Westerbeke Diesel 55d Four Technical Manual
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Engines Generators 11 08WMDW1 006 SUGGESTED SPARE PARTS MARINE ENGINES CONTACJ YOUR WESTERBEKE DEALER FORSUGGESTIONS ANDADDITlONAL INFORMATION GLOW PLUGS WESTERBEKE RECOMMENDS CARRYING ENOUGH SPARE FUEl LINE FILTERS OWNER OIL YOUR BRANDfOR AN OIL CHANGE AND A GAUON Of PREMIXED COOLANT SPARE PARTS KITS WESTERBEKE also offers two Spare Parts Kits each packaged in a rugged hinged toolbox Kit A includes the basic spares Kit B is for more extensive offshore KIT A ZINC ANODES DRIVE BELTS OIL FILTER FUEL FILTER HEAT EXCHANGER GASKET IMPELLER KIT FUEL SYSTEM HARDWARE IIT FUEL PUMP INLET FILTER Engines Generators 63 KIT B ZINC ANODES DRIVE BELTS OIL FILTER FUEL FILTER HEAT EXCHANGER GASKET IMPELLER KIT INJECTOR OVERHAUL GASKET KIT AIR FILTER GLOW PLUG FUEL SYSTEM HARDWARE KIT FUEL PUMP INLET FILTER AND METRIC CONVERSION DATA LENGTHDISTANCE Inches inx 254 Millimeters mmx 0394 Inches Feet ftx 305 Meters mx 3281 Feet Miles x 1609 Kilometers kmx 0621 Miles DISTANCE EQUIVALENTS 1 Degree of Latitude 60 Nm 111120 km 1 Minute of Latitude 1 Nm 1852 km VOLUME Cubic Inches inSx 16387 Cubic Centimeters x 061 Ins Imperia Pints IMP ptx 568 Liters Lx 176 IMP pt Imperial Quarts IMP qtx 1137 Liters Lx88 IMP qt Imperial Gallons IMP galx 4546 Liters Lx 22 IMP gal Imperial Quarts IMP qtx 1201 US Quarts US Qtx 833 IMP qt Imperial Gallons IMP galx 1201 US Gallons US galx 833 IMP gal Fluid Ounces x 29573 Milliliters x 034 Ounces US Pints US ptx 473 LitersLx 2113 Pints US Quarts US qtx 946 Liters Lx 1057 Quarts US Gallons US galx 3785 Liters Lx 264 Gallons MASSWEIGHT Ounces ozx 2835 Grams gx 035 Ounces Pounds Ibx 454 Kilograms kgx 2205 Pounds PRESSURE Pounds Per Sq In psix 6895 Kilopascals kPax 145 psi Inches of Mercury Hgx 4912 psi x 2036 Hg Inches of Mercury Hgx 3377 Kilopascals kPax 2961 Hg Inches of Water H20x 07355 Inches of Mercury x 13783 H20 Inches of Water H20x 03613 psi x 27684 H20 Inches of Water H20x 248 Kilopascals kPax 4026 H20 TORQUE PoundsForce Inches in267lbx 113 Newton Meters Nmx 885 inIb PoundsForce Feet ftlbx 1356 Newton Meters Nmx 738 fHb VELOCITY Miles Per Hour MPHx 1609 Kilometers Per Hour KPHx 621 MPH POWER Horsepower Hpx 745 Kilowatts Kwx 134 MPH FUEL CONSUMPTION Miles Per Hour IMP MPGx 354 Kilometers Per Liter KmLKilometers Per Liter KmLx 2352 IMP MPG Miles Per Gallons US MPGx 425 Kilometers Per Liter KmLKilometers Per liter KmLx 2352 US MPG TEMPERATURE Degree Fahrenheit OF oG X 18 32 Degree Celsius OC OF 32x 56 LIQUID WEIGHTS Diesel oil t us galon 713 Ibs Fresh Water 1 US gallon 833 Ibs Gasoline 1 US gallon 61 Ibs Salt Water 1 US gallon 856 Ibs Engines Generators 62 Decimal inTORQUE DATA Lbft km Cylinder head bolts 63 BCFour 108BCSix 7lC Four 8085 110117 7IB Four 82B Four 85 90 118 125 Connecting rod caps 63BCFour 7lC Four 50 S4 69 75 71B Four 82B Four 59 65 82 90 108 BCSix 5S 60 76 83 Main Bearing Caps All Models 8085 110117 Injection Pump Gear All Models 29 52 47 Oil Pan Bolts 63BCFour 59 07 12 7lBCFour 82B Four 108 BCSix 12 17 16 23 Crankshaft Pulley Nut 63BCFour 14S 181 2025 7lBCFour 82B Four 253 289 35 40 108 BCSix 282 304 3942 Glow Plugs All Models 7 11 10 15 Intake Manifold All Models 12 17 16 24 Exhaust Manifold 63BCFour 12 17 1624 71BC82B Four and 108BCSix 2024 27 33 Oil Pressure Switch Sender All Models 913 1218 Injection HIP Line Nut All Models 18 22 25 30 Fresh Water Pump Mounting Bolts All Models 913 12 18 Timing Gear Cover All Models 12 17 1623 Flywheel bolts 63BCFour 108 BCSix 95 137 l31 190 7lB Four 82B Four 112118 155 163 71CFour 130 144 179199 Water Temperature Sender Switch All Models 18 29 25 40 Fuel Injector 71C Four 82B Four 43 50 60 70 Back Plate All Models 243S 33 48 Engines Generators 60 AdobeUCSany and 5 the same AdobeUCSBORG WARNER VELVET DRIVE TRANSMISSION MAINTENANCE Transmission maintenance is minimaL Keep the exterior housing clean check the fluid level as part of your regular routine and change the fluid every 300 operating hOUTS Periodically inspect the transmission and the cooler for leaks and corrosion Make certain the air vent is clear and when checking the fluid level look for signs of water contamination fluid will appear as strawberry Storage requires special care Follow these procedures o Drain the water from the transmission oil cooler and replace it with a proper mixture of antifreeze coolant NOTE This operation will usually occur when the engine raw water cooling system is properly winterized o Clean up the transmission and touchup unpainted areas use heat resistant painto Fill the transmission with Dextron III ATF fluid to prevent internal corrosion Extended storage only 12 months or moreo Loosen attaching hardware froin the transmission output flange and propeller shaft coupling flange before removing the boat from the water Separate the flanges and spray with lubricant o Inspect the gear shift cable linkage and attachments Look for corrosion of the end fittings cracks or cuts in the conduit and bending of the actuator rods Lubricate all moving parts NOTE ljthe transmission is to be storedfor a long time twelve months or moreit slwuld be topped offwith fluid to prevent internal corrosion Reduce the fluid level before putting tlze engine back into service OIL COOLERS The continued flow of raw water through the cooler will in time erode the inside of the cooler causing cross leaks to occur These internal cooler leaks will cause one of the following two problems 1 Transmission fluid will leak into the flow of raw water and be discharged overboard through the engine exhaust A loss of transmission fluid will cause tlze transmission to faiL 2 The raw water will leak into the transmission fluid caus255ing an increase in transmission fluid This contaminated fluid will appear as strawberry cream The transmission will eventually fail Either case requires an immediate response 1 Install a new oil cooler 2 Refill the transmission with DEXTRON III ATF WARRANTY NOTES Service manuals are available from your BORG WARNER dealer For assistance contact BORG WARiTER 200 Theodory Rice Blvd New Bedford MA 02745 Tel 5089794881 BORG WARNER is aware of the shock loads that can be placed on its gears as the result of mechanical propeller oper255ation or fully reversing of the propeller blades while shifting Therefore torque loads and directional changes should be made at low engine speeds If it is found that a failure was caused by a shock load any warranty claim will be denied A CAUTION Systemrelated noises or vibrations can occur at low engine speeds which can cause gear rattle resulting in damage to the engine andor transmission BORG WARNER is not responsible for total torsional vibration of this type If any problems occur with the transmission see TRANSMISSION in this manual If water has contaminated the fluid the transmission fluid needs to be cleaned out and replaced with fresh fluid It will take several fluid changes to get rid of the contamination Check your dipstick each time until it appears as pure fluid Change the transmission filter and clean out the fluid lines that connect to the cooler If the transmission fails to shift properly it will most likely need the attention of a qualified transmission service facility A transmission cooler may last ten years or more but in some circumstances depending on operating hours tropical waters maintenance etc it might only last half that time WESTERBEKE recommends having a spare cooler aboard Engines Generators 57 BORG WARNER VELVET DRIVE TRANSMISSION FORWARD NEUTRAl REVERSE TRANSMISSION ACTUATING LEVER POSITIONS DAILY OPERATION o Check the transmission fluid o Visually check the gear shift linkage and transmission o Start the engine in neutral Allow a few minutes at idle for the fluid to warm NOTE Too Iowan idle speed will produce a chattering noise from the transmission gear and damper plate In such cases the idle speed should be increased o Shift into gear A CAUTION Shifting gears above 1000 rpm can cause damage to the engine damper plate Pulling the throttle back to Idle when shifting gears will save wear on the transmission and the damper plate INSPECTION o Visually check for oil leaks at the hydraulic connections Check for wear on the hydraulic lines and replace if worn o Lubricate the detent ball and shift cable attachments Inspect the shift linkage o Inspect the transmission bolts retorque if necessary A CAUTION Clutch failure will occur if the shift lever does not fully engage the detent ball posItions CHANGING THE TRANSMISSION FLUID After the initial 50 hour change the transmission fluid should be changed at every 300 operating hours thereafter or at win255ter haulout However the fluid must be changed whenever it becomes contaminated changes color or smells rancid o Remove the oil filler cap and dipstick Remove the oil cooler return line and allow the oil to drain into a container o Reconnect the oil cooler return line o Use a suction pump to remove the transmission oil through the filler capdipstick hole o Clean off the transmission and properly dispose of the used fluid o Refill the transmission with DEXTRON III ATF The quantity will vary depending on the transmission model and the installation angle Fill through the dipstick hole D Check the dipstick for the proper fluid level Replace the oil filler cap and dipstick press the dipstick into place and tum clockwise until fingertighto Run the engine shutdown and recheck the fluid level A WARNING Never pullout the dipstick while the engIne is running Hot fluId will splash from the dipstick hole This could cause severe burns Oil Capacity Approximately 25 quarts 236 literswill fill most to the oilleveI fill mark on the dipstick Many variables have a direct relationship to the oil capacity Additional oil will be required to fill the oil cooler and the cooler lines The angle of installation will make a difference in the quantity of oil required to fill the transmission CERTAIN THE RUBBER SEAL IS SCREWED TIGHT TOTHE HANDLE Oil Temperature FLUID LEVEL FULL A maximum oil temperature of 190260F 88260Cis recom255mended Discontinue operation anytime sump oil tempera255ture exceeds 230260F GAUGE An optional mechanical pressure gauge can be installed at the control panel to constantly monitor the pressure of the transmission fluid A normal reading at 2000 rpm in forward gear should indicate 95 120 Ibin2 67 84 kgcm2and be constant EnClines Generators 56 BORG WARNER VELVET DRIVE TRANSMISSION OPTIONAL TRANSMISSION SHIPMENT BORG WARNER VELVET nRIVE TRANSlVISSION For safety reasons the transmission is not filled with transmission fluid during shipment and the selector lever is temporarily attached to the actuating shaft Before leaving the WESlERBEKE plant each transmission undergoes a test run with Dextron III ATF transmission fluid The residual fluid remaining in the transmission after draining acts as a preservative and provides protection against corrosion for at least one year if properly stored TRANSMISSION fLUID Check the transmission fluid level on the dipstick If the transmission has not been filled fill with Dextran III and continue to use this fluid During the first 25 hours of operation keep a lookout for any leakage at the bell housing output shaft and transmission cooler This fluid should be changed after the first 25 hours and approximately every 300 operating hours thereafter andlor at winter layup A CAUTION Bs CBrtain the transmission Is filled and the correct size cooler is properly instaled before starting the engine SHIFT LEVER POSITION The gear shift control mechanism and linkage must position the actuating lever on the transmission exactly in Forward FNeutral Nand Reverse Rshifting positions A deteball located behind the transmission lever must work freely to center the lever in each position The gear shift positions at the helm must be coordinated with those of the Velvet Drive actuating lever through shift mechanism adjustments An improperly adjusted shift mechanism can cause damage to the transmission The shifting mechanism and transmission actuating lever should be free of dirt and well lubricated to ensure proper operation Shifting Into Gear Place the gear shift in Neutral before starting the engine Shifting from one selector position to another selector posi255tion may be made at any time below 1000 rpm and in any order Shifts should be made at the lowest practical engine speed Start the engine and set the throttle at idle speed allow the transmission fluid to warm up for a few minutes Neutral Move the gear shift lever to the middle position You should feel the detent This centers the actuating lever on the With the control in this position hydraulic power is completely interrupted and the output shaft of the does not turn NOTE Some transmissions are equipped with a neutral safety switch Unless the transmission actuating lever is perfectly aligned in neutral the engine starter will not activate Forward Move the gear shift lever to the forward position You should feel the detent The actuating lever267 on the transmission is in the forward position The output shaft and the propeller shaft move the boat in a forward direction Reverse Move the gear shift lever to the reverse position You should feel the detent The actuating lever on the transmission is in the reverse position The output shaft and the propeller should move the boat in a reverse direction asternNOTE Moving the transmission actuating lever from Neutral Position to Forward is always toward the engine Reverse is always away from the engine If boat moves backwards with the gear shift control in the forward position shut off the engine This problem may be a result of incorrect movement of the actuating lever by the gear shift lever WESIERBEKE I Engines Generators 55 ZF MARINE TRANSMISSIONS OPERATING TEMPERATURE A CAUTION If the transmission fluid temperature is too high stop the engine immediately and check the transmission fluid Norn1al operating temperature of the transmission fluid should be in the range of 1220 F 500 Cto 2120 F 1000 C A maximum temperature of 2660 F 1300 Cmay only reached for a short time Make certain there is enough space around the transmission to provide good ventilation and cooling TRANSMISSION COOLER Coolers are standard equipment for the ZF 10M ZF 12M ZF 15M ZF 15MA ZF 15MIV and the ZF 25M The cooler is a separate part of the transmission which prevents any possibilities of coolant diluting the transmission fluid However the continued flow of coolant thru the cooler will in time erode the inside of the cooler causing external leaks A transmission cooler may last ten years or more but in some circumstances depending on operating hours tropical waters maintenance etc it might only last half that time WESTERBEKE recommends having a spare cooler aboard TRANSMISSION COOLER PERIODICAUY INSPECT FOR EROSION AND LEAKAGE MAINTENANCE Transmission maintenance is minimal Keep the exterior housing clean check the fluid level as part of your regular routine and change the fluid every 300 operating hours Periodically inspect the transmission and the cooler for leaks and corrosion Make certain the air vent is clear and when checldng the fluid level look for signs of water contamination fluid will appear as strawberry Storage requires special care Follow these procedures Drain water from tlle transmission oil cooler and replace with a proper mixture of antifreeze coolant NOTE 11zis operation will nonnally occur when the engine raw water cooling is properly winterized o Clean up the transmission and touch up unpainted areas use heat resistant paintFill the transmission with De1ron III ATF fluid to prevent internal corrosion extended storage only twelve months or moreo Loosen attaching hardware from the transmission output flange and propeller shaft coupling flange before removing the boat from the water Separate the flanges and spray with lubricant Inspect the gear shift cable linkage and attachments Look for corrosion of the end fittings cracks or cuts in the conduit and bending of the actuator rods Lubricate all moving parts NOTE If the transmission is to be stored for a long time twelve months or moreit should be topped offwith fluid to prevent inte172al corrosion Reduce the fluid level before putting the engine back into service GEAR SHIFT For additional infonnation contact ZF MARINE GEAR ZF Industries Marine US Headquarters 3131 SW 42nd Street Fort Lauderdale FL 33312 Tel 9545814040 Fax 9545814077 Engines Generators 54 thrust AdobeUCSthe pipe ZF TRANSMISSIONS SHIPMENT For safety reasons the transmission is not filled with transmission fluid during shipment and the selector lever is temporarily attached to the actuating shaft Before leaving the WESTERBEKE plant each transmission undergoes a test run with Dextron II ATF transmission fluid The residual fluid remaining in the transmission after draining acts as a preservative and provides protection against corrosion for at least one year if properly stored FILTER ASSEMBLY OUTPUT COUPLING 0ZF63 OIL COOLER The oil cooler mounted above the transmission provides continuous cooling for the transmission fluid Raw water passes through the tubes of the cooler and discharges overboard The transmission fluid is cooled as it flows around the tubes and back into the transmission WESTERBEKE RECOMMENDS HAVING A SPARE COOLER ABOARD 225 RAW WATER CONNECTION FLUID CONNECTIONS RAW WATER CONNECTION TRANSMISSION FLUID ZF COOLER Fill the transmission with Dextron III ATF The fluid level should be up to the mark on the dipstick After checking the level press the dipstick into the case and it to tighten During the first 25 operating hours inspect the bell housing output shaft and transmission cooler for leakage The fluid should be changed after the first 25 hours and every 300 hours thereafter NEUTRAL SWITCH These transmissions are equipped with a neutral safety switch This is to prevent the engine from starting in gear Unless the transmission selector lever is perfectly aligned in neutral the engine starter will not activate INITIAL OPERATION Set the shifting lever to neutral position NStart the engine and let it run long enough in idle to fill the cooler and hoses with transmission fluid Shift into gear forward and reverse shifting should be smooth and positive Direct changes from forward to reverse are permissible since the multiple disc clutch permits changing at high rpm including sudden reversing at high speeds in the event of danger After initial operation make a visuaI inspection of the output coupling oil cooler and hoses and the cable connections to the transmission LOCKING THE PROPELLER Locking of the propellyr shaft by an additional brake is not required use the gear shift lever position opposite your direction of travel for this purpose Never put the gear shift in the position corresponding to the direction of travel of the boat WHEN UNDER SAIL OR BEING TOWED Rotation of the propeller without a load such as when the boat is being sailed being towed or anchored in a river as well as operation of the engine with the propeller stopped for charging the batterywill have no detrimental effects on the transmission NOTE When the boat is being sailed engine stoppedthe gear shift must be in the neutral position The propeller is at idle and can freewheel DAILY OPERATION o Check the transmission fluid Visually check the gear shift linkage and transmission Start the engine in neutral allowing a few minutes at idle to warm the fluid D Shift into gear NOTE Too Iowan idle speed will produce a chattering noise from the transmission gear and damper plate In such cases the idle speed should be increased Operating Temperature The operating temperature of the transmission should not exceed 176260F 80260CA connection for a temperature probe is provided At maximum output of the engine the fluid may reach 220260F 104 0cA CAUTION If the transmission fluid temperature is too high stop the engine immediately and check the transmission fluid Engines Generators 51 AdobeUCSchange the and suck AdobeUCSZF MARINE TRANSMISSIONS DESCRIPTION The information below is specific to the ZF Transmissions the TRANSMISSION SECTION applies to aU models CONNECTION OF GEAR BOX WITH PROPELLER HEW recommend a flexible connection between the transmission gearbox and the propeller shaft if the engine is flexibly mounted in order to compensate for angular deflections The installation of a special propeller thrust bearing is not required since the propeller thrust will be taken by the transmission bearing provided the value specified under SPECIFICATIONS is not exceeded However the output shaft should be protected from additional loads Special care should be taken to prevent torsional vibration When using a universal joint shaft make certain to observe the manufacturers instructions Even with the engine solidly mounted the use of flexible coupling or DRIVESAVER will reduce stress in the gearbox bearings caused by hull distortions especially in wooden boats or where the distance between transmission output flange and stem gland is less than about 800mm ZF 15M A CAUTION The position of the mechanism behind the actll6ting lever is to ensure equal shift lever travel from neutral position A and B If this mechanism is in any way tampered with the transmission warranty will be void DID v is a product of Globe Marine Rockland MA NOTE When installing the transmission make certain that shifting is not impeded by restricted movability of the Bowden cable or rod linkage by unsuitably positioned guide sheaves too small a bending radius etc In order to mount a support for shift control cable connections use the two threaded holes located above the shift cover on top of the gear housing Refer to the WESTERBEKE parts list CONTROL CABLES The transmission is suitable for single lever remote control Upon loosening the retaining screw the actuating lever can be moved to any position required for the control elements cable or rod linkageMake certain that the shift lever does not contact the actuating lever cover plate the minimum distance between lever and cover should be O5mm The control cable or rod should be arranged at right angle to the actuating shift lever when in the neutral position The neutral position of the operating lever on the control console should coincide with the neutral position of this lever The shifting travel as measured at the pivot point of the actuating lever between the neutral position and end positions A and B should be at least 35mm for the outer and 30mm for the inner pivot point A greater amount of shift lever travel is in no way detrimental and is recommended However if the lever travel is shorter proper clutch engagement might be impeded which in tum would mean premature wear excessive heat generation and clutch plate failure This would be indicated by slow clutch engagement or no engagement at all NOTE Checkfor proper lever travel at least each season CONTROL CABLE NEUTRAL SHIFT LEVER N I COVER O5rnrn J MINIMUM DISTANCE Engines Generators 49 AdobeUCSD x 4 2 5 1 AdobeUCSD x 1 D x D x OIL PRESSURE NOTE WESTERBEKE recommends that the following engine adjustments he peifomled by a competent engine mechanic The infomtation below is provided to assist the mechanic DESCRIPTION The lubricating system is a pressure feeding system using an oil pump The engine oil is drawn from the oil sump by the oil pump which drives the oil under pressure through the oil filter and various lubricating points in the engine The oil then returns to the oil sump to repeat the continuous cycle When the oil pressurc exceeds the specified pressure the oil pushes open the relief valve in the oil pump and returns to the oil sump keeping the oil pressure within its specified range TESTING OIL PRESSURE To test the oil pressure remove the oil pressure sender then install a mechanical oil pressure gauge in its place After warming up the engine set the engine speed at 1800 rpm and read the oil pressure gauge Oil Pressure Between 55 and 75 psi at 1800 rpm Note A newly started coldengine may have an oil pressure up to 70 or 80 psi A warmed engine can have an oil pressure as low as 40 psi Oil pressure will vary depending on the load placed on the generator OIL PRESSURE The engines oil pressure during operation is indicated by the oil pressure gauge on the ins1n1ment panel During normal operation the oil pressure will range between 40 and 85 psi NOTE A newly started cold engine can have an oil pressure reading up to 85 psi A warmed engine can have an oil pressure reading as low as 25 psi These readings win vary depending upon the temperature of the engine and the pms Low OH Pressure The specified safe minimum oil pressure is 5 10 psi A gradual loss of oil pressure usually indicates worn bearings For additional information on low oil pressure readings see the ENGINE chart Testing Oil Pressure To test oil pressure remove the oil pressure sender then install a mechanical oil pressure gauge in its place After warming up the engine set the engine speed at idle and read the oil pressure gauge MECHANICAL OIL PRESSURE GAUGE OIL PRESSURE SWITCH TYPICAL ARRANGEMENT Engines Generators 44 charging AdobeUCSENGINE ADJUSTMENTS NOTE WESTERBEKE recommends that the following engine adjust255ments be performed by a competent engine mechanic The information below is provided to assist the mechanic ENGINE IDLING SPEED The engine idling speed is preset at the factory but once the boat is operating in the water other variables such as pro255peller size shaft length and the transmission can affect the idle speed The normal idle speed for these engines is 650950 RPM however simply put the idle speed should feel comfortable It should be quiet and smooth not racing but not so low that it causes transmission damper plate chatter SETTING THE IDLING SPEED To adjust the engine idle speed engine runningloosen the locknut of the idle adjustment bolt and tum the bolt clockwise to increase idle speed and to reduce Once the speed is set to your satisfaction tighten the locknut FUEL INJECTION PUMP TOPENGINE COMPRESSION Check the compression pressure To do this warm the engine remove all fuel injectors or glow plugs disconnect the fuel shutoff solenoid wire and install a compression adapter in the injector hole or glow plug hole Connect a compression tester on the adapter and crank the engine with the starter motor until the pressure reaches a maximum value Repeat this process for each cylinder Look for cylinders with dramatically at least 20lower compression than the average of the others Compression pressure should not differ by more than 427 psi 30 kgcm2at 200 rpm COMPRESSIO GAUGE INJECTION PUMP SERVICE For disassembly inspection reassembly and internal adjustments of the injection pump it is recommended the pump be taken to a qualified injection service shop authorized to service Diesel KiKi or Zexel injection equipment ENGINE STOP SOLENOID This solenoid is insralled on the top rear of the injection pump and is activated by 12 VDC electrical current 1 The solenoid does not operate when the keyswitch is turned ON a Are the engine batteries turned ON b Is the 20 amp circuit breaker set c Is 12 VDC present at the solenoid connection 2 The solenoid does not stop the engine when SPRING the keyswitch is switched OFF r a Check to see if 12 VDC is still present tPLUNGER at the solenoid electrical lead with the key off bRemove solenoid from injection pump and ensure plunger and spring in the solenoid are not sticking If a weak cylinder is flanked by healthy cylinder the problem is either valve or piston related Check the valve clearances for the weak cylinder adjust as needed and test again If the cylinder is still low apply a small amount of oil into the cylinder to seal the rings and repeat the test If compression comes up the rings are faulty Engines Generators 43 SCHEDULE CYLINDER HEAD BOLT TORQUING Tighten the cylinder head bolts to the specified torque before making valve adjustments When No1 cylinder IS at top dead enler J 1 I i TINCEX liN fEX When No1 cylinder is at top dead center 1 J T 1 EX i fiN rEX When NoA cylinder IS a t top dead center 63BXC71BC 82BFOUR Valve Clearance Intake Exhaust 0012 inch 030 romProcedure to adjust 108BXCSIX 1 Position the piston 1 cylinder approximately IDC Top Dead Centerof its compression stroke Adjust the valve clearance on the values for the cylinders specified 4 Cylinder Model Intake valves No 1 and No2 cylinders Exhaust valves No1 and No3 cylinders 6 Cylinder Model Intake valves No1 2 and 4 cylinders Exhaust valves No1 3 and 5 cylinders 2 Tum the crankshaft 3600 one complete revolutionand adjust the valve clearances on the valves for the cylinders specified 4 Cylinder Model Intake valves NO3 and NO4 cylinders Exhaust valves NO2 and No4 cylinders 6 Cylinder Model Intake valves No3 5 and 6 cylinders Exhaust valves No2 4 and 6 cylinders Engines Generators 42 AdobeUCS9 5 4 8 chafed or SCHEDULE Servicing After Every 100 Hours of Operation 1 Change the engines lubrication oil and oil filter 2 Adjust the alternator and water pump drive belt tension if required 3 Lubricate panel keyswitch use Lockeze only4 Inspect the syphonbreak assembly for proper operation When After Every 250 Hours of Operation Replace the fuel filter elements in the onengine fuel filter and in the optional watersediment separator NOTE Items marked by an asterisk should be performed by a competent mechanic Serviciug After Every 500 Hours of Operation 1 Torque the cylinder head holddown bolts 2 Adjust the valve clearances 3 Drain flush and refill the fresh water cooling system 4 Check the condition of the starter motor drive pinion lubricate pinion 5 Check the resistance of the glow plugs Check circuit operation 6 Check raw water pump for internal wear Examine the pumps cover cam and internal housing Replace worn parts as needed Check for leaks at seals or gaskets and repair them as needed 7 Check the internal condition of the water injected exhaust elbow Inspect exhaust and water passages Remove any carbon andor corrosion build up Replace elbow if needed Servicing Mter Every 800 Hours of Operation 1 Remove and check fuel injectors Injector spray pressure 1920 psi 71 psi 135 kgcm2 5 kgcm2NOTE Poor fuel quality and contaminants will shorten the injector and injector pump service life Eliminate undesirable injection conditions after dripping 2 Check the compression pressure Remove each glow plug and check each cylinders compression pressure The engines speed is at 280 rpm 3 Check the alternator for proper operation 4 Check the tightness of bolts nuts and clamps Engines Generators 39 AdobeUCSENGINE Problem Probable Cause Engine slows and stops 1 Fuel lift pump failure 1 Fuel lift pump should make a distinct ticking sound Replace pump with spare 2 Switches andor wiring loose 2 Inspect wiring for short circuits and loose connections or disconnected Inspect switches for proper operation 3 Fuel starvation S Check fuel supply fuel valves fuel lift pump 4 20 Amp circuit breaker tripping 4 Check for high DC amperage draw during operation Ensure breaker is not overly sensitive to heat which would cause tripping 5 Exhaust system is restricted 5 Check for blockage collapsed hose carbon buildup at exhaust elbow 6 Water in fuel 6 Pump water from fuel tankschange filters and bleed fuel system 7 Air intake obstruction 7 Check air Intake filter cartridge Engine overheatsshuts down 1 Raw water not circulating 1 Raw water pump failure Check impeller replace 2 Coolant not circulating 2 Obstruction at raw water intake or raw water filter 2a Themnostat remove and tesl in hot water Replace thermostat 2b Loss of coolant check hoses hose clamps drain plug etc for leaks 2e Broken or loose belts tightenreplace 2d Air leak in system run engine and open the pressure cap to bleed air Add coolant as needed Engine alarm sound pulsates 1 Loss of oil 1 Check dipstick look for oil leaks at oil filter and at oil drain hose connection 2 Oil pressure switch 2 Replace oil pressure switch Engine alarm sounds continuously 1 Engine coolant 1 Check engine coolant level 2 High temperature switch opens at 2 Check for satisfactory operation with switch bypassed too Iowa temperature check with ohmmeter replace if faully Exhaust smoke problems 1 Blue smoke 1 Incorrect grade of engine 011 1a Crankcase is overfilled with engine oil oil is blowing out through the eXhaust2 White smoke 2 Engine is running cold 2a Faully injector or incorrect injector timing 3 Black smoke 3 Improper grade of fuel 3a Fuel bum incomplete due to high backpressure in exhaust or insufficient air for proper combustion check for restrictions in exhaust system check air timed injectors or valves or poor compression 3c Lack of air check air intake and air filter Check for proper ventilation 3d Overload COOLANT TEMPERATURE AND OIL PRESSURE GAUGES If Ihe gauge reading is other dlatl what is normally indicated by Ihe gauge when Ihe instrument panel is energized the first step is to check for 12 volts DC between dle ignition Band Ihe Negative Bterminals of Ihe gauge Assuming Ihat Ihere is 12 volts as required leave Ihe instrument panel energized and perrorm Ihe following steps 1 Disconnect the sender wire at Ihe gauge and see if the gauge reads zero which is dle normal reading for this situation 2 Remove the wire attached to the sender terminal at Ihe sender and connect it to ground See if the gauge reads full scale which is the normal reading for driB situation If both of the above gauge tests are positive the gauge is undoubtedly OK and the problem lies either with the conductor from the sender to the gauge or with the sender If either of the above gauge tests are negative the gauge is probably defective and should be replaced Assuming the gauge is OK check the conductor from the sender to the sender terminal at the gauge for continuity Check that the engine block is connected to the ground Some starters have isolated ground terminals and if the battery is connected to the starter both plus and minus le11Ilinalsthe ground side will not necessarily be connected to the block Engines Generators 38 ENGINE The following table describes certain problems relating to engine service the probable causes of these prob255lems and the to overcome these problems Problem Probable Cause No panel indications fuel solenoid 1 Battery switch not on or fuel pump is no working key switch is on and PREHEAT button is depressed2 20amp circuit breaker tripped 3 10amp breaker tripped on preheat solenoid 4 Loose battery connections 5 Preheat solenoid not operating START button is depressed no starter 1 Connection to solenOid faulty engagement 2 Gear shift not in neutrel 3 Faulty switch 4 Faulty solenoid 5 Loose battery connections 6 Low battery START button is depressed panel 1 Poor connections to fuel solerlOid indications OK starter solenoid OK fuel solenoid not functioning 2 Defective fuel solenoid Engine cranks but does not 1 Faulty fueling system start fuel solenoid energized 2 Preheat solenoid faulty 3 Low battery power Engine cant be stopped 1 Faulty DC alternator 2 Disconnect fuel shutoff cable NOTE The engine 8 electrical system is protected by a 20 ampere manual reset circuit breaker located on a bracket at the back of the engine The preheat solenoid is mounted on the same bracket 1 Check switch andor battery connections 2 Reset breaker if breaker trips again check preheat solenoid circuit and check circuit for shorts to ground 3 Check the voltage both at and after the breaker on the preheat solenoid 4 Check connection to starter solenoid and connection to engine ground stud Check battery cable connections 5 Check solenoid S terminal for voltage 1 Check connection 2 Gear shift must be in neutral see NEUTRAL SWTCHunder HURTH Check switch with ohmmeter 4 Check thaI 12 volts are present at the solenoid connection 5 Check battery connections 6 Check battery charge state 1 Check connections 2 Check that 12 volts are present at the connection on the fuel run solenoid 1 Check that fuel valves are open 1 a Check for air in fuel system Bleed air from fuel system 1 b Fuel filters clogged Replace filters and bleed air from fuel system 2 Check solenoid 3 Switch to combine house and start batteries 3a Replace batteries 1 Remove Exc connection at alternator repair alternator 2 Check connection at shutoff lever Pull lever back to close offthe fuel 3 Fuel nm solenoid will not 3 Manually disconnect the 12 volt connection to the fuel run solenoid at the injection pump Battery runs down 1 Oil pressure switch 1 Observe if gauges and panel lights are activated when engine is not running Test the oil pressure 2 High resistance leak to ground 2 Check wiring Insert sensitive 0 25 ampmeter in battery lines Do not start engineRemove connections and replace after short is located 3 Low resistance leak 3 Check all wires for temperature rise to locate the fault 4 Poor battery connections 4 Check cable connections at battery for loose connections corrosion 5 DC altemator not cHarging 5 Check connections check belt tension test altemator See tachometer not operatingDC ELECTRICAL Battery not charging 1 DC charge circuit faulty 1 Pertorm DC voltage check of generator charging circuit See Testing the BattelJl Charging Circuit 2 Alternator drive 2 Check drive belt tension alternator should furn freely Check for loose connections Check output with voltmeter Ensure 12 volts are present at the Exc terminal Generators 37 BATTERY TESTING THE OUTPUT CIRCUIT ENGINE RUNNING TO STARTER SOLENOIO TESTING THE EXCITATION CIRCUIT 1 Connect the positive multimeter probe to the excitation terminal R on the alternator and the negative probe to the ground terminal E on the alternator 2 Turn the ignition switch to the on position and note the multimeter reading The reading should be 13 to 25 volts see illustration3 If the reading is between 75 and 11 volts the rotor field circuit probably is shorted or grounded 4 If the reading is between 60 and 70 volts the rotor field circuit probably is open 5 If no reading is obtained an open exists in the lead or in the excitation circuit of the regulator Disconnect the lead from exe terminal R Connect the positive multimeter probe to the excitation lead and the negative multimeter probe to ground terminal E If the multimeter now indicates an approximate battery voltage the voltage regulator is defective and must be replaced If no voltage is indicated check the excitation circuit for loose or dirty connections or damaged wiring CHECKING THE SERVICE BATTERY Check the voltage of the service battery This battery should have a voltage between 13 and 14 volts when the engine is running If not there is a problem in the service battery charging circuit Troubleshoot the service battery charging circuit by checking the wiring and connections the solenoid isolator battery switch and the battery itself When the problem has been solved and before the alternator is back in operation take the time to tighten and clean the terminal studs Also clean the connecting tenninals from the wiring harness ALTERNATOR REPAIR If tests indicate a failed alternator it will need to be disassembled and repaired Any good alternator service shop can do the job NOTE WESTERBEKES Service Manual has detailed instructions for the disassembly and repair of their standard altemators BATTERY CARE The minimum recommended capacity of the battery used in the engines 12 volt DC control circuit is 600900 Cold Cranking Amps CCAReview the manufacturers and then establish a systematic maintenance schedule for your engines starting batteries and house batteries 225 Monitor your voltmeter for proper charging during engine operation 225 Check the electrolyte level and specific gravity with a hydrometer 225 Use only distilled water to bring electrolytes to a proper level 225 Make certain that battery cable connections are clean and tight to the battery posts and to your IEnafnes Generators 267363 through 8 check the output circuit SEE WIRING DIAGRAM FOR WIRE CONNECTIONS TO OPTIONAL ALTERNATORS 50AMP ALTERNATOR EXCITER TERMINAL l NOTE FOR CORRECT WIRING HARNESS CONNECTIONS TO THE ALTERNATOR REFER TO THE WIRING DIAGRAMS IN THIS MANUAL DESCRIPTION The following infonnation applies to the standard alternators that are supplied with WESTERBEKES Marine Engines and Marine Generators ELECTRICAL CHARGING CIRCUIT The charging system consists of an alternator with a voltage regulator an engine DC wiring harness a DC circuit breaker and a battery with connecting cable and wires Because of the use of integrated circuits Iesthe electronic voltage regulator is very compact and is mounted internally or on the back of the alternator It is desirable to test the charging system alternator and voltage regulatorin the boat using the wiring harness and electrical loads that are a pennanent part of the system Inboat testing will then provide the technician with an operational test of the charging system as well as the major components of the electrical system ALTERNATOR DESCRIPTION The stator is connected to a threephase fullwave bridge rectifier package which contains six diodes The bridge converts the AC generated in the stator to a DC output for battery charging and accessories such as a radio heater lights refrigerator depth sounder etc Power to the regulator and the field of the integral regulator alternator is provided by the field diode or diode triopackage contained in the alternator These alternators produce a rated output of 50 or 51 amps Rated output is achieved at approximately 6000 alternator rpm at an ambient temperature of75260F 238260CThe alternators are designed to operate in an ambient temperature range of 40260 to 212260F 400 to 100260CVOLTAGE REGULATOR The integral voltage regulator is an electronic switching device which senses the system voltage level and switches the voltage applied to the field in order to maintain a proper system voltage The regulator design utilizes allsilicon semi conductors and thickfilm assembly techniques After the voltage has been adjusted to the proper regulating value the entire circuit is encapsulated to protect the circuit and the components from possible damage due to handling or vibration and moisture encountered in a vessel ALTERNATOR Use this section to determine if a problem exists with the charging circuit or with the alternator If it is determined that the alternator or voltage regulator is faulty have a qualified technician check it LOW BATTERYFAULTY CIRCUIT If the starter only moans or makes a clicking sound instead of spinning the engine to life it is likely a low battery or a faulty connection in the starting circuit and not an alternator problem A simple test is to try starting again with a cabin light on if the light dims significantly or goes out the battery is dead If the light remains bright look for a poor connection in the starting circuit A WARNING A working alternator runs hot i a failed alternator can become very hot Do not touch the alternator until it has cooled fIVIWESTERBEKE I Engines Generators 34 the positive AdobeUCSwire to the alternator pulley If voltage is present you should feel the magnetic field If not the problem may be the brushes worn J or the rotor open Using the cable sizes indicated LENGTH REQUIRED UP iJPro 12 2 WIREUP TO 20 lWIRE ALWAYS USE FINE STRAND CABLE1 S Make certain that the batteries negative post ground cable to the engine block is the same heavy gauge as the positive cable 6 Mount the regulator to a flat surface in a cool dry location a Connect the black wire to the ground terminal on the alternator A CAUTION Do not connect any power source with255out first grounding the regulator b Plug the 2pin connector into the alternator make certain it is firmly seated c The red battery sense wire should be connected to the batteries positive the positive ONE MOTOR A WARNING When performing these procedures position yourself safely away from the moving parts of the engine in case the engine startsup Also warn other crew members of the danger POSITIVE TERMINAL IGNITION TERMINAL Test again by jumping the two large terminal studs Hold the screwdriver blade finnly between the studs Do not allow the screwdriver blade to touch the solenoid or starter casing this would cause a short A WARNING There will be arching as the full starting current should be flowing thru the blade of the screwdriver If the starter spins the solenoid is faulty If the starter fails to spin the motor is probably faulty If no arching occurred there is no juice reaching the solenoid NOTE Starter motors are either inertia type or preengaged In the preengaged model the solenoid also moves an arm that engages the starter motor to the flywheel of the engine using a screwdriver to bypass the solenoid on such a starter will run the motor without engaging the flywheel Tum the starter switch on to provide power to the solenoid Hopefully it will create enough magnetic field for the arm to move even though the contacts inside the solenoid are bad EMERGENCY START Corrosion to the starter brushes andor the solenoid contacts can cause the sporadic problem of the engine starting one time but not another If corrosion is the problem the starter will need to be rebuilt It is however sometimes possible to get started by taping the starter lightly with a small hammer With the battery switch off and no ignition tap lightly on the casing as shown then try to start the engine CAREFULLY NOT TO HIT FITTINGS OR WIRE CONNECTioNS I TAP LIGHTLY WHERE INDICATED If that fails tum the battery switch on and have a crew member tum the ignition on and off rapidly as you tap again with the hammer This may loosen the brushes and allow contact to start the engine When you reach a repair facility the starter will need to be repaired SERVICE WESTERBEKE uses a standard starter motor which can be serviced or rebuilt at any starter motor automotive service center If replacing the starter motor make certain the new motor is certified for marine use Automotive starters do not meet USCG standards If in doubt contact your WESTERBEKE dealer TO REMOVE FOR SERVICE 1 Disconnect the negative battery cable 2 If necessary remove any components to gain full access to the starter motor 3 Label and disconnect the wiring from the starter Do not allow wires to touch tape over the terminals4 Remove the starter mounting bolts 5 Remove the starter from the engine In some cases the starter will have to be turned to a different angle to clear obstructions En Jines Generators 3D AdobeUCSthe solenoid Check the AdobeUCSGLOW PLUGS DESCRIPTION The glow plugs are wired through the preheat solenoid When PREHEAT is pressed at the control panel this solenoid should click on and the glow plug should begin to get hot INSPECTION To inspect the plug remove the electrical terminal cOJmec255tions then unscrew or unclamp each plug from the cylinder head Thoroughly clean each plugs tip and threads with a soft brush and cleaning solution to remove all the carbon and oil deposits While cleaning examine the tip for wear and burn erosion if it has eroded too much replace the plug TESTING An accurate way to test glow plugs is with an ohmmeter Touch one prod to 267the glow plugs wire connection and the other the body of the glow plug as shown A good glow plug WIll have a 10 15 ohm resistance This method can be used with the plug in or out of the engine You can also use an multimeter to test the power drain 8 9 amps per plugA WARNING These glow plugs will become very hot to the touch Be careful not to burn your fingers when testing the plugs GLOW PLUG Reinstall the plugs in the engine and test them again The plugs should get very hot at the terminal endwithin 7 to 15 seconds If the plugs dont heat up quickly check for a short circuit When reinstalling the glow plugs use antiseize compound on the threads A WARNING 00 not keep a gowplug on for more than 30 seconds GLOW PLUG TIGHTENING TORQUE 10267 15 MKG 7 26711 FTLBTESTING WITH AN OHMMETER PREHEAT ON USING A TEST LIGHT I TERMINAL END Engines Generators 28 AdobeUCSWIRING SCHEMATIC 12 VDe StdHR 0 I I 1 I I PftItUT SOL Ill I r I AlHtUtATOA p T IS PROTECTED SY A XCUIYE CURRENT WILL TItE eUILOEROWNtR IIISUED TO PREVEII RESET CIRCuIT SRrR THE SRUKEIt 10 nl9 A SURE THAT THE tNST T eErrEE ELECTRIC 1 AN QIjorr SWITCH SHOULD BE INSTALtED BUWtEfI TH243 8AfTrR ANTART243R TO SWITCH SHOUlHOi BE uS243O TO OR 8RtAf THE UICUIT J THE PINK WIRt AT PlUG 1 IS UNUSED AND SHOULD at HiULATED CAPUN PAN243 0111 4 THE GRAY WIRE AT PLUG 2 IS UNUSEO AIriIIStlQIJtO BE INSULATED ONUl PANE ONIY Fun CAPTAIN PANEL 99 AMP All ALI 114 BRN PRESTOlIE 1 Z AMP Al I t I 0 REO lESIH 100 AMP ALT ALE CONNECTOR ON THIS SIO243 1111 REO NOTE 18E fOR BATTERY AnATCMEIIY win NHD TO BE UOEO TO AN 225225 AUGE HOW 10 GAUGE 14 BRN 14 GRA 14 PINK 14 LI 6L UNIVERSAL PROPULSlfrN PREHouTE 51 AMP AT WIRING SCHEMATIC 39144 MALE CONNECTOR 011 THIS SlOE tTACHllj A l4 GSA NOT USEDlJ14 RrO RM REO t14 tT BLU 14 PHIK BL tl4aU CASE GH I SCOCT JUWPU F242fI uS WITH TWO eHT243AI243S OPT IONAL AL TE R NA TORS 256 13iA 160 191A LESTU ALTERNATORS IAlblSU ON lH243 W50S 6glV GxrtV HgV 821CfV IOgVI IOSIVl Engines Generators 27 51 AMP ALTERNATOR sr ANDARO ALTERNATOR ON IHE 68 a Be a 716 01 826 a I aee 11l loec 11l AdobeUCS2 I J I IIOTE An onoff switch should be installed In this circuit to disconnect the starter from the battery in 811 emergency and when leaving the boat Twelve volt engine staffers typically draw 200 to 300 amps when cranking A switch with a continuous rating of 175 amps at 12 VDC will normally serve this function but a switch must never be used to I make273 the starter circuit I I I I I I I I I tlO lU WIRING DIAGRAM 2m p ALARM C SUllER Btu ADMIRAL PANEL J r255I I I I I 1 I 1 I 1 I o tl8 I UI MOonSE LIFT PUMP WIRING DIAGRAM 39144 AdobeUCSWATER HEATER CONNECTION KIT 638 AND 63C ONLYHOSE CONNECTION TO THE TANK Remove the hex head plug at the thermostat assembly and install the WATER HEATER CONNECTION KIT Attach the heater hose to the water heater connection kit and check that all connections are tight THERMOSTAT HOUSING MAKE CERTAIN THE RESTRICTOR NIPPLE IS INSTALLED WATER HEATER CONNECTION KIT OPERATION Remove the manifold cap and replace any lost coolant Run the engine at idle 1800 rpm for generatorswith the heat exchanger petcock open slowly add coolant as needed Once coolant flows from the petcock close it and replace the manifold cap When circulation is present to and from the hot water tank feel hosesrecheck the manifoldit should be topped off with coolant Also fill the coolant recovery tank half fulL With the engine running inspect for leaks and check for normal temperature RETURN HOSE CONNECTION FROM THE TANK Locate the hose and piping that comes off the engines fresh water pump and cut into the smaller hose that leads to the oil cooler Install the T fitting reconnect the cooler hose and install the hot water tank return hose to the bottom of the T fitting as shown below Make certain all connections are tight 58 T FITTING OWNER INSTALLED HEATER HOSE TO HOT WATER TANK A7TACH HOT WATER HOSE FROM HOT WATER TANK A CAUTION Bewam of the hot engine cooant wear proper gloves TO OIL COOLER A WARNING With the engine running stay clear of the drive belts Generator267 keep ben guards in place NOTE For additional information on the proper installation of your hot water system refer to your operators manual or contact your WESTERBEKE dealer Engines Generators 25 WATER HEATER CONNECTIONS 71 C 828 FOURFOR PRODUCTION MODELS FROM MARCH 2004 ON WESTERBEKE provides easy access for connecting to an onboard hot water system These connections allow for the engines hot water coolantto flow to the ships hot water tank heating the fresh water and then cycling back to the engine The water heater should be mounted in a convenient location either in a high or low position in relation to the engine so that the connecting hoses from the heater to the engine can run in a reasonably direct line without any loops which might trap air Hoses should rise continuously from their low point at the heater to the engine so that air will rise naturally from the heater to the engine If trapped air is able to rise to the heater then an air bleed petcock must be installed at the higher fitting on the heater for bleeding air while filling the system THERMOSTAT HOUSING TD CONNECT TO THE WATER HEATER AIR BLEED PETCOCK NOTE An air bleed petcock is located on the engineV heat exchanger and on the thermostat housing Open these petcocks when filling the engine s coolant system to allow air to escape Close both tightly after all the air is removed NOTE If any portion 0 the heating circuit rises above the engine S closed cooling system pressure cap then a pressurized aluminumremote expansion tank Kit 024177must be installed in the circuit to become the highest point Tee the remote expansion tank into the heater circuit choos255ing the higher athe two connectionsor the return Tee at the heater and plumb a single line up to the tanks location and the other back to the engines return Install the remote expansion tank in a convenient location so the fresh water coolant level can easily be checked The remote expansion tank will now serve as a check and system fill point The plastic coolant recovery tank is not used when the remote expansion tank kit is installed since this267 tank serves the same function DISCONNECT THE EXISTING HOSE AND ATTACH THE HEATER HOSE AT THIS COUPLING REMOVE THE EXISTING BYPASS HOSE DISCONNECT THE EXISTING HOSE AND ATTACH THE HEATER HOSE TO THIS FITTING Engines Generators 24 The pressure cap on the engines manifold should be installed once the engines cooling system is filled with coolant Finish filling the cooling system from the remote tank once the system is filled and is free of air and exhibits good coolant circulation During engine operation checking the engines coolant should be done at the remote tank and not at the engine manifold cap The hose connection from the heater to the remote expansion tank should be routed and supported so as to rise continuously from the heater to the tank enabling any air in the system to rise NOTE An air bleed petcock is located at the top center of the engines heat exchanger Open this petccek when filling the freshwater system to allow air in the exchanger to escape Close tightly once all air is removed Exchanger Pressure Cap is Rated Lower than Manifold Cap HEATER ABOVE ENGINE Engines Generators 23 Heater Coils Located Above Manifold Pressure Cap AdobeUCSWATER HEATER CONNECTION KIT 71B C 82B FOUR 107 B CThe models refered to in this manual are equipped with connections for the plumbing of engine freshwater coolant to a domestic hot water heater One connection tois located on the lower side ofthe exhaust manifold The other connection returnis located on the center outer surface of the heat exchanger Both of these connections have square head 12 NPT plugs in them to plumb a domestic hot water heater into the engines freshwater system Remove both of these plugs and install the appropriate hose nipple 12 NPT x 34 ID to route hose to and return from the domestic water heater Installation The heater should be mounted conveniently either in a high or low position in relation to the engine so that the connecting hoses from the heater to the engine can run in a reasonably direct line without any loops which might trap air Air Bleed Petcock Heat Exchanger HEATER BELOW ENGINE Hoses should rise continuously from their low point at the heater to the engine so that trapped air will rise naturally from the heater to the engine If trapped air is able rise to the heater then an air bleed petcock must be installed at the higher fitting on the heater for bleeding air while filling the system Avoid loops in hose runs which will trap air NOTE If any portion of the heating circuit rises above the engines own pressure cap then a pressurized aluminumremote expansion tank must be installed in the circuit to become the highest point The remote expansion tanks part number is 24177 Tee the remote expansion tank into the heater circuit at the heater connection choosing the higher of the two for the return Tee right at the heater and plumb a single line up to the tanks location and the other back to the engines retUrn install the remote expansion tank in a convenient location such as In a sail locker so the fresh water coolant level can easily be checked The remote expansion tank will now serve as a check and system fill point The plastic coolant recovery tank is not used when the remote expansion tank kit is installed since this tank serves the same function Engines Generators 22 REMOTE OIL FILTER fhls popular accessory is used to relocate the engines oil fil255ter from the engine to a more convenient location such as an NOTE Westerbeke is lWt responsible for engine failure due to incorrect installation of the Remote Oil Filter room bulkhead NOTE Refer to ENGINE OIL CHANGE in this rnarwalfor instructions on removing the oil filter lro install simply remove the engine oil filter and thread on WBSTERBEKBs remote oil filter kit as shown Always 1nstall this kit with the oil filter facing down as illustrated Contact your WESTERBEKB dealer for more information THE OUT CONNECTION MUST ATTACH TO THE IN CONNECTION AT THE REMOTE Oil FILTER APPLY A THIN COAT OF ClEAN OIL TO THE O267RING WHEN INSTALLING THIS KIT THREAD THE KIT ON THEN HAND TIGHTEN AN AODlTIONAL 34 TURN AFTER THE O267RING CONTACTS THE BASE THE IN CONNECTION HOSE MUST ATTACH TO THE OUT CONNECTION ATTl1E RIMOTI Oil FILTER A CAUTION It is vital to Install the oil lines cor255rectlylf the 011 flows In the reverse direction the by pass valve in the filter assembly will pf1vent the oil from reaching the engine causing an Intemal engine failure If there is no 011 pressure reading shutdown immediately and check the hose Ci rmnirlctions APPLY A THIN COAT OF CLEAN OIL TO THE FIlTER GASKET WHEN INSTALLING AFTER TliE FILTER CQNTACTS IHE BASE TIGHTEN IT AN ADDITIONAL fMIWESTERBEKE i Engines Generators 21 AdobeUCSENGINE LUBRICATING OIL When installing the new oil filter element wipe the filter gaskets sealing surface on the bracket free of oil and apply a thin coat of clean engine oil to the rubber gasket on the new oil filter Screw the filter onto the threaded oil filter nipple on the oil filter bracket and then tighten the filter firmly by hand NOTE The engine oil is cooled by engine coolant flowing through passages in the oil jilter bracket housing assembly A WARNING Used engine oil contains harmful contaminants Avoid prolonged skin contact Clean skin and nails thoroughly using soap and water Launder Dr discard clothing Of rags containing used oil Discard used oil properly NOTE Generic jilters are not recommended as the material standards or diameters of important items on generic parts might be entirely different from genuine parts Immediately after an oil jilter change and oil fill run the engine to make sure the oil pressure is nonnal and that thef245l are oil leaks around the new oil filter 3 Filling the Oil Sump Add new oil through the oil filler cap on the top of the engine or through the side oil fill Mter refilling run the engine for a few moments while checking the oil pressure Make sure there is no leakage around the new oil filter or from the oil drain system and stop the engine Then check the quantity of oil with the lube oil dipstick Fill to but not over the high mark on the dipstick should the engine require additional oil ENGINE OIL Use a heavy duty engine oil with an API classification of CF CG4 CHA or CI4 Change the engine oil after an initial 50 hours ofbreakin operation and every 100 hours of operation thereafter For reconnnended oil use SAE 15W40 oil reconnnends the use of synthetic oil Engines Generators 20 before SYSTEM Zinc Anode A zinc anode or pencil is located in the raw water cooling circuit within the heat exchanger The purpose of having the zinc is to sacrifice them to electrolysis action taking place ill the raw water cooling circuit thereby reducing the effects of electrolysis on other components of the system The condition of the zinc anode should be checked monthly and the anode cleaned or replaced as required Spare anodes should be carried on board NEW REPLACE REPLACE CLEAN AND REUSE ZINC ANODES action is the result of each particular uzstallation and vessel location not that of the engine ZINC ANODE DO NOT USE SEALANT ON THE THREADS TYPICAL HEAT EXCHANGER ASSEMBLY If the zinc anodes need replacement hold the hex boss into which the zinc anode is threaded with a wrench while loos255ening the anode with another wrench This prevents the hex boss from possibly tearing off the exchanger shell After removing the Zinc note the condition Qf it If the zinc is in poor condition there are probably a lot of zinc flakes within the exchanger Remove the end of the heat exchanger and clean the inside of all zinc debris Always have a spare heat exchanger end gasket in case the present one becomes dam255aged when removing the end cover Replace the gasket refer tc your engine models heat exchanger end gasket part num255berOring and cover and install a new zinc anode NOTE The threads of the zinc anodes are pipe threads and do not require sealant Sealant should not be used as it may insulate the zinc from the metal of the heat exchanger hous255ing preventing electrolysis action on the zinc Heat Exchanger Service After approximately 1000 hours of operation remove clean and pressure test the engines heat exchanger A local auto255motive radiator shop should be able to clean and test the heat exchangerNOTE Operating in silty andor tropical waters may require that a heat exchanger cleaning be perfonned more often than every 1000 hours IR BLEED PETCOCK COVER SECURING BOLT WATER CLEAN our EVERY DRAIN INSPECT BOTH ENDS 100 HOURS CLfAN OUT DEBRis HEAT EXCHANGER NOTE When installing the heat exchanger end covers Be sure that the end cover securing bolts sealing Oring is installed Failure to install this sealing Oring can result in end plate failuresea water leakage Engines Generators 18 SYSTEM RAW WATER PUMP The raw water pump is a selfpriming rotary pump with a nonferrous housing and a Neoprene impeller The impeller has flexible blades which wipe against a curved cam plate within the impeller housing producing the pumping action On no account should this pump be run dry There should always be a spare impeller and impeller cover gasket aboard an impeller kitRaw water pump impeller failures occur when lubricant raw wateris not present during engine operation Such failures are not warrantable and operators are cautioned to make sure raw water flow is present at start255up The raw water pump should be inspected periodically for brokeno tom impeller blades See MAINTENANCE SCHEDULE NOTE Should a failure occur with the pump s iliternal parts seals and bearingsit may be more cost efficient to purchase a new pump and rebuild the original pump as a spare AIR INTAKE NOTE To operate efficiently a diesel engine must intake a continuous volume of clear air Hard starting an erratic idle and black e245zaust smoke are all symptoms of a restricted air intake Changing the Raw Water Pump Impeller Close the raw water intake valve Remove the pump cover and with the aid of two small screwdrivers carefully pry the impeller out of the pump Install the new impeller and gasket Move the blades to confonn to the curved cam plate and push the impeller into the pumps housing When assembling apply a thin coating of lubricant to the impeller and gasket Open the raw water intake valve A CAUTION If any of the vanes have broken off the impeller they must be found to prevent blockage in the cooling circuit They often can be found in the heat exchanger or in the discharge fitting of the pump RAW WATER PUMP ALIGN WITH THE SLOT IN THE SHAFT l INSPECTION CHECK ATTHE BASE OF I EACH BLADE BY BENDING VIGOROUSLY REPLACE THE IMPELLER IF THERE RAW WATER IN ARE ANY CRACKS WHEN INSTALLING TAKE CARE TO ALIGN THE IMPELLER KEYWAY WITH THE SHAFT KEY FOLD THE IMPELLER BLADES IN EITHER DIRECTION THEY WILL TURN IN THE CORRECT POSITION WHEN THE PUMP STARTSAPPLY LIQUID SOAP AT ASSEMBLY Engines Generators 17 COOLING SYSTEM THERMOSTAT A thennostat located near the manifold at the front of the engine controls the coolant temperature as the coolant continuously flows through the closed cooling circuit When the engine is first started the closed thennostat prevents coolant from flowing some coolant is bypassed through a hole in the thennostat to prevent the exhaust manifold from overheatingAs the engine wanns up the thennostat gradually opens The thennostat is accessible and can be checked cleaned or replaced easily Cany a spare thennostat and gasket Replacing the Thermostat Remove the cap screws and disassemble the thennostat housing as shown When installing the new thennostat and gasket apply a thin coat of sealant on both sides of the gasket before pressing it into place Do not overtighten the cap screws Run the engine and check for nonnal temperatures and that there are no leaks at the thennostat housing TEMPERATURE SENDER THERMOSTAT ASSEMBLY TYPICALRAW WATER INTAKE STRAINER NOTE Always install the strainer at or below the waterline so the strainer will always be selfpriming A clean raw water intake strainer is a vital component of the engines cooling system Include a visual inspection of this strainer when making your periodic engine check The water in the glass should be clear Perfonn the following maintenance after every 100 hours of operation 1 Close the raw water seacock 2 Remove and clean the strainer filter 3 Clean the glass 4 Replace the washer jf necessary 5 Reassemble and install the strainer 6 Open the seacock 7 Run the engine and check for leaks NOTE Also follow the above procedure after having run hard aground If the engine temperature gauge ever shows a higher than nonnal reading the cause may be that silt leaves or grass may have been caught up in the strainer slowing the flow of raw water through the cooling system WASHER TYPICAL RAW WATER STRAINER OWNER RAW WATER SEACOCK INSPfCTAND CLEAN EVERY 100 HOURS Engines Generators 16 SYSTEM FRESH WATER COOLING CIRCUIT NOTE Refer to the ENGINE COOLANT page for the recommended antifreeze and water mixture to be used as the fresh water coolant Fresh water coolant is pumped through the engine by a circulating pump absorbing heat from the engine The coolant then passes through the thermostat into the manifold to the heat exchanger where it is cooled and returned to the engine block via the suction side of the circulating pump When the engine is started cold external coolant flow is prevented by the closed thermostat although some coolant flow is bypassed around the thermostat to prevent the exhaust manifold from overheatingAs the engine warms up the thermostat gradually opens allowing full flow of the engines coolant to flow unrestricted to the external portion of the cooling system Coolant Recovery Tank A coolant recovery tank allows for engine Coolant expansion and contraction during engine any significant loss of coolant and without introducing air into the cooling system This tank should be located at or above the engine manifold level and should be easily accessible COOLANT RECOVERY TANK NOTE PeriodicaUy check the condition of the manifold pressure cap Ensure that the upper and lower rubber seals are in good condition and check that the vacuum valve opens and closes tightly Carry a spare cap SEAL CHECKING THE PRESSURE CAP CHANGING COOLANT The engines coolant must be changed according to the MAINTENANCE SCHEDULE If the coolant is allowed to become contaminated it can lead to ovetbeating problems A CAUTION Proper cooling system maintenance is triflcal a substantial number of engine failures can be traced back to cooling system corrosion Drain the engine coolant by removing the drain plug on the engine block and opening the manifold pressure cap Flush tQe system with fresh water then reinstall the drain and start the refill process Refer to the illustration below NOTE The drain petcock on the heat exchanger can also be used to help drain engine coolant A WARNING Beware of the hot engine coolant Wear protective gloves Refilling the Coolant After replacing the engine block drain plug close the heat exchangers coolant petcock Then run he engine at idle and slowly poor clean premixed coolant into the manifold Monitor the coolant in the manifold and add as needed Fill the manifold to the filler neck and install the manifold pressure cap Remove the cap on the coolant recovery tank and fill with coolant mix to halfway between LOW and MAX and replace the cap Run the engine and observe the coolant expansion flow into the recovery tank After checking for leaks stop the engine and allow it to cool Coolant should draw back into the cooling system as the engine cools down Add coolant to the recovery tank if needed and check the coolant in the manifold Clean up any spilled coolant TO COOLANT RECOVERY TANK FROM COOLANT RECOVERY TANK KEEP THE COOLANT PASSAGE CLEAR COOLANT EXPANSION PRESSURE CAP Enfline Generators 15 injection equipment MAINTENANCE Raw Water Pump Coolant System Electric Fuel lift Pump Inlet Fuel Filter DC Alternator Fuellniectors Starter Motor Preheat Circuit Englne Cylinder Compression Torque Cylinder Head Holddown bolts MAINTENANCE SCHEDULE NOTE Use the engine hour meter gauge to log your engine hours or record your engine hours by running time CHECK HOURS OF OPERATION EACH EXPLANATION OF SCHEDULED DAY 50 100 250 SOD 750 1000 1250 MAINTENANCE 0 0 0 Remove the pump cover and inspect impeller gasket cam and cover for wear Check the bearings and seals the shaft can turn but not when reassembling 0 Drain flush and refill cooling system with appropriate antifreeze mixture compatible with various cooling system metals 0 0 0 0 0 0 Periodically check the wiring connections and inspect the fuel line connections 0 0 0 0 0 Replace 0 0 0 Check DC charge from alternator Check the mounting bracket tighten electrical connections 0 Check and adjust injection opening pressure and spray condition see ENGINE ADJUSTMENTS0 0 Check solenoid and motor for corrosion Remove and lubricate Clean and lubricate the starter motor pinion drive 0 0 Check operation of preheat solenoid Remove and clean glow plugs check resistance 46 ohmsReinstall with anti seize compound on threads D 0 Check compression pressure and timing see Engine Adjustments0 0 0 At first 50 hours then every 500 hours see ENGINE the Valve Clearances 0 0 0 Adjust Valve Clearances see ENGINE Exchanger 0 Remove have profeSSionally cleaned and pressure tested WESTERBEKE recommends this service be performed by an authorized mechanic Engines Generators 13 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 WARNING LIGHTS ALARMS CIRCUIT BREAKER ALTERNATOR WARNINGS LOW OIL PRESSURE ALARM SWITCH The Captain Control Panel indicates alternator low discharge with a red warning light A low oil pressure alarm switch is located off the engines oil gallery This switchs sensor monitors the engines oil pressure Should the engines oil pressure fall to 5 10 psi 04 07 kgcm2this switch will activate a pulsating alarm The Admiral Control Panel uses a voltmeter to monitor the performance of the alternator COOLANT TEMPERATURE SWITCH A coolant temperature switch is located on the thermostat housing This switch will activate a continuous alarm if the coolants operating temperature reaches approximately 210260F 99260CTO CONTROL PANEL TYPICAL ARRANGEMENT ENGINE CIRCUIT BREAKER The DC harness on the engine is protected by an manual reset circuit breaker 20 amps DCExcessive current draw or electrical overload anywhere in the instrument panel wiring or engine wiring will cause the breaker to trip In this event most engines will shut down because the opened breaker disconnects the fuel supply If this should occur check and repair the source of the problem After repairing the fault reset the breaker and restart the engine COOLANT SEND OR THERMOSTAT ASSEMBLY Engines Generators 11 ENGINE BREAKIN PROCEDURE DESCRIPTION Although your engine has experienced a minimum of one hour of test operations at the factory to make sure accurate assembly procedures were followed and that the engine oper255ated properly a breakin time is required The service life of your engine is dependent upon how the engine is operated and serviced during its initial 50 hours of use Breakingin a new engine basically involves seating the pis255ton rings to the cylinder walls Excessive oil consumption and smoky operation indicate that the cylinder walls are scored which is caused by overloading the engine during the breakin period Your new engine requires approximately 50 hours of initial conditioning operation to break in each moving part in order to maximize the performance and service life of the engine Perfonn this conditioning carefully keeping in mind the fol255lowing 1 Start the engine according to the STARTING PROCE255DURE section Run the engine at fast idle while checking that all systems raw water pump oil pressure battery chargingare functioning 2 Allow the engine to wann up preferably by running at fast idleuntil the water temperature gauge moves into the 130 140260F 55 60260Crange 3 While using the vessel run the engine at various engine speeds for the first 25 hours Avoid prolonged periods of idling 4 Avoid rapid acceleration especially with a cold engine 5 Use caution not to overload the engine The presence of a grey or black exhaust and the inability of the engine to reach its full rated speed are signs of an overload 6 During the next 25 hours the engine may be operated at varying engine speeds with short runs at full rated rpm Avoid prolonged idling during this breakin period CHECK LIST D Monitor the control panel gauges D Check for leaks of fuel and engine oil D Check for abnormal noise such as knocking friction vibration and blowback sounds D Confinn exhaust smoke When the engine is cold white smoke When the engine is warm almost smokeless When the engine is overloaded some black smoke and soot NOTE See the TRANSMISSION section of this manual for breakin information on your transmission Engines G200merators 10 STARTING STOPPING PROCEDURE CHECKLIST Follow this check list each day before starting your engine D Visually inspect the engine for fuel oil or water leaks D Check the engine oil level dipstickD Check the coolant level in coolant recovery tank Periodically check the manifold coolant leveL D Check the transmission fluid level D Check your fuel supply D Look for clean fuel in the fuel filterwater separator transparent bowL Check for loose wires at the alternator and make sure its mounting is secure D Check the starting batteries weeklyD Check drive belts for wear and proper tension weeklyD Visually inspect the raw water pump for leakage STARTING THE ENGINE 1 Place the transmission in neutral throttle advanced NOTE Hydraulically operated transmissions have a neutral safety switch through which the starter solenoid energizing circuit passes This switch is open when the transmission is in gear so the starter solenoid will not energize 2 Tum the KEY SWITCH to the ON position 2 oclockIf the panel is energized gauges are litand the alarm buzzer will pulse 3 Press the PREHEAT BUTfON and hold for 5 to 15 seconds depending how cold it is The foellift pump is priming the engine and the preheat is activated4 Continue pressing the PREHEAT BUTTON and press the START BUTTON The starter motor is cranking the engine5 Release the START and PREHEAT BUTTON as the engine starts The alarm buzzer should silence as the oil pressure rises 6 With the engine running check the instruments for proper oil pressure and battery charging voltage Also check for overboard discharge of exhaust water The water temperature will rise slowly until the thermostat opens Do not engage the gear shift until the temperature is close to nonnal NOTE Never attempt to engage the starter while the engine is ntnning It is important to closely monitor the panel gauges Become aware of the normal engine readings and take immediate action if these readings start to vary If a smart regulator is part of the charging system allow about 50 for the RPM gauge to activate FAILURE TO START If the engine fails to start when the start button is pressed for 5 seconds wait for at least 30 seconds and repeat the starting procedure Make certain the transmission control is in neutral position as some engines have a neutral safety SWItch to prevent starting in gear Never run the starter for more then 30 seconds If the engine fails to start refer to the CHART in this manual A CAUTION Prolonged cranking intervals without the engine starting can result in the engine exhaust system filling with raw water This may happen because the pump is pumping raw water through the raw water cooling system during cranking This raw water can enter the engines cylinders by way of the exhaust manifold once the exhaust system tills Prevent this from happening by clOSing the raw water supply throughhull shutoff draining the exhaust muffler and correcting the cause of the excessive engine cranking Engine damage resulting from raw water entry is not a warrantable issue the owneroperator should keep this in mind STOPPING PROCEDURE To stop the engine bring the throttle to an idle position and place the transmission in neutral Allow the engine to idle for a few moments to stabilize temperatures then shut the engine down by turning off the key switch NOTE When starting A voltage drop will occur when the preheat button is depressed Engines Generators 9 FOR INITIAL STARTUP Before starting your engine for the first time or after a prolonged layoff check the following items o Check the engine oil level Add oil to maintain the level at the high mark on the dipstick o Turn on the fuel supply then check the fuel supply and examine the fuel filterwater separator bowl for contaminants o Check the transmission fluid level o Check the DC electrical system Inspect wire connections and battery cable connections Make certain the positive battery cable is connected to the starter solenoid and the negative cable is connected to the engine ground stud this location is taggedo Check the coolant level in both the plastic recovery tank and at the manifold NOTE If the engine has not yet been filled with coolant refer to the COOliNG SYSTEM section of this manual D Visually examine the engine Look for loose or missing parts disconnected wires and unattached hoses Check the threaded connections and engine attachments D Make certain there is proper ventilation around the engine An ample supply is necessary for proper engine performance D Make sure the mounting installation is secure D Ensure the propeller shaft is securely attached to the transmission D Open the thruhull and make certain raw water is primed to the raw water strainer SIDE OIL FILL TYPICALEngines Generators 8 COOlANT RECOVERY TANK OIL DIPSTICK PRESS IN TIGHT FULL FUEL ENGINE OIL AND ENGINE COOLANT DIESEL FUEL Use fuel1hat meets 1he requirements or specification of Class 2D ASTMand has a cetane rating of 45 or better Care Of The Fuel Supply Use only clean diesel fuel The clearance of1he components in your fuel injection pump is very critical invisible dirt particles which might pass through 1he filter can damage these finely finished parts It is important to buy clean fuel and keep it clean The best fuel can be rendered unsatisfactory by careless handling or improper storage facilities To assure that the fuel going into the tank for your engines daily use is clean and pure the following practice is advisable Purchase a wellknown brand of fuel Install and regularly service a good visualtype fuel filterwater separator between the fuel tank and the engine The Raycor 500 FG or 900 FG are good examples of such filters ENGINE OIL Use a heavy duty engine oil with an API classification of Cf or CG4 or better Change the engine oil after an initial 50 hours of breakin operation and every 100 hours of operation 1hereafter For recommended oil use sAE 15W40 oil viscosityand stay with 1he same brand of oil thruout the life of the engine A CAUTION Do not allow two Dr mDre brands of engine oil to mix Each brand contains its own additives additives of different brands could reacl in the mixture to produce properties harmful tD your engine ENGINE COOLANT WESTERBEKE recommends a mixture of 50 antifreeze and 50 distilled water Distilled water is free from the chemicals that can corrode internal surfaces The antifreeze performs double duty It allows the engine to run at proper temperatures by transferring heat away from the engine to the coolant and lubricates and protects the cooling circuit from rust and corrosion Look for a good quality antifreeze 1hat contains Supplemental Cooling Additives SCAsthat keep the antifreeze chemically balanced crucial to long term protection The distilled water and antifreeze should be premixed before being poured into the cooling circuit NOTE Lookfor the new long lasting antifreeze that is now available PURCHASING ANTIFREEZE Rather than preparing the mixture WESTERBEKE recommends buying the premixed antifreeze so that so that when adding coolant the mixture will always be correct There are two common types of antifreeze Ethylene Glycol greenand Propylene Glycol can be used but do not mix the two and if changing from one to another flush the engine thoroughly Premixed antifreeze for DIESEL Engines Specification ASTM 5345 MAINTENANCE Change the engine coolant every five years regardless of the number of operating hours as the chemical additives that protect and lubricate the engine have a limited life COOLANT RECOVERY TANK A coolant recovery tank kit is supplied with each generator The purpose of this recovery tank is to allow for engine coolant expansion and contraction during engine operation without the loss of coolant and without introducing air into the cooling system II Engines Generators 7 CONTROL PANEL DESCRIPTION This control panel is equipped with a KEY switch an RPM gauge PREHEAT and START but255tons an JNSTRLMEITT JEST button and three indicator lamps one for AL1ERNATOR DISCHARGE one for low OIL PRESSURE and one for high ENGINE COOLANT 1EMPERATURE RPM GAUGE REGISTERS REVOLUTIONS PER MINUTE OF THE ENGINE AND CAN BE RECALIBRATED FOR ACCURACY FROM THE REAR OFTHE PANEL Oil PRESSURE ALTERNATOR ALARM LIGHT ALARM LIGHT WATER TEMPERATURE ALARMUGHT 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 The panel also includes an alarm buzzer for low OIL PRESSURE or high COOLANT 1EMPERATURE The RPM gauge is illuminated when the KEY switch is turned on and remains illuminated while the engine is in operation ALARM THE ALARM WILL SOUND IF THE ENG1NES OIL PRESSURE FALLS BELOW 5 10 psi 04 07 kgemIN THIS EVENT THE ALARM WILL EMIT A PULSATING SIGNAL THE ALARM WILL ALSO SOUND IF THE COOLANT TEMPERATURE IN THE FRESHWATER COOLING CIRCUIT RISES TO 210aF 99260CIN THiS EVENT THE ALARM WILL EMIT A CONTINUOUS SIGNAL NOTE THE ALARM WILL SOUND WHEN THE KEY SWITCH IS TURNED ON THIS SOUNDING IS NORMAL ONCE THE ENGINE STARTS AND THE ENGINES OIL PRESSURE REACHES 15 pSi 11 kgemTHE ALARM WILL SILENCE TEST BUTTON WHEN PRESSED TESTS THE ALTERNATOR THE OIL PRESSURE AND THE COOLANT TEMPERA255TURE CONTROL CIR255CUITS WHEN PRESSED THE ALTERNATOR THE OIL PRESSURE AND THE WATER TEMPERA255TURE INDICATOR LIGHTS ILLUMINATE IN ADDITION TO SOUND255ING THE ALARM BUZZER KEY SWITCH PROVIDES POWER ONLY TO THE lNSTRUMErijT PANEL CLUSTER BUTTON WHEN PRESSED ENERGIZES THE ALTERNATORS EXCITER THE FUEL LIFT PUMP THE FUEL SOLENOID ON THE INJECTION PUMP AND THE ENGINES GLOW PLUGS AND BYPASSES THE ENGINES OIL PRES255SURE ALARM SWITCH IN ADDITION THIS BUTTON ENER255GIZES THE START BUTTON Engines Generators 6 ADMIRAL CONTROL PANEL DESCRIPTION This control panel is equipped with a KEY switch and RPM gauge with an ELAPSED TIME meter which measures the engines running time in hours and in 1110 hours The panel also includes a WA1ER 1EMPER255ATURE gauge which indicates water temperature in degrees Fahrenheit an OIL PRESSURE gauge which measures the engines oil pressure in pounds per square inch and a DC control circuit VOLTAGE gauge which measures the sys255tems voltage All gauges are illuminated when the key switch is turned on and remain illuminated while the engine is in operation The panel also contains two rubberbooted pushbuttons one for PREHEAT and one for START RPM GAUGE REGIS267 TERS REVOLUTIONS PER MINUTE OF THE ENGINE AND CAN BE RECALIBRATEO FOR ACCURACY FROM THE REAR OF THE PANEL HOURMETER REGISTERS ELAPSED TIME AND SHOULD BE USED AS A GUIDE FOR THE MAINTENANCE SCHEDULE WATER TEMPERATURE GAUGE THIS GAUGE IS GRADUATED IN DEGREES FAHRENHEIT AND IS IlWMINATED WHILE THE KEY SWITCH IS TURNED ON THE ENGINES NORMAL OPERATING TEMPERATURE IS 170 190267 F 77 aa267cPREHEAT PRESSED ENERGIZES THE ALTERNATORS EXCITER THE FUEL LIFT PUMP THE FUEL SOLENOID ON THE INJECTION PUMP AND THE ENGINES GLOW PLUGS IT BYPASSES THE ENGINES OIL PRESSURE ALARM SWITCH IN ADDITION THIS BUTTON ENERGIZES THE START BUTTON 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 When the engine is shut down with the key switch 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 oil pressure gauge will fall to zero when the key switch is turned off The temperature gauge will once again register the engines true temperature when electrical power is restored to the gauge A separate alarm buzzer with harness is supplied with every Admiral Panel The installer is responsible for electrically con255necting the buzzer to the fourpin connection on the engines electrical harness The installer is also responsible for installing the buzzer in a location where it will be dry and where 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 the engines oil pressure rises above 15 psi 11 kglcm2Oil PRESSURE GAUGE THIS GAUGE IS GRADU255ATED IN POUNDS PER SQUARE INCH PSIAND IS ILLUMINATED WHILE THE KEY SWITCH IS TURNED ON THE ENGINES NORMAL OPERATING OIL PRESSURE RANGES BElWEEN 30 60 psi 21 42 kgemAUTOMATIC ALARM SYSTEM SWITCH PROVIDES POWER ONLY TO THE INSTRUMENT PANEL CLUSTER DC VOLTMETER INDICATES THE AMOUNT THE BATTERY IS BEING CHARGED SHOULb SHOW 13VTO 14V COOLANT TEMPERATURE ALARM AN ALARM BUZZER HAS BEEN SUPPLIED WITH THE INSTRUMENT PANEL IF THE ENGINES COOLANT REACHES 210 F 99CTHIS SWITCH WILL CLOSE SOUNDING THE ALARM WHICH WILL EMIT A CONTINUOUS SIGNAL Oil PRESSURE ALARM AN OIL PRESSURE ALARM SWITCH IS LOCATED OFF THE ENGINES OIL GALLERY THIS SWITCH MONITORS THE ENGINES OIL PRESSURE SHOULD THE ENGINES OIL PRESSURE FALL TO 5 10 psi OA 07 kgemTHE SWITCH WILL CLOSE SOUND255ING THE ALARM IN THIS EVENT THE ALARM WILL EMIT A PULSATING SIGNAL Engines Generators 5 black nameplate This WESTERBEKE Diesel Engine is a product of WESTERBEKEs long years of experience and advanced technology We take great pride in the superior durability and dependable performance of our engines and generators Thank you for selecting WESTERBEKE In order to get the full use and benefit from your engine it is important that you operate and maintain it correctly This manual is designed to help you do this Please read this man255ual carefully and observe an the safety precautions through255out Should your engine require servicing contact your nearest WESTERBEKE dealer for assistance This is your operators manual A parts catalog is also provided and a technical manual is available from your WESTERBEKE dealer If you are planning to install this equipment contact your WESTERBEKE dealer for WESTERBEKES installation manual WARRANTY PROCEDURES Your WESTERBEKE Warranty is included in a separate folder If after 60 days of submitting the Warranty Registry form you have not received a customer identification card registering your warranty please contact the factory in writing with model information including the engines serial number and commission date Customer Identification Card WOWESTERBEKE Customer Identification MR ENGINE OWNER NUUNSTREET HOMETOWN Model Ser PRODUCT SOFTWARE Product software technical data parts lists manuals brochures and from sources other than WESTERBEKE are not within WESTERBEKEs control WESTERBEKE CANNOT BE RESPONSIBLE FOR THE CONTENT OF SUCH SOFTWARE MAKES NO WAR255RANTIES OR WITH RESPECT THERETO INCLUDING ACCURACY TIMELINESS OR COMPLETENESS THEREOF AND WILL IN NO EVENT BE UABLE FOR ANY TYPE OF DAMAGE OR INJURY INCURRED IN CONNECTION WITH OR ARISING OUT OF THE FURNISHING OR USE OF SUCH SOF1WARE WESTERBEKE customers should keep in mind the time span between printings ofWESTERBEKE product software and the unavoidable existence of earlier WESTERBEKE product software The product software provided with WESTERBEKE products whether from WESTERBEKE or other suppliers must not and cannot be relied upon exclu255sively as the definitive authority on the respective product It not only makes good sense but is imperative that appropriate of WESTERBEKE or the supplier in question be consulted to determine the accuracy and currentness of the product software being consulted by the customer NOTES CAUTIONS AND WARNINGS As this manual takes you through the operating procedures maintenance schedules and of your marine engine critical information will be highlighted by NOTES CAUTIONS and WARNINGS An explanation follows NOTE An operating procedure essential to note A CAUTION Procedures which if nDt strictly observed can result in the damage Dr destruction of your engine A WARNING Procedures which if not properly fol255lowed can result in personal injury or loss of life Engines Generators 3 PARTS IDENTIFICATION ASSEMBLY DC CHARGING ALTERNATOR COOlANT PRESSURE CAP CONNECTION DRIVE BELT CRANKSHAFT PULLEY OIL DRAIN HOSE FUEL LIFT PUMP PREHEAT SOLENOID ZOAMP CIRCUIT BREAKER HBW HURTH TRANSMISSION REAR TYPICALLEFT SIDE SHIFT LEVER FILL ENGINE BLOCK DRAIN PLUG Engines Generators 2 WATER INJECTED EXHAUST ELBOW Oil PRESSURE SENDOR COOLER Fill FILTER AIR INTAKE SILENCER REAR FILTER FLEXIBLE MOUNT THERMOSTAT FRONT MANIFOLD 10 PLATE ALTERNATOR AdobeUCSTABLE OF CONTENTS Parts Identification 2 Remote Oil Filter Optional 21 Introduction 3 Water Heat Connections 22 Warranty Procedures 3 Serial Number Location 4 Admiral Control Panel 5 Captain Control Panel 6 Wiring Diagram 26 Wiring Schematic 27 Glow Plugs 28 Starter Motor 29 Fuel Engine Oil and Coolant 7 Preparations for Initial StartUp 8 The Daily Operation 9 Engine BreakIn Procedure 10 Dual Output Alternators 31 Alternator 34 Engine 37 Service Schedule 41 Warning Lights Alarms and Circuit Breaker 11 Cylinder Head Torque 42 Maintenance Schedule 12 Engine Adjustments 43 Fuel System 14 Oil Pressure 44 FueliWater Separator 14 Tachometer 43A Fuel Filters 14 Engine Specifications 45 Cooling System 15 ZF Marine Transmission 49 Changing Coolant 15 Thermostat 16 Raw Water Intake Strainer 16 Borg Warner Transmission 49 LayUp and 58 Raw Water Pump 17 Torque Data 60 Heat Exchanger 18 Metric Chart 6 Zinc Anode 18 Engine Lubricating Oil 19 Suggested Spare Parts 63 Changing the Oil Filter 19 Changing the Oil 19 Engines Generators 1 INSTALLATION When installing WESTERBEKE engines and generators it is important that strict attention be paid to the following infom1ation CODES AND REGULATIONS Strict federal regulations ABYC guidelines and safety codes must be complied with when installing engines and generators in a marine environment SIPHONBREAK For installations where the exhaust manifoldwater injected exhaust elbow is close to or will be below the vessels waterline provisions must be made to install a siphon255break in the raw water supply hose to the exhaust elbow This hose must be looped a minimum of 20 above the vessels waterline Failure to use a siphonbreak when the exhaust manifold injection port is at or below the load waterline will result in raw water damage to the engine and possible flooding of the boat If you have any doubt about the position of the waterinjected exhaust elbow relative to the vessels waterline under the vessels various operating conditions install a siphonbreak NOTE A siphonbreak requires periodic inspection and cleaning to ensure proper operation Failure to properly maintain a siphonbreak can result in catastrophic engine damage Consult the siphonbreak manufacturer for proper maintenance EXHAUST SYSTEM The exhaust hose must be certified for marine use The system must be desigued to prevent water from entering the exhaust under any sea conditions and at any angle of the vessels hull A detailed 40 page Marine Installation Manual covering gasoline and diesel engines and generators is available from your WESTERBEKE dealer Engines Generators iv AVAILABLE FROM YOUR WESTERBEKE DEALER SAFETY INSTRUCTIONS 225 Do not wear loose clothing or jewelry when servicing equipment tie back long hair and avoid wearing loose jackets shirts sleeves rings necklaces or bracelets that could be caught in moving parts 225 Make sure all attaching hardware is properly tightened Keep protective shields and guards in their respective places at all times 225 Do not check fluid levels or the drive belts tension while the engine is operating 225 Stay clear of the drive shaft and the transmission coupling when the engine is running hair and clothing can easily be caught in these rotating parts HAZARDOUS NOISE A WARNING High noise levels can cause hearing loss 225 Never operate an engine without its muffler installed 225 Do not run an engine with the air intake 225 Do not run engines for long periods with their enclosures open A WARNING Do not work on machinery when you are mentally or physically incapacitated by fatigue OPERATORS MANUAL Many of the preceding safety tips and wamings are repeated in your Operators Manual along with other cautions and notes to highlight critical information Read your manual carefully maintain your equipment and foHow all safety procedures GASOLINE ENGINE AND GENERATOR INSTALLATIONS Preparations to install an engine should begin with a thorough examination of the American Boat and Yacht Councils ABYCstandards These standards are a combination of sources including the USCG and the NFPA Sections of the ABYC standards of particular interest are H2 Ventilation Pl Exhaust Systems PA Inboard Engines E9 DC Electrical Systems All installations must comply with the Federal Code of Regulations FCRABye NFPA AND USCG PUBLICATIONS FOR INSTALLING DIESEL ENGINES Read the following ABYC NFPA and USCG publications for safety codes and standards Follow their when installing your engine ABYC American Boat and Yacht CouncilSafety Standards for Small Craft Order from ABYC 3069 Solomons Island Rd Edgewater MD 21037 NFPA National Fire Protection Protection Standard for Motor Craft Order from NFPA 11 Tracy Drive Avon Industrial Park Avon MA 02322 USCG United States Coast GuardUSCG 33CFR183 Order from US Goverument Printing Office Washington DC 20404 Engines Generators iii SAFETY INSTRUCTIONS ACCIDENTAL STARTING A WARNING Accidental starting can cause injury or death 225 Disconnect the battery cables before servicing the engine generator Remove the negative lead first and reconnect it last 225 Make certain all personnel are clear of the engine before starting 225 Make certain all covers guards and hatches are reinstalled before starting the engine BATTERY EXPLOSION A WARNING Battery explosion can cause injury or death 225 Do not smoke or allow an open flame near the battery being serviced Lead acid batteries emit hydrogen a highly explosive gas which can be ignited by electrical arcing or by lit tobacco products Shut off all electrical equipment in the vicinity to prevent electrical arcing during servicing 225 Never connect the negative battery cable to the positive connection terminal of the starter solenoid Do not test the battery condition by shorting the terminals together Sparks could ignite battery gases or fuel vapors Ventilate any compartment containing batteries to prevent accumulation of explosive gases To avoid sparks do not disturb the battery charger connections while the battery is being charged 225 Avoid contacting the terminals with tools etc to prevent bums or sparks that could cause an explosion Remove wristwatch rings and any other jewelry before handling the battery 225 Always tum the battery charger off before disconnecting the battery connections Remove the negative lead first and reconnect it last when disconnecting the battery BATTERY ACID A WARNING Sulfuric acid in batteries can cause severe injury or death 225 When servicing the battery or checking the electrolyte level wear rubber gloves a rubber apron and eye protection Batteries contain sulfuric acid which is destructive If it comes in contact with your skin wash it off at once with water Acid may splash on the skin or into the eyes inadvertently when removing electrolyte caps TOXIC EXHAUST GASES A WARNING Carbon monoxide COIs a deadly gas 225 Ensure that the exhaust system is adequate to expel gases discharged from the engine Check the exhaust system regularly for leaks and make sure the exhaust elbow L securely attached 225 Be sure the unit and its surroundings are well ventilated Run blowers when running the generator set or engine 225 Do not run the generator set or engine unless the boat is equipped with a functioning marine carbon monoxide detector that complies with ABYCA24 Consult your boat builder or dealer for installation of approved detectors 225 For additional information refer to ABYC T22 educational information on Carbon MonoxideA WARNING Carbon monoxide COis an invisible odorless gas Inhalation produces flulike symptoms nausea or death 225 Do not use copper tubing in diesel exhaust systems Diesel fumes can rapidly destroy copper tubing in exhaust systems Exhaust sulfur causes rapid deterioration of copper tubing resulting in exhaustwater leakage 225 Do not install exhaust outlet where exhaust can be drawn through portholes vents or air conditioners If the engine exhaust discharge outlet is near the waterline water could enter the exhaust discharge outlet and close or restrict the flow of exhaust Avoid overloading the craft 225 Although diesel engine exhaust gases are not as toxic as exhaust fumes from gasoline engines carbon monoxide gas is present in diesel exhaust fumes Some of the symptoms or signs of carbon monoxide inhalation or poisoning are Vomiting Inability to think coherently Dizziness Headache Nausea Throbbing in temples Muscular twitching Weakness and sleepiness AVOID MOVING PARTS A WARNING Rotating parts can cause injury or death 225 Do not service the engine while it is running If a situation arises in which it is absolutely necessary to make operating adjustments use extreme care to avoid touching moving parts and hot exhaust system components Engines Generators II SAFETY INSTRUCTIONS INTRODUCTION Read this safety manual carefully Most accidents are caused by failure to follow fundamental rules and precau255tions Know when dangerous conditions exist and take the necessary precautions to protect yourself your personne4 and your machinery The following safety instructions are in compliance with the American Boat and Yacht Council ABYCstandards PREVENT ELECTRIC SHOCK A WARNING Do not touch AC electrical connections while engine is running Lethal voltage is present at these connections 225 Do not operate this machinery without electrical enclosures and covers in place 225 Shut off electrical power before accessing electrical equipment 225 Use insulated mats whenever working on electrical equipment 225 Make sure your clothing and skin are dry not damp particularly shoeswhen handlipg electrical equipment 225 Remove wristwatch and all jewelry when working on electrical equipment 225 Electrical shock results from handling a charged capacitor Discharge capacitor by shorting terminals together PREVENT BURNS HOT ENGINE A WARNING Do not touch hot engine parts Dr exhaust system components A running engine gets very hot 225 Always check the engine coolant level at the coolant recovery tame A WARNING Steam can cause injury or death 225 In case of an engine overheat allow the engine to cool before touching the engine or checking the coolant PREVENT BURNS FIRE A WARNING Fire can cause injury Dr death 225 Prevent flash fires Do not smoke or permit flames or sparks to occur near the carburetor fuel line filter fuel pump or other potential sources of spilled fuel or fuel vapors Use a suitable container to catch all fuel when removing the fuel line carburetor or fuel filters 225 Do not operate with the air removed Backfire can cause severe injury or death 225 Do not smoke or permit flames or sparks to occur near the fuel system Keep the compartment and the clean and free of debris to minimize the chances of fire Wipe up all spilled fuel and engine oil 225 Be aware Diesel fuel will bum PREVENT BURNS EXPLOSION A WARNING Explosions from fuel vapors can cause injury or death 225 All fuel vapors are highly explosive Use extreme care when handling and storing fuels Store fuel in a wellventilated area away from sparkproducing equipment and out of the reach of children 225 Do 110t fill the fueltankswhile the engine is mnning 225 Shut off the fuel service valve at the engine when servicing the fuel system Take care in catching any fuel that might spill DO NOT allow any smoking open flames or other sources of fire near the fuel system or engine when servicing Ensure proper ventilation exists when servicing the fuel system 225 Do not alter or modify the fuel system 225 Be sure all fuel supplies have a positive shutoff valve 225 Be certain fuel line fittings are adequately tightened and free of leaks 225 Make sure a fire extinguisher is installed nearby and is properly maintained Be familiar with its proper use Extinguishers rated ABC by the NFPA are appropriate for all applications encountered in this environment ACCIDENTAL STARTING A WARNING Accidental starting can cause injury Dr death 225 To prevent accidental starting when servicing the generator remove the 8 amp fuse from the control panel 225 Disconnect the battery cables before servicing the engine generator Remove the negative lead first and reconnect it last 225 Make certain all personnel are clear of the engine before starting 225 Make certain all covers guards and hatches are reinstalled before starting the engine Engines Generators R N MANUAL 638 and 63C FOUR 71 8 and 71 C FOUR 828 FOUR 1088 and 108C SIX MARINE DIESEL ENGINES PUBLICATION NO 038922 EDITION FIVE OCTOBER 2006 WESTERBEKE CORPORATION 150 JOHN HANCOCK ROAD MYLES STANDISH INDUSTRIAL PARK TAUNTON MA 02780 WEBSITE
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