEMBLY 136 019370 PIVOT FUEL SHUTOFF LEVER 137 014744 SHAFT INJECTION PUMP DRIVE 138 012402 GASKET INJECTION PUMP MOUNT 139 031323 CIRCLIP HUB 1401 031324 BEARING ASSEMBLY 1402 031322 BUSHING HUB 141 020004 HUB DRIVE 142 019989 GEAR INJECTION PUMP DRIVE 1431 012614 SHAFT SEA WATER PUMP DRIVE 1432 023764 SHAFT SEA WATER PUMP DRIVE 0001 OS 144 019944 BRACKET STOP LEVER SPRING 145 014674 SPRING STOP LEVER 1 123 75 56 Iy 111 45 60 J f 111 III 111 53 111 74 9 N C 111 r J J f 111 3 131 35 29 32 30 WESTERBEKE 40A FUEL SYSTEMREF PN NAME REMARKS QUAN 46 012641 LINE INJECTOR 1 1 47 012645 LINE INJECTOR 2 1 48 012646 LINE INJECTOR 3 1 49 012647 LINE INJECTOR 4 1 50 035374 INJECTOR FUEL 4 51 012653 FLANGE INJECTOR MOUNTING 4 52 035375 NOZZLE INJECTOR 4 53 011945 WASHER 4 54 012495 STUD INJECTORSHORT 4 55 012501 STUD INJECTORLONG 4 561 019500 FERRULE RUBBERFUEL LINE 2 562 013343 FERRULE 2 57 013517 LINE INJECTOR RETURN 1 58 011 935 BOLT BANJO 4 59 011943 WASHER BANJO M 8 8 60 019510 LINE INJECTOR RETURN TO FILTER 1 61 015197 LINE FILTER TO STANDPIPE 1 621 011014 STANDPIPE WHEN OPTIONAL HEATER INSTALLED 1 622 013755 BRACKET RAISES STANDPIPE WHEN ALTNR IN UP RT POS 1 631 023612 LINE STANDPIPE TO HEATER 1 632 037394 LINE ASSY STANDPIPE TO HEATERBRACKET 013755 1 64 011530 HEATER MANIFOLD 12 VDC OPTIONAL 1 65 013345 ELBOW 18NPT MALE TO 316 COMPRESSION 1 661 031583 CAPSCREW 516NF X 134 2 662 031758 LOCKWASHER 516 2 671 013343 FERRULE COMPRESSION 316 2 672 013344 NUT COMPRESSION 316 2 68 013346 CONNECTOR 18NPT MALE TO 316 COMPRESSION 2 69 016676 NUT COMPRESSION 14 2 70 019501 FERRULE FUEL LINE 2 71 011 934 FERRULE FUEL LINE 2 72 031765 WASHER FLAT 38 2 73 031764 LOCKWASHER 38 2 74 031630 CAPSCREW 38NF X 1 2 75 013344 NUT COMPRESSION 316 2 761 023920 CLAMP FUEL LINE 4 762 SCREW 1032 X 78 RH 2 763 NUT 1032 LOCKING 2 77 031760 NUT 516NF 8 78 031578 CAPSCREW 516NF X 34 3 79 031758 LOCKWASHER 516 3 80 031759 WASHER FLAT 516 3 81 019442 WASHER 1 125 4 18 17 f PI J PI 1 0 50 I 2 to PI PI 22 0 to II I U I J I 23 1 n 7 25 A 1 J ji PI Z C 0ru IKCY It1 I I I I I r 35 l7 39 c A Z t I J I 41 n 4 44 J J 0 42 z I 0 27 ts III 1i16 I Jlbll iYl1I11 c z z J J 32 PI I 31 WESTERBEKE 40A BACK END TRANSMISSION MOUNTING SYSTEMREF PN NAME REMARKS QUAN 1 034589 CAPSCREW M 10 X 30 DIN 933 2 2 019262 LOCKWASHER M1 0 DIN 127 2 3 031789 WASHER M1 0 DIN 125 2 4 030593 MOTOR STARTER 12 VDC 1 5 034589 CAPSCREU Ml0 X 30 DIN 933 4 6 019262 LOCKWASHER M10 DIN 127 4 7 011498 DOUEL BACKPLATE TO BLOCK 2 8 031764 LOCKUASHER 716 5 9 031630 CAPSCREW 716NF X 1 5 10 034833 CAPSCREW Ml0 X 60 DIN 912 FULLY THREADED 1 11 019262 LOCKUASHER Ml0 DIN 127 2 12 035332 PLATE BACK 1 131 034502 FLYUHEEL ASSEMBLY INCL RING GEARBALANCED 1 132 030230 GEAR RING 1 141 034544 COOLER HBU GEAR 78 HOSE 1 142 036648 COOLER HBU GEAR 1 HOSE 1 151 030183 ELBOU 12NPT TO 78 HOSE 1 152 036614 ELBOU 34NPT TO 1 HOSE 1 lEil 017196 CAPSCREU M 8 X 20 DIN 933 4162 031786 LOCKUASHER M 8 DIN 127 417 031789 UASHER Ml0 DIN 125 118 015887 NUT Ml0 DIN 934 2191 020650 CAPSCREU M 8 X 18 DIN 933 HBU150 6192 013629 CAPSCREW Ml0 X 25 DIN 933 HBU VDRIVE 6201 031786 LOCKUASHER M 8 DIN 127 HBU150 6202 031790 LOCKUASHER Ml0 DIN 137B HBU VDRIVE 621 024778 CAPSCREU DAMPER TO FLYUHEEL 5221 031267 ADAPTER HBU150 TO HOUSING 1222 030063 ADAPTER HBU VDRIVE TO HOUSING 1231 031248 HBU GEAR MODEL 150 16 TO 1 1232 024631 HBU GEAR MODEL 150 19 TO 1 1233 030049 HBU GEAR MODEL 150 26 TO 1 124 024950 NUT Ml0 X 125 DIN 934 425 019262 LOCKUASHER Ml0 DIN 127 426 031228 CAPSCREU Ml0 X 125 X 30 DIN 961 4271 023679 COUPLING BORE 075 1272 023680 COUPLING BORE 0875 1273 023681 COUPLING BORE 10 1274 023682 COUPLING BORE 1 125 1275 023683 COUPLING BORE 125 1276 023684 COUPLING BORE 1375 1277 023685 COUPLING BORE 15 1281 023450 SETSCREU COUPLING 716NC X 1 2282 023651 SETSCREU COUPLING 38NC X 34 2283 023652 SETSCREU COUPLING 38NC X 1 2 127 4 C 11 f i 1 11 0 50 D 11 11 14 48 22 o 49 23 D n 7 25 11 Z c i 0N z 440 f 3 41 f f 42 a z 3 a c z i Z f f i 11 3 31 ESTERBEKE 40A BACK END TRANSMISSION MOUNTING SYSTEMREF PN NAME REMARKS QUAN29 013629 CAPSCRE Ml0 X 25 DIN 933 430 031790 LOCKIoIASHER Ml0 DIN 137B 4311 023706 COUPLING VDRIVE BORE 075 1312 023707 COUPLING VDRIVE BORE 0875 1313 023708 COUPLING VDRIVE BORE 10 1314 023709 COUPLING VDRIVE BORE 1125 1315 023710 COUPLING VDRIVE BORE 125 1316 023711 COUPLING VDRIVE BORE 1375 1317 023712 COUPLING VDRIVE BORE 15 1321 031249 HB GEAR VDRIVE 18 TO 1 1322 030048 HB GEAR VDRIVE 21 TO 1 1323 031250 HBIoI GEAR VDRIVE 3 TO 1 1331 013629 CAPSCREIoI Ml0 X 25 DIN 933 HBIoI150 6332 034589 CAPSCREIoI Ml0 X 30 DIN 933 HBIoI VDRIVE 634 019262 LOCKIoIASHER Ml0 DIN 127 635 019039 DOEL ADAPTER TO HOUSING 236 019398 DAMPER 137 031926 CAPSCRE Ml0 X 35 DIN 933 238 031789 ASHER Ml0 DIN 125 239 034682 HOUSING FLYHEEL 140 031928 CAPSCREIoI 716NF X 1 GRADE 8 541 034504 MOUNT Ldv1 REAR 2421 036341 ISOLATOR INCLUDING LOCKING NUTS 4422 036334 ISOLATOR INCLUDING LOCKING NUTS1oI40NA 443 036338 NUT M16 DIN 985 LOCKING 8 44 034589 CAPSCRE Ml0 X 30 DIN 933 645 019262 LOCKIoIASHER Ml0 DIN 127 646 031681 CAPSCREIoI 716NF X 114 447 031770 LOCKIoIASHER 716 4481 013132 MOUNT FRONT LEFT 1482 013133 MOUNT FRONT RIGHT 149 013919 DOIolEL HOUSING TO BACKPLATE 2501 019059 HOSE 78 IDINCHES REQUIRED 24502 011 779 HOSE lIDINCHES REQUIRED 24511 011386 CLAMP HOSE 12 2512 011405 CLAMP HOSE 16 2 129WESTERBEKE 40A HBW TRANSMISSION SHIFTING BRACKET 4 3 13 7 6 5 130 WESTERBEKE 40A HBW TRANSMISSION SHIFTING BRACKETREF PN NAME REMARKS QUAN 1 030756 NUT PILLAR M 8 2 2 030181 BRACKET SHIFT CABLE TOP ENTRY 1 3 031786 LOCKWASHER M 8 DIN 127 2 4 013630 CAPSCREW M 8 X 25 DIN 933 2 5 031847 NUT 1032 2 6 031849 LOCKWASHER 10 2 7 013870 SHIM CABLE CLAMP 1 8 013325 CLAMP CABLE 1 9 031873 SCREW 1032 X 58 2 10 033482 BALL JOINT 1 11 031752 LOCKWASHER 14 1 12 031754 NUT 14NF 1 13 032161 BRACKET SHIFT CABLE REAR ENTRY 1 131 WESTERBEKE 40A STANDARD ALTERNATOR OIL MANIFOLD 12 4 7 20 21 132 WESTERBEKE 40A STANDARD ALTERNATOR OIL MANIFOLDREF PN NAME REMARKS QUAN 1 031709 CAPSCREW 12NC X 2 1 2 031776 LOCKWASHER 12 1 3 024684 ALTERNATOR 51 AMP 12 VDC 1 41 031555 CAPSCREW 516NC X 1 1 42 031758 LOCKWASHER 516 1 43 033381 WASHER ADJUSTING STRAP 1 6 011969 MANIFOLD OILTO MOUNT SWITCHES 1 7 011615 PLUG 18NPT AR 8 036395 HOSE BLOCK TO OIL MANIFOLD 1 9 015122 ELBOW 45 DEGREE 1 10 013328 ELBOW 90 DEGREE 1 11 011492 NIPPLE 1 12 012060 BRACKET ALTERNATOR 1 13 035338 STRAP ADJUSTING 1 14 011548 PULLEY ALTERNATOR 1 15 035759 BELT ALTERNATOR AND FRESH WATER PUMP 1 16 012955 BRACKET THROTTLE AND STOP CABLES 1 17 013325 CLAMP THROTTLE CABLE 1 18 013870 SHIM THROTTLE CABLE CLAMP 1 19 013871 CLAMP STOP CABLE 120 024132 SENDER OIL PRESSURE 1211 033935 SW ITCH OIL PIN HARNESS 1212 034761 SWITCH OIL PRESSUREALARM8 PIN HARNESS 1221 031631 CAPSCREW 38NF X 114 2222 031764 LOCKWASHER 38 223 024152 SPACER THROTTLE CABLE CLAMP 1 133WESTERBEKE 40A ELECTRICAL HARNESS 6 7 134 WESTERBEKE 40A ELECTRICAL HARNESSREF PN NAME REMARKS QUAN 1 024639 SOLENOID PREHEAT 1 3 031678 CAPSCREW 716NF X 34 2 4 031770 LOCKWASHER 716 2 5 024683 BREAKER CIRCUIT 20 AMP 1 6 035772 BRACKET CIRCUIT BREAKER AND SOLENOID 1 7 020005 NUT PILLAR 2 81 036079 HARNESS 8 PIN 1 82 036602 HARNESS 12 PIN 1 9 030125 SW ITCH WATER 1 10 035109 SENDER WATER TEMPERATURE 1 11 032119 BUSHING REDUCER 12NPT TO 18NPT 2 12 013355 BUZZER ALARM 1 135 WESTERBEKE 40A INSTRUMENT PANEL 4 53 L 67 7 8 10 11 14 I 12 0 fi 1 13 19 00 16 136 WESTERBEKE 40A INSTRUMENT PANELREF PN NAME REMARKS QUAN 1 033866 PANEL INSTRUMENT ASSEMBLY 1 2 030913 SCREW 1 3 030119 COVER PANEL REAR 1 4 035118 HOLDER LAMPIJEDGE BASE AR 5 035114 LAMP BASE AR 6 035108 METER IJATER TEMPERATURE 1 7 03511 0 METER OIL PRESSURE 1 8 033865 PANEL PLATE 1 9 033693 SWITCH KEY 1 10 030003 NUT NYLON LOCKING 632 1 11 033684 COVER FACEPLATE 1 12 030002 SPACER NYLON 1 13 024996 WINDOW KEYSIJ ITCH COVER 1 14 030001 SCREW NYLON 632 X 12 IJASHER HEAD 1 15 035111 VOLTMETER 12 VDC 1 16 033682 DECAL SWITCH IDENTIFICATION 1 17 030148 CABLE PANEL TO ENGINE 1 181 033764 SIJITCH PUSH BUTTON STARTPREHEAT 2 182 019031 CAP SWITCH COVER REPLACEMENT AR 19 011917 METER TACHOMETERHOUR 1 20 036630 DRAWING TEMPLATE TO INSTALL PANEL 1 137WESTERBEKE W40NA ALTERNATORS AND COMPRESSOR MOUNTING SYSTEM iY 0 e 138 WESTERBEKE W40NA ALTERNATORS AND COMPRESSOR MOUNTING SYSTEMREF PN NAME REMARKS QUAN 1 031719 CAPSCREW 12NC X 412 1 2 011548 PULLEY ALTERNATOR 2 3 036430 SPACER 1 4 024684 ALTERNATOR 51 AMP 12 VDC 2 5 036429 SPACER 1 6 031776 LOCKWASHER 12 2 7 031774 NUT 12NC 1 8 036427 BRACKET ALTERNATOR 1 9 031553 CAPSCREW 516NC X 34 2 10 031758 LOCKWASHER 516 2 11 033381 WASHER ADJUSTING STRAP 212 033064 STRAP ADJUSTING 213 031764 LOCKWASHER 38 214 031633 CAPSCREW 38NF X 134 115 031632 CAPSCREW 38NF X 112 116 036452 BRACKET COMPRESSOR 117 033537 CAPSCREw 38NC X 118 418 031765 WASHER FLAT 38 419 031764 LOCKWASHER 38 420 031762 NUT 38NC 421 036413 BRACKET COMPRESSOR 122 031553 CAPSCREW 516NC X 34 223 CAPSCREW 516NF 224 031758 LOCKWASHER 516 225 031274 CAPSCREW 38NC X 2 FULLY THREADED 126 033361 BELT ALTERNATOR AND FRESH WATER PUMP 227 036428 PULLEY 4 GROOVE 128 031752 LOCKWASHER 14 429 CAPS CREW 114NF X 1118 430 031559 CAPSCREW 516NC X 2 131 031758 LOCKWASHER 516 132 031759 WASHER FLAT 516 133 012225 PULLEY FRESH WATER PUMP 2 GROOVE 134 031758 LOCKWASHER 516 235 031756 NUT 516NC 236 036426 BRACKET ALTERNATOR 137 031554 CAPSCREW 516NC X 78 138 033713 SPACER 139 031713 CAPSCREW 12NC X3 140 031108 SPACER 141 036457 BELT COMPRESSORMUST BE MATCHED PAIR 242 037248 DIAGRAM WIRING 1 139 ESTERBEKE 40A PN NAME REMARKS QUAN 3 019934 GASKET SET UPPER 1 4 020719 GASKET SET LOIJER 1 5 020720 GASKET SET COMPLETE 1 6 032974 FILTER TRAP 1 7 013758 PAINT RED AEROSOL SPRAY CAN 1 8 015010 STRAINER SEA ATER 1 9 020654 SPLITTER ALTERNATOR OUTPUT 1 10 011988 KIT FUEL HARDIJARE 1 11 020502 MANUAL TECHNICAL 1 12 012169 LINE FLEXIBLE STEEL 12 LONG 1 131 034936 MUFFLER HYDROHUSH C UNIVERSAL MOUNT 1 132 033340 CONNECTOR HOSESTRAIGHT 178 AR 133 033341 CONNECTOR HOSE 45 DEGREE 178 AR 134 033342 CONNECTOR HOSE 90 DEGREE 178 AR 135 036680 ADAPTER 178 TO 2 HOSE AR 136 033943 KIT HOSE COUPLING AND CLAMPS 1 14 033327 VALVE ANTISIPHON 1 140
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