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Westerbeke Diesel 30c Three Technical Manual



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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

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