Westerbeke Diesel 108c Six Parts Manual
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YOUR NOTES AdobeUCS1 9 AdobeUCS F Failures Exhaust System Installation Checks 17 Filters Fuel 30 FORWARD 2 Foundation for the Engine 12 Fresh Water Circuit 39 Fresh Water Cooling System Layup and 67 Fuel Diesel 30 Fuel Filters 30 Fuel Filter Elements Replacing the 31 Fuel Injection Pump 32 Fuel System Installation Checks 19 Fuel System Layup and 68 FUEL SYSTEM 30 Fuel System Priming the 31 G Galleries Connecting Pressure Sensing Devices to Oil Installation Checks 18 GENERAL 4 GENERAL SPECiFiCATIONS 7 H HARDWARE TIGHTENING TORQUES TABLE OF STANDARD 71 HBW 50 TRANSMISSION 50 Head Bolts Torquing Cylinder 63 Hot Water Domestic 45 INDEX 74 Injection Pump Fuel 32 Injection Pump Timing Adjustment 65 I nspection of Equipment 2 INSTALLATION CHECKS 10 PANELS DESCRIPTION OF 23 Intake Manifold and ThroughHull Exhaust Layup and 68 Intake System Sea Water Installation Checks 19 L LAYUP AND 67 Lifting Rigging and Installation Checks 11 Location Installation Checks 10 Lubrication BW 3 Transmission 54 Lubrication Cylinder Layup and 69 Lubrication HBW 50 Transmission 50 Lubrication System Layup and 67 Westerbeke Diesel Engines 76 Lubrication Layup and 69 CAUTIONS ENGINE NOT SHIPPED WITH OIL 10 LIFTING SLINGS 11 SCOOPTYPE HULL FITTINGS 18 PROLONGED CRANKING INTERVALS 26 ENGINE SHUTDOWN 28 PROLONGED CRANKING INTERVALS 31 DAMAGE TO BATTERY CiRCUiT 33 QUICKCHARGING BATTERY 33 ALTERNATOR TESTING 33 EXCESSIVE BELT TENSION 42 TRANSMISSION GEAR COVER 53 TRANSMISSION GEAR COVER 56 D DC Control CirCUIT Engine 12Volt 33 DC WIRING DIAGRAM 36844 ADMIRALS PANEL 36 and 37 DC WIRING DIAGRAM 36467 CAPTAINS PANEL 34 and 35 DESCRIPTION OF INSTRUMENT PANELS 23 Description of Starting System 22 Devices to oil Galleries Connecting Pressure Sensing Installation Checks 18 Diesel Engine Understanding the 4 Diesel Fuel 30 DISCLAIMER PRODUCT SOFTWARE 1 Domestic Hot Water 45 Drain Oil Installation Checks 17 E Electrical System Installation Checks 19 ELECTRICAL SySTEM 33 Elements Replacing the Fuel Filter 31 Engine 12Volt DC Control Circuit 33 Engine Alignment of the Installation Checks 13 Engine Breakin Procedures 28 Engine Bolts Installation Checks 12 Engine Diesel Understanding the 4 Engine Foundation forthe Installation Checks 12 Engine Oil 47 Engine Oil Change to include filter 48 ENGINE 57 Equipment Inspection of 2 Exhaust BackPressure Installation Checks 16 Exhaust Intake Manifold and ThroughHull Layup and 68 Exhaust System Installation Checks 15 Exhaust System Failures Installation Checks 17 75 Westerbeke Diesel Engines iNDEX A Adjustment Injection Pump Timing 65 ADJUSTMENTS MAINTENANCE AND 60 Adjustment Valve Clearance 63 Admirals Panel 24 ADMIRALS PANEL DC WIRING DIAGRAM 36844 36 and 37 Alignment BW 3 Transmission 55 Alignment HBW 50 Transmission 51 Alternator 33 Alternator and Water Pump Drive Belt Tension42 Alignment of the Engine Installation Checks 13 ANTIFREEZE CONCENTRATION DATA 40 Automatic Alarm System Installation Checks 18 B BackPressure Exhaust Installation Checks 16 Batteries Layup and 69 Battery Specification 33 Belt Tension Alternator and Water Pump Drive 42 Bolts Engine Installation Checks 12 Bolts Torquing Cylinder Head 63 Breakin Procedures Engine 28 BW 3 TRANSMiSSiON 54 c Captains Panel 23 CAPTAINS PANEL DC WIRING DIAGRAM 38467 34 and 35 Change Engine Oil to include filter 48 Charging Voltage Test 38 CHECKS INSTALLATION 1 0 CirCUIT Fresh Water 39 Circuit Sea Water 42 Circutt Sea Water Layup and 68 Clearance Adjustment Valve 63 Cold Conditions Starting Under 29 CONCENTRATION DATA ANTIFREEZE 40 Conditions Starting Under Cold 29 Conditions Starting Under Normal 29 Connecting Pressure Sensing Devices to Oil Galleries Installation Checks 18 Controls BW 3 Transmission 55 Controls HBW 50 Transmission 52 Cooling System Installation Checks 18 COOLING SYSTEM 39 Cooling System Fresh Water Layup and Circuit Engine 12Volt DC 33 Coupling Propeller Installation Checks 13 Coupling Propeller Layup and 67 Cylinder Head Bolts Torquing 63 Westerbeke Diesel Engines 74 SPARE PARTS Since a possibility exists in which the engine may need to be serviced at sea or while in a port other than your home port certain spare parts should be kept on board to help minimize delays in your voyage Please refer to your engines Parts List for part numbers when ordering spare parts Listed below are those spare parts that should be carried on board at all times 1 An I mpeller Kit 2 A Fuel System hardware Kit 3 An Electric Fuel Lift Pump Filter and a Secondary Fuel Filter 4 An AlternatorSea Water Pump Belt 5 Hose Clamps 6 A Spare Oil Filter with a Spare Quart of Diesel Service Engine Oil along with a Quart of Transmission Lubricant and a Gallon of Premixed Antifreeze Other parts whose life expectancy cannot be accurately predetermined should be carried on board in ad255dition to those listed if the vessel is to be taken on long ocean voyages These parts are listed below 1 Fuel Injectors 2 Glow Plugs 3 Cooling System Hoses 4 An Alternator 5 A Starter 6 A 20 Amp DC Circuit Breaker 7 An Electric Fuel Lift Pump 8 A Sea Water Pump 9 Battery Terminal Connectors The spare parts listed directly above are those we recommend be carried on board during long ocean voyages You may wish to ask other boat owners who have similar crafts and who have completed long ocean voyages as to what spare parts they carried on board and what parts were needed at specific times of the voyage From the list provided directly above and from these inquiries you can determine what spare parts may be needed In addition you are planning a long ocean voyage consult your local Westerbeke dealer for a listing of the Westerbeke dealers located on your route 73 Westerbeke Diesel Engines AdobeUCSTORQUE SPECIFICATIONS Cylinder head bolt Ma 253 289 35 40 See the Tightening Cylinder Head Bolts section of this manual on page 63Rocker cover nut Ma36 51 05 07 Connecting rod cap nut 231 253 32 35 Flywheel bolt 470 506 65 70 Crankshaft pulley nut M241085 1447 15 20 Oil drain plug 362 434 50 60 Oil filter 79 94 11 13 or tighten firmly by handNozzle holder 362 434 50 60 Nozzle holder and retaining nut 434 579 60 BO Glow plug 108 145 15 20 Starter B terminal nut on copper stud72 87 10 12 NOTE MB indicates Metric 8 mm thread diameter Westerbeke Diesel Engines 72 9 4 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 sys255tem When the engine is put Into operation the system will selfflush in a short period of time with no ad255verse affects 5 Start the engine in accordance with procedures in the PREPARATIONS FOR STARTING section of this manual page 21 Westerbeke Diesel Engines 70 Cylinder Lubrication It is not necessary to remove the fuel injectors from the cylinder head to squirt light lubricating oil into the cylinders for the few months of normal layup However if you anticipate a longer layup period 12 months or morewe recommended that this procedure be performed The light oil in the cylinders will prevent the pistons rings from sticking to the cylinder walls Ensure that you have replacements for the injector and return line sealing washers Spares Layup time provides a good opportunity to inspect your Westerbeke engine to see if external items such as drive belts or coolant hoses need replacement Check your basic spares kit and order items not on hand or replace those items used during the layup such as filters and zinc anodes Batteries If batteries are to be left on board during the layup period ensure that they are fully charged and will remain that way to prevent them from freezing If there exists any doubt that the batteries will not remain fully charged or that they will be subjected to severe environmental conditions remove the batteries and store them in a warmer more compatible environment The of your Westerbeke engine after a seasonal layup generally follows the same proce255dures as those presented in the PREPARATIONS FOR STARTING section page 21 regarding preparation for starting and normal starts However some of the layup procedures will need to be counteracted before starting the engine 1 Remove the oilsoaked cloths from the intake manifold and from the throughhull exhaust port 2 Remove the sea water pump cover and gasket and discard the old gasket Install the sea water pump impeller removed during layup or a replacement if 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 battery being serviced Shut off all electrical equipment in the Vicinity to prevent electrical ar255cing during servicing 3 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 69 Westerbeke Diesel Engines AdobeUCSoil in also help strains This If the specified injection timing 250 BTDGcannot be attained adjust the timing by increasing or decreas255ing the thickness of the injection pump mounting shim Changing the shim thickness by 0004 inch 001 mmchanges the injection timing by approximately one degree To advance the timing decrease the shim thick255ness as required To retard the timing increase the shim thickness as required Refer to your engines parts List for shim part numbers Westerbeke Diesel Engines DELIVERY VALVE HOLDER INJECTION PUMP ADJUSTING SHIM Fuel Injection Pump wtth an Adjusting Shim 66 B A AdobeUCS3 Facing the front of the engine rotate the crankshaft 170 clockwise to position the No2 piston at TOC of its compression stroke Now adjust the No2 pistons intake and exhaust valves NOTE Adjust all valves to 00098 inches 025 mmwith the engine cold ADJUST VALVES TO 88898 INCHES 825 Adjusting a valves clearance with a feeler gauge Westerbeke Diesel Engines 64 Cylinder Head Bolts Tighten the cylinder head bolts according to the sequence shown in the illustration shown to the right Make sure the engine is cold when this is done Loosen one head bold onehalf turn and then tighten it between 56 to 59 Ibft 78 to 82 kgmThen proceed to the next head bolt in the sequence numbering shown Valve Clearance Adjustment NOTE Retorque the cylinder head bolts before adjusting the engines valves 1 Remove the rocker arm cover 2 Position the No1 piston at Top Dead Center TDCof its compression stroke To do this align the timing mark on the gear case with that on the crankshaft pulley refer to the photograph shown the NO1 pistons intake and exhaust valves MARK ON CASE 63 25 BlOC INJECTION PUMP TIMING MARK TOP DEAD CENTER ALIGNMENT MARK Westerbeke Diesel Engines After Every 800 Hours 01 Operation 1 Remove and check fuel injectors I njector spray pressure 1991 psi 140 psi 140 kglcm2 10 undesirable injection conditions including after dripping 2 Check the engines compression pressure Remove each glow plug and check each cylinders compression pressure The engines cranking speed is at 280 rpm Standard Minimum POOR GOOD 455 psi 32 kgcm23697 psi 26 kglcm2Maximum difference between cylinders 355 psi 25 kgcm23 Check the alternator for proper operation 4 Check the tightness of bolts nuts and clamps Servicing 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 exchangerNOTE Operating in silty andor tropical waters may require that a heat exchanger cleaning be performed more often than every 1000 hours 2 Check the injection pumps timing Westerbeke Diesel Engines 62 AdobeUCS3 Torque the cylinder head boits 4 Adjust valve clearances 5 Adjust the alternator and water pump drive belt tension IT required 6 Lubricate the throttle the RUN linkage cable and the transmissions remote control cable 7 Change the transmissions transmission fluid IT your engine is equipped with a HBW 50 transmission or change the transmission oil IT your engine is equipped with a BW 3 transmission Servicing After Every 100 Hours of Operation 1 Change the engines lubrication oil and oil filter 2 Adjust the alternator and water pump drive belt tension IT required 3 Check the transmission fluid or oil level Servicing After Every 250 Hours of Operation 1 Replace the fuellilter elements in Ihe electric fuel lift pump and in the optional watersediment separator 2 Change the transmissions transmission fluid IT your engine is equipped with a HBW 50 transmission or change the transmission oil if your engine is equipped with a BW 3 transmission Servicing After Every 500 Hours 01 Operation 1 Torque the cylinder head bolts 2 Adjust the valve clearances 3 Drain flush and relill the fresh water cooling system The illustration on page 5 shows the heat ex255changer and the zinc anode location The drain plug for the fresh water system is next to the zinc anode 4 Check the condition 01 the starler motor drive pinion lubricate the pinion 5 Check the resiste11ce of the glow plugs 4 to 6 ohmsNOTE Items highlighted by an asterisk should be performed by a competent mechanic 61 Westerbeke Diesel Engines starting bat2551 Problem 8T ART switch is de255pressed no starter engagement Engine cranks but does not start Failure to stop Westerbeke Diesel Engines ENGINE Probable Calise 1 Connection to solenoid faulty 2 Faulty 8T ART switch 3 Faulty solenoid 4 Loose battery connection 5 Low batteries 1 Shutoff valve at fuel tank 2 Faulty fueling system to engine 3 Air is in the fuel system 4 Fuel pump is not operating 5 Fuel filters are clogged 1 Mechanical Run linkage disconnected 58 1 Check connection S at the starter solenoid for 12 volts with the switch depressed 2 Check SWitch with an ohmmeter 3 Twelve volts is present at the S terminal of the starter solenoid 4 Check battery connections at both the and ground 5 Check battery charge state Low voltrage at the solenoids S terminal with no activation 1 Return shutoff valve to its ON position Now bleed the fuel system 2 Check for fuel 3 Bleed the fuel system Locate the leak and correct it 4 Check pump operation 5 Cleanreplace filters 1 Stop engine by man255ually moving the RUN linkage to STOP That failing shut off fuel and air ENGINE Introduction The tables which follow indicate procedures based upon certain problem indicators the probable causes of the problems and the to overcome these problems Note that the engines control system electrical systemis protected by a 20Ampere manual reset circuit breaker located on the rear lifting bracket Problem Key switch ON but no panel or test function PREHEAT switch is de255pressed no preheat solenoid activation no electric fuel pump or alternator excitation Probable Cause 1 Battery OFF 2 20 Amp circuit breaker is tripped 3 Loose battery cable connection 1 Faulty solenoid connections or switch 2 Faulty connection or tripped 10 Amp breaker on the I terminal on the preheat solenoid 57 1 Turn Battery ON 2 Reset the breaker by pushing in the button 3 Check the connection to the starter and the connection to the ground stud on the bell housing 1 Connection for 12 volts at S terminal of the solenoid is faulty 1 Check the preheat switch 2 Check for 12 volts at the 10 Amp breaker Check for 12 volts at fuel lift pump and at the R terminal on the alternator when the preheat button is pushed Weserbeke Diesel Engines D x 6 P D x 6 P transmission oil may also be removed by inserting a small tube through the dipstick opening where the oil is addedand attaching a pump onto the tube so the old oil may be sucked out The operating oil temperature must not exceed 266 F 130 CIf this temperature is to be exceeded during normal operation an optional transmission fluid cooler should be installed Consult you local Westerbeke Dealer for details on this cooler NOTE To check the transmission fluid level remove the dipstick and wipe off all transmission oil on the dipstick and place the dipstick back in the hole where it was removed making sure that the dipsticks rubber head is properly inserted into the oil port Now remove the dipstick and see where the oil measures on the dipstick If the transmissions oil level lies below the notch add enough transmission oil to raise the level back up to the notch Do not overfill the transmission DO NOT force the dipstick into the oil port to check the transmission oil level Excessive pres255sure can ruin the dipstick Make sure that the dipstick is properly inserted into the oil port before and while the engine is operating Alignment Misalignment between the transmissions coupling and the propeller shafts coupling can create serious problems Ensure that the alignment procedures outlined in the Propeller Coupling the Propeller and the Alignment of the Engine sections of this manual are followed pages 13 and 14 Controls The only controls required to operate the transmission is a single lever remote control cable The cable should be attached to the gear box lever using the cable bracket supplied with the unit Both the gear box lever and the remote control lever must be in the NEUTRAL pOSition when the cable is attached to the gear box lever The shift cable when properly adjusted should allow for an equal throw of the transmission shift lever into FORWARD or REVERSE from the NEUTRAL position without running out of cable Allow 1 12 inches of cable throw from the NEUTRAL position on the transmissions gear box lever to the each of the two drive positions Minimum Travel mner hole usedj N 1 12 1 12 Shit Cable AttaChment tram Rear 55 Westerbeke Diesel Engines after the x 6 P x 6 P x 8 P x 6 P Controls The only controls required to operate the transmission is a single lever remote control cable The cable should be attached to the gear box lever using the cable bracket supplied with the unit Both the gear box lever and the remote control lever must be in the NEUTRAL position when the cable is attached to the gear box lever This allows the remote cable an equal throw distance to shift the gear box into FORWARD or into REVERSE from the NEUTRAL posttion without running out of cable Allow approximately 118 inches 1 316of cable throw from the NEUTRAL position on the transmissions gear box lever to the each of the two drive positions NOTE If the throw distance or travelof the remote cable is too short the gear box lever cannot fully engage the transmission into FORWARD or REVERSE In this situation the transmissions clutch plates will wear prematurely and the transmission will eventually fail Minimum Travel Inner nole uSed 118 N 118 30mm 30mm i I 0 GD J 0 I j 267 7f J G5 j t I I I I Shllt Cable AttaChment Iram Rear 11 o o 020 tncnes Shltt Arm Securing Boll NOTE Excessive throw distance in the remote control lever is not detrimental to the Note that the position of the remote control lever should align with the NEUTRAL mark255ing on its bracket when the transmission is really in NEUTRAL Shifting To shift the transmission from NEUTRAL into FORWARD exert a heavy push to the remote control lever A gentle throw may not carry enough force to actually shift the transmissions internal gears A gentle throw is signalled by the transmission not engaging into the desired drive Make sure the remote control lever is lubricated at lease once each operating season Shift the transmission while the engine is running at 1200 rpm or below The clutch pack within the transmission makes an audiable clunk when engaging into gear Westerbeke Diesel Engines 52 Ensure alignment procedures AdobeUCSTHE HBW 50 TRANSMISSION General The HBW 50 transmission is equipped with a helical gearing sys255tem The servooperated multipledisc clutch requires only a minimum effort to change drives This feature makes the transmission suitable for a singlelever remote control with a rod linkage such as a Morse or Bow255den cable For safety reasons the transmission is NOT filled with transmission fluid for shipment Before leaving the factory however each transmission is thoroughly tested with fluid in the transmission This test255ing among other things provides all internal parts with a coating of transmission fluid This fluid acts as a preservative providing reliable protection against corrosion for at least one year if the transmission is proper255ly stored DIPSTICKFIll PORT Lubrication The HBW 50 transmission is an type Fill the transmission up to or near the top of the machined notch cut on the dipstick with approximately 032 US quarts 03 Ikersof automatic fluid ATFChange the transmission fluid after the first 30 hours of engine operation and thereafter every 250 hours or once per year minimumThe HBW 50 transmission has a drain plug for draining the old transmission fluid To ensure that most of the old fluid is drained from the transmission run the engine in NEUTRAL for 10 to 15 minutes so the transmission fluid may warm and flow better from the transmission This transmission fluid may also be removed by inserting a small tube through the dipstick opening where the transmission fluid is addedand attaching a pump onto the tube so the old fluid may be sucked out Westerbeke Diesel Engines 50 3 Filling the Oil Sump Add fresh oil through the oil filler cap on the valve cover refer to the photographs on pages 5 and 6 for the location of the oil filler cap and lube oil dipstickAfter refilling the oil run the engine for a few moments while checking the engines oil pressure Ensure there is no leakage around the new oil filter or from the oil drain system and then stop the engine Then check the quantity of oil with the lube oil dipstick Fill to but not over the high mark on the dipstick should the engine require additional oil 49 Westerbeke Diesel Engines Engine Oil Change to include filter1 Draining the Oil Sump Discharge the old oil through the sump drain hose attached at the front of the enginewhile engine is still warm Drain the old oil completely replace the hose in ITS bracket and replace the end cap securely Always observe the old oil as IT is removed A yellowgray emulsion indicates the presence of water in the oil Although this condition is rare IT does require prompt attention to prevent serious damage Call a competent mechanic should water be present in the oil Sea water present in the oil can be the result of a fault in the exhaust system attached to the engine andor a siphoning through the sea water cooling cir255cuit into the exhaust filling IT up into the engine refer to the installation illustrations on page 152 Replacement of the Oil Filter When removing the used oil filter you may find IT helpful and cleaner to punch a hole in the upper and lower portion of the old filter to drain the oil from IT into a container before remov255ing it This helps to lessen spillage A small style automotive filter wrench should be helpful in removing the old oil filter Place some paper towels and a plastic bag around the filter when unscrewing it to catch any all left in the filter Oil or any other fluid on the engine reduces the engines cooling ability Please keep your generators engine cleanInspect the old oil filter as it is ret110ved to make sure that the rubber sealing gasket came off with the old oil filter If this rubber sealing gasket remains sealed against the engine block gently remove it The replaceable cartridgetype oil filter requires no cleaning inside so it may be properly disposed of When installing the new oil filter element wipe the filter gaskets sealing surface on the engine block free of oil and apply a thin coat of clean engine oil to the rubber gasket on the oil filter Screw the filter onto the threaded oil filter stub and then tighten the filter firmly by hand II II 1 I I I II i II I NOTE Generic filters are not recommended as the material standards or diameters of im255portant items on generic parts might be entirely different from genuine parts Immediately after an oil filter cnange and oil fill run the engine to ensure that the oil pressure Is normal and that there are no oil leaks around the new oil filter Westerbeke Diesel Engines 48 SYSTEM Engine Oil For engine lubrication use lubricating oil designated for diesel service These oils are classified according to the API specifications Into service grades CA CB CC and CD The use of CC or higher CDgrades made by wellknown manufacturers is recommended The oil selected should be used thereafter Engine Oil Viscosity SAE NumberUse an oil having a viscostty best sutted to the atmospheric temperature Use of an allseason oil SAE 10W30 with minimum visCOSITY change under different temperatures is suggested Atmospheric Temperature 68260 F 20260 Cor higher 41260 F 5260 C68260 F 20260 C41 260 F5260 Cor lower Viscostty SAE 30 or 1 SAE 20 or 1 SAE 10W30 NOTE Do not use an engine lubricating oil wtth an SAE number greater than 30 in the engine Oil Pressure The engines 011 pressure during operation is indicated by the oil pressure gauge on the Admiral Panel see page 24During normal operation the oil pressure will range between 35 and 55 psi At Idle speed the oil pressure will range between 20 and 35 psi Atthetime 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 Engines AdobeUCSHoses should rise continuously from their low point at the heater to the engine so that trapped air will rise naturally from the heater to the engine If trapped air is able rise to the heater then an air bleed petcock must be installed at the higher fitting on the heater for bleeding air while filling the system Avoid loops in hose runs which will trap air Note If any portion of the heating circuit rises above the engines own pressure cap then a pressurized aluminumremote expansion tank must be installed in the circuit to become the highest point The remote expansion tanks part number is 24177 Install the remote expan255sion tank in a convenient location such as in a sail locker so the fresh water coolant level can easily be checked The cap on the engine mounted expansion tank should not be opened once the remote system is installed and filled The hose connection from the heater to the remote expansion tank should be rou1ed and supported so as to rise continuously from the heater to the tank enabling any air in the system to rise Refer to the illustrations on the previous page Westerbeke Diesel Engines 46 Domestic Hot Water The 12B TWO engine is equipped with domestic hot water heater connections If the owneroperator wishes to connect a hot water heater remove only the small hose that connects with the thermostat housing and the exhaust manifold and connect to these hose connections the hoses that run to the heater General With the small hose removed there remain two connecting points for hoses to run to and from the water heater These connections when plumbed correct255ly should allow for a flow of heated engine cooling system water to and from the domestic water heater without effecting the operation of the engines cooling system ATTACH HOSE REMOVE THIS HOSE RUNNING FROM WATER HEATER ATTACH HOSE RUNNING TO WATER HEATER Installation The heater should be mounted conveniently either in a high or low position in relation to the en255gine so that the connecting hoses from the heater to the engine can run in a reasonably direct line without any loops which might trap air The connection made to the thermostat housing should connect to the lower of the two connections on the water heater while the upper connection on the heater returns to the connec255tion on the exhaust manifold Note Use a good grade of wire reinforced 1 inch 10 hose to plumb from the engines connections to the hot water heaterFLOW FROM ItERTER INTO ENGINE IoiAMIFOLO FLOW I T V HEATER THE PRESSURE CfH OM TilE REMOTE EXPANSION TlHIIC MUST BE RATED LOWER IHAN THE PRESSURE CAP ON THE IIANIFOLD REMOTE EXPANSION TANK TANI KIT 24177J ENGINE CRP FLOW BACI Hno HEATER COILS ABOU PREGGURE en FLOW INTO HEATR HEATER COILS BELOW PRESSURE CRP ENGINE FLOW OUT OF 243tGIN243 The illustrations shown above are Flow Control designs which have been adapted to operate with the single pass manifolds installed on the 12B TWO diesel engine 45 Westerbeke Diesel Engines their remote expansion The alternator and water pump drive beltsisare property adjusted if the belt can be deflected no less than 38 inch and no more than 12 inch 10 mm 12 mmas the belt is depressed with the thumb at the midpoint between the two pulleys on the longest span of the belt See the figure belowA spare drive belt should be carried on board Alternator and Water Pump Belt Tension 43 I I Westerbeke Diesel Engines Sea Water Circuil The sea water flow is created by a belt255driven positive displacement neoprene im255peller pump The pump draws sea water directly from the ocean through the sea cock and sea water strainer and passes the water to the heat exchangers sea water inlet The sea water passes through the heat exchangers tubes from which heat from the fresh water system is absorbed and then the sea water is discharged from the cooling sys255tem overboard through the waterinjected wet exhaust system NEW AHODE REPLACE REPLACE Zinc Anode Conditions CL EAN OR REPLACE A zinc anode or pencil is located in the sea water cooling circuit within the heat exchanger The purpose of the zinc anode is to sacrifice itself to electrolysis action taking place in the sea water cooling circuit there255by reducing the effects of electrolysis on other components of the system The condition of the zinc anode should be checked monthly and the anode cleaned or replaced as required Spare anodes should be car255ried on board Sea Water Pump The sea water pump is a sellpriming beltdriven rotary pump with a nonferrous housing and a neoprene impeller The impeller has flexible vanes which wipe against a curved cam plate within the impeller housing producing the pumping action On no account should this pump be run dry There should always be a spare impeller and impeller cover gasket aboard an impeller kitSea water failures occur when lubricant sea wateris not present Such failures are not warrantable and the operators are cautioned to ensure that sea water flow is present at startup Alternator and Water Pump Drive Belt 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 tempera255ture as well as insufficient alternator output Westerbeke Diesel Engines 42 COOLANT RECOVERY TANI F 267J267i I 1 I CAP UANIFOLD Coolant Recovery Tank Recommended Installation Fill the fresh water system as follows 1 Remove the pressure cap from the manifold 2 Pour a clean antifreeze mixture into the manifold and allow enough time for the coolant to fill the fresh water cooling system 3 Start the engine and allow it to come up to its operating temperature Monitor the coolant in the manifold and add antifreeze coolant as air is expelled Once all air is expelled from the system fill the manifold to the filler neck and install the pressure cap 4 Remove the plastic cap from the plastic coolant recovery tank and fill the tank with coolant halfway be255tween the ADD mark and the MAX mark Replace the plastic cap 5 Run the engine and observe the coolants expansion flow into the plastic recovery tank 6 Check for leaks between the pressure capfiller neck and then plastic recovery tank Stop the engine and allow it to cool Coolant should be drawn back into the cooling system as the engines temperature comes down 7 Add coolant to the recovery tank as required to top off the fresh water coolant system Thermostat Generally thermostats are of two types One is simply a choking device which opens and closes as the engines temperature rises and falls The second type has a bypass mechanism Usually this is a disc on the bottom olthe thermostat which moves downward to close off an internal bypass passage within the head Since 1980 each type of thermostat has a hole punched through it The hole is a bypass to prevent the ex255haust manifold from overheating during the engines warmup Replacement thermostats must have this design characteristic 41 Westerbeke Diesel Engines CONCENTRATION DATA Antifreeze Concentration 13 23 30 35 45 50 60 Freezing Temperature F 23 14 5 4 22 40 58 It is advisable that an antifreeze concentration be selected on the basis of a tempera255ture which Is about 10 F 5 Clower than the actual atmospheric temperature expected B Filling the Fresh Water System A coolant recovery tank kit is supplied with each Westerbeke diesel engine The purpose of this recovery tank is to allow for engine coolant expansion and contraction during engine operation Without the loss of coolant and without introducing air into the cooling system This coolant recovery tank should be installed at or above engine manifold level in a location where it can be easily monitored and where coolant can be easily added if needed see the figure belowA stainless steel mounting bracket is supplied with each ktt along with a 3Dinch length of clear plastic hose and clamps to connect the hose between the engines manifold fitting to the hose spud on the base of the recovery tank FUNCTION OF MANIFOLD PRESSURE CAP From Coolant Tenk COOLANT RETRACTION to Coolant Tank COOLANT EXPANSION Coolant from the engine when heated during engine operation will expand lifting the springloaded manifold pressure cap and enter the recovery tank by way of the hose connecting the recovery tank to the manifold When the engine is shut down and cools a small check valve in the pressure cap is opened by the contrac255tion of the engine coolant allowing some of the coolant in the recovery tank to be drawn back into the engines cooling system free of air and without loss Westerbeke Diesel Engines 40 COOLING SYSTEM Description Westerbeke marine diesel engines are designed and equipped for fresh water cooling Heat produced in the engine by combustion and friction is transferred to fresh water which circulates throughout the engine This circulating fresh water cools the engine block and its internal moving parts The heat is transferred external255ly 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 the tubes engine heat transferred to the fresh water is conducted through the tube walls to the sea water which is then pumped into the exhaust system where finally itis discharged overboard In other words the engine is cooled by fresh water the fresh water is cooled by sea water and the sea water carries the transferred heat over the side through the exhaust system The fresh water and sea water circuits are independent of each other Using only fresh water within the engine allows the cooling water passages to stay clean and free from harm255ful deposits The two independent circuits and their components are discussed in the following paragraphs Fresh 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 sys255tem Fresh water is pumped through the engine by a beltdriven Circulating pump absorbing heat from the en255gine The fresh water coolant circulates through the engines block absorbing heat then passes through the thermostat into the exhaust manifold to the heat exchanger where it is cooled and then is returned to the engine block through the suction side of the fresh water circulating pump When the engine is started cold external fresh water flow is prevented by the closed thermostat although some fresh water flow is bypassed around the thermostat to prevent exhaust manifold from overheatingAs the engine warms up the thermo255stat 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 It is recommended that a freshwater and antifreeze mixture be used yearround Water when it freezes ex255pands sufficiently to split the heat exchanger and crack the engine block A mixture of proper concentration will prevent freezing see page 40 for an mixture chartUse soft water with few impurities such as tap water potable wateror rainwater Never use hard or foul water Use of hard water or water containing impurities will lead to the collection of scale in the engine and heat exchanger which will reduce the cooling systems efficiency Antifreeze 01 poor quality or without rust inhibitors will cause corrosion within the cooling system Always use antifreeze which is compatible with aluminum cooling system components and is made by a reliable manufacturer Never mix different brands 01 antifreeze Make sure that the cooling system of the engine is well cleaned before adding antifreeze Recommended an255tifreeze for year round use is ZEREX or PRESTONE with rust inhibitors In order to control the concentration of the mixture mix the antifreeze and freshwater thoroughly before ad267 ding it to the cooling system 39 Weslerbeke Diesel Engines A 40 R 50 AJ AdobeUCSDC Wiring Diagram 36844 Showing the Admirals Panel Wiring page 2 of 2 SCHEMATIC DIAGRAM 12 VOLT DC START r SOL I t STARTER tSOlI f II GLQWPLUGS i lI NOTE i I 0AL T L10A i lIFTPUMP I P 1 I I 225 SOL I I I L OP DP SNDR GSW 0 I WT SNDRj A I 1 THIS PRODUCT IS PROTECTED BY A MANUAL RESET CIRCUIT BREAKER LOCATED NEAR THE STARTER EXCESSIVE CURRENT DRAIN WilL CAUSE THE BREAKER TO TRIP AND THE ENGINE Will SHUT DOWN THE BUILDEROWNER MUST BE SURE THAT THE INSTRUMENT PANEL WIRING AND ENGINE ARE INSTALLED TO PREVENT CONTACT BETWEEN ELECTRICAL DEVICES AND SALTWATER 2 AN ONOFF SWITCH SHOULD BE INSTALLED BETWEEN THE BATTERY AND STARTER TO DIS267 CONNECT THE BATTERY IN AN EMERGENCY AND WHEN LEAVING THE BOAT A SWITCH WITH A CONTINUOUS RATING OF 175 AMPS AT 12 VOLTS DC WILL SERVE THIS FUNCTION THIS SWITCH SHOULD NOT BE USED TO MAKE OR BREAK THE CIRCUIT 3 THE GRAY WIRE AT PLUG 2 IS UNUSED AND SHOULD BE INSULATED 37 Westerbeke Diesel Engines SOLENOID WIRING DIAGRAM ALTERNATOR G 35 A 40 A 50 A75 SENDER SWITCH I I 14LTBLUE I 1 Wi 1l14LTBLUE I I Ii i SWITCH I I I I I I II p til I 1 iIZ Ll 1 USED ON SOME MODELS1I Ii a I 1 I 111 j7i1 FUEL SOLENOID i I OIL USEDINSOME I I i PRESSURE I I MODELSi I I SENDER i I STARTER GROUND TO ENGINE BLOCK BATIERY 12 VDC CCuT GRD 1 I i 1 I I BREAKER Ii II i ir NEUTRAL I I I IfSAFETY SWITCH I I USED ON SOME MODELS u Pl s 1 i I i 3 1 z tol 1 i 1 1 S21 C 01 P2C c I i i AdobeUCSDC Wiring Diagram 36467 Showing the Captains Panel Wiring page 2 012 r 2VOC SCHEMATIC DIAGRAM 0 CLOIJPUlGS II j LTURN Ev TO ON POSITION THE WIn SOUND Olt PRESSURE NOTES 8ATTEIIf INDICATORS WilL PREHEAT SW11CH FOP 15 Tv GO SECONDS AS REOUIRD AlARN IL STot VJHILE CONTiNUING TC PUSH PREKEAT SITCHPUSI THE START s ncl LSC WHEN nlE ENGINE STARTS RELEASE THE START SIoIITC ONLY wll243I THE OIL PRESSURE INDICATO lAIoP GOES OUT RELEASE T E PRrIAT oIITCI1 THIS PROOUC 15 PlIOTECTEO By A MANUAL CIRCUIT BREAKP lOChTt Nt THE STARTAEXCESlVE CURRl DAAIN WILL CAUSE BREhKE 10 TRoll AND T E ENGINE WILL SHUT OOIoN SUIlE TT TNt PANEWIFlING ENGINE ARE IN5TAllEC it PRElENT COrTAC ETWEEII EJEClIICAl DElICES AND SAlTwATR 2AN SW267ITCH SOUlD BE INSTALLED BET EEr THE ElAnE 5TAE DISCONNECT THE SAnERV IrI All ArlO HEN lEAlJlNG TI1E eOtT tS ITe WIT A CONTiNUOUS ATNG OF 17 r1210C WILL SERvE iHIS FUNCTtOr nns 5o11TCH SHOULD NOT BE USEITO MAKE 0R BREAI THE CIReUI 35 Westerbeke Diesel Engines AdobeUCSDC Wiring Diagram 36467 Showing the Captains Panel Wiring page 1 of 2 WRIV DItRAM Vi HER GIOWPlUGS r Tf p 0 50NOfR 0 I I 1 I 1 I I A r I W L I c Il leur SCcUIIt BLU RL 7 PRESSlJRE I e r RL I TT1 uS243D 50Ht tr 1 I I I 0 2l I I I JIL SENDER CllICUoT 1 0000 C iTARTE BLOC bee NEUTRAL SAFETY 5WTC I 0 I a i J lj o I IE Ul1 il ii i fi 52 C I E I I I Westerbeke Diesel Engines 34 I I I 1 I 1 I 1 jIl FUEL SO 225225 1 LlIWoo PUMP CAPTAIN PANEL SYSTEM Engine 12Volt DC Control Circuit The Westerbeke W 128 TWO propulsion engine has a 12Volt DC electrical control circuit as shown on the wiring diagrams which follow on pages 34 to 37 Refer to these diagrams when or servic255ing electrical 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 Shut off the engine battery switch however to avoid electrical shorts when working on the en255gine electrical circutt Battery Specification The minimum recommended capacity of the battery used in the engines 12Volt DC control circuit is 90 125 Amperehours minimumCAUTION When quickcharging the battery with an external charger be sure to disconnect the battery cables from the battery Leaving the charging circutt connected while quickcharging will damage the alternators diodes Alternator CAUTION When testing the alternator circuit charging cirCUITdo not use a highvoltage tester such as a rnegger damaged diodes could result During highspeed operation of the engine do not disconnect the positive terminal of the bat255tery from the B terminal of the alternator nor disconnect the negative terminal of the battery from the ground When cleaning the engine wtth a steam cleaner be careful to keep steam away from the aller255nator Refer to pages 34 to 37 for the two electrical system wiring schematics one is used for the Captains panel and the other for the Admirals Panel33 Westerbeke Diesel Engines Fuel Injection Pump The illustration shown below is an exploded view of the W 128 TWOs fuel system The fuel injection pump located at the lower righthand corner is one of the most important components of the diesel engine and therefore call s for the utmost caution in handling Furthermore the fuel injection pump has been thorough255ly benchtested and should not be tampered with Idle speed and timing adjustment are the only adjustments the servicing dealer can perform on the injection pump Other types of adjustments or repairs must be performed by a qualified injection service shop FUfl SUPPLY W 128 TWOs Fuel System To obtain long and satisfactory service from the injection pump always use fuel which is free from impurities and maintain a good filtration and water separation system between the fuel tank and generator engine Ser255vice this system regularly the injection pump it saves may be your own Westerbeke Diesel Engines 32 exhaust system exhaust system 9 9 FUEL SYSTEM Diesel Fuel Use No2 diesel fuel with a cetane rating of 45 Never use kerosene or home heating oil I n cold weather particularly water vapor is produced by condensation when air is present in the fuel tank Keep fuel tanksfull and completely free of dirt and water Fuel Filters A primary fuel filter of the water entrapment type must be installed be255tween the fuel tank and the engine Such a filter shown here is available from your local Westerbeke or your boatbuilder This fil255ter adapted for boatbuilder use comes complete with fittings for either hose or metal tubing Mount it in an accessible place inspect it often and drain off water accumulation fre255quently If a water trap type filter is not installed between the fuel lank and the fuel system any water in the fuel system will tend to lay in the bot255tom of the electric lift pump Internal metal parts of the lift pump will rust Particles will pass on to filters and eventually to the injection pump and injectors with damaging results and the possibility of expensive repairs Remember water damage to the fuel system is not covered under the Westerbeke warranty HOSE FITTING INSTALLATION INSTRUCTIOHS 1 aotT SECUR243l TO ACCESSIBLE SIRUtlURE SO PDSIlIONEO 111M R RECHTICLE TU cueH tAM BE PUUD UWOR IT 2 IF FUEL IS TO BE PIPED VITH COPPER BUMn IURlM USE NUIS FERRULES PROVUED BE URE TH TUBING PROJECts 14 ntH THROUGH UE FEAQULE BHORE TIHTEMIMG THE MUT 3 IF FUEL 15 TO BE PIPEO nlW HOS USE THE TWO UAGS BIIRBEO AND WASHERS BUPPtIU BE CERUU IHAI THE HOSE SELECHD HAS BRUO INSERTED ITO ClIliS 011 U243 8ARBTlIU IT 15 NEOPRENE LIMED lIND THIIT IT IS 225 If VAIn IS PIIESENT 1M IH FUEL IT ULt COLLECT SlBWLY U THE BOTTOI Of THE 5EnINEMIER WilE THE REIFLOAT RIMG REACMES THE LIME OM 111243 PLum Bon LOOStN THE BOllOM CRAIN PLUS ALL WAIU RUMS DUI 5 TIGHTEN DRUN PLUS ECUUtv SO MO AIR NTH THE sun 6 EMERG12E THE run PUIIP TO UrILl IHE BOWL In addition any gasoline in the fuel system will damage the engines fuel lift pump assembly as gasoline does not have the same lubricating qualities as diesel fuel as well as have a damaging effect on the injec255tion pump and the injectors Although most boatbuilders supply a water trapfilter some do not Westerbeke offers a trapfilter as an optional extra at moderate cost The filter is supplied with fittings for etther hose or metal tubing fuel lines Westerbeke Diesel Engines 30 AdobeUCSon board STOPPING PROCEDURES A manual pull type stop control tee handle or knobis provided by the installer in a location close to the engines controls Know the location of this control before attempting to start the engine To stop the en255gine pull out on this tee handle or knob fully and hold it out until the engine comes to a complete stop Push back on this control to return it to the engine run position otherwise the engine will not restart With the engine stopped turn the key switch to the OFF position 12 oclockIf the key switch is left ON the battery will discharge The alarm buzzer will sound in the Admirals Panel but not in the Captains Panel should the key switch be left ON The best method of preventing the battery from discharge is to remove the key from the key switch after stopping the engine CAUTION DO NOT attempt to shutdown the engine by turning the key switch OFF The key switch only provides power to the instrument panel the engine will continue running even if the key switch is turned OFF An optional key shutoff package is available however This option allows the operator to shutoff the en255gine by turning the key switch OFF which turns OFF an electrically run Fuel Run Solenoid This electrical shutoff option is installed at the factory upon the specific requestorder of the BreakIn Procedures Although your engine has experienced a minimum of one hour of test operations to ensure accurate as255sembly and proper operation of all systems breakin time is required The service life of your engine is de255pendent upon how the engine is operated and serviced during its initial hours of use Your new engine requires approximately 50 hours of initial conditioning operation to break in each moving part in order to maximize the performance and service life of the engine Perform this conditioning careful255ly 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 chargingare function255ing 2 Allow the engine to warm up preferably by running at fast idleuntil the water temperature gauge moves into the 1301400 F range 3 While using the vessel run the engine at varying engine speeds for the first 25 hours 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 6 During the neX1 25 hours the engine may be operated at varying engine speeds with short runs at full rated speed Avoid idling the engine for prolonged periods of time Westerbeke Diesel Engines 28 Once the engine starts run it at idle for a few minutes to warm up the engine and check instruments for proper oil pressure and battery charging voltage Never attempt to engage the starter while the engine is running 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 Cis reached 27 Westerbeke Diesel Engines button Check NOTE An alarm buzzer is supplied with every Admiral Panel The installer is responsible for electrically connecting the buzzer to the fourpin connection on the engines electrical har255ness The installer is also responsible for installing the buzzer in a dry location so that it will be audible to the operator should it sound while the engine is running The buzzer will sound when the ignition key is turned ON and should silence when the engine has started and when the engines oil pressure rises above 15 psi 25 Westerbeke Diesel Engines 56Iarm The alarm is located above the lest button and will sound if the engines oil pressure falls below 15 psi In this event the alarm will emil apulsating signal The alarm will also sound if the water tempera255ture in the fresh water cooling circuit rises to 210 F In this event the alarm will emit continuous sig255nal Admirals Panel General This control panel is equipped with a key switch and an RPM gauge with an ELAPSED TIME meter which measures the engines running time in HOURS and in 110 hours The panel also includes a water temperature gauge which indicates water temperature in degrees Fahrenheit WATER Fan oil pressure gauge which measures the engines oil pressure in pounds per square inch OIL PSIand a DC control circuit voltage gauge which measures the systems voltage VOLTSAll gauges are illuminated when the key switch is turned ON and remain illuminated while the engine is in operation The panel also contains two rubberbooted push buttons one for PREHEAT and one for START 1 Key Switch The Key Switch provides power only to the instrument cluster Refer to the STOPPING PROCEDURE section of this manual page 28 2 PREHEAT The PREHEAT button activates the alternators exciter the engines glow plugs and bypas255ses the engines protective oil pressure switch In addition this button is energizes the START button 3 SI8BI 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 time Weslerbeke Diesel Engines 24 When this Description of Starting System Westerbeke diesel engines use electric starters assisted by glow plugs for both normal and cold weather starting The figure below shows a crosssectional view of one cylinder The glow plug is located in the com255bustion chamber so that its tip is in the injector nozzles spray path When the glow plug is energized by the PREHEAT button the plug glows red at the tip and assists in igniting the fuel The result is a rapid start with less wear on the starter This system is common to Westerbeke Diesels The start circuitry is designed so that the PREHEAT button must be depressed for the time specified in the Preheat chart shown on page 26 Then while keeping the PREHEAT button engaged the START button is depressed to crank the engine GLOW PLUG Combustion Chamber NOTE The START button will not energize unless the PREHEAT button is depressed When depressing the preheat switch we are activating the glow plugs in the cylinder head so use the preheat Intermittently so as not to overheat the glow plugs Westerbeke Diesel Engines 22 PREPARATION FOR STARTING This section of the manual provides the operator with preparation initial starting breakin starting cold or warmand stopping procedures Follow the procedures as presented for the conditions indicated and your Westerbeke engine set will give you reliable performance and long service life Fill your engine with oil up to or near the upper limit on the dipstick the installation angle may have an effect on the dipstick readingSelect readily available lubricat255ing oil with an API specification of CC or CD and an SAE number suitable for the temperature in your operating area see page 47For the quantity of oil needed in this engine refer to the SYSTEM SPECIFICATION section of this manual page 8 Fill the transmission to the FULL mark on the dipstick with the correct lubricant Refer to the SYSTEM SPECIFICATIONS section of this manual page 9Each unit is supplied with a coolant recovery kit 24977as standard equipment to which the following applies UPPER LIMIT IEORMAL LEVELLOWER LIMIT A Remove the pressure cap from the engines exhaust manifold and slowly fill the engines cooling sys255tem wtth a mixture of water and antifreeze suitable for your temperature zone See the COOLING SyS255TEM section of this manual page 39Operate the engine and observe the coolant level in the manifold Maintain this level 10 the base of the filler neck Once the engine reaches its operating temperature 170 1900 Fensure that there is coolant flow to the domestic water heaters when installed Top off the cooling system and install the pressure cap B Make sure the plastic recovery tank is property mounted near the untt with the bracket providedin 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 aiter the engine has been started and operating temperature has been reached to ensure that all air is expelled from the manHold 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 needed Fill the fuel tank with a good grade of NO2 diesel fuel and prime the fuel system up to the engine see page 31When returning fuel is free of air the engines fuel system is bled and the engine is ready to start NOTE When the PREHEAT is depressed the glow plugs in the cylinder head are ener255gized use the PREHEAT switch intermittently to prevent overheating the glow plugs Ensure that the Installation Checks have been made in accordance with those specified in the CHECKS section of this manual refer to page 1021 Westerbeke Diesel Engines AdobeUCSnot smoke AdobeUCSand return high water Exhaust System Failures When the engines sea water is fed into an exhaust system so that the full stream of this water strikes a sur255face erosion takes place This erosion may cause premature failures The proper design of either a water jacketed or water injected Wet exhaust system to prevent this problem requires that the sea water inlet be positioned so that the entering stream of sea water does not directly strike a surface In addition the velocity of the entering sea water stream should be as low as possible which can be achieved by having inlet fittings as big in diameter as possible The best protection against exhaust system leaks is to routinely inspect the complete exhaust system Check for leaks around manifolds gaskets and welds Make sure exhaust lines are not heating surrounding areas excessively If excessive heat is present correct the situation immediately If you notice a change in the sound or appearance of the exhaust system inspect the exhaust system and correct the cause Exhaust risers installed off the exhaust manifold should not exceed 8 Ibs in total weight when rigidly con255nected Excessive weight and vibration can result in a manifold failure andor the fracturing of the riser from the manifold at Its attachment Dry portions of the exhaust connected to the manifold which lay before the water injected exhaust system MUST be properly insulated to retain the exhaust heat within the exhaust pipe IWARNINGI Although diesel engine exhaust gases are not as toxic as exhaust fumes from gasoline en255gines 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 o Dizziness o Vomiting o I ntense Headache o Muscular Twitching o Weakness and Sleepiness o Throbbing in Temples If you experience any of the above symptoms get out into fresh air immediately Make sure there are no unnecessary objects suspended from any portion of the exhaust lines Excessive weight could cause deflection or distortion of the lines resulting in damage or leaks Inspect insulated por255tions of the exhaust system to ensure there is no deterioration of the insulation Oil Drain An oil sump drain hose is installed on the engine with the discharge end secured by a bracket at the front of the engine Oil may be drained from this hose by removing the cap and the discharge end of the hose from the support bracket and lowering the hose into a container The hose cap fitting is 14 inch NPT National Pipe Tapand can be extended or have a pump added for easier removal of the old oil if desired 17 Westerbeke Diesel Engines hose must Exhaust System The exhaust system provides an outlet line to vent engine exhaust gases out of and away from the vessel The system also discharges sea water which has passed through the engines sea water circuit by mixing it with hot exhalJst gases This mixing helps cool the exhaust gases and exhaust elbow and plumbing The ex255haust system and the sea water supply to the exhaust must be configured to prevent the siphoning of sea water into the exhaust through the sea water cooling circuit and to prevent the entry of sea water into the ex255haust through the circuits thruhull discharge port If not prevented sea water entering through the dis255charge port can lill the exhaust system muffler and enter the engines cylinders This will prevent proper starting and possibly cause damage to internal engine components The sea water supply hose to the exhaust system water injection elbow should be routed loopedat least 12 inches above the vessel water line An antiSiphon break should be installed when needed at the top of this loop The top of the loop should be placed high enough above the vessels water line so as to remain above the water line when the vessel is underway no matter what the angle of heel or roll may be ENCINE INSTALLATIONS WITH EXHAUST INJECTEDELBOW MINIMUM OF 6 INCHES ABOVE VESSELWATER LINE 6267 ENGINE INSTALLATIONS WITH EXHAUST INJECTED ELBOW AT OR BELOW VESSEL WATER LINE 1 ID 2 10 48 m 12 mEn The sea water supply thruhull sea cock fittings must be of the flushhull type Highspeed scoop type of fit255tings should not be used as they tend to encourage siphoning The exhaust discharge from the water lift muffler should be routed well above the water line then downward to the thruhull discharge This routing will prevent sea water entry if the thruhull discharge fitting becomes submerged when the vessel heels or rolls while under way or is subjected to following sea conditions Refer to the figures shown above lor recommended exhaust system installations 15 Weslerbeke Diesel Engines AdobeUCSTake plenty of time in making this alignment and do not be satisfied with anything less than perfect results The alignment is correct when the shaft can be easily slipped backward and forward into the counterbore and when a feeler gauge indicates thaI the flanges come together at all points The alignment between the propeller shaft coupling and the engines coupling can contain an error no greater than one thousandth of an inch per inch of the coupling diameter For ex255ample if your propeller shaft coupling is three inches in diameter the maximum error thaI can be allowed in the alignment is three thousandths of an inch 003I n making the final check for alignment the engines half coupling should be held in one position and the alignment with the propeller coupling tested with the propeller coupling in each offour positions Awhile rotaled 900 be255tween each position This test will also check whetherthe propellers halfcoupling is in exact alignment on its shaft Then keeping the propeller coupling in one position the align255ment should be checked by rotating the engines halfcoupling in 900 increments checking dimension A while in each 900 posi255tion until the halfcoupling has been rotated lull circle The engines alignment should be rechecked after the boat has been in service lor one 10 three weeks and If necessary perform the alignment again Usually it will be found that the engine is no longer in alignment This does not mean Ihat the work has been done im255properly at first rather it means Iha the boat has taken some time to take its final shape and that the engines bed and stringers have probably absorbed some moisture It may even be necessary to realign the coupling hal255ves again at a later time Weslerbeke Diesel Engines 14 333 FEELER GAGE PROPELLER SHAFT Propeller Coupling The propeller shaft coupling fitted to the transmissions output flange must transmit not only the power of the engine to turn the propeller shaft and propeller but must also transmit the thrust of the either ahead or astern The coupling bore should be carefully machined for a slight forced fit onto the shaft and an accurate mating surtace for the coupling to the output flange of the transmission For all engine models a propeller halfcoupling bored to shaft size for the specific order is supplied The coupling either has a keyway with set screws or is of the clamping type The fOlWard end of the propeller shaft has a long straight keyway Any burrs should be removed from the shafts end The coupling should be a light drive fit on the shaft and the shaft should not have to be scraped down or filed in order to get a fit It is important that the key be properly fitted both to the shaft and to the coupling The key should fit the side of the keyway closely but should not touch the top of the keyway in the hub of the coupling If driving the coupling over the shaft is difficult the coupling can be expanded by heating it in a pail of boil255ing water The face of the propeller coupling must be exactly perpendicular to the centerline or axis of the propeller shaft Propeller The type and size of propeller varies with the gear ratio and must be selected to fit the application based upon boat tests To utilize the full power of the engine and to achieve ideal loading conditions use a propeller which will permit the engine to reach its full rated RPM at full throttle while under a normal load and while it is moving the boat fOlWard through the water See pages 53 and 56Alignment of the Engine The engine must be exactly aligned with the propeller shaft in the proper fashion 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 is launched 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 appear Misalignment between the engine and the propeller shaft often creates serious problems which are often blamed on other areas suspected of causing the trouble Misalignment will cause excessive bearing wear rapid shaft wear and will in many cases reduce the life of the boats hull by loosening the hulls fastenings A bent propeller shaft will have the exact effect as those just stated therefore a pertectly straight propeller shaft is absolutely necessary One particularly annoying result of misalignment may be leakage of oil through the transmissions rear oil seal If oil is leaking from this seal check and make sure that the couplings alignment is within the limits prescribed on page 14 Never attempt a final alignment with the boat on land The boat should be in the water and have had an op255portunity to assume its final water form The best time to pertorm the propeller coupling alignment is with the fuel and water tanks about half full and all the usual equipment on board and after the main mast has been stepped and the final rigging has been accomplished 13 Westerbeke Diesel Engines Engine Bolts Bronze or stainless steel hanger bolts of appropriate size are recommended for use through the engines flexible mounts Less preferred are lag screws because their hold on the wood is weakened every time they are moved whereas the hanger bolts stay in position If the nut on top of the hanger bolt is removed to allow the engine to be lifted from its resting place the hanger bolt itself remains in place as a stud the bond between the hanger bolt and the wood is not weakened by the removal of the nut or the engine Foundation for the Engine A good engine bed contributes much toward the satisfactory operation of the engine The engines bed must be rigidly constructed and neither deflect nor twist when it is subjected to the engines weight or to the pressures that the boat may experience while operating in rough seas The bed must keep the engines alignment within one or two thousandths of an inch of this position at all times The bed has to withstand the forward push of the propeller shaft which pushes against the thrust washer bearing which finally pushes against the engines bolts and bed In fiberglass hulls we recommend that similar wooden stringers as in wooden hulls be formed fitted and then glassed securely to the hull This allows the hanger bolts to be installed firmly in the wood thereby reducing noise and transmitted vibration The engine support stringers must be as wide or wider than the engine mounting isolator Isolator overhang andor rounded stringer surfaces are detrimental to the isolators ability to retain vibration Preformed fiberglass engine beds when used should be of sufficient thickness to properly support the en255gine and should be wellglassed to the hull when installed The temptation to install the engine on a pair of fiberglass angle irons must be resisted Such construction will allow engine vibration to pass through to the hull Flexible mounts require a firm foundation against which they must act if they are to perform their function When possible follow bed design A and avoid bed design B refer to the between the bed stringers and extend255ing from the stringers to the hull may be required for proper support and to aid in the absorption of vibrations Westerbeke Diesel Engines GOOD A BAD B Note Avoid excessive height use solid stringer construction Al 12 Rigging lind lilting The engine is fitted lifting eyes Rope or chain slings capable of supporting the engines weight should be attached to the eyes and the engine lifted by means of tackle attached to these slings The lifting eyes have 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 signijicant 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 ENGINE SLING LIFTING MUST NOT EXCEEO 10267 LIFTING EYE The general rule in moving engines is to see that all of the equipment used is amply strong and firmly fixed in place Move the engine a little at a time and see that IT is firmly supported Eliminate the possibility of ac255cidents by avoiding haste Do nollift the engine by its propeller coupling or pry against this coupling with a crowbar because excessive pressure of this type may distort the coupling In certain situations it may be necessary to lift the engine in positions other than the horizontal position Cer255lain situations exist by which the engine must be lowered endwise through a small hatchway which cannot be made larger Under these conditions if the opening of the hatchway is extremely narrow tt is possible to reduce to some extent the outside dimensions of the engine by removing external components such as the alternator the cooling systems piping the heat exchanger certain filters the mounting lugs and other obstructive equipment This accessory equipment should be removed by a competent mechanic and spe255cial care should be taken to avoid damaging any exposed parts In addition be careful not to allow dirt from entering any opening created by the removal of equipment Parts removed should be returned to their respec255tive position as soon as the engine has cleared the hatchway In case it becomes necessary to hoist the engine either frontend upwards or upwards the attachment of slings must be done carefully to avoid the possibility of damaging the parts on which the weight may bear Special rigging work is best done by someone experienced and competent in handling heavy machinery 11 Westerbeke Diesel Engines CHECKS General Because the crafts in which Westerbeke engines are installed vary in design installation procedures will vary according to your crafts specific design It is not the intent of this section to advise boatyards or installers on procedures and wellunderstood However it is important that the owneroperator realize there are details of the installation which require periodic checks to ensure the best operating condi255tions for the equipment and safe operating conditions for the personnel on board Proper location and of the diesel engine in the vessel are of prime importance Factors in the installation that must be considered are ventilation to aid in cooling and to provide air for en255gine combustion exhaust system to property discharge raw cooling water quiet the exhaust and expel ex255haust gas cooling water supply fuel supply and electrical connections CAUTION For safety reasons the engine and transmission are NOT filled with lubricating oil for ship255ment 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 oil This oil acts as a preservative providing reliable protection against corrosion for at least one year if the engine and transmission are property stored Location The location should be such that it is dry and away from being splashed by bilge water or water from above The engine should be properly ventilated and accessible for minor servicing and repairs access for major repairs should be given consideration as wellThe location must be property ventilated to provide fresh air for engine combustion The engines lubrication oil sump dipstick the fresh water and oil fills and the transmissions dipstick and transmission or oil fill port must be accessible riLL CAP COOLANT RECOVERY COCKPIT TANK AL MOUN11NC STIlAI POSITIONS CABIN INSTALLATION ANGLE MUST HOT EXCEED 14 Please note that the engines installation angle cannot exceed 14 from the horizontal plain Westerbeke Diesel Engines 10 AdobeUCSW 128 TWO SYSTEM SPECIFICATIONS Operating Oil Pressure Oil Grade ELECTRICAL SYSTEM Starting Battery Battery Capacity Starting Aid Starter Motor DC NoLoad Current Cold Cranking Current Alternator Regulator TRANSMISSION HBW50 BW3 Standard Gear Ratio Optional Gear Ratio Direction of Rotation Lubrication Fluid Sump Capacity Standard Gear Ratio Direction of Rotation Lubricating Oil Grade SAE Grade Sump Capacity 35 55 psi 246 386 kglcm2API specification CC or CD 12Volt 35 AH negative ground recommended45 AH cold areas90 125 sheathed type glow plug 12Volt 12KW solenoid actuated shift 60 Amps at 115 Volts 6500 rpm min209 Amps at 12 Volts 12Volt DC 35 Amps Internal regulator built into alternator 144 Volts DC 261 3 Volts 21 251 Right handed standard transmission Automatic Transmission Fluid ATFType A or Dexron II 032 US qts 03 2471 Right handed standard transmission API specification of CC or CD SAE 20 or SAE 30 exclusively 037 US qts 035 9 Westerbeke Diesel Engines W 12B TWO SYSTEM SPECIFICATIONS FUEL SYSTEM Fuel I njection Pump I njection Timing Nozzle I njection Starting Pressure Lift Pump Fuel Filter on engineAir Cleaner Air Flow engine SYSTEM General Operating Temperature Fresh Water Pump Sea Water Pump Sea Water Flow at 3600 rpm measured before discharging into exhaust elbowSystem Capacity fresh SYSTEM General Oil Filter Sump Capacity includes Diesel Engines Open flow totally selfbleeding No2 diesel oil cetana rating of 45 or Bosch M type25260 261 OS BTDC StaticThrottle type 22752 psi 160 kgcm212Volt DC lift capacity 6 ft 18 mCanister type with replaceable element Metal screen type cleanable 270cfm O77cmmFresh water cooled block with sea water exchanger system 170 190260 F 77 88260 CCentrifugal type metal impeller beltdriven Positive displacement rubber impeller beltdriven gpm Ipmapproximate 40 qts 378 litersForced lubrication by gear pump Paper element spinon type 327 US qls 31 liters8 engine coldW 12B TWO Marine Diesel Engine Fresh Water Fill Cap Lube Oil Fill Fresh Water Air Bleed 0 Sea Water Pump DC Charging Alternator Lube Oil Drain Starter with Sol Westerbeke Diesel Engines DC Battery Ground Connection 6 Amp DC Circuit Breaker Pretlet Solenoid gOO Exhaust Elbow eat Exchanger Gear Dipstick Oil Filler BW Marine Gear Assembly Adjustable Engine Isolator W 12B TWO Marine Diesel Engine Exhaust Manifold gOO Exhaust Elbow Heat Exchanger Zinc Anode Gear Shift Lever Fuel Lift Pump Oil Pressure Swi Fresh Water Fill Cap Lube Oil Dipstick Fuel Injection Pump Fresh Water Lever Shutoff Lever Oil Pressure Sender Lube Oil Drain Hose 5 Weserbeke Diesel Engines Introduction This manual contains the equipment operating procedures as well as additional information needed to help the operator keep the equipment in proper working order Study and follow the instructions carefully A planned maintenance program is included in this manual adhering to the program will result in better equip255ment performance and longer equipment life Proper diagnosis of a problem is the most important step to satisfactory repair therefore a table is included Understanding the Diesel Engine The diesel engine closely resembles the gasoline engine since the mechanism is essentially the same The cylinders are arranged above a closed crankcase the crankshaft is of the same general type as that of a gasoline engine and the diesel engine has the same type of valves camshaft pistons connecting rods and lubricating system Therefore to a great extent a diesel engine requires the same preventive maintenance as a gasoline engine The most impOltant factors are proper ventilation and proper maintenance of the luel lubricating and cool255ing systems Replacement of fuel and iubricating filter elements at the time periods specified is a must and frequent checking for contamination that is water sediment or allegein the luel system is also essential Another important factor is the use of the same brand of high detel267gent diesel lubricating oil designed lor diesel engines Be careful not to put gasoline in the diesel fuel tanksGasoline does not have the same lubricating qualities as diesel fuel consequently gasoline in the fuel lines will damage components in the fuel lift pump assembly fuel injection pump and injectors The diesel engine does differ from the gasoline engine however in its handling and firing of fuel The car255buretor and ignition systems are done away with and in their place are two components the fuel injection pump and the fuel injectors Ordering Paris When contacting your Westerbeke dealer parts distributor or the factory concerning your Westerbeke unit always provide the engines model and serial number and transmission number as they appear on the black and silver Westerbeke plate which is mounted on the engines exhaust manrrold When ordering parts for your Westerbeke engine be sure to insist upon Westerbeke factory packaged parts because will fit or generic parts are frequently not made to the same specifications as original equipment Note that component locations in the rnanual are referenced from the front of the engine which is the pul255leydrive belt end The end is the rear endLeft and right sides are determined by the engine imagine straddling the engine and facing in the same direction as the front of the engine the left side is at your left the right side is your right Westerbeke engines and generator sets are thoroughly checked and given a final run under various load conditions before leaving the factory Test running the engine ensure dependable operation long service and a satisfied owner Care at the factory during assembly and thorough testing have resulted in a Westerbeke diesel engine capable of many thousands of hours of dependable service However the manufacturer cannot control the treatment the unit receives in the field That part is up to the owneroperator Westerbeke Diesel Engines 4 TABLE OF CONTENTS Section Page W 12B TWO MARINE DIESEL ENGINE GENERAL SPECIFICATIONS 7 W 12B TWO SYSTEM SPECIFICATIONS 8 INSTALLATION CHECKS 10 PREPARATION FOR STARTING 21 DESCRIPTION OF INSTRUMENT PANELS 23 STARTING PROCEDURE 26 STOPPING PROCEDURE 28 FUEL SYSTEM 30 ELECTRICAL SySTEM 33 DC WIRING DIAGRAM 36467 SHOWING THE CAPTAINS PANEL WIRING 34 35 DC WIRING DIAGRAM 36844 SHOWING THE ADMIRALS PANEL WIRING 36 37 COOLING SySTEM 39 LUBRICATION SYSTEM 47 HBW 50 TRANSMISSION 50 BW 3 TRANSMISSION 54 ENGINE 57 MAINTENANCE ADJUSTMENTS 60 LAYUP 67 TABLE OF STANDARD HARDWARE TIGHTENING TORQUES 71 TORQUE SPECiFiCATIONS 72 SPARE PARTS 73 INDEX 74 3 Westerbeke Diesel Engines FOREWORD Thank you for selecting a Westerbeke marine product for your use We at Westerbeke are pleased to have you as a customer Read this manual carefully and observe all safety precautions included throughout Operating procedures periodic preventive maintenance procedures installation checks system descriptions and minor adjust255ment procedures are included herein so you can operate your equipment safely and properly maintain the equipment at a high level of efficiency and expect dependable performance and long service life in return Should your unit require special attention contact your Westerbeke dealer for assistance The Westerbeke Service Organization is trained to provide the support necessary to ensure longterm dependable perfor255mance If within 60 days of submitting the Warranty Registration Form for your unit you have not received a Cus255tomer Identification Card see your warranty please contact the factory in writing with Model information including the engines serial number and commission date from WESlER8EKE CORPORA liON AVON INDUSTRIAL PARK AVON 02322 fiIT I WESTERBEKE CUSTOMER IDENTIFICATION Adall Smith Mail To 85 Maple Street Alden 1M 12234 Model N 12 TWO Set 225 1234706 EJCpiree 7788 Inspection of Equipment The engine is shipped from the factory mounted securely and properly crated Accessory equipment is shipped in a separate small box usually packed within the engines crate Before accepting shipment of the engine from the transportation company the crate should be opened and the contents inspected for concealed damage If either visible or concealed damage is noted you should require that the delivery agent sign Received in damaged condition on the proper delivery receipt Also check the contents of the shipment against the packing list and make sure that the proper notation is made if any discrepancies exist These noted discrepancies are your protection against loss or damage Claims concerning loss or damage must be made to the carrier not to the Westerbeke Corporation Westerbeke Diesel Engines 2 AdobeUCSrarely has SAFETY PRECAUTIONS The following symbols appear in this manual to call attention to and emphasize conditions potentially dangerous to the operator IWARNING The above symbol is used in the manual to warn of possible serious personal injury or loss of life CAUTION The above symbol is used in the manual to caution personnel of possible damage to equipment Read the manual carefully and thoroughly before attempting to operate the equipment Know when dangerous conditions can exist and take necessary precautions to protect personnel and equipment Fuels exhaust gases batteries electrical equipment and moving and hot parts are potential hazards that could result in serious personal injury or death Follow recommended proce255dures carefully Always operate bHge blowers for at least five minutes before starting engine ensure no gasoline fumes are present before starting Prevent Electric Shock Shut off electric power before accessing electrical equip255ment Use insulated mats whenever working on electrical equip255ment Make sure your clothing is dry not damp particularly shoesand keep your skin surfaces dry when handling electrical equipment Remove wristwatch and jewelry when working on electri255cal equipment Do not connect utility shore power to vessels AC circuits except through a shipAoshore doublethrow transfer switch Damage to vessels AC generator may result if this is not done Be extremely careful when working on electrical com255ponents High voltage can cause injury or death 225 Exhaust Gases Are Toxic 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 225 Use Extreme Care When Handling Engine Fuel A constant danger of explosion or fire existsDo not fill fuel tankswhile the engine is running Do not smoke or use an open flame near the engine or the fuel tank 225 Do Not Alter or Modify the Fllel System Be sure all fuel supplies have a positive shutoff valve Be certain fuel line fittings are adequately tightened and free of leaks Make sure a 1ire extinguisher is installed nearby and is properly maintained Be familiar with its proper use rated ABC by the NFPA are appropriate for all applications encountered in this environment 225 Use Extreme Care When Servicing Batteries 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 by a lighted cigarette cigar or pipe Do not smoke or allow an open flame near the battery being serviced Shut off all electri255cal equipment in the vicinity to prevent electrical arcing during servicing 225 Ayoid Moving Ea1l Do not service the unit while the unit is running if a situa255tion arises in which it is absolutely necessary to make operating adjustments use extreme care to avoid moving parts and hot exhaust system components Do not wear loose clothing or jewelry when servicing equipment avoid wearing loose jackets shirts or sleeves rings necklaces or bracelets that might be caught in moving parts Make sure all attaching hardware is properly tightened Keep protective shields and guards in their respective place at all times Do not check fluid levels or the drivebelts tension while the unit is operating Do not work on the equipment when mentally or physical255ly incapacitated by fatigue OPERATORS MANUAL WESTERBEKE 12B TWO MARINE DIESEL ENGINE Publication 37185 Edition One January 1988 vWESJERBEKE WESTERBEKE CORPORATION AVON INDUSTRIAL PARK AVON MA 02322 TEL 6175887700
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