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Westerbeke Diesel 65b Four Technical Manual



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OPERATORS 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: WWW.WESTERBEKECOM
                            A WARNING
Exhaust gasses contain carbon Monoxide, an odorless and
colorless gas. Carbon Monoxide is poisonous and can cause
unconsciousness and death. Symptoms of Carbon Monoxide
exposure can include:
-Dizziness                   - Throbbing in Temples
-Nausea                      - Muscular Twitching
-Headache                    - Vomiting
- Weakness and Sleepiness -Inability to Think Coherently

IF YOU OR ANYONE ELSE EXPERIENCE ANY OF THESE SYMPTOMS,
GET OUT INTO THE FRESH AIR IMMEDIATELY. If symptoms persist,
seek medical attention. Shut down the unit and do not restart
until it has been Inspected and repaired.
            ~---------'

             X
              '~                           A WARNING DECAL is provided by
                                           WESTERBEKE and should be nxed to a

   CO
  ..
 WA RNINGI
                                           bulkhead near your engine or generator.
                                      \ WESTERBEKE also recommends installing
                                      ..\ CARBON MONOXIDE DETECTORS in the
                                           living/sleeping quarters of your vessel.
  'C-enerators Produye CARBON M9NOXIDE. The u are ine""ensive and easilu
         Regular M",ntenance Required    !''''.                           ,
 l            ~~~~~                      J obtainable at your local marine store.



                        CALIFORNIA
                   PROPOSITION 65 WARNING
               Marine diesel and gasoline engine
              exhaust and some of its constituents
              are known to the State of California
                to cause cancer, birth defects,
                 and other reproductive harm.
                                              SAFETY INSTRUCTIONS
INTRODUCTION                                                         · Do not operate with the air cleaner/silencer removed.
                                                                       Backfire can cause severe injury or death.
Read this safety manual carefully. Most accidents are
caused by failure to follow fundamental rules and precau-            · Do not smoke or permit flames or sparks to occur near
                                                                       the fuel system. Keep the compartment and the
tions. Know when dangerous conditions exist and take the
                                                                       engine/generator clean and free of debris to minimize the
necessary precautions to protect yourself, your personne4              chances of fire. Wipe up all spilled fuel and engine oil.
and your machinery.
The following safety instructions are in compliance with             · Be aware - Diesel fuel will bum.
the American Boat and Yacht Council (ABYC) standards.
                                                                     PREVENT BURNS - EXPLOSION
PREVENT ELECTRIC SHOCK                                                   A WARNING: Explosions from fuel vapors can cause
                                                                         injury or death!
    A WARNING: Do not touch AC electrical connections
    while engine is running. Lethal voltage is present at            · All fuel vapors are highly explosive. Use extreme care
                                                                       when handling and storing fuels. Store fuel in a
    these connections!
                                                                       well-ventilated area away from spark-producing
·    Do not operate this machinery without electrical                  equipment and out of the reach of children.
     enclosures and covers in place.                                 · Do 110t fill the fuel.tank(s) while the engine is mnning.
· Shut off electrical power before accessing electrical              · Shut off the fuel service valve at the engine when servicing
  equipment.                                                           the fuel system. Take care in catching any fuel that might
· Use insulated mats whenever working on electrical                    spill. DO NOT allow any smoking, open flames, or other
  equipment.                                                           sources of fire near the fuel system or engine when
                                                                       servicing. Ensure proper ventilation exists when servicing
· Make sure your clothing and skin are dry, not damp                   the fuel system.
  (particularly shoes) when handlipg electrical equipment.
                                                                     · Do not alter or modify the fuel system.
· Remove wristwatch and all jewelry when working on
  electrical equipment.                                              · Be sure all fuel supplies have a positive shutoff valve.
· Electrical shock results from handling a charged                   · Be certain fuel line fittings are adequately tightened and
  capacitor. Discharge capacitor by shorting terminals                 free of leaks.
  together.                                                          · Make sure a fire extinguisher is installed nearby and is
                                                                       properly maintained. Be familiar with its proper use.
PREVENT BURNS - HOT ENGINE                                             Extinguishers rated ABC by the NFPA are appropriate
                                                                       for all applications encountered in this environment.

    A WARNING: Do not touch hot engine parts Dr                      ACCIDENTAL STARTING
    exhaust system components. A running engine gets
    very hot!                                                            A WARNING: Accidental starting can cause injury
                                                                         Dr death!
·    Always check the engine coolant level at the coolant
     recovery tame
                                                                     · To prevent accidental starting when servicing the
                                                                       generator, remove the 8 amp fuse from the control panel.
    A WARNING: Steam can cause injury or death!                      · Disconnect the battery cables before servicing the engine!
                                                                       generator. Remove the negative lead first and reconnect
·    In case of an engine overheat, allow the engine to cool           it last.
     before touching the engine or checking the coolant.             · Make certain all personnel are clear of the engine before
                                                                       starting.
PREVENT BURNS - FIRE                                                 · Make certain all covers, guards, and hatches are
                                                                       re-installed before starting the engine.
    A WARNING: Fire can cause injury Dr death!
· 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.


                                                            Engines & Generators
                                            SAFETY INSTRUCTIONS
ACCIDENTAL STARTING                                                  TOXIC EXHAUST GASES

    A WARNING: Accidental starting can cause injury                      A WARNING: Carbon monoxide (CO) Is a deadly gas!
    or death!
                                                                     · Ensure that the exhaust system is adequate to expel gases
· Disconnect the battery cables before servicing the engine/
                                                                       discharged from the engine. Check the exhaust system
  generator. Remove the negative lead first and reconnect
                                                                       regularly for leaks and make sure the exhaust
  it last.
                                                                       manifolds/water-injected elbow L" securely attached.
· Make certain all personnel are clear of the engine before
  starting.                                                          · Be sure the unit and its surroundings are well ventilated.
                                                                       Run blowers when running the generator set or engine.
· Make certain all covers, guards, and hatches are
  re-installed before starting the engine.                           · Do not run the generator set or engine unless the boat is
                                                                       equipped with a functioning marine carbon monoxide
                                                                       detector that complies with ABYCA-24. Consult your
BATTERY EXPLOSION                                                      boat builder or dealer for installation of approved
                                                                       detectors.
    A WARNING: Battery explosion can cause injury                    · For additional information refer to ABYC T-22
    or death!                                                          (educational information on Carbon Monoxide).

· Do not smoke or allow an open flame near the battery
  being serviced. Lead acid batteries emit hydrogen, a                   A WARNING: Carbon monoxide (CO) is an invisible
  highly explosive gas, which can be ignited by electrical               odorless gas. Inhalation produces flu-like symptoms,
  arcing or by lit tobacco products. Shut off all electrical             nausea or death!
  equipment in the vicinity to prevent electrical arcing
  during servicing.                                                  · Do not use copper tubing in diesel exhaust systems. Diesel
· Never connect the negative (-) battery cable to the                  fumes can rapidly destroy copper tubing in exhaust
  positive (+) connection terminal of the starter solenoid.            systems. Exhaust sulfur causes rapid deterioration of
  Do not test the battery condition by shorting the terminals          copper tubing resulting in exhaust/water leakage.
  together. Sparks could ignite battery gases or fuel vapors.        · Do not install exhaust outlet where exhaust can be drawn
  Ventilate any compartment containing batteries to prevent            through portholes, vents, or air conditioners. If the engine
  accumulation of explosive gases. To avoid sparks, do not             exhaust discharge outlet is near the waterline, water could
  disturb the battery charger connections while the battery            enter the exhaust discharge outlet and close or restrict the
  is being charged.                                                    flow of exhaust. Avoid overloading the craft.
· Avoid contacting the terminals with tools, etc., to prevent        · Although diesel engine exhaust gases are not as toxic as
  bums or sparks that could cause an explosion. Remove                 exhaust fumes from "gasoline engines, carbon monoxide
  wristwatch, rings, and any other jewelry before handling             gas is present in diesel exhaust fumes. Some of the
  the battery.                                                         symptoms or signs of carbon monoxide inhalation or
· Always tum the battery charger off before disconnecting              poisoning are:
  the battery connections. Remove the negative lead first              Vomiting        Inability to think coherently
  and reconnect it last when disconnecting the battery.
                                                                       Dizziness       Throbbing in temples
BATTERY ACID                                                           Headache        Muscular twitching
                                                                       Nausea          Weakness and sleepiness
    A WARNING: Sulfuric acid in batteries can cause                  AVOID MOVING PARTS
    severe injury or death!

· When servicing the battery or checking the electrolyte                 A WARNING: Rotating parts can cause injury
  level, wear rubber gloves, a rubber apron, and eye                     or death!
  protection. Batteries contain sulfuric acid which is
  destructive. If it comes in contact with your skin, wash it        ·     Do not service the engine while it is running. If a
  off at once with water. Acid may splash on the skin or                   situation arises in which it is absolutely necessary to
  into the eyes inadvertently when removing electrolyte                    make operating adjustments, use extreme care to avoid
  caps.                                                                    touching moving parts and hot exhaust system
                                                                           components.




                                                         Engines & Generators
                                                                --
                                                                II
                                              SAFETY INSTRUCTIONS
· Do not wear loose clothing or jewelry when servicing                  ABye, NFPA AND USCG PUBLICATIONS FOR
  equipment; tie back long hair and avoid wearing loose
  jackets, shirts, sleeves, rings, necklaces or bracelets that
                                                                        INSTALLING DIESEL ENGINES
  could be caught in moving parts.                                      Read the following ABYC, NFPA and USCG publications
                                                                        for safety codes and standards. Follow their
· Make sure all attaching hardware is properly tightened.
                                                                        recommendations when installing your engine.
  Keep protective shields and guards in their respective
  places at all times.                                                  ABYC (American Boat and Yacht Council)
                                                                        "Safety Standards for Small Craft"
· Do not check fluid levels or the drive belts tension while
  the engine is operating.                                              Order from:
· Stay clear of the drive shaft and the transmission coupling              ABYC
  when the engine is running; hair and clothing can easily                 3069 Solomon's Island Rd.
  be caught in these rotating parts.                                       Edgewater, MD 21037
                                                                        NFPA (National Fire Protection Association)
HAZARDOUS NOISE                                                         "Fire Protection Standard for Motor Craft"
                                                                        Order from:
    A WARNING: High noise levels can cause hearing                          NFPA
    loss/                                                                   11 Tracy Drive
                                                                            Avon Industrial Park
·     Never operate an engine without its muffler installed.                Avon, MA 02322
·     Do not run an engine with the air intake (silencer)               USCG (United States Coast Guard)
      removed.                                                          "USCG 33CFR183"
·     Do not run engines for long periods with their enclosures         Order from:
      open.
                                                                            U.S. Goverument Printing Office
                                                                           Washington, D.C. 20404
    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
Council's (ABYC) standards. These standards are a
combination of sources including the USCG and the NFPA.
Sections of the ABYC standards of particular interest are:
      H-2 Ventilation
      P-l Exhaust Systems
      PA Inboard Engines
      E-9 DC Electrical Systems
All installations must comply with the Federal Code of
Regulations (FCR).




                                                           Engines & Generators

                                                                  iii
                                        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.

SIPHON-BREAK
For installations where the exhaust manifold/water injected exhaust elbow is close to
or will be below the vessel's waterline, provisions must be made to install a siphon-
break in the raw water supply hose to the exhaust elbow. This hose must be looped a
minimum of 20" above the vessel's waterline. Failure to use a siphon-break 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 water-injected exhaust elbow relative
to the vessel's waterline under the vessel's various operating conditions, install a
siphon-break.
NOTE: A siphon-break requires periodic inspection and cleaning to ensure proper         AVAILABLE FROM
                                                                                        YOUR WESTERBEKE
operation. Failure to properly maintain a siphon-break can result in catastrophic       DEALER
engine damage. Consult the siphon-break 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
                                                     TABLE OF CONTENTS

Parts Identification .............................................2           Remote Oil Filter (Optional) ..............................21
Introduction .........................................................3       Water Heat Connections ................................... 22
  Warranty Procedures ........................................ .3             Wiring Diagram .................................................26
  Serial Number Location .................................. .4                Wiring Schematic ..............................................27
Admiral Control Panel .........................................5              Glow Plugs .........................................................28
Captain Control Panel .........................................6              Starter Motor ............. ........................................29
Fuel, Engine Oil, and Coolant. ............................7                  Dual Output Alternators ....................................31
Preparations for Initial Start-Up .........................8                  Alternator TestingJTroubleshooting .................. 34
The Daily Operation ..... ........................................9           Engine Troubleshooting .....................................37
Engine Break-In Procedure ............................... 10                  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
                                                                              Borg Warner Transmission ............................... .49
 Thermostat ...................................................... 16
 Raw Water Intake Strainer.............................. 16                   Lay-Up and Recommissioning ...........................58
 Raw Water Pump ............................................ 17               Torque Data .......................................................60
 Heat Exchanger .............................................. 18             Metric Chart ......................................................6]
 Zinc Anode ..................................................... 18          Suggested Spare Parts ......................................63
Engine Lubricating Oil ....................................... 19
 Changing the Oil Filter................................... 19
 Changing the Oil ............................................ 19




                                                                 Engines & Generators

                                                                          1
                                 PARTS IDENTIFICATION
                                         (TYPICAL)
                                                      FILL
                      COOlANT                                                 WATER INJECTED
                      PRESSURE CAP                                            EXHAUST ELBOW




         ASSEMBLY
                                                                                                           FILTER
DC CHARGING
ALTERNATOR                                                                                         AIR INTAKE
                                                                                                   SILENCER
WMERHtAltK·-------~
CONNECTION



                                                                                              REAR
                                                                                                           FLEXIBLE
                                                                                                           MOUNT
DRIVE BELT

RAWWATERP~                                                                                      FILTER

CRANKSHAFT                                                                          COOLER
PULLEY
                                                                    Oil PRESSURE
                OIL DRAIN HOSE
                                     LEFT SIDE                      SENDOR



                                                                                   Fill

                                                                                            THERMOSTAT
                                                                                          _",~"o;;l"'DLY




   FUEL LIFT PUMP

                                                                                                    ALTERNATOR

 PREHEAT
 SOLENOID - - - -

 ZOAMP
 CIRCUIT
 BREAKER
                                                                                   FRONT

 HBW
 HURTH
 TRANSMISSION
                                                                          MANIFOLD
                                                                          1.0. PLATE
                                                     ENGINE BLOCK
                                                     DRAIN PLUG

                    REAR               SHIFT LEVER




                                       Engines & Generators

                                             2
                                                     INTRODUCTION
This WESTERBEKE Diesel Engine is a product of                          PRODUCT SOFTWARE
WESTERBEKE's long years of experience and advanced                     Product software, (technical data, parts lists, manuals,
technology. We take great pride in the superior durability and         brochures and catalogs), provided from sources other than
dependable performance of our engines and generators.                  WESTERBEKE are not within WESTERBEKE's control.
Thank you for selecting WESTERBEKE.
                                                                        WESTERBEKE CANNOT BE RESPONSIBLE FOR THE
In order to get the full use and benefit from your engine, it is       CONTENT OF SUCH SOFTWARE, MAKES NO WAR-
important that you operate and maintain it correctly. This             RANTIES OR REPRESENTATIONS WITH RESPECT
manual is designed to help you do this. Please read this man-          THERETO, INCLUDING ACCURACY, TIMELINESS OR
ual carefully and observe an the safety precautions through-           COMPLETENESS THEREOF AND WILL IN NO EVENT
out. Should your engine require servicing, contact your                BE UABLE FOR ANY TYPE OF DAMAGE OR INJURY
nearest WESTERBEKE dealer for assistance.                              INCURRED IN CONNECTION WITH OR ARISING OUT
This is your operators manual. A parts catalog is also                 OF THE FURNISHING OR USE OF SUCH SOF1WARE.
provided and a technical manual is available from your                 WESTERBEKE customers should keep in mind the time
WESTERBEKE dealer. If you are planning to install this                 span between printings ofWESTERBEKE product software
equipment, contact your WESTERBEKE dealer for                          and the unavoidable existence of earlier WESTERBEKE
WESTERBEKE'S installation manual.
                                                                       product software. The product software provided with
WARRANTY PROCEDURES                                                    WESTERBEKE products, whether from WESTERBEKE or
                                                                       other suppliers, must not and cannot be relied upon exclu-
Your WESTERBEKE Warranty is included in a separate                     sively as the definitive authority on the respective product. It
folder. If, after 60 days of submitting the Warranty Registry          not only makes good sense but is imperative that appropriate
form you have not received a customer identification card              representatives of WESTERBEKE or the supplier in question
registering your warranty, please contact the factory in               be consulted to determine the accuracy and currentness of the
writing with model information, including the engine's                 product software being consulted by the customer.
serial number and commission date.
                                                                       NOTES, CAUTIONS AND. WARNINGS
Customer Identification Card
                                                                       As this manual takes you through the operating procedures,


                   ,
         /WO/WESTERBEKE
                                                                       maintenance schedules, and troubleshooting of your marine
                                                                       engine, critical information will be highlighted by NOTES,
                                                                       CAUTIONS, and WARNINGS. An explanation follows:
                                                                       NOTE: An operating procedure essential to note.
 Customer Identification
 MR. ENGINE OWNER _ __
 NUUNSTREET ___________                                                 A CAUTION: Procedures which, if nDt strictly
 HOMETOWN,                                                              observed, can result in the damage Dr destruction of
 Model _ _ _ __                  Ser.# _ _ __                           your engine.


                                                                        A WARNING: Procedures which, if not properly fol-
                                                                        lowed, can result in personal injury or loss of life.




                                                         Engines & Generators

                                                                   3
                                                           INTRODUCTION
   SERIAL NUMBER LOCATION                                                 ORDERING PARTS
   The engine's model number and serial number are located on             Whenever replacement parts are needed, always provide the
   a nameplate mounted on the side of the engine's manifold.              engine model number and serial number as they appear on
   The engine's serial number can also be found stamped into              the silver and black nameplate located on the manifold. You
   the engine block on the flat sutface of the block just above           must provide us with this infonnation so we may properly
   and inboard of the injection pump. Take the time to enter this         identify your engine. In addition, include a complete part
   information on the illustration of the nameplate shown below,          description and part number for each part needed (see the
   as this will provide a quick reference when seeking technical          separately furnished Parts List). Insist upon WES1ERBEKE
   information andlor ordering repair parts.                              packaged parts because will fit or generic parts are frequently
                                                                          not made to the same specifications as original equipment.
                                                                          SPARES AND ACCESSORIES
                                                                          Certain spares will be needed to support and maintain your
                                                                          WES1ERBEKE engine. Your local WES1ERBEKE dealer
                                                                          will assist you in preparing an inventory of spare parts.
                                                                          See the SPARE PARTS page in this manual. For engine
                                                                          accessories, see WESTERBEKE'S ACCESSORIES brochure.
   UNDERSTANDING THE DIESEL ENGINE                                        RAW WATER COOLING SYSTEM
   The diesel engine closely resembles the gasoline engine,               Siphon-Break
   since the mechanism is essentially the same. The cylinders             For installations where the water injected exhaust elbow is
   are arranged above a closed crankcase. The crankshaft is the           close to or will be below the vessels waterline, provisions
   same general type as a gasoline engine, and the diesel engine          must be made to install a siphon·break in the raw water
   has the same type of valves, camshaft, pistons, connecting             supply hose to the water injected exhaust elbow. The siphon·
   rods and lubricating system.                                           break provides an air vent in the raw water cooling system to
   Therefore, to a great extent, a diesel engine requires the same        prevent raw water from filling the exhaust system and the
   preventive maintenance as a gasoline engine. The most                  engine's cylinders when the engine is shutdown.
   important factors are proper ventilation and proper mainte·
   nance of the fuel, lubricating and cooling systems. Fuel and
   lubricating filter elements must be replaced at the time                 A    CAUTION: Failure to use a siphon-break when
   periods specified, and frequent checking for contaminant's               the exhaust manifold injection port is at or below the
   (water, sediment, etc.) in the fuel system is also essential.            load waterline will result in raw water damage to the
   Another important factor is the consistent use of the same               engine and possible flooding of the boat.
   brand of high detergent diesel lubrication oil designed
   specifically for diesel engines.
   The diesel engine does differ from the gasoline engine,                If you have any doubt about the position of the water·
   however, in its method of handling and firing of fuel. The             injected exhaust elbow relative to the vessels waterline under
   carburetor and ignition systems are replaced by a single               the vessels various operating conditions, install a siphon-
   component - the fuel injection pump - which performs the               break. This precaution is necessary to protect your engine.
   function of both.                                                      The siphon·break must be installed in the highest point of a
                                                                          hose that is looped a minimum of 20 inches (51cm) above
                                                                          the vessels waterline. This siphon·break must always be
               GLOW PLUG,                                                 above the waterline during all angles of vessel operation to
ENERGIZED BY THE PREHEAT    1TT£'Al""""""",",
                                                                          prevent siphoning.
                                                                          NOTE: A siphon·break requires periodic inspection and
                                                                          cleaning to ensure proper operation. Failure to properly
                                                l--~- DIESEL FUEL SPRAY
                                                                          maintain a siphon-break can result in catastrophic engine
                                                                          damage. Consult the siphon-break manufacturer for proper
                                                                          maintenance.




                                                                            SIPHON-BREAK WITH STAINLESS
                                                                            LOOP FOR 314" HOSE
                                                                            PART NO.045368




                                                                Engines & Generators

                                                                      4
                                                ADMIRAL CONTROL PANEL
  DESCRIPTION                                                                  When the engine is shut down with the key switch turned off,
                                                                               the water temperature gauge will continue to register the last
 This manually-operated control panel is equipped with a                       temperature reading indicated by the gauge before electrical
 KEY switch and RPM gauge with an ELAPSED TIME                                 power was turned off. The oil pressure gauge will fall to zero
 meter which measures the engine's running time in hours and                   when the key switch is turned off. The temperature gauge
 in 1110 hours. The panel also includes a WA1ER 1EMPER-                        will once again register the engine's true temperature when
 ATURE gauge which indicates water temperature in degrees                      electrical power is restored to the gauge.
 Fahrenheit, an OIL PRESSURE gauge which measures the
 engine's oil pressure in pounds per square inch, and a DC                     A separate alarm buzzer with harness is supplied with every
 control circuit VOLTAGE gauge which measures the sys-                         Admiral Panel. The installer is responsible for electrically con-
 tem's voltage. All gauges are illuminated when the key                        necting the buzzer to the four-pin connection on the engine's
 switch is turned on and remain illuminated while the engine                   electrical harness. The installer is also responsible for installing
 is in operation. The panel also contains two rubber-booted                    the buzzer in a location where it will be dry and where it will
 pushbuttons, one for PREHEAT and one for START.                               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
                                                                               engine's oil pressure rises above 15 psi (1.1 kglcm2).

                                                                                                       Oil PRESSURE GAUGE: THIS GAUGE IS GRADU-
                                                                                                       ATED IN POUNDS PER SQUARE INCH (PSI) AND IS
                                WATER TEMPERATURE GAUGE: THIS GAUGE IS                                 ILLUMINATED WHILE THE KEY SWITCH IS TURNED
                                GRADUATED IN DEGREES FAHRENHEIT AND IS                                 ON. THE ENGINE'S NORMAL OPERATING OIL
                                IlWMINATED WHILE THE KEY SWITCH IS                                     PRESSURE RANGES BElWEEN 30 - 60 psi
                                TURNED ON. THE ENGINE'S NORMAL OPERATING                               (2.1 - 4.2 kg/em').
                                TEMPERATURE IS 170' -190· F(77" - aa·c).

RPM GAUGE: REGIS·
TERS REVOLUTIONS
PER MINUTE OF THE
ENGINE AND CAN BE
RECALIBRATEO FOR
ACCURACY FROM THE
REAR OF THE PANEL.



HOURMETER:                                                                                                                  _ _-"'" SWITCH: PROVIDES
REGISTERS ELAPSED
                                                                                                                                POWER ONLY TO THE
TIME, AND SHOULD BE
                                                                                                                                INSTRUMENT PANEL
USED AS A GUIDE FOR
                                                                                                                                CLUSTER
THE MAINTENANCE
SCHEDULE.




                                                                                                                                  DC VOLTMETER:
                                                                                                                                  INDICATES THE AMOUNT THE
                                                                                                                                  BATTERY IS BEING CHARGED.
PREHEAT                PRESSED, ENERGIZES THE                                                                                     SHOULb SHOW 13VTO 14V.
ALTERNATOR'S EXCITER, THE FUEL LIFT PUMP, THE                                       AUTOMATIC ALARM SYSTEM
FUEL SOLENOID ON THE INJECTION PUMP, AND THE
ENGINE'S GLOW PLUGS. IT BYPASSES THE ENGINE'S                                       COOLANT TEMPERATURE ALARM: AN ALARM BUZZER HAS BEEN
OIL PRESSURE ALARM SWITCH. IN ADDITION, THIS                                        SUPPLIED WITH THE INSTRUMENT PANEL. IF THE ENGINE'S COOLANT
BUTTON ENERGIZES THE START BUTTON.                                                  REACHES 210" F(99"C), THIS SWITCH WILL CLOSE SOUNDING THE
                                                                                    ALARM WHICH WILL EMIT A CONTINUOUS SIGNAL.
START BUTTON: WHEN PRESSED. ENERGIZES THE
STARTER'S SOLENOID WHICH CRANKS THE ENGINE.                                         Oil PRESSURE ALARM: AN OIL PRESSURE ALARM SWITCH IS
THIS BUTTON WILL NOT OPERATE ELECTRICALLY                                           LOCATED OFF THE ENGINE'S OIL GALLERY. THIS SWITCH MONITORS
UNLESS THE PREHEAT BUTTON IS PRESSED AND HELD                                       THE ENGINE'S OIL PRESSURE. SHOULD THE ENGINE'S OIL PRESSURE
AT THE SAME TIME.                                                                   FALL TO 5 -10 psi (OA - 0.7 kg/em'), THE SWITCH WILL CLOSE SOUND-
                                                                                    ING THE ALARM. IN THIS EVENT, THE ALARM WILL EMIT A PULSATING
                                                                                    SIGNAL




                                                                Engines & Generators

                                                                           5
                                             CAPTAIN CONTROL PANEL
DESCRIPTION                                                             The panel also includes an alarm buzzer for low OIL
                                                                        PRESSURE or high COOLANT 1EMPERATURE. The
This manually-operated control panel is equipped with a
                                                                        RPM gauge is illuminated when the KEY switch is turned on
KEY switch, an RPM gauge, PREHEAT and START but-
                                                                        and remains illuminated while the engine is in operation.
tons, an JNSTRL'MEI\TT JEST button and three indicator
lamps, one for AL1ERNATOR DISCHARGE, one for low
OIL PRESSURE, and one for high ENGINE COOLANT
1EMPERATURE.




                                                                        ALARM: THE ALARM WILL SOUND IF THE ENG1NE'S OIL PRESSURE FALLS
                                                                        BELOW 5 -10 psi (0.4 -0.7 kg/em'). IN THIS EVENT, THE ALARM WILL EMIT A
                                                                        PULSATING SIGNAL. THE ALARM WILL ALSO SOUND IF THE COOLANT
RPM GAUGE: REGISTERS REVOLUTIONS                                        TEMPERATURE IN THE FRESHWATER COOLING CIRCUIT RISES TO
PER MINUTE OF THE ENGINE AND CAN BE                                     210 a F (99°C). IN THiS EVENT, THE ALARM WILL EMIT A CONTINUOUS SIGNAL.
RECALIBRATED FOR ACCURACY FROM                                          NOTE: THE ALARM WILL SOUND WHEN THE KEY SWITCH IS TURNED ON. THIS
THE REAR OFTHE PANEL.                                                   SOUNDING IS NORMAL. ONCE THE ENGINE STARTS AND THE ENGINE'S OIL
                                                                        PRESSURE REACHES 15 pSi (1.1 kg/em'), THE ALARM WILL SILENCE.

                                      Oil PRESSURE   ALTERNATOR
                                      ALARM LIGHT    ALARM LIGHT


                                                                                                                        TEST BUTTON: WHEN
                                                                                                                        PRESSED, TESTS THE
                                                                                                                        ALTERNATOR, THE OIL
                                                                                                                        PRESSURE, AND THE
                                                                                                                        COOLANT TEMPERA-
                                                                                                                        TURE CONTROL CIR-
                                                                                                                        CUITS. WHEN PRESSED,
                                                                                                                        THE ALTERNATOR, THE
                                                                                                                        OIL PRESSURE, AND
                                                                                                                        THE WATER TEMPERA-
                                                                                                                        TURE INDICATOR
                                                                                                                        LIGHTS ILLUMINATE IN
                                                                                                                        ADDITION TO SOUND-
                                                                                                                        ING THE ALARM
                                                                                                                        BUZZER,



                                                                                                                        KEY SWITCH: PROVIDES
                                                                                                                        POWER ONLY TO THE
                                                                                                                        lNSTRUMErijT PANEL
                                                                                                                        CLUSTER.



                                  WATER TEMPERATURE
                                  ALARMUGHT



                     START BUTTON: WHEN PRESSED, ENERGIZES THE
                     STARTER'S SOLENOID WHICH CRANKS THE ENGINE. THIS                               BUTTON: WHEN PRESSED, ENERGIZES THE
                     BUTTON WILL NOT OPERATE ELECTRICALLY UNLESS THE                       ALTERNATOR'S EXCITER, THE FUEL LIFT PUMP, THE FUEL
                     PREHEAT BUTTON IS PRESSED AND HELD AT THE SAME                        SOLENOID ON THE INJECTION PUMP, AND THE ENGINE'S
                     TIME.                                                                 GLOW PLUGS, AND BYPASSES THE ENGINE'S OIL PRES-
                                                                                           SURE ALARM SWITCH. IN ADDITION, THIS BUTTON ENER-
                                                                                           GIZES THE START BUTTON.




                                                            Engines & Generators

                                                                   6
                      DIESEL FUEL, ENGINE OIL AND ENGINE COOLANT
DIESEL FUEL                                                            ENGINE COOLANT
Use fuel1hat meets 1he requirements or specification of Class          WESTERBEKE recommends a mixture of 50% antifreeze
2-D (ASTM), and has a cetane rating of #45 or better.                  and 50% distilled water. Distilled water is free from the
                                                                       chemicals that can corrode internal engin~ surfaces.
Care Of The Fuel Supply                                                The antifreeze performs double duty. It allows the engine to
Use only clean diesel fuel! The clearance of1he components             run at proper temperatures by transferring heat away from
in your fuel injection pump is very critical; invisible dirt           the engine to the coolant, and lubricates and protects the
particles which might pass through 1he filter can damage               cooling circuit from rust and corrosion. Look for a good
these finely finished parts. It is important to buy clean fuel,        quality antifreeze 1hat contains Supplemental Cooling
and keep it clean. The best fuel can be rendered                       Additives (SCAs) that keep the antifreeze chemically
unsatisfactory by careless handling or improper storage                balanced, crucial to long term protection.
facilities. To assure that the fuel going into the tank for your       The distilled water and antifreeze should be premixed before
engine's daily use is clean and pure, the following practice           being poured into the cooling circuit.
is advisable:
Purchase a well-known brand of fuel.                                   NOTE: Lookfor the new environmentally-frierully long lasting
                                                                       antifreeze that is now available.
Install and regularly service a good, visual-type fuel
filter/water separator between the fuel tank and the engine.           PURCHASING ANTIFREEZE
The Raycor 500 FG or 900 FG are good examples of such
filters.                                                               Rather than preparing the mixture, WESTERBEKE
                                                                       recommends buying the premixed antifreeze so that so that
ENGINE OIL                                                             when adding coolant the mixture will always be correct
                                                                       There are two common types of antifreeze, Ethylene Glycol
Use a heavy duty engine oil with an API classification of Cf
                                                                       (green) and Propylene Glycol (red/purple), either can be used
or CG-4 or better. Change the engine oil after an initial 50
                                                                       but do not mix the two and if changing from one to another,
hours of break-in operation, and every 100 hours of operation
                                                                       flush the engine thoroughly.
1hereafter. For recommended oil ,use sAE 15W-40
(oil viscosity) and stay with 1he same brand of oil thru-out           Premixed antifreeze for DIESEL Engines:
the life of the engine.                                                Specification #ASTM 5345.
                                                                       MAINTENANCE
                                                                       Change the engine coolant every five years regardless of the
 A CAUTION: Do not allow two Dr mDre brands of                         number of operating hours as the chemical additives that
 engine oil to mix. Each brand contains its own additives;             protect and lubricate the engine have a limited life.
 additives of different brands could reacl in the mixture
 to produce properties harmful tD your engine.
                                                                       COOLANT RECOVERY TANK
                                                                       A coolant recovery tank kit is supplied with each generator.
                                                                                                         is
                                                                       The purpose of this recovery tank 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
                               PREPARATIONS FOR INITIAL START-UP
PRESTARTINSPECTION
Before starting your engine for the first time or after a
prolonged layoff, check the following items:
                                                                                 COOlANT
o Check the engine oil level. Add oil to maintain the level                      'RECOVERY
    at the high mark on the dipstick.                                             TANK
o Turn on the fuel supply, then check the fuel supply and
    examine the fuel filter/water 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 tagged).
o   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 thru-hull and make certain raw water is primed
  to the raw water strainer.                                                                 ,-""-_- OIL DIPSTICK
                                                                                                      PRESS IN TIGHT



                                                                                               /!~_    FULL (MAX)




               SIDE OIL FILL
               (TYPICAL)




                                                          Engines & Generators

                                                                 8
                                 STARTING - STOPPING PROCEDURE
CHECKLIST                                                            FAILURE TO START
Follow this check list each day before starting your engine.         If the engine fails to start when the start button is pressed for
D Visually inspect the engine for fuel, oil, or water leaks.         5 seconds, wait for at least 30 seconds and repeat the starting
                                                                     procedure. Make certain the transmission control is in th~
D Check the engine oil level (dipstick).                             neutral position as some engines have a neutral safety SWItch
D Check the coolant level in coolant recovery tank.                  to prevent starting in gear.
    Periodically check the manifold coolant leveL.                   Never run the starter for more then 30 seconds. If the engine
D Check the transmission fluid level.                                fails to start, refer to the TROUBLESHOOTING CHART in
D Check your fuel supply.                                            this manual.
D Look for clean fuel in the fuel filter/water separator
    transparent bowL
    Check for loose wires at the alternator and make sure its
                                                                       A CAUTION: Prolonged cranking intervals without
                                                                       the engine starting can result in the engine exhaust
    mounting is secure.
                                                                       system filling with raw water. This may happen because
D Check the starting batteries (weekly)                                the pump is pumping raw water through the raw water
D Check drive belts for wear and proper tension (weekly).              cooling system during cranking. This raw water can
D Visually inspect the raw water pump for leakage.                     enter the engine's cylinders by way of the exhaust
STARTING THE ENGINE                                                    manifold once the exhaust system tills. Prevent this
1. Place the transmission in neutral, throttle advanced.               from happening by clOSing the raw water supply
                                                                       through-hull shutoff, draining the exhaust muffler, and
    NOTE: Hydraulically operated transmissions have a                  correcting the cause of the excessive engine cranking.
    neutral safety switch through which the starter solenoid
    energizing circuit passes. This switch is open when the            Engine damage resulting from raw water entry is not a
    transmission is in gear so the starter solenoid will not           warrantable issue; the owner/operator should keep this
    energize.                                                          in mind.
2. Tum the KEY SWITCH to the ON position (2 o'clock).
   (If the panel is energized, gauges are lit) and the alarm         STOPPING PROCEDURE
   buzzer will pulse.
                                                                     To stop the engine, bring the throttle to an idle position and
3. Press the PREHEAT BUTfON, and hold for 5 to 15                    place the transmission in neutral. Allow the engine to idle for
   seconds depending how cold it is .. (The foellift pump is         a few moments to stabilize temperatures, then shut the
   priming the engine and the preheat is activated).                 engine down by turning off the key switch.
4. Continue pressing the PREHEAT BUTTON and press
   the START BUTTON. (The starter motor is cranking the
   engine).
5. Release the START and PREHEAT BUTTON as the                       NOTE: When starting:
   engine starts. The alarm buzzer should silence as the oil         A voltage drop will occur
   pressure rises.                                                   when the preheat button
6. With the engine running, check the instruments for                is depressed.
   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 second~ for the RPM gauge to activate.




                                                           Engines & Generators

                                                                 9
                                      ENGINE BREAK-IN PROCEDURE
DESCRIPTION                                                         3. While using the vessel, run the engine at various engine
                                                                       speeds for the first 25 hours. Avoid prolonged periods of
Although your engine has experienced a minimum of one
                                                                       idling.
hour of test operations at the factory to make sure accurate
assembly procedures were followed and that the engine oper-         4. Avoid rapid acceleration, especially with a cold engine.
ated properly, a break-in time is required. The service life of     5. Use caution not to overload the engine. The presence of a
your engine is dependent upon how the engine is operated               grey or black exhaust and the inability of the engine to
and serviced during its initial 50 hours of use.                       reach its full rated speed are signs of an overload.
Breaking-in a new engine basically involves seating the pis-       .6. During the next 25 hours, the engine may be operated at
ton rings to the cylinder walls. Excessive oil consumption             varying engine speeds, with short runs at full rated rpm.
and smoky operation indicate that the cylinder walls are               Avoid prolonged idling during this break-in period.
scored, which is caused by overloading the engine during the
break-in period.                                                   CHECK LIST
Your new engine requires approximately 50 hours of initial         D Monitor the control panel gauges.
conditioning operation to break in each moving part in order       D Check for leaks of fuel and engine oil.
to maximize the performance and service life of the engine.        D Check for abnormal noise such as knocking, friction,
Perfonn this conditioning carefully, keeping in mind the fol-          vibration and blow-back sounds.
lowing:
                                                                   D Confinn exhaust smoke:
1. Start the engine according to the STARTING PROCE-                 When the engine is cold - white smoke.
    DURE section. Run the engine at fast idle while checking           When the engine is warm - almost smokeless.
    that all systems (raw water pump, oil pressure, battery            When the engine is overloaded - some black smoke and soot
    charging) are functioning.
2. Allow the engine to wann up (preferably by running at
                                                                   NOTE: See the TRANSMISSION section of this manual for
                                                                   break-in information on your transmission.
    fast idle) until the water temperature gauge moves into
    the 130 - 140°F (55 - 60°C) range.




                                                        Engines & Gmerators

                                                              10
                         WARNING LIGHTS, ALARMS &CIRCUIT BREAKER
    ALTERNATOR WARNINGS                                                      LOW OIL PRESSURE ALARM SWITCH
    The Captain Control Panel indicates alternator low discharge             A low oil pressure alarm switch is located off the engine's
    with a red warning light                                                 oil gallery. This switch's sensor monitors the engine's oil
    The Admiral Control Panel uses a voltmeter to monitor the                pressure. Should the engine's oil pressure fall to 5 -10 psi
    performance of the alternator.                                           (0.4 - 0.7 kg/cm2), this switch will activate a pulsating alarm.

    COOLANT TEMPERATURE SWITCH                                               ENGINE CIRCUIT BREAKER
    A coolant temperature switch is located on the thermostat                The DC harness on the engine is protected by an engine-
    housing. This switch will activate a continuous alarm if the             mounted manual reset circuit breaker (20 amps DC).
    coolant's operating temperature reaches approximately                    Excessive current draw or electrical overload anywhere in
    210°F (99°C).                                                            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.




TO CONTROL PANEL




              TYPICAL ARRANGEMENT
                                                     <
                                                    COOLANT TFIIIIPFI
  Sparks could cause an explosion and fire.

Prior to testing, make certain the ships batteries are at full
charge and that the starting system wiring connections
(terminals) are clean and tight. Pay particular attention to
the ground wire connections on the engine block.                        IGNITION
                                                                        TERMINAL
To check the wiring, try cranking the starter for a few
seconds, never more than 10 seconds at a time, then run your
hand along the wires and terminals looking for warm spots
that indicate resistance. Repair or replace any trouble spots.
Using a multimeter, test the voltage between the positive                                                               ~
terminal stud on the start solenoid and the engine block              If nothing happens at all, the solenoid is not getting
(ground).                                                             current. Check the battery isolation switch and inspect the
If you read 12 volts, the starter is faulty.                          wiring connections. it is also possible that the solenoid is
                                                                      defective.

                                                                        A WARNING: There will be arching and sparks will
                                                                        fly when jumping terminals. Be certain the engine
                                                                        space is free of potentially explosive fumes, especially
                                                                        gasoline, and that there are 1!!1 flammable solvents Dr
                                                                        materials stored nearby.




                                                       Engines & Generators

                                                                 29
                                                               STARTER MOTOR
                                                                                  EMERGENCY START
 A WARNING: When performing these procedures,                                     Corrosion to the starter brushes and/or the solenoid contacts
 position yourself safely away from the moving parts of                           can cause the sporadic problem of the engine starting one
 the engine in case the engine starts-up_ Also warn                               time but not another. If corrosion is the problem, the starter
 other crew members of the danger.                                                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
                                                                                  starter/solenoid casing as shown, then try to start the engine.

                                                                                  CAREFULLY NOT TO HIT   /'
                                                                                  FITTINGS OR WIRE CONNECTioNS


                                      -------,-'~""
                                                        (+) POSITIVE
                                                      )TERMINAL                             I
                                 ~.--




                                 ~;:----~-(M)                 TERMINAL
                                                                                                                                    TAP LIGHTLY WHERE
IGNITION                                                                                                                         \. INDICATED
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                                     If that fails, tum the battery switch on and have a crew
                                                                                   member tum the ignition on and off rapidly as you tap again
  starting current should be flowing thru the blade of                             with the hammer., This may loosen the brushes and allow
  the screwdriver.                                                                 contact to start the engine. When you reach a repair facility,
                                                                                   the starter will need to be repaired.
If the starter spins, the solenoid is faulty.                                      SERVICE
If the starter fails to spin, the motor is probably faulty.                        WESTERBEKE uses a standard starter motor which can be
If no arching occurred, there is no juice reaching the                             serviced or rebuilt at any starter motor automotive service
solenoid.                                                                          center,
NOTE: Starter motors are either inertia type or pre-engaged.                       If replacing the starter motor, make certain the new motor is
In the pre-engaged model, the solenoid also moves an arm                           certified for marine use. Automotive starters do not meet
that engages the starter motor to the flywheel of the engine.                      USCG standards. If in doubt, contact your WESTERBEKE
using a screwdriver to bypass the solenoid on such a starter                       dealer.
will run the motor without engaging the flywheel. Tum the
starter switch on to provide power to the solenoid. Hopefully                      TO REMOVE FOR SERVICE
it will create enough magnetic field for the arm to move even                      1. Disconnect the negative battery cable.
though the contacts inside the solenoid are bad.                                   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 terminals).
                                                                                   4. 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
                                         DUAL OUTPUT ALTERNATORS                                                 SPACER TO MOUNTING
                                                                                                                 BRACKET

DESCRIPTION
Dual output and high output alternators are available as
optional equipment on most WESTERBEKE engines. These
altemators can be installed during factory assembly or as
add-on equipment at anytime.
Dual alternators can be configured to charge two banks of
batteries at the same time or, using a battery selector switch,
charge each set of batteries separately.                    TO

INSTALLATION
If an optional dual alternator has already been factory installed,
simply follow the WESTERBEKE wiring diagram and the
engine installation instructions.
If the new dual alternator is being added to an existing "in-
the-boat" engine, carefully follow the alternator installation
instructions below:
1. Disconnect the alternators negative cable from the
    battery.
2. Remove the alternator and disconnect or tape off the
    output [positive] cable. Do not reuse.
3. Install the new alternator.
4. Attach a new heavy gauge output cable[s] from the
    alternator's output terminal [s). Using the cable sizes
    indicated.
                                                                                                    DUAL OUTPUT ALTERNATOR
    LENGTH REQUIRED   UP TD-7.6'..---;c#4~W~rRE
   ------iJPro               12' #2 WIRE----                                                        [CHARGING ONE BATTERY]
                      UP TO 20'      #(lWIRE _
   [ALWAYS USE FINE STRAND CABLE1

S. Make certain that the batteries negative post ground
                                                                     BATTERY 1
   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 with-
  out first grounding the regulator.


   b. Plug the 2-pin connector into the alternator, make
      certain it is firmly seated.
   c. The red "battery sense" wire should be connected to
                                                                                 ~;:::.....c=--   "BATTERY SENSE"
      the batteries positive [+] post [or the positive cable],                                    TO BATTERY POSITIVE POST
   d. The brown wire "keyed ignition" is the key circuit
      which actuates the regulator, this wire must connect                        IJl(OlY.   ~ONNECTS         TO PINK AND
      to a switched [+] 12 volt source. Refer to the                                     ;st.       BLUE LEADS. THE PINK
                                                                                                   ,WIRE CONNECTS TO THE
     WESTERBEKE WIRING DIAGRAM for the proper                                                      'ALARM BUZZER. THE BLUE
     connection.                                                                                    WIRE CONNECTS TO THE
                                                                                                    OIL PRESSURE SWITCH.
Dual Pulleys
A variety of accessory pulleys for high powered and dual                                     DUAL OUTPUT ALTERNATOR
charging alternators are available from your                                                 [CHARGING TWO BATTERIES1
dealer.


                                                          Engines & Generators

                                                                  31
                                               DUAL OUTPUT ALTERNATORS
TROUBLESHOOTING                                                           Alternator Testing
NOTE: Before troubleshooting, make certain that the drive                 The regulator is functioning properly and the batteries
belts are tight and the batteries are in good condition.                  are in good condition.
Regulator Testing                                                         1. Test the voltage at the alternator plug with the engine
                                                                              off-key on. The voltage at the alternator terminal F and
The red "battery sensing" wire A connects to the battery, it                  the voltage in the plug [blue wire F] from the regulator
must always read battery voltage. If battery voltage is not                   should read the same.
present, trace the wire for a bad connection.
                                                                          2. Hold a screw driver close [112") to the alternator pulley.
The orange wire S should read 0 volts with the key off, 12                    If voltage is present you should feel the magnetic field. If
volts [approximately] with the key on. If the readings are                   .not, the problem may be the brushes [wornJor the rotor
incorrect, trace the wire for a bad connection.                               (open circuit].
The blue wire F supplies current to the alternator fields, its            3. Start the engine, at fast idle the output terminals should
voltage will vary depending on the battery charge or actual                   indicate 14.2 volts [no load]. A reading of 12.6 would
load/rpm. The readings can vary from 4 to 12 volts with the                   indicate the alternator is not performing properly.
key on, 0 volts with the key off.
                                                                              Apply a load such as an electric bilge pump, the voltage
KEY ON - NO VOLTAGE     REGULATOR IS DEFECTIVE                                should maintain at least 13.8 volts. 13 volts or less
KEY OFF - BATTERY VOLTAGE   REGULATOR 15 DEFECTIVE                            indicates the alternator is faulty.
REGULATOR TEST POINTS AND PROPER VOLTAGE
Terminal/COlor   Ignition Off   Ignition On     Engine Running
                                                                          NOTES:
 I Brown         o volts        2 -12 volts     14.2 volts                    When the engine is first started, it takes a few moments
 A Red           12.6 volts     12 volts        14.2 volts                    for the alternator to "kick in" and take the load. There
 5 Orange         ovolts        ovolts          6· holts                     is a noticeable change in the sound of the engine and the
 F Blue           ovolts        10 ·11 volts    4 ·12 volts                  RPM gauge will excite.
 Alt. Output     12.6 volts     12 volts        14.2 volts                D A slight whine is normal when running with a full load
                                                                            on the alternator.
                                                                          D When the alternator is producing high amperage, it will
                                                                             become very hot.
                                                                          D When replacing the alternator drive belts, always
                                                                             purchase and replace dual belts in matched pairs.




                                                                 Engines & Generators

                                                                     32
                                              DUAL OUTPUT ALTERNATORS
DESCRIPTION                                                                       5. Make certain that the batteries negative post ground cable
                                                                                     to the engine block is the same heavy gauge as the
Dual output and high output alternators are available as
                                                                                     positive cable.
optional equipment on most WESTERBEKE engines. These
alternators can be installed during factory assembly or as                        6. Mount the regulator to a flat surface in a cool dry location.
add-on equipment at anytime.                                                         a. Connect the black wires to the mounting bolt on the
Dual alternators can be configured to charge two banks of                            alternator (ground)
batteries at the same time or, using a battery selector switch,
charge each set of batteries separately.
                                                                                         A         CAUTION: Do not connect any power source
                                                                                         without first grounding the regulator.
INSTALLATION
If an optional dual alternator has already been factory
installed, simply follow the WESTERBEKE wiring diagram                               b. Plug the 2-pil'f connector into the alternator connection
and the engine installation instructions.                                               and make certain it is fmnly seated.
If the new dual alternator is being added to an existing "in-                        c. The red "battery sense" wire should be connected to the
the-boat" engine, carefully follow the alternator and regulator                         batteries positive [+] post [or the positive cable].
instructions below:                                                                  d. The brown wire "keyed ignition" is the key circuit
1. Disconnect the alternators neg~tive cable from the bat-                              which actuates the regulator, this wire must connect
     tery.                                                                              t«, a switched [+] 12 volt source. Such as the oil
                                                                                        pressure switch.
2. Remove the alternator and disconnect or tape off the
     output [positive] cable. Do not reuse.                                          e. A brown wire from the electric tachometer connects to
                                                                                        the regulator.
3. Install the new alternator.
4. Attach a new heavy gauge output cable[s] from the                              Dual Pulleys
     alternator's output terminal [s]. Using the cable sizes
     indicated.                                                                   A variety of accessory pulleys for high powered and dual
                                                                                  charging alternators are available from your WESTERBEKE
    LENGTH REQUIRED    UP TO 6'  #4 WIRE                                          dealer.
                       UP TO 12' #2 WIRE
        ,              UP TO 20' #0 WIRE
                                                        #14 BWElI14 PINK                                            BALMAR 100 AMP AlTERNATOR
    {ALWAYS USE FINE STRAND CABLE]                      IGNITIONB+

                                                                                                                    #14 BlACK/GROUND


                                  #4 RED TO STARTING'
                                  BATTERY 8+ WHEN                                                         #14 RED
                                  USING TWO BATTERIES                                                     SENSE

                                                                                                       #18 BROWN
                                                                                                       NOTUSED
                                                     MALE CONNECTOR               U0
                                                   . TH'E!JDE\                       o
#14 BWE/#14 PINK
IGNITiON B1' ~~:,,,,,,,
                    ___
                                    '14 BROWN'
                                                                  '-
                                    TACHOMETER                                                          114 BLUE
                                                                                                        FIELD                          AlTERNATOR MOUNT (GROUND)

                             .;   ---------                                   .#4 RED TO STARTING
                                                                              'BA1TERY Bf WHEN
                                                                               USING TWO BArrERIES.:'=-===::;::;;~!-i


                                                                            -~-


                                                                            ~--




                                                                                    114BWE
                                                                                    FlEW
                                                                                        #14 WHITE
                                                                                         STATOR.




                                                                       ~ngineS & Generators
                                                         '...",WESTERBEKE
                                                                            33
                            ALTERNATORS TESTING/TROUBLESHOOTING
                                                   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                                                           VOLTAGE REGULATOR
  The following infonnation applies to the standard alternators         The integral voltage regulator is an electronic switching
  that are supplied with WESTERBEKE'S Marine Engines                    device which senses the system voltage level and switches
  and Marine Generators.                                                the voltage applied to the field in order to maintain a proper
                                                                        system voltage.
  ELECTRICAL CHARGING CIRCUIT                                           The regulator design utilizes all-silicon semi conductors and
  The charging system consists of an alternator with a voltage          thick-film assembly techniques. After the voltage has been
  regulator, an engine DC wiring harness. a DC circuit breaker          adjusted to the proper regulating value, the entire circuit is
  and a battery with connecting cable and wires. Because of             encapsulated to protect the circuit and the components from
  the use of integrated circuits (Ie's), the electronic voltage         possible damage due to handling or vibration and moisture
  regulator is very compact and is mounted internally or on the         encountered in a vessel.
  back of the alternator.
  It is desirable to test the charging system (alternator and
                                                                        ALTERNATOR TROUBLESHOOTING
  voltage regulator) in the boat using the wiring harness and           Use this troubleshooting section to determine if a problem
  electrical loads that are a pennanent part of the system.             exists with the charging circuit or with the alternator. If it is
  In-boat testing will then provide the technician with an              determined that the alternator or voltage regulator is faulty,
  operational test of the charging system as well as the major          have a qualified technician check it.
  components of the electrical system.
                                                                        LOW BATTERY/FAULTY CIRCUIT
  ALTERNATOR DESCRIPTION                                                If the starter only moans or makes a clicking sound instead
  The stator is connected to a three-phase, full-wave bridge            of spinning the engine to life it is likely a low battery or a
  rectifier package which contains six diodes. The bridge               faulty connection in the starting circuit and not an alternator
  converts the AC generated in the stator to a DC output for            problem.
  battery charging and accessories such as a radio, heater,
  lights, refrigerator, depth sounder, etc.                             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
  Power to the regulator and the field of the integral regulator        the light remains bright, look for a poor connection in the
  alternator is provided by the field diode (or diode trio)             starting circuit.
  package 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 of75°F (23.8°C). The
                                                                          A WARNING: A working alternator runs hot. a failed    i


                                                                          alternator can become very hot. Do not touch the
  alternators are designed to operate in an ambient temperature
  range of 40° to 212°F (-400 to 100°C).                                  alternator until it has cooled.




                                                   /"fIV'IWESTERBEKE
                                                          I Engines & Generators
                                                                   34
                             ALTERNATORS TESTING/TROUBLESHOOTING
PRELIMINARY INSPECTION                                                   3. Thrn off the engine. Inspect all wiring and connections.
Before starting the actual alternator and voltage regulator,                Ensure that the battery terminals and the engine ground
testing the following checks are recommended.                               connections are tight and clean.
                                                                         4. If a battery selector switch is in the charging circuit,
1. Make certain your alternator is securely mounted.                        ensure that it is on the correct setting.
2. Check the drive belt for proper tension. Replace the belt             S. 'furn on the ignition switch, but do not start the
   if it is worn or glazed.                                                 engine.
3. Check that all terminals, connectors and plugs are clean              6. Check the battery voltage. If the battery is in good
   and tight. loose or corroded connections cause high                      condition, the reading should be 12 to 13 volts.
   resistance and this could cause overcharging,
   undercharging or damage to the charging system. Badly
   corroded battery cables could prevent the battery from
   reaching a fully charged condition.
4. Check the condition of the battery and charge if
   necessary. A low or discharged battery may cause false
   or misleading readings on the in-vessel tests.
   NOTE: An isolator with a diode, a solenoid, or a battery
   selector switch is usually mounted in the circuit to isolate
   the batteries so the starting battery is not discharged
   along with the house batteries. If the isolator is charging                                                      MEASURING
                                                                                                                    BATTERY VOLTAGE
   the starting battery but not the house battery, the                                                              (IGNITION ON
   alternator is Ok and the problem is in the battery                                                               ENGINE OFF)
   charging circuit.

TESTING THE ALTERNATOR
                                                                         Testing The Output Circuit
  A    CAUTION: Before starling the engine make                          1. Connect the positive probe to the output terminal B and
  cerlain that everyone Is clear of moving parts! Keep                      connect the negative probe to the ground terminal E on
  away from sheaves and belts during test procedures.                       the alternator.
                                                                         2. Wiggle the engine wiring harness while observing the
1. Start the engine.                                                        voltmeter. The meter should indicate the approximate
2. After the engine has run for a few minutes, measure the                  battery voltage, and should not vary. If no reading is
   starting battery voltage at the battery terminals using a                obtained, or if the reading varies, check the alternator
   multimeter set on DC volts.                                              output circuit for loose or dirty connections or
                                                                            damaged wiring.
   a. If the voltage is increasing toward 14 volts, the
      alternator is working; omit Steps 3 through 8 and go               3. Start the engine.
      directly to "Checking the Servic~ Battery".                        4. Repeat the same measurement, the negative probe to E,
   b.Ifthe voltage remains around 12 volts, a problem                       the positive probe to B with the engine running. The
      exists with either the alternator or the charging circuit;            voltage reading should be between 13.5 and 14.5 volts.
      continue with Steps 3 through 8.                                      If your alternator is over or under-charging, have it
                                                                            repaired at a reliable service shop.

                                                                         5. If the previous test reads only battery voltage at
                                                                            terminal B use the meter to measure the DC excitation
                                                                            terminal. If 12 volts is not present at exciter terminal
                                                                            R, inspect the wiring for breaks and poor connections.
                                                                            Jump 12 volts from a 12 volt source (such as the
                                                                            battery) and operate the alternator. If voltage output is
                                                                            13-14 volts, then the alternator is OK.

                                            MEASURING
                                            BATTERY
                                            VOLTAGE
                                            ENGINE RUNNING




                                                           Enaloes & Generators

                                                                   .35
                         ALTERNATORS TESTING/TROUBLESHOOTING


                                         TESTING THE
                                         OUTPUT CIRCUIT
                                         ENGINE RUNNING




                                                                    5. If no reading is obtained, an open exists in the
                                                                       alternator-excitation 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
                                                  TO STARTER           approximate battery voltage, the voltage regulator is
                                                  SOLENOIO             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
  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
TESTING
      '.
         THE EXCITATION CIRCUIT                                     wiring harness.,
1. Connect the positive (+) multimeter probe to the
   excitation terminal R on the alternator and the negative         ALTERNATOR REPAIR
   (-) probe to the ground terminal E on the alternator.           If tests indicate a failed alternator, it will need to be
2. Turn the ignition switch to the on position and note            disassembled and repaired. Any good alternator service
   the multimeter reading. The reading should be 1.3 to            shop can do the job.
   2.5 volts (see illustration).                                   NOTE: WESTERBEKE'S 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 engine's 12 volt DC control circuit is 600-900 Cold
                                                                    Cranking Amps (CCA).
                                                                    Review the manufacturer's recommendations and then
                                                                    establish a systematic maintenance schedule for your
                                                                    engine's starting batteries and house batteries.
3. If the reading is between .75 and 1.1 volts, the                 · Monitor your voltmeter for proper charging during
   rotor field circuit probably is shorted or grounded.                 engine operation.
                                                                    · Check the electrolyte level and specific gravity with a
4. If the reading is between 6.0 and 7.0 volts, the rotor               hydrometer.
   field circuit probably is open.
                                                                    · Use only distilled water to bring electrolytes to a proper
                                                                        level.
                                                                    · Make certain that battery cable connections are clean and
                                                                        tight to the battery posts (and to your engine).

                                              '-w'IWESTERBEKE
                                                       IEnafnes & Generators
                                                               . ·36--
                                              ENGINE TROUBLESHOOTING
The following troubleshooting table describes certain problems                      NOTE: The engine '8 electrical system is protected by a 20
relating to engine service, the probable causes of these prob-                      ampere manual reset circuit breaker located on a bracket at
lems, and the recommendations to overcome these problems.                           the back of the engine. The preheat solenoid is mounted on
                                                                                    the same bracket.
                Problem                              Probable Cause                                           VerificationJRemedy
 No panel indications; fuel solenoid       1. Battery switch not on.                        1. Check switch and/or battery connections.
 or fuel pump is no! working (key switch
 is on and PREHEAT button is depressed).   2. 20-amp circuit breaker tripped.               2. Reset breaker; if breaker trips again, check preheat solenoid
                                                                                               circuit and check circuit for shorts to ground.
                                           3. 10-amp breaker tripped on                     3. Check the voltage both at and after the breaker on the
                                              preheat solenoid                                 preheat solenoid.
                                           4. Loose battery connections.                    4. Check (+) connection to starter solenoid and (-) connection to
                                                                                                engine ground stud. Check battery cable connections.
                                           5. Preheat solenoid not operating.               5. Check solenoid "S" terminal for voltage.
 START button is depressed, no starter     1. Connection to solenOid faulty.                1. Check connection.
 engagement.
                                           2. Gear shift not in neutrel.                    2. Gear shift must be in neutral (see NEUTRAL SW/TCHunder
                                                                                               HURTH HSWTRANSMISSIONS).
                                           3. Faulty switch.                                3. Check switch with ohmmeter.
                                           4. Faulty solenoid.                              4. Check thaI 12 volts are present at the solenoid connection.
                                           5. Loose battery connections.                    5. Check battery connections.
                                           6. Low battery.                                  6. Check battery charge state.
 START button is depressed; panel          1. Poor connections to fuel solerlOid.           1. Check connections.
 indications OK; starter solenoid OK;
 fuel solenoid not functioning.            2. Defective fuel solenoid.                      2. Check that 12 volts are present at the (+) connection on the
                                                                                               fuel run solenoid.
 Engine cranks, but does not               1. Faulty fueling system.                        1. Check that fuel valves are open.
 start, fuel solenoid energized.
                                                                                            1a. Check for air in fuel system. Bleed air from fuel system.
                                                                                            1b. Fuel filters clogged. Replace filters and bleed air from
                                                                                                fuel system.
                                           2. Preheat solenoid faulty.                      2. Check solenoid.
                                           3. Low battery power.                            3. Switch to combine house and start batteries.
                                                                                            3a. Replace batteries.
 Engine can't be stopped.                  1. Faulty DC alternator.                         1. Remove Exc. connection at alternator, repair alternator.
                                           2. Disconnect fuel shut-off cable.               2. Check connection at shut-off lever. Pull lever back to close
                                                                                               offthe fuel
                                           3. Fuel nm solenoid will not de-en~rgize.        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 switc~.
                                           2. High resistance leak to ground.               2. Check wiring. Insert sensitive (0 - .25 amp) meter in battery
                                                                                               lines. (Do not start engine.) Remove 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 operating).                      DC ELECTRICAL SYSTEM/ALTERNATOR.
 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.


                                                                                                                                                   (con.tinued)


                                                                      Engines & Generators

                                                                             37
                                          ENGINE TROUBLESHOOTING
               Problem                           Probable Cause                                         Verification/Remedy
  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 and/or 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 tank(s); change filters and
                                                                                         bleed fuel system.
                                       7. Air intake obstruction.                     7. Check air Intake filter cartridge.
 Engine overheats/shuts 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 - tighten/replace.
                                                                                      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 eXhaust).
                                       2. 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 back-pressure in exhaust or
                                                                                         insufficient air for proper combustion (check for restrictions in
                                                                                         exhaust system; check air Intake).
                                                                                      3b.lmproperly timed injectors or valves, or poor compression.
                                                                                      3c. Lack of air - check air intake and air filter. Check for proper
                                                                                          ventilation.
                                                                                      3d. Overload.

                         TROUBLESHOOTING COOLANT TEMPERATURE AND OIL PRESSURE GAUGES
If Ihe gauge reading is other dlatl what is normally indicated               If both of the above gauge tests are positive, the gauge is
by Ihe gauge when Ihe instrument panel is energized, the first               undoubtedly OK and the problem lies either with the
step is to check for 12 volts DC between dle ignition (B+)                   conductor from the sender to the gauge or with the sender.
and Ihe Negative (B-) terminals of Ihe gauge.                                If either of the above gauge tests are negative, the gauge is
Assuming Ihat Ihere is 12 volts as required, leave Ihe                       probably defective and should be replaced.
instrument panel energized and perrorm Ihe following steps:                  Assuming the gauge is OK., check the conductor from the
1. Disconnect the sender wire at Ihe gauge and see if the                    sender to the sender terminal at the gauge for continuity.
     gauge reads zero, which is dle normal reading for this                  Check that the engine block is connected to the ground.
     situation.                                                              Some starters have isolated ground terminals and if the
2. Remove the wire attached to the sender terminal at Ihe                    battery is connected to the starter (both plus and minus
     sender and connect it to ground. See if the gauge reads                 le11Ilinals), the ground side will not necessarily be connected
   . full scale, which is the normal reading for driB situation.             to the block.


                                                              Engines &: Generators

                                                                       38
                                           SERVICE SCHEDULE
Servicing After Every 100 Hours of Operation

 1. Change the engine's lubrication oil and oil filter.

 2. Adjust the alternator and water pump drive belt tension, if required.

 3. Lubricate panel keyswitch (use "Lockeze" only).

 4. Inspect the syphon-break assembly for proper operation. (When installed)

Servicing After Every 250 Hours of Operation

Replace the fuel filter elements in the on-engine fuel filter and in the optional water/sediment 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 hold-down 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 pump's 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 and/or 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 kg/cm2 + 5 kg/cm2)

NOTE: Poor fuel quality and contaminants
will shorten the injector and injector pump
service life.

Eliminate undesirable injection conditions
incl~ing after dripping.

 *2. Check the compression pressure. Remove each glow plug and check each cylinder's compression
 pressure. The engine's speed is at 280 rpm.

 *3. Check the battery-charging alternator for proper operation.

 *4. Check the tightness of bolts, nuts, and clamps.


                                                   Engines & Generators
                                                      . 39
                                       SERVICE SCHEDULE
This section contains a scheduled preventive maintenance program and several adjustment procedures the
owner/operator can petform without the bene.fit of sophisticated and eXlJensive tools and instruments.

Preventive Maintenance

Perform the preventive maintenance in accordance with the schedules listed in the following paragraphs.
Adherence to these schedules will ensure the equipment is maintained in the best possible condition and
that it will petform to expectations. Those items marked by an asterisk (*) are recommended to be
performed by an authorized dealer or distributor.

Daily (before each   US~)


 I. Check the oil sump level. Maintain the oil level at or near the upper level mark on dipstick.

 2. Check the coolant level in the plas~ic recovery tank. Maintain this level at or above the level marked
 ADD.
         -
 3. Check transmission's lubricant level, and add additional lubricant as needed.

 4. Visually inspect the unit: check for loose belts, chafed or broken wires, loose brackets and fittings,
 damaged hoses, loose clamps, and other .equipment not properly secured.

 5. Check the fuel supply. Fill tank(s) with a good grade of No.2 diesel fuel, if required.

 6. Check the primary filter/water separator. Drain and service as required. (A primary filter/water
 separator is optional, but strongly recommended.)

 7. Check the engine's gauges or lights for proper oil pressure, operating temperature, and starting
 battery charging voltage once the engine is operating.

 8. Check the alternator's output gauge (if installed) for proper DC voltage.

Monthly

Check the condition of the zinc anode in the heat exchanger's sea water circuit. Clean or replace the
anode, as required. Keep the area inside the heat exchanger clean of zinc anode debris.

Servicing After Initinl 50 Hours of Operation

 1. Change the engine's lubrication oil and oil filter.

 2. Replace the secondary fuel filter and the filter element in the base of the fuel pump. Service the
 primary system filter is installed.

*3. Torque the cylinder head hold-down bolts.

*4. Adjust valve clearances.

 5. Adjust the alternator and water pump drive belt tension, if required.

 6. Lubricate the throttle and the transmission's control cable check for proper operation and movement.

  7. Change the transmission's lubricant.

  8. Adjust the engine's idle speed (750 - 1000 rpm).
                                       ~    WESTERBEKE
                                            Engines & Generators

                                                 40
                                               SERVICE SCHEDULE
                                      CYLINDER HEAD BOLT TORQUING
     Servicing After Every 1000 Hours of Operation

       1. Remove, clean, and pressure test the primary heat exchanger. (A local automotive radiator shop should be able
     to clean and test the heat exchanger.)

                 NOTE: Operating in silty and/or tropical waters may require that a heat exchanger cleaning be
                 performed more often than every 1000 hours.

     *2. Check the injection pump's timing.

     CyUnder Head Bolt Torquing

     Tighten the cylinder head bolts according to the sequence shown in the illustration for your model. The engine
     should be at room temperature. Prior to applying torque to each bolt, loosen it one half tum then apply the required
     torque.                .




18




     \      13        9    5          4    8    12


                           828 FOUR
                                                                                   1088 and 108C SIX




                                                                                    Tightening Torque

                                                                 63 (B) & (C) Four, 71C Four             80 - 85 ft-lb
                                                                      & 108 (B)(C) Six              (11.0 to 11.7 m-kg)

                                                                 7IB Four & 82B Four                      85 - 89 ft·lb
                                                                                                    (11.8 to 12.5 m-kg)




         638 & 63C FOUR and 71C FOUR and 718 FOUR




                                                      Engines & Generators

                                                           41
                                                    SERVICE SCHEDULE
                                        CYLINDER HEAD BOLT TORQUING


                Tighten the cylinder head bolts to the specified torque before making valve adjustments.
     When No.1 cylinder   IS   at top dead enler

        J. 1                                                                          When No.1 cylinder is at top dead center

        TINC!.'EX   liN
                     I                    i
                                         fEX
                                                                                                                          (l~EX



                            1 '~31IN             J (rEX
                                                      T
                           \1 EX i               (fiN
                    When NoA cylinder     IS   a t top dead center

         63(BXC)FOUR, 71(B)(C)FOUR                                                                    108(BXC) SIX
                      & 82BFOUR

Valve Clearance: Intake & Exhaust 0.012 inch (0.30 rom)

Procedure to adjust

1. Position the piston #1 cylinder approximately IDC (Top Dead Center) of its compression stroke. Adjust the
valve clearance on the values for the cylinders specified.

    4 Cylinder Model

Intake valves - No. 1 and No.2 cylinders

Exhaust valves - No.1 and No.3 cylinders

     6 Cylinder Model

Intake valves - No.1, 2 and 4 cylinders

Exhaust valves - No.1, 3 and 5 cylinders

2. Tum the crankshaft 3600 (one complete
revolution) and adjust the valve clearances
on the valves for the cylinders specified.

     4 Cylinder Model

Intake valves - NO.3 and NO.4 cylinders

Exhaust valves - NO.2 and No.4 cylinders

     6 Cylinder Model

Intake valves - No.3, 5 and 6 cylinders

Exhaust valves - No.2, 4 and 6 cylinders




                                                               Engines & Generators

                                                                     42
                                                 ENGINE ADJUSTMENTS
                                   NOTE: WESTERBEKE recommends that the following engine adjust-
                                   ments be performed by a competent engine mechanic. The information
                                   below is provided to assist the mechanic.

   ENGINE IDLING SPEED                                                  INJECTION PUMP SERVICE
   The engine idling speed is pre-set at the factory but once the       For disassembly, inspection, reassembly and internal
   boat is operating in the water other variables such as pro-          adjustments of the injection pump, it is recommended the
   peller size, shaft length, and the transmission can affect the       pump be taken to a qualified injection service shop
   idle speed.                                                          authorized to service Diesel KiKi or Zexel injection
   The normal idle speed for these engines is 650-950 RPM,              equipment.
   however, simply put, the idle speed should feel comfortable.
   It should be quiet and smooth, not racing but not so low that        ENGINE STOP SOLENOID
   it causes transmission damper plate chatter.                         This solenoid is insralled on the top rear of the injection
                                                                        pump and is activated by 12 VDC electrical current.
    SETTING THE IDLING SPEED
    To adjust the engine idle speed (engine running), loosen the
                                                                        Troubleshooting
    locknut of the idle adjustment bolt and tum the bolt                1. The solenoid does not operate when
    clockwise to increase idle speed and counterclockwise to               the keyswitch is turned "ON".
    reduce. Once the speed is set to your satisfaction, tighten the        a. Are the engine batteries turned "ON"?
    locknut.                                                               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
                                                                              at the solenoid electrical lead with the
                                                                                                                             t-
                                                                                                                             PLUNGER

                                                                              key off.
                                                                           b.Remove solenoid from injection
                                                                              pump and ensure plunger and spring
                                                                              in the solenoid are not sticking.

              FUEL INJECTION PUMP (TOP)




    ENGINE COMPRESSION
                                                                           If a weak cylinder is flanked by healthy cylinder, the problem
    Check the compression pressure. To do this, warm the
                                                                           is either valve or piston related. Check the valve clearances
    engine? remove all fuel injectors, or glow plugs, disconnect
                                                                           for the weak cylinder, adjust as needed and test again.
    the fuel shut-off solenoid wire, and install a compression
                                                                           If the cylinder is still low, apply a small amount of oil into
    adapter in the injector hole or glow plug hole. Connect a
                                                                           the cylinder to seal the rings and repeat the test
    compression tester on the adapter and crank the engine with
                                                                           If compression comes up - the rings are faulty.
    the starter motor until the pressure reaches a maximum value.
    Repeat this process for each cylinder. Look for cylinders with
    dramatically (at least 20%) lower compression than the
    average of the others. Compression pressure should not differ
    by more than 42.7 psi (3.0 kg/cm2) at 200 rpm.




COMPRESSIO. GAUGE!




                                                                 Engines & Generators

                                                                      43
                                                     TACHOMETER
TACHOMETER/HOUR METER                                              NOTE: Current model tachometers use a coarse adjustment
The tachometerlhour meter used in propulsion engine instru-        dial to set the tachometer to the crankshaft pulley rpms. The
                                                                   calibrating screw is then used for fine tuning.
ment panels contains two separate electrical circuits with a
common ground. One circuit operates the hour meter and the
other the taehometer. The hour meter circuit operates on 12
volts alternator charging voltage supplied to the (+) terminal
on the baek of the instrument.
The tachometer circuit operates on AC voltage 6-8 volts, fed
from one of the diodes in the alternator and supplied to the
tachometer input telminal while the engine is running, and
the alternator producing battery charging voltage 13.0-14.8                                                                 ) TERMINAL
volts DC.
The following are proeedures to follow when troubleshooting
a fault in either of the two cireuits in a tachometerlhour
meter.
Hour meter Inoperative                                                                                    CALIBRATION
Check for the proper DC voltage between (+) and (-)
terminals.                                                         TACHOMETER CHECK (New Installation)
1. Voltage present meter is defective repair or replace.           NOTE: In a new installation having new instrument panels,
                                                                   the tachometer may not always be correctly calibrated to the
2. Voltage not present trace (+) and (-) electrical con-
                                                                   engine's rpm. This calibration should be checked in all new
   nections for fault. (Jump 12 volts DC to meter (+)
                                                                   installations.
   terminal to verify the operation.)
                                                                   1. Warm up the engine to nonnal operating temperature,
Tachometer Inoperative                                                 Remove any specks on the crankshaft pulley with a clean
Check for the proper AC voltage between tachometer input               cloth and place a piece of suitable reflecting tape on the
tenninal and (-) tenninal with the engine running.                     pulley to facilitate use of a photoelectric type tachometer.
1. Voltage present attempt adjusting meter through calibra-        2. Start and idle the engine.
   tion access hole. No results, repair or replace meter.          3. Aim the light of the tachometer onto the reflecting tape to
2. AC voltage not present check for proper alternator DC              confirm the engine speed. Check the instrument panel
   output voltage.                                                    tachometer reading. Adjust the tachometer in the panel by
3. Check for AC voltage at tach tenninal on alternator to             using the instrument coarse adjustment to calibrate the
   ground.                                                            instrument reading to the closest R.P.M. that the photo tach
                                                                      is showing, Then use the fine calibration adjustment to
4. Check electrical connections from tachometer input ter-            bring the instrument to the exact reading as the photo tach.
   minal to alternator connection.
                                                                   4. Set the tachometer to the idle speed (the engine idle speed
Tachometer Sticking                                                   has been factory adjusted and the idle screws and high
1. Check for proper AC voltage between "tach inp."                    speed screws have been locked in place).
   terminal and (-) terminal.                                                                                           r
2. Check for good ground connection between meter (-)
   terminal and alternator.
3. Check that alternator is well grounded to engine block at
   alternator pivot bolt.
Tachometer Inaccurate                                                             !"
                                                                                  ~
                                                                            ill   ::   !            ~     !"
                                                                                                          ii                   I
a. With a hand-held tach on the front of the crankshaft                                \'j          I:'

   pulley retaining nut or with a strobe-type tach, read the
                                                                        r
                                                                            -     ~
                                                                                  ;
                                                                                       -                                       -
   front crankshaft pulley rpm at idle.
b. Adjust the tachometer with a small Phillips type screw-
   driver through the calibration access hole in the rear of
   the tachometer. Zero the tach and bring it to the rpm                                                                                 I·
   indicated by the strobe or hand tach. (Verify the rpm at
   idle and at high speed and adjust the tach as needed).




                                                         Engines & Generators

                                                                 43A
                                                                  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                                                                         OIL PRESSURE
The lubricating system is a pressure feeding system using an                        The engine's oil pressure, during operation, is indicated
oil pump. The engine oil is drawn from the oil sump by the                          by the oil pressure gauge on the ins1n1ment panel. During
oil pump, which drives the oil, under pressure, through the                         normal operation, the oil pressure will range between 40 and
oil filter and various lubricating points in the engine. The oil                    85 psi.
then returns to the oil sump to repeat the continuous cycle.
When the oil pressurc exceeds the specified pressure, the oil                       NOTE: A newly started, cold engine can have an oil pressure
pushes open the relief valve in the oil pump and returns to                         reading up to 85 psi. A warmed engine can have an oil
the oil sump, keeping the oil pressure within its specified                         pressure reading as low as 25 psi. These readings win vary
range.                                                                              depending upon the temperature of the engine and the 'pms.

TESTING OIL PRESSURE                                                                Low OH Pressure
To test the oil pressure, remove the oil pressure sender, then                      The specified safe minimum oil pressure is 5 - 10 psi. A
install a mechanical oil pressure gauge in it's place. After                        gradual loss of oil pressure usually indicates worn bearings.
warming up the engine, set the engine speed at 1800 rpm and                         For additional information on low oil pressure readings, see
read the oil pressure gauge.                                                        the ENGINE TROUBLESHOOTING chart.
Oil Pressure     Between 55 and 75 psi at 1800 rpm.
Note: A newly started (cold) engine may have an oil pressure up to 70 or 80
                                                                                    Testing Oil Pressure
psi. A warmed engine can have an oil pressure as low as 40 psi. Oil pressure        To test oil pressure, remove the oil pressure sender then
will vary depending on the load placed on the generator.                            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.




                                                                                                                                   OIL PRESSURE
                                                                                                                                   SWITCH
                                                                                                                                '~..

                                                                                                                         ~
                                                                                                                         .
                                                                                             MECHANICAL                  ~
                                                                                                                               \
                                                                                             OIL PRESSURE
                                                                                             GAUGE

                                                                                                                  TYPICAL ARRANGEMENT




                                                                        Engines & Generators

                                                                               44
         SPECIFICATIONS 638 AND 63C FOUR MARINE DIESEL ENGINES
                   ENGINE SPECIFICATIONS                                                                     COOLING SYSTEM
Engine Type               Diesel, four-cycle, fresh water-cooled, vertical        General                      Fresh water-cooled block, themnostatically-
                          in-line (63 hp at 3600 rpm maximum)                                                  controlled with raw water heat exchanger sys-
Governor                  Integral ofthe injection pump, mechanical               tem
                          flywheel type                                           Operating Temperature        170 -190° F(77 - 88° G)
Valve mechanism           Overhead                                                Fresh Water Pump             Gentrifugal type, metal impeller, belt-driven
Combustion Ghamber        Swirl chamber type                                      Raw Water Pump               Positive displacement, rubber impeller,
Bore & Stroke             3.50 x 3.51 inches (88.9 x 89.1 mm)                                                  gear-driven.
Piston Displacement       134.8 cubic inches (2.21 liters)                        Raw Water Row,               12.0 US gpm (45.4lpm) (measured
                                                                                  at 3600 rpm                  before discharging into exhaust elbow).
Firing Order              1-3-4-2
                                                                                  System Capacity              10 qts (9.9 liters)
Direction of Rotation     Glockwise, when viewed from the front                   (fresh water)
Maximum Torque            931b-ft (10.92 kg-m)
(at 2900 rpm)                                                                                           LUBRICATION SYSTEM
Compression Ratio         21 : 1
                                                                                  General                      Pressure fed, rotor type, driven by spiral gears
Compression Pressure      427 psi (30.0 kg/cm') at 200 rpm                                                     from camshaft
Valve Seat Angle          Intake 45°        Exhaust 45°                           Oil Filter                   Full flow, paper element. spin-on type
Valve Clearance           Intake 0.12 inches (0.3 mm)                             Sump Capacity                5.3 U.S. qts (5.0 liters)
(engine cold)             Exhaust 0.12 inches (0.3 mm)                            (not including finer)
Dimensions                Height: 25.30 inches (642.6 mm)                         Operating Oil Pressure       30 - 60 psi (2.1 - 4.2 kg/em') at maximum
                          Width: 21.19 inches (538.2 mm)                                                       engine rpm and at normal operating temperature
                          Length: 38.75 inches (984.3 mm)
                                                                                  Oil Grade                    API Specification CF, CG-4, CH-4 or CI-4
Inclination               Gontinuous 14°
                          Temporary 25° (not to exceed 30 min.)
                                                                                                            ELECTRICAL SYSTEM
Dry Weight                6111bs (192 kgs)
                                                                                  Starting Battery             12-Volt, (-) negative ground recommended
Engine Speed              Idle speed: 750-1000 rpm
                          Cruising Speed: 2500 - 3000 rpm                         Battery Gapacity             400 - 600 Cold Cranking Amps (CCA)
Fuel Consumption          1.2 US gph (4.5Iph) at 2500 rpm (approx.)               Starter                      12-Volt, actuated shift reduction geared
                          when the propeller allows 3600 rpm at full open         Starting Aid                 Glow plugs
                          throttle while underway in forward gear                 DC No-Load Current           100 Amps at 11.5 volts (3000 rpm. min)
                         FUEL SYSTEM                                              Cold Cranking Current        280 - 300 Amps at 10 volts (250 rpm. min)
                                                                                  Aiternator                   12 Volt DC, 50 amps
Fuel                      No.2 diesel oil (cetane rating of 45 or higher)
                                                                                  Regulator                    Intemal regulation, built into alternator
Injection Pump            Diesel KiKi mechanical governed
Fuel Injection Timing     0° TOC (Top Dead Center)                                                    TRANSMISSION SYSTEM
Nozzle                    Throttle type
                                                                                  General                      ZFIHURTH Standard Transmission - case
Injection Pressure        1920 psi (135 kg/cm2)                                                                hardened, helical gears with servo-operated
Lift Pump                 12 volt plunger type                                                                 multiple disc clutch
Fuel Filter               Spin-on (Replaceable)                                   Gear ratio (standard)        2.7:1
(on engine)                                                                       Propeller Shaft              right handed - standard transmission
Air cleaner               Metal screen type - cleanable                           (direction of rotation)
Air Flow                                                                          Propeller                    20 Dx 14 P-2 blade or 18 Dx 16 P-3 blade
(engine combustion)       140.0 cfm (3.9 cmm) at 3600 rpm                         Recommendations              Propeller should allow the engine to reach its full
(engine cooling)          250 cfm (7.0 cmm)                                                                    rated RPM (3600 + 000 -100) at full open
                                                                                                               throttle while underway
                        EXHAUST SYSTEM                                            Lubricating Fluid            ATF - Dexron II or Dexron III
Exhaust Elbow             70 degree elbow                                         Transmission Sump            0.79 US qts. (0.75 liters approximate)
                                                                                  Capacity                     (Fill to "fu\l" mark on dipstick)
Hose Size                 3 inch I.D. hose
Muffler Size              12 inch x 12 inch (min)




                                                                      Engines & Generators

                                                                             45
         SPECIFICATIONS 71 BAND 71 CFOUR MARINE DIESEL ENGINES
                   ENGINE SPECIFICATIONS                                                                     COOLING SYSTEM
Engine Type               Diesel, four-cycle, four cylinder, fresh               General                       Fresh water-cooled block, thermostatically-
                          water-cooled, vertical in-line                                                       controlled with raw water heat exchanger sys-
                          (71 hp at 3600 rpm maximum)                            tem
Govemor                   Integral of the injection pump, mechanical             Operating Temperature         170 190· F (77 - 88° C)
                          flywheel type                                          Fresh Water Pump              Centrifugal type, metal impeller, belt-driven
Valve mechanism           Overhead                                               Raw Water Pump                Positive displacement, rubber impeller,
Combustion Chamber        Swirl chamber type                                                                   gear-driven.
Bore & Stroke             3.50 x 4.0 inches (88.9 x 101.6 mm)                    Raw Water Row,                10.0 US gpm (37.8Ipm) (measured
Piston Displacement       154.0 cubic inches (2.5 liters)                        at 3600 rpm                   before discharging into exhaust elbow).
Firing Order              1 3-4-2                                                System Capacity               11.5 qts (10.9 liters)
                                                                                 (fresh water)
Direction of Rotation     Clockwise, when viewed from the front
Maximum Torque            1181b-ft (15.31 kg-m)                                                           LUBRICATION SYSTEM
(at 2200 rpm)
Compression Ratio         21 : 1                                                 General                       Pressure fed, rotor type, driven by spiral gears
                                                                                                               from camshaft
Compression Pressure      427 psi (30.0 kg/cm") at 200 rpm
                                                                                 Oil Riter                     Full flow, paper element, spin-on type
Valve Seat Angle          Intake 45°        Exhaust 30°
                                                                                 Sump Capacity                 6.3 U.S. qts (6.0 liters)
Valve Clearance           Intake 0.12 inches (0.3 mm)                            (not including filter)
(engine cold)             Exhaust 0.12 inches (0.3 mm)
                                                                                 Operating Oil Pressure        30 60 psi (2.1 - 4.2 kg/em') at maximum
DimenSions                Height: 26.9 inches (684.2 mm)                                                       engine rpm and at normal operating temperature
                          Width: 22.2 inches (563.6 mm)
                          Length: 39.5 inches (1003.3 mm)                        Oil Grade                     API Specification CF, CG-4, CH-4 or CI-4
Inclination               Continuous 140                                                                    ELECTRICAL SYSTEM
                          Temporary 25° (not to exceed 30 min.)
Dry Weight                652 Ibs (295.9 kgs) - B-Four                           Starting Battery              12-Volt, (-) negative ground
                          687 Ibs (311.8 kgs) - C-Four                           Battery Capacity              400 - 600 Cold Cranking Amps (CCA)
Engine Speed              Idle speed: 750-1000 rpm                               Starter                       12-Volt, actuated shift reduction geared
                          Cruising Speed: 2500 - 3000 rpm                        Starti ng Aid                 Glow plugs
Fuel Consumption          1.4 US gph (5.2Iph) at 2500 rpm (approx.)              DC No-Load Current            100 Amps at 11.5 volts (3000 rpm. min)
                          when the propeller allows 3600 rpm at full
                          open throttle while underway in forward gear           Cold Cranking Current         250 - 300 Amps at 10 volts (250 rpm. min)
                                                                                 Alternator                    12 Volt DC, 50 amps
                         FUEL SYSTEM                                             Regulator                     Intemal regulation, built into alternator
Fuel                      No.2 diesel oil (cetane rating of 45 or higher)
Injection Pump            Diesel KiKi mechanical govemed                                              TRANSMISSION SYSTEM
Fuellnjaction Timing      00 TOC (Top Dead Center)                               General                       ZFIHURTH Standard Transmission - case
Nozzle                    Throttle type                                                                        hardened, helical gears with servo-operated
                                                                                                               multiple disc clutch
Injection Pressure        1920 psi (135 kg/em')
                                                                                 Gear ratio (standard)         2.74:1
Lift Pump                 12 volt plunger type
                                                                                 Propeller Shaft               right handed - standard transmission
Fuel Riter                Spin-on (Replaceable)                                  (di rection of rotation)
(on engine)
                                                                                 Propeller                     20 Dx 14 P-2 blade or 200 x 12 P-3 blade
Air cleaner               Metal screen type - cleanable                          Recommendations               Propeller should allow the engine to reach its full
AirFlow                                                                                                        rated RPM (3600 + 000 -1 00) at full open
(engine combustion)       160.4 cfm (4.5 cmm) at 3600 rpm                                                      throttle while underway
                                                                                 Lubricating Fluid             ATF - Dexron II or Oexron III
                        EXHAUST SYSTEM                                           Transmission Sump             0.79 US qts. (0.75 liters approximate)
Exhaust Elbow             70 degree elbow                                        Capacity                      (Fill to "full" mark on dipstick)
Hose Size                 3 inch 1.0. hose
Muffler Size              12 inch x 12 inch (min)




                                                                       Engines & Generators

                                                                            46
                     SPECIFICATIONS 828 FOUR MARINE DIESEL ENGINE

                    ENGINE SPECIFICATIONS                                                                   FUEL SYSTEM
Engine Type                 Diesel, four-cylinder, four-cycle, fresh              General                    Open flow, self priming - 1 bleed point.
                            water-cooled, vertical in-line overhead valve         Fuel                       No.2 diesel oil (cetane rating of 45 or higher)
                            mechanism.
                                                                                  Fuel Injection Pump        ZEXEL Model VE Distributor. (Diesel KiKi)
Aspiration                  Naturally aspirated
                                                                                  Fuel Injection Timing      0° TOC (Top Dead Center)
Combustion Chamber          Swirl type
                                                                                  Nozzle                     Th rottle type
Bore &Stroke                3.74 x 4.13 inches (95 x 105 mm)
                                                                                  Fuel Filter                Spin-on type, full flow
Piston Displacement         182 cubic inches (2.98 liters)                        (on engine)
Firing Order                1-3 4 2                                               Air cleaner                 Metal screen type - cleanable
Direction of Rotation       Clockwise, when viewed from the front                 Air Flow                    94.6 cfm (2.7 cmm)
Compression Ratio           21 : 1                                                (engine combustion)
Dimensions                  Height: 27,3 inches (694.0 mm)
                            Width: 25.5 inches (647.7 mm)                                                  COOLING SYSTEM
                            Length: 38.8 inches (985.8 mm)                        General                     Fresh water-cooled block, thermostatically-
Weight                      6781bs (307 kgs)                                                                  controlled with heat exchanger.
Inclination                 Continuous 15·                                        Operating Temperature       170 - 190° F (77 - 88° C)
                            TemporarY 25· (not to exceed 20 min.)
                                                                                  Fresh Water Pump            Centrifugal type, metal impeller, ben-driven
Generator Power Take Off    40 Hp (Maximum)                                       Raw Water Pump              Positive displacemen~ rubber impeller,
                                                                                                              belt-driven.
                   TUNE-UP SPECIFICATIONS                                         Raw Water Flow,             15.0 gpm (56.7lpm) (measured
Compression Pressure         427 psi (30 kg/em') at 200 rpm                       at 2600 rpm                 before discharging into exhaust elbow),
(Limit of difference between                                                      System capacity             13.0 qts (12.3 liters)
cylinders)                   (47.2 psi {3,0 kg/em'})                              (coolant)
Valve Timing                 Intake Opens 17" BTDC
                             Intake Closes 47" ABDC                                                   LUBRICATION SYSTEM
                            Exhaust Opens 51 ° BB DC                              General                     Pressure fed system
                            Exhaust Closes 13° ATDC                               Oil Filter                  Full flow, paper element, spin-on type
Valve Seat Angle            Intake 45°                                            Sump Capacity               6.5 U.S. qts (6.15Iiters)
                            Exhaust 30·                                           (not including filter)      plus filter/cooler assembly
Valve Clearance             Intake 0.012 inches (0.3 mm)                          Operating Oil Pressure      50 - 60 psi (3,5 - 4.2 kg/em»
                            Exhaust 0.012 inches (0.3 mm)                         (engine hot)
Injector Pressure           1920 + 71 - 0 psi (135 + 5 - 0 kg/em')                Oil Grade                   API Specification CF. CG-4, CH-4 or CI-4
Engine Timing               Static timed - drop valve method
                            0.205 ± .005 inches BTOC                                                      ELECTRICAL SYSTEM
                                                                                  Starting BatterY            12-Volt, (-) negative ground
              EXHAUST EMISSIONS SYSTEMS
                                                                                  BatterY Capacity            600 - 800 Cold Cranking Amps (CCA)
Emission Control            Indirect Fuel Injection
                                                                                  Starter                     12-Volt, reduction
Systems
                                                                                  Starting Aid                Glow plugs, sheathed type
                                                                                  BatterY Charging            51 Amps
                                                                                  Alternator




                                                                       Engines & Generators

                                                                            47
      SPECIFICATIONS 1088 AND 108C FOUR MARINE DIESEL ENGINES
                   ENGINE SPECIFICATIONS                                                                    COOLING SYSTEM
Engine Type               Diesel, four-cycle, four cylinder, fresh               General                      Fresh water-cooled block, thermostatically-
                          water-cooled, vertical in-line                                                      controlled with raw water heat exchanger sys-
                          (108 hp at 3600 rpm maximum)                           tem
Governor                  Integral of the injection pump, mechanical             Operating Temperature        170 -190° F (77 - 88° C)
                          flywheel type                                          Fresh Water Pump             Centrifugal type, metal impeller, belt-driven
Valve mechanism           Overhead                                               Raw Water Pump               Positive displacement, rubber impeller,
Combustion Chamber        Swirl chamber type                                                                  gear-driven.
Bore & Stroke             3.62 x 3.40 inches (91.9 x 101.6 mm)                   Raw Water Row,               14.0 US gpm (53Ipm) (measured
Piston Displacement       247.2 cubie inches (4.05 liters)                       at 3600 rpm                  before discharging into exhaust elbow).
Firing Order              1 5-3-6-2-4                                            Sys1em Capacity              16 qts (15.1 liters)
                                                                                 (fresh water)
Direction of Rotation     Clockwise, when viewed from the Iront
Maximum Torque            1881b-ft (26.0 kg-m)                                                            LUBRICATION SYSTEM
(at 2900 rpm)
Compression Ratio         21 : 1                                                 General                      Pressure fed, rotor type, driven by spiral gears
                                                                                                              from camshaft
Compression Pressure      427 psi (30.0 kg/em') at 200 rpm
                                                                                 Oil Filter                   Full flow, paper element, spin-on type
Valve Seat Angle          Intake 45°       Exhaust 30'
                                                                                 Sump Capacity                11.9 U.S. qts (11.3 liters)
Valve Clearance           Intake 0.12 inches (0.3 mm)                            (not including filter)
(engine cold)             Exhaus1 0.12 inches (0.3 mm)
                                                                                 Operating Oil Pressure       30 - 60 psi (2.1 - 4.2 kg/cm') at maximum
Dimensions                Height 29.3 inches (742.9 mm)                                                       engine rpm and at normal operating temperature
                          Width: 26.9 inches (682.6 mm)
                          Length: 53.3 inches (11353.8 mm)                       Oil Grade                    API Specification CF, CG-4, CH-4 or CI-4
Inclination               Continuous 14'
                          Temporary 25° (not to exceed 30 min.)
                                                                                                           ELECTRICAL SYSTEM
DryWeighl                 9321bs (422.8 kgs)                                     Starting Battery             12-Volt, (-) negative ground
Engine Speed              Idle speed: 750-1000 rpm                               Battery Capacity             400 - 600 Cold Cranking Amps (CCA)
                          Cruising Speed: 2500 - 3000 rpm                        Starter                      12-Volt, actuated shift reduction geared
Fuel Consumption          2.1 US gph (7.9Iph) at 2500 rpm (approx.).             Starting Aid                 Glow plugs
                                                                                 DC No-Load Current           100 Amps at 11.5 volts (3000 rpm. min)
                         FUEL SYSTEM                                             Cold Cranking Current        250 - 300 Amps at 10 volts (250 rpm. min)
Fuel                      No.2 diesel oil (cetane rating 0145 or higher)         Alternator                   12 Volt DC, 50 amps
Injection Pump            Diesel KiKi mechanical governed                        Regulator                    Internal regulation, built into alternator
Fuel Injection Timing     0° TOC (Top Dead Center)
Nozzle                    Throttle type                                                               TRANSMISSION SYSTEM
Injection Pressure        1920 psi (135 kg/cm')                                  General                      ZFIHURTH Standard Transmission - case
LiftPump                  12 volt plunger type                                                                hardened, helical gears with servo-operated
Fuel Finer                Spin-on (Replaceable)                                                               multiple disc clutch
(on engine)                                                                      Gear ratio (standard)        2.04:1
Air cleaner               Metal screen type - cleanable                          Propeller Shaft              right handed - standard transmission
AirFlow                                                                          (direction of rotation)
(engine combustion)       257 cfm (2.9 cmm) at 3600 rpm                          Propeller                    20 Dx 14 P-2 blade or 200 x 10 P-3 blade
(engine COOling)          250 elm (7.0 cmm) at 3600 rpm                          Recommendations              Propeller should allow the engine to reach its full
                                                                                                              rated RPM (3600 + 000 -100) at full open
                        EXHAUST SYSTEM                                                                        throttle while underway
                                                                                 Lubricating Fluid            ATF - Dexron II or Dexron III
Exhaust Elbow             70 deg ree elbow
                                                                                 Transmission Sump            0.79 US qts. (0.75 liters approximate)
Hose Size                 3 inch 1.0. hose                                       Capacity                     (Fill to ''full" mark on dipstick)
Muffler Size              12 inch x 12 inch (min)




                                                                       Engines & Generators

                                                                            48
                                       ZF MARINE TRANSMISSIONS
DESCRIPTION                                                          NOTE: When installing the transmission, make certain that
The information below is specific to the ZF Transmissions,           shifting is not impeded by restricted movability of the
the TRANSMISSION TROUBLESHOOTING SECTION                             Bowden cable or rod linkage, by unsuitably positioned guide
applies to aU models.                                                sheaves, too small a bending radius, etc. In order to mount a
                                                                     support for shift control cable connections, use the two
CONNECTION OF GEAR BOX WITH PROPELLER                                threaded holes located above the shift cover on top of the
HEW recommend a flexible connection between the                      gear housing. Refer to the WESTERBEKE parts list.
transmission gearbox and the propeller shaft if the engine is        CONTROL CABLES
flexibly mounted, in order to compensate for angular
deflections. The installation of a special propeller thrust          The transmission is suitable for single lever remote control.
bearing is not required, since the propeller thrust will be          Upon loosening the retaining screw, the actuating lever can
taken by the transmission bearing, provided the value                be moved to any position required for the control elements
specified under SPECIFICATIONS is not exceeded.                      (cable or rod linkage). Make certain that the shift lever does
However, the output shaft should be protected from                   not contact the actuating lever cover plate: the minimum
additional loads. Special care should be taken to prevent            distance between lever and cover should be O.5mm.
torsional vibration. When using a universal joint shaft, make        The control cable or rod should be arranged at right angle to
certain to observe the manufacturers instructions.                   the actuating shift lever when in the neutral position. The
Even with the engine solidly mounted, the use of flexible            neutral position of the operating lever on the control console
coupling or "DRIVESAVER" will reduce stress in the                   should coincide with the neutral position of this lever.
gearbox bearings caused by hull distortions, especially in           The shifting travel, as measured at the pivot point of the
wooden boats or where the distance between transmission              actuating lever, between the neutral position and end
output flange and stem gland is less than about 800mm.               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
                               ,./'-       ZF 15M                    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.
                                                                                                          NEUTRAL
                                                                                                             N




                                                                           CONTROL
                                                                           CABLE




  A CAUTION: The position of the mechanism behind                                                SHIFT
  the actll6ting lever is factory~adjusted to ensure equal                                       LEVER
  shift lever travel from neutral position Aand B. If
  this mechanism is in any way tampered with, the                                                               I   COVER
  transmission warranty will be void.

* DID v ~AVER is a product of Globe Marine, Rockland, MA.
                                                                                                     ~F
                                                                                                    O.5rnrn J
                                                                                                    MINIMUM DISTANCE
                                                       Engines & Generators

                                                                49
                                                ZF MARINE TRANSMISSIONS
 INITIAL OPERATION                                                       OPERATING TEMPERATURE
All HBW marine transmissions are test-run on atest stand                The maximum pennissible ATF temperature should not exceed
 with the engine at the factory prior to delivery. For safety           230" (110°). This temperature can only be reached for a short
reasons the fluid is drained before shipment.                           time.
FilI the gearbox with Automatic Transmission Fluid
(DEXRON n or DEXTRON ill). The fluid lev~l should be                      A CAUTION: If the transmission Huld temperature Is
up to the index mark on the dipstick. To check the fluid level,           too high# stop the engine immediately and check the
just insert the dipstick, do not screw it in. Screw the dipstick          transmissiou Huld.
into the case after the fluid level is checked and tighten. Do .
not forget the sealing ring under the hexhead of the dipstick.
Check for leaks and change the fluid after the first 25 hours,          LOCKING THE PROPELLER
also make a visual inspection of the coupling, oil cooler and           Locking of the propeller shaft by an additional brake is not
hoses, and shift cables.                                                required: use the gear shift lever position opposite your direc-
                                                                        tion of travel for this pUlpose. 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 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 charg-
                                                                        ing the battery), will have no detrimental effects on the trans-
                                                                        mission
                                                                        DAILY OPERATION
                                                                        o     Check the transmission fluid.
                                         FLUID LEVEL                          VIsually check the gear shift linkage and tiansrnission.
                                                                         o Start the engine in neutral, allowing a few minutes at
                                                                             idle to wann the fluid.
                    I                                                    o Shift into gear.
FLUID CHANGE                                                            NOTE: Too low an idle speed will produce a chattering noise
Change the fluid for the first time after about 25 hours of             from the transmission gear and damper plate. In such cases
operation, then every 250 operating hours or at least once a            the idle speed should be increased
year or when you change engine oil.                                     For additional infonnation refer to the following text in this
                                                                        Transmission Section: SHAFT COUPLINGS, MAINTENANCE
Removing the fluid                                                      AND TRANSMISSION TROUBLESHOOTING.
Push a suction pump hose down through the dipstick hole to
the bottom of the housing and suck out the fluid. (If space
allows, use the transmission drain). Remove the drain plug                      ZF TRANSMISSIONS SPECIFICATIONS
from the bottom of the transmission and allow the fluid to
drain into a container, then reinstall the plug with its sealing          General                    (ZF Standard Transmission) Case
washer. Wipe down the transmission and properly dispose of                                           hardened helical gears, with a
the used fluid. After running the engine, shut down and                                              servo-operated multiple disc clutch
recheck the fluid level.                                                 Gear Ratio (optional)       ZF 15MA (1.88:1 or 2.63:1 )
Drain plug torque       20 · 25 fI/Ibs                                   Note: There are a variety   ZF 10MA (1.79:1)
                                                                         of gear ratios available.   If 12MA (2.63:1)
                                                                         Only a few are listed.      ZF 15MIV (2.13:1 or 2.72:1)
NOTE: When changing the fluid, take care not to lose the
drain plug sealing washer. The drain plug wiilleak without               Lubricating Fluid           ATF · Type A or Dextron · II or III
this sealing washer.                                                     Propeller Shaft             Right-hand rotation for above models
                                                                         Direction of Rotation       listed.

  A WARNING: Never pull out the dipstick while the
  engine is running. Hot fluid will splash from the dip-
  stick hole. This could cause severe burns.




                                                         Engines & Generators

                                                                   50
                                                  ZF TRANSMISSIONS
SHIPMENT                                                                  INITIAL OPERATION
For safety reasons, the transmission is not filled with                   Set the shifting lever to neutral position (N). Start the engine
transmission fluid during shipment and the selector lever is              and let it run long enough in idle to fill the cooler and hoses
temporarily attached to the actuating shaft.                              with transmission fluid. Shift into gear, forward and reverse;
Before leaving the WESTERBEKE plant, each transmission                    shifting should be smooth and positive. Direct changes from
undergoes a test run, with Dextron /II ATF transmission fluid.            forward to reverse are permissible since the multiple disc
The residual fluid remaining in the transmission after                    clutch permits changing at high rpm including sudden
draining acts as a preservative and provides protection                   reversing at high speeds in the event of danger.
against corrosion for at least one year if properly stored.               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
                                        ~~t....::..J.1-   FILTER          boat.
                                                          ASSEMBLY
                                                                          WHEN UNDER SAIL OR BEING TOWED
                                                                          Rotation of the propeller without a load, such as when the
    OUTPUT                                                                boat is being sailed, being towed or anchored in a river, as
    COUPLING: ---'0"-                                                     well as operation of the engine with the propeller stopped
                                           ZF-63                          (for charging the battery), will have no detrimental effects on
                                                                          the transmission.
OIL COOLER
                                                                          NOTE: When the boat is being sailed (engine stopped), the
The oil cooler, mounted above the transmission, provides
                                                                          gear shift must be in the neutral position. The propeller is at
continuous cooling for the transmission fluid. Raw water
                                                                          idle and can free-wheel.
passes through the tubes of the cooler and discharges
overboard. The transmission fluid is cooled as it flows around            DAILY OPERATION
the tubes and back into the transmission.
                                                                          o Check the transmission fluid.
  WESTERBEKE RECOMMENDS                                                     Visually check the gear shift linkage and transmission.
                                                     ·RAW WATER
  HAVING A SPARE COOLER                               CONNECTION            Start the engine in neutral, allowing a few minutes at idle
  ABOARD                                                                    to warm the fluid.
                                                                          D Shift into gear.
                        '.A?JJ·J-;---TRANSMISSION                         NOTE: Too Iowan idle speed will produce a chattering noise
                                       FLUID CONNECTIONS                  from the transmission gear and damper plate. In such cases
RAW WATER                                                                  the idle speed should be increased.
CONNECTION                 ZF COOLER
                                                                          Operating Temperature
TRANSMISSION FLUID                                                        The operating temperature of the transmission should not
Fill the transmission with Dextron III ATF. The fluid level               exceed 176°F (80°C). A connection for a temperature probe
should be up to the mark on the dipstick. After checking the              is provided. At maximum output of the engine, the fluid may
level, press the dipstick into the case and ~ it to tighten.              reach 220°F (104 0c).
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                   A CAUTION: If the transmission fluid temperature is
hours thereafter.                                                          too high, stop the engine immediately and check the
                                                                           transmission fluid.
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.




                                                              Engines & Generators

                                                                     51
                                                  ZF TRANSMISSIONS
  CHANGING THE TRANSMISSION FLUID                                         Replacing the Fluid
                                                                          Pour in new Dextron 1II ATF fluid and check the quantity
                                                                          with the dipstick.
                                                                          Transmission fluid quantities will vary with the use of cool-
                                                                          ers,length of hoses and'the angle of the transmission.
                                                                                              Approximate Quantities
                                                                                       ZF 45 - 2.12 quarts (2.0 Liters)
                                                                                       ZF 63 - 3.2 quarts (3.0 Liters)
                                                                                       ZF 63V -4.2 quarts (4.0 Liters)
                                                                          Reinsert the filter assembly into the housing. Press it in place
                                                                          and tighten the Allen screw.
                                                                          NOTE: Some ZF transmissions use a "Tn handle in place ofa
16MM.(8") SCREW                                                           screw on their filter assemblies.
                                                                          After running the engine, shut down 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.

                                                                          MAINTENANCE
                         O-RINGS
                                          ZF·45                           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
                         FILTER                                           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 cream).
                                                                          Lay-up/Winterize
  Filter Element                                                          Storage requires special care. Follow these procedures:
  The ZF transmission has a filter element located opposite the           D Drain water from the transmission oil cooler and replace
  dipstick. This filter must be replaced whenever the fluid is                with a proper mixture of antifreeze coolant
  changed.                                                                    NOTE: This operation wiU nonnally occur when the
  Remove the filter by loosening the screw on the cover using                 engine raw water cooling system is properly winterized.
  a 6mm Allen wrench.
                                                                              Clean up the transmission and touch up unpainted areas
  1\vist and pull out the filter and remove the element. Place                (use heat resistant paint).
  the new filter onto the cover and lock it into place by turning
  it clockwise. Check the O-rings for damage and replace if
                                                                          o   Fill the transmission with Dextron III ATF fluid to
                                                                              prevent internal corrosion (extended storage only, twelve
  necessary. Replacement filters can be obtained from your
                                                                              months or more).
  local WESTERBEKE dealer or ZF dealer.!>
                                                                              Loosen attaching hardwarf? from the transmission output
  Removing the Fluid                                                          flange and propeller shaft coupling flange before
  Push a suction pump hose down through the pipe hole (under                  removing the boat from the water. Separate the flanges
  the filter) to the bottom of the housing and suck out the fluid.            and spray with lubricant.
  Remove the oil return line from the cooler and allow the oil            o   Inspect the gear shift cable, linkage, and attachments.
  to drain into a container, then reconnect the oil return line.              Look for corrosion of the end fittings, cracks or cuts in
                                                                              the conduit, and bending of the actuator rods. Lubricate
  Wipe down the transmission and properly dispose of the used                 all moving parts.
  fluid.
                                                                              NOTE: If the transmission is to be stored for a long time
                                                                              (twelve months or more), it slwuid be topped offwith
                                                                              fluid to prevent internal corrosion. Reduce thf' fl1lii/ level
                                                                              before putting the engine back into service.


                                                            Engines & Generators

                                                                     52
                                                IF TRANSMISSIONS
CABLE CONNECTIONS                                                   SHAFT COUPLINGS
The transmission is suitable for a single lever gear shift.        WESTERBEKE recommends a flexible conneCtion between
Upon loosening the retaining screw, the actuating lever (see       the transmission and the propeller shaft if the engine is flexi-
illustration) can be moved to any position required for the        bly mounted, in order to compensate for angular deflections.
control elements (cable or rod linkage). Make certain that the     The installation of a special propeller thrust bearing is not
actuating lever does not contact the lever hub: the minimum        required, since the propeller thrust will be absorbed by the
distance between the lever and the hub should be O.02in            transmission bearing, provided the value specified under
(O.5mm).                                                           SPECIFICATIONS is not exceeded. However, the output
The control cable or rod should be arranged at a right angle       shaft should be protected from additional loads. Special care
to the actuating lever when in the neutral position. The           should be taken to prevent torsional vibration. When using a
neutral position of the gear shift lever on the control console    universal joint shaft, make certain to observe the manufac-
should coincide with the neutral position of the lever on the      turer's instructions.
transmission.                                                      Even with the engine solidly mounted the use of a flexible
The shifting travel, as measured at the pivot point of the         coupling or "DRNESAVER" will reduce stress in the gear-
actuating lever between the neutral position and end positions     box bearings caused by hull distortions, especially in wooden
A and B, should be at least I-3/8in (3Smm) for the outer and       boats or where the distance between the transmission output
1-31l6in (3Omm) for the inner pivot point                          coupling and stem gland is less than about 800nnn.
                                                                   NOTE: When installing the transmission, make certain tlwt
                                            N                      shifting is not impedR.d by restricted movability of the cable
                                                                   or rod linkage, by unsuitably positioned guide sheaves, too
                                                                   small a bending radius or other r,5trictions. In order to
                                                                   mount a support for shift control cable connections, use the
                                                                   two threaded lwles located on the cable bracket mounted on
    PROPELLEa----                                                  the gear lwusing. Refer to the WESTERBEKE parts list.
    ROTATION
    A=RH                N                                          For additional infonnation contact:
    N-NEUTRAL
    B=LH     .A                                                          ZF Industries
                                                                         Marine US Headquarters
                                                                         3131 SW 42nd Street
                                                                         Fort Lauderdale, FL 33312
                                                                         Thl.: (954) 581-4040
                                                                         Fax: (954) 5814077
                                                                         FOR ADDITIONAL INFORMATION
                                                                         WWW.zF-MARINE.COM




A greater amount of actuating lever travel is in no way
detrimental and is recommended. However, if the lever travel                                                    I~-GEAR
is shorter, proper clutch engagement might be impeded                                                                  'SHIFT
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 (see
CONTROL CABLES under TRANSMISSUJN
TROUBLESHOOTING)
NOTE: Check for proper actuating lever travel at least each                        TYPICAL STEERING STATION
season.

 A    CAUTION: The position of the mechanism behind
 the actuating lever is factory-adjusted to ensure equal
 shift lever travel from neutral position to Aand B. If
 this mechanism is in any way tampered with, the
 transmission wananty will be void.



                                                           Engines & Generators

                                                                  53
                                            ZF MARINE TRANSMISSIONS
    OPERATING TEMPERATURE                                              MAINTENANCE
                                                                       Transmission maintenance is minimal. Keep the exterior
                                                                       housing clean, check the fluid level as part of your regular
      A CAUTION: If the transmission fluid temperature is              routine, and change the fluid every 300 operating hours.
      too high, stop the engine immediately and check the              Periodically inspect the transmission and the cooler for leaks
      transmission fluid.                                              and corrosion. Make certain the air vent is clear and when
                                                                       checldng the fluid level look for signs of water contamination
    Norn1al operating temperature of the transmission fluid            (fluid will appear as strawberry cream).
    should be in the range of 1220 F (500 C) to 2120 F (1000 C) ..
    A maximum temperature of 2660 F (1300 C) may b~ only               Lay-up/Winterize
    reached for a short time.                                          Storage requires special care. Follow these procedures:
    Make certain there is enough space around the transmission             Drain water from tlle transmission oil cooler and replace
    to provide good ventilation and cooling.                               with a proper mixture of antifreeze coolant.
    TRANSMISSION COOLER                                                    NOTE: 11zis operation will nonnally occur when the
    Coolers are standard equipment for the ZF 10M, ZF 12M,                 engine raw water cooling syst~m is properly winterized.
    ZF 15M, ZF 15MA, ZF 15MIV; and the ZF 25M.                         o   Clean up the transmission and touch up unpainted areas
    The cooler is a separate part of the transmission which                (use heat resistant paint).
    prevents any possibilities of coolant diluting the transmission        Fill the transmission with De:>.1ron III ATF fluid to
    fluid. However, the continued flow of coolant thru the cooler          prevent internal corrosion (extended storage only, twelve
    will, in time, erode the inside of the cooler causing external         months or more).
    leaks.
    A transmission cooler may last ten years or more but, in
                                                                       o   Loosen attaching hardware from the transmission output
                                                                           flange and propeller shaft coupling flange before
    some circumstances, depending on operating hours, tropical             removing the boat from the water. Separate the flanges
    waters, maintenance, etc. it might only last half that time.           and spray with lubricant.
    WESTERBEKE recommends having a spare cooler aboard.                    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 more), it should be topped offwith
                                                                           fluid to prevent inte172al corrosion. Reduce the fluid level
                                                                           before putting the engine back into service
TRANSMISSION COOLER



                                            PERIODICAUY INSPECTFOR
                                            EROSION AND LEAKAGE




                                                                                                                                -GEAR
                                                                                                                                   SHIFT




                                                                                                 For additional infonnation contact:
                                                                                                 ZF MARINE GEAR
                                                                                                 ZF Industries
                                                                                                 Marine US Headquarters
                                                                                                 3131 SW 42nd Street
                                                                                                 Fort Lauderdale, FL 33312
                                                                                                 Tel.: (954) 581-4040
                                                                                                 Fax: (954) 5814077
                                                                                                 WWW.ZF·MARlNE.COM



                                                              Engines & Generators

                                                                      54
                                      TRANSMISSION TROUBLESHOOTING [ZF]
CONTROL CABLES
The majority of transmission difficulties arise as a result of                           A new cable and perhaps a new linkage mechanism may be
improper clutch adjustments (manual transmissions) or                                   needed. While the cable is loose, shift the transmission in and
problems with control cables (hydraulic transmissions)                                  out of gear using the lever on the side of the transmission to
rather than fTom problems with the transmission itself.                                 make sure there's no binding inside the case.
ZF clutches, in particular, are very sensitive to improper                              If the transmission passes these tests, crank the engine and
cable adjustments.                                                                      have a helper put it in forward and reverse while you observe
If you experience operating problems with the transmission,                             the propeller shaft; if the shaft isn't turning, the transmission
shut the engine down. First check the transmission-fluid                                needs professional attention. If it does tum but there's no
level, then have a helper move the cockpit shift lever through                          thrust, check to see you still have a propeller on the end of
the full range - from neutral to full forward, back to                                  the shaft or, if you have a folding or feathering propeller, that
neutral, into full reverse, and back to neutral - while you                             it isn't stuck in the "no pitch" position.
observe the actuating lever on the transmission. If the remote                          NOTE: lfyou suspect a major problem in your transmission,
is stiff to operate, break the cable loose at the transmission                          immediately contact your WESTERBEKE dealer or an
and try again. If it is still stiff, check the cable for kinks or                       autlwrized marine transmission facility.
excessively tight bends, and check any linkage for binding.

                Problem                                 Probable Cause                                           Veriftcation/Remedy
 Transmission gears cannot be shifted.        1. Actuating lever is loose.                        1. Tighten damping bolt on shifting lever.
 Fails to move into gear.
                                              2. Shifting cable is broken, bent or                2. Check the cable, reattach or replace.
                                                  unattached. Cable radius is too severe.
                                              3. Actuating lever is binding against the           3. Detach the shift cable and operate the actuating lever by
                                                                                                      hand. Clearance should be 0.02 in (0.5mm).
 Transmission shifts into gear,               1. Output coupling is not tuming.                   1. Transmission needs professional attention.
 but fails to propel the boat.
                                              2. Propeller shaft is not turning.                  2. The coupling bolts are sheared or the coupling is slipping
                                                  Output coupling is turning.                         on the propeller shaft. TIghten or replace set screws, keys,
                                                                                                      pins and coupling bolts as necessary.
                                              3. Output coupling and                              3. Inspect the propeller. It may be missing or damaged.
                                                  propeller shaft are turning.                       A folding propeller may be jammed. A variable pitch
                                                                                                     propeller may be in "no pitch" position.
 Delay of gear engagement or engages          1. Actuating lever travel Nto B not                 1. Adjust cover plate until the lever is exact mid-position.
 only after an increase in speed.                equal to Nto A.                                     See ACTUATING LEVER TEXT AND DIAGRAM.
                                              2. Actuating level travel in insufficient           2. Check shift lever cable length. See ACTUATING LEVER
                                                                                                      DIAGRAM.
                                              3. Actuating lever is binding against cover plate. 3. Check clearance, adjust if necessary.
 Transmission noise becomes louder.           1. Damage starting on flexible coupling due         1. Check alignment, inspect flexible coupling. If noise perSists,
                                                  to wear or fatigue, possibly due to                inspect the damper plate between the transmission and the
                                                  misalignment between engine and                    engine. Replace if necessary.
                                                  transmission.
                                              2. Beginning damage of bearings in                  2. Transmission needs professional attention.
                                                 transmission due to torsional vibrations,
                                                 running without fluid, overload, wrong
                                                 alignment of transmission, or excessive
                                                 engine output.
 Chattering transmission noise,               1. lhe engine or propeller generates torsional      1. Mount aflexible coupling with another stiffness factor
 mainly at low engine speed.                      vibrations in the drive unit which produces         between the engine and transmission; a coupling with
                                                  a "chattering" noise in the transmiSsion.           a higher stiffness factor might be sufficient.
                                                                                                  2. Inspect the damper plate between the engine and the
                                                                                                     transmission. Replace if necessary.
 Boat falls to attain specified max. speed.   1. Operating temperature is high.                   1. Wrong type of fluid. Use Dextron III, check fluid level.
                                              2. Operating without cooling.                       2. Check cooler. Inspect coolant hoses and coolant flow.
 Oil Leakage.                                 1. Corrosion at radial sealing ring and shaft.      1. Transmission needs professional attention.
                                                 Damaged sealing ring.
                                              2. Misalignment of output flanges.                  2. Check alignment. Must be within 0.003 in (0.08mm).




                                                                         Engines & Generators

                                                                                   54A
                        BORG WARNER VELVET DRIVE TRANSMISSION
                                                 OPTIONAL TRANSMISSION
                                                                      SHIFT LEVER POSITION
                                                                       The gear shift control mechanism and linkage must position
                                                                       the actuating lever on the transmission exactly in Forward
                                                                       (F), Neutral (N), and Reverse (R) shifting positions. A dete])t
                                                                       ball 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 posi-
                                                                      tion may be made at any time below 1000 rpm and in any
                                                 BORG WARNER          order. Shifts should be made at the lowest practical engine
                                                 VELVET nRIVE         speed. Start the engine and set the throttle at idle speed;
                                               , TRANSlV!ISSION.      allow the transmission fluid to warm up for a few minutes.
SHIPMENT
For safety reasons, the transmission is not filled with               Neutral
transmission fluid during shipment and the selector lever             Move the gear shift lever to the middle position. You should
is temporarily attached to the actuating shaft.                       feel the detent. This centers the actuating lever on the trans-
Before leaving the WESlERBEKE plant, each transmission                mission. With the control in this position, hydraulic power is
undergoes a test run, with Dextron III ATF transmission               completely interrupted and the output shaft of the transmis-
fluid. The residual fluid remaining in the transmission after         sion does not turn.
draining acts as a preservative and provides protection
against corrosion for at least one year if properly stored.           NOTE: Some transmissions are equipped with a neutral safety
                                                                      switch. Unless the transmission actuating lever is perfectly
TRANSMISSION fLUID                                                    aligned in neutral, the engine starter will not activate.
Check the transmission fluid level on the dipstick. If the
transmission has not been filled, fill with Dextran III and           Forward
continue to use this fluid. During the first 25 hours of              Move the gear shift lever to the forward position. You should
operation, keep a lookout for any leakage at the bell housing,        feel the detent. The actuating lever· on the transmission is in
output shaft and transmission cooler. This fluid should be            the forward position. The output shaft and the propeller shaft
changed after the first 25 hours and approximately every              move the boat in a forward direction.
300 operating hours thereafter andlor at winter lay-up.
                                                                      Reverse
                                                                      Move the gear shift lever to the reverse position. You should
 A CAUTION: Bs CBrtain the transmission Is filled                     feel the detent. The actuating lever on the transmission is in
 and the correct size cooler is properly instal/ed before             the reverse position. The output shaft and the propeller
 starting the engine.                                                 should move the boat in a reverse direction (astern).
                                                                     NOTE: Moving the transmission actuati:n.g 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.




                                              '''''''WESIE'RBEKE
                                                     I Engines & Generators
                                                                55
                        BORG WARNER VELVET DRIVE TRANSMISSION
                                                                       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 finger-tight.)
                                                                       o   Run the engine, shutdown and recheck the fluid level.
 FORWARD                   NEUTRAl.                 REVERSE
      TRANSMISSION ACTUATING LEVER POSITIONS
                                                                        A WARNING: Never pullout the dipstick while the
                                                                        engIne is running. Hot fluId will splash from the dipstick
DAILY OPERATION                                                         hole. This could cause severe burns.
o   Check the transmission fluid.
o   Visually check the gear shift linkage and transmission.            Oil Capacity
o   Start the engine in neutral. Allow a few minutes at idle           Approximately 2.5 quarts (2.36 liters) will fill most transmis-
    for the fluid to warm.                                             sions to the oilleveI fill mark on the dipstick. Many variables
    NOTE: Too Iowan idle speed will produce a chattering               have a direct relationship to the oil capacity. Additional oil
    noise from the transmission gear and damper plate. In              will be required to fill the oil cooler and the cooler lines. The
    such cases the idle speed should be increased.                     angle of installation will make a difference in the quantity of -
                                                                       oil required to fill the transmission.
o   Shift into gear.

 A    CAUTION: Shifting gears above 1000 rpm can
 cause damage to the engine damper plate. Pulling the                  DlPSTICK·-----.,...-                    FLUID LEVEL
 throttle back to Idle when shifting gears will save wear              MAKE CERTAIN THE
                                                                       RUBBER SEAL IS
 on the transmission and the damper plate;                             SCREWED                                 FULL .
                                                                       TIGHT TO-THE
INSPECTION                                                             HANDLE

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.
                                                                       Oil Temperature
o   Inspect the transmission bolts; retorque if necessary.
                                                                       A maximum oil temperature of 190°F (88°C) is recom-
                                                                       mended. Discontinue operation anytime sump oil tempera-
 A    CAUTION: Clutch failure will occur if the transmis-              ture exceeds 230°F (1lO°C).
 sIon shift lever does not fully engage the detent ball                PRESSURE GAUGE
 posItions.                                                            An optional mechanical pressure gauge can be installed at
                             '"                                        the control panel to constantly monitor the pressure of the
CHANGING THE TRANSMISSION FLUID                                        transmission fluid. A normal reading at 2000 rpm in forward
After the initial 50 hour change, the transmission fluid should        gear should indicate 95 - 120 Ib-in2 (6.7 8.4 kg-cm2) and be
be changed at every 300 operating hours thereafter or at win-          constant.
ter haul-out 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 cap/dipstick hole.


                                                         EnClines & Generators
                                                                  56
                         BORG WARNER VELVET DRIVE TRANSMISSION
MAINTENANCE                                                            WARRANTY NOTES
Transmission maintenance is minimaL Keep the exterior                  Service manuals are available from your BORG WARNER
housing clean, check the fluid level as part of your regular           dealer.
routine, and change the fluid every 300 operating hOUTS.               For assistance, contact:
Periodically inspect the transmission and the cooler for leaks                BORG WAR.i'.TER
and corrosion. Make certain the air vent is clear and when                   200 Theodory Rice Blvd.
checking the fluid level look for signs of water contamination                New Bedford, MA 02745
(fluid will appear as strawberry cream).                                     Tel.: (508) 979-4881
Lay"up/Winterize                                                       BORG WARNER is aware of the shock loads that can be
                                                                       placed on its gears as the result of mechanical propeller oper-
Storage requires special care. Follow these procedures:                ation or fully reversing of the propeller blades while shifting.
o   Drain the water from the transmission oil cooler and               Therefore torque loads and directional changes should be
    replace it with a proper mixture of antifreeze coolant.            made at low engine speeds. If it is found that a failure was
    NOTE: This operation will usually occur when the engine            caused by a shock load, any warranty claim will be denied.
    raw water cooling system is properly winterized.
o   Clean up the transmission and touch-up unpainted areas              A CAUTION: System-related noises or vibrations can
    (use heat resistant paint).                                         occur at low engine speeds which can cause gear rattle
o   Fill the transmission with Dextron III ATF fluid to                 resulting in damage to the engine and/or transmission.
    prevent internal corrosion. (Extended storage only,                 BORG WARNER is not responsible for total system-
    12 months or more).                                                 related torsional vibration of this type.
o   Loosen attaching hardware froin the transmission
    output flange and propeller shaft coupling flange before           If any problems occur with the transmission, see
    removing the boat from the water. Separate the flanges             TRANSMISSION TROUfJLESHOOTING in this manual.
    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 more), it 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            If water has contaminated the fluid, the transmission fluid
time, erode the inside of the cooler causing cross leaks to            needs to be cleaned out and replaced with fresh fluid. It will
occur. These internal cooler leaks will cause one of the               take several fluid changes to get rid of the contamination.
following two problems:                                                Check your dipstick each time until it appears as pure trans-
                                                                       mission fluid. Change the transmission filter and clean out
1. Transmission fluid will leak into the flow of raw water             the fluid lines that connect to the cooler.
     and be discharged overboard through the engine exhaust.
    A loss of transmission fluid will cause tlze transmission to       If the transmission fails to shift properly, it will most likely
    faiL                                                               need the attention of a qualified transmission service facility.
2. The raw water will leak into the transmission fluid caus-           A transmission cooler may last ten years or more but, in
     ing an increase in transmission fluid. This contaminated          some circumstances. depending on operating hours, tropical
     fluid will appear as strawberry cream. The transmission           waters, maintenance, etc. it might only last half that time.
     will eventually fail.                                             WESTERBEKE recommends having a spare cooler aboard.
Either case requires an immediate response:
1. Install a new oil cooler.
2. Refill the transmission with DEXTRON III ATF.




                                                       Engines & Generators

                                                                  57
                                       LAY-UP &RECOMMISSIONING
GENERAL                                                            Fuel System [Gasoline]
Many owners rely on their boatyards to prepare their craft,        Top off your fuel tanks with unleaded gasoline of 89 octane
including engines and generators, for lay-up during the            or higher. A fuel conditioner such as Sta-Bil gasoline
off-season or for long periods of inactivity. Others prefer        stabilizer should be added. Change the element in your
to accomplish lay-up preparation themselves.                       gasoline/water separator and clean the metal bowL Re-install
The procedures which follow will allow you to perform your         and make certain there are no leaks. Clean up any spilled
own lay-up and recommissioning, or you may use them as a           fuel.
check list if others do the procedures.                            Fuel System [Diesel]
These procedures should afford your engine protection              Top off your fuel tanks with No.2 diesel fueL Fuel additives
during a lay-up and also help familiarize you with the             such as BioBor and Sta-Bil should be added at this time to
maintenance needs of your engine.                                  control algae and condition the fueL Care should be taken
If you have any questions regarding lay-up procedures, call        that the additives used are compatible with the primary fuel
your local servicing dealer; he will be more than willing to       filter/water separator used in the system. Change the element
provide assistance.                                                in your primary fuel filter/water separator, if the fuel system
                                                                   has one, and clean the separator sediment bowL
Propeller Shaft Coupling [Propulsion Engine]
                                                                   Change the fuel filter elements on the engine and bleed the
The transmission and propeller half couplings should always        fuel system, as needed. Start the engine and allow it to run
be opened up and the bolts removed when the boat is hauled
                                                                   for 5 - 10 minutes to make sure no air is left in the fuel
out of the. water or moved from land to water, and during          system. Check for any leaks that may have been created in
storage in the cradle. The flexibility of the boat often puts a    the fuel system during this servicing, correcting them as
severe strain on the propeller shaft or coupling or both, while    needed. Operating the engine for 5 10 minutes will help
the boat is taken out or put in the water. In some cases, the      allow movement of the treated fuel through the injection
shaft has actually been bent by these strains. This does not       equipment on the engine.
apply to small boats that are hauled out of the water when
not in use, unless they have been dry for a considerable           Raw Water Cooling Circuit
period of time.                                                    Close the through-hull seacock. Remove the raw water intake
Fresh Water Cooling Circuit [Propulsion Engine]                    hose from the seacock. Place the end of this hose into a five
                                                                   gallon bucket of clean fresh water. Before starting the engine,
A 50-50 solution of antifreeze and distilled water is              check the zinc anode found in the primary heat exchanger on
recommended for use in the coolant system at all times.            the engine and clean or replace it as required, and also clean
This solution may require a higher concentration of
                                                                   any zinc debris from inside the heat exchanger where the
antifreeze, depending on the area's winter climate. Check the      zinc anode is located. Clean the raw water strainer.
solution to make sure the antifreeze protection is adequate.
                                                                   Start the engine and allow the raw water pump to draw the
Should more antifreeze be needed, drain an appropriate             fresh water through the system. When the bucket is empty,
amount from the engine block and add a more concentrated           stop the engine and refill the bucket with an antifreeze
mixture. Operate the engine to ensure a complete circulation       solution slightly stronger than needed for winter freeze
and mixture of the antifreeze concentration throughout the         protection in your area.
cooling system. Now recheck the antifreeze solution's strength.
                                                                   Start the engine and allow all of this mixture to be drawn
Lubrication System                                                 through the raw water system. Once the bucket is empty, stop
With the engine warm, drain all the engine oil from the oil        the engine. This antifreeze mixture should protect the raw
sump. Remove and replace the oil filter and fill the sump          water circuit from freezing during the winter lay-up, as well
with new oil. Use the correct grade of oil. Refer to the           as providing corrosion protection.
ENGINE LUBRICATING OIL pages in this manual for the                Remove the impeller from your raw water pump (some
oil changing procedure. Run the engine and check for proper        antifreeze mixture will accompany it, so catch it in a bucket).
oil pressure and make sure there are no leaks.                     Examine the impeller. Acquire a replacement, if needed, and
                                                                   a cover gasket. Do not replace the impeller (into the pump)
                                                                   until recommissioning, but replace the cover and gasket.
 A CAUTION: 00 not leave the enginets old engine oil               Intake Manifold and Thru-Hull Exhaust
  in the sump over the lay-up period. Lubricating oil and
                                                                   Place a clean cloth, lightly soaked in lubricating oil, in the
  combustion deposits combine to produce harmful
                                                                   opening of the intake manifold to block the opening. Do not
  chemicals which can reduce the life of your ~nginets             shove the cloth out of sight. (If it is not visible at
  internal parts.                                .                 recommissioning, and an attempt is made to start the engine,
                                                                   you may_ need assistance of the servicing dealer. Make a
                                                                   note to remove the cloth prior to start-up. The thru-hull
                                                                   exhaust port can be blocked in the same manner.




                                                             Engines & Generators
                                                                  58
                                       LAY-UP & RECOMMISSIONING
Starter Motor                                                           Spare Parts
Lubrication and cleaning of the starter drive pinion is advisable,      Lay-up time provides a good opportunity to inspect your
if access to the starter permits its easy removal. Make sure the        Westerbeke engine to see if external items such as drive belts
battery connections are shut off before attempting to remove            or coolant hoses need replacement. Check your basic spares
the starter. Take care in properly replacing any electrical             kit and order items not on hand, or replace those items used
connections removed from the starter.                                   during the lay-up, such as filters and zinc anodes. Refer to the
                                                                        SPARE PARTS section of this manual.
Cylinder Lubrication [Diesel]                                           RecommiSSioning
If you anticipate a long lay-up period (12 months or more)              The recommissioning of your Westerbeke engine after a
WESTERBEKE recommends removing the fuel injectors for                   seasonal lay-up generally follows the same procedures as
access to the cylinders. Squirt light lubricating oil into the          those described in the PREPARATIONS FOR STARTING sec-
cylinders to prevent the piston rings from sticking to the              tion regarding preparation for starting and normal starts.
cylinder walls.                                                         However, some of the lay-up procedures will need to be
Make sure you have a replacements for the injector and return           counteracted before starting the engine.
line sealing washers.                                                   1. Remove the oil-soaked cloths from the intake manifold.
Intake Manifold [Gasoline]                                              2. Remove the raw water pump cover and gasket and
Clean the filter screen in the flame arrester, and place a clean            discard the old gasket. Install the raw water pump impeller
cloth lightly soaked in lube oil around the flame arrester to               removed during lay-up (or a replacement, if required).
block any opening. Also place an oil-soaked cloth in the                    Install the raw water pump cover with a new cover gasket.
through-hull exhaust port, Make a note to remove cloths prior           3. Reinstall the batteries that were removed during the
to start-up!                                                                lay-up, and reconnect the battery cables, making sure the
                                                                            terminals are clean and that the connections are tight.
Cylinder Lubrication [Gasoline]                                             Check to make sure that the batteries are fully charged.
Spray fogging oil into the open air intake, with the flame
arrester removed, while the engine is running. The fogging oil
will stall out the engine and coat the valves, cylinders and spark       A CAUTION: Wear rubber gloves, a rubber apron,
plugs for winter protection.                                              and eye protection when servicing batteries. Lead acid
NOTE: The spark plugs will need to be removed for cleaning                batteries emit hydrogen, a highly explosive gas, which
and re-gapping at spring commissioning.                                   can be ignited by electrical arcing Dr a lighted
Batteries                                                                 cigarette, cigar, or pipe. Do not smoke Dr allow an open
If batteries are to be left on board during the lay-up period,            Bame near the battery being serviced. Shut off all
make sure that they are fully charged, and will remain that way,          electrical equipment in the vicinity to prevent electrical
to prevent them from freezing. If there is any doubt that the             arcing during serviCing.
batteries will not remain fully charged, or that they will be
subjected to severe environmental conditions, remove the
batteries and store them in a warmer, more compatible                   4. Remove the spark plugs, wipe clean, re-gap, and install to
environment.                                                               proper tightness {gasoline].
                                                                        5. Check the condition of the zinc anode in the raw water
                                                                           circuit and clean or replace the anode as needed. Note
  A WARNING: Lead acid batteries emit hydrogen, a                          that it is not necessary to flush the antifreeze/fresh water
  highly-explosive gas, which can be ignited by electrical                 solution from the raw water coolant system. When the
  arcing or a lighted Cigarette, cigar, or pipe. Do not                    engine is put into operation, the system will self-flush in a
  smoke or allow an open flame near the battery being                      short period of time with no adverse affects. It is
                                                                           advisable, as either an end of season or recommissioning
  serviced. Shut off all electrical equipment in the vicinity              service, to inspect the area where the zinc is located in the
  to prevent electrical arcing during servicing.                           heat exchanger and clear any and all zinc debris from that
                                                                           area.
                                                                        6. Start the engine in accordance with procedures described
Transmission [Propulsion Engine]                                           in the PREPARATIONS FOR STARTING section of this
Check or change the fluid in the transmission as required Wipe             manual.
off grime and grease and touch up any unpainted areas. Protect
the coupling and the output flange with an anti-corrosion
coating. Check that the transmission vent is open. For
additional information, refer to the TRANSMISSION SECTION.




                                                          Engines & Generators

                                                                   59
                                             TORQUE DATA
                                                                        Lb-ft        km
 Cylinder head bolts
 ~ 63 (B)(C) Four, 108(B)(C) Six & 7lC Four                             80- 85     11.0-11.7
 - 7IB Four & 82B Four                                                  85 -90     11.8 - 12.5

 Connecting rod caps
 - 63(B)(C) Four & 7lC Four                                             50 - S4     6.9 -7.5
 - 71B Four & 82B Four                                                  59 - 65     8.2 - 9.0
 -  108 (B)(C) Six                                                      5S - 60     7.6 - 8.3

 Main Bearing Caps - All Models                                         80- 85     11.0-11.7

 Injection Pump Gear - All Models                                       29 - 52       4-7

 Oil Pan Bolts
 - 63(B)(C) Four                                                         5-9        0.7 - 1.2
 - 7l(B)(C) Four & 82B Four & 108 (B)(C) Six                            12 - 17     1.6 - 2.3

 Crankshaft Pulley Nut
 - 63(B)(C) Four                                                       14S - 181    20-25
 - 7l(B)(C) Four & 82B Four                                            253 - 289    35 -40
 - 108 (B)(C) Six                                                      282 - 304    39-42

 Glow Plugs - All Models                                                7 - 11      1.0 - 1.5

 Intake Manifold - All Models                                           12 -17      1.6 - 2.4

 Exhaust Manifold
 - 63(B)(C) Four                                                        12 -17      1.6-2.4
 - 71(B)(C), 82B Four, and 108(B)(C) Six                                20-24       2.7 - 3.3

 Oil Pressure Switch & Sender - All Models                              9-13        1.2- 1.8

 Injection HIP Line Nut - All Models                                    18 - 22     2.5 - 3.0

 Fresh Water Pump Mounting Bolts - All Models                           9-13        1.2 - 1.8

 Timing Gear Cover - All Models                                         12 - 17     1.6-2.3

  Flywheel bolts
  - 63(B)(C) Four & 108 (B)(C) Six                                     95 -137     l3.1 - 19.0
  - 7lB Four & 82B Four                                                112-118     15.5 - 16.3
. - 71CFour                                                            130 - 144   17.9-19.9

 Water Temperature Sender & Switch - All Models                         18 - 29     2.5 - 4.0

 Fuel Injector
 - 71C Four & 82B Four                                                  43 -50      6.0 -7.0

 Back: Plate - All Models                                               24- 3S      3.3 - 4.8




                                                Engines & Generators

                                                     60
                DECIMAL TO METRIC EQUIVALENT CHART
Fractions of                                       Fractions of


                                to.
               Decimal (in.)     Metric (mm)                      Decimal (in.)   Metric (mm)
  an inch                                            an inch
    1164         0.015625           39688             33/64         0.515625       13.09687
    1/32         0.03125           0.79375            17/32         0.53125        13.49375
    3/64         0.046875          1.19062            35/64         0.546875       13.89062
    1/16          0.0625           1.58750             9116          0.5625        14.28750
    5/64         " " .. n"?F;      1.98437            37/64         0.578125       14.68437
    3/32         0.09375           2.38125            19/32         0.59375        15.08125
    7/64         0.109375         '2.77812            39/64         0.609375       15.47812
       1/8         0.125            3.175              5/8           0.625         15.87500
    9/64         0.140625          3.57187            41/64         0.640625       16.27187
    5/32          0.15625          3.96875            21/32          0.65625       16.66875
   11/64         0.171875          4.36562            43/64         0.671875       17.06562
    3116          0.1875           4.76250            11/16          0.6875        17.46250
   13/64         0.203125          5.15937            45/64         0.703125       17.85937
    7/32         0.21875           5.55625            23/32         0.71875        18.25625
   15/64                375        5.95312            47/64         0.734375       18.65312
       1/4         0.250           6.35000             3/4            0.750        19.05000
   17/64         0.265625          6.74687            49/64         0.765625       19.44687
    9/32          0.28125          7.14375            25/32          0.78125       19.84375
   19/64         0.296875          7.54062     I      1':1/64       0.796875       20.24062
    5/16          0.3125           7.93750            13/16          0.8125        20.63750
   21/64         0.328125          8.33437            53/64         0.828125          03437
   11/32          0.34375          8.73125            27/32          0.84375       21.43125
   23/64         0.359375          9.12812            55/64         0.859375       21.82812
       3/8         0.375           9.52500             7/8            0.875        22.22500
                 0.390625          9.92187            57/64         0.890625       22.62187
   1             0.40625          10.31875            29/32         0.90625        23.01875
   27/64         0.421875         10.71562            59/64         0.921875       23.41562
    7/16          0.4375          11.11250            15/16          0.9375        23.81250
   29/64         0.453125         11.50937            61/64         0.953125       24.20937
   15/32         0.46875          11.90625            31/32         0.96875        24.60625
   31/64         0.484375         12.30312            63/64         0.984375       25.00312
       1/2         0.500          12.70000              1             1.00         25.40000




                                        Engines & Generators

                                               61
STANDARD AND METRIC CONVERSION DATA
LENGTH-DISTANCE
   Inches (in) x 25.4 '" Millimeters (mm) x .0394;; Inches
   Feet (ft) x .305 ::: Meters (m) x 3.281 " Feet
   Miles x1.609:::: Kilometers (km) x .0621 :::: Miles

DISTANCE EQUIVALENTS
   1 Degree of Latitude:::: 60 Nm :::: 111.120 km
   1 Minute of Latitude:::: 1 Nm :::: 1.852 km
VOLUME                                                           s
   Cubic Inches (inS) x 16.387:::: Cubic Centimeters x .061 =In
   Imperia! Pints (IMP pt) x .568 :::: Liters (L) x1.76 = IMP pt
   Imperial Quarts (IMP qt) x 1.137:= Liters (L) x.88 :::: IMP qt
   Imperial Gallons (IMP gal) x 4.546:::: Liters (L) x .22 :::: IMP gal
   Imperial Quarts (IMP qt) x1.201 ::: US Quarts (US Qt) x .833 :::: IMP qt
   Imperial Gallons (IMP gal) x 1.201 :::: US Gallons (US gal) x .833 :::: IMP gal
   Fluid Ounces x 29.573 := Milliliters x .034 :::: Ounces
   US Pints (US pt) x .473:::: Liters(L) x 2.113:::: Pints
   US Quarts (US qt) x .946 := Liters (L) x 1.057 :::: Quarts
   US Gallons (US gal) x 3.785 :::: Liters (L) x .264 :::: Gallons
MASS-WEIGHT
   Ounces (oz) x 28.35 :::: Grams (g) x .035:::: Ounces
   Pounds (Ib) x .454:::: Kilograms (kg) x 2.205:::: Pounds
PRESSURE
   Pounds Per Sq In (psi) x 6.895 :::: Kilopascals (kPa) x .145:::: psi
   Inches of Mercury (Hg) x .4912:: psi x2.036:::: Hg
   Inches of Mercury (Hg) x 3.377 = Kilopascals (kPa) x .2961 Hg
   Inches of Water (H20) x .07355:::: Inches of Mercury x13.783:::: H20
   Inches of Water (H20) x .03613 ::: psi x 27.684::: H20
   Inches of Water (H20) x .248 :: Kilopascals (kPa) x 4.026 =H20

TORQUE
   Pounds-Force Inches (in·lb) x .113:: Newton Meters (Nm) x 8.85 =in-Ib
   Pounds-Force Feet (ft-lb) x 1.356 := Newton Meters (Nm) x .738 ::: fHb

VELOCITY                                                                             "
   Miles Per Hour (MPH) x1.609 =Kilometers Per Hour (KPH) x .621             MPH

POWER
   Horsepower (Hp) x .745 :: Kilowatts (Kw) x 1.34 = MPH
FUEL CONSUMPTION
   Miles Per Hour IMP (MPG) x .354 =Kilometers Per Liter (Km/L)
   Kilometers Per Liter (Km/L) x 2.352 ::: IMP MPG
   Miles Per Gallons US (MPG) x .425 =Kilometers Per Liter (Km/L)
   Kilometers Per liter (Km/L) x 2.352 = US MPG
TEMPERATURE .
   Degree Fahrenheit (OF) = (oG X 1.8) + 32
   Degree Celsius (OC) :: (OF - 32) x .56

LIQUID WEIGHTS
   Diesel oil:: t us gal/on"" 7.13 Ibs
   Fresh Water =: 1 US gallon 8.33 Ibs
   Gasoline 1 US gallon::: 6.1 Ibs
   Salt Water = 1 US gallon = 8.56 Ibs



                                   Engines & Generators

                                          62
                                              SUGGESTED SPARE PARTS
                                                        ,MARINE ENGINES
                    CONTACJ YOUR WESTERBEKE DEALER FOR,SUGGESTIONS ANDADDITlONAL INFORMATION

                    GLOW PLUGS




                      WESTERBEKE RECOMMENDS CARRYING ENOUGH SPARE
                      ENGINE OIL (YOUR BRAND) fOR AN OIL CHANGE
                      AND A GAUON Of PREMIXED COOLANT.




FUEl LINE FILTERS
(OWNER INSTALLED)




                                                  SPARE PARTS KITS
    WESTERBEKE also offers two Spare Parts Kits,                                  KIT B
    each packaged in a rugged hinged toolbox.                                     ZINC ANODES
    Kit "A" includes the basic spares.                                            DRIVE BELTS
    Kit "B" is for more extensive off-shore CIUl:smg~                             OIL FILTER
           KIT A                                                                  FUEL FILTER
           ZINC ANODES                                                            HEAT EXCHANGER GASKET
           DRIVE BELTS                                                            IMPELLER KIT
           OIL FILTER                                                             INJECTOR
           FUEL FILTER                                                            OVERHAUL GASKET KIT
           HEAT EXCHANGER GASKET                                                  AIR FILTER
           IMPELLER KIT                                                           GLOW PLUG
           FUEL SYSTEM HARDWARE I(IT                                              FUEL SYSTEM HARDWARE KIT
           FUEL PUMP INLET FILTER                                                 FUEL PUMP INLET FILTER
                                                           Engines & Generators

                                                                 63
                  Engines & Generators




11 08WMDW1 0/06


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