Westerbeke Diesel Apr 99 Technical Manual

OPERATORS MANUAL WESTER8EKE 358 THREE 388 FOUR 428 FOUR MARINE DIESEL ENGINES Publication 37435 Edition One March 1988 WESIERBEKE 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 Filelto and emphasize conditions potentially dangerous to the A constant danger of explosion or fire existsoperator Do not fill fuel tanks while the engine is running IIWARNINGII Do not smoke or use an open flame near the engine or the fuel tank The above symbol is used in the manual to warn of personal injury or loss of life Do Not Alter or Modify the Filel System Be sure all fuel supplies have a positive shutoff valve CAUTION Be certain fuel line fitting 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 aUcan 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 Prevent 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 Do 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 or 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 all 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 Ensure1hatthe 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 01 all kinds such as brochures drawings technical data operators and parts lists and parts price lists and other related information instructions and from sources other than Westerbeke Is not within Westerbekes control and accordingly isprovided to Westerbeke customers only as a courtesy and service WESTERBEKE CANNOT BE RESPONSIBLE FOR THE CONTENT OF SUEH SOFTWARE MAKES NO WARRANTIES OR RESPECT THERETO INCLUDING THE ACCURACY TIMELINESS OR COMPLETENESS THEREOFAND WILL IN NO EVENT BE LIABLE FOR ANY TYPE OF DAMAGES OR INJURY INCURRED IN CONNECTION WITH OR ARISING 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 Westerbeke must 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 software untilafter such changes take 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 most Westerbeke products include special features that frequently do notinclude 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 FOREWORDThank you for selecting a Westerbeke marine product for your use We at Westerbeke are pleased to haveyou as a customerRead this manual carefully and observe ali safety precautions included throughout Operating preventive maintenance procedures installation checks system descriptions and minor adjustment procedures are included herein so you can operate your equipment safely and properly maintain theequipment at a high level of efficiency and expect dependable performance and long service life in returnShould your unit require special attention contact your Westerbeke dealer for assistance The Organization is trained to provide the support necessary to ensure longterm dependable performanceIf within 60 days of submitting the Warranty Registration Form for your unit you have not received a Customer Identification Card see below registering your warranty please contact the factory in writing withModel information including the engines serial number and commission date from WESTERBEKE CORPORATION AVON INDUSTRIAL PARK AVON MA 02322 Tit 5 0 CUSTOMER IDENTIFICATION Adam Smith 85 Maple Street Mail To Alden 1M 12234 Model W 358 THREE Ser It 1234C7G6 Expires of EquipmentThe engine is shipped from the factory mounted securely and properly crated Accessory equipment isshipped in a separate small box usually packed within the engines crateBefore accepting shipment of the engine from the transportation company the craie should be opened andthe contents inspected lor concealed damage if either visible or concealed damage is noted you shouldrequire that the delivery agent sign Received in damaged condition on the proper delivery receipt Alsocheck the contents of the shipment against the packing list and make sure that the proper notation is madeif any discrepancies exist These noted discrepancies are your protection against loss or damage loss or damage must be rnade to the carrier not to the Westerbeke Diesel Engines TABLE OF PageW 358 THREE MARINE DIESEL ENGINEGENERAL SPECIFICATIONS 12W 35B THREE SYSTEM SPECiFiCATIONS 13W 38B FOUR MARINE DIESEL ENGINEGENERAL SPECIFICATIONS 15W 38B FOUR SYSTEM SPECiFiCATIONS 16W 42B FOUR MARINE DIESEL ENGINEGENERAL SPECIFICATIONS 18W 428 FOUR SYSTEM SPECiFiCATIONS 19INSTALLATION CHECKS 21PREPARATION FOR STARTING 33DESCRIPTION OF INSTRUMENT PANELS 35STARTING PROCEDURE 39STOPPING PROCEDURE 41FUEL SYSTEM 43ELECTRICAL SYSTEM 46CAPTAINS PANEL DC CONTROL CIRCUITWIRING DIAGRAM 36467 48 49ADMIRALS PANEL DC CONTROL CIRCUITWIRING DIAGRAM 36844 50 51COOLING SySTEM 52LUBRICATION SYSTEM 60JS TRANSMISSION 63OPTIONAL TRANSMISSIONS 66ENGINE 79MAINTENANCE ADJUSTMENTS 82 3 Westerbeke Diesel Engines TABLE OF CONTENTS CONTINUED LAYUP 89 TABLE OF STANDARD HARDWARE TIGHTENING TORQUES 93 TORQUE SPECiFiCATIONS 94 SPARE PARTS 95 INDEX 96Westerbeke Diesel Engines 4 manual contains the equipment operating procedures as well as additional information needed to helpthe operator keep the equipment in proper working order Study and follow the instructions carefully Aplanned maintenance program is included in this manual adhering to the program will result in better equipment performance and longer equipment life Proper diagnosis of a problem is the most important step tosatisfactory repair therefore a table is the Diesel EngineThe diesel engine closely resembles the gasoline engine since the mechanism is essentially the same Thecylinders are arranged above a closed crankcase the crankshaft is of the same general type as that of agasoline engine and the diesel engine has the same type of valves camshaft pistons connecting rods andlubricating to a great extent a diesel engine requires the same preventive maintenance as a gasoline engineThe most important factors are proper ventilation and proper maintenance of the fuel lubricating and cooling systems Replacement of fuel and lubricating filter elements at the time periods specified is a must andfrequent checking for contamination that is water sediment or algae in the fuel system is also important factor is the use of the same brand of high detergent diesel lubricating oil designed specifically for diesel engines Be careful not to put gasoline in the diesel fuel tanks Gasoline does not have thesame lubricating qualities as diesel fuel consequently gasoline in the fuel lines will damage components inthe fuel lift pump assembly fuel injection pump and injectorsThe diesel engine does differ from the gasoline engine however in its handling and firing of fuel The carburetor and ignition systems are done away with and in their place are two components the fuel injectionpump and the fuel PartsWhen contacting your Westerbeke dealer parts distributor or the factory concerning your Westerbeke unitalways provide the engines model and serial number and transmission number as they appear on the blackand silver Westerbeke plate Which is mounted on the engines exhaust manHold When ordering parts foryour Westerbeke engine be sure to insist upon Westerbeke factory packaged parts because will fit orgeneric parts are frequently not made to the same specHications as original equipmentNote that component locations in the manual are referenced from the front of the engine which is the pulleydrive belt end The end is the rear end Left and right sides are determined bythe engine imagine straddling the engine and facing in the same direction as the front of the engine the leftside is at your left the right side is your engines and generator sets afe thoroughly checked and given a final run under various loadconditions before leaving the factory Test running the engine ensures dependable operation long serviceand a satisfied ownerCare at the factory during assembly and thorough testing have resulted in a Westerbeke diesel enginecapable of many thousands of hours of dependable service However the manufacturer cannot control thetreatment the unit receives in the field That part is up to the owneroperator 5 Westerbeke Diesel Engines W 358 THREE Marine Diesel Engine Fresh Water Fill Fresh Water Air Bleed Unit Data Plate 20 Amp DC Circuit Breaker 90 Exhaust Elbow Fresh Water Circulating Heat Exchanger Pump Transmission Shift Lever Sea Water Pump Engine Isolator DC Battery Starter with Solenoid Ground Diesel Engines W 35B THREE Marine Diesel Engine Top Lube Oil Fill 20 Amp DC Circuit Breaker Fresh Water Preheat Solenoid Air Bleed DC Charging Fuel Lift Plmp Instrument Connections Side Lube Secondary Oil Fill Fuel Filter Zinc Anode Shutoff Lever Transmission Dipstick Throttle Lever Lube OilJS Transmission Drain Hose Fresh Water Block Drain Switch Lube Oil Dipstick Oil Pressure Sender 7 Westerbeke Diesel Engines W 38B FOUR Marine Diesel Engine Top Engine Oil Fill Diesel Engines W 388 FOUR Marine Diesel Engine Top Engine Oil Fill Air Intake SilElnCler Fuel Lift Secondary Fuel Filter Zinc Anode Oil Throttle lever lube Oil Dipstick Oil Pressure Oil Pressure Sender Switch lube Oil Filter Westerbeke Diesel Engines W 4213 FOUR Marine Diesel Engine Top Engine Oil Fill 90 Exhaust Elbow Lever Diesel Eng ines 10 W 428 FOUR Marine Diesel Engine Top Oil Fill Fuel Lift pumpFuel Filler Zinc Anode Oil Throttle lever Lube Oil Dipstick Oil Pressure Oil Pressure Sender Switch Lube Oil Filler 11 Westerbeke Diesel Engines W 358 THREE MARINE DIESEL ENGINE GENERAL SPECIFICATIONS Engine Type Diesel fourcycle threecylinder fresh watercooled vertical inline 32 hp at 3600 rpm maximum Governor Mechanical centrifugal weight type Valve Mechanism Overhead Combustion Chamber Swirl chamber type Bore Stroke 307 x 307 inches 78 x 78 mm Piston Displacement 6823 cubic inches 1118 liters Firing Order 132 Direction of Rotation Clockwise when viewed from the front Maximum Torque at 2300 rpm 41 Ibsft 567 kgsm Compression Ratio 231 Compression Pressure 455 psi 32 kgcm2 at 320 rpm Valve Seat Angle Intake 45 Exhaust 45 Valve Clearance Intake 0010 inches 025 mm engine cold Exhaust 0010 inches 025 mm Dimensions Height 2125 inches 53975 mm Width 1837 inches 46660 mm Max Length 3010 inches 76454 mm Inclination Continuous 14 Temporary 25 not to exceed 30 min Dry Weight 3681bs 1669 kgs Fuel Consumption 042 US gph 159 Iph running at 2500 rpm approximate Idle Speed 800 1000 rpm Cruise RPM 2500 3000 rpmWesterbeke Diesel Engines 12 W 35B THREE SYSTEM SYSTEM Open flow totally selfbleeding Fuel No2 diesel oil cetane rating of 45 or higher Injection Pump Nippondenso Bosch M type Injection Timing 23 OS BTDC Static Nozzle Throttle type Injection Starting Pressure 2275 psi 160 kgcm2 Lift Pump with filter element 12Volt DC lift capacy 6 ft 18 m Fuel Filter on engine Canistertype with replaceable element Air Cleaner Metal screen type cleanable Air Flow engine combustion 71 cfm 20 cmmCOOLING SYSTEM General Fresh watercooled block wh sea water exchanger system Operating Temperature 170 190 F 77 88 C Fresh Water Pump Centrifugal type metal impeller beltJriven Sea Water Pump Positive displacement rubber impeller gearJriven Sea Water Flow at 3600 rpm gpm Ipm approximate measured before discharging into exhaust elbow System Capacity fresh water 6 US qts SYSTEM General Forced lubrication by gear pump Oil Filter Paper element spinon type Sump Capacity includes filter 422 US qts 41ers 13 Westerbeke Diesel Engines W 358 THREE SYSTEM SPECIFICATIONS Operating Oil Pressure 35 55 psi 246 386 kgcm 2 Oil Grade API specijication CC or CDELECTRICAL SYSTEM Starting Battery 12Volt 35 AH negative ground recommended 45 AH cold areas Battery Capactty 90 125 AmpereHours Starting Aid 12Voit sheathed type glow plug Starter Motor 12Volt 12KW solenoid actuated shift DC NoLoad Current 60 Amps at 115 Volts 6500 rpm min Cold Cranking Current 190 Amps at 12 Volts Alternator 12Volt DC 50 Amps Regulator Internal regulator built into alternator 144 Volts DC 3 General Casehardened helical gears with an intermediate JS Transmission reverse gear Reversing carried out by a servo double disc system Standard Gear Ratio 2471 Propeller Shaft Direction of Rotation Right handed standard transmission Propeller 16 D x 12 P 2 blade or 16 D x lOP 3 blade using JS transmission Propeller should allow the engine to reach 2471 reduction tts full rated RPM 3600 000 100 at full open throttle while underway Lubricating Oil Grade API specification of CC CD SC SD or SE SAE Grade SAE 20W20 or SAE 30 exclusively DO NOT mix grades of oil DO NOT use multigrade oils Transmission Sump Capacity 1 qt 1 Diesel Engines 14 W 38B FOUR MARINE DIESEL ENGINE GENERAL Type Diesel fourcycle fourcylinder fresh watercooled vertical inline 37 hp at 3600 rpm Mechanical centrifugal weight typeValve Mechanism Chamber Swirl chamber typeBore Stroke 287 x 307 inches 73 x 78 mmPiston Displacement 7964 cubic inches 1305 litersFiring Order 1324Direction of Rotation Clockwise when viewed from the frontMaximum Torque at 2400 rpm 53 Ibsft 733 Ratio 231Compression Pressure 455 psi 32 kgJcm 2 at 320 rpmValve Seat Angle Intake 45 Exhaust 45Valve Clearance Intake 00098 inches 025 mmengine cold Exhaust 00098 inches 025 mmDimensions Height 2370 inches 60198 mm Width 1837 inches 46660 mm Max Length 3377 inches 85776 mmInclination Continuous 14 Temporary 25 not to exceed 30 minDry Weight 4191bs 190 kgsFuel Consumption 042 US gph 159 Iph running at 2500 rpm Speed 750 950 rpmCruise RPM 2500 3000 rpm 15 Westerbeke Diesel Engines W 38B FOUR SYSTEM SYSTEM Open flow totally selfbleeding Fuel No2 diesel oil cetane rating of 45 or higher Injection Pump Nippondenso Bosch M type Injection Timing 23 OS BTDC Static Nozzle Throttle type Injection Starting Pressure 2275 psi 160 kgcm2 Lift Pump 12Volt DC lift capacity 6 ft 18 m Fuel Filter on engine Canister type with replaceable element Air Cleaner Metal screen type cleanable Air Flow engine combustion 829 cfm 234 cmmCOOLING SYSTEM General Fresh water cooled block with sea water exchanger system Operating Temperature 170 190 F 77 88 C Fresh Water Pump Centrifugal type metal impeller beltdriven Sea Water Pump Positive displacement rubber impeller geardriven Sea Water Flow at 3600 rpm gpm Ipm approximate measured before discharging into exhaust elbow System Capacity fresh water 7 US qts 66 SYSTEM General Forced lubrication by gear pump Oil Filter Paper element spinon type Sump Capacity includes filter 475 US qts 45 Diesel Engines 16 W 38B FOUR SYSTEM SPECIFICATIONS Operating Oil Pressure 35 55 psi 246 386 kgcm 2 Oil Grade API specification CC or CDELECTRICAL SYSTEM Starting Battery 12Volt 35 AH negative ground recommended 45 AH cold areas Battery Capacity 90 125 AmpereHours Starting Aid 12Volt sheathed type glow plug Starter Motor 12Volt 12KW solenoid actuated shift DC NoLoad Current 60 Amps at 115 Volts 6500 rpm min Cold Cranking Current 190 Amps at 12 Volts Alternator 12Volt DC 50 Amps Regulator Internal regulator built into alternator 144 Volts DC 3 General Casehardened helical gears with an intermediate JS Transmission reverse gear Reversing carried out by a servo double disc system Standard Gear Ratio 2471 Propeller Shaft Direction of Rotation Right handed standard transmission Propeller 180 x 12 P 2 blade or 18 0 x 10 P 3 blade using JS transmission Propeller should allow the engine to reach 2471 reduction its full rated RPM 3600 000 100 at full open throttle while underway Lubricating Oil Grade API specification of CC CD SC SO or SE SAE Grade SAE 20W20 or SAE 30 exclusively DO NOT mix grades of oil 1 DO NOT use multigrade oils Transmission Sump Capacity 1 qt 1 liter 17 Westerbeke Diesel Engines W 42B FOUR MARINE DIESEL ENGINE GENERAL SPECIFICATIONS Engine Type Diesel fourcycle fourcylinder fresh watercooled vertical inline 42 hp at 3600 rpm maximum Governor Mechanical centrifugal weight type Valve Mechanism Overhead Combustion Chamber Swirl chamber type Bore Stroke 307 x 307 inches 78 x 78 mm Piston Displacement 9093 cubic inches 149 liters Firing Order 1324 Direction of Rotation Clockwise when viewed from the front Maximum Torque at 2500 rpm 561bft 774 kgm Compression Ratio 231 2 Compression Pressure 455 psi 32 kgcm at 320 rpm Valve Seat Angle Intake 45 Exhaust 45 Valve Clearance Intake 00098 inches 025 mm engine cold Exhaust 00098 inches 025 mm Dimensions Height 2370 inches 60198 mm Width 1837 inches 46660 mm Max Length 3377 inches 85776 mm Inclination Continuous 14 Temporary 25 not to exceed 30 min Dry Weight 4191bs 190 kgs Fuel Consumption 042 US gph 159 Iph running at 2500 rpm approximate Idle Speed 750 950 rpm Cruise RPM 2500 3000 rpmWesterbeke Diesel Engines 18 W 42B FOUR SYSTEM SYSTEM Open flow totally selfbleeding Fuel NO2 diesel oil cetane rating 0145 or higher Injection Pump Nippondenso Bosch M type Injection Timing 23 05 BTDC Static Nozzle Throttle type Injection Starting Pressure 2275 psi 160 kgcm 2 Lift Pump 12Volt DC lift capacity 6 ft 18 m Fuel Filter on engine Canister type with replaceable element Air Cleaner Metal screen type cleanable Air Flow engine combustion 940 clm 266 cmmCOOLING SYSTEM General Fresh water cooled block with sea water exchanger system Operating Temperature 170 190 F 77 88 C Fresh Water Pump Centrifugal type metal impeller beltdriven Sea Water Pump Positive displacement rubber impeller geardriven Sea Water Flow at 3600 rpm gpm Ipm approximate measured before discharging into exhaust elbow System Capacity fresh water 7 US qts 66 SYSTEM General Forced lubrication by gear pump Oil Filter Paper element spinon type Sump Capacity includes filter 475 US qts 45 liters 19 Westerbeke Diesel Engines W 42B FOUR SYSTEM SPECIFICATIONS Operating Oil Pressure 35 55 psi 246 386 kgcm2 Oil Grade API specification CC or CDELECTRICAL SYSTEM Starting Battery 12Volt 35 AH negative ground recommended 45 AH cold areas Battery Capacity 90 125 AmpereHours Starting Aid 12Volt sheathed type glow plug Starter Motor 12Volt 12KW solenoid actuated shift DC NoLoad Current 60 Amps at 115 Volts 6500 rpm min Cold Cranking Current 190 Amps at 12 Volts Alternator 12Volt DC 50 Amps Regulator Internal regulator built into alternator 144 Volts DC 3 General Casehardened helical gears with an intermediate JS Transmission reverse gear Reversing carried out by a servo double disc system Standard Gear Ratio 2471 Propeller Shaft Direction of Rotation Right handed standard transmission Propeller 18 D x 13 P 2 blade or 18 D x 11 P 3 blade using JS transmission Propeller should allow the engine to reach 2471 reduction its full rated RPM 3600 000 100 at full open throttle while underway Lubricating Oil Grade API specification of CC CD SC SD or SE SAE Grade SAE 20W20 or SAE 30 exclusively DO NOT mix grades of oil DO NOT use multigrade oils Transmission Sump Capacity 1 q 1 Diesel Engines 20 INSTALLATION the crafts in which Westerbeke engines are installed vary in design installation procedures will varyaccording to your crafts specific design The intent of this section is not to advise boatyards or installerson procedures and wellunderstood However the owneroperator must realize thereare details of the installation which require periodic checks to ensure the best operating conditions for theequipment and safe operating conditions for the personnel on board Proper location and installation of thediesel 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 oil 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 dry and in an area where bilge water or water from above cannot splash on the engine The engine should be properly ventilated and accessible for minor servicing and repairs access formajor repairs should be given consideration as well The location must be properly ventilated to providefresh air for engine combustion The engines lubrication oil sump dipstick the fresh water and oil fills andthe transmissions dipstick and transmission or oil fill port must be accessible FILL CM COOLANT COCKPIT RECOVERV TANK fr AlnIlNanB MOUNTING STRAP POSITIONS CABIN IHSTLATIOH RHGL MUST NOT IOXCEED 14 Please note that the engines installation angle cannot exceed 14 from the horizontal plain 21 Westerbeke Diesel EnginesRigging 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 ordesired CAUTION Slings must not be so short as to place significant sheer stress on the engines lifting eyes Strain placed on the engines lifting eyes by the lifting sling must not be in excess of 100 from the vertical plain 10 SLING LIFTING ANGLE MUST NOT EXCEED 10 LIFT ING 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 it is firmly supported Eliminate the possibility of accidents by avoiding haste Do not lift the engine by its 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 otherthan 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 it 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 position as soon as the engine has cleared the obstructionIn 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 Diesel Engines 22Engine BollsBronze 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 its resting place the hanger bolt itself 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 lor the Eng ineA 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 when installedThe temptation to install the engine on a pair offiberglass angle irons must be resisted Such construction will allow engine vibration to pass through GOODto the hull Flexible mounts require a firm which they must act if they are to perform theirfunction When possible follow bed design A andavoid bed design B refer to the illustration ASupports between the bed stringers and extendingfrom the stringers to the hull may be required forproper support and to aid in the absorption of vibrations BAD B Note Avoid excessive height use solid stringer construction A 23 Westerbeke Diesel Shaft CouplingThe propeller shaft coupling fitted to the transmissions output flange must transmit not only the power ofthe engine to turn the propeller shaft and propeller but must also transmit the thrust of the either 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 all engine models a propeller halfcoupling bored to shaft size for the specific order is supplied Thecoupling either has a keyway with set screws or is of the clamping typeThe forward end of the propeller shaft has a long straight keyway Any burrs should be removed from theshafts end The coupling should be a light drive fit on the shaft and the shaft should not have to be scrapeddown or filed in order to get a fit It is important that the key be properly fitted both to the shaft and to thecoupling The key should fit the side of the keyway closely but should not touch the top of the keyway inthe hub of the couplingIf driving the coupling over the shaft is difficult the coupling can be expanded by heating it in a pail of boiling water The face of the propeller coupling must be exactly perpendicular to the centerline or axis of thepropeller type and size of propeller varies with the gear ratio and must be selected to fit the application basedupon boat tests To utilize the full power of the engine and to achieve ideal loading conditions use a propellerwhich will permit the engine to reach its full rated RPM at full throttle while under a normal load and while itis moving the boat forward through the walerAlignment of the EngineThe engine must be exactly aligned with the propeller shaft in the proper fashion No matter what materialis used to build a boat the material will be found to be flexible to some extent hence the boats hull willchange its shape to a greater extent than is usually realized when the boat is launched and operated in thewater Therefore it becomes extremely important to check the engines alignment at frequent intervals andto 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 me 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 seal If oil is leaking from this seal check and make sure that thecouplings alignment is within the limits prescribed on page 25 Never attempt a final alignment with the boa on land The boat should be in the water and have had an op portunity to assume its final water form The best lime to perform 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 Westerbeke Diesel Engines 24Take plenty of time in making this alignment and do not besatisfied with anything less than perfect resultsThe alignment is correct when the shaft can be easily B93 FEELER GAGEslipped backward and forward into the counterbore andwhen a feeler gauge indicates that the flanges cometogether at all points The alignment between the propeller PROPELLER SHAFTshaft coupling and the engines coupling can contain anerror no greater than one thousandth of an inch per inch ofthe coupling diameter For example if your propeller shaftcoupling is three inches in diameter the maximum errorthat can be allowed in the alignment is three thousandthsof an inch 003In making the final check for alignment theengines half coupling should be held in oneposition and the alignment with the tested with the propeller coupling ineach of four 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 dimension A while in each 90 position until the halfcoupling has been rotated full circleThe engines alignment should be recheckedafter the boat has been in service for one tothree weeks and if necessary perform thealignment again Usually it will be found thatthe engine is no longer in alignment This doesnot mean that the work has been done improperly at first rather it means that the boathas taken some time to take its final shape andthat the engines bed and stringers haveprobably absorbed some moisture It mayeven be necessary to realign the coupling halves again at a later time 25 Westerbeke Diesel EnginesExhaust SystemThe exhaust system provides an outlet line to vent engine exhaust gases out 01 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 Theexhaust 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 theexhaust through the circuits throughhull discharge port If not prevented sea water entering through thedischarge 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 lop 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 HGINEaboye Wgttr line l LD INSULAT E 1 LD 4B MAX ELBOW NINIMU OF 6 INCHES ABOVE VESSELS WATER LINE ENGINEbelow water line HYDROHUSH J SrPItOH EAK IART If 33327 CAIJIION Vented loop Must be in a location where it will remin bove the water line during all angles of vessel ENGINE INSTALLATIONS WITH EXHAUST MANI operation FOLDWATER INJECTED ELBOW AT OR BELOW VESSELS WATER LINEThe sea water supply throughhull sea cock fittings must be of the flushhull type Highspeed scoop typeof fittings should nol 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 ligures shown above for recommended exhaust system Diesel Engines 26Exhaust exhaust discharge hose must be of adequate size and minimal run to prevent excessive exhaust backpressure should be checked before the engine is put into Refer to the illustration Excessive backpressure will affect the engines performanceTo measure for backpressure use a mercury manometer a pressure gauge or a water column A boatyard or marine mechanic Exhaustshould have a manometer or a pressure gaugeMeasure backpressure at the exhaust elbow when the engine is Elbow running at 3600 rpm Backpressure as measured by a 2 a pressure gauge or water column should not be over the specifications listed below I Mercury NOTE Other pressure gauges may be available to test for Manometer exhaust baCkpressure Check with a competent mechanicA water column can be made by taking a clear plastic tube andtaping one end of the tube along a yardstick and fitting the otherend of the tube with a 14 inch NPT National Pipe Tap pipe fittingMeasure backpressure at the exhaust elbow when the engine isrunning at 3600 rpmDimension A cannot exceed 39 inches of as measured by a gauge instrument should notexceed the following 3 inches 01 mercury 0104 kgcm 2 39 inches 01 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 heat 21 Westerbeke Diesel EnginesExhaust 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 surtace 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 manifold should not exceed 8 Ibs in total weight when rigidly connected Excessive weight and vibration can result in a manifold failure andor the fracturing of the riser fromthe manifold at its 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 within the exhaustpipe 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 o Dizziness o Vomiting o Intense 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 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 make sure there is no deterioration of the insulation Westerbeke Diesel Engines 28Exhaust Elbow Westerbeke Corporation offers a 45and 900 exhaustelbow as well as an exhaust riser you can install on yourpropulsion engine Refer to the instructions below wheninstalling the exhaust elbow purchased for your engine1 Coat only one side of the exhaust gasket with High Tack adhesive sealant Place this coated surface against the exhaust manifolds exhaust port flange the gasket should stick to the flange without falling off2 Place the clamp over the elbows flange Place your ex haust elbow against the exhaust manifolds flange so the exhaust manifolds flange rests snug against the ex haust elbows flange with the gasket centered between the two Now slip the exhaust clamp over both flanges CLAMP 45 ELBOW3 A Tighten the clamp just enough so the exhaust elbow can remain attached to the manifold and still be rotated B The exhaust elbow discharge must be directed downward so the mixture of sea water and exhaust gases will flowfall downward into the exhaust muf fler which must be positioned below the exhaust elbow There should be no loops or rises in the ex haust hose connected between the exhaust elbow and the muffler as these would trap water and pos sibly allow water to flow back into the engine during ClAMP starting or at shut down 90 ELBOW4 Adjust the elbow by rotating it until the desired align ment with the exhaust piping is acquired5 Carefully tighlen the clamp between 2 to 3 IbI or 24 to 35 Ibin or 02710 041 kgm CAUTION Approach the I Ibf torque limit with caution The clamps threads will break if more than I Ib tI is applied to lhe clamp6 When the engine is started for the first time with the new elbow check Ihis exhaust manifoldelbow connection for leaks II a leak exists correct it immediately EXHAUST RISER Manufactured by Permatex Company Brooklyn NY CLAMP 29 Weslerbeke Diesel EnginesOil Drain HoseAn oil sump drain hose is installed on the engine with the discharge end secured by a bracket at the front ofthe engine Oil may be drained from this hose by removing the cap and the discharge end of the hose fromthe support bracket and lowering the hose into a container The hose cap fitting is 14 inch NPT NationalPipe Tap and can be extended or have a pump added for easier removal of the old oil if 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 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 discharge 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 throughhull fitting using a wirereinforced hose between the throughhull fitting and the sea water pump The sea water should be a visualtype sea water strainer which will trap debris before reaches the sea water pump and theheat exchanger and then be delivered to the pump Hoses routed from the throughhull fitting to the strainerand to the sea water pump should be wirereinforced to prevent the hose from collapsing while the engineis running suction from the pump may collapse a nonreinforced hose The sea water strainer should bemounted at or below the water line to make sure the sea water line remains primed 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 Diesel Engines 30Automatic Alarm System High Water Temperature AlarmA high water temperature alarm buzzer has been supplied with the instrument panel If the engines freshwater coolant reaches 205 F 96 C a water temperature switch on the engine closes causing the alarmbuzzer to emit a continuous signal Refer to the DESCRIPTION OF INSTRUMENT PANELS section of thismanual for the location of the alarm in your engine panel page 35 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 PANELSsection of this manual for the location of the alarm in your engine panel page 35Sea Water Intake SystemMake sure the intake system sea water cooling system is in proper order Check that the hull inlet seacock and strainer are unobstructed Sea cocks and strainers should be at least one size greater than theinlet thread of the sea water pump The strainer should be of the type that may be withdrawn for cleaningwhile the vessel is at sea and should be mounted below the water line to ensure selfpriming Inspect thesea water lines to make sure there are no collapsed sections which would restrict water flow Make surethere are no air leaks at any of the SystemThe fuel system should be installed in such a manner as to allow the enginemounted fuel lift pump to maintain a positive inlet pressure to the injection pump under all operating condftions The minimum size of thefuel supply line and fuel return line is 14 inch inside diameter and there shOUld be a primary fuel filter installed between the fuel tank and the fuel lift pump Only one fuel filter is installed on the engine betweenthe mechanical fuel lift pump and the injection pump this Iilter has a replaceable filter elementThe fuel tanks fuel pickup tube should be clear and unobstructed No screens 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 fittingsare 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 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 the pickup tube otherwise fuel siphoning out of the enginesfuel system through the return will take place 31 Westerbeke Diesel EnginesMake sure the fuel tank filler is properly sealed to prevent water entry should it 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 SystemThe electrical system should be checked to make sure all wiring harnesses are tied down properly withclamps or plastic ties spaced at intervals close enough to prevent chafing from vibration Check to makesure all the engines harness connections are tight and that they are made 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 When servicing the battery or checking the electrolyte level wear rubber gloves a rubber apron and eye protection Battery acid may inadvertently splash on skin or into eyes when removing electrolyte capsCheck level and specHic 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 heated air produced during engine operation and of potentially toxic andflammable diesel fumes Refer to the SYSTEM SPECIFICATIONS section of this manual for engine page 13 for the W 35B page 16 for the W 38B and page 19 for the W 42BWeslerbeke Diesel Engines 32 PREPARATION FOR STARTINGThis section of the manual provides the operator wtth 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 your engine with oil up to or near the upper limn on thedipstick the installation angle may have an effect on thedipstick reading Select readily available lubricating oil withan API specification of CC or CD and an SAE number suitablefor the temperature in your operating area see page 60 Forthe quantity 01 oil needed in your engine refer to the SYS UPPER LIMITTEM SPECIFICATION section 01 this manual page 13 for the HORMRL LEVELW 35B page 16 lorthe W 38B and page 19 for the W 42B LOWER LIMITFill the JS transmission to the FULL mark on the dipstick withthe correct lubricant The JS transmission takes 1 US qt or1 liter of oil Refer 10 your engines SYSTEM SPECIFICATION section of this manual lor a listing of oil grades to beused in this engineEach unit is supplied with a coolant recovery kit 24977 as standard equipment to which the following applies A Remove the pressure cap from the engines exhaust manifold and slowly fill the engines COOling sys tem with a mixture of water and antifreeze suitable for your temperature zone See the COOLING SYS TEM section 01 this manual page 53 Operate the engine and observe the coolant level in the manifold Maintain this level to the base 01 the Iiller neck Once the engine reaches its operating temperature 170 190 F make sure there is coolant flow to the domestic water heaters when installed Top off the cool ing system and Instalilha pressure cap 8 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 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 after the engines operating temperature has been reached to make sure all air is expelled from the manifold and the engines cool ing 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 lank with a good grade of NO2 diesel fuel and prime the fuel system up to the engine see page44 When returning fuel is free 01 air the engines fuel system is bled and the engine is ready to start NOTE When the PREHEAT switch is depressed the glow plugs in the cylinder head are ener gized use the PREHEAT switch intermittently to prevent overheating the glow plugsMake sure the Installation Checks have been made in accordance with those specified in the INSTALLATION CHECKS section 01 this manual refer to page 21 33 Westerbeke Diesel of Starting diesel engines use electric starters assisted by glow plugs for both normal and cold The figure below shows a crosssectional view of one cylinder The glow plug is located in the combustion chamber so that its tip is in the injector nozzles spray path When the glow plug is energized by thePREHEAT button the plug glows red at the tip and assists in igniting the fuel The result is a rapid start withless wear on the starterThis system is common to Westerbeke Diesels The start cirCUITry is designed so that the PREHEAT buttonmust be depressed for the time specified in the Preheat chart shown on page 39 Then while keeping thePREHEAT 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 Diesel Engines 34 DESCRIPTION OF INSTRUMENT offers two types of control panels as optional equipment for the W 35B the W 38B and the W42B engines Read the following instructions that apply to the panel you purchased with your engine Captains Captains Panel is equipped with a Key Switch an RPM gauge a PREHEAT andSTART button and an instrument test button along with a low oil pressurehigh water temperature alarmThe RPM gauge is illuminated when the key switch is turned ON and remains illuminated while the engine isin operation The key switch and the three buttons serve the following functions 1 Key Switch The Key Switch provides power only to the instrument panel cluster Refer to the STOP PING PROCEDURE section of this manual page 41 2 PREHEAT The PREHEAT button energizes the alternators regulator the engines glow plugs and bypasses the engines oil pressure alarm switch In addition this button energizes the START button 3 START 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 4 Test Button The Test Button located above the Key Switch tests the alternator the oil pressure and the water temperature control circuits When this button is pressed the alternator the oil pressure and the water temperature indicator lights illuminate in addttion to sounding the alarm 35 Weslerbeke Diesel Engines 5 Alarm The alarm is located above the test button and will sound if the engines oil pressure falls below 15 psi In this event the alarm will emit a pulsating signal The alarm will also sound if the watertempera ture in the fresh water cooling circuit rises to 210 F In this event the alarm will emit continuous sig nal6 Water Temperature Gauge This gauge is graduated in degrees Fahrenheit and is illuminated while the Key Switch is turned ON The engines normal operating temperature is 170 190 F 77 88C7 Oil Pressure Gauge This gauge is graduated in pounds per square inch PSI and is illuminated while the Key Switch is turned ON The engines normal operating oil pressure ranges between 30 60 PSI NOTE When the engine is manually shut down and the engines Key Switch 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 The oil pressure gauge will fall to zero when the engine is manually shut downWesterbeke Diesel Engines 36 Admirals Admirals Panel is equipped with a Key Switch and an RPM gauge with an ELAPSEDTIME meter which measures the engines running time in HOURS and in 110 hours The panel also includesa water temperature gauge which indicates water temperature in degrees Fahrenheit WATER 0 F an oilpressure gauge which measures the engines oil pressure in pounds per square inch OIL PSI and a DCcontrol circuit voltage gauge which measures the systems voltage VOLTS All gauges are illuminated whenthe key switch is turned ON and remain illuminated while the engine is in operation The panel also containstwo 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 41 2 PREHEAT The PREHEAT button activates the alternators exciter the engines glow plugs and bypas ses the engines protective oil pressure switch In addition this button is 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 time 37 Westerbeke Diesel Engines 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 har ness 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 psi5 Water Temperature Gauge This gauge is graduated in degrees Fahrenheit and is illuminated while the Key Switch 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 Key Switch is turned ON The engines normal operating oil pressure ranges between 30 60 PSI NOTE When the engine is manually shut down and the engines Key Switch 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 The oil pressure gauge will fall to zero when the engine is manually shut downWesterbeke Diesel Engines 38 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 Key Switch to the ON position 2 oclock 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 41 F 5 C to 23 F 5 C Approx 20 sec 23 F 5 C or lower Approx 30 sec Limit of continuous use 30 seconds before crankingProper glow plug function is indicated by a voltmeter dropwhen the PREHEAT switch is depressed This drop will beslight but discernible If no voltage drop is noted it may indicate defective glow plugs or a faulty preheat circuit check forloose holding the PREHEAT button depressed depress theSTART button The starter motor will run thereby cranking theengine As soon as the engine runs release the START buttonand PREHEAT button Check your for properengine operation Make sure sea water discharges with the exhaust the engine not start when the START button isdepressed for 10 to 12 seconds release both buttons and wait30 seconds repeat the previous procedure Never run thestarter motor for more than 30 seconds at a time CAUTION Prolonged cranking inlervals 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 01 the exhaust manifold once the exhaust system fills Prevent Ihis from happening by closing the sea water supply throughhull shutoil drain the exhaust muffler and correct the cause for the excessive engine cranking needed 10 obtain a start Engine damage resulting from this type of sea water entry is not a warrantable issue Ihe owneroperator should keep this in mind 39 Westerbeke Diesel EnginesOnce the engine starts run tt at idle for a few minutes to warm up the engine and check instruments forproper oil pressure and battery charging voltage Never attempt to engage the starter while the engine isrunning NOTE Some unstable running may occur in a cold engine but this condition should smooth out as the operating temperature of 130 150 F 55 66 C is reached 0 0 Westerbeke Diesel Engines 40 STOPPING PROCEDURESA manual pull type stop control tee handle or knob is provided by the installer in a location close to theengines controls Know the location of this control before attempting to start the engine To stop the engine pull out on this tee handle or knob fully and hold it out until the engine comes to a complete stop Pushback on this control to return it to the engine run position otherwise the engine will not restartWith the engine stopped turn the Key Switch to the OFF position 12 oclock If the Key Switch is left ONthe battery will discharge The alarm buzzer will sound in the Admirals Panel but not in the Captains Panelshould the Key Switch be left ON The best method of preventing the battery from discharge is to removethe 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 OFFAn optional key shutoff package is available however This option allows the operator to shutoff the engine by turning the Key Switch OFF which turns OFF an electrically run Fuel Run Solenoid This option is installed at the factory upon the specffic requestorder of the BreakIn your engine has experienced a minimum of one hour of test operations to make sure accurate assembly procedures were followed and that the engine operated properly a breakin time is required Theservice life of your engine is dependent upon how the engine is operated and serviced during its initial hoursof 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 39 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 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 that is operating the engine with 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 speed Avoid idling the engine for prolonged periods of time 41 Westerbeke Diesel 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 resultsAs 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 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 section of this manual page 33 4 Check for oil and fuel leaks particularly Hsigns of such leaks are found on the bottom of the engine or below the engineStart the engine in accordance with the STARTING PROCEDURE instructions found on page 39 and allowthe engines operating temperature to reach 140 150 F before operating the engine 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 60 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 OFTHE INTAKE AIR IS LOW AND THE COMPRESSION TEMPERATURE DOES NOTRISE ENOUGH Allow the glow plugs to operate sufficiently to aid in starting during the preheat period whenever the temperature of the intake air is low and when the compression temperature does not rise enoughRefer to the preheat chart found in the STARTING PROCEDURE section page 39Westerbeke Diesel Engines 42 FUEL SYSTEMDiesel FuelUse No2 diesel fuel with a cetane rating of 45 or higher Never use kerosene or home heating oil sincethese fuels do not have the same lubricating properties as No2 diesel fuelIn cold weather particularly water vapor is produced by condensation when air is present in the fuel tankKeep fuel tanks full and completely free of dirt and waterFuel FillersA primary fuel filter of the water entrapmenttype must be installed between the fuel XNSTRLLRTION and the engine A primary fuel filter L BOLT SEDIEHTfA1ER TRAP SHURELl TO HOSE FITTING RII ACCESSIBLE STRUCTUII SO here is available from your local TIIU 1 RECEITICL Tn CATCH DRAINAGE CAM BE PUtED IIMOER IIWesterbeke representative or your boatbuilder This filter adapted for boatbuilder 2 IF FUEL IS TO BE IIIIED nTH COPPER 011 BUMD IUBUS USE NUTS AMD FUULESuse comes complete with fittings for either PRaUIDED BE SUlIE THE HIllING PROJECTS 114 IlCH THROUIIH THE FERRULE BEFIUhose or metal tubing Mount tt in an acces TlSHTEMING TNE HUtsible place inspect tt often and drain off 3 If FUEl IS Til BE PIPU mil HOSE USEwater accumulation frequently THE TMD BRASS BARBED FIITIIiSS AWO WASHERS SUPPLIED SE CERIAU IHAI THE HOSE SElEtlED HAS IIUGOMAL BRAID INSERTED no CLUG ON lHE BARB TIIRT IT IS NDPREIIE LINED AMO THRTIf a water trap type filter is not installed be IT IS gl APPRDIlDtween the fuel tank and the engine 4 IF ATR IS lRESEMT IN THE FUEL IT Ullmounted fuel system any water in the fuel ClltlECT StDtV III THE BOTTCH or THsystem will tend to lay in the bottom of the SEllINEMTER 1I11EN TilE REO HOAT RIMS UERCHU THE ORAIN LIIiE 011 THE PLWICelectric lift pump Internal metal parts of the BOWL l005EK THE BonUM DIIAU PlUS UNTIL ALL ArEA RUNS OUTlift pump will rust Particles will pass on to 6 lUHlEN ORRIN PLUI SECURELY SO O An CAWfilters and eventually to the injection pump ENlER THE SUrEand injectors wtth damaging results and 6 HUGI2E THE rUEL PUMP TO RErILL TilEthe possibility of expensive repairs 901fLRemember water damage to the fuel system is not covered under the addttion any gasoline in the fuel systemwill damage the engines fuel injection pump assembly and injectors as gasoline does not have the qualtties 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 43 Westerbeke Diesel EnginesPriming the Fuel SystemThe Westerbeke selfbleeding fuel system is semiautomatic in operation The selfbleeding feature of the fuelsystem allows for easy servicing 01 the fuel filters Simply remove the and replace the filter elements takecare in catching any fuel that may drain out 01 the fuel filtering assemblies as described In the Replacingthe Fuel Filter Elements section below Energize the PREHEAT switch and allow the electric fuel pump tooperate for 20 to 30 seconds to prime and bleed air from the system No fittings should be opened Thenproceed to start the engine as you normally would If the engine does not start stop and wait a few moments and then repeat the bleed procedure as indicated above When the PREHEAT SWITch is depressedthe preheat elements the glow plugs are energized so take care not to over heat them 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 01 the exhaust manifold once the exhaust system Iills Prevent this irom 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 II slart Engine damage resulting from this type of sea water entry is nol II warrantable issue the owneroperator should keep this in mindReplacing the Fuel Filler ElementsWhile it is unlikely that the operator will be forced to service the system at sea the possibility does existTherefore it is recommended that banjo washers injector seat washers electric lift pump filter and gasketfuel filter and gasket be carried on board at all times Select the parts for your engine from the Parts List andpurchase spares from your local Westerbeke Dealer orDistributor For example hardware kit 33093 includes replacement elements with gaskets items 68 20 21 If a leak should develop at a fuel banjo orsealing washer location that cannot be remedied by aslight tightening of the filter cup retainer replace the filter along with the Orings supplied with the new filterAfter the first 50 hours of operation loosen retainer ring 23 and discard filter element 21 Clean bowl 22and install a new filter using a new 20 gasket Be careful to catch any fuel that may spill from within these Ifuel filter assemblies This same service is required of the 6 filter element in the electric fuel lift pumpSimilarly install a new 6 filter element along with anew 8 gasket The base of the electric fuel pump isremoved with the aid of an open end wrench Twist the base off the pumps locking tabs and reinstall the baseby twisting it back on the locking tabs Place thewrench on the hex nut cast into the base IAfter the first 50hour change the change period maybe increased to 200 hours or once per Diesel Engines 44Fuel Injection PumpThe illustration below shows the W 356 THREEs fuel system The W 386 FOUR and W 426 FOURs fuelsystem differ in that they have an additional fuel Injector and injector pump plunger The fuel injection pumplocated to the right is one of the most important components of the diesel engine and therefore calls forthe utmost caution in handling Furthermore the fuel injection pump has been thoroughly benchtested andshould 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 shop FUEL INJECTORS ElECTRIC FUEL LIFT PUMP FUEL PUMP FILTER THROTTLE INJECTION PUMP OIL PUMP OIL FILTER Fuel Injection SystemTo 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 engine Service thissystem regularly the injection pump it saves will be your own 45 Westerbeke Diesel Engines ELECTRICAL SYSTEMEngine 12Volt DC Control CircuitThe Westerbeke 35B 38B and 42B propulsion engines have a 12Volt DC electrical control circuit as shownon the wiring diagrams which follow on pages 48 to 51 Refer to these diagrams when orservicing 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 engine electrical circuitBattery minimum recommended capacity of the battery used in the engines 12Volt DC control circuit is 90 125 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 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 When cleaning the engine with a steam cleaner be careful to keep steam away from the al ternatorRefer to pages 48 to 51 for the two electrical system wiring schematics one is used for the Captains paneland the other for the Admirals Diesel Engines 46The charging system consists of an alternator with an internal voltage regulator an enginemounted circuitbreaker a battery and connecting wiresBecause of the use of ICs integrated circuits the electronic voltage regulator is very compact and is builtinto 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 Al TERNATOR 135 n 40 A 50 Al il I I I for Charging Voltage Test1 Using a voltmeter connect the voltmeters red wire clip to the B output terminal on the alternator Refer to the schematic shown above2 Connect the other wire clip to a ground on the engine3 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 it replaced or rebuilt by a reliable service shop Note Before removing the alternator for repair make sure 12Volts excitation is present at the R terminal should the above test show only battery voltage at the B output terminal 47 Westerbeke Diesel Engines Captains Panel DC Control Circuit Wiring Diagram 36467 page 1 of 2 DIAGRAM GLOWLUGS WATER TEMP ATER TEMP lO6 tI il SENDER SWITCH OfPD 01 1llP loTIONAL NU aEIOI T ST iNDERS PAtU CIRCUIT l 1 0 PflEHEh 1 SOLENOtO r o 1 rioll Gj Q 0 Q i ilIJi 0 f lQ Q J1 i I I I fT tir 0 SO 8 OP cuE 1 r 15 TEST SwiTCH STIlRT ILSe Ifli Ir ro I L Apl 14 I I I 48 I E PREHEAT LAtPt W T 4sUr TACHOMETER I I SITCH 18 Bl I Gc I I BBL I I oSL I Westerbeke Diesel Engines 48Captains Panel DC Control Circuit Wiring Diagram 36467 page 2 of 2 r 2VOC SCHEMATIC CB IQA 1 hi X n 5TIIOIT SWTCH n Go ALARM START ITURN KEY TO ON POSITION THE ALARt WILL SOUNDOIL PRESSURE NO BATTERY CHARGE INQICATORS HILL LIGHT 2PUSH pqEHEAT SWITCH FOR 15 TO 50 SECONDS AS REQUIRED ALARM WILL STOP 3WHILE CONTINUING TO PUSH PREHEAT SWITCHPUSH THE START SWITCH ALSO IrlEN THE ENGINE STAins gElEASE THE START SWITCH ONLY lWHEN THE OIL PRESSURE INDICATOR LAMP GOEs our RELEASE THE PREHEAT SWITCH STOP TURN THE KEY TO THE OFF POSITION I THIS PRODUCT IS PROTECTED a A MANUAL RESET CIRCUIT BREAKER LOCATED EAR THE CURRENT DRAIN WILL CAUSE THE BREAKER TO 7RIf AND THE ENGINE WILL SHUT OOiN THE BUILDEReWNE MUST 8E SURE THAT THE ICiSTHUMENT PANElWIRING AND ENGINE IRE INSTALLED TO PREVENT CONTACT BETWEEJ ELECTRICAL DEVICES AND SALTWATER 2AN ONOFF SWITCH SHOULD BE INSTALLEO BETIEEN THE BATTEA AND STARTER TO DISCONNECT THE BATTER IN AN EMERGENCY AND WHEN LEAVING THE EOAT A SWITCH WITH A CONTIlUOUS RATING OF 17AMPS AT 12VDC WILLSERVE THIS FUNCTION THIS SWITCH SHOULD NOT 8E USED TO MAKE 0R BREAK TH CIRCUIT PINK WIRE AT PLUG 2 IS UNUSEf AND SHOULD BE ItISULATEiJ 49 Westerbeke Diesel Engines Admirals Panel DC Control Circuil Wiring Diagram 36844 page 1012 ALTERNATOR CORED rt cAl JFs CRCUITn AR r C EAKER I ccccJilIF LT BLUE L I 1 PREHEAT SOLENOID D It r7j n M1 14LTBLUe I I I wi I RED lil I SSUREHtr tJt jT Ic 1 IUrRDDELSI IJ UDD rPJ E2 C STARTER I CIRCUIT I BREAKER 0 J 20 A c 1m II iRE I III i r l GROUND TO ENGINE BLOCK I 1 OIL 3 1 USED IN SOME GRONO TO I 1 ENGINE BLOCK t ill NEUTRAL SAFETY SWITCH USED ON SOME I I PUMP r LMDDEI irt1 BAITYI 12VDC w 1 1 i z il I D It D c 52 6 C 0 1 1 o I I jJ 1 J c Ill I 16 1lmi3 3 It It It 111 it 1 11 1l1i J FJE3l U jJ RTi I F ALARM BUZZER I I I T ilI I I I OIL PRESS WATERTE GAUGE GAUGE I I NI e 21E II I IYEL 1 I I 1 I I I I I IGRN cJGt V Gl II I W 0 14GRN cco I I Z i lJiTART PREHEAT KEY SWITCH SWITCH SWITCH VOLTMETER oel IWesterbeke Diesel Engines 50 Admirals Panel DC Control Circuit Wiring Diagram 36844 page 2 of 2 SCHEMATIC DIAGRAM NEUTRA Isw T 1 11 I 11 PI 11 I 1KEY W r sw I I eo p ALARM I I PREHEAT WNOTE1 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 SALT WATER2 AN ONOFF SWITCH SHOULD BE INSTALLED BETWEEN THE BATTERY AND STARTER TO 015 CDNNECTTHE BATTERY IN AN EMEAGENCYANO 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 CIRCUIT3 THE GRAY WIRE AT PLUG 21S UNUSED AND SHOULD BE INSULATED 51 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 its 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 it 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 circuits are independent ofeach other Using only fresh water within the engine allows the cooling water passages to stay clean andfree from harmful deposits The two independent circuits and their components are discussed in the follow ing 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 systemFresh water is pumped through the engine by a beltdriven circulating pump absorbing heat from the engine The fresh water coolant circulates through the engines block absorbing heat then passes throughthe thermostat into the exhaust manifold to the heat exchanger where it is cooled and then is returned tothe engine block through the suction side of the fresh water circulating pump When the engine is startedcold external fresh water flow is prevented by the closed thermostat although some fresh water flow isbypassed around the thermostat to prevent exhaust manifold from overheating As the engine warms upthe thermostat gradually opens allowing full flow of the engines fresh water coolant to flow unrestricted tothe external portion of the cooling system A Fresh Water Coolant Antifreeze MixtureA freshwater and antifreeze mixture should be used yearround in the cooling system Water when it freezesexpands sufficiently to split the heat exchanger and crack the engine block A waterantWreeze mixture ofproper concentration will prevent freezing see page 53 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 Alwaysuse antrrreeze which is compatible wah 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 for year round use is ZEREX or PRESTONE with rust inhiMorsIn order to control the concentration of the mixture mix the antifreeze and freshwater thoroughly before adding it to the cooling Diesel Engines 52 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 wtth each Westerbeke diesel engine The purpose of this recoverytank is to allow lor 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 30inch 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 FUNCTION OF MANIFOLD PRESSURE CAP From Coolant Tank COOLANT RETRACTION to Coolant Tank COOLANT from the engine when heated during engine operation will expand lifting the springloaded cap and enter the recovery tank by way of the hose connecting the recovery tank to the manifoldWhen the engine is shut down and cools a small check valve in the pressure cap is opened by the contraction olthe engine coolant allowing some of the coolant in the recovery tank to be drawn back into the enginescooling system Iree of air and without loss Periodically check that the passage A between the 90 littingon the manifold and the filler neck in the manifold is clear so coolant can flow in either direction 53 Westerbeke Diesel Engines COOLANT RECOIIERY TAI 1 i I 1 I 1 I 1 1I Coolant Recovery Tank Recommended the fresh water system as follows1 Remove the pressure cap from the manifold2 Pour a clean antifreeze mixture into the manifold and allow enough time for the coolant to fill the fresh water cooling system3 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 cap4 Remove the plastic cap from the plastic coolant recovery tank and fill the tank with coolant halfway be tween the ADD mark and the MAX mark Replace the plastic cap5 Run the engine and observe the coolants expansion flow into the plastic recovery tank6 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 down7 Add coolant to the recovery tank as required to top off the fresh water coolant 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 of the thermostat which moves downward to close off an internal bypass passage within thehead Since 1980 each type of thermostat has a hole punched through it The hole is a bypass to preventthe exhaust manifold from overheating during the engines warmup Replacement thermostats must havethis design Diesel Engines 54Sea Waler CircuitThe sea water flow is created by a beldriven positive displacement neoprene impeller pump The pump draws seawater directly from the ocean through the sea cock and sea water strainer and pas ses the water to the heat exchangers seawater inlet The sea water passes throughthe heat exchangers lUbes from which i heat from the fresh water system is absorbed and then the sea water is discharged from the cooling through the waterinjected wetexhaust system Be sure to clean zinc CLEAN NEW ORdebris from the area inside of the heat ex ANODE REPLACE REPLACE REPLACEchanger where the zinc anode is positioned Zinc Anode CondttionsA zinc anode or pencil is located in the sea water cooling circuit within the heat exchanger The purposeof the zinc anode is to sacrifice itsell to electrolysis action taking place in the sea water cooling circuit thereby reducing the effects of electrolysis on other components of the system The condition of the zinc anodeshould be checked monthly and the anode cleaned or replaced as required Spare anodes should be carried on boardSea 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 make sure seawaler flow is present at and Waler Pump Drive Bel Tension IWARNING 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 lile of the fresh water pump and alternator shaft bearings Excessive slack or the presence 01 oil on the belt can cause belt slipping resulting in high operating tempera ture as well as insufficient alternator output 55 Weslerbeke Diesel EnginesThe alternator and water pump drive belts isare properly adjusted Wthe 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 belt shouldbe carried on board Alternator and Water Pump Selt Diesel Engines 56Illustrated below is a typical Westerbeke engines cooling system Both fresh water and sea water flowthrough their independent cooling circutts Refer to your engines Parts List for part numbers and if you need to order cooling system parts for your engine NOTE When the remote expansion tank 24177 is used the plastic coolant recovery tank should be removed and discarded and its connection point on the exhaust manifold plugged with a 18 NPT fitting WATER INJECTED ELBOW EXHAUST WATER COOLANT RECOVERY TANK HEAT CONTROllER OVERHEAT ALARM FRESH WATER PUMP f IMCOMING SEA VATER Typical Cooling System 57 Westerbeke Diesel Hoi WaterAll engine covered in this manual areequipped with a domestic hot water connection If the owneroperator wishes toconnect a hot water heater remove thebypass hose and connect a heater asdescribed in the instructions With the bypass hose Part 30962 removed there remain two connecting points A and e for hoses to run toand from the water heater These connections assure a How of hot water throughthe heater at all times but do not effect theflow of coolant through the engine Flow The heater should be mounted conveniently either in a high or low position in relation to theengine so that the connecting hoses from the heater to the engine can run in a reasonably direct line withoutany loops which might trap air Connection point A on the Flow Control housing should connect to the lowerof the two connections on the water heater while the upper connection on the heater returns to connectione nearest to the heat exchanger REMOTE EXPRNSION TRNK PRESSURE CAP IS RATED LOWER THRN MANIFOLD CAP HEATER COILS ABOVE PRESSURE CRP ON ENGINE MANIFOLD HEATER COILS BELOW REMOVE RETURN BEND FROM PRESSURE CAP ON ENGINE ENGINE fLOW CONTROLLER MANIFOLD A AIR BLEED PET COCK HEATER BELOW ENGINE HEATER ABOVE ENGINEThe illustrations shown above are Flow Control designs that have been adapted to operate with the singlepass manifolds installed on the W 358 the W 388 and the W 428 Diesel Engines 58Hoses should rise continuously from their low point at the heater to the engine so that trapped air will risenaturally from the heater to the engine If trapped air is able rise to the heater then an air bleed petcock mustbe installed at the higher fitting on the heater for bleeding air while filling the system Avoid loops in hoseruns which will trap air Note If any portion of the heating circuit rises above the engines own pressure cap then a pressurized aluminum remote expansion tank must be installed in the circuit to become the highest point The remote expansion tanks part number is 24177 Install the remote expan sion tank in a convenient location such as in a sail locker so the fresh water coolant level can easily be c hec kedThe cap on the engine mounted expansion tank should not be opened once the remote system is installedand filledThe hose connection from the heater to the remote expansion tank should be routed and supported so asto rise continuously from the heater to the lank enabling any air in the system to riseRefer to the illustrations on the previous page 59 Westerbeke Diesel Engines LUBRICATION SYSTEMEngine OilFor engine lubrication use lubricating oil designated for diesel service These oils are classified accordingto the API specifications into service grades CA CB CC and CD The use of CC or higher CD gradesmade by 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 10W30 41 F 5 C 68 F 20 C SAE 20 or 10W30 41 F5 C or lower SAE 10W30 NOTE Do not use an engine lubricating oil with an SAE number greater than 30 in the en gineOil PressureThe engines oil pressure during operation is indicated by the oil pressure gauge on the Admirals Panelsee page 37During normal operation the oil pressure will range between 35 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 Diesel Engines 60Engine Oil Change to include IiIter1 Draining the Oil SumpRemove the oil drain hose from its attachment bracket and lower it into a container and allow the oil todrain or attach a pump to the end of the drain hoseand pump the old oil out Make sure the oil drain hoseis properly secured in its holder after all of the old oilhas been drainedAlways 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 theoil Sea water present in the oil can be the result of afault in the exhaust system attached to the engineandor a siphoning through the sea water cooling circuit into the exhaust filling it up into the engine referto the installation illustrations on page 262 Replacement of the Oil FilterWhen removing the used oil filter you may find it helpful and cleaner to punch a hole in the upper and lowerportion of the old filter to drain the oil from it into acontainer before removing it This helps to lessenspillage A small style automotive filter wrenchshould be helpful in removing the old oil filter Placesome paper towels and a plastic bag around the filter when unscrewing it to catch any oil left in the filter Oil or any other fluid on the engine reduces the engines cooling ability Please keep your engine clean Inspect the old oil filter as it is removed to make sure that the rubber sealing gasket came offwith the old oil filter If this rubber sealing gasket remains sealed against the engine block gently remove it The replaceable cartridgetype oil filter re quires no cleaning inside so it may be properly dis posed ofWhen installing the new oil filter element wipe the filter gaskets sealing surface on the engine block free ofoil and apply a thin coat of clean engine oil to the rubber gasket on the oil filter Screw the filter onto thethreaded oil filter stub and then tighten the filter firmly by hand NOTE Generic filters are not recommended as the material standards or diameters of im portant items on generic parts might be entirely different from genuine parts Immediately after an oil filter change and oil fill run the engine to make sure the oil pressure is normal and that there are no oil leaks around the new oil filter Westerbeke Diesel Engines3 Filling the Oil SumpAdd fresh oil through the oil filler cap on the valve coverrefer to the photographs on pages 6 and 7 for the W Oil Filler Cap35B pages 8 and 9 for the W 38B and pages 10 and 11 Rocker overfor the W 42B for the location olthe oil filler cap and lubeoil dipstick After refilling the oil run the engine for afew moments while checking the engines oil pressureMake sure there is no leakage around the new oil filteror from the oil drain system and then stop the engineThen check the quanttty of oil wtth the lube oil dipstick Oil DipstickFill to but not over the high mark on the dipstick shouldthe engine require additional oil Upper Liit INor l Levelfl l 0 il Lii tr Diesel Engines 62 JS TRANSMISSION transmissions gear ratio is 247 to 1 The JS transmission is made of a lightweight highstrength aluminum alloy suitable for the marine environment This manual transmission rotates opposite to the engine when in forward gear The JS transmits its power with casehardened helical gears andin reverse an intermediate gear The reversing process is carried out by a servo double disc system Forsafety reasons the transmission is NOT filled with lubricating oil lor shipment Before leaving the factoryhowever each transmission is thoroughly tested with oil in the transmission This testing among other thingsprovides all internal parts with a coating 01 oil This oil acts as a preservative providing reliable corrosion for at least one year if the transmission is property stored BEll flOIlSlltG GEAR BOX tOH1ROl LEVER OIL IlRAIH HOG Allen Wrench size is JS transmission is an type Fill the transmission up to or near the top of themachined notch cut on the dipstick with SAE 20 W20 or SAE 30 weight engine oil exclusively Multigradeoils are not to be used in this transmission DO NOT mix grades of oil Lubricating oils may have an of CC CD SC SO or SEThe oil capacity for the JS transmission is approximately 10 quart 10 liter Check the oil level daily afterthe engine has been warmed and stopped The oil level shOUld be maintained at the top of the machinedflat on the dipstick when the dipstick is completely inserted into the transmission housing Make sure thetwo Oring gaskets on the dipstick are in good shape These Orings will help keep the dipstick in placeChange the transmission oil after the lirst 30 hours 01 engine operation and thereafter every 250 hours oronce per year minimum The JS has a 6 mm Allen wrench drain plug for draining the old oil To make suremost of the old oil will drained from the transmission run the engine in NEUTRAL for approximately 10 to 15minutes so the oil may warm and flow better from the transmission This oil may also be removed by inserting a small tube through the dipstick opening where the oil is added and attaching a pump onto the tubeso the oil may be sucked out The operating oil temperature must not exceed 2500 F 120 0 C 63 Wasterbeke Diesel between the transmissions coupling and the propeller shafts coupling can create Make sure the alignment procedures outlined in the Propeller Shaft Coupling the Propeller and the Alignment of the Engine sections of this manual are followed pages 24 and 25ControlsThe only controls required to operate is a single lever remote controlcable The cable should be attached to thegear box lever using the cable bracket sup GEAR BOX SHIFT LEVERplied with the unit Both the gear box leverand the remote control lever must be in theNEUTRAL position when the cable is attached to the gear box lever This allows theremote cable an equal throw distance to shiftthe gear box into FORWARD or intoREVERSE from the NEUTRAL running out of cable Allow approximately 1 12 inches of cable throw fromthe NEUTRAL position on the transmissions gear box lever to the each of the two drive positions REVERSE fORIIARD NOTE lithe throw distance or travel NEUTRAL of the remote cable is too short the gear box lever cannot fully engage the transmission into FORWARD or REVERSE In this situation the transmissions internal clutches will wear prematurely and the transmis sion may not properly engage will over heat and eventually fail NOTE Excessive throw distance in the remote control lever is not detrimental to the transmission Note that the posi tion of the remote control lever should align with the NEUTRAL marking on its bracket when the transmission is real ly in NEUTRAL Weslerbeke Diesel Engines 64ShiftingTo 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 throw issignalled 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 1000 rpmor below CAUTION NEVER remove or loosen the twobolt gear box lever cover from transmission The position 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 OperationThe JS transmission should be left in NEUTRAL while sailing Leaving the transmission in NEUTRAL whilesailing alleviates unnecessary drag on the vessel because the propeller is able to freewheel spin Howeverto lock the propeller shaft and to prevent it from rotating place the transmission into FORWARD gearServiceIf any seal on the transmission shows signs of leaking have the transmission looked at by a qualnied Westerbeke Dealer This problem especially concerning the rear seal Is often attributed to an improper alignmentof the transmissions coupling and the propeller shafts coupling Refer to the Alignment of the Engine section of this manual page 24Never loosen the gear box lever cover screws except in the course of qualified servicing this upsets olthe transmission in the field is not recommended If an overhaul or repair is needed the workshould be done by Westerbeke or an authorized Westerbeke service JS transmission is sea watercooled Sea water enters the transmission through a stainless steel inletpipe located at the base of the bell housing This water helps to cool the transmissions lubricating oiL 65 Westerbeke Diesel Engines OPTIONAL TRANSMISSIONS HBW 100 150 150V Transmissions DIPSTICK FIll PORT DIPSTICKFIll PORT HBW 150V HBW 100 and 150 All HBW models turn right hand propellers All HBW models have their own oil sumps and dipsticks All HBW models use ATF lubricant All HBW models should be shifted into gear in one swift motion not allowed to slip in slowlyControl Of Gearbox 33G CABLE SHIFTING LEVER1 The gearbox is sui table for o A B single lever remote control using 33C cable j TRANSMISSION o CO2 The cable should attach at right angles to the actuating lever using the cable bracket supplied o o3 Both gear box lever and remote lever must be in neutral position when cable is attached so that travel of gearbox lever will be equal forward or reverse4 Check that actuating lever hub does not touch cover plate hub Maintain at least 05 mm 0002 clearance r5 Over travel of the actuating lever does no harm OSmm However if the travel is too short to give full Control of engagement premature wear excessive heat Gearbox generation and gear failure may result Westerbeke Diesel Engines 66 DIPSTICK6 The position of the cover plate underneath the actuating lever is factory adjusted to ensure TO CHECK OIL LEVEL equal lever travel from neutral TRANSMISSION IN OPERATION to A and B DO NOT LOOSEN THE CAPSCREWS HOLDING THIS ASSEMBLY Doing this voids transmission warranty VENT kc II I Ll I i 7 Fill gearbox with automatic I tr ansmission fluid to the level it indicated by the dipstick mark See the illustration to the right8 Note that to check oil level the dipstick drops on the FLUID LEVEL housing It does not screw in9 The HBW gear box can be free wheeled in Neutral To stop prope 11 er shaf t ro t a t 10n whl 1 e DRAIN PLUG under sail place the gear into Reverse Dipstick Oil Levels NOTE The transmission is vented through a small hole in the dipstick Keep this vent cleared Each engine model can be fitted with any of the transmissions listed below Transmission Gear Ratios HBW 100 151 21 251 HBW 150 151 21 251 HBW 150V 151 21 251 These transmissions each have their own oil sumps and dipsticks The HBW transmis sion uses Automatic Transmission Fluid ATF type A or Dextron II 67 Westerbeke Diesel Engines Warner Hydraulic Transmissions FROM COOLER 2101 ONLY SHIFT LEVER DIPSTICK ASSEMBLY FROM 10131014 COOLER FROM COOLER 1011018 EXCEPT 21011 CONTROL LEVER POSITIONThe position of the control lever on transmission when in forwardshould be shifted to the point where it covers the letter p on thecase casting and is located in its proper position by the poppetball The Warranty is cancelled if the shift lever poppet spr ingandor ball is permanently removed or if the the control lever ischanged in any manner or repositioned or if linkage between remotecontrol and transmission shift lever does not have sufficient travelin both directions This does not apply to transmissions equippedwith Warner Gear electrical shift control2 LUBRICATIONThe properties of the oil used in the transmission are to the proper function of the hydraulic system Thereforeit is extremely important that the recommended oil fluid ATF Type A or Dexron II be usedNOTE Be sure the cooler is properly installed when required andthe transmission contains oil before cranking or starting the engine Westerbeke Diesel Engines 68 Filling and Checking the Hydraulic SystemThe oil level should be maintained at the full mark on the dipstickCheck oil level prior to starting engine Check daily before startingengine The hydraulic circuit includes the transmission oil coolercooler lines and any gauge lines connected to the circuit Thecomplete hydr aulic circui t must be filled when filling and this requires purging the system of air before theoil level check can be made The air will be purged from the systemif the oil level is maintained above the pump suction opening whilethe engine is running at approximately 1500 RPM The presence of airbubbles on the dipstick indicates that the system has not been purgedof airNew applications or a problem installation should be checked to makesure the oil does not drain back into the transmission from the coolerand cooler lines Check the oil level for this drain back check after the engine has been shut off and again after theengine has been stopped for more than one hour overnight isexcellent A noticeable increase in the oil level after this waitingperiod indicates that the oil is draining from the cooler and coolerlines The external plumbing should be changed to prevent any drainback Starling the EngineMove the shift lever to the center position where the enters the chamfered hole in the side of the shift lever and properly locates lever in neutral position before starting engine ShiftingShifts from any selector position to any other selector position maybe made at any time and in any order if the engine speed is below 1000RPM however it is recommended that all shifts be made at the lowestfeasible engine speed Move the shift lever to the extreme where the spring loaded ball enters the chamfered hole in theside of the shift lever and properly locates lever in transmission shift lever to the extreme rearward position wherethe spr ingloaded ball enter s the chamfered hole in the side of theshift lever and properly locates it in the reverse position sail with the propeller turning or at trolling speeds with oneof two engines shut down the design of the gear maintains and lubrication Attempting to place the gear into forward orreverse while under sail to stop propeller shaft rotation will haveno effect TO stop propeller shaft rotation while under sail amechanical shaft brake would be needed 69 Westerbeke Diesel Engines Cooling ProblemsWater passages inside of the cooler will sometimes become clogged andthis will reduce cooling capacity and cause overpressur ing Backflushing of the cooler will sometimes help to flush the from the cooler passages The cooler and hose should bethoroughly flushed or replaced in the event a failure has particles from the failure tend to collect in the case of thecooler and gradually flow back into the lube system Replace oilcooler to prevent contamination of the new hoses may collapse and reduce or completely shut off all flow tothe cooler Collapsed hoses are usually caused by aging of the hosesor improper hose installation Hose installation should be made withno sharp bends Hoses should be routed so there is no possibility forengine shifting to cause hoses to pull loose or become pinched Avisual inspection of hoses while under way will sometimes allow detection of faulty hosesReduction or complete loss of water flow can be caused by a faultywater pump A rubber water pump impeller will sometimes fail andafter such a failure the cooler passages may be restricted by the particles of rubber from the failed impeller Water pump cavitation maybe caused by improper or faulty plumbing or an air leak on the inletside of the pump The water pump may not prime itself or may lose itsprime when inlet plumbing is not properly installedIt is possible for cross leaks to occur inside the cooler permittingoil to flow into the water or water flow into the oil fluid levels at each days use will help spot such a happening undetectable loss of fluid andor emulsified fluid Westerbeke Diesel Engines 70 Annual Checks1 PROPELLER AND OUTPUT SHAFT ALIGNMENT This check should also bemade any time the propeller strikes a heavy object and after any accident where the boat is stopped suddenly Shaft alignment should alsobe checked after the boat has been lifted by a hoist or moved on atrailer2 SHIFT LEVER POSITIONING The selector controls must position theshift lever exactly in F N and R selection positions with the ballpoppet centered in the shift lever hole for each position3 BOLT TORQUE Check all bolts for tightness4 COOLER CONNECTIONS Check water lines oil lines and connectionsfor leakage Make sure lines are securely fastened to CHANGING OIL A seasonal oil change is recommended in pleasureboats Work boats require more frequent changes Change oil any timethe oil becomes contaminated changes color or becomes rancidsmelling Automatic transmission fluids ATF Type A is recommendedfor use Daily Checks1 Check transmission oil level2 Check for any signs of oil leakage in the bellhousing at gasket sealing surfaces or at the output shaft oil seal3 A quick visual check of the general condition of the equipment may cause faulty equipment to be detected4 Listen for any unusual noises and investigate to determine the cause of any such noises Note Low engine idle speed can produce drive damper chatter Winter Checks Drain water from transmission oil cooler This will prevent freezing in cooler climates and prevent harmful deposits from collecting General Checks1 Check coupling alignment each time a transmission is replaced in the boat 71 Westerbeke Diesel Engines2 Check shift linkage adjustment to ensure that the transmission shift lever is positioned so that the spring loaded ball enters the chamfered hole in the side of the shift lever3 Connect an oil cooler into the cooler circuit before cranking or starting the engine various cooler circuits have been used and the correct cooler connections should be found from service literature prior to makeing the cooler installation4 Use a cooler or sufficient size to ensure proper cooling5 Check engine rotation and transmission pump setting and the pro peller rotation prior to assembling the transmission to engine6 Check oil pressue and temperature when transmission function indicates that a problem exist7 Use the recommended fluid for filling the transmission8 Fill the transmission prior to starting the engine9 Check oil level immediately after the engine has been shut off10 Use a clean container for handling transmission fluid11 Replace cooler and lines after a transmission failure prior to installing a new or rebuilt transmission12 Check fluid level at operating temperature Westerbeke Diesel Engines 72 Walter VDrives Flange Alignment Direct Coupled Models Install the propeller shaft flange onto the propeller shaft and tighten the twoclamping bolts on the spli t hub none onRVlOD A selflocking set screw is pro GEAR SHAFT SET SCREWvided for the propeller shaft flange FLANGESpot dr ill the propeller shaft and thensecurely tighten the set screw Many are ruined by improper shaft FEELERflange alignment Accurate alignment will GAGEensure a smooth operating drive train andeliminate many problems that arise due tomisalignment Final alignment should notbe attempted until the boat has beenallowed to settle in the water After CLAMPINGthe engine has been installed adjust the BOLTSmounts per manufacturers instructions FLANGE ALIGNMENTuntil the pilot diameters of the gearshaft flange and the propeller shaftflange engage freely Butt the flangefaces together Without rotating either flange check with a feelergauge in at least four places as shown in the illustration If themaximum feeler gauge that can slip between the flange faces at anypoint is 003 the unit is properly aligned If a thicker gauge canbe inserted at any point the engine must be readjusted until is obtained Turn the propeller shaft flange 14 of a turnwithout moving the gear shaft change Try inserting the 003 feelergauge as descr ibed above The gap will not change i f the propellershaft is straight If it increases the shaft or flange is bent andmust be removed and straightened Rotate the propeller shaft flangein two more 14 turn increments and repeat the procedure The pilotdiameters must be rechecked to ensure that they still engage freelySecure the two flanges together with the heat treated bolts and special high collared lockwashers supplied Engine Alignment Independent Models The engine must be adjusted so that the alignment of the flexiblejoint is within 3 An accurate steel rule should be used for thispurpose as shown in the illustration On short installations using aflexible joint assembly the faces of the flexible joint must beparallel within 18 Measure this in at least four places around thediameter without rotating the assembly With long installations usingthe 36 tubular drive shaft also on all RVlODS the distance fromthe 33A spool adapter to the bores in the universal joint which iswelded to the tubular shaft must be measured on both sides of thejoint Rotate the shaft exactly 14 of a turn and measure to the samejoint The four distances must be equal within 18 DO not measure 73 Westerbeke Diesel Engines to the joint end that is on the spool adapter This distance will not H vary wi th misalignment RI Slnce the joint is bolted and cannot move Put the 31A alignment gauge on the machined diameter Z YNCO lJftClIN of the 24 cover and slide it com pletely around It will indicate how the engine must be moved to center the spline shaft in the oil seal Remeasure the joints to see ifthey are still parallel within 18 It isimportant that both alignments be It is possible for the spline shaftto be perfectly centered and the flexible jointto be out more than 3 Premature failure of the26 selfaligning bearing and seals may occur dueto misalignment The zerk fitting located onthe cross of the universal joint should begreased with a light alemite lubricant Theabove procedure should be repeated after the boathas been placed in operation It is possible forthe engine to slightly shift and settle especially if it has rubber mounts Flange Alignmenl Independenl Models Install the propeller shaft flange on to thepropeller shaft and tighten the two clamping boltson the split hub none on RVIO A selflocking LOCKING NUT ADJUST I SChEWset screw is provided for the propeller shaft LOOSEN TOflange spot drill the propeller shaft and secure AOJUS T BRACK T5ly tighten the set screws MOlJjTING All Vdrives are supplied with 3way adjustable HOLEmounting brackets 2way on the RVIO and RV20 as standard equipment The brackets must face downward as shown in the illustration to properlyabsorb propeller thrust The mounting plates canbe removed and rever sed to fi t wider eng ine bed RVIO RV20centers Before installing the Vdrive loosen allthe nuts on the mounting brackets and check to seethat the studs are in the center of the slots Retighten the nuts place the Vdrive on the engine bed lining it upWby eye to the propeller shaft flange as closely as possible Firmlybolt it down through the holes provided in the mounting platesLoosen the locking nuts on the adjusting screws Slightly loosen thenuts on the mounting brackets just enough to be able to move the vdrive Many good installations are ruined by improper propeller shaftflange alignment Accurate alignment will ensure a smooth operatingdrive train and eliminate many problems that arise due to misalign Weslerbeke Diesel Engines 74ment Final alignment should not be attempted until the boat has beenallowed to settle in the water Adj ust the Vdr i ve until the pilotdiameters of the gear shaft flange and the propeller shaft flangeengage freely Butt the flange faces together Without rotatingeither flange check with a feeler gauge in at least four places asshown in the illustration If the maximum feeler gauge that can slipbetween the flange faces at any point is 003 the unit is If a thicker gauge can be inserted at any point the Vdrivemust be readjusted until proper alignment is obtained Turn the propeller shaft flange 14 of a turn without moving the gear shaftflange Try inserting the 003 feeler gauge as described above Thegap will not change if the propeller shaft is straight If itincreases the shaft or flange is bent and must be removed Rotate the propeller shaft flange in two more 14 turnincrements and repeat the procedure The pilot diameters must berechecked to ensure that they still engage freely Tighten the nutson the mounting brackets and the locking nuts on the adjusting screwsRemove the set screws from the brackets none on RVIO or RV20 spotdrill and securely tighten Recheck the flange alignment to make surethe Vdrive did not move out of alignment Secure the two with the heat treated bolts and special high collared lockwashers supplied ADJUSTING SCREW LOCKING NUT GEAR SHAFT FLANGE SET SCREw 7 i TO ADJUST LOOSEN SLIGHTLY BRACKETS a i MOUNTING ll 4 HOLE FEELER GAGE a p 0 dP 7 o MOUNTING PLATE FLANGE ALIGNMENT Water and Switch Connections Hook up the water lines to the two pipe connections on the Vdriveintake and exhaust lines are Generally one linefrom the seacock to the Vdr i ve and another from the Vdr i ve to theintake of the engine water circulating pump are utilized In somecases scuppers through the hull are connected to and from the Vdriveto provide independent watercooling and are actuated by the movementof the water With closed cooling systems the Vdrive should beincorporated into the system between the cooler and the suction sideof the water pump Proper operating temperatures are from 140 toISOF although safe operating temperatures may be as high as 210FOn the models equipped with an oil circulating pump the 49 oil 75 Westerbeke Diesel drop switch and the 12 volt H9A warning light should behooked up per the wiring diagram The switch may be grounded to anypart of the Vdrive or engine either terminal may be used for thegroundOil Fill Pullout the 21 oil level gaugeUnscrew the 12 breather cap and fill the 12 BREATHER CAP ATER mAINVdrive with SAE i30 motor oil through the UNSCREW FOR Oil Filll12A breather elbow On the RVIO only WATER LINE L LEVEL c GAthe oil may be added by removing the plug J I PULL UP TO REMlVEin the 60 top cover See table below forapproximate oil capaci ties The amountvaries with the angle of oil level should be checked wi th theoil level gauge fully inserted in theunit The proper level is between the Hand L marks on the gauge Add a 2 ouncetube of Molykote molybdenum disulfidewhich is supplied with each Vdrive for 12A BREATHER ELBOWextra lubrication and breakin It provides protection against scoring or gallingof gears bearings and other moving Molykote after breakin is not required Reinstall thebreather cap The oil level should be rechecked after the unit hasbeen run and allowed to sit for about a minute Add oil if necessary RVIO RV20 RV30 RV40 RV48Oil capaci ty 1 pint 2 pints 3 pints 4 pints 4 pintsApprox Dealer Preparation The propeller shaft and engine alignment must be checked andcorrected if necessary before the boat is delivered Final alignment should not be attempted until the boat is allowed to settle inthe water The oil level must be checked and oil added if requiredWhile the boat is being run the water connections should be checkedfor leaks The oil pressure drop switch and warning light if theV dd ve is equipped wi th an oil circulating pump should be checkedfor proper operation Do not transport the boat with the propellershaft coupling connected Damage to the shaft shaft log and Vdrivecan result Weslerbeke Diesel Engines 76 Operation A pressure drop warning light ismounted on the instrument panel onVdrives equipped with an oil circulating pump The warning light willstay on until the boat gets under wayand the engine speed increases to sufficient RPM for the pump to This normally occurs 1200 RPM but the actualspeed may vary by as much as 400 RPMExtended cruising at low RPM such aswhen trolling is not harmful to theVdrive even though the warning lightmay stay lit Normal operation isbetween 6 to 12 PSI The light willgo on when the oil pressure dropsbelow 2 PSI Loss of oil oil level are the majorcauses of pressure drop The oillevel should immediately be restoredand while running the boat the unit should be checked for leaks Ifthe oil level is normal and the light stays lit when the boat reachesnormal cruising speed the wir ing should be checked for loose andorcorroded connections If the wiring is correct and the light remainslit the 49 pressure drop switch which is mounted on the side of theVdr i ve see illustration should be checked for proper oper ationThe switch can easily be removed and an accurate oil pressure gaugeinstalled in its place If the pressure is normal the switch shouldbe replaced If the pressure is below normal the oil lines should bechecked for blockage The pump should be inspected and replaced ifnecessary The pump is standard on the RV48 and an optional featureon other models not available on the RVIO The oil level should be checked several times during the on Vdrives whitout pumps see OIL FILL A clatter or rattle in the Vdrive at low RPM is due to the overriding of the propeller during the compression stroke of the engineAlthough annoying it is not harmful It may be reduced by adjustingthe idle speed andor tuning up the engine for smoother operation Maintenance1 OIL CHANGE AND JOINT LUBE After the first 100 hours of operation and every season andor500 hours thereafter the oil should be changed Run the boat to warmup the Vdrive to operating temperature Turn off the engine Removethe plug in the 6B bottom cover that is opposite the 438 oilstrainer Reinstall after draining Disconnect the oil hose leadingfrom the 438 strainer leave the elbow on the strainer Unscrew thestrainer and clean the outside surface Reinstall the strainer andreconnect the oil hose Unscrew the two 22 magnetic plugs that arelocated on diagonally opposite corners of the lC main housing 77 Westerbeke Diesel Engines The plugs can be checked to see ifthey are magnetic only after removalTouch the inside face with a metallicobject such as a screwdriver Cleanthem and reinstall Usually thereare four plugs in the bottom part ofthe main housing Only two of theseare magnetic The other two need notbe removed see illustration Refillwi th SAE 30 motor oil to the properlevel see INSTALLATION OIL FILLThe Zerk fitting on the external universal joint should be greased with alight alemite lubricant see ENGINEAL I GNMENT 2 WATER DRAIN For protection from freezing during winter layup remove thesmall pipe plugs located diagonally opposite on the front and backof the housing marked Water Drain see illutration On the RVIOonly one of the water lines going into the 6 watercooled bottomcover must be disconnected to drain the water3 FLANGE AND ENGINE REALIGNMENT When the boat is launched after being in drydock the lineup ofthe vdrive to the propeller shaft flange and the engine to the Vdrive should be rechecked and corrected i f necessary Some engineswith rubber mounts may sag and must be raised with adjustments orshims for proper alignment see Flange Alignment and n Westerbeke Diesel Engines 78 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 switch ON 1 Battery OFF 1 Turn Battery ONbut no panel ortest function 2 20 Amp circuit 2 Reset the breaker by breaker is tripped pushing in the button 3 Loose battery 3 Check the connection cable connection to the starter and the connection to the ground stud on the bell housingPREHEAT switch is de 1 Faulty solenoid 1 Connection for 12 volts atpressed no preheat connections or switch S terminal of the solenoid issolenoid activation faultyno electric fuel pump oralternator excitation 1 Check the preheat switch 2 Faulty connection or 2 Check for 12 volts at the tripped 10 Amp breaker 10 Amp breaker Check on the I terminal on the for 12 volts at fuellifl pump preheat solenoid and at the R terminal on the alternator when the preheat button is pushed 79 Westerbeke Diesel EnginesProblem probable Cause switch is de 1 Connection to starter 1 Check connection S at thepressed no starter solenoid faulty starter solenoid for 12 with the SWITch depressed 2 Faully START switch 2 Check switch with an ohmmeter 3 Faulty solenoid 3 Twelve volts is present at the S terminal of the starter solenoid 4 Loose battery 4 Check battery connections connection at both the and ground 5 Low batteries 5 Check battery charge state Low voltage at the solenoids S terminal with no cranks 1 Shutoff valve at 1 Return shutoff valve tobut does not start fuel tank ITS ON pOSITion Now bleed the fuel system 2 Faulty fueling system 2 Check for fuel to engine 3 Air is in the fuel 3 Bleed the fuel system system Locate the leak and correct ff 4 Fuel pump is not 4 Check pump operation operating Check for 12Volts at pump 5 Fuellilters are clogged 5 Cleanreplace fillersFailure to stop 1 Mechanical Run 1 Stop engine by man linkage is ually moving the disconnected RUN linkage to STOP That failing shut OFF fuel and airWeslerbeke Diesel Engines 80Problem Probable Cause Stops 1 Fuel starvation 1 Check to see that the Fuel shutoff is turned shutoff valve at the OFF fuel tank is ON 2 Fuel pump is 2 Inspect the fuel pump for inoperative 12 volt and to see if it is pumping 3 Water is in the 3 Pump water out of the fuel bottom of the fuel tanks change the fuel filters and bleed the fuel system 4 Exhaust system is 4 Check exhaust system for restricted some type of blockage such as carbon buildup at the exhaust elbow Check for a fault In the muffler Check for a collapsed exhaust hoseBattery runs down 1 Alternator output 1 Check drive belt tension is low Perform an output check wh a voltmeter at the B terminal on the alternator 2 Faulty alternator 2 Voltage leak through the alternator when not operating 3 Bad battery 3 Connections are corroded connections or loose at the battery orand at the engine 81 Westerbeke Diesel Engines MAINTENANCE AND section contains a scheduled preventive maintenance program and several adjustment procedures can perform 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 it will perform to expectations Those items marked by an asterisk are recommended to be performed by an authorized dealer or before each use 1 Check the oil sump level Maintain the oil 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 unit check for loose belts chafed or broken wires loose brackets and fittings damaged hoses loose clamps and other equipment not properly secured This check should include the propeller shaft coupling to the transmissions output flange 5 Check the fuel supply Fill tanks with a good grade of No2 diesel fuel if required 6 Check the primary filterwater separator Drain and service as required A primary filterWater separator is optional but strongly recommended 7 Check the engines gauges or lights for proper oil pressure operating temperature and starting bat tery charging voltage once the engine is operating 8 Check the alternators output gauge if installed for proper DC voltage 9 Check to make sure the propeller shaft is securely connected to the transmission the condition 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 Diesel Engines 82Servicing Alter Initial 50 Hours 01 Operation 1 Change the engines lubrication oil and oil filter 2 Replace the fuel filter element in the electric fuel lift pump and in the enginemounted secondary fuel fil ter Change the fuel filter element and clean the optional filterwater sediment or Ha separator has been installed and il the model type permits cleaning 3 Torque the cylinder head bolts 4 Adjust valve clearances 5 Adjust the alternator and water pump drive belt tension if required 6 Lubricate the throttle the RUN linkage cable and the transmissions remote control cable 7 Change the transmissions oil 8 Adjusts the engines idle speed as needed 9 Check to make sure the propeller shaft is securely connected to the transmission Alter Every 100 Hours of Operation 1 Change the engines lubrication oil and oil filter 2 Adjust the alternator and water pump drive belt tension if required 3 Check the transmission fluid or oil levelServicing Alter Every 250 Hours of Operation 1 Replace the fuel filter elements in the electric fuel lift pump and in the enginemounted secondary fuel filter 2 Change the transmissions oilServicing Alter Every SOO Hours 01 Operation 1 Torque the cylinder head bolts 2 Adjust the valve clearances 3 Drain flush and refill the fresh water cooling system The illustration on pages 6 to 11 show the heat exchanger and the zinc anode location The drain plug for the fresh water system is next to the zinc anode 4 Check the condition of the starter motor drive pinion lubricate the pinion 83 Westerbeke Diesel Engines 5 Check the resistance of the glow plugs 4 to 6 ohms 6 Check the sea water pump for internal wear Examine the pumps cover cam and internal housing Replace worn parts as needed Check for leaks and repair as needed NOTE Items highlighted by an asterisk should be performed by a competent Aller Every 800 Hours 01 Operation 1 Remove and check fuel injectors Injector spray pressure 1991 psi 140 psi 140 kgcm 2 10 kglcm 2Eliminate undesirable injection conditions including POORaller dripping 2 Check the engines compression pressure Remove each glow plug and check each i f4 ir 10104i dI cylinders compression pressure The engines GOOD cranking speed is at 280 rpm Standard Minimum 455 psi 3697 psi 32 kgcm 2 26 kglcm2 Maximum difference between cyfinders 355 psi 25 kgcm2 3 Check the alternator for proper operation 4 Check the tightness of bolts nuts and Aller 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 injection pumps Diesel Engines 84Torquing Cylinder Head Bolts CN 35B THREE EngineTighten the cylinder head bolts according to thesequence shown in the illustration shown to theright Make sure the engine is cold when this is FRONT OF ENGINEdone Before applying the specHied torque to the bolt loosen it 14 to 12 of a turn and thenapply the torque Follow this procedure according to the numbered sequence shown in 0 0 0 7 5 11the illustration to the right 4 6 8Bolts 45678910 and 11 are tightened be 0 0 01ween 795 to 868Ibft 11 to 12 kgm 02 01 03Bolts 12 and 3 are tightened be1ween 506 to578 Ibft 7 to 8 kgmTorquing Cylinder Head Bolts W 38B FOUR and W 42B FOUR EngineTighten the cylinder head bolts according tothe sequence shown in the illustration shownto the right Make sure the engine is cold whenthis is done Before applying the spec Hied FRONT OF ENGINEtorque to the bolt loosen IT 14 to 12 of a turn and then apply the torque Follow this procedure according to the numbered sequence 0 0 0 0shown in the illustration to the right 6 1 5 11 14 8 2 1 13Bolts 45678910 and 11 are tightened be 0 10 0 4 0 3 0 9 01ween 795 to 868Ibft 1110 12 kgm 0 0 0 0Bolts 12 and 3 are tightened be1ween 506to 578 Ibft 7 to 8 kgm 85 Westerbeke Diesel EnginesValve Clearance Adjustment rN 35B THREE Engine CAUTION Adjust the valve clearance when the engine is cold Valves are adjusted by TOC MRRK Cylinder Koll cylinder in the firing order of the en gine Tighten the cylinder head bolts to the specified torque before adjusting the valves See page 851 Pull off the air breather pipe from the rock TO C MA RK er cover and take off the rocker cover C y li n d e r bolts and the rocker cover No3 12 Adjust the valve clearances at TDC Top TOC MARK Dead Center for each cylinder when they Cylinder No2l are on their compression stroke see below Remember the engines firing order is 132 You may find that turning the engines crankshaft is more easily accomplished when the engines glow plugs are removed before the crankshaft is rotated A Align the timing mark on the gear case with the timing mark on the crankshaft pulley indicated for cylinder NO1 the one next to the three injection timing marks In this position the NO1 cylinder is at ks top Timing Mark while dead center on ks compression stroke Check both intake and exhaust valve clearances for this cylinder If the valves have no specified clearance adjust by means of the ad justing screws Remember to align the timing marks properly if not the valve may be pushed up by the piston depending on the position of the cam lobe Be sure to check the valves for this cylinder they both should be closed B Next the No3 cylinder Turn the crankshaft clockwise 240 so the TDC mark for the NO3 cylinder on the front crankshaft pulley is approximately at the position shown in the illustration above Now adjust the intake and exhaust valves for cylinder No3 Be sure to check the valves for this cylinderthey both should be closed ADJUST VALVES TO 0010 INCHES 025 MMJ C Last is the No2 cylinder Turn the crankshaft clockwise another 240 to position the TDC mark on the crankshaft pulley approximately at the position shown in the illustration shown above Now adjust the intake and exhaust valves for cylinder NO2 Be sure to check the valves for this cylinder they both should be closedAdjust each valves clearance by inserting a 0010inch 025 mm feeler gauge between the rockerarm and the valve stemWesterbeke Diesel Engines 86Valve Clearance Adjustment W 38B FOUR and W 42B FOUR Engines CAUTION Adjust the valve clearance when the engine is cold TDC MARK Position for Tighten the cylinder head bolts to the Cylinder No1 and 4 specHied torque before adjusting the valves See page 851 Pull off the air breather pipe from the rock er cover and take off the rocker cover bolts and the rocker cover2 Adjust the valve clearances atTDC fop TOC MARK Dead Center for each cylinder when they Po i t ion for are on their compression stroke Remem Cy 1 i n d r s berthe engines firing order is 1342 The No2 and 3 CRANKSHAFT engines valves must be adjusted in this PULLEY order while the valves are closed You may find that turning the engines crankshaft is more easily accomplished when the engines glow plugs are removed before the crankshaft is rotated A Rotate the engine in the normal direction of rotation placing the NO1 cylinder at the top of its compres sion stroke The TDC mark on the crankshaft pulley should be in line with the pointer on the front of the gear case cover and the valves for the No1 cylinder should be closed Now adjust the intake and ex haust valves for cylinder NO1 B After adjusting the valves for cylinder No1 rotate the front crankshaft pulley clockwise 180 so the TDC mark on the pulley is positioned approximately in the position shown in the illustration shown above for cylinder No3 Now adjust the intake and exhaust valves for cylinder NO3 C Rotate the crankshaft pulley clockwise another 180 and adjust the valve clearances ADJUST VALVES TO 0010 INCHES for the Intake and exhaust valves for cylinder 025 MMJ No4 D Rotate the crankshaft pulley clockwise another 180 and adjust the valve clearances for the intake and exhaust valves for cylinder NO2Adjust each valves clearance by inserting a 0010inch 025 mm feeler gauge between the rockerarm and the valve stem 87 Westerbeke Diesel Pump Timing Adjustment Spill TimingIf your engines fuel injection timing is not property adjusted the engine will not operate property and will bedifficult to start Have the injection pump delivery rate checked by a fuel Injection shop Adjust the injection timing as follows NOTE The fuel shutoff lever must be In the RUN posHion while making the adjustment or no fuel will flow from the fuel injection pumpRefer to the illustration below when servicing the fuel injection pump First remove the highpressure fuelline from between the No1 injector and the No1 fuel delivery valve holder Remove the NO1 fuel deliveryvalve holder and remove the delivery valve spring beneath the holder Reinstall only the delivery valve holderand reattach the high pressure fuel line to the delivery holder Attach H so that the end that would connectto the fuel injector is pointing away from the engine Fuel will flow from this line during the timing check DELIVERY VALVE HOLDERRotate the engines crankshaft in Hsnormal direction of rotation to posi DELIVERY VALVE SPRINGtion piston No1 at the beginning ofits compression stroke DELIV VALVEMove the throttle lever to Hs full openposition and operate the electric liftpump Slowly rotate the as viewed from thefront catching the fuel from the No BAR REL 17TtJt11 fuel line until the Instant the fuelcompletely stops flowing no drips 7ICONTROL RACKAt this instant the 230 BTDC timing PLUNGERmark on the crankshaft pulley CONTROLshould be directly aligned wHh the PINIONtiming indicator on the front of thegear case refer to the pages 86 and 87 TAPPET PLUNGER SPRINGIf the specified injection timing 230 BTDC cannot be attained adjust the timing by increasing or decreasing the thickness of shim material under the injection pumps mounting flange to change the injection timingpoint Changing the shim thickness by 0004 inch 001 mm changes the injection timing by degree To advance the timing decrease the shim thickness as required To retard the timing increasethe shim thickness as required Refer to your engines Parts List for shim part Diesel Engines 88 LAYUP AND owners rely on their boatyards to prepare their cralt including engines and generators for layupduring the offseason or lor 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 il others do the procedures should afford your engine protection during a layup and also help familiarize you withthe maintenance needs of your engineIf you have any questions regarding layup procedures call your local servicing dealer he will be more thanwilling to provide Shall CouplingThe transmission and propeller half couplings should always be opened up and the bolts removed whenever the boat is hauled out of the water or moved Irom land to water and during storage in a cradle Theflexibility 01 the boat often puis a severe strain on the propeller shalt or coupling or both while the boat istaken out or put in the water In some cases the shalt has actually been bent by these strains This doesnot apply to small boats that are hauled out 01 the water when not in use unless they have been dry for aconsiderable period of timeFresh Water Cooling SystemA 5050 solution 01 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 make sure the antifreeze protection is adequateShould more antifreeze be needed drain an appropriate amountfrom 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 strengthEngine lubrication SystemWith rhe 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 13 forthe W 358 page 16 for the W 38B and page 19 forthe W 42B Use an oii with an API specification 01 CC or CD Run the engine and check for proper oil pressure and make sure there are no leaks 89 Weslerbeke 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 lubrication SystemFill the transmission completely full of the same oil that was use during its operating season DO NOT mixgrades of oil Filling the transmission immerses the transmissions internal components in oil which protectsthem against corrosion during the layup periodFuel 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 make sure 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 and also clean any zincdebris from inside the heat exchanger where the zinc anode is located Clean the sea strainer if 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 bucketis empty stop the engine and refill the bucket wah an antifreeze solution slightly stronger than needed forwinter freeze protection in your areaStart the engine and allow all of this mixture to be drawn through the sea water system Once the bucketis empty stop the engine This antifreeze mixture should protect the sea water circuit from freezing duringthe winter 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 if needed and a cover gasket Do not replace theimpeller into the pump until but replace the cover and Diesel Engines 90Intllke Manifold and ThroughHull ExhaustPlace a clean clolh 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 prior10 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 Make sure the battery connections are shut off before attempting to remove the starter Take carein properly replacing any electrical connections removed from the 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 monthsor more 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 ff external items suchas drive 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 will remainthaI way to prevent them from freezing If there exists any doubt that the batteries will not remain fullycharged or that they will be subjected to severe environmental conditions remove the batteries and storethem in a warmer more compatible 01 your Westerbeke engine after a seasonal layup generally follows the same procedures as lhose presented in the PREPARATIONS FOR STARTING seclion page 33 regarding preparationfor starting and normal starts However some of the layup procedures will need to be counteracted beforeslarting the engine1 Remove the oilsoaked cloths from the intake manifold and from the throughhull exhaust port2 Remove Ihe sea water pump cover and gasket and discard the old gasket Install the sea water pump impeller removed during layup or a replacement if required Install the sea water pump cover with a new cover gasket 91 Weslerbeke Diesel Engines3 Drain the transmission of all oil Fill the transmission to the proper level with the correcttype of oil specified in your engines SYSTEM SPECIFICATIONS section of this manual IWARNINGI 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 ar cing 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 make sure that the batteries are fullycharged4 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 ofthis manual page 33Weslerbeke Diesel Engines 92 TABLE OF STANDARD HARDWARE TIGHTENING TORQUESUnless stated otherwise for a specific assembly use the following torque values when tightening Pitch Ibft kgmGrnde 4T 6mm bolt headnut 1 29 51 04 07 Bmm bolt headnut 125 72 116 10 16 10mm bolt headnut 125 137 224 19 31 10mm bolt headnut 15 130 217 18 30 12mm boll headnut 125 ISO 253 398 35 55 12mm bolt headnut 15 253 398 35 55 12mm bolt headnut 175 217 362 30 50 13mm bolt headnut 15 325 506 45 70 14mm bolt headnut 15 362 579 50 80 14mm bolt headnut 2 340 557 47 77 16mm bolt headnut 15 542 796 75110 16mm bolt headnut 2 514767 71 106Grade6T 6mm bolt headnut 1 43 65 06 09 8mm bolt headnut 125 108 159 15 22 10mm bolt headnut 125 217 325 30 45 10mm bolt headnut 15 195 304 27 42 12mm bolt headnut 125 ISO 362 579 50 80 12mm bolt headnut 15 362 506 50 70 12mm bolt headnut 175 347 492 48 68Grade 7T aT ad ll Smm bolt headnut 58 87 08 12 Bmm bolt headnut 125 145 217 20 30 lOmm bolt headnut 125 289 398 40 55 1Dmm bolt headnut 15 268 37S 37 52 12mm bolt headnut 125 ISO 542 759 75105 12mm bolt headnut 15 506 651 70 90 12mm bolt headnut 175 434 615 60 85 13mm bolt headnut 15 579 868 80 120 14mm bolt headnut 15 723 1085 100 150 14mm bolt headnut 2 687 1013 95 140 16mm bolt headnut 15 1085 1664 150 230 16mm bolt headnut 2 1013 1591 140 220Grade QapSQ9W 14 UNC 9 11 12 15 14 UNF 11 13 15 18 516 UNC 18 20 25 28 516 UNF 21 23 29 32 38 UNC 28 33 37 46 38 UNF 30 35 41 48 716 UNC 44 49 61 68 716 UNF 50 55 69 76 12 UNC 68 73 94101 12 UNF 73 80 101111 93 Westerbeke Diesel Engines TORQUE head bolt M10 507 579 70 80 M12 796 868 110120 See the Torquing Cylinder Head Bolts section of this manual on page 85Crankshaft pulley nut 1085 1808 200 250Main bearing cap bolt 362 434 50 55Connecting rod cap nut 231 253 32 35Flywheel bolt WITh separate washers 832 904 115 125Flywheel bolt washer attached 950 1000 130 140Oil pan drain plug 362 434 50 60Oil filter 80 94 11 13 or tighten firmly by handDelivery valve holder injection pump 289 362 40 50Nozzle mounting bolt 108 145 15 20Nozzle holder and retaining nut 434 579 60 80Glow plug 108 145 15 20 NOTE M8 indicates Metric 8 mm thread Diesel Engines 94 SPARE PARTSSince a possibility exists in which the engine may need to be serviced at sea or while in a port other thanyour home port certain spare parts should be kept on board to help minimize delays in your voyage Pleaserefer to your engines Parts List for part numbers when ordering spare partsListed below are those spare parts that should be carried on board at all times 1 An Impeller 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 Oil and a Gallon of Premixed parts whose Ine expectancy cannot be accurately predetermined should be carried on board in addition to those listed above especially if the vessel is to be taken on long ocean voyages These parts arelisted 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 ora Major Overhaul Kit the pumps part number is found on the cover of the pump 9 Battery Terminal ConnectorsThe spare parts listed directly above are those we recommend be carried on board during long oceanvoyages You may wish to ask other boat owners who have similar crafts and who have completed longocean voyages as to what spare parts they carried on board and what parts were needed at specific timesof the voyage From the list provided directly above and from these inquiries you can determine what spareparts may be needed In addition if you are planning a long ocean voyage consult your local for a listing of the Westerbeke dealers located on your route 95 Westerbeke Diesel Engines INDEX AAdjustment Injection Pump Timing 88ADJUSTMENTS MAINTENANCE AND 82Adjustment Valve Clearance 0N 35B THREE Engine 86Adjustment Valve Clearance 0N 38B FOUR and W 42B FOUR Engines 87Admirals Panel 37Admirals Panel Control Circutt DC Wiring Diagram 36844 50 and 51Alignment of the Engine Installation Checks 24Alternator 46Alternator and Water Pump Drive Belt Tension 55ANTIFREEZE CONCENTRATION DATA 53Automatic Alarm System 31 BBatteries Layup and 91Battery Specification 46Belt Tension Alternator and Water Pump Drive 55Bolts Engine Installation Checks 23Bolts Torquing Cylinder Head 0N 35B THREE Engine 85Bolts Torquing Cylinder Head 0N 38B FOUR and W 42B FOUR Engines 85Breakin Procedures Engine 41 C CAUTIONS SHIPPING ENGINE WITHOUT ENGINE OIL 21 LIFTING SUNGS 22 TIGHTENING THE EXHAUST ELBOW CLAMP 29 THROUGHHULL FITTINGS 30 PROLONGED ENGINE CRANKING 39 SHUTTING DOWN THE ENGINE 41 PROLONGED ENGINE CRANKING 44 BATTERY CIRCUIT 46 QUICKCHARGING THE BATTERIES 46 TESTING THE ALTERNATOR 46 EXCESSIVE BELT TENSION 55 TRANSMISSION GEAR BOX LEVER COVER BOLTS 65 ADJUSTING VALVE CLEARANCES 86 ADJUSTING VALVE CLEARANCES 87 LEAVING OLD ENGINE OIL IN SUMP OVER LAYUP 90 Captains Panel 35 Captains Panel Control Circuit DC Wiring Diagram 36467 48 and 49 Change Engine Oil to include filter 61 Charging Voltage Test 47 CHECKS INSTALLATION 21 Westerbeke Diesel Engines 96Circuit Fresh Water 52Circutt Sea Water 55Clearance Adjustment Valve 0N 358 THREE Engine 86Clearance Adjustment Valve 0N 388 FOUR and W 428 FOUR Engines 87Connecting Pressure Sensing Devices to Oil Galleries Installation Checks 30CONTENTS TABLE OF 3Cooling JS Transmission 65COOLING SySTEM 52Cooling System Installation Checks 30Controls JS Transmission 64Coupling Propeller Shalt Installation Checks 24Coupling Propeller Shalt Layup and 89Cylinder Head Bolts Torquing 0N 358 THREE Engine 85Cylinder Head Bolts Torquing 0N 38B FOUR and W 42B FOUR Engines 85Cylinder Lubrication Layup and 91DC Wiring Diagram 36844 Admirals Panel Control Circuit 50 and 51DC Wiring Diagram 38467 Captains Panel Control Circuit 48 and 49DESCRIPTION OF INSTRUMENT PANELS 35Description of Starting System 34Diesel Engine Understanding the 5Diesel Fuel 43DISCLAIMER IMPORTANT PRODUCT SOFTWARE 1Domestic HoI Waler 58Drain Hose Oil Installation Checks 30 EELECTRICAL SYSTEM 46Electrical System Installation Checks 32Engine Alignment of the Installation Checks 24Engine Bolts Installation Checks 23Engine Breakin Procedures 41Engine Diesel Understanding the 5Engine Foundation lor the Installation Checks 23Engine Lubrication System Layup and 89Engine Oil 60Engine Oil Change to include filter 61Engine Oil Viscosity SAE Number 60ENGINE 79EqUipment Inspection of 2Exhaust BackPressure Installation Checks 27Exhaust Elbow Installation Installation Checks 29Exhaust System Installation Checks 26Exhaust System Failures Installation Checks 28 91 Westerbeke Diesel Engines FFORWARD 2Foundation for the Engine Installation Checks 23Fresh Water Circuit 52Fresh Water Cooling System Layup and 89Fuel Diesel 43Fuel Filters 43Fuel Filter Elements Replacing 44Fuel Injection Pump 45Fuel System Installation Checks 31Fuel System Layup and 90Fuel System Priming the 44FUEL SYSTEM 43 GGENERAL 5GENERAL SPECIFICATIONS W 35B 12GENERAL SPECIFICATIONS W 38B 15GENERAL SPECIFICATIONS W 42B 18 HHARDWARE TIGHTENING TORQUES TABLE OF STANDARD 93Head Bolts Torquing Cylinder W 35B THREE Engine 85Head Bolts Torquing Cylinder W 38B FOUR and W 42B FOUR Engines 85Hose Oil Drain Installation Checks 30Hot Water Domestic 58Hydraulic Transmissions Warner 68IMPORTANT PRODUCT SOFTWARE DISCLAIMER 1INDEX 96Injection Pump Fuel 45Injection Pump Timing Adjustment 88Inspection of Equipment 2INSTALLATION CHECKS 21INSTRUMENT PANELS DESCRIPTION OF35Intake Manifold and ThroughHull Exhaust Layup and 91Intake System Sea Water Installation Checks 31 JJS Transmission 63Weslerbeke Diesel Engines 98 lLAYUP AND 89Lifting Rigging and Installation Checks 22Location Installation Checks 21Lubrication JS Transmission 63LUBRICATION SYSTEM 60 IVMAINTENANCE AND ADJUSTMENTS 69Motor Starter Layup and 91 oOil Change to include filter Engine 61Oil Drain Hose Installation Checks 30Oil Engine 60Oil Engine Viscosity SAE Number 60Oil Galleries Connecting Pressure Sensing Devices to Installation Checks 30Oil Pressure 60OPTIONAL TRANSMISSIONS 66Ordering Parts 5Panel Admirals 37Panel Captains 35PANELS DESCRIPTION OF INSTRUMENT 35Parts Ordering 5PARTS SPARE 95PREPARATION FOR STARTING 33Pressure Oil 60Pressure Sensing Devices to Oil Galleries Connecting Installation Checks 30Priming the Fuel System 44PROCEDURE STARTING 39PROCEDURE STOPPiNG 41PRODUCT SOFTWARE DISCLAIMER IMPORTANT 1Propeller Installation Checks 24Propeller Shaft Coupling Installation Checks 24Propeller Shaft Coupling Layup and 89Pump Fuel Injection 45Pump Sea Water 55Pump Timing Adjustment Injection 88 99 Westerbeke Diesel Engines Layup and 91Replacing the Fuel Filter Elements 44Rigging and Lifting Installation Checks 22 SSailing Operation JS Transmission 65Service JS Transmission 65Sea Water Circuit 55Sea Water Circuit Layup and 90Sea Water Pump 55Sea Water Intake System Installation Checks 31Shaft Coupling Propeller Installation Checks 24Shaft Coupling Propeller Layup and 89Shifting JS Transmission 65SOFTWARE DISCLAIMER IMPORTANT PRODUCT 1Spares Layup and 91SPARE PARTS 95Starter Motor Layup and 91STARTING PREPARATION FOR 33STARTING PROCEDURE 39Starting System Description 01 34Starting Under Cold Conditions 42Starting Under Normal Conditions 42STOPPING PROCEDURE 41SYSTEM SPECIFICATIONS W 35B 13SYSTEM SPECIFICATIONS W 38B 16SYSTEM SPECIFICATIONS W 42B 19 TTABLE OF CONTENTS 3TABLE OF STANDARD HARDWARE TIGHTENING TORQUES 93Test Charging Voltage 47Timing Adjustment Injection Pump 88Thermostat 54TORQUE SPECiFiCATIONS 94Torquing Cylinder Head Bolts 0N 35B THREE Engine 85Torquing Cylinder Head Bolts W 38B FOUR and W 42B FOUR Engines 85Transmission Lubrication System Layup and OPTIONAL Warner Hydraulic ENGINE 79 Weslerbeke Diesel Engines 100 uUnder Cold Conditions Starting 42Under Normal Conditions Starting the Diesel Engine 5 vValve Clearance Adjustment 0N 35B THREE Engine 86Valve Clearance Adjustment 0N 38B FOUR and W 42B FOUR Engines 87VDrives 73Ventilation 32Viscosity SAE Number Engine Oil 60Voltage Test Charging 47 W IWARNINGsl DIESEL FUMES 28 FLAMES NEAR BATTERIES 32 SERVICING BATTERIES 32 ADJUSTING DRIVE BELT TENSION 55 SERVICING BATTERIES 92Walter VDrives 73Warner Hydraulic Transmissions 68Water Domestic Hot 58Water Fresh Circuit 52Water Sea Circuit 55Water Intake System Sea Installation Checks 31Water Pump Sea 55Water Pump Belt Tension Alternator and 55Wiring Diagram 36844 Admirals Panel Control Circuit DC 50 and 51Wiring Diagram 36467 Captains Panel Control Circuit DC 48 and 49 101 Westerbeke Diesel Engines YOUR Diesel Engines 102YOUR NOTES 103 Weslerbeke Diesel Engines YOUR Diesel Engines 104