Westerbeke Diesel 44a Four Technical Manual

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Engines Generators I EUROPEAN MARITIME COUNCIL REGISTRATION EUROPEAN ECONOMIC COUNCIL INTERNATIONAL MARINE CERTIFICATION INSTITUTE Rond Point Schuman 6 Box 6 B t040 BRUXELLES BELGIQUE tel 32 OJ 22387892 fax 32 OJ 22387700 CERTKFKCATE We hereby certify that the enginessstated below meet the EC Directive 9425EC 19991MC1 Power Rating Report I MANUFACTURER I Westerbeke Corporation I I ADDRESS I 150 John Hancock Road Myles Standish Industrial Park Taunton MA 02780 USA I MODEL NAME I 3SCThree SPECIFICATIONS EnaineType Inboard Fuel Type Diesel Aspiration Type Natural Ratina Level Hiahest Output 1 jgL 3J4Lowest Power jkW21 267 267 267 267 Propeller shaft Power kW20 267 267 267 267 at RPM min3600 267 267 267 267 CertHication Number WESTERIDOQ4 Signed I rU 7Name Lars E Granholm litle Managing Director EU Not Hied Body No 0609 Date 3April2000 verHication statement Power rating is in with IMCI I verHied in I wijh ISO 8665 and ISO 15584 only for inboard petrol en linesThis application form has not been lodged with any other notHied body Company Date Name Carl F Bryant litle 7 225 Chief Operatina Officer Signature 1YYA or Engines Generators 58 AdobeUCS2 3 4 SPARE PARTS WESTERBEKE MARINE DIESEL ENGINES CONTACT YOUR WESTERBEKE DEALER FOR SUGGESTIONS AND ADDITIONAL INFORMATION HARDWARE KIT RAW WATER PUMP IMPELLERGASKET AIR INTAKE FILTER WATER SEPERATOR FILTER FUEL LIFT PUMP WESTERBEKE RECOMMENDS CARRYING ENOUGH SPARE ENGINE OIL YOUR BRANDFOR AN OIL CHANGE 5 OTSAND A GALLON OF PREMIXED COOLANT SPARE PARTS KITS WESTERBEKE also offers two Spare Parts Kits each packaged in a rugged hinged toolbox Kit A includes the basic spares Kit B is for more extensive offshore cruising A Kit Impeller Kit Heat Exchanger Gasket Fuel Filter with Gasket Oil Filter Drive Belt Zinc Anodes I fIVWESTERBEKE I EnaitJes Generators 56 B Kit Impeller Kit Water Pump Repair Kit Thermostat Kit Zinc Anodes Complete Gasket Kit Heat Exchanger Gasket Injector Fuel Filter with Gasket Oil Filter Drive Belt AND METRIC CONVERSION DATA LENGTHDISTANCE Inches inx 254 Millimeters mmx 0394 Inches Feet ftx 305 Meters mx 3281 Feet Miles x 1609 Kilometers kmx 0621 Miles VOLUME Cubic Inches in3x 16387 Cubic Centimeters x 061 i n 3 Imperial Pints IMP ptx 568 Liters Lx 176 IMP pt Imperial Quarts IMP qtx 1137 Liters Lx88 IMP qt Imperial Gallons IMP galx 4546 Liters Lx 22 IMP gal Imperial Quarts IMP qtx 1201 US Quarts US qtx 833 IMP qt Imperial Gallons IMP galx 1201 US Gallons US galx 833 IMP gal Fluid Ounces x 29573 Milliliters x 034 Ounces US Pints US ptx 473 LitersLx 2113 Pints US Quarts US qtx 946 Liters Lx 1057 Quarts US Gallons US galx 3785 Liters Lx 264 Gallons MASSWEIGHT Ounces ozx 2835 Grams gx 035 Ounces Pounds Ibx 454 Kilograms kgx 2205 Pounds PRESSURE Pounds Per Sq In psix 6895 Kilopascals kPax 145 psi Inches of Mercury Hgx 4912 psi x 2036 Hg Inches of Mercury Hgx 3377 Kilopascals kPax 2961 Hg Inches of Water H20x 07355 Inches of Mercury x 13783 H20 Inches of Water H20x 03613 psi x 27684 H20 Inches of Water H20x 248 Kilopascals kPax 4026 H20 TORQUE PoundsForce Inches inIbx 113 Newton Meters Nmx 885 inIb PoundsForce Feet ftIbx 1356 Newton Meters Nmx 738 ftIb VELOCITY Miles Per Hour MPHx 1609 Kilometers Per Hour KPHx 621 MPH POWER Horsepower Hpx 745 Kilowatts Kwx 134 MPH FUEL CONSUMPTION Miles Per Hour IMP MPGx 354 Kilometers Per Liter KmLKilometers Per Liter KmLx 2352 IMP MPG Miles Per Gallons US MPGx 425 Kilometers Per Liter KmLKilometers Per Liter KmLx 2352 US MPG TEMPERATURE Degree Fahrenheit OF OC X 18 32 Degree Celsius 0C OF 32x 56 Engines Generators 55 FHbNmFHbNm261 4 12 16 261 5 261 3 261 4 1 3 2 5 44A 448 FOUR ENGINE SPECIFICATIONS Engine Type Displacement Aspiration Combustion Chamber Bore Stroke Firing Order Direction of Rotation SPECIFICATIONS Diesel fourcycle fourcylinder fresh water255cooled vertical inline overhead valve mechanism 1073 cubic inches 1758 literNaturally aspirated Swirl type 307 x 362 inches 78 x 92 mm1 3 42 Clockwise when viewed from the front Compression Ratio 221 Dimensions inches mmHeight 186 inches 4724 mmEngine Only Width 230 inches 5842 mmWeight Fuel Consumption Inclination Length256 inches 9144 mm331 Ibs 150 kgswithout transmission 25 glhr 97Itrlhrat 3600 rpm Continuous 15260 Temporary 25260 not to exceed 30 minTUNEUP SPECIFICATIONS Compression Pressure 427 psi 30 kgcmat 280 rpm Minimum 384 psi 27 kgcmValve liming I ntake Opens Intake Closes Spilled liming Static17260 spillValve Seat Angle 45260 Engine Speed 3600 rpm 44AlFour3000 rpm 44BFourValve Seat Angle Intake 45260 Exhaust 30260 Valve Clearance 025 inches 00098 mmengine coldInjector Pressure 1991 71 0 psi 140 5 0 kgfcmEngine liming 17260 BTDC ELECTRICAL SYSTEM Starting Battery Battery Capacity DC Charging Alternator Starting Aid Starter 12 Volt negative ground 400 600 Cold Cranking Amps CCA51 Amp rated beltdriven Glow plugs sheathed type 12 Volt reduction gear General Fuel Fuel Injection Pump Nozzle Fuel Filter Air cleaner AirAow engine combustionFuel Lift Pump General Operating Temperature Fresh Water Pump Raw Water Pump Raw Water Flow measured before discharge into exhaust System Capacity Fresh WaterFUEL SYSTEM Open flow self priming No2 diesel oil cetane rating of 45 or higherInline plunger type BOSCHThrottle type Spinon replaceable Replaceable paper filter cartridge 140 cfm 39 cmmat 3600 rpm 93 cfm 262 cmmat 3000 rpm 12 volt DC lift capacity of 5 15 mmsolid state COOLING SYSTEM Fresh watercooled block with heat exchanger 170 190260 F 77 88260 CCentrifugal type metal impeller beltdriven Positive displacement rubber impeller beltdriven 44AJFour 44BFour 95 gpm at 3600 rpm 80 gpm at 3000 rpm 26780 US qts 76 SYSTEM General Oil Filter Sump Capacity not including Oil Pressure engine hotOil Grade Pressure fed system Full flow paper element spinon type 52 US qts 54 liters50 60 psi 35 42 kgcmAPI Specification CF or CG4 SAE 30 10W30 15W40 Rev July 2002 Engines Generators 51 J Clean the filter screen in the flame arrester and place a clean cloth lightly soaked in lube oil around the flame arrester to block any opening Also place an oilsoaked clqth in the throughhull exhaust port Make a note to remove cloths prior to startup Intake Manifold and ThruHull clean cloth Engine J Check or change the fluid in the transmission as required Wipe off grime and grease and touch up any unpainted areas Protect the coupling and the output flange with an coating Check that the transmission vent is open For additional information refer to the TRANSMISSION SECTION Spare Parts Layup time provides a good opportunity to inspect your WES1ERBEKE engine to see if external items such as drive belts or coolant hoses need replacement Check your basic spares kit and order items not on hand or replace those items used during the layup such as filters and zinc anodes Refer to SPARE PARTS section of this manual The of your WES1ERBEKE engine after a seasonal layup generally follows the same procedures as those presented in the PREPARATIONS FOR STARTING section regarding preparation for starting and normal starts However some of the layup procedures will need to be counteracted before starting the engine 1 Remove the oilsoaked cloths from the intake manifold 2 Remove the raw water pump cover and gasket and discard the old gasket Install the raw water pump impeller removed during layup or a replacement if the raw water pump cover with a new cover gasket 3 Reinstall the batteries that were removed during the lay255up and reconnect the battery cables making sure the terminals are clean and that the connections are tight Check to make sure that the batteries are fully charged A CAUTION Wear rubber gloves a rubber apron and eye protection when servicing batteries Lead acid batteries emit hydrogen a highly explosive gas which can be ignited by electrical arcing Dr a lighted cigarette cigar Dr pipe Do not smoke Dr allow an open flame near the battery being serviced Shut off all electrical equipment in the vicinity to prevent electrical arcing during servicing 4 Remove the spark plugs wipe clean regap and install to proper tightness any and AdobeUCS5 5 RECOMMENDATION CHART 44A FOUR 40 hp3600 rpm35C THREE 29 hp3600 rpm44B FOUR 39 hp3000 rpm35C THREE 31 hp3000 RATIO PROPELLER DIAMETERPITCH PROPELLER BLADE RH201 225225225225 170 x 10P 225 2 Blade 170 x BP 225225225 3 Blade 2471 225225 1BO x 11P 225225225225 2 Blade 1BO x 9P 3 Blade 2721 225 1BO x 13P 225225225 2 Blade 1BO x 11P 225225 3 Blade 2991 200 x 13P 225 2 Blade 200 x 11P 3 Blade 201 225225225225 140x 10P 2 Blade 140 x BP 225225 3 Blade 2471 225225225 160 x 11P 225225225225 2 Blade 160 x 9P 3 Blade 2631 170 x 13P 225225 2 Blade 170 x 11P 3 Blade 2991 225 1BO x 13P 2 Blade 1BO x 11P 225225225225 3 Blade 201 225225225 170 x 11P 225225225225 2 Blade 170 x 9P 225225225 3 Blade 2471 225225 200 x 13P 225 2 Blade 200 x 11P 225 3 Blade 2721 225225225 200 x 14P 2 Blade 200 x 12P 3 Blade 2991 225225 220 x 15P 2 Blade 220 x 13P 225225225 3 Blade 201 160 x 10P 2 Blade 160 x BP 225225225225 3 Blade 2471 225 1BO x 13P 225225225225 2 Blade 1BO x 11P 225225225 225225225 3 Blade 2721 200 x 12P 225225 2 Blade 200 x 10P 225 3 Blade 2991 225225 220 x 13P 225225225225 2 Blade 220 x 11P 225225 3 Blade NOTE For reductions not included consult the WESTERBEKE factory for Engines Generators 48 the transmission AdobeUCS A AdobeUCSPRM NEWAGE TRANSMISSIONS MODELS 80 AND 120 THE MODEL 720 HAS A BREATHER FITTING ON THE TOP OF THE CASE Push a suction pump hose down through the dipstick hole to the bottom of the housing and suck out the fluid If space allows use the transmission drainRemove the drain plug from the bottom of the transmission I with sealing washerand allow the fluid to drain into a container then reinstall the plug with its sealing washer Wipe down the transmission and properly dispose of the used fluid After running the engine shut down and recheck the fluid level rllDnrV 72 HEX PLUG MODEL 80 MODEL 720 USES NOTE When changing the fluid take care not to lose the A 8MM HEX PLUG drain plug sealing washer The drain plug will leak without this sealing washer A WARNING Never pullout the dipstick while the engine is running Hot fluid will splash from the dipstick hole This could cause severe burns DAILY OPERATION o Check the transmission fluid FULL 0 Visually check the gear shift linkage and transmission o Start the engine in neutral allowing a few minutes at LOW idle to warm the fluid 0 Shift into gear Too low an idle speed will produce a chattering noise from the transmission gear and damper plate In such cases SEAUNG WASHER the idle speed should be increased GEAR SHIFTING INITIAL OPERATION Remove the dipstick and fill the gear box with automatic transmission fluid ATFDextron m Fill the transmission with the recommended capacity of fluid Model PRM8010 US pint 06LModel PRM 12014 US pints 08LNOTE Always clean the area around the dipstick plug before filling with fluid Replace the dipstick by screwing it down Run the engine to warm up the fluid and after shutting down the engine recheck the fluid level CHANGING THE TRANSMISSION FLUID Change the fluid for the first time after about 25 hours of operation then every 250 operating hours or at least once a year or when you change engine oil Check for leaks and make a visual inspection of the shift cables and shaft coupling The engine must be at idle Pause in neutral before selecting ahead or astern Transmission models PRM 80 and 120 are ideal for single lever engine controls controlling both the throttle and the gear shift at one time A WARNING When shifting gears bring the engine throttle to idle and pause in neutral before shifting ahead or astern LOCKING THE PROPELLER Locking of the propeller shaft by an additional brake is not required use the gear shift lever position opposite your direction of travel for this purpose Never put the gear shift in the position corresponding to the direction of travel of the boat WHEN UNDER SAIL OR BEING TOWED Rotation of the propeller without load such as when the boat is being sailed being towed or anchored in a river as well as operation of the engine with the propeller stopped for charging the batterywill have no detrimental effects on the transmission Engines Generators 45 hardware the AdobeUCSshift cover be made speed should smells rancid AdobeUCSBORG WARNER VELVET DRIVE TRANSMISSION OPTIONAL TRANSMISSION 44 FOUR ONLY OIL BORG WARNER VELVET DRIVE SHIPMENT For safety reasons the transmission is not filled with fluid during shipment and the selector lever is tem225 porarily attached to the actuating shaft Before leaving the WESTERBEKE plant each transmission undergoes a test run with Dextron III ATF transmission fluid The residual fluid remaining in the transmission after drain255ing acts as a preservative and provides protection against corrosion for at least one year if properly stored TRANSMISSION FLUID Check the transmission fluid level on the dipstick If the transmission has not been filled fill with Dextron III and continue to use this fluid During the first 25 hours of opera255tion keep a lookout for any leakage at the bell housing out255put shaft and transmission cooler This fluid should be changed after the first 25 hours and approximately every 300 operating hours thereafter andor at winter layup A CAUTION Be certain the transmission is filled and the correct size cooler is properly installed before starting the engine SHIFT LEVER POSITION The gear shift control mechanism and linkage must position the actuating lever on the transmission exactly in Forward FNeutral Nand Reverse Rshifting positions A detent ball located behind the transmission lever must work freely to center the lever in each position The gear shift positions at the helm must be coordinated with those of the Velvet Drive actuating lever through shift mechanism adjustments An improperly adjusted shift mechanism can cause damage to the transmission The shifting mechanism and transmission actuating lever should be free of dirt and well lubricated to ensure proper operation Shifting Into Gear Place the gear shift in Neutral before starting the engine Shifting from one selector position to another selector posi255tion may be made at any time below 1000 rpm and in any order Shifts should be made at the lowest practical engine speed Start the engine and set the throttle at idle speed allow the transmission fluid to warm up for a few minutes Neutral Move the gear shift lever to the middle position You should feel the detent This centers the actuating lever on the With the control in this position hydraulic power is completely interrupted and the output shaft of the does not tum NOTE Some transmissions are equipped with a neutral safety switch Unless the transmission actuating lever is perfectly aligned in neutral the engine starter will not activate Forward Move the gear shift lever to the forward position You should feel the detent The actuating lever on the transmission is in the forward position The output shaft and the propeller shaft move the boat in a forward direction Reverse Move the gear shift lever to the reverse position You should feel the detent The actuating lever on the transmission is in the reverse position The output shaft and the propeller should move the boat in a reverse direction asternNOTE Moving the transmission actuating lever from Neutral Position to Forward is always toward the engine Reverse is always away from the engine If boat moves backwards with the gear shift control in the forward position shut off the engine This problem may be a result of incorrect movement of the actuating lever by the gear shift lever Engines Generators 39 AdobeUCS 1 water water AdobeUCSa 6 AdobeUCS2 3 AdobeUCSfilter is AdobeUCS1000 calibration adjustment the AdobeUCSENGINE The following table describes certain problems relating to engine service the probable causes of these prob255lems and the to overcome these problems NOTE The engine s electrical system is protected by a 20 ampere manual reset circuit breaker located on a bracket at the back of the engine The preheat solenoid is mounted on the same bracket Problem No panel indications fuel solenoid 1 or fuel pump is not working key switch is on and PREHEAT button is depressed2 3 4 5 START button is depressed no starter 1 engagement 2 3 4 5 6 START button is depressed panel 1 indications OK starter solenoid OK fuel solenoid not functioning 2 Engine cranks but does not 1 start fuel solenoid energized 2 3 Engine cant be stopped 1 2 3 Battery runs down 1 2 3 4 5 Battery not charging 1 2 Probable Cause Battery switch not on 20amp circuit breaker tripped 10amp breaker tripped on preheat solenoid Loose battery connections Preheat solenoid not operating Connection to solenoid faulty Gear shift not in neutral Faulty switch Faulty solenoid Loose battery connections Low battery Poor connections to fuel solenoid Defective fuel solenoid Faulty fueling system Preheat solenoid faulty Low battery power Faulty DC altemator Disconnect fuel shutoff cable Fuel run solenoid will not deenergize Oil pressu re switch High resistance leak to ground Low resistance leak Poor battery connections DC altemator not charging tachometer not operatingDC charge circuit faulty Alternator drive 1 Check switch andor battery connections 2 Reset breaker if breaker trips again check preheat solenoid circuit and check circuit for shorts to ground 3 Check the voltage both at and after the breaker on the preheat solenoid 4 Check connection to starter solenoid and connection to engine ground stud Check battery cable connections 5 Check solenoid S terminal for voltage 1 Check connection 2 Gear shift must be in neutral see NEUTRAL SWITCH under HURTH HSW TRANSMISSIONS3 Check switch with ohmmeter 4 Check that 12 volts are present at the solenoid connection 5 Check battery connections 6 Check battery charge state 1 Check connections 2 Check that 12 volts are present at the connection on the fuel run solenoid 1 Check that fuel valves are open 1 a Check for air in fuel system Bleed air from fuel system 1b Fuel filters clogged Replace filters and bleed air from fuel system 2 Check solenoid 3 Switch to combine house and start batteries 3a Replace batteries 1 2 3 1 2 3 4 5 1 2 Remove Exc connection at alternator repair alternator Check connection at shutoff lever Pull lever back to close off the fuel Manually disconnect the 12 volt connection to the fuel run solenoid at the injection pump Observe if gauges and panel lights are activated when engine is not running Test the oil pressure switch Check wiring Insert sensitive 0 25 ampmeter in battery lines Do not start engineRemove connections and replace after short is located Check all wires for temperature rise to locate the fault Check cable connections at battery for loose connections corrosion Check connections check belt tension test alternator See DC ELECTRICAL Perform DC voltage check of generator charging circuit See Testing the Battery Charging Circuit Check drive belt tension alternator should turn freely Check for loose connections Check output with voltmeter Ensure 12 volts are present at the Exc terminal Generators 31 AdobeUCSTO THE START SWITCH TO THE TACHOMETER GROUND TO THE B TERM OF KEYSWITCH TO THES TERM OF KEYSWITCH TO THE 5 TERM OF WT GUAGE fill 0 THE P TERM OF ALARM BUZZER o THE C TERM OF ALARM BUZZER iiJln TO THE I TERM OF KEYSWITCH iii TO THES TERM OF TACH o THE TERM OF ALARM BUZZER il I 01 0 Ii 0 0 110 WHT I 114 GRH 110 RED 114 PUR 114 VEL 114 L T BLU 114 TAN 110 REDWHT 114 BRH 114 PINK rl I 10 I a IIJ n I II I I I I I I e II s n Z i Gt aPi 111 a eZ z Gt m eII em a z 0 n m 0 z t Z en m eoen 01 273 II I t SOL SURfER MARINE ENGINE WIRING SCHEMATIC 39144 NOTES 12 VDC r THIS PRODUCT IS PRQTICTED BY A MANUAL RESET CIRCUIT BREAKER LOCATED NEAR THE STARTER ExCESSIVE CURRENT WilL CAUSE THE BREAKER TO TRIP AND THE ENGINE Will SHUT DCWN THE BUILDEROWNER MUST BE SURE THAT THE INSTRUMENT PANEL WIRING AND BAT KEY sw IG ENGINE ARE INSTALLED TO PREVENT CONTACT BETWEEN ELECTRICAL DEVICES AND SEAWATER 2 AN QNOFF SWITCH SHOULD BE INSTALLED BETWEEN THE BATTERY AND STARTER TO 1 I DISCONNECT THE BATTERY IN AN EMERGENCY AND WHEN LEAVING THE BOAT A SWITCH WITH A CONTINUOUS RATING OF 175 AMPS AT 12 voe Will SERVE THIS FUNCTION THI SWITCH SHOULD NOT BE USED TO MAKE OR BREAK THE CIRCUIT THE PINK WIRE AT PLUG 2 IS UNUSED AND SHOULD BE INSULATED CAPTAIN PANEL ONLY 4 THE GRAY WIRE AT PLUG 2 IS UNUSED AND SHOULD I3E INSULATED ADMIRAL PANEL ONLY LIFT PUMP MITSU81SHI 50 AMP ALT FUEL lfHN r OP SENDER 1 14 GRA 90 AMP ALT TACHOMETER OUltO s GNO ADMIRAL PANEL o ALARM SATTUY 225 U RED AC TA 14 eRtl VOL TMETER GNINOTE WIRE FOR 6ATTERY ATTATCHMENT WILL NEED TO BE UPGRADED TO AN 8 GAUGE FROM 10 GAUGE 0 OP GAUGE GNO LAMP TEST sw CAPTAIN PANEL 51 AMP ALTERNATOR STANDARD ALTERNATOR ON THE 638 Il 63C Il liB Il 828 or 1088 D 108C267D PRESTOllTE 72 AMP ALI 14 8RN 14 GRA 14 PINK 14 LT BL UNIVERSAL PROPULSION PRESTOLlTE 51 AMP ALL ALE CONNECTOR ON THIS SIDE RED OPT I ONAl ALTERNATORS 256 135A 160A liOA LESTEK ALTERNATORS 0 63C n 718 II IlZ8Jb 198ft XI 10llC iI 0HLV Engines Generators 28 Revised December 2002 AdobeUCSSEE NOTE I I I I I NOTE An onoff switch should be installed in this circuit to disconnect the starter from the battery in an emergency and when leaving the boat Twelve volt engine starters typically draw 200 to 300 amps when cranking A switch with a continuous rating of 175 amps at 12 VDC will normally serve this function but a switch must never be used to make the starter circuit rMARINE ENGINE WIRING DIAGRAM 39144 rI I 0 AED PI o p ALARM C BUZZER ALT 225 GP 225 ADMIRAL PANEL CAPTAIN PANEL T LIFT PUMPS l 11 elK e BLK slIe l Engines Generators 27 Revised December 2002 AdobeUCSDC ELECTRICAL SYSTEM 7 Now check the voltage between the alternator output ter255minal Band ground If the circuit is good the voltage at the alternator will be the same as the battery or if an isola255tor is in the circuit the alternator voltage will be zero If neither of the above is true a problem exists in the circuit between the alternator and the battery Check all the connections look for an opening in the charging circuit TESTING THE STARTING BATTERY IALTERNATOR ENGINE RUNNINGENGINE c GROUND 8 Start the engine again Check the voltage between the alternator output and ground The voltage reading for a properly operating alternator should be between 135 and 145 volts If your alternator is overor undercharging have it repaired at a reliable service facility NOTE Before removing the alternator for repair use a voltmeter to ensure that 12 volts DC excitation is present at the EXC terminal if the previous test showed only bat255tery voltage at the B output terminal If 12 volts is not present at the EXC terminal trace the wiring and lookfor breaks and poor connections 12 VOLT DC CONTROL CIRCUIT The engine has a 12 volt DC electrical control circuit that is shown on the wiring diagrams that follow Refer to these diagrams when or when servicing the DC electrical system A CAUTION To avoid damage to the battery charging circuit never shut off the engine battery switch while the engine is running Shut off the engine battery Switch however to avoid electrical shorts when working on the engines electrical circuit BATTERY The minimum recommended capacity of the battery used in the engines 12 volt DC control circuit is 600 900 Cold Cranking Amps CCAChecking the Service Battery Check the voltage of the service battery This battery should have a voltage between 13 and 14 volts when the engine is running If not there is a problem in the service battery charging circuit Troubleshoot the service battery charging circuit by checking the wiring and connections the solenoid isolator battery switch and the battery itself MUlTIMETE G COM GROUND SERVICE BATTERY TESTING THE SERVICE BATTERY ENGINE RUNNINGA CAUTION To avoid damaging the altemator diodes do not use a high voltage tester ie a meggerwhen performing tests on the altemator charging circuit Battery Care Review the manufacturers and then establish a systematic maintenance schedule for your engines starting batteries and house batteries o Monitor your voltmeter for proper charging during engine operation o Check the electrolyte level and specific gravity with a hydrometer o Use only distilled water to bring electrolytes to a proper level o Make certain that battery cable connections are clean and tight to the battery posts and to your engineo Keep your batteries clean and free of corrosion A WARNING Sulfuric acid In lead batteries can caUSII severe burns on skin and damage clothing Wear protective gear Engines Generators 26 along with AdobeUCStanks location AdobeUCSREMOTE OIL FILTER OPTIONAL INSTALLATION This popular accessory is used to relocate the engines oil fil255ter from the engine to a more convenient location such as an engine room bulkhead NOTE Refer to ENGINE OIL CHANGE in this manualfor instructions on removing the oil filter APPLY A THIN COAT OF CLEAN OIL TO THE ORING WHEN INSTALLING THIS KIT THREAD THE KIT ON THEN HAND TIGHTEN AN ADDITIONAL 34 TURN AFTER THE ORING CONTACTS THE BASE NOTE THE IN AND OUT MARKINGS ON THE ADAPTER WHEN THE HOSES ARE REMOVED FOR INSTALLATION SO THEY WILL BE RECONNECTED CORRECTLY A CAUTION It is vital to install the oil lines cor255rectly If the oil flows in the reverse the by255pass valve in the filter assembly will prevent the oil from reaching the engine causing an Intemal engine failure If there is no oil pressure shutdown immediately and check the hose connections To install simply remove the engine oil filter and thread on WESTERBEKEs remote oil filter kit as shown Always install this kit with the oil filter facing down as illustrated Contact your WESTERBEKE dealer for more information NOTE Westerbeke is not responsible for engine failure due to incorrect installation of the Remote Oil Filter FASTEN SECURELY TO A BULKHEAD SCREWS ARE OWNER SUPPLIEDAPPLY A THIN267 COAT DF CLEAN OIL TO THE FIL255TER GASKET WHEN INSTALLING AFTER THE FILTER CDNTACTS THE BASE TIGHTEN IT AN ADDITIONAL 34 TURN Engines Generators 23 AdobeUCSm oil pressure AdobeUCSENGINE LUBRICATING OIL BMM LUBRICATION DIAGRAM OIL PRESSURE OIL PRESSURE lHI SWITCH OIL ENGINE OIL CHANGE 1 Draining the Oil Sump Discharge the used oil through the sump drain hose attached to the front of the enginewhile the engine is warm Drain the used oil completely replace the hose in its bracket and replace the end cap securely NOTE Thread size for the lube oil drain hose capped end is 114NPT 1116 INCH SOCKET ORAl HOSE Always observe the used oil as it is removed A yellowgray 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 quali255fied mechanic should water be 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 andor a siphoning of raw water through the raw water cooling circuit into the exhaust filling the engine This problem is often caused by the absence of an antisiphon valve its poor location or lack of maintenance 2 Replacing the Oil Filter When removing the used oil fil255ter 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 A small automotive filter wrench should be helpful in removing the old oil filter NOTE Do not punch this hole without first loosening the filter to make certain it can be removed Place some paper towels and a plastic bag around the fil255ter when unscrewing it to catch any oil left in the filter Oil or any other fluid on the engine reduces the engines cooling ability Keep your engine cleanInspect the old oil filter as it is removed to make sure that the rubber sealing gasket comes off with the old oil filter If this rub255ber sealing gasket remains sealed against the filter bracket gently remove it SEALING GASKET APPLY CLEAN ENGINE OIL WHEN INSTALLING SPIN ON TURN ON HAND TIGHT When installing the new oil filter element wipe the filter gaskets sealing surface on the bracket free of oil and apply a thin coat of clean engine oil to the rubber gasket on the new oil filter Screw the filter onto the threaded oil filter nipple on the oil filter bracket and then tighten the filter firmly by hand NOTE Generic filters are not recommended as the mater255ial standards or diameters of important items on generic parts might be entirely different from genuine parts Immediately after an oil filter change and oil fill run the engine to make sure the oil pressure is normal and that there are no oil leaks around the new oil filter 3 Filling the Oil Sump Add new oil through the oil filler cap on the top of the engine or through the side oil fill After refilling run the engine for a few moments while checking the oil pressure Make sure there is no leakage around the new oil filter or from the oil drain system and stop the engine Then check the quantity of oil with the lube oil dipstick Fill to but not over the high mark on the dipstick should the engine require additional oil Engines Generators 21 AdobeUCS6 AdobeUCSfollow the SYSTEM Zinc Anode or pencil is located in the raw water cooling CIrCUIt wIthin the heat exchanger The purpose of having zinc is to sacrifice them to electrolysis action taking place In the raw water cooling circuit thereby reducing the effects of electrolysis on other components of the system The condition of the zinc anode should be checked monthly and the anode cleaned or replaced as required Spare anodes should be carned on board NEW REPLACE CLEAN REUSE NOTE Electrolysis action is the resultof each particular installation and vessel location not that of the engine If the zinc anodes need replacement hold the hex boss into which the zinc anode is threaded with a wrench while loos255ening the anode with another wrench This prevents the hex boss from possibly tearing off the exchanger shell After removing the zinc note the condition of it If the zinc is in poor condition there are probably a lot of zinc flakes within the exchanger Remove the end of the heat exchanger and clean the inside of all zinc debris Always have a spare heat exchanger end gasket in case the present one becomes dam255aged when removing the end cover Replace the gasket refer to your engine models heat exchanger end gasket part num255berOring and cover and install a new zinc anode NOTE The threads of the zinc anodes are pipe threads and do not require sealant Sealant should not be used as it may insulate the zinc from the metal of the heat exchanger hous255ing preventing electrolysis action on the zinc Heat Exchanger Service After approximately 1000 hours of operation remove clean and pressure test the engines heat exchanger A local auto255motive radiator shop should be able to clean and test the heat exchangerNOTE Operating in silty andor tropical waters may require that a heat exchanger cleaning be performed more often than every 1000 hours AIR INTAKE I SILENCER Description A marine diesel engine running at high speed will typically consume more than 6000 cubic feet of air per hour Not only must the engine room be well ventilated the air flow into the engine must be unrestricted Air Filter The air filter cartridge prevents engine room dust and dirt from entering the engine Maintenance The filter should be cleaned every 100 operating hours Tap the cartridge on a flat surface to dislodge loose dirt or clean off with compressed air If the cartridge is badly contaminated or oily replace it Engines Generators 18 CARTRIDGE AdobeUCSwill always AdobeUCSblock drain sure cap around unfasten the D D D D D D D D D D D D D D D D D D D D D 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 THE DAILY OPERATION CHECK LIST Follow this check list each day before starting your engine D Record the hounneter reading in your log engine hours relate to the maintenance scheduleD Visually inspect the engine for fuel oil or water leaks D Check the oil level dipstickD Check the coolant level in the coolant recovery tank Periodically check the manifold coolant level D Check the transmission fluid level D Check your diesel fuel supply D Look for clean fuel in the fuel filterwater separator trans255parent bowl D Check for loose wires at the alternator and make sure its mounting is secure D Check the starting batteries weeklyD Check drive belts for wear and proper tension weeklyD Check the raw water pump to make sure its mounting is secure STARTING THE ENGINE NOTE See PROCEDURE in this manual for more detailed instructions 1 Put the transmission in neutral throttle advanced NOTE Hydraulically operated transmissions have a neutral safety switch through which the starter solenoid energizing circuit passes This switch is open when the transmission is in gear so the starter solenoid will not energize 2 Tum the KEY to the ON position 2 oclock3 Depress PREHEAT 10 to 15 seconds4 While pressing PREHEAT push START As the engine fires release START S Hold PREHEAT until the oil pressure reaches 15 psi andor the alarm shuts off NOTE Some unstable running may occur in a cold engine This condition should abate as normal operating temperature is reached and loads are applied NOTE Should the engine fail to start wait 30 seconds then repeat the above procedure and PREHEAT longer 6 Allow a few minutes for the engine to warm at a com255fortable rpm approximately 1000 rpmthen reduce the rpm and get underway Engines Generators 12 ENGINE BREAKIN PROCEDURE DESCRIPTION Although your engine has experienced a minimum of one hour of test operations at the factory to make sure accurate assembly procedures were followed and that the engine oper255ated properly a breakin time is required The service life of your engine is dependent upon how the engine is operated and serviced during its initial 50 hours of use Breakingin a new engine basically involves seating the pis255ton rings to the cylinder walls Excessive oil consumption and smoky operation indicate that the cylinder walls are scored which is caused by overloading the engine during the breakin period Your new engine requires approximately 50 hours of initial conditioning operation to break in each moving part in order to maximize the performance and service life of the engine Perform this conditioning carefully keeping in mind the fol255lowing 1 Start the engine according to the STARTING PROCE255DURE section Run the engine at fast idle while checking that all systems raw water pump oil pressure battery chargingare functioning 2 Allow the engine to warm up preferably by running at fast idleuntil the water temperature gauge moves into the 130 1400P 55 60260Crange 3 While using the vessel run the engine at various engine speeds for the first 25 hours Avoid prolonged periods of idling 4 Avoid rapid acceleration especially with a cold engine S Use caution not to overload the engine The presence of a grey or black exhaust and the inability of the engine to reach its full rated speed are signs of an overload 6 During the next 25 hours the engine may be operated at varying engine speeds with short runs at full rated rpm Avoid prolonged idling during this breakin period CHECK LIST o Monitor the control panel gauges o Check for leaks of fuel and engine oil o Check for abnormal noise such as knocking friction vibration and blowback sounds o Confirm exhaust smoke When the engine is cold white smoke When the engine is warm almost smokeless When the engine is overloaded some black smoke and soot NOTE See the TRANSMISSION section of this manual for breakin information on your transmission Engines Generators 11 5 PROCEDURE THE STARTING SYSTEM The 44N35Cdiesel engine has a 12V DC electric starter The start circuitry is designed so that the PREHEAT button must be depressed for the time specified in the preheat chart Then while keeping the PREHEAT button engaged the START button is depressed to crank the engine Starting Procedure 1 Place the transmission in neutral and advance the throttle control to slightly open A CAUTION Make certain the transmission is in neutral Starting in gear could result in serious damage to your transmission your boat and vessels nearby 2 Tum the KEY SWITCH to the ON position 2 oclock3 Depress the PREHEAT switch The voltrrieter panel lights gauges meters and fuel solenoid will be activated The PREHEAT switch should be depressed in accor255dance with the following chart Atmospheric Temperature Preheating Time 41260F5260Cor higher Approx 10 seconds 41260F5260Cto 23260F 5260CApprox 15 seconds 23260F5260Cor lower Approx 20 seconds Limit of continuous use 30 seconds before cranking NOTE The START button will not energize unless the PRE255HEAT button is depressed Depressing the PREHEAT button activates the glow plugs in the cylinder head so use the PRE255HEAT intermittently to avoid overheating the glow plugs 4 While still depressing the PREHEAT button depress the START button This will engage the starter solenoid Upon engine starting release the START switch Do not release the PREHEAT switch until the oil pressure reaches 5 10 psi Then as long as the high water temperature and low oil pressure protective circuits do not activate the engine will remain energized and continue to run NOTE When starting A voltage drop will occur when the preheat button is depressed 5 Should the engine not start when the START button is depressed for 10 to 20 seconds release both buttons and wait 30 seconds repeat the procedure above and preheat longer Never run the starter for more than 30 seconds A CAUTION Prolonged cranking intervals without the engine starting can result in the engine exhaust system filling with raw water This may happen because the pump is pumping raw water through the raw water cooling system during cranking This raw water can enter the engines cylinders by way of the exhaust manifold once the exhaust system fills Prevent this from happening by closing the raw water supply throughhull shutoff draining the exhaust muffler and correcting the cause of the excessive engine cranking Engine damage resulting from raw water entry is not a warrantable issue the owneroperator should keep this in mind 6 Once the engine starts check the instruments for proper oil pressure and battery charging voltage NOTE Never attempt to engage the starter while the engine is running NOTE Some unstable running may occur in a cold engine Depressing the PREHEAT button for 1015 second intervals will help stabilize the engine rpm until the engine operating temperature reaches 170 190260F 77 88260Cand a propeller load is applied to the engine When the engine is running and the PREHEAT button is depressed a charging load on the DC alternator will be discernible Starting Under Cold Conditions Make sure the lubricating oil is appropriate for the prevailing temperature Use oil with an API Specification of CF or CG4 SAE 30 lOW30 or 15W40 The battery should be fully charged to minimize voltage drop Use a sufficient amount of preheat to aid in starting See the chart elsewhere in this section Stopping Procedure To stop the engine bring the throttle to an idle position and place the transmission in neutral Allow the engine to idle for a few moments to stabilize temperatures Turn the engine off using the stop control cable If your engine is equipped with an optional fuel shut off solenoid turn off the key switch at the control panel NOTE Make certain this key switch is in the OFF position 12 oclockIf the key switch is left ON the battery will discharge An engine alarm buzzer is provided to warn the operator of this condition key switch ONThe best method of preventing the battery from discharging is to remove the key from the key switch after stopping the engine Engines Generators 9 this manual AdobeUCSDIESEL FUEL ENGINE OIL AND ENGINE COOLANT DIESEL FUEL Use fuel that meets the requirements or specification of Class 2D ASTMand has a cetane rating of45 or better Care Of The Fuel Supply Use only clean diesel fuel The clearance of the components in your fuel injection pump is very critical invisible dirt par255ticles which might pass through the filter can damage these finely finished parts It is important to buy clean fuel and keep it clean The best fuel can be rendered unsatisfactory by careless handling or improper storage facilities To assure that the fuel going into the tank for your engines daily use is clean and pure the following practice is advisable Purchase a wellknown brand of fuel Install and regularly service a good visualtype fuel filterwater separator between the fuel tank and the engine The Raycor 500 FG or 900 FG are good examples of such filters ENGINE OIL Use a heavy duty engine oil with an API classification of CF or CG4 or better Change the engine oil after an initial 50 hours of breakin operation and every 100 hours of operation thereafter For recommended oil viscosity see the following chart Operating Temperature Oil Viscosity Above 68260F 20260CSAE 30 10W30 or 15W40 41260 68260F 5 20260CSAE 20 10W30 or 15W40 Below 41260F 5260CSAE 10W30 or 15W40 A CAUTION Do 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 OIL PRESSURE The engines oil pressure during operation is indicated by the oil pressure gauge on the instrument panel During nonnal operation the oil pressure will range between 35 and 55 psi 25 and 39 kglcm2NOTE A newly started cold engine can have an oil pressure reading up to 60 psi 42 kglcm2A warmed engine can have an oil pressure reading as low as 25 psi 18 kglcm2These readings will vary depending upon the temperature of the engine the load placed on the engine and the RPMs TRANSMISSION FLUID Refer to the TRANSMISSION SECTION of this manual for type of fluid and quantity for each transmission model ENGINE COOLANT WESTERBEKE recommends a mixture of 50 antifreeze and 50 distilled water Distilled water is free from the chemicals that can corrode internal engine surfaces The antifreeze perfonns double duty It allows the engine to run at proper temperatures by transferring heat away from the engine to the coolant and lubricates and protects the cooling circuit from rust and corrosion Look for a good quality antifreeze that contains Supplemental Cooling Additives SCAsthat keep the antifreeze chemically bal255anced crucial to long tenn protection The distilled water and antifreeze should be premixed before being poured into the cooling circuit NOTE Look for the new long lasting antifreeze that is now available Antifreeze mixtures will protect against an unexpected freeze and they are beneficial to the engines cooling system They retard rust and add to the life of the circulating pump seal ANTIFREEZE PROTECTION Antifreeze Concentration 23 30 35 50 Freezing Temperature 14260F 8260F 4260F 40260F RECOVERY TANK A coolant recovery tank kit is supplied with each WESTERBEKE diesel engine The purpose of this recovery tank is to allow for engine coolant expansion and contraction during engine operation without the loss of coolant and without introducing air into the cooling system This kit is provided and must be installed before operating the engine NOTE This tank with its short run of plastic hose is best located at or above the level of the engines manifold but it can be located below the level of the engines manifold if the particular installation makes this necessary Engines Generators 7 CAPTAIN CONTROL PANEL DESCRIPTION This control panel is equipped with a KEY switch an RPM gauge PREHEAT and START but255tons an INSTRUMENT 1EST button and three indicator lamps one for ALlERNATOR DISCHARGE one for low OIL PRESSURE and one for high ENGINE COOLANT lEMPERATURE RPM GAUGE REGISTERS REVOLUTIONS PER MINUTE OF THE ENGINE AND CAN BE RECALIBRATED FOR ACCURACY FROM THE REAR OF THE PANEL WATER TEMPERJlTI ALARM LIGHT START BUTTON WHEN PRESSED ENERGIZES THE STARTERS SOLENOID WHICH CRANKS THE ENGINE THIS BUTTON WILL NOT OPERATE ELECTRICALLY UNLESS THE PREHEAT BUTTON IS PRESSED AND HELD AT THE SAME TIME The panel also includes an alarm buzzer for low OIL PRESSURE or high COOLANT lEMPERATURE The RPM gauge is illuminated when the KEY switch is turned on and remains illuminated while the engine is in operation ALARM THE ALARM WILL SOUND IFTHE ENGINES OIL PRESSURE FALLS BELOW 5 10 psi 04 07 kgemIN THIS EVENT THE ALARM WILL EMIT A PULSATING SIGNAL THE ALARM WILL ALSO SOUND IF THE COOLANT TEMPERATURE IN THE FRESHWATER COOLING CIRCUIT RISES TO 210260F 99260CIN THIS EVENT THE ALARM WILL EMIT A CONTINUOUS SIGNAL NOTE THE ALARM WILL SOUND WHEN THE KEY SWITCH IS TURNED ON THIS SOUNDING IS NORMAL ONCE THE ENGINE STARTS AND THE ENGINES OIL PRESSURE REACHES 15 psi 11 kgemTHE ALARM WILL SILENCE TEST BUTTON WHEN PRESSED TESTS THE ALTERNATOR THE OIL PRESSURE AND THE COOLANT TEMPERA255TURE CONTROL CIR255CUITS WHEN PRESSED THE ALTERNATOR THE OIL PRESSURE AND THE WATER TEMPERA255TURE INDICATOR LIGHTS ILLUMINATE IN ADDITION TO SOUND255ING THE ALARM BUZZER KEY SWITCH PROVIDES POWER ONLY TO THE INSTRUMENT PANEL CLUSTER PREHEAT BUTTON WHEN PRESSED ENERGIZES THE ALTERNATORS EXCITER THE FUEL LIFT PUMP THE FUEL SOLENOID ON THE INJECTION PUMp AND THE ENGINES GLOW PLUGS AND BYPASSES THE ENGINES OIL PRES255SURE ALARM SWITCH IN ADDITION THIS BUTTON ENER255GIZES THE START BUTTON Engines Generators 2676 rises diesel dependable performance important that AdobeUCSPARTS IDENTIFICATION 44A FOUR35C THREE WATER INJECTED EXHAUST ELBOW 20ACIRCUIT BREAKER REAR ZINC ANODE OIL FILTER COOLANT PRESSURE CAP OIL COOLER THERMOSTAT ASSEMBLY WATER HEATER CONNECTION FRONT SIDE OIL FILL RIGHT SIDE AIR INTAKEAIR FILTER OIL FILL FRONT PREHEAT SOLENOID DC ALTERNATOR FUEL FILTER RAW WATER PUMP REAR UNIT ID PLATE START MOTOR LEFT SIDE ATFDRAIN Engines Generators TABLE OF CONTENTS Parts Identification 2 Water Heater 24 Introduction 3 DC Electrical System 25 Warranty Procedures 3 Alternator 25 Serial Number Location 4 Battery 26 Control Panels 5 Wiring 27 Admirals Panel 5 Engine 31 Captains Panel 6 Tachometer 33 Diesel Fuel Engine Oil and Engine Coolant 7 Engine Adjustments 34 Oil Pressure 7 Testing Engine Compression 35 Preparations for Initial StartUp 8 Procedure 9 Warning Lights Alarms and Circuit Breaker 10 Engine Breakin Procedure 11 The Daily Operation 12 RPMs Guide 12 Fuel Injectors 35 Valve Adjustments 36 JS and BW Transmission 37 Borg Warner Velvet Drive Transmission 39 Hurth HBW Transmission 42 PRM Newage Transmissions 45 Maintenance Schedule 13 Transmission 47 Cooling System 15 Propeller Recommendation Chart 48 Thermostat 16 L U dR267267267 ayp an ecommlsslonmg 49 Raw WaterPump 16 Heat Exchanger 17 Air IntakeSilencer 18 Fuel System 19 Fuel Lift Pump 19 Fuel Filters 19 44 Four Engine Specifications 51 35 Three Engine Specifications 52 44 Four and 35 Three Torque Specifications 53 Standard Hardware 54 Sealants Lubricants 54 Fuel Water Separator 16 Standard and Metric Conversion Data 55 Clow Plugs 20 Engine Lubricating Oil 21 Oil Change 21 Oil Pressure 22 Suggested Spare Parts 56 Spare Parts Kits 56 European Maritime Council Registration 57 Remote Oil Filter 23 Engines Generators 1 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 SIPHONBREAK For installations where the exhaust manifoldwater injected exhaust elbow is close to or will be below the vessels waterline provisions must be made to install a siphon255break in the raw water supply hose to the exhaust elbow This hose must be looped a minimum of 20 above the vessels waterline Failure to use a siphonbreak when the exhaust manifold injection port is at or below the load waterline will result in raw water damage to the engine and possible flooding of the boat If you have any doubt about the position of the waterinjected exhaust elbow relative to the vessels waterline under the vessels various operating conditions install a siphonbreak NOTE A siphonbreak requires periodic inspection and cleaning to ensure proper operation Failure to properly maintain a siphonbreak can result in catastrophic engine damage Consult the siphonbreak manufacturer for proper maintenance EXHAUST SYSTEM The exhaust hose must be certified for marine use The system must be 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 air intake being serviced i i SAFETY INSTRUCTIONS INTRODUCTION Read this safety manual carefully Most accidents are caused by failure to follow fundamental rules and precau255tions Know when dangerous conditions exist and take the necessary precautions to protect yourself your personnel and your machinery The following safety instructions are in compliance with the American Boat and Yacht Council ABYCstandards PREVENT ELECTRIC SHOCK A WARNING 00 not touch AC electrical connections while engine is running or when connected to shore power Lethal voltage is present at these connections 225 Do not operate this machinery without electrical enclosures and covers in place 225 Shut off electrical power before accessing electrical equipment 225 Use insulated mats whenever working on electrical equipment 225 Make sure your clothing and skin are dry not damp particularly shoeswhen handling electrical equipment 225 Remove wristwatch and all jewelry when working on electrical equipment 225 Do not connect utility shore power to vessels AC circuits except through a shiptoshore double throw transfer switch Damage to vessels AC generator may result if this procedure is not followed 225 Electrical shock results from handling a charged capaci255tor Discharge capacitor by shorting terminals together PREVENT BURNS HOT ENGINE A WARNING 00 not touch hot engine parts or exhaust system components A running engine gets very hot 225 Always check the engine coolant level at the coolant recovery tank A WARNING Steam can cause injury or death 225 In case of an engine overheat allow the engine to cool before touching the engine or checking the coolant PREVENT BURNS FIRE A WARNING Fire can cause injury or death 225 Prevent flash fires Do not smoke or permit flames or sparks to occur near the carburetor fuel line filter fuel pump or other potential sources of spilled fuel or fuel vapors Use a suitable container to catch all fuel when removing the fuel line carburetor or fuel filters 225 Do not operate with a Coast Guard Approved flame arrester removed Backfire can cause severe injury or death 225 Do not operate with the air removed Backfire can cause severe injury or death 225 Do not smoke or permit flames or sparks to occur near the fuel system Keep the compartment and the clean and free of debris to minimize the chances of fire Wipe up all spilled fuel and engine oil 225 Be aware diesel fuel will bum PREVENT BURNS EXPLOSION A WARNING Explosions from fuel vapors can cause injury or death 225 Follow refueling safety instructions Keep the vessels hatches closed when fueling Open and ventilate cabin after fueling Check below for fumesvapor before run255ning the blower Run the blower for four minutes before starting your engine 225 All fuel vapors are highly explosive Use extreme care when handling and storing fuels Store fuel in a area away from sparkproducing equipment and out of the reach of children 225 Do not fill the fuel tankswhile the engine is running 225 Shut off the fuel service valve at the engine when serviCing the fuel system Take care in catching any fuel that might spill DO NOT allow any smoking open flames or other sources of fire near the fuel system or engine when servic255ing Ensure proper ventilation exists when servicing the fuel system 225 Do not alter or modify the fuel system 225 Be sure all fuel supplies have a positive shutoff valve 225 Be certain fuel line fittings are adequately tightened and free of leaks 225 Make sure a fire extinguisher is installed nearby and is properly maintained Be familiar with its proper use Extinguishers rated ABC by the NFPA are appropriate for all applications encountered in this environment Engines Generators 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 A WARNING Exhaust gasses contain Carbon Monoxide an odorless and colorless gas Carbon Monoxide is poisonous and can cause and death Symptoms of Carbon Monoxide exposure can include Dizziness Nausea Headache Weakness and Sleepiness Throbbing in Temples Muscular Twitching Vomiting Inability to Think Coherently IF YOU OR ANYONE ELSE EXPERIENCE ANY OF THESE SYMPTOMS GET OUT INTO THE FRESH AIR IMMEDIATELY If symptoms persist seek medical attention Shut down the unit and do not restart until it has been inspected and repaired I RII It f II t o q LP OPERATORS MANUAL FOR THE 44A FOUR 35C THREE AND THE 448 FOUR 350 THREE MARINE DIESEL ENGINES PUBLICATION NO 44180 2nd Edition I October 2001 WESTERBEKE CORPORA TION 225 150 JOHN HANCOCK ROAD MYLES STANDISH INDUSTRIAL PARK267 TAUNTON MA 02780 WEBSITE AIIIl Mmber Nali01llll MIlIiM MIIIufOClu ArociDlion AdobeUCS

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