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Westerbeke Diesel 44c Four Technical Manual



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 OPERATORS MANUAL

    WESTERBEKE
MARINE DIESEL ENGINE
     55A FOUR


                PUBLICATION 041562
              2nd Edition I February 1997




 l~ 'WESTERBEKE
          ~
              WESTERBEKE CORPORATION ·150 JOHN HANCOCK ROAD
              MYLES STANDISH INDUSTRIAL PARK· TAUNTON, MA 02780
              WEBSITE: www.WESTERBEKE.COM




    ----
     ""'''''''''''-
     AlMMA Member National Marine Manufacturers Association
         CALIFORNIA
     Proposition 65 Warning
Diesel engine exhaust and some
of its constituents are known to
the State of California to cause
cancer, birth defects, and other
reproductive harm.




     I~I WESJ"ERBEKE
        I Engines & Generators
                                            SAFETY INSTRUCTIONS

INTRODUCTION                                                       PREVENT BURNS - FIRE
Read this safety manual carefully. Most accidents are caused
by failure to foUow fundamental rules and precautions.
Know when dangerous conditions exist and take the                    A WARNING: Fire can cause injury or death!
necessary precautions to protect yourself, your personne~
and your machinery.                                                · Prevent flash fires. Do not smoke or permit flames or
The foUowing safety instructions are in compliance with              sparks to occur near the carburetor, fuel line, filter, fuel
the American Boat and Yacht Council (ABYC) standards.                pump, or other potential sources of spilled fuel or fuel
                                                                     vapors. Use a suitable container to catch all fuel when
PREVENT ELECTRIC SHOCK                                               removing the fuel line, carburetor, or fuel filters.
                                                                   · Do not operate with a Coast Guard Approved flame
                                                                     arrester removed. Backfire can cause severe injury or
 A WARNING: Do not touch AC electrical connections                   death.
 while engine is running, or when connected to shore               · Do not operate with the air cleaner/silencer removed.
 power. Lethal voltage is present at these connections!              Backfire can cause severe injury or death.
                                                                   · Do not smoke or permit flames or sparks to occur near the
· Do not operate this machinery without electrical                   fuel system. Keep the compartment and the engine/gener-
  enclosures and covers in place.                                    ator clean and free of debris to minimize the chances of
· Shut off electrical power before accessing electrical              fire. Wipe up all spilled fuel and engine oil.
  equipment.                                                       · Be aware -     diesel fuel will bum.
· Use insulated mats whenever working on electrical
  equipment.                                                       PREVENT BURNS - EXPLOSION
· Make sure your clothing and skin are dry, not damp
  (particularly shoes) when handling electrical equipment.
· Remove wristwatch and all jewelry when working on
                                                                     A WARNING: Explosions from fuel vapors can cause
                                                                     injury or death!
  electrical equipment.
· Do not connect utility shore power to vessel's AC
  circuits, except through a ship-to-shore double throw            · Follow re-fueling safety instructions. Keep the vessel's
  transfer switch. Damage to vessel's AC generator may               hatches closed when fueling. Open and ventilate cabin
  result if this procedure is not followed.                          after fueling. Check below for fumes/vapor before running
                                                                     the blower. Run the blower for four minutes before start-
· Electrical shock results from handling a charged capacitor.        ing your engine.
  Discharge capacitor by shorting terminals together.
                                                                   · All fuel vapors are highly explosive. Use extreme care when
PREVENT BURNS - HOT ENGINE                                           handling and storing fuels. Store fuel in a well-ventilated
                                                                     area away from spark-producing equipment and out of the
                                                                     reach of children.
  A WARNING: Do not touch hot engine parts or                      · Do not fill the fuel tank(s) while the engine is running.
  exhaust system components. A running engine gets
                                                                   · Shut off the fuel service valve at the engine when servicing
  very hot!                                                          the fuel system. Take care in catching any fuel that might
                                                                     spill. DO NOT allow any smoking, open flames, or other
· Always check the engine coolant level at the coolant               sources of fire near the fuel system or engine when servicing.
  recovery tank.                                                     Ensure proper ventilation exists when servicing the fuel
                                                                     system.

  A WARNING: Steam can cause injury or death!                      · Do not alter or modify the fuel system.
                                                                   · Be sure all fuel supplies have a positive shutoff valve.
· In case of an engine overheat, allow the engine to cool          · Be certain fuel line fittings are adequately tightened and
  before touching the engine or checking the coolant.                free of leaks.
                                                                   · Make sure a fire extinguisher is installed nearby and is
                                                                     properly maintained. Be familiar with its proper use.
                                                                     Extinguishers rated ABC by the NFPA are appropriate
                                                                     for all applications encountered in this environment.




                                                          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 manifolds
  it last.                                                                are securely attached and no warping exists. Pay close
                                                                          attention to the manifold, water injection elbow, and
· Make certain all personnel are clear of the engine before
                                                                          exhaust pipe nipple. .
  starting.
                                                                        · Be sure the unit and its surroundings are well ventilated.
· Make certain all covers, guards, and hatches are re-
  installed before starting the engine.                                 · In addition to routine inspection of the exhaust system,
                                                                          install a carbon monoxide detector. Consult your boat
BATTERY EXPLOSION                                                         builder or dealer for installation of approved detectors.
                                                                        · For additional information refer to ABYC T-22 (educa-
 A    WARNING: Battery explosion can cause injury                         tional information on Carbon Monoxide).
 or death!
                                                                         A    WARNING: Carbon monoxide (CO) is an invisible
· Do not smoke or allow an open flame near the battery                   odorless gas. Inhalation produces flu-like symptoms,
  being serviced. Lead acid batteries emit hydrogen, a                   nausea or death!
  highly explosive gas, which can be ignited by electrical
  arcing or by lit tobacco products. Shut off all electrical            · Do not use copper tubing in diesel exhaust systems. Diesel
  equipment in the vicinity to prevent electrical arcing during           fumes can rapidly destroy copper tubing in exhaust sys-
  servicing.                                                              tems. Exhaust sulfur causes rapid deterioration of copper
· Never connect the negative (-) battery cable to the posi-               tubing resulting in exhaust/water leakage.
  tive (+) connection terminal of the starter solenoid. Do not          · Do not install exhaust outlet where exhaust can be drawn
  test the battery condition by shorting the terminals                    through portholes, vents, or air conditioners. If the engine
  together. Sparks could ignite battery gases or fuel vapors.             exhaust discharge outlet is near the waterline, water could
  Ventilate any compartment containing batteries to prevent               enter the exhaust discharge outlet and close or restrict the
  accumulation of explosive gases. To avoid sparks, do not                flow of exhaust. Avoid overloading the craft.
  disturb the battery charger connections while the battery is
  being charged.                                                        · Although diesel engine exhaust gases are not as toxic as
                                                                          exhaust fumes from gasoline engines, carbon monoxide
· Avoid contacting the terminals with tools, etc., to prevent             gas is present in diesel exhaust fumes. Some of the symp-
  bums or sparks that could cause an explosion. Remove                    toms or signs of carbon monoxide inhalation or poisoning
  wristwatch, rings, and any other jewelry before handling                are:
  the battery.
                                                                               Vomiting
· Always tum the battery charger off before disconnecting
  the battery connections. Remove the negative lead first                      Dizziness
  and reconnect it last when servicing the battery.                           Throbbing in temples
                                                                               Muscular twitching
BATTERY ACID
                                                                               Intense headache

 A    WARNING: Sulphuric acid in batteries can cause                           Weakness and sleepiness
 severe injury or death!                                                AVOID MOVING PARTS
· When servicing the battery or checking the electrolyte
  level, wear rubber gloves, a rubber apron, and eye protec-             A    WARNING: Rotating parts can cause injury
  tion. Batteries contain sulfuric acid which is destructive. If         or death!
  it comes in contact with your skin, wash it off at once
  with water. Acid may splash on the skin or into the eyes              · Do not service the engine/generator while it is running. If a
  inadvertently when removing electrolyte caps.                           situation arises in which it is absolutely necessary to make




                                                          Engines & Generators
                                                                   ii
                                            SAFETY INSTRUCTIONS
   operating adjustments, use extreme care to avoid touching          ABYC, NFPA AND USCG PUBLICATIONS FOR
   moving parts and hot exhaust system components.
                                                                      INSTALLING GASOLINE AND DIESEL ENGINES AND
· Do not wear loose clothing or jewelry when servicing
  equipment; avoid wearing loose jackets, shirts, sleeves,
                                                                      GENERATORS
  rings, necklaces or bracelets that could be caught in               Read the following ABYC, NFPA and USCG publications
  moving parts.                                                       for safety codes and standards. Follow their recommenda-
                                                                      tions when installing your WESTERBEKE engine/generator.
· Make sure all attaching hardware is properly tightened.
  Keep protective shields and guards in their respective              ABYC (American Boat and Yacht Council)
  places at all times.                                                "Safety Standards for Small Craft"
· Do not check fluid levels or the drive belts' tension while         Order From:
  the engine/generator is operating.                                    ABYC
                                                                        15 East 26th ~treet
· Stay clear of the drive shaft and the transmission coupling
                                                                        New York, NY 10010
  when the engine is running; hair and clothing can easily
  be caught in these rotating parts.                                  NFPA (National Fire Protection Association)
                                                                      "Fire Protection Standard for Motor Craft"
HAZARDOUS NOISE                                                       Order From:
                                                                        NFPA
 A       WARNING: High noise levels can cause hearing                   1 Batterymarch Park
                                                                        P.O. Box 9101
 loss!                                                                  Quincy, MA 02269-9101
· Never operate a generator without its muffler installed.            USCG (United States Coast Guard)
                                                                      "USCG 33CFR183"
· Do not run an engine with the air intake (silencer)
  removed.                                                            Order From:
                                                                        U.S. Government Printing Office
· Do not run engines or generators for long periods with                Washington, D.C. 20404
  their enclosures open.


 A       WARNING: 00 not work on machinery when you
 are mentally or physically incapaCitated by fatigue!

OPERATORS MANUAL
Many of the preceding safety tips and warnings are repeated
in your Operators Manual along with other cautions and
notes to highlight critical information. Read your manual
carefully, maintain your equipment, and follow all safety
procedures.
GASOLINE ENGINE AND GENERATOR
INSTALLATIONS
Preparations to install a gasoline engine or generator should
begin with a thorough examination of the American Boat and
Yacht Council's (ABYC) standards. These standards are from
a combination of sources including the USCG and the NFPA.
Sections of the ABYC standards of particular interest are:
H-2 Ventilation
H-24 Gasoline fuel systems
P-l Exhaust systems
P-4 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 information:

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 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 18" 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.

EXHAUST SYSTEM
The exhaust hose must be certified for marine use. The system must be designed 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
Introduction .............................................................. 2        Engine Oil Change ................................................. 15
Warranty Procedures .............................................. 2                 Fuel System ............................................................. 16
   Product Software ................................................... 2              Fuel Filters ........................................................... 16
   Notes, Cautions and Wamings .............................. 2                        Fuel Water Separator ........................................... 16
   Serial Number Location ........................................ 3                   Fuel Injection Pump Control ............................... 16
   Understanding the Diesel Engine .......................... 3                        Priming (Bleeding) the Fuel System .................... 17
   Ordering Parts ........................................................ 3           Air Cleaner .......................................................... 17
Control Panels .......................................................... 4          DC Electrical System ............................................. 18
   Admirals Panel ...................................................... 4             Charging Voltage ................................................. 18
   Captains Panel ....................................................... 5            Alternator Drive Belt Adjustment ....................... 19
Diesel Fuel, Engine Oil and Engine Coolant.. ........ 6                                Battery Care ......................................................... 19
   Diesel FueL ............................................................ 6          DC Wiring Diagrams ........................................... 20
   Engine Oil .............................................................. 6       Water Heater .......................................................... 22
   Engine Coolant ...................................................... 6             Water Heater Installations ................................... 22
Preparations For Initial Start-Up ........................... 7                      Engine Adjustments .............. ,................................ 23
   Prestart Inspection ................................................. 7             Adjusting Valve Clearances ................................ 23
Starting/Stopping Procedure .................................. 8                       Timing Belt Inspection and Replacement... ......... 24
Break-In Procedure ................................................. 9                 Compression Test ................................................ 26
The Daily Routine .......................................... '" ..... 10               Fuel Injection Nozzle Test... ................................ 26
   Check List. ........................................................... 10        HBW Transmission ................................................ 27
   Start Your Engine ................................................ 10             Borg Warner Velvet Drive Transmission ............ 29
Maintenance Schedule ........................................... 11                  Engine Troubleshooting ......................................... 31
Engine Coolant ....................................................... 13              Troubleshooting Water Temperature and
   Changing the Coolant .......................................... 13                  Oil Pressure Gauges ............................................ 32
   Thermostat ........................................................... 13         Lay-up and Recommissioning ............................... 33
Raw Water System ................................................. 14                WESTERBEKE 55A Torque Specifications ........ 35
   Raw Water Cooling Circuit.. ............................... 14                    Standard Hardware Torques ................................ 36
   Raw Water Pump ................................................. 14               WESTERBEKE 55A FOUR Specifications ......... 37
   Zinc Anode ........................................................... 14         WESTERBEKE 55A FOUR Parts Identification38
   Raw Water Pump Belt Adjustment ..................... 14




                                                                WESTERBEKE
                                                               WESTERBEKE CORPORATION' AVON INDUSTRIAL PARK
                                                               AVON, MA 02322' TEL: (508)'588-7700·' FAX: (508) 559-9323




                                                                                 1
                                                           INTRODUCTION
This WESTERBEKE Marine Diesel Engine is a product                                         PRODUCT SOFTWARE
of WESTERBEKE' S long years of experience and ad-                                         Product software (tech data, parts lists, manuals,
vanced technology. We take great pride in the superior                                    brochures and catalogs) provided from sources other than
durability and dependable performance of our engines                                      WESTERBEKE are not within WESTERBEKE'S
and generators. Thank you for selecting WESTERBEKE.                                       CONTROL.
In order to get the full use and benefit from your                                        WESTERBEKE CANNOT BE RESPONSIBLE FOR
engine, it is important that you operate and maintain it                                  THE CONTENT OF SUCH SOFTWARE, MAKES NO
correctly. This manual is designed to help you do this.                                   WARRANTIES OR REPRESENTATIONS WITH
Please read this manual carefully and observe all the                                     RESPECT THERETO, INCLUDING ACCURACY,
safety precautions throughout. Should your engine re-                                     TIMELINESS OR COMPLETENESS THEREOF AND
quire servicing, contact your nearest WESTERBEKE                                          WILL IN NO EVENT BE LIABLE FOR ANY TYPE OF
dealer for assistance.                                                                    DAMAGE OR INJURY INCURRED IN CONNECTION
This is your operators manual. A Parts Catalog is                                         WITH OR ARISING OUT OF THE FURNISHING OR
also provided and a Technical Manual is available from                                    USE OF SUCH SOFTWARE.
your WESTERBEKE dealer. Also, if you are planning                                         WESTERBEKE customers should also keep in mind
to install this equipment, contact your WESTERBEKE                                        the time span between printings of WESTERBEKE
dealer for WESTERBEKE'S installation manual.                                              product software and the unavoidable existence of earlier
                                                                                          WESTERBEKE manuals. In summation, product soft-
WARRANTY PROCEDURES                                                                       ware provided with WESTERBEKE products, whether
Your WESTERBEKE Warranty is included in a                                                 from WESTERBEKE or other suppliers, must not and
separate folder. If you have not received a customer                                      cannot be relied upon exclusively as the definitive
identification card registering your warranty 60 days after                               authority on the respective product. It not only makes
submitting the warranty registration form, please contact                                 good sense but is imperative that appropriate representa-
the factory in writing with model information, including                                  tives of WESTERBEKE or the supplier in question be
the unit's serial number and commission date.                                             consulted to determine the accuracy and currentness of
                                                                                          the product software being consulted by the customer.
       TYPICAL CUSTOMER IDENTIFICATION CARD
                                                                                          NOTES, CAUTIONS AND WARNINGS
                                                                                          As this manual takes you through the operating proce-
                                                                                          dures, maintenance schedules, and troubleshooting of
                 WESTERBEKE CORPORATION· AVON INDUSTRIAL PARK
                 AVON, MA 02322· TEL: (508) 558·7700· FAX: (508) 559-9323                 your marine engine, critical information will be high-
 Customer Identification                                                                  lighted by NOTES, CAUTIONS, and WARNINGS. An
 WESTERBEKE OWNER                                                                         explanation follows:
 MAIN STREET
 HOMETOWN, USA                                                                            NOTE: An operating procedure essential to note.


  Model 55A Four               Ser. #U53890-48
                                                                                           A CAUTION: Procedures, which if not strictly
                                                                                           observed, can result in the damage or destruction of
                                                                                           your engine.
  Expires 7/20/97


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




                                                             I"VVI WESTERBEKE
                                                                            I Engines &   Generators


                                                                                   2
                                            INTRODUCTION
                                                (Continued)

SERIAL NUMBER LOCATION                                            ORDERING PARTS
An identification nameplate that displays the engine              Whenever replacement parts are needed, always pro-
model number and engine serial number is mounted on               vide the engine model number and engine serial number
the side of the engine manifold. Take the time to enter           as they appear on the silver and black identification
this information on the blank decal provided below. This          nameplate located on the manifold. You must provide us
will provide a quick reference when seeking technical in-         with this information so we can identify your engine. In
formation and/or ordering parts.                                  addition, include a complete part description and part
                                                                  number for each part needed (see the separately furnished
                                                                  Parts Catalog). Also insist upon WESTERBEKE pack-
                                                                  aged parts because will fit or generic parts are frequently
                                                                  not made to the same specifications as original equip-
                                                                  ment.
                                                                  NOTE: Component locations in this manual are refer-
                                                                  enced from the front of the engine which is the pulley/
UNDERSTANDING THE DIESEL ENGINE                                   drive belt end. Left and right sides are determined as
                                                                  follows: imagine straddling the engine, facing in the
The diesel engine closely resembles the gasoline                  same direction as the front of the engine: the left side
engine, since the mechanism is essentially the same.               is at your left, the right side is at your right.
The cylinders are arranged above a closed crankcase;
the crankshaft is of the same general type as that of a           PROTECTING YOUR INVESTMENT
gasoline engine, and the diesel engine has the same
types of valves, camshaft, pistons, connecting rods and           Care at the factory during assembly and thorough testing
lubricating system.                                               have resulted in a WESTERBEKE diesel engine capable
                                                                  of many thousands of hours of dependable service. How-
To a great extent, a diesel engine requires the same              ever the manufacturer cannot control how or where the
preventive maintenance as a gasoline engine. Most                 engine is installed in the vessel or the manner in which
important are proper ventilation and proper maintenance           the unit is operated and serviced in the field. This is up
of the fuel, lubricating and cooling systems. Replacement         to the buyer/owner-operator.
of fuel and lubricating filter elements at the time periods
specified and frequent checking for contamination                 NOTE: Six important steps to ensure long engine life:
(water, sediment, etc.) in the fuel system are essential.         o   Proper engine installation and alignment.
Also important is the consistant use of a brand of high
detergent diesel lubrication oil designed specifically for        o   An efficient well-designed exhaust system that in-
diesel engines.                                                       cludes an anti-siphon break to prevent water from
                                                                      entering the engine.
The diesel engine does differ from the gasoline engine,
however, in its method of handling and firing of fuel. The        o   Changing the engine oil and oil filters every 200 op-
carburetor and ignition systems are done away                         erating hours.
with and in their place is a single component - the fuel          o   Proper maintenance of all engine components
injection pump - which performs the function of both.                 according to the maintenance schedule in this
                                                                      manual.
                                                                  o   Use clean, filtered diesel fueL
                                                                  o   Winterize your engine according to the "Lay-up and
                                                                      Recommissioning" section in this manual.




                                             I~I WSJERBEKE
                                                I Engines & Generators

                                                              3
                                                CONTROL PANELS
WESTERBEKE offers two optional panels- select                               You will notice that when the engine is shut down with
the instruction page that applies to the panel you pur-                     the Key Switch turned OFF, the water temperature gauge
chased.                                                                     will continue to register the last temperature reading in-
                                                                            dicated by the gauge before electrical power was turned
ADMIRALS PANEL                                                              OFF. The oil pressure gauge will also hold its reading.
This manually-operated control panel is equipped with a                     The temperature gauge will once again register the en-
KEY SWITCH and RPM gauge with an ELAPSED                                    gine's true temperature when electrical power is restored
TIME meter which measures the engine's running time                         to the gauge
in hours and in 1110 hours. The panel also includes a
                                                                            A separate alarm buzzer with harness is supplied with
WATER TEMPERATURE gauge which indicates water
                                                                            every Admiral Panel. The installer is responsible for
temperature in degrees Fahrenheit, an OIL PRESSURE
                                                                            electrically connecting the buzzer to the four-pin connec-
gauge which measures the engine's oil pressure in
                                                                            tion on the engine's electrical harness. The installer
pounds per square inch, and a DC control circuit VOLT-
                                                                            is also responsible for installing the buzzer in a location
AGE gauge which measures the system's voltage. All
                                                                            where it will be dry and where it will be audible to the
gauges are illuminated when the key switch is turned ON
                                                                            operator should it sound while the engine is running.
and remain illuminated while the engine is in operation.
                                                                            The buzzer will sound when the ignition key is turned
The panel also contains two rubber-booted push buttons,
                                                                            ON and should silence when the engine has started and
one for PREHEAT and one for START.
                                                                            the engine's oil pressure rises above 15 psi.

                                WATER TEMPERATURE GAUGE: THIS GAUGE IS                                 OIL PRESSURE GAUGE: THIS GAUGE IS GRADU-
                                GRADUATED IN DEGREES FAHRENHEIT AND IS                                 ATED IN POUNDS PER SQUARE INCH (PSI) AND IS
                                ILLUMINATED WHILE THE KEY SWITCH IS                                    ILLUMINATED WHILE THE KEY SWITCH IS
                                TURNED ON. THE ENGINE'S NORMAL OPERATING                               TURNED ON. THE ENGINE'S NORMAL OPERATING
                                TEMPERATURE IS 170°·190° F                                             OIL PRESSURE RANGES BETWEEN 30-60 PSI.

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



                                                                                                                               KEY SWITCH: PROVIDES
HOUR METER: REGIS-
TERS ELAPSED TIME,                                                                                                             POWER ONLY TO THE
                                                                                                                               INSTRUMENT PANEL
AND SHOULD BE USED
AS A GUIDE FOR THE                                                                                                             CLUSTER. THE KEY
MAINTENANCE                                                                                                                    SWITCH SHUTS THE
                                                                                                                               ENGINE DOWN WHEN
SCHEDULE.
                                                                                                                               THE KEY IS TURNED OFF.




                                                                                                                               DC VOLTMETER:
                                                                                                                               INDICATES THE AMOUNT
                                                                                   /                                           THE BATTERY IS BEING
PREHEAT BUTTON: WHEN PRESSED, ENERGIZES                                                                                        CHARGED. SHOULD
THE ALTERNATOR'S EXCITER, THE FUEL LIFT                                                                                        SHOW 13V TO 14V.
PUMP, THE FUEL SOLENOID ON THE INJECTION                                          AUTOMATIC ALARM SYSTEM
PUMP, AND THE ENGINE'S GLOW PLUGS. IT BY-
PASSES THE ENGINE'S PROTECTIVE OIL PRES-                                      /   HIGH WATER TEMPERATURE ALARM: AN ALARM BUZZER HAS
SURE ALARM SWITCH. IN ADDITION, THIS                                              BEEN SUPPLIED WITH THE INSTRUMENT PANEL. IF THE ENGINE'S
BUTTON ENERGIZES THE START BUTTON.                                                FRESH WATER COOLANT REACHES 210° F (98°C), THIS SWITCH
                                                                                  WILL CLOSE SOUNDING THE ALARM WHICH WILL EMIT A CON-
                                                                                  TINUOUS SIGNAL.
                                                                                  LOW OIL PRESSURE ALARM: A LOW OIL PRESSURE ALARM
START BUTTON: WHEN PRESSED, ENERGIZES                                             SWITCH IS LOCATED OFF THE ENGINE'S OIL GALLERY. THIS
THE STARTER'S SOLENOID WHICH CRANKS THE                                           SWITCH MONITORS THE ENGINE'S OIL PRESSURE. SHOULD THE
ENGINE. THIS BUTTON WILL NOT OPERATE                                              ENGINE'S OIL PRESSURE FALL TO 5 -10 PSI, THE SWITCH WILL
ELECTRICALLY UNLESS THE PREHEAT BUTTON                                            CLOSE SOUNDING THE ALARM. IN THIS EVENT, THE ALARM WILL
IS PRESSED AND HELD AT THE SAME TIME.                                             EMIT A PULSATING SIGNAL.


                                                     l-vvl WESJERBEKE
                                                              I Engines &   Generators


                                                                      4
                                                 CONTROL     PANELS
                                                     (Continued)

CAPTAINS PANEL                                                                 COOLANT TEMPERATURE; and an alarm buzzer
This manually-operated control panel is equipped with                          for low OIL PRESSURE or high WATER TEMPERA-
a KEY SWITCH; an RPM gauge; PREHEAT and                                        TURE. The RPM gauge is illuminated when the key
START buttons; an INSTRUMENT TEST button; three                                switch is turned ON and remains illuminated while the
indicator lamps, one for ALTERNATOR DISCHARGE,                                 engine is in operation.
one for low OIL PRESSURE, and one for high ENGINE



                                                                               ALARM: THE ALARM WILL SOUND IF THE ENGINE'S OIL PRESSURE
                                                                               FALLS BELOW 15 PSI. IN THIS EVENT, THE ALARM WILL EMIT A
                                                                               PULSATING SIGNAL. THE ALARM WILL ALSO SOUND IF THE WATER
 RPM GAUGE: REGISTERS REVOLUTIONS PER                                          TEMPERATURE IN THE FRESHWATER COOLING CIRCUIT RISES TO
'MINUTE OF THE ENGINE AND CAN BE RECALI-                                       205°F. IN THIS EVENT, THE ALARM WILL EMIT A CONTINUOUS SIGNAL.
 BRATED FOR ACCURACY FROM THE REAR OF                                          NOTE: THE ALARM WILL SOUND WHEN THE KEY SWITCH IS TURNED
 THE PANEL.                                                                    ON. THIS SOUNDING IS NORMAL. ONCE THE ENGINE STARTS AND THE
                                                                               ENGINE'S OIL PRESSURE REACHES 15 PSI, THE ALARM WILL SILENCE.




                                                                                                                               TEST BUTTON: WHEN
                                                                                                                               PRESSED, TESTS THE
                                                                                                                               ALTERNATOR, THE OIL
                                                                                                                               PRESSURE, AND THE
                                                                                                                               WATER TEMPERATURE
                                                                                                                               CONTROL CIRCUITS.
                                                                                                                               WHEN PRESSED, THE
                                                                                                                               ALTERNATOR, THE OIL
                                                                                                                         /     PRESSURE, AND THE
                                                                                                                               WATER TEMPERATURE
                                                                                                                               INDICATOR LIGHTS IL-
                                                                                                                               LUMINATE IN ADDITION
                                                                                                                               TO SOUNDING THE
                                                                                                                               ALARM BUZZER.




                                                                                                                                KEY SWITCH: PROVIDES
                                                                                                                                POWER ONLY TO THE IN-
                                                                                                                                STRUMENT PANEL CLUSTER.
                                                                                                                              , THE KEY SWITCH SHUTS THE
                                                                                                                                ENGINE DOWN WHEN THE
                                                                                                                                KEY IS TURNED OFF,



                                                                                                PREHEAT BUTTON: WHEN PRESSED, ENERGIZES
                                    START BUTTON: WHEN PRESSED, ENERGIZES                       THE ALTERNATOR'S REGULATOR, THE FUEL LIFT
                                    THE STARTER'S SOLENOID WHICH CRANKS THE                     PUMP, THE FUEL SOLENOID ON THE INJECTION
                                    ENGINE. IT WILL NOT OPERATE ELECTRICALLY                    PUMP, AND THE ENGINE'S GLOW PLUGS. IT BY-
                                    UNLESS THE PREHEAT BUTTON IS PRESSED AND                    PASSES THE ENGINE'S OIL PRESSURE ALARM
                                    HELD AT THE SAME TIME,                                      SWITCH, IN ADDITION, THIS BUTTON ENERGIZES
                                                                                                THE START BUTTON.




                                                      ,....,., WESJERBEKE
                                                               I Engines &     Generators


                                                                        5
                                 DIESEL FUEL, ENGINE OIL
                                  AND ENGINE COOLANT
DIESEL FUEL                                                       ENGINE COOLANT
Use fuel that meets the requirements or specification             The use of an antifreeze mixture of 50/50 is recom-
of Class 2-D (ASTM), and has a cetane rating of #45               mended for year-round use. Use antifreeze that is com-
or better.               .                                        patible with aluminium components, and never mix
                                                                  different brands of antifreeze. Do not use straight water,
Care Of The Fuel Supply                                           this can be detrimental to the cooling system compo-
Use only clean diesel fuel! The clearance of the compo-           nents.
nents in your fuel injection pump is very critical; invisi-       NOTE: Lookfor the new environmentally-friendly long
ble dirt particles which might pass through the filter can        lasting antifreeze that is now available.
damage these finely finished parts. It is important to buy
clean fuel, and keep it clean. The best fuel can be ren-          Antifreeze mixtures will protect against an unexpected
dered unsatisfactory by careless handling or improper             freeze and they are beneficial to the engine's cooling
storage facilities. To assure that the fuel going into the        system. They retard rust and add to the life of the circu-
tank for your engine's daily use is clean and pure, the           lating pump seal.
following practice is advisable:                                                          ANTIFREEZE PROTECTION
Purchase a well-known brand of fuel.                               Antifreeze concentration      23%       35%         50%       60%
                                                                                                  14°F      -4°F       -40°F     -58°F
Install and regularly service a good, visual-type filterl          Freezing Temperature
                                                                                                 (-5°C)   (-20°C)     (-40°C)   (-50°C)
water separator between the fuel tank and the engine.
Raycor 500 FG or 900 FG is a good example of such                 COOLANT RECOVERY TANK
a filter.
                                                                  A coolant recovery tank kit is supplied with each
                                                                  WESTERBEKE diesel engine. The purpose of this re-
ENGINE OIL                                                        covery tank is to allow for engine coolant expansion
Use a heavy duty engine oil with an API classification of         and contraction during engine operation, without the loss
CF or CG4 or better. Change the engine oil after an               of coolant and without introducing air into the cooling
initial 50 hours of break-in operation, and every 200 hours
of operation thereafter. For recommended oil viscosity,           system.
see the following chart:


    Operating Temperature               Oil Viscosity
       Above 68°F (20°C)              SAE 30 or 10W-30
        41°-68°F 5-20°C)              SAE 20 or 10W-30
        Below 41°F (5°C)                 SAE 10W-30



 A CAUTION: 00 not allow two or more brands
 of engine oil to mix. Each brand contains its own
 additives; additives of different brands could react
 in the mixture to produce properties harmful to
 your engine.                                                                                 COOLANT RECOVERY TANK




                                                              6
                PREPARATIONS FOR INITIAL START-UP
PRESTART INSPECTION                                              o   Check the DC electrical system. Inspect wire
Before starting your engine for the first time or after a            connections and battery cable connections.
prolonged layoff - check the following items.                    o   Visually examine the unit. Look for loose or missing
o   Check the engine oil level; add oil to maintain the              parts, disconnected wires, unattached hoses, and
    level at the high mark on the dipstick.                          check threaded connections.

o   Check the fuel supply and examine the fuel                   o   Check the coolant level in the plastic recovery tank
    filter/separator bowls for contaminants.                         and at the manifold.

o   Check the transmission fluid level.                          NOTE: If the engine has not yet been filled with coolant,
                                                                 refer to the "Engine Coolant" section of this manual.
NOTE: Refer to the specifications pages in this manual for
fuel, oil, and transmission types and quantities.



                                     OIL
                                     DIPSTICK
                             FULL



                                                                                               COOLANT
                                                                                               RECOVERY
                       LDW----~1l!J                                                            TANK




                                                                                MANIFOLD
                                                                                PRESSURE CAP




                                                l-vvl WESJERBEKE
                                                      I Engines & Generators

                                                             7
                          STARTING/STOPPING PROCEDURE
STARTING PROCEDURE
Place the transmission in neutral and advance the throttle
                                                                        A    CAUTION: Prolonged cranking intervals without
                                                                        the engine starting can result in the engine exhaust
control to slightly open.                                               system filling with raw water. This may happen be-
                                                                        cause the pump is pumping raw water through the
 A    CAUTION: Make certain the transmission is                         raw water cooling system during cranking. This raw
                                                                        water can enter the engine's cylinders by way of the
 in neutral. Starting in gear could result in serious
                                                                        exhaust manifold once the exhaust system fills. Pre-
 damage to your transmission, your boat, and
                                                                        vent this from happening by closing the raw water
 vessels nearby.                                                        supply through-hull shut-off, draining the exhaust
                                                                        muffler, and correcting the cause of the excessive
Tum the KEY SWITCH to the ON position (2            0' clock)
                                                                        engine cranking. Engine damage resulting from raw
PREHEAT: Depress the PREHEAT switch. The voltmeter,                     water entry is not a warrantable issue; the
panel lights, gauges and meters, and fuel solenoid will be
                                                                        owner/operator should keep this in mind.
activated. The PREHEAT switch should be depressed in                  Once the engine starts, check instruments for proper oil
accordance with the following chart:                                  pressure and battery charging voltage.
                      Temperature/Preheat                             NOTE: Never attempt to engage the starter while the
                                                                      engine is running.
   Atmospheric Temperature             Preheating Time
      +41 °F( +5°C) or higher         Approx. 10 seconds              NOTE: Some unstable running may occur in a cold engine.
                                                                      Depressing the Preheat switch for 10-15 second intervals
    +41 °F( +5°C) to 23°F (-5°C)      Approx. 15 seconds
                                                                      will help stabilize the engine RPM until the operating tem-
       +23°F(-5°C) or lower           Approx. 20 seconds              perature reaches 170°-190°F (77°-88°C) and a propeller
      Limit of continuous use      30 seconds before cranking         load is applied to the engine. When the engine is running
                                                                      and the preheat switch is depressed, a charging load on
START: While still depressing the PREHEAT switch, de-                 the DC alternator will be discernible.
press the START switch. This will engage the start sole-
noid. Upon engine firing, release the START switch. Do
                                                                      STARTING UNDER COLD CONDITIONS
not release the PREHEAT switch until the oil pressure                 Make certain the lubricating oil conforms with the ratings for
reaches 15 psi. Then as long as the high water tempera-               the prevailing temperature. Check the table on the engine
ture and low oil pressure protective circuits do not acti-            oil section of this manual.
vate, the engine will remain energized and continue                   The battery should be fully charged to minimize voltage
to run.                                                               drop.
                                                                      Use a sufficient amount of preheat to aid in starting.
                                                                      See TemperaturelPreheat chart on this page.
NOTE: When starting:                                                  STOPPING PROCEDURE
A voltage drop will occur
                                                                      To stop the engine, bring the throttle to an idle position
when the preheat switch
                                                                      and place the transmission in neutral. Allow the engine to
is depressed.
                                                                      idle for a few moments to stabilize temperatures. Tum
                                                                      the key to the OFF position. This opens the DC circuit to
                                                                      the instrument panel and engine, de-energizing the fuel
                                                                      solenoid on the injection pump, stopping fuel flow from
Should the engine not start when the START switch is                  it and stopping the engine.
depressed for 10 to 20 seconds, release both switches and
                                                                      Made certain the key switch is in the OFF position
wait 30 seconds; repeat the procedure above and preheat
                                                                      (12 o'clock). If the Key Switch is left ON, the battery
longer. Never run the starter for more than                           will discharge. An engine alarm buzzer is provided to
30 seconds.                                                           warn the operator of this condition (Key Switch ON).
                                                                      The best method of preventing the battery from discharge
                                                                      is to remove the key from the Key Switch after stopping
                                                                      the engine.


                                                 /"VVI WESJERBEKE
                                                           I Engines & GeneratDrs

                                                                  8
                                   BREAK-IN PROCEDURE
THE FIRST 50 HOURS                                                4. Avoid rapid acceleration, especially with a cold
Although your engine has experienced a minimum of one                engine.
hour of test operations to ensure accurate assembly and           S. Use caution not to overload the engine. The presence
proper operation of all systems, break-in time is required.          of a gray or black exhaust, and the inability of the
The service life of your engine is dependent upon how                engine to reach its full rated speed, are signs of an
the engine is operated and serviced during its initial 50            overload.
hours of use.
                                                                  6. During the next 25 hours, the engine may be operated
Your new engine requires approximately 50 hours of ini-              at varying engine speeds, with short runs at full rated
tial conditioning operation to break in each moving part             rpm. A void prolonged idling during this break-in pe-
in order to maximize the performance and service life of             riod.
the engine. Perform this conditioning carefully, keeping
in mind the following:                                            Breaking-in a new engine basically involves seating
                                                                  the piston rings to the cylinder walls. This cannot be
1. Start the engine according to the Starting Procedure           accomplished by long periods of running at idle, nor by
   section in this manual; run the engine at fast idle            early running at full rpm. Idle running may glaze the
   while checking that all systems (raw water pump, oil           cylinder walls, resulting in excessive oil consumption
   pressure, battery charging) are functioning.                   and smoky operation. Excessive speed or heavy over-
2. Allow the engine to warm up (preferably by running             loading, especially with a cold engine, may cause scoring
   at fast idle) until the water temperature gauge moves          of the cylinder walls, producing similar results. Operate
   into the 130° -140°F range.                                    the engine in moderation during the 50-hour break-in pe-
                                                                  riod. (Don't baby the engine, but do not abuse it.)
3. While using the vessel, run the engine at varying en-
   gine speeds for the first 25 hours.                            NOTE: See the Transmission section of this manual for
                                                                  break-in information on your transmission.




                                             rVtTl WESJERBEKE
                                                     I Engi_s & Generators

                                                              9
                                       THE DAILY ROUTINE
CHECK LIST                                                       START YOUR ENGINE
Each day before starting your engine, take a few                 NOTE: See Starting/Stopping Procedure in this manual for
moments to run this check list:                                  more detailed instructions.
o   Visually inspect the engine for fuel, oil, or water          1. Put transmission in neutral, throttle advanced.
    leaks.
                                                                 2. Tum KEY to the ON position (2 o'clock)
o   Check the oil level (dipstick).
                                                                 3. Depress PREHEAT (10 to 15 seconds).
o   Check the transmission fluid level.
                                                                 4. While pressing PREHEAT, push START. As engine
o   Check for loose wires at the alternator.                        fires - release START.
o   Check the starting batteries level (weekly)                  5. Hold PREHEAT until oil pressure reaches 15 psi
                                                                    and/or alarm shuts off.
o   Check drive belts for wear and proper tension
    (weekly).                                                    NOTE: Should engine fail to start, wait 30 seconds, repeat
                                                                 the above procedure, and PREHEAT longer.
o   Log your engine running time. These hours relate to
    scheduled maintenance.                                       6. Allow a few minutes for the engine to warm at a
                                                                    comfortable rpm (approx. 1200 rpm), then reduce the
o   Check fuel supply; always keep fuel tank(s) as full as
                                                                    rpm, shift into gear, and get underway.
    possible.
o   Look for clean fuel in the fuel/water separator bowl.
o   Check the coolant level in the plastic recovery tank.
NOTE: Excessive loss of coolant indicates a cooling sys-
tem leak. Check the entire system. If necessary, use a
cooling system pressure tester to pressurize the cooling
system to locate the area of leakage. In cases of excessive
coolant loss, refill the system as outlined in Preparations
for Initial Start-Up in this manual.




                                               l-vvl WESTERBEKE
                                                      r Engines & Generators
                                                            10
                                 MAINTENANCE SCHEDULE

                    A WARNING: Never attempt to perform any service while the engine is running.
                    Wear the proper safety equipment such as goggles and gloves, and use the correct
                    tools for each job. Disconnect the battery terminals when servicing any of the
                    engine's DC electrical equipment.

                  NOTE: Many of the following maintenance jobs are simple but others are more difficult
                  and may require the expert knowledge of a service mechanic. A complete service
                  manual is availablefrom your WESTERBEKE dealer.

                                  CHECK                 HOURS OF OPERATION
SCHEDULED MAINTENANCE                                                                                     EXPLANATION OF SCHEDULED
                                   EACH
                                                                                                                MAINTENANCE
                                    DAY      50   100     250     500     750     1000 1250
 Fuel Supply                        0                                                              Diesel No.2 octane rating of 45 cetane or better.

 Fuel/Water Separator               0                                                              Check for water and dirt in fuel (drain/replace if
                                                                                                   necessary).

 Engine Oil Level                   0                                                              Oil level should indicate between MAX. and LOW
                                                                                                   on dipstick.

 Transmission Fluid Level           0                                                              Fluid level should indicate between MAX. and
                                                                                                   LOW on dipstick

 Coolant Level                      0                                                              Check at recovery tank; if empty, check at
                                                                                                   manifold. Add coolant if needed.

 Drive Belts                        0                                                              Inspect for proper tension ('h " to 'Is" depression)
                                                                                                   and adjust if needed. Check belt edges for wear.
 Visual Inspection of Engine        0      NOTE: Please keep engine surface clean. Dirt and        Check for fuel, oil and water leaks. Inspect
                                                                                                   wiring and electrical connections. Keep bolts &
                                           oil will inhibit the engine's ability to remain cool.
                                                                                                   nuts tight.

 Throttle and Transmission
 Control Cable
                                            0              0               0               0       Check for loose fittings, cotter pins, etc.
                                                                                                   Lubricate with WD-40 or equivalent.

 Adjust Engine Idle Speed                   0                                                      Adjust to (750-1000 rpm).

 Fuel Filter                                0              0                               0       Initial change at 50 hrs, then change every
                                                                                                   250 hrs.
 Starting Batteries
 (and House Batteries)
                                            0       Every 50 operating hours check electrolyte levels and make sure connections are very tight.
                                                    Clean off excessive corrosion.

 Engine Oil                                 0       Initial engine oil & filter change at 50 hrs., then change both every 100 hours.

· Adjust the Valve Clearances               0                      0               0               Initial adjustment at 50 hrs., then every 50Q hrs.
                                                                                                   (Do not retorque the cylinder head)
 Lubricate Panel Key Switch
 with" Lockeze"
                                                   0       0       0       0       0       0       At 1st 100 hrs. then each year at winterizing.


 TransmiSSion Fluid                         0              0       0       0               0       Initial fluid change at 50 hrs., then every 250
                                                                                                   hrs. or at winterizing.

 Air Cleaner                                                       0                       0       Replace element filter. Clean or replace elements.

 Exhaust System                             0              0               0               0       Initial check at 50 hrs., then every 250 hrs.
                                                                                                   Inspect for leaks. Tight connections check,
                                                                                                   siphon brake operation. Check the exhaust
                                                                                                   elbow for carbon and/or corrosion buildup on
                                                                                                   inside passages; clean and replace as
                                                                                                   necessary.

·WESTERBEKE recommends this service be performed by an authorized mechanic.



                                                  /"VVI WESJERBEKE
                                                           I Engines &     GeneratDrs


                                                                    11
                                    MAINTENANCE       SCHEDULE
                                            (Continued)

                                   NOTE: Use engine hour meter gauge to log your engine hours
                                         or record your engine hours by running time.

                                     CHECK                HOURS OF OPERATION
 SCHEDULED MAINTENANCE                                                                          EXPLANATION OF SCHEDULED
                                      EACH
                                                                                                      MAINTENANCE
                                      DAY     50    100     250   500   750   1000 1250
  Engine Hoses                                       D D D D D D                          Hose should be hard & tight. Replace if soft or
                                                                                          spongy. Check & tighten all hose clamps.

  Heat Exchanger
  Zinc Anode
                                              D D D D D D D                               Clean or replace. Open heat exchanger end cap
                                                                                          and clean out debris.
  Electric Fuel Lift Pump Filter
  (if applicable)
                                              D             D D D D D                     Initial filter change at 50 hours, then change
                                                                                          filter every 250 hours.

  Raw Water Pump                                            D            D         D      Remove pump cover and inspect impeller for
                                                                                          wear; replace if needed. Also replace gasket.
                                                                                          Lubricate both when reassembling.

  Coolant System                                                   D                D     Drain, flush, and refill cooling system with
                                                                                          appropriate anti-freeze mix.

 *Fuellnjectors                                                          D                Check and adjust injection opening pressure and
                                                                                          spray condition (see Engine Adjustments).

 *Starter Motor                                                   D                D      Check solenoid and motor for corrosion.
                                                                                          Remove and lubricate. Start. motor pinion drive.
                                                                                          Clean and lubricate.

 *Preheat Circuit                                                  D                D     Check operation of preheat solenoid. Remove
                                                                                          and clean glow plugs; check resistance
                                                                                          (4-6 ohms).

 *Engine Cylinder Compression
  and Valve Clearance
                                                                   D               D      Incorrect valve clearance will result in poor
                                                                                          engine performance; check compression
                                                                                          pressure and timing, and adjust valve clearances.

  DC Alternator                                             D            D         D      Check DC charge from alternator. Check mount-
                                                                                          ing bracket; tighten electrical connections.

  Heat Exchanger                                                               D          Remove; have professionally cleaned and
                                                                                          press ure tested.

  Transmission Oil Cooler                                                      D          Remove; have professionally cleaned and
                                                                                          pressure tested.

  Engine Transmission
  Damper Plate
                                                                               D          Chattering at idle and low rpms is an indication
                                                                                          of damper plate wear. Remove and replace.

  Engine Timing Belt                                                           D          Remove and replace.
                                                                                          NOTE: Failure to replace the timing belt at the
                                                                                          recommended interval could result in timing
                                                                                          belt failure resulting in major damage to the
                                                                                          engine.

'WESTERBEKE recommends this service be performed by an authorized mechanic.




                                                   I~l WSJERBEKE
                                                      I Engines & Gene",tors

                                                                   12
                                            ENGINE COOLANT
CHANGING THE COOLANT                                                  Start the engine and bring it to operating temperature.
The engine's coolant must be changed every eight to                   Monitor the coolant in the manifold and add as needed.
twelve months depending on the engine's use. If the                   Fill the manifold to the filler neck and install the pressure
coolant is allowed to become contaminated, it can lead                cap.
to overheating problems.                                              Remove the cap on the coolant recovery tank, fill with
A coolant recovery tank allows for engine coolant expan-              coolant to halfway between LOW and MAX, and replace
sion and contraction during engine operation, without any sig-        the cap.
nificant loss of coolant and without introducing air into the         Run the engine and observe the coolant expansion flow
cooling system. This tank should be located at or above the           into the recovery tank.
engine manifold level, and be easily accessible.
                                                                      After checking for leaks, stop the engine and allow
                            .\:>?i~:":';';~---    COOLANT             it to cool. Coolant should draw back into the cooling
                                                  RECOVERY
                                                  TANK CAP            system as the engine cools down. Add coolant to the
                                                                      recovery tank if needed. Clean up any spilled coolant.

                                       ~--- COOLANT
                                                                      NOTE: Periodically check the condition of the pressure cap.
                                                  RECOVERY            Ensure that the upper and lower rubber seals are in good
                                                  TANK
                                                                      condition and check that the vacuum valve opens and
                                                                      closes tightly. Carry a spare cap.

                                                                      THERMOSTAT
                                                                      A thermostat, located near the manifold at the front of the
                                          COOLANT EXPANSION           engine, controls the coolant temperature as it contin-
                                                                      uously flows through the closed cooling circuit. When
                                                                      the engine is first started the closed thermostat prevents
                                                                      coolant from flowing (some coolant is by-passed through
                                                                      a hole in the thermostat to prevent the exhaust manifold
Drain the engine coolant by loosening the drain plug on               from overheating). As the engine warms up the thermo-
the engine block and opening the manifold pressure cap.               stat gradually opens. The thermostat is accessible and can
Flush the system with fresh water, then start the refill              be checked, cleaned, or replaced easily. Carry a spare
process. See the Parts Identification photos in this man-             thermostat and gasket.
ual for locations.
                                                                                                                         WATER
NOTE: The petcock on the heat exchanger can also be                                                                      TEMPERATURE
                                                                                                                         ALARM
used to drain engine coolant.


  A WARNING: Beware of the hot engine coolant.                                                                           WATER
                                                                                                                         TEMPERATURE
  Wear protective gloves.                                                                                                SENDER



TO REFILL WITH COOLANT
With the enginge running in idle, slowly pour clean
premixed coolant into the manifold.
NOTE: Open the air bleed petcock on the heat exchanger
to help remove air from the system. When a steady flow
of coolant appears at the drain plug opening, close the
water drain plug and continue to fill the system until the
manifold remains full. Close the petcock on the heat
exchanger when antifreeze flows from it.
                                                                                                 THERMOSTAT
                                                I~l WSJ&lBEKE
                                                   I Engines & GeneratDrs

                                                                 13
                                         ENGINE OIL CHANGE
DRAIN THE SUMP                                                         filter when unscrewing it to catch any oil left in the filter.
The engine oil should be warm. Remove the oil drain                    Inspect the old oil filter as it is removed to make sure that
hose from its attachment bracket and lower it into a con-              the rubber sealing gasket comes off with the old oil filter.
tainer and allow the oil to drain, or attach a pump to the             If this rubber sealing gasket remains sealed against the
end of the drain hose and pump out the old oil. Make sure              engine block, gently remove it. When installing the new
the oil drain hose is capped and properly secured in its               oil filter element, wipe the filter gasket's sealing surface
holder after all the old oil has been drained.                         on the engine block free of oil and apply a thin coat of
                                                                       clean engine oil to the rubber gasket on the new oil filter.
NOTE: Thread size for the lube oil drain hose capped end               Screw the filter onto the threaded oil filter stub, and
is 1/4 NPT.                                                            tighten the filter firmly by hand.
Always observe the old oil as it is removed. A yellow/
gray emulsion indicates the presence of water in the oil.
Although this condition is rare, it does require prompt
attention to prevent serious damage. Call a competent                                                                     SPIN-ON
                                                                                                                          OIL FILTER
mechanic if water is present in the oil. Raw water present
in the oil can be the result of a fault in the exhaust system
attached to the engine and/or a siphoning of raw water
through the raw water cooling circuit into the exhaust,
filling the engine. This problem is often caused by the
poor location of the syphon brake. See WESTERBEKE'S
                                                                                                             q _ _-OIL
Installation Manual.                                                                                                  COOLER



                                                                   NOTE: Use genuine WESTERBEKE oil filters - generic
                                                                   filters are not recommended.

                                                                       REFILL THE OIL SUMP
                                                                       Add fresh oil through the filler cap. After refilling
                                                                       the oil, run the engine for a few moments while checking
                                                                       the engine's oil pressure. Make sure there is no leakage
                                                                       around the new oil filter or from the oil drain system, and
                                                                       then stop the engine. Then check the quantity of oil with
          ~                   OIL DRAIN HOSE
                                                                       the lube oil dipstick. If the engine requires additional oil,
          ~ OIL CONTAINER                                              fill to, but not over, the high mark on the dipstick.


  A   WARNING: Used engine oil contains harmful
 contaminants. Avoid prolonged skin contact. Clean                               FULL-+--ra
 skin and nails thoroughly using soap and water.
                                                                           LOW-_ _~1frI
 Launder or discard clothing or rags containing used
 oil. Discard used oil properly.

REPLACE THE OIL FILTER
When removing the used oil filter, you may find it helpful
and cleaner to punch a hole in the upper and lower portion of
the old filter to drain the oil from it into a container before
removing it. This helps to lessen spillage. An automotive fil-
ter wrench should be helpful in removing the old oil filter.
Place some paper towels and a plastic bag around the

                                                !-VVI WESTERBEKE
                                                         rEngines & Generators
                                                                  15
                                                FUEL SYSTEM
                                                                    FUEL WATER SEPARATOR
 A WARNING: Shut off the fuel valve at the tank                 A primary fuel filter of the water separating type must be
 when servicing the fuel system. Take care in                   installed between the fuel tank and the engine to remove
 catching any fuel that may spill. DO NOT allow any             water and other contaminants from the fuel before they
 smoking, open flames or other sources of fire near             can be carried to the fuel system on the engine.
 the fuel system when servicing. Ensure proper venti-
 lation exists when servicing the fuel system.                      Most installers include a type of filter/water separator
                                                                    with the installation package as they are aware of the
                                                                    problems that contaminants in the fuel can cause.
FUEL FILTERS
The fuel injection pump and the fuel injectors are                  A typical fuel filter/water separator is illustrated in this
precisely manufactured and they must receive clean                  diagram. This is the Raycor Model 500 MA. Keep in
diesel fuel, free from water and dirt. To ensure this flow          mind that if a water separator type filter is not installed
of clean fuel, the fuel must pass through at least two fuel         between the fuel supply tank and engine-mounted fuel
filters, a fuel/water separator and the engines spin-on fuel        system, any water in the fuel will affect the fuel pump,
filter. Visually inspect, clean, and change these filters           engine filter, and injection equipment. The ownerl
according to the maintenance schedule in this manual.               operator is responsible for making certain the fuel
                                                                    reaching the engine's injection equipment is free of
                                                                    impurities. This process is accomplished by installing
                                                                    and maintaining a proper filtration/separation system.

           O-RING----


           SPIN-ON
           FUEL FILTER-_---JI~~~                                                                                FILTER/WATER
                                                                                                        L   /SEPARATOR


1. Shut fuel supply off.
2. Loosen the fuel filter, turning counterclockwise with
   a filter wrench.
3. Using a rag, wipe clean the sealing face on the
   housing bracket so the new filter can be seated
   properly.
4. Lightly oil the sealing O-ring on the new filter.
   To reinstall, turn the filter assembly counterclockwise
   carefully until the O-ring contacts the sealing surface          FUEL INJECTION PUMP CONTROL
   of the housing bracket. Turn 2/3 further with the filter         The fuel injection pump is precisely adjusted; most
   wrench.                                                          of the adjustments are sealed, so be careful not to break
5. Turn on the fuel and manually prime the fuel filter              them. When an adjustment is necessary, contact your
   using the priming pump on top ofthe housing. Use                 WESTERBEKE dealer.
   a slow steady pumping action until resistance is felt.           NOTE: There is no warranty on engines with broken high
   The filter is now primed and the engine is ready                 rpm governor adjustment seals.
   to start.
                                                                    NOTE: The idle adjustment screw can be readjusted to pro-
NOTE: The cartridge contains fuel. Take care not to spill           vide for a satisfactory idle speed with each specific installa-
it during disassembly. Peiform the "fuel system air                 tion.
bleeding" after replacing the spin-on filter.




                                                f"VtTf WESJERBEKE
                                                      (Engines & Generators


                                                               16
                                                 FUEL  SYSTEM
                                                    (Continued)

FUEL ADDITIVES
If fungus or bacteria is causing fuel problems, you should
                                                                     A CAUTION: When using the preheat function,
have an authorized dealer correct these problems. Then
                                                                     keep in mind that the preheat elements (glow plugs)
use a diesel fuel biocide to sterilize the fuel (follow the
                                                                     are also energized; take care not to overheat them!
manufacturer's instructions).
                                                                Once the fuel filter assembly is free of air and the bleed
                                                                screw tightened, use the preheat button or slowly pump
SPARES                                                          the primer pump for 10 to 20 seconds to force any air
While the likelihood of having to service the fuel system       between the filter housing and injection pump out of the
at sea is slim, the possibility does exist. Therefore, we       system to the tank via the return line.
recommend that banjo washers, injector seat washers,
and a fuel filter be carried on board at all times. (See the    In cases where excessive amounts of air exist in the
Spares And Accessories brochure"). Purchase needed              fuel system, follow the above procedure but in addition,
spares from your local WESTERBEKE dealer or                     loosen all the high pressure injector lines (not injectors)
distributor. If a leak should develop at a banjo washer         and crank the engine starter motor; as fuel spurts from
that cannot be corrected by a simple tightening of the          between the nut and the line, tighten the injector lines in
fitting, replace the sealing washer with a replacement          sequence and then tighten the bleed screw.
found in the engine fuel hardware kit for your model.               NOTE: Do not attempt this procedure on a hot engine.
PRIMING (BLEEDING) THE FUEL SYSTEM
The on-engine fuel system is virtually self priming.
                                                                     A WARNING: Always wear protective clothing,
                                                                     safety glasses and gloves when bleeding high pres-
Under ordinary circumstances the engine's electric fuel
                                                                     sure injector lines.
lift pump, which is energized by the key switch/preheat
button, will supply a continuous flow of fuel from the
tank. This fuel is drawn through the fuel/water separator           AIR CLEANER
to the engine lift pump, the primary spin-on fuel filter,       Dual air cleaner filters are located on the top of the
and the injection pump.                                         engine manifold. These filters should be inspected,
                                                                cleaned, and/or replaced at maintenance periods. With
                                                                the engine turned off, remove the single hex bolt, lift the
                                                                manifold top, and the dual air cleaner filters become
                                                                accessible. When reassembling, make certain the filters
                                                                are positioned properly, and do not overtighten when
                                                                refastening the bolt.


                                FUEL LIFT PUMP


  A  WARNING: 00 not allow smoking or open flames
 near the fuel system when servicing. Also provide
 proper ventilation.

If it becomes necessary to bleed air from the system, use
the following procedure:
Open the bleed screw by turning the thumbscrew on
the fuel filter 1 or 2 turns. Energize the preheat button
(key ON) for 10 to 20 seconds or do it manually using
the palm of your hand to pump the primer pump on the
top of the fuel filter housing. When fuel flows freely
                                                                                               AIR CLEANER
from the bleed screw, tighten, but do not overtighten,
the screw.



                                                               17
                                     DC ELECTRICAL SYSTEM
 DESCRIPTION
 The charging system consists of an alternator with a mounted             A. WARNING: Before starting the engine make certain
 voltage regulator, an engine DC wiring harness, a mounted                that everyone is clear of moving parts! Keep away from
 DC circuit breaker, and a battery and connection wires.                  sheaves and belts during test procedures.
 Because of the use of integrated circuits (IC's) the electronic
 voltage regulator is very compact and is mounted internally
 or on the back of the alternator.                                       5. Start the engine.
                                                                         6. The voltage reading for a properly operating alternator
 Alternator Troubleshooting                                                 should be between 13.5 and 14.5 volts. If your alternator
                                                                            is over- or undercharging, have it repaired at a reliable
 If you suspect that the alternator is not producing enough                 service shop.
 voltage to charge the engine's battery, check the following:
                                                                         NOTE: Before removing the alternator for repair, use your
                                                                         voltmeter to ensure that i 2 volts DC excitation is present at
  A WARNING: Afailed alternator can become very                          the R terminal if the previous test showed only battery volt-
  hot. 00 not touch until the alternator has cooled down.                age at the B output terminal.


 o Make certain your alternator is securely mounted.                 .14 GRAY=====O=~_-r-_

 o Check the drive belts for proper tension.
 o Inspect for loose or disconnected wires at the alternator.          ~~e;~~~~~F~ ~~i#====#14BRDWN
 NOTE: An isolator with a diode, a solenoid, or a battery           '14 PINKJBlUE -tHH4I?~
 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 the starting
 battery but not the house battery, the alternator is OK and
 the problem is in the battery charging circuit.


  A WARNING: Shut off the engine battery switch or                                                         TYPICAL 51 AMP
                                                                                                           ALTERNATOR CONNECTIONS
  disconnect from the battery when working on the engine
  electrical system.
                                                                    '14 BRD\"'N=====i~@
 Checking for Proper Voltage                                                                          ~~~~=f10RED
                                                                      .14 RED==f==~~iS-+......
 If you suspect the alternator has failed perform the following
 tests with the engine off:
 1. Using a voltmeter, connect the voltmeter red wire clip to
    the output terminal B+.
 2. Connect the voltmeter negative wire to any ground on the
    engine.
. 3. Check the battery voltage. It should read 12 to 12 volts.
 4. Check the voltage between the alternator (+) positive ter-
    minal B and any engine ground. If the circuit is good, the
    voltage at the alternator should be the same as the battery
                                                                                                   .l;;.2\,I:;' ~~::=C:CC3l!§   .14 PINKJBlUE
    (unless there's an isolator in the circuit, then the reading
    would be zero).                                                                                     rr!?J~~=:::. .14 BROWN

  A CAUTION: To avoid damage to the battery charging
  circuit, never shut off the engine battery switch when
  the engine is running!


                                                                                                                OPTIONAL 72 AMP   ,
                                                   rvvl WESIERBEKE                                           ALTERNATOR CONNECTIONS
                                                           I Engines & Generators

                                                                    18
                                DC ELECTRICAL
                                        (Continued)
                                                    SYSTEM
DRIVE BELT ADJUSTMENT                                             BATTERY CARE
                                                                  Review the manufacturer's recommendations and then
 A CAUTION: Drive belts must be properly                          establish a systematic maintenance schedule for your
 tensioned. Loose drive belts will not provide proper             engine starting batteries and house batteries.
 alternator charging and will eventually damage the
 alternator.                                                      o   Monitor your voltmeter for proper charging during
                                                                      engine operation.
 Drive belts that are too tight will pull the alternator
 out of alignment and/or cause the alternator to wear             o   Check the electrolyte level and specific gravity with a
 out prematurely.                                                     hydrometer.
                                                                  o   Use only distilled water to bring electrolytes to a
Belt tension adjustment is made by pivoting the                       proper level.
    alternator on its base mounting bolt.
                                                                  o   Make certain that battery cable connections are clean
1. Loosen the alternator adjusting strap bolt and the base            and tight to the battery posts (and to your engine).
   mounting bolt.
                                                                  o   Keep your batteries clean and free of corrosion.
2. Pivot the alternator on the base mounting bolt to the
   left or right as required.
3. Tighten the base mounting bolt and the adjusting
                                                                   A   WARNING: Sulfuric acid in lead batteries can
                                                                   cause severe burns on skin and damage clothing.
   strap bolt.                                                     Wear protective gear.
4. Operate the engine for about 5 minutes at idle, then
   shut down and recheck belt tension.


 A    CAUTION: Use only genuine WESTERBEKE Drive
 Belts; poor quality belts will lead to premature wear
 and belt elongation resulting in alternator damage.




                      BELT TENSION




                                            I~I WESJERBEKE
                                               I Engines & Generators

                                                             19
                                 DC ELECTRICAL SYSTEM
                                                     WIRING DIAGRAM #39144
                                                                                                              "
                                                                                 "    110      R.   R




                                                                                                                  IU PHI(




                                                                                                                        r~11
                                                                                                                        I   Il!ll.
                                                                                                                        I(~E
                                                                                                                            MOOnS.




             i6i                                                                                                       11

             '~


                                                                                                                            -9'
  SEE NOTE



                 I
                 I

             +~
             ~~
                 BAnERY
                                                                                ®
                                                             $I




      NOTE:
AN ON-OFF SWITCH
SHOULD BE IN-
STALLED BETWEEN                                                                                              ADMIRAL
THE BATIERY AND                                                                                              PANEL
STARTER TO DIS-
CONNECT THE BAT-
TERY IN AN EMER-
GENCY AND WHEN
                                                                                                        -,
LEAVING THE BOAT
A SWITCH WITH A
CONTINUOUS
RATING OF 175
AMPS AT 12 VDC
WILL SERVE THIS
FUNCTION. THIS
SWITCH SHOULD
NOT BE USED TO
MAKE OR BREAK
THE CIRCUIT.



                                                             "
                                                                                                             CAPTAIN
                                                                  oz
                                                                  ;;                                         PANEL




                                             ~~~~~--,
                                              o              III ORN
                                                                                     ALT.
                                                                                     UIP
                                                                                                                              I
                                                                                                                              I
                                                                                                                              I
                                                                                                                              I
                                                                                                                              I
                                                                                                                              I
                                                                                                                              I
                                                                                     .......
                                                                                      OP.
                                                                                                                              I
                                                                                                                              I
                                                                                                                              I
                                                                                                                              I
                                                                                                                       RN
                                                                                                                              I
                                                                                                                              I
                                                                  I,a BlK                                                     I
                                                                  118BlK                                                      I
             L   _   _   _   _   _   _   _   _   _
                                                     L~:::::::j'tt"~"~'::::::::::::::::::::::::::::::::~____l
                                                                  111I8l11                                         ____      ..JI


                                                          !"'MTI WESJERBEKE
                                                                       I     Engines & Generators
                                                                                                                                     Revised
                                                                                                                                     October 2000
                                                                                     20
                             DC ELECTRICAL SYSTEM
                                              WIRING DIAGRAM #39144

                                                                                   -----1
          r---~~--------------------_+                                                                   I
                                                                                                         I
                                                                                                         I
                                                                                                         I
                                      AL TERIfATOR                                                       I
                                                                                                         I
                                                                                                         I
                                                                                                         I
                                                                                                         I

                                                         LIFT PUMP
                                                                                         rT;,;-;.~-----1
                                                                                     I       -R- TERM.   I        fUn        I
                ~-+~-r------r.-~P
                                                                                         U .jDac~l:
                                                                                                     ~            SOL.       I
                    .--+-+-+____---<'-'5run
                                        0.=.: &II~I_
                                                                   .WM(I

                                                                                     I
                                                  O.P.
                                               SENDER                                    I                                =1
                                                                                         12080 &. 308ITI ONLY               I
                                                                                         L __        ~~~~                __ I
                                                                                                             NOTES:
                                                                                                             I.   THIS PRODUCT IS PROTECTED BT A MANUAL RESET CIRCUIT BR[AKER LOCATEO NEAR THE
                                                                                                                  STARTER.    EXCESSIVE CURRENT WILL CAUSE THE BREAKER TO TRIP AND THE [NGINE WILL
                                                                                                                  SHUT DOWIf.   THE aUILOER/OWNER MUST BE SURE THAT THE INSTRUMENT PANEL · · IRING, AND
                                                                                                                  [NGIIf[ ARE INSTAllED TO PREVENT CONTACT BETW[EN [LEeTAICAL DEVICES AND SEAWATER.

                                                                                                             l. AN ON-Off SWITCH SHOULD BE INSTALLED BETW[(N THE !!IArTUY AND STARTER TO
                                                                                                                  DISCONNECT THE BATTERY IN AN [M[RGENCY AND WH[N LEAVING THE SOAT.   A SWITCH
                                                                                                                  WITH A CONTINUOUS RATING  or115 AMPS.  AT 11 YDC WILL SERVE THIS FUNCTION.   THIS
                                                                                                                  SWITCH SHOULD NOT SE USED TO MAlE OR BREAK THE CIRCUIT.
                                                                                                             3. THE PINK WIRE AT PLUG 2 IS UMUS[D AND SHOULD 8E Irc$ULAT(D. CAPTAIN PArcEL ONLY ·
                                                                                                             ··   THE GRAT WIRE AT PLUG 2 IS UNUSED AND SHOULD 8E     INSULATED. ADMIRAL PANEL ONLY.
                                                                                   ADMIRAL
 'AT                                              rACHON£TER
                                                                                   PANEL                                               MITSUBISHI         50 AMp   ALT.
    NET                                              S     GND
    sw.
  OG.




                                                                                                                                 110   RN



                                                                                                                                 114 P R



                                                                                                                                 II 4 GRA

                                                                                                                    PRESTOllTE\LEECE-NEVILLE 90 AMP. ALT.




                                                                                                                                                                   NOTE;
                                                                                                                                                                   WIRE rOR BATTERT ATTATCHMENT WILL NEED
                                                                                                                                                                   TO BE UPGRADED TO AN 8 GAUGE FROM 10 GAUGE


                                                                                                                                                 IICTA"
                                                                                                                                                 IU BRN
                                                                               CAPTAIN
                                                                               PANEL
                                                             LAMP
                                                             TEST
                                                             sw.


                                                                                                                                                    1104 PINK
                                         n   03




                                       51    AMP            ALTERNATOR                                       ~PRESTQLITE                 72 AMP             At T
                                       STANDARD ALTERNATOR ON THE
                                       mBlJ:i.6:C,~c             ~B        IlI:.   B2B       IlI:.\-_________________
                                                                                                             It 14 BRN




                                                                                                   0UNIVERSAI PROPUlSION
                                                                                                    PRESTOI I TE 51 AMP AL T

                  OPTIONAL AI TERNATORS®
                       USA, ISOA. ItoA, LESlU ALTERNATORS
AYAIlAIIl( Q" THE !tsaR UItIY nr;:IY lOCIY eZltIY     IOgYI          'lom;;YI ONP

                ®

                                                         /-vvl WESTERBEKE
                                                                            I Engines &                  Generators
                                                                                                                                                                                                       Revised

                                                                                              21                                                                                                       October 2000
                                                WATER HEATER
WATER HEATER INSTALLATIONS                                       The pressure cap on the engine's manifold should be in-
This engine is equipped with connections for the plumb-          stalled after the engine's cooling system is filled with
ing of engine coolant to heat an on-board water heater.          coolant. Finish filling the cooling system from the remote
The water heater should be mounted in a convenient lo-           tank after the system is filled and is free of air and exhib-
cation either in a high or low position in relation to the       its good coolant circulation. During engine operation,
engine, so that the connecting hoses from the heater to          checking the engine's coolant should be done at
the engine can run in a reasonably direct line without any       the remote tank and not at the engine manifold cap. The
loops which might trap air.                                      hose connection from the heater to the remote expansion
                                                                 tank should be routed and supported so it rises continu-
                                                                 ously from the heater to the tank, enabling any air in the
                                                                 system to rise up to the tank and out of the system.


                                          (~-...J'.~~                                REMOTE EXPANSION
                                          I
                                          I
                                                                                     TANK 1124117


                                      I  I
                                      I  I
                                      ,
                                    ...J,
                                         I
                            .....         I
 OIL
                                    "....J
 COOLER
               HEATER BELOW THE ENGINE

Hoses should rise continuously from their low point at
the heater to the engine so that air will rise naturally
from the heater to the engine. If trapped air is able to rise
                                                                                                          I
to the heater, then an air bleed petcock must be installed
at the higher fitting on the heater for bleeding air while                                                I '
filling the system.                                                                                       i
                                                                                                          ,I
                                                                                                            !
                                                                                                      )       I

NOTE: If any portion of the heating circuit rises above                                      ,

                                                                                                 "
                                                                                                        J

the engine's own pressure cap, then a pressurized                                            .     '
                                                                                                     _./.
                                                                                     HEATER ABOVE THE ENGINE
(aluminum) remote expansion tank (Kit #024177) must
be installed in the circuit to become the highest point.             NOTE: An air bleed petcock is located on the engine's
Tee the remote expansion tank into the heater circuit,               heat exchanger. Open this petcock when filling the en-
choosing the higher of the two connections for the return.           gine's fresh water system to allow air in the exchanger to
Tee at the heater, and plumb a single line up to the tank's          escape. Close tightly after all the air is removed.
location and the other back to the engine's return. Install
the remote expansion tank in a convenient location
so the fresh water coolant level can easily be checked. The
remote expansion tank will now serve as a check and
system fill point. The plastic coolant recovery tank is not
used when the remote expansion tank kit is installed,
since this tank serves the same function.




                                                  I~I WESIERBEKE
                                                     I Engines & Generators

                                                                22
                                 -ENGINE ADJUSTMENTS
ADJUSTING VALVE CLEARANCES                                       7. Using a small screwdriver or magnet, remove the
                                                                    adjusting disc.
1. Remove the cylinder head rocker cover.
                                                                 8. Select an appropriate disc thickness depending on the
2. Manually rotate the engine crankshaft and bring #1
                                                                    clearance measured. Install it and verify proper
   piston up on TDC of its compression stroke.                      clearance.
   NOTE: When this occurs, the intake and exhaust cam
   lobes will face upwards.




                                                                    EXAMPLE (Intake Valve): The thickness of the disc
                                                                    removed plus the clearance measured minus the
                                                                    standard clearance will give the thickness of the new
3. Measure the valve clearance of #1 cylinder by using a            adjusting disc.
   thickness gauge.                                                      4.0 mm + (0.30 - 0.25 mm) =4.05 mm
                                                                         0.157 in + (0.012 - 0.010 in) = 0.159 in
       Standard Valve Clearances (Engine Cold):
       Intake: 0.20 - 0.30mm (0.008 - 0.012 in)
       Exhaust: 0.30 - 0.40mm (0.012 - 0.016 in)


   VALVE
   CLEARANCE
   MEASUREMENT.




                                                                    NOTE: The number marked on the disc indicates
                                                                    its thickness. Example: 3825 means 3.825mm (0.1056
                                                                    in). Adjusting discs are available in 25 different
                                                                    thicknesses between 3.40 and 4.60mm (0.1339-
                                                                    0.1811 in) range, at variations of 0.050 mm (0.002
   If the valves clearances are not within standard                 in).
   values, continue using the following procedure to
   adjust the valves.                                            9. Measure and adjust as needed the valves in cylinders
                                                                    #3, #4 and #2 following the instructions above.
4. Rotate the valve cam lobe so that it points straight
   upward.
                                                                               CAM (INTAKE)'\...
5. Rotate the tappet so that one of the notches is facing
   the exhaust manifold. This allows for better access to
   the adjusting disc.
                                                                                                         VALVE
6. Using the tappet holder WESTERBEKE #41978,                                                            CLEARANCE
   press the tappet down to the position where the
   adjusting disc becomes accessible.




                                                            23
                                    ENGINE ADJUSTMENTS
                                           (Continued)

TIMING BELT INSPECTION AND                                          Timing Belt Tensioner
REPLACEMENT'                                                        1. Check the rotation of the timing belt tensioner pulley.
1. Before removing the timing belt and timing belt                     Check for play or abnormal noise.
   tensioner, rotate the engine crankshaft by hand and
                                                                    NOTE: Do not clean the timing belt tensioner with clean-
   align the three timing marks as shown in the
                                                                    ing solvents. If dirty, use a clean rag to wipe it clean.
   illustration.
                                                                    Avoid scratching the suiface the belt travels over.

  A CAUTION: After removal of the timing belt,
 DO NOT rotate the crankshaft or camshaft; the
 pistons will damage the opened valves.
                                                                          OAMAGE,/



                       ~nM"G.AA~
                                                                          WEAR


                                                                                                                     OAMAGE,
                                                                                                                     WEAR


                                                                                                            I   ",
                                                                                                        . I:" .
                                                                                                                 .
                                                                                                         . ' ',',~

                                                                                                              ...
                                              TIMING
                                              MARKS
                                                                                                        . :., :.

                                                                    Timing Belt, Camshaft And Injection Pump Gears
                                                                    1. Check the gear teeth for any indication of damage,
                                                                       wear, deformation, etc. Replace if any faults are
                                                                       found.
NOTE: If the timing belt is to be reused, draw an arrow on
the belt pointing in the direction of the belts rotation.
Replace it in the same direction.
                                                                    Timing Belt Installation
                                                                    1. Check to ensure that the timing marks on the gears
                                                                       are properly aligned with the marks on the case.

    DIRECTION                                                       2. Loosely install the timing belt tensioner, locking bolt
    ARROW                                                              and spring. Push the timing belt tensioner toward the
                                                                       lock bolt to the left as far as it will go and then tighten
                                                                       the locking bolt to temporarily hold the tensioner
                                                                       in place.




Inspection
1. Replace the timing belt if it is contaminated with oil,
   grease or water.
2. Check for damage, wear, peeling, cracks or
   hardening. Replace if suspect.
                                                                           LOCKING
                                                                           BOLT
NOTE: Never forcefully twist the timing belt; turn it inside
out or bend it.
                                                                                              TIMING BELT
                                                                                              TENSIONER


                                               I~l WESTERBEKE
                                                  I Engines & Generators

                                                               24
                                    ENGINE ADJUSTMENTS
                                           (Continued)

3. Install the timing belt.                                    7. Re-check the timing mark positions between the three
                                                                  gears and the gear case. Check the timing belt
    NOTE: If reinstalling the original belt, be sure to           deflection at the point on the belt shown in the
    install with the arrow in the correct direction of belt
                                                                  illustration with a pushing force of 10 kg (22Ib).
    rotation.
                                                                       Standard Deflection (unit cold):
                                                                       10.8-12.9 mm (0.43-0.51 in)
           DIRECTION
           ARROW




4. Release the timing belt tensioner lock bolt to allow
   the tensioning spring tensionor to bring pressure on
   the timing belt.
                                                                   8. Install the timing belt left cover with its rubber seal.
                                                                   9. Install the timing belt right cover with its rubber seal.

                                                                       Bolt torque for timing belt cover bolts:
                                                                       0.7-1.0 m-kg (5-7 ft-Ib)

                                                                   10. Install the crankshaft pulley and torsional damper
                                                                       onto the timing belt drive gear with the semicircular
                                                                       (woodruff) key. Tighten the attachment.
                                                                       Crankshaft pulley bolt torque:
                                                                       2.3-3.3 m-kg (17-24 ft-Ib)
5. Turn the crankshaft twice in the direction of normal
   engine rotation (clockwise) to equalize tension on the              NOTE: When installing the torsional damper onto the
   timing belt.                                                        timing belt drive gear, align the mark on the damper
                                                                       with the knock pin on the gear.
    NOTE: Do not turn the engine in reverse of its normal
    rotation.
6. Tighten the timing belt tensioner lock bolt.                              TIMING BELT
                                                                             COVER (RIGHT)
   Lock bolt torque: 3.2-4.7 m-kg (23-34 ft-Ib)


                                                                                                                      TIMING BELT
                                                                                                                      COVER (LEFT)




                                               I"VVJ WESJERBEKE
                                                   r Engines & Generators
                                                              25
                                 ENGINE ADJUSTMENTS
                                        (Continued)

COMPRESSION TEST                                                  FUEL INJECTION NOZZLE TEST
1. Warm the engine up to operating temperature.                   When the injection starting pressure is too high or too
                                                                  low or the fuel spray pattern is improper, an abnormal
2. Stop the engine.
                                                                  fuel combustion takes place in the engine leading to
3. Remove all four glow plugs.                                    lowered power output, blackish exhaust smoke and un-
                                                                  wanted combustion noise. Further, it can cause a piston
4. Disconnect the DC power connection to the fuel
                                                                  seizure or piston damage if not corrected. In such cases,
   shutoff solenoid on the injection pump.
                                                                  the injection nozzle test should be performed and the
5. Install the compression tester glow plug adapter in            faulty nozzle(s) replaced as required.
   the glo\y plug opening of #1 cylinder. Connect the
                                                                  Use an injection nozzle tester to check the static injection
   compression gauge to the glow plug adapter.
                                                                  starting pressure and condition of the spray pattern every
6. Crank the engine with the starter and allow the gauge          800 operating hours.
   to reach its maximum reading.
                                                                  Injection nozzle pressure is 1920 psi + 71 psi
7. Record the reading and proceed to the next cylinder.           (135 kg/cm2 + 5 kg/cm2.

8. Compare readings to the table below. Take corrective
   action as needed.                                               A    WARNING: When testing a nozzle beware that
                                                                   high pressure might blow off the light oil and cause
   Compression pressure          kg/cm 2(lb/in2)-rpm               injury. Keep away from the nozzle end!

           Standard                30 (426) - 200

           Limit                   27 (384) - 200




                                                                          GOOO                                       POOR




NOTE: Whenpeiforming the compression test, shut off the
raw water supply to the engine mounted raw water pump.
This is to prevent filling of the exhaust system with raw
water while peiforming the test.




                                           l-vvl WESTERBEKE
                                                    I Engines &   Generators


                                                            26
                                     HBW TRANSMISSION
INITIAL OPERATION                                               LOCKING THE PROP
All HBW marine transmissions are test-run on a test             Locking of the propeller shaft by an additional brake is
stand with the engine at the factory prior to delivery.         not required: use the gear lever position opposite your di-
For safety reasons the fluid is drained before shipment.        rection of travel for this purpose. Never put the gear lever
                                                                in the position corresponding to the direction of travel of
Fill the gearbox with Automatic Transmission Fluid
                                                                the boat.
(DEXRON II or DEXTRON Ill). The fluid level should be
up to the index mark on the dipstick. To check the fluid
level, just insert the dipstick, do not screw it in. Screw
                                                                    CONTROL CABLES
the dipstick into the case after the fluid level is checked,    The gearbox is suitable for single lever remote control.
and tighten. Do not forget the sealing ring under the hex-      Upon loosening the retaining screw, the shift lever can be
head of the dipstick. Check for leaks and change the fluid      moved to any position required for the control elements
after the first 25 hours.                                       (cable or rod linkage). Make certain that the shift lever
                                                                does not contact the shift lever cover plate: the minimum
                                            TRANSMISSION
                                            IN OPERATION        distance between lever and cover should be O.5mm.
                                                                    The control cable or rod should be arranged at a right
                                                                    angle to the shift lever when in the neutral position. The
                                                                    neutral position of the operating lever on the control con-
                                                                    sole should coincide with the neutral position of the shift
                                                                    lever on the gear box.
                                                                    The shifting travel, as measured at the pivot point of the
                                                                    shift lever, between the neutral position and end positions
                                                                    A and B should be at least 35mm for the outer and 30mm
                                                                    for the inner pivot point.
                                                                    A greater amount of shift lever travel is in no way
                                                                    detrimental, and is recommended. However, if the shift
                                                                    lever travel is shorter, proper clutch engagement might be
The neutral position of the operating lever on the control
                                                                    impeded which, in tum, would mean premature wear, ex-
console must coincide with the neutral position of the
                                                                    cessive heat generation and clutch plate failure. This
actuating lever on the transmission. Shifting is initiated
                                                                    would be indicated by slow clutch engagement or no
by a cable or rod linkage via the actuating lever and an
                                                                    engagement at all.
actuating cam. The completion of the gear changing op-
eration is servo-automatically controlled within the gear.          NOTE: Checkfor proper shift lever travel at least each
Gear changing should be smooth, not too slow, and con-              season.
tinuous (without interruption). Direct changes from for-
ward to reverse are permissible, since the multiple-disc
clutch permits gear changing at high rpm, including sud-
den reversing at top speeds in the event of danger.

WHEN UNDER SAIL OR BEING TOWED
                                                                                                                                  CLOCKWISE
Rotation of the propeller without load such as when the
boat is sailing, being towed, or anchored in a river, as
well as operation of the engine with the propeller stopped
(for charging the battery), will have no detrimental ef-
fects on the gearbox.
NOTE: When the boat is sailing (engine stopped), the gear
                                                                                                   COVER PLATE HUB
lever must be in neutral position. The propeller is at idle
and can free wheel.




                                                               27
                                     HBW TRANSMISSION
                                           (Continued)
                                                                   Checking the Bowden Cable or Rod Linkage
 A CAUTION: The position of the cover plate                    The Bowden cable or rod linkage should be checked at
 underneath the actuating lever is factory-adjusted to         regular intervals. Check the neutral position of the operat-
 ensure equal shift lever travel from neutral position         ing lever (on the control console) and the actuating lever
 to A and B. If this side shift cover is removed or in         (on the gearbox). The minimum lever travel from the
 any way tampered with, the transmission warranty              neutral position to the operating positions (0 - A =0 - B)
 will be void. Authorized Hurth personnel only may             should be 35mm for the outer and 30mm for the inner
 adjust or remove this cover.                                  pivot point. Make certain that these minimum values are
                                                               safely reached. Check the cable or rod linkage for easy
NOTE: When installing the gearbox, make certain that           movability a~d proper attachment.
shifting is not impeded by restricted movability of the
Bowden cable or rod linkage, by unsuitably positioned
                                                                   Connection of Gearbox with Propeller
guide sheaves, too small a bending radius, etc. In order
to mount a support for shift control cable connections,        HBW recommends a flexible connection between the
use the two threaded holes located above the shift cover       gearbox and the propeller shaft if the engine is flexibly
on top of the gear housing. Refer to the WESTERBEKE            mounted, in order to compensate for angular deflections.
parts list.                                                    The installation of a special propeller thrust bearing is not
                                                               required, since the propeller thrust will be taken by the
MAINTENANCE                                                    transmission bearing, provided the value specified under
                                                               SPECIFICATIONS is not exceeded. However, the output
Transmission Fluid                                             shaft should be protected from additional loads. Special
To ensure trouble-free operation of the gearbox, only          care should be taken to prevent torsional vibration. When
use Automatic Transmission Fluid (ATF), (Dexron II             using a universal joint shaft, make certain to observe the
or Ill).                                                       manufacturer's instructions.

Capacity                                                           Even with the engine solidly mounted, the use of a flexi-
                                                                   ble coupling reduces stresses in the gearbox bearings
Add the fluid quantity for the proper model transmission           caused by hull distortions, especially in wooden boats or
to the gearbox. After filling, check the fluid level with          where the distance between the gearbox output flange
the dipstick. Adjust level as needed. Install the dipstick         and the stem gland is less than about 800mm.
with the sealing washer, operate unit, check fluid, check
for leaks.

     Transmission Fluid                 Quantity
      HBW 150                  0.59 Quarts (0.56 Liters)
      HBW 150V                 1.10 Quarts (1.05 Liters)
      HBW250                   1.84 Quarts (1.75 Liters)

Fluid Change
Change the fluid for the first time after about 50 hours of
operation, then every 250 operating hours or at least once
a year or when you change engine oil. When changing
the fluid, also check the gearbox cooling device and               Lay-up/Winterize
clean or replace it as necessary.                                  If the transmission is not used for periods of more than
NOTE: When changing the fluid, take care not to lose the           one year, it should be completely filled with fluid of the
drain plug sealing washer. The drain plug will leak with-          same grade to prevent corrosion. Protect the input shaft
out this sealing washer.                                           and the output flange by means of an anticorrosive coat-
                                                                   ing, as required.




                                             I~l WESJERBEKE
                                                I Engines & Generators

                                                              28
                           BORG WARNER VELVET DRIVE
                                 TRANSMISSION
INITIAL OPERATION                                                  NOTE: If the boat moves backwards with the selector
Transmission Fluid                                                 control in the forward position, shut off the engine! This
                                                                   problem may be the result of incorrect movement of the
Check transmission fluid level on the dipstick. If the             shift lever by the shift control.
transmission has not been filled, fill with Dextron III and
continue to use this fluid. During the first 50 hours of           DAILY OPERATION
operation, keep a lookout for any leakage at the bell
housing, output shaft, and transmission cooler. This               o   Check transmission fluid.
fluid should be changed after the first 50 hours and               o   Visually check transmission and gear shift linkage.
approximately every 1000 operating hours or at winter
lay-up.                                                            o   Start engine in neutral. Allow a few minutes for fluid
                                                                       to warm.
NOTE: Some transmissions are equipped with a neutral
safety switch. Unless the transmission shift lever I per-          NOTE: Too Iowan idle speed will produce a chattering
fectly aligned in neutral the engine starter will not              noise from the gear and damper plate. In such cases the
activate.                                                          idle speed should be increased.
                                                                   o   Shift into gear.
Shifting Into Gear
Place the transmission selector control in Neutral before
starting the engine. Shifting from one selector position to
                                                                    A  WARNING: Shifting gears above 1000 rpm can
                                                                    damage the engine and transmission.
another selector position may be made at any time below
1000 rpm and in any order. Shifts should be made at the
lowest practical engine speed. Start the engine and s~t            SHIFT LEVER POSITION
the throttle at idle speed; allow the transmission fluid to      The selector control mechanism and linkage must position
warm up for a few minutes.                                       the shift lever on the transmission exactly in Forward (F),
                                                                 Neutral (N), and Reverse (R) shifting positions. A detent
Neutral
                                                                 ball located behind the transmission shift lever must work
Move selector lever to the middle position. You should
                                                                 freely to center the lever in each position. The selector con-
feel the detent. Center the shift lever on the transmission
                                                                 trol positions at the helm(s) must be coordinated with those
through the linkage to the selector lever. With the control
                                                                 of the Velvet Drive shift lever through shift mechanism ad-
in this position, hydraulic power is completely interupted
                                                                 justments. An improperly adjusted shift mechanism can
and the output shaft of the transmission does not turn.
                                                                 cause damage to the transmission. The shifting mechanism
Forward                                                          and transmission shift lever should be free of dirt to ensure
Move selector lever to the forward position. You should          proper operation.
feel the detent. The shift lever on the transmission is in
the forward position. The output shaft and the propeller
                                                                   NOTE: Do not remove detent ball!
shaft move the boat in a forward direction.

Reverse
Move selector lever to the reverse position. You should
feel the detent. The shift lever on the transmission is in
the reverse position. The output shaft and the propeller
should move the boat in a reverse direction (astern).

NOTE: Moving the transmission shift lever from Neutral
Position to Forward is always towards the engine. Re-
                                                                        FORWARD                 NEUTRAL                  REVERSE
verse is always away from the engine.
NOTE: Be aware of any unusual noises or vibrations and
investigate to determine the cause.


                                              l-vvl WESIERBEKE
                                                      I Engines & Generators

                                                              29
                           BORG WARNER VELVET DRIVE
                              TRANSMISSION (Continued)
MAINTENANCE                                                                                           OIL FILLER CAP
D Visually check for oil leaks at hydraulic connections.                                              AND DIPSTICK
                                                                                                      ASSEMBLY
  Check wear on hydraulic lines and replace if worn.
D Lubricate detent ball and shift cable attachments.
                                                                    OIL FILLER CAP
D Inspect shift linkage.                                            AND DIPSTICK --==--M
                                                                    ASSEMBLY HOLE
D Inspect transmission bolts; retorque if necessary.

 A    CAUTION: Clutch failure will occur if the trans-
 mission shift lever does not fully engage the detent
 ball positions.
                                                                 Lay-up/Winterize
Changing Transmission Fluid                                      Storage requires special care. Follow these procedures:
After the initial 50 hour change, the transmission fluid         D Drain water from the transmission oil cooler and
should be changed at 1000 operating hours or at winter             replace with a proper mixture of antifreeze coolant.
haul-out. However, fluid must be changed whenever it             NOTE: This operation will occur normally when the
becomes contaminated, changes color or smells rancid.            engine raw water cooling system is properly winterized.
D Remove oil filler cap and dipstick.                            D Clean up the transmission and touch up unpainted
D Remove oil cooler return line and allow oil to drain             areas (use heat resistant paint).
  into a container.                                              D Fill the transmission with Dextron II or III fluid to
                                                                   prevent internal corrosion.
D Reconnect oil cooler return line.
                                                                 D Loosen attaching hardware from the transmission
D Use a suction pump to remove transmission oil                    output flange and propeller shaft coupling flange
  through the filler cap/dipstick hole.                            before removing the boat from the water. Separate
D Clean off the transmission and properly dispose of               the flanges.
  the used fluid.                                                D Spray the flanges with an anticorrosive coating.
D Refill the transmission with Dextron II or III trans-          WARRANTY NOTES
  mission fluid. The quantity will vary depending on .
                                                                 Service manuals are available from your BORG
  the transmission model and installation angle. Fill
                                                                 WARNER dealer.
  through the dipstick hole.
                                                                 BORG WARNER is aware of the shock loads that can be
D Check dipstick for proper fluid level.                         placed on its gears as the result of mechanical propeller
D Replace oil filler cap/dipstick. (Dipstick is pressed          operation or fully reversing of propeller blades while
  into place and turned clockwise until finger-tight.)           shifting. Therefore torque loads and directional changes
                                                                 should be made at low engine speeds. If it is found that
D Run engine -     then shutdown and recheck fluid level.        the failure was caused by a shock load, the warranty
                                                                 claim will be denied.
 A   WARNING: Never pull the dipstick with the en-               Oil temperature maximum is 190°F (105°C) during
 gine running. Hot fluid will splash from the dipstick           operation. If oil temperature runs too high, consult your
 hole. This could cause severe burns.                            BORG WARNER distributor.

                                                                  A    CAUTION: System-related noises or vibrations
                                                                  can occur at low engine speeds which can cause
                                                                  gear ranle resulting in damage to the engine and/or
                                                                  transmission. BORG WARNER is not responsible for
                                                                  total system-related torsional vibration of this type.

                                            tvv/ WESIERBEKE
                                                    (Engines & Generators

                                                            30
                                        ENGINE TROUBLESHOOTING
The following troubleshooting table describes certain                             NOTE: The engine's electrical system is protected by a
problems, the probable causes of the problems, and the                            20-Ampere manual reset circuit breaker located on a
recommendations to overcome the problems.                                         bracket on the left front side of the engine. The preheat
                                                                                  solenoid is mounted on the same bracket.

                Problem                                 Probable Cause                                        Verification/Remedy
   Key Switch on, PREHEAT switch           1. Battery switch not on.                     1. Check switch and/or battery connections.
   depressed: no panel indications;
   fuel solenoid, electrical fuel pump     2. 20-Amp circuit breaker tripped.            2. Reset breaker; if breaker trips again, check preheat sole-
   and preheat solenoid not energized.                                                      noid circuit and check circuit for shorts to ground.
                                           3. 10 Amp breaker tripped.                    3. Check voltage at and after breaker.
                                           4. Loose battery connections.                 4. Check (+) connection on starter solenoid and (-) connection to
                                                                                            engine ground stud. Check battery cable connections.
                                           5. Preheat solenoid not operating.            5. Check Solenoid.
   Key Switch on, PREHEAT switch           1. Connection to solenoid faulty.             1. Check connection at solenoid.
   depressed; START switch
   depressed; no starter engagement.       2. Faulty START switch.                       2. Check switch with ohmmeter.
                                           3. Faulty solenoid.                           3. Check that 12 volts are present at starter solenoid
                                                                                            activation connection.
                                           4. Neutral safety switch open.                4. Shift lever in neutral - check switch.
                                           5. Loose battery connection.                  5. Check battery connection.
                                           S. Low batteries.                             6. Check battery charge state.
   START switch is depressed; panel        1. Poor connections to fuel solenoid.         1. Check connections.
   indications OK; start 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.
   No ignition: 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 engine fuel
                                                                                             system.
                                                                                         1b. Filters clogged. (Replace filters and bleed fuel system of air.)
                                           2. Preheat solenoid faulty.                   2. Check solenoid.
   No ignition. Fuel solenoid energized.   1. Starting battery failure                   1. Check start batteries.
   Engine cranks slowly, then fails.
                                                                                         1a. Switch to combine house and start batteries.
                                                                                         1b. Replace batteries.
                                           2. Water in engine                            2. Exhaust system failure - raw water has backed into cylin-
                                                                                            ders. Water must be removed from engine - a serious
                                                                                            problem that can be corrected.
   Engine can't be stopped.                1. STOP switch failure.                       1. Check switch will not open run circuit. Manually move the
                                                                                            shutoff lever on the injection pump side. Test switch with
                                                                                            ohmmeter.
                                           2. Fuel run solenoid will not de-energize.    2a. Manually disconnect the 12 volt connection to the fuel run
                                                                                             solenoid at the injection pump.
                                                                                         2b. Loosen high pressure injector lines at each injector. Be-
                                                                                             ware of fuel spray.
                                           3. Check DC alternator for feedback           3. Disconnect the R terminal.
                                              through regulator circuit.
   Engine 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 or dis-       2. Inspect all wiring for short circuits and loose connections.
                                              connected.                                    Inspect switches for proper operation.
                                           3. Fuel Starvation                            3. Check fuel supply, fuel valves, fuel lift pump.
                                           4. 20-amp. circuit breaker tripping.          4. Check for high DC amperage draw during operation. En-
                                                                                            sure switch 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.
   Battery not charging.                   1. Alternator drive                           1. Check drive belt tension. Alternator should turn freely.
                                                                                            Check for loose connections. Check output with voltmeter.

                                                         I~l WESJERBEKE
                                                            I Engines & Generators

                                                                            31
                                      ENGINE TROUBLESHOOTING
                                               (Continued)
                                                                                                Ensure 12 volts are present at the "R" terminal.
                 Problem                                Probable Cause                                         Verification/Remedy
   Battery runs down.                      1. Oil pressure switch.                        1. Observe if gauges and panel lights are activated when en-
                                                                                             gine is not running. Test the oil pressure switch.
                                           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 re-
                                                                                             place after short is located.
                                           3. Low resistance leak.
                                                                                          3. Check all wires for temperature rise to locate the fault.
                                           4. Alternator.                                 4. Disconnect alternator at output, after a good battery
                                                                                             charging. If leakage stops, remove alternator and bench
                                                                                             test. Repair or replace.
                                           5. Poor battery connections.                   5. Check cable connections at battery.
   Engine overheat.                        1. Raw water not Circulating.                  1.  Broken or loose belt at raw water pump.
   NOTE: Shut engine down immediately.     2. Coolant not circulating.                    2.  Raw water pump failure. Check impeller - replace.
                                                                                          2a. Obstruction at raw water intake or raw water filter.
                                                                                          2b. Thermostat - remove and test in hot water. Replace
                                                                                              thermostat.
                                                                                          2c. Loss of coolant - check hoses, hose clamps, drain plug,
                                                                                              etc. for leaks.
                                                                                          2d. Broken or loose belts - tighten/replace.
                                                                                          2e. Air leak in system; run engine and open cooling system
                                                                                              petcocks, heat exchanger, manifold, etc. to bleed air.
                                                                                              Add coolant as needed.
   Exhaust smoking problems.               1. Blue smoke.                                 1. Incorrect grade of engine oil.
                                                                                          1a. Crankcase overfilled with engine oil
                                                                                              (oil is blowing out through the exhaust).
                                           2. White smoke.                                2. Engine is running cold.
                                                                                          2a. Faulty injector or incorrect injector timing.
                                           3. Black or gray smoke.                        3. Improper grade of fuel.
                                                                                          3a. Fuel burn incomplete due to high back pressure in exhaust
                                                                                              or insufficient air for proper combustion. (Check for re-
                                                                                              strictions in exhaust system; check air intake.)
                                                                                          3b. Improperly timed injectors or valves or poor compression.
   Transmission will not shift in or out   1. Transmission failure.                       1a. Check cable connections at steering station and at trans-
   of gear, or drive the vessel.                                                              mission lever.
                                                                                          1b. Check transmission fluid.
                                                                                          1c. Check shaft couplings or engine damper plate.
                                                                                          1d. Check drive damper
                                           2. Transmission oil cooler failure.            2a. Replace oil cooler.

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

                                                         1"VV1 WESJERBEKE
                                                                     I   Engines & Generators


                                                                              32
                        LAY-UP AND RECOMMISSIONING
GENERAL                                                            small amount of oil on the rubber sealing gasket at the
Many owners rely on their boatyards to prepare their               base of the filter. Fill the sump with the correct amou'nt
craft, including engines and generators, for lay-up during         of oil for your engine model. (Refer to the SPECIFICA-
the off-season or for long periods of inactivity. Others           TIONS section of this manual.) Use an oilwith an API
prefer to accomplish lay-up preparation themselves.                specification of CF or CG4. Run the engine and check for
                                                                   proper oil pressure and make sure there are not leaks.
The following procedures will allow you to perform your
                                                                   Stop the engine, check oil level and add oil as needed to
own lay-up and recommissioning, or you may use them
                                                                   bring level to dipstick full mark.
as a check list for others. These procedures should afford
your engine protection during a lay-up and also help
familiarize you with the maintenance needs of your en-              ACAUTION: Do not leave the engine's old engine
gine.                                                               oil in the sump over the lay-up period. Engine oil and
                                                                    combustion depOSits combine to produce harm-
If you have any questions regarding lay-up procedures,
                                                                    ful chemicals which can reduce the life of the en-
call your local servicing dealer; he will be more than
                                                                    gine's internal parts.
willing to provide assistance.

PROPELLER SHAFT COUPLING                                           FUEL SYSTEM
The transmission and propeller half couplings should al-           Top off your fuel tanks with No.2 diesel fuel. Fuel addi-
ways be opened up and the bolts removed when the boat              tives should be added at this time to control algae, and a
is hauled out of the water or moved from land to water,            fuel conditioner such as STABIL. Care should be taken
and during storage in a cradle. The flexibility of the boat        that the additives used are compatible with the primary
often puts a severe strain on the propeller shaft or cou-          filter/water separator used in the system. Change the
pling, or both, while the boat is taken out or put in the          element in your primary fuel filter/water separator, if
water. In some cases, the shaft has actually been bent by          the fuel system contains one, and clean the separator
these strains. This does not apply to small boats that are         sediment bowl.
hauled out of the water when not in use, unless they have          Change the fuel filter elements on the engine and bleed
been dry for a considerable period of time.                        the system, as needed. Start the engine and allow it to run
                                                                   for 5-10 minutes to make sure no air is left in the fuel
FRESH WATER COOLING SYSTEM                                         system. Check for any leaks that may have been created
A 50-50 solution of antifreeze and fresh water is recom-           in the fuel system during this servicing, correcting them
mended for use in the freshwater cooling system at all             as needed.
times. This solution may require a higher concentration
of antifreeze, depending on the area's winter climate.             RAW WATER CIRCUIT
Check the solution to make sure the antifreeze protection          Close the through-hull fitting. Remove the raw water in-
is adequate.                                                       take hose from the fitting. Place the end of this hose into
Should more antifreeze be needed, drain an appropriate             a 5-gallon bucket of clean fresh water. Before starting the
amount from the engine block and add a more concen-                engine, check the zinc anode found in the heat exchanger
trated mixture. Operate the engine to ensure a complete            on the engine and clean or replace it as required. Clean
circulation and mixture of the antifreeze concentration            the raw water strainer, if one is installed in the inside of
throughout the cooling system. Now recheck the anti-               the hull.
freeze solution's strength.                                        Start the engine and allow the raw water pump to draw
                                                                   fresh water through the system. When the bucket is
LUBRICATION SYSTEM                                                 empty, stop the engine and refill the bucket with an anti-
With the engine warm, drain all the engine oil from the            freeze solution slightly stronger then needed for winter
oil sump. Remove and replace the oil filter. (Place some           freeze protection in your area.
paper towels and a plastic bag around the filter to catch
                                                                   Start the engine again and allow all of this mixture to be
the oil during its removal.)
                                                                   drawn through the raw water system. Once the bucket is
When installing the new oil filter, be sure to apply a             empty, stop the engine. This antifreeze mixture should

                                             tvvl WESTERBEKE
                                                     I Engines & Generators

                                                              33
                        LAY-UP AND RECOMMISSIONING
                                   (Continued)
protect the raw water circuit from freezing during the             BATTERIES
winter lay-up, as well as providing corrosion protection.        If batteries are to be left on board during the lay-up pe-
Rempve the impeller from your raw water pump (some anti-         riod, make sure they are fully charged and will remain
freeze mixture will accompany it, so catch it in a bucket).      that way, to prevent them from freezing. If you have any
Examine the impeller. Acquire replacement, if needed,            doubt that the batteries will not remain fully charged, or
                                                                 that they will be subjected to severe environmental con-
and a cover gasket. Do not replace the impeller (into the
                                                                 ditions, remove the batteries and store them in a warmer,
pump) until recommissioning, but replace the cover and
                                                                 more compatible environment.
gasket.

INTAKE MANIFOLD                                                     AWARNING: Lead acid baneries emit hydrogen, a
Open the intake manifold and inspect the filter elements
                                                                    highly explosive gas, which can be ignited by elec-
                                                                    trical arcing or lighted tobacco products. Do not
inside. Clean with low pressure compressed air or replace
                                                                    smoke or allow an open flame near the banery being
if needed. Do not leave filters installed during
                                                                    serviced. Shut off all electrical equipment
lay-up period. Filter elements should be stored in a clean
                                                                    in the vicinity to prevent electrical arcing during
dry area. Place an oil rag in the intake opening to keep
                                                                    servicing. Wear rubber gloves, a rubber apron and
dampness out.                                                       eye protection when servicing batteries.
STARTER MOTOR
                                                                   RECOMMISSIONING
Lubrication and cleaning of the starter drive pinion is
advisable, if access to the starter permits its removal.           The recommissioning of your WESTERBEKE engine
Make sure the battery connections are shut off before at-          after a seasonal lay-up generally follows the same proce-
tempting to remove the starter. Take care in properly re-          dures as those presented in the PREPARATION FOR
                                                                   STARTING section regarding preparation for starting and
placing any electrical connections removed from the
                                                                   normal starts. However, some of the lay-up procedures
starter.
                                                                   will need to be counteracted before starting the engine.
CYLINDER LUBRICATION                                               1. Remove the oil-soaked cloths from the intake mani-
                                                                   fold and from the through-hull exhaust port.
It is not necessary to remove the glow plugs from the
cylinder head to squirt light engine oil into the cylinders        2. Remove the raw water pump cover and gasket. Dis-
for the few months of normal lay-up. However, if you               card the gasket. Install the raw water pump impeller re-
anticipate a longer lay-up period (12 months or more),             moved during lay-up (or a replacement, if required).
we recommend that this procedure be performed. The                 Install the raw water pump cover with a new cover gas-
light oil in the cylinders will prevent the pistons' rings         ket.
from sticking to the cylinder walls. With oil in the cylin-        3. Reconnect the shaft coupling and check for proper
ders, tum the engine over by hand two revolutions.                 alignment.
                                                                   4. Reinstall the batteries that were removed during the
TRANSMISSION                                                       lay-up, and reconnect the battery cables, making sure the
Check or change fluid in the transmission as required.             terminals are clean and that the connections are tight.
Wipe off grime and grease and touch up unpainted areas.            Check to make sure the batteries are fully charged.
Protect coupling and output flange with anticorrosion
                                                                   5. Check the condition of the zinc anode in the raw wa-
coating. Check that transmission vent is open.
                                                                   ter circuit and clean or replace the anode as needed. Note
                                                                   that it is not necessary to flush the antifreeze/fresh-
SPARES                                                             water solution from the raw water coolant system. When
Lay-up time provides a good opportunity to inspect your            the engine is put into operation, the system will self-flush
WESTERBEKE engine to see if external items such as                 in a short period of time with no adverse affects.
drive belts or coolant hoses need replacement. Check
                                                                   6. Start the engine in accordance with procedures in the
your basic spares kit and order items not on hand, or re-          PREPARATION FOR INITIAL START-UP section of this
place those items used during the lay-up, such as filters          manual.
and zinc anodes.

                                              !-VVI WSJERBEKE
                                                      I Engines & Generatol'S

                                                              34
                 WESTERBEKE 55A FOUR
                TORQUE SPECIFICATIONS
                                                             Ib-ft               kg-m

Cylinder Head Bolts                                         Cylinder head bolts are not
                                                            retorqued. Bolts are torqued
                                                            only during engine assembly.
Connecting Rod Cap Bolts                                    51-54                7.0-7.5
Main Bearing Cap Bolts                                       61-65               8.4-9.0
Injection Pump Drive Gear                                   43-52                6.0-7.0
Oil Pan Bolts                                                 5-7                0.7-1.0
Crankshaft Pulley Bolts                                      17-24               2.3-3.3
Glow Plugs                                                   11-15               1.5-2.0
Intake Manifold Bolts                                        12-20               1.6-2.7
Exhaust Manifold Bolts                                       16-20               2.2-2.7
Switches and Senders                                          9-13               1.2-1.8
Injector HIP Line Nuts                                       13-17               1.8-2.3
Freshwater Pump Mounting Bolts                              23-34                3.2-4.7
Timing Belt Covers                                           5-7                 0.7-1.0
Flywheel Bolts                                              130-137              18-19
Camshaft Cap Bolts                                           15-20               2.0-2.7
Block Oil Jets                                               9-13                1.2-1.8
Rocker Cover Bolts                                           5-7                 0.7-1.0
Back Plate Bolts                                             12-17               1.6-2.3
Rear Oil Seal Housing                                        5-7                 0.7-1.0
Oil Strainer Pick-Up                                         5-7                 0.7-1.0
Timing Belt Drive Gear Bolt                                 116-123              16-17
Thermostat Assembly                                          12-17               1.6-2.3
Oil Cooler Assembly Bolts                          MIO      23-24                3.2-4.7
                                                   M6        5-7                 0.7-1.0




                           l-vvl WESJERBEKE                                                /
                                 I Engines &   Generators


                                       35
         STANDARD HARDWARE TORQUES
              NOTE: Unless stated otherwise for a specific assembly, use the
              following torque values when tightening standard hardware.
                                     Pitch                    lb-ft             kg-m
Grade 4
     6mm bolt head/nut               1                     2.9-5.1             0.4--0.7
     8mm bolt head/nut               1.25                  7.2-11.6            1.0-1.6
    10mm bolt head/nut               1.25                 13.7-22.4            1.9-3.1
    10mm bolt head/nut               1.5                  13.0-21.7            1.8-3.0
    12mm bolt head/nut               1.25 (ISO)           25.3-39.8            3.5-5.5
    12mm bolt head/nut               1.5                  25.3-39.8            3.5-5.5
    12mm bolt head/nut               1.75                 21.7-36.2            3.0-5.0
    13mm bolt head/nut               1.5                  32.5-50.6            4.5-7.0
    14mm bolt head/nut               1.5                  36.2-57.9            5.0-8.0
    14mm bolt head/nut               2                    34.0-55.7            4.7-7.7
    16mm bolt head/nut               1.5                  54.2-79.6            7.5-11.0
    16mm bolt head/nut               2                    51.4-76.7            7.1-10.6

Grade6T
     6mm bolt head/nut               1                     4.3-6.5             0.6-0.9
     8mm bolt head/nut               1.25                 10.8-15.9            1.5-2.2
    10mm bolt head/nut               1.25                 21.7-32.5            3.0-4.5
    IOmm bolt head/nut               1.5                  19.5-30.4            2.7-4.2
    12mm bolt head/nut               1.25 (ISO)           36.2-57.9            5.0-8.0
    12mm bolt head/nut               1.5                  36.2-50.6            5.0-7.0
    12mm bolt head/nut               1.75                 34.7-49.2            4.8-6.8

Grade 7T, 8T and 8.8
     6mm bolt head/nut               1                     5.8-8.7              0.8-1.2
     8mm bolt head/nut               1.25                 14.5-21.7             2.0-3.0
    IOmm bolt head/nut               1.25                 28.9-39.8             4.0-5.5
    10mm bolt head/nut               1.5                  26.8-37.6             3.7-5.2
    12mm bolt head/nut               1.25 (ISO)           54.2-75.9             7.5-10.5
    12mm bolt head/nut               1.5                  50.6-65.1             7.0-9.0
    12mm bolt head/nut               1.75                 43.4-61.5             6.0-8.5
    13mm bolt head/nut               1.5                  57.9-86.8             8.0-12.0
    14mm bolt head/nut               1.5                  72.3-108.5           10.0-15.0
    14mm bolt head/nut               2                    68.7-101.3            9.5-14.0
    16mm bolt head/nut               1.5                 108.5-166.4           15.0-23.0
    16mm bolt head/nut               2                   101.3-159.1           14.0-22.0

Grade 5 Cap Screw
    114 UNC                                                    9-11             1.2-1.5
    114 UNF                                                   11-13             1.5-1.8
    5116 UNC                                                  18-20             2.5-2.8
    5116 UNF                                                  21-23             2.9-3.2
    3/8 UNC                                                   28-33             3.7-4.6
    3/8 UNF                                                   30-35             4.1-4.8
    7/16 UNC                                                  44-49             6.1-6.8
    7/16 UNF                                                  50-55             6.9-7.6
    1I2UNC                                                    68-73             9.4-10.1
    112 UNF                                                   73-80            10.1-11.1

                              l-vvl WESJmBEKE
                                     r Engines & Gene",tors
                                             36
               WESTERBEKE 55A FOUR SPECIFICATIONS
                        ENGINE SPECIFICATIONS                                                                  COOLING SYSTEM
Engine Type                  Diesel, four-cycle, four-cylinder, freshwater-        General                         Freshwater-cooled block, thermostatically-
                             cooled, vertical, in-line (55 hp at 3600 rpm                                          controlled with raw water exchanger system.
                             maximum)
                                                                                   Operating Temperature           170 - 190°F (77 - 88°C)
Governor                     Integral of the injection pump, mechanical
                             flyweig ht type                                       Fresh Water Pump                Centrifugal type, metal impeller belt-driven

Valve Mechanism              Overhead                                              Sea Water Pump                  POSitive displacement, rubber impeller,
                                                                                                                   belt driven
Combustion Chamber           Swirl chamber type
                                                                                   Sea Water Flow, at 3600 rpm 16.0 gpm (60.5 Ipm) approximate
Bore &Stroke                 3.38 x 3.70 inches (86.0 x 94.0 mm)                   (measured before discharg-
Piston Displacement          133.2 cubic inches {2.18 liters)                      ing into exhaust elbow)
Firing Drder                 1-3-4-2                                               System Capacity                 9.5 U.S. qts (10.0 liters)
                                                                                   (fresh water)
Direction of Rotation        Clockwise, when viewed from the front
Maximum Torque               93 Ib-ft (12.9 kg-m)                                                           ELECTRICAL SYSTEM
(at 1920 rpm)                                                                      Starting Battery                12-volt, (-) negative ground
Compression Ratio            22.7 :1                                               Battery Capacity                300 - 400 Cold Cranking amps (CCA) (min.)
Compression Pressure         427 psi (3D kg/cm2) at 200 rpm
                                                                                   Starter Motor                   12-volt, 1.6kw, solenoid, actuated shift
Valve Seat Angle             Intake 45°, Exhaust 45°                                                               reduction gear
Valve Clearance              Intake .008 - 0.012 in.{0.20 - 0.30mm)                Starting Aid                    Glow plug
(engine cold)                Exhaust 0.012 - 0.016 in. (0.30 - 0.40mm)
                                                                                   DC No-Load Current              100 amps at 11.5 volts (3000 rpm, min.)
Dimensions                   Height: 26.78 inches (680.2 mm)
                             Width: 50.0 inches (546.1 mm)                         Cold Cranking Current           280 - 300 amps at 10 volts (250 rpm, min.)
                             Length: 35.0 inches (889.0 mm)
                                                                                   Alternator (Standard)           12-volt, DC, 50 amps
Inclination                  Continuous 14°, Temporary 25°
                             (not to exceed 30 min.)                               Regulator                       Internal regulator, built into alternator

Dry Weight                   470 Ibs (213.2 kgs)                                                                  TRANSMISSION
Engine Speed                  Idle speed: 750 - 1000 rpm                           General                         (Hurth Standard Transmission) Case-
                              Cruising speed: 2500 - 3000 rpm                                                      hardened helical gears, with a servo-
                              No load: 4200 - 4500 rpm                                                             operated multiple disc clutch.
Fuel Consumption             1.5 U.S. gph (5.6 Iph) running at 2500 rpm            Gear ratio (standard)           2.74: 1 (HBW250 - 3R)
                             (approximate) when the 'propeller allows
                             3600 rpm at full open throttle while                  Propeller Shaft Direction       Right handed - standard transmission
                             un~erway in forward gear.                             of Rotation
                                                                                   Propeller Recommendations       20 Dx 13 P- 2 blade or 20 Dx 11 P- 3 blade
                            FUEL SYSTEM                                            (using standard transmission    propeller should allow the engine to reach its
                                                                                   2.74:1 reduction)               full rated rpm (3600 + 000 - 100) at full
Fuel                          No.2 dies'el oil                                                                     open throttle while underway in forward
                              (cetane rating of 45 or higher)                                                      gear.
Injection Pump               Zexel mechanical governed                             Lubricating Fluid               ATF - type A or Dextran - /I OR 11/
Injection Timing             OOTDC                                                 Transmission Sump               0.79 U.S. qts (0.75 liters) approximate
                                                                                   Capacity
Injectors                    Th rottle type
Injection Pressure            1920 psi + 71 psi
                                                                                                            ENGINE OIL SYSTEM
                              (135 kg/cm 2+ 5 kg/cm2)
                                                                                   General                         Pressure feed, rotor type, driven by spiral
Lift Pump                     12 volt - plunger type                                                               gears from camshaft
Fuel Filter (on engine)       Spin-on type (replaceable)                           Oil Filler                      Full flow, paper element, spin-on type

Air Cleaner                   Replaceable paper filter element                     Sump Capacity                   4.5 U.S. qts (5.9 liters) including filter

Air Flow                                                                           Operating Oil Pressure          30 - 60 psi (2.1 - 4.2 kg/cm2) at maximum
(engine combustion)           140 cfm (3.9 cmm) at 3600 rpm                                                        engine rpm and at normal operating
(engine cooling)              250 cfm (7.0 cmm) .                                                                  temperature
                                                                                   Oil Grade                       API Specification CF or CG4
                          EXHAUST SYSTEM
Exhaust Elbow                 45° elbow
Exhaust Hose Size             2-1/2 inch 1.0. hose
Muffler Size (min.)           14 inch x 14 inch


                                                           I"VtTI WESJERBEKE
                                                                   (Engines & Generators
                                                                                                                                                         Revised
                                                                                                                                                         October 2000
                                                                              37
  WESTERBEKE CORPORATION· AVON INDUSTRIAL PARK
  AVON, MA 02322· TEL: (508) 588-7700 · FAX: (508) 559-9323

 ---
~ Member National Marine ManufacturersAssocUztion


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