Tuesday, September17, 2019 L-36.com

Westerbeke Diesel 71c Four Technical Manual



Note:

This is the new page for displaying documents. It allows documents to display on devices without pdf viewers specifically mobile devices, a new Google requirement. Note also that some documents have blank pages. Just click on "Next Page" if that happens.
Previous Page    Next Page Go to page number Note: Page number may not agree with index page numbers


Previous Page    Next Page
Go to page number
Note: Page number may not agree with index page numbers

PDF to Text.

                                                   f4t.
                     o                         q
                         IiLD~'




OPERATORS MANUAL
      .       -


    7A·1 and 11A·1
 MARINE DIESEL ENGINES



                  PUBLICATION NO. 45145
                   1st Edition!April 2001




          J     WESTERBEKE CORPORATION· MYLES STANDISH INDUSTRIAL PARK
               150 JOHN HANCOCK ROAD, TAUNTON, MA 02780-7319 U.S.A.
              TEL: (508)823-7677. FAX: (508)884-9688. WEBSITE: www.WESTERBEKECOM

      ~~~~
     NMMA Member National Marine Manufacturers Association ,
     ~"'~
OPERATORS MANUAL
    7A·1 and 11A·1
 MARINE DIESEL ENGINES



           PUBLICATION NO. 45145
            15t Edition!April 2001




  ~r~ 'WESTERBEKE
      ~     W£ST£RB£K£ CORPORATION· MYL£S STANDISH INDUSTRIAL PARK
           150 JOHN HANCOCK ROAD, TAUNTON, MA 02780-7319 U.S.A.
          TEL: (508)823-7677· FAX: (508)884-9688· WEBSITE www.WESTERBEKECOM

      ~~~~
     NHHA
     ~,.,~
               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.




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

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


                        This WARNING DECAL is provided by
                        WESTERBEKE and should be fixed to a
                        bulkhead near your engine or generator.
                        WESTERBEKE a/so recommends installing
                        CARBON MONOXIDE DETECTORS in the
                        Iiving/sleeping quarters of your vessel.
                        They are inexpensive and easily
                        obtainable at your local marine store.
                                             SAFETY INSTRUCTIONS
INTRODUCTION                                                          PREVENT BURNS - FIRE
Read these safety instructions carefuUy. Most accidents are
caused by failure to follow fundamental rules and precau-                 A WARNING: Fire can cause injury or death!
tions. Know when dangerous conditions exist and take the
necessary precautions to protect yourself, your personnel,            · Prevent flash fires. Do not smoke or permit flames or
and your machinery.                                                     sparks to occur near the fuel line, filter, fuel pump, or
The foUowing safety instructions are in compliance with                 other potential sources of spilled fuel or fuel vapors. Use
the American Boat and Yacht Council (ABYC) standards.                   a suitable container to catch all fuel when removing the
                                                                        fuel line or fuel filters.
PREVENT ELECTRIC SHOCK                                                · Keep the compartment and the engine clean and free of
                                                                        debris to minimize the chances of fire. Wipe up all spilled
                                                                        fuel and engine oil.
    A WARNING: lID nDt touch AC electrical CfJIInectiDIIS             · Be aware - diesel fuel will burn.
    while engine is running, Of wlren connected to shore
    power. Lethal voltage is present at these connections!            PREVENT BURNS - EXPLOSION
· Do not operate this machinery without electrical
  enclosures and covers in place.                                         A WARNING: Explosions from fuel rapors can cause
· Shut off electrical power before accessing electrical
                                                                          injury Of death!
  equipment.
                                                                      ·     Follow re-fueling safety instructions. Keep the vessel's
· Use insulated mats whenever working on electrical                         hatches closed when fueling. Open and ventilate cabin
  equipment.                                                                after fueling. Check below for fumes/vapor before run-
· Make sure your clothing and skin are dry, not damp                        ning the blower. Run the blower for four minutes before
  (particularly shoes) when handling electrical equipment.                  starting your engine.
· Remove wristwatch and all jewelry when working on                   ·     All fuel vapors are highly explosive. Use extreme care
  electrical equipment.                                                     when handling and storing fuels. Store fuel in a well-ven-
· Do not connect utility shore power to vessel's AC                         tilated area away from spark-producing equipment and
  circuits, except through a ship-ta-shore double throw                     out of the reach of children.
  transfer switch. Damage to vessel's AC generator may                ·     Do not fill the fuel tank(s) while the engine is running.
  result if this procedure is not followed.                           ·     Shut off the fuel service valve at the engine when servicing
· Electrical shock results from handling a charged                          the fuel system. Take care in catching any fuel that might
  capacitor. Discharge capacitor by shorting terminals                      spill. DO NOT allow any smoking, open flames, or other
  together with an insulated tool.                                          sources of fire near the fuel system or engine when servic-
                                                                            ing. Ensure proper ventilation exists when servicing the
PREVENT BURNS - HOT ENGINE                                                  fuel system.
                                                                      ·     Do not alter or modifY the fuel system.
    A WARNING: lID not touch hot engine parts        Of
                                                                      ·
                                                                      ·
                                                                            Be sure all fuel supplies have a positive shutoff valve.
                                                                            Be certain fuel line fittings are adequately tightened and
    exhaust system components. A running engine gets
                                                                            free of leaks.
    very hot!
                                                                      ·     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
    A WARNING: Steam can cause injury         Of death!                      for all applications encountered in this environment.

·     In case of an engine overheat, allow the engine to cool
      before touching the engine or checking the coolant.




                                                            Engines & Generators

                                                                  i
                                               SAFETY INSTRUCTIONS
ACCIDENTAL STARTING                                                       TOXIC EXHAUST GASES
    A WARNING: Accidental starling can cause injury                           A WARNING: Carbon monoxide (CO) is a deadly gas!
    or death!
· Disconnect the battery cables before servicing the engine.              ·        Ensure that the exhaust system is adequate to expel gases
                                                                                   discharged from the engine. Check the exhaust system
  Remove the negative lead first and reconnect it last.
                                                                                   regularly for leaks and make sure the exhaust manifold!
· Make certain all personnel are clear of the engine before                        water-injected exhaust elbow is securely attached.
  starting.
· Make certain all covers, guards, and hatches are                        ·        Be sure the unit and its surroundings are well ventilated.
  re-installed before starting the engine.                                         Run blowers when running the generator set or engine.
                                                                          ·        Don't run the generator set or engine unless the boat is
BATTERY EXPLOSION                                                                  equipped with a functioning marine carbon monoxide
                                                                                   detector that complies with ABYC A-24. Consult your
                                                                                   boat builder or dealer for installation of approved detectors.
    A WARNING: Battery explosion can cause injury                         ·        For additional information refer to ABYC T-22
    or death!
                                                                                   (educational information on Carbon Monoxide).
· Do not smoke or allow an open flame near the battery
  being serviced. Lead acid batteries emit hydrogen, a
  highly explosive gas, which can be ignited by electrical
                                                                                    A WARNING: Carbon monoxide (CO) is an invisible
  arcing or by lit tobacco products. Shut off all electrical                         odorless gas. Inhalation produces flu-like symptoms,
  equipment in the vicinity to prevent electrical arcing                             nausea or death!
  during servicing.
· Never connect the negative (-) battery cable to the                     ·        Do not use copper tubing in diesel exhaust systems. Diesel
  positive (+) connection terminal of the starter solenoid.                 fumes can rapidly destroy copper tubing in exhaust
  Do not test the battery condition by shorting the terminals               systems. Exhaust sulfur causes rapid deterioration of
  together. Sparks could ignite battery gases or fuel vapors.               copper tubing resulting in exhaust/water leakage.
  Ventilate any compartment containing batteries to prevent               · Do not install exhaust outlet where exhaust can be drawn
  accumulation of explosive gases. To avoid sparks, do not                  through portholes, vents, or air conditioners. If the engine
  disturb the battery charger connections while the battery                 exhaust discharge outlet is near the waterline, water could
  is being charged.                                                         enter the exhaust discharge outlet and close or restrict the
· Avoid contacting the terminals with tools, etc., to prevent               flow of exhaust. Avoid overloading the craft.
  burns or sparks that could cause an explosion. Remove                   · Although diesel engine exhaust gases are not as toxic as
  wristwatch, rings, and any other jewelry before handling                  exhaust fumes from gasoline engines, carbon monoxide
  the battery.                                                              gas is present in diesel exhaust fumes. Some of the
· Always turn the battery charger offbefore disconnecting                   symptoms or signs of carbon monoxide inhalation or
  the battery connections. Remove the negative lead first                   poisoning are:
  and reconnect it last when servicing the battery.                            Dizziness       Throbbing in temples
                                                                               Headache        Muscular twitching
BATTERY ACID                                                                   Nausea          Weakness and sleepiness
                                                                               Vomiting        Inability to think coherently
    A WARNING: Sulfuric acid in batteries can cause                       AVOID MOVING PARTS
    severe injury or death!
·      When servicing the battery or checking the electrolyte
                                                                                  A WARNING: Rotating parts can cause injury
       level, wear rubber gloves, a rubber apron, and eye                         or death!
       protection. Batteries contain sulfuric acid which is
       destructive. If it comes in contact with your skin, wash it            ·     Do not service the engine while it is running. If a
       off at once with water. Acid may splash on the skin or                       situation arises in which it is absolutely necessary to
       into the eyes inadvertently when removing                                    make operating adjustments, use extreme care to avoid
       electrolyte caps.                                                            touching moving parts and hot exhaust system
                                                                                    components.




                                                              Engines & Generators

                                                                     ii
                                              SAFETY INSTRUCTIONS
· Do not wear loose clothing or jewelty when servicing                    ABYC, NFPA AND USCG PUBLICATIONS FOR
  equipment; tie back long hair and avoid wearing loose
  jackets, shirts, sleeves, rings, necklaces or bracelets that            INSTAlliNG DIESEL ENGINES
  could be caught in moving parts.                                        Read the following ABYC, NFPA and USCG pUblications
                                                                          for safety codes and standards. Follow their recommenda-
· Make sure all attaching hardware is properly tightened.
  Keep protective shields and guards in their respective                  tions when installing your engine.
  places at all times.                                                    ABYC (American Boat and Yacht Council)
                                                                          Safety Standards for Small Craft
· Do not check fluid levels while the engine is operating.
                                                                          Order from:
HAZARDOUS NOISE                                                             ABYC
                                                                            3069 Solomons Island Rd.
    A WARNING: High noise levels can cause                                  Edgewater, MD 21037
    hearing loss!                                                         NFPA (National Fire Protection Association)
                                                                          Fire Protection Standardfor Motor Craft
·     Never operate an engine without its mufiler installed.              Order from:
·     Do not run engines for long periods with their                        NFPA
      enclosures open.                                                      11 Tracy Drive
                                                                            Avon Industrial Park
    A WARNING: 011 not WllrIc lin machinery when Yllu are                   Avon, MA 02322
    mentally IIr physically incapaCitated by fatigue!                     USCG (United States Coast Guard)
                                                                          USCG 33CFR183
                                                                          Order from:
ENGINE INSTALLATIONS
                                                                            U.S. Government Printing Office
Preparations to install an engine should begin with a thor-                 Washington, D.C. 20404
ough examination of the American Boat and Yacht Council's
(ABYC) standards. These standards are a combination of
sources including the USCG and the NFPA.
Sections of the ABYC standards of particular interest are:
      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
Federal regulations, ABYC guidelines and safety codes must be complied with when
installing engines and generators in a marine environment.

SIPHON-BREAK
For installations where the exhaust manifold/water-injected exhaust elbow is close to or
will be below the vessel's waterline, provisions must be made to install a siphon-break
in the raw water supply hose to the exhaust elbow. This hose must be looped a mini-
mum of 20 in. (51 cm) above the vessel's waterline. Failure to use a siphon-break
when the exhaust manifold injection port is at or below the load waterline will result
in raw water damage to the engine and possible flooding of the boat.
If you have any doubt about the position of the water-injected exhaust elbow relative to
the vessel's waterline under any of the vessel's various operating conditions or when
the vessel is not underway, install a siphon-break. This precaution is necessary to pro-
tect your engine.
NOTE: A siphon-break requires periodic inspection and cleaning to ensure proper oper-
ation. Failure to properly maintain a siphon-break can result in catastrophic engine
damage. Consult the siphon-break manufacturer for a proper maintenance schedule.

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 vessel's 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       Cooling System (continued)
      Warranty Procedures ............................................................ 2                    Raw Water Pump................................................................. 22
      Product Software................................................................. 2                         Inspecting/Changing the Raw Water Pump Impeller... 22
      Notes, Caution and Warnings .............................................. 2                          Raw Water Intake ................................................................. 22
      Model No.lSerial No. Location ........................................... 2                           Raw Water Intake Strainer................................................... 22
      Component Locations .......................................................... 3                      Siphon-Break....................................................................... 23
      Understanding the Diesel Engine ........................................ 3                            Draining the Cooling System ............................................... 23
      Ordering Parts ...................................................................... 3          Air Intake Filter............................................................................24
      Spares and Accessories ........................................................ 3                     Description........................................................................... 24
      Protecting Your Investment................................................. 3                               Air Filter....................................................................... 24
7A-1 Diesel Engine Specifications ............................................. 4                                 Maintenance ................................................................. 24
7A-1 Diesel Engine Parts Identification ..................................... 5                        Water Heater................................................................................24
11A-1 Diesel Engine Specifications ............................................6                            Water Heater Installations .................................................... 24
11A-1 Diesel Engine Parts Identlfication ....................................7                         Fuel System ................................................................................. 25
Preparations for Initial Start-Up ................................................. 8                       Diesel FueL .......................................................................... 25
       Diesel FueL .......................................................................... 8              Fuel Additives ...................................................................... 25
            Care of the Fuel Supply............................................... 8                         Care of the Fuel Supply........................................................25
            Fuel Additives ............................................................. 8                   Fuel Lift Pump..................................................................... 25
       Engine OiL .......................................................................... 8               Fuel Filter............................................................................. 25
       Transmission Fluid.............................................................. 8                         Replacing the Fuel Filter.............................................. 25
       Pre-Start Inspection............................................................. 8                   Fuel Lines ............................................................................. 26
Starting/Stopping Procedure .......................................................9                         Fuel FilterlWater Separator.................................................. 26
       Electric Starting ................................................................... 9               Fuel Injection Pump............................................................. 26
            Electric Starting Procedure .......................................... 9                         Fuel Injector......................................................................... 26
            Low Battery Electric Starting Procedure.....................9                                    Bleeding the Fuel System .................................................... 26
       Manual Starting (Hand Cranking) ....................................... 9                             Spare Parts ............................................................................ 26
            Automatic Decompression Device ............................ IO                             DC Electrical System ................................................................... 27
            Cold Starting Device .................................................. 10                       12 Volt DC Control Circuit... ............................................... 27
            Manual Starting Procedure........................................ 11                             Control Panel. ....................................................................... 27
            Starting Under Cold Conditions ................................ 12                               Engine Circuit Breaker......................................................... 27
       Operating the Engine ......................................................... 12                     Battery.................................................................................. 27
            Initial Start-Up Check List... ..................................... .12                               Battery Care ................................................................. 27
       Stopping the Engine ........................................................... 12                          Checking the Service Battery....................................... 27
Engine Break-In Procedure ....................................................... 13                         Alternator Troubleshooting .................................................. 28
      Engine Break-In Procedure................................................ 13                                 Testing the Alternator................................................... 28
      Break-In Check List. .......................................................... 13                           Checking the Service Battery....................................... 29
      Transmission Break-In....................................................... 13                        7A-I Marine Diesel Engine Wiring Diagram #45593 ......... 30
 Daily Operation ..........................................................................13                7A-I Marine Diesel Engine Wiring Schematic #45593 ...... 31
           Daily Operation Check-List. ...................................... 13                             11A-1 Marine Diesel Engine Wiring Diagram #44542 ....... 32
          Transmission .............................................................. 13                     11A-l Marine Diesel Engine Wiring Schematic #44542 .... 33
 Maintenance Schedule .............................................................. 14                Glow Plugs (ModeI7A-1 only) ................................................... 34
 Exhaust System ......................................................................... 16           Engine Adjustments ..................................................................... 35
      Description ......................................................................... 16               Tightening the Cylinder Head.............................................. 35
           Siphon-Break............................................................. 16                      Valve Clearance Adjustment. ............................................... 35
      Exhaust System Precautions .............................................. 16                           Engine Compression Test. .................................................... 35
           Carbon Monoxide ...................................................... 16                         Testing the Fuel Injector...................................................... .36
           Carbon Monoxide Warning Decal ............................. 16                                          Removing the Fuel Injector.......................................... 36
           Carbon Monoxide Detectors ...................................... 17                                     Fuel Injector Components ............................................ 36
           Insulation ................................................................... .17                      Checking the Injection Starting Pressure ..................... 36
           Overcranking.............................................................. 17                           Tightness of the Valve Seat. ......................................... 37
 Lubrication System ....................................................................18                         Inspecting the Spray Pattern........................................ 37
      Description......................................................................... 18                      Checking the Nozzle Body and Needle Valve............. 37
           Oil Pressure ReliefValve........................................... 18                                  Reassembly................................................................... 37
           Low Oil Pressure Alarm Switch ................................ 18                                       Injector Installation ...................................................... 37
      Engine OiL ......................................................................... 18                Drive Belt Adjustment. ........................................................ 38
      Checking the Oil ................................................................ 18                         Checking Belt Tension ................................................. 38
      Changing the OiL .............................................................. 19                           Adjusting Belt Tension ................................................. 38
           Removing the Old Oil ............................................... .19                     Engine Troubleshooting ............................................................... 39
           Changing the Oil Filter (Model llA-l only) ............ 19                                   Hurth HBW Transmission .............................................................42
           Adding the New Oil... ............................................... 20                     Hurth HBW Transmission Troubleshooting ..................................45
      Testing the Oil Pressure ..................................................... 20                 Lay-Up and Recommissioning .....................................................46
 Cooling System ......................................................................... 21            7A-1 &11A-1 Torque Specifications ........................................... 48
      Raw Water Cooling System.............................................. 21                         Standard Hardware/Sealants &Lubricants ................................ 49
      Thermostat. ........................................................................ 21           Metric Conversions ......................................................................50
           CheckinglReplacing the Thermostat... ...................... 21                               Standard and Metric Conversion Oata ........................................ 51
      Coolant Temperature Switch............................................. 21                        Suggested Spare Parts Kits ......................................................... 52


                                                                                           Engines & Generators

                                                                                                   1
                                                        INTRODUCTION
This WESlERBEKE Diesel Engine is a product of                          PRODUCT SOFTWARE
WESlERBEKE'S many years of experience and advanced
                                                                       Product software (tech data, parts lists, manuals, brochures
technology. We take great pride in the superior durability and
dependable performance of our engines and generators. Thank            and catalogs) provided from sources other than
                                                                       WESTERBEKE are not within WESTERBEKE's control.
you for selecting WESlERBEKE.
                                                                       WESTERBEKE CANNOT BE RESPONSIBLE FOR THE
This is the Operators Manual for the 7A-I and IIA-I Marine             CONTENT OF SUCH SOFTWARE, MAKES NO
Diesel Engines. Most of the information in this manual applies to      WARRANTIES OR REPRESENTATIONS WITH RESPECT
both models; where information applies to only one of the two          THERETO, INCLUDING ACCURACY, TIMEUNESS OR
models, the applicable model name will be indicated. A Parts           COMPLETENESS THEREOF AND WIll. IN NO EVENT
Catalog is also provided for your engine, and a Service Manual is      BE UABLE FOR ANY TYPE OF DAMAGE OR INJURY
available from your WESlERBEKE dealer. If you are planning             INCURRED IN CONNECTION WITH OR ARISING OUT
to install this equipment, contact your WESlERBEKE dealer for          OF THE FURNISHING OR USE OF SUCH SOFTWARE.
WESlERBEKE'S Installation Manual.
                                                                       WESlERBEKE customers should keep in mind the time span
 In order to get the full use and benefit from your engine,            between printings of WESlERBEKE product software and the
 it is important that you operate and maintain it correctly. This      unavoidable existence of earlier WESlERBEKE product
 manual is designed to help you do this. Please read this manual       software. The product software provided with WESlERBEKE
 carefully and observe all the safety precautions throughout.          products, whether from WESlERBEKE or other suppliers, must
 Should your engine require servicing, contact your nearest            not and cannot be relied upon exclusively as the definitive
 WESlERBEKE dealer for assistance.                                     authority on the respective product. It not only makes good sense
                                                                       but is imperative that appropriate representatives of
WARRANTY PROCEDURES                                                    WESlERBEKE or the supplier in question be consulted to
Your WESlERBEKE Warranty is included in the documentation              determine the accuracy and currentness of the product software
package. If you have not received a customer identification card       being consulted by the customer.
registering your warranty 60 days after submitting the warranty           NOTES, CAUTIONS AND WARNINGS
registration form, please contact the factory in writing with model
information, including the unit's serial number and                       As this manual takes you through the operating procedures,
commission date.                                                          maintenance schedules, and troubleshooting of your marine
                                                                          engine, critical information will be highlighted by NOlES,
Customer Identification Card                                              CAUTIONS, and WARNINGS. An explanation follows:
                                                                          NOTE: An operating procedure essential to note.

   I~'WESIERBEKE
      I Engines & Generators                                               A     CAUTION: Procedures which. if not strictly
                                                                            observed. can result in the damage Dr destruction of
   Customer Identification                                                  your engine.

   WESTERBEKE OWNER
   MAIN STREET                                                             A    WARNING: Procedures which. if not properly
   HOMETOWN, USA                                                           followed. can result in pelSDnai injury or loss of life.
   Mode17A-1
   Expires 3116102                                                        MODEL NO./SERIAL NO. LOCATION
   Ser. #74860/197-E003
                                                                          The engine's model number and serial number are located on an
                                                                          identification plate mounted on the engine block, below the
 Your WESlERBEKE 7A-I/IIA-I Engine serial number is an                    exhaust manifold/elbow. Take the time to enter this information
 alphanumeric number that indicates the date of manufacture. The          on the illustration of the nameplate shown below, as his will pro-
 date code is at the end of the serial number, and consists of a          vide a quick reference when seeking technical information and/or
 character followed by three numbers. The character indicates the         ordering repair parts.
 decade (D= 1990s, E=2000s), the fITSt number after the character
 represents the year in the decade, and the second and third
 numbers after the character represent the month of manufacture.




                                                                                                ENGINE mEITIFICATION PlATE



                                                               Engines & Generators

                                                                      2
                                                         INTRODUCTION
COMPONENT LOCATIONS                                                        SPARES AND ACCESSORIES
Component locations in this manual are referenced from the front           Certain spare parts will be needed to support and main-
of the engine which is the end at which the raw water pump is              tain your WESTERBEKE engine when cruising (see
located. Left and right sides are detennined as follows: imagine           SUGGESTED SPARE PARTS KITS). Often even a
straddling the engine, facing the front of the engine: the left side       simple item such as a proper fuel filter can be difficult
is at your left, the right side is at your right.                          to obtain along the way. WESTERBEKE can provide
                                                                           you with a suggested spares and accessories brochure to
UNDERSTANDING THE DIESEL ENGINE                                            assist you in preparing an on-board inventory of the
                                                                           proper WESTERBEKE parts.
The diesel engine closely resembles the gasoline engine, since the
mechanism is essentially the same. The cylinder is arranged                PROTECTING YOUR INVESTMENT
above a closed crankcase. The crankshaft is of the same general
type as on a gasoline engine, and the diesel engine has the same           Care at the factory during assembly and thorough testing have
types of valves, camshaft, piston, connecting rod and lubricating          resulted in a WESTERBEKE engine capable of many
system.                                                                    thousands of hours of dependable service. However, the
                                                                           manufacturer cannot control how or where the engine is installed
Therefore, to a great extent, a diesel engine requires the same pre-       in the vessel or the manner in which the unit is operated and ser-
ventive maintenance as a gasoline engine. The most important               viced in the field. This is up to the buyer/owner-operator.
factors are proper ventilation and proper maintenance of the fuel,
lubricating and cooling systems. Fuel filter elements must be              NOTE: Six important steps to ensure long engine life:
replaced at the time periods specified. and frequent checking for          ·   Proper engine installation.
contaminants (water, sediment, etc.) in the fuel system is also
                                                                           ·   An efficient well-designed exhaust system that includes an
essential. Another important factor is the consistent use of the               anti-siphon break to prevent water from entering the engine.
same brand of high detergent diesel lubrication oil designed
specifically for diesel engines.                                           ·   Changing the engine oil every 100 operating hours.
The diesel engine does differ from the gasoline engine, however,           ·   Proper maintenance of all engine components according to the
in its method of handling and firing of fuel. The carburetor and               maintenance schedule in this manual.
ignition systems are replaced by a single component - the fuel             ·   Use clean, filtered diesel fuel.
 injection pump - which performs the function of both.                     ·   Wmterize your engine according to the LAY-UP AND
                                                                               RECOMMISSIONING section in this manual.
ORDERING PARTS
Whenever replacement parts are needed, always provide
the engine model number and serial number. You must
provide us with this information so we may properly iden-
tify your engine. In addition, include a complete part
description and part number for each part needed (see the
Parts List). Insist upon Westerbeke packaged parts
because will fit or generic parts are frequently not made to
the same specifications as original equipment.




                                                                Engines & Generators

                                                                       3
                                       7A-1 DIESEL ENGINE SPECIFICATIONS
                    ENGINE SPECIFICATIONS                                                                       LUBRICATION SYSTEM
Engine Type                   Diesel, four-cycle, one cylinder, raw water cooled,       Lubrication System                Forced lubrication by gear-driven pump
                              vertical, in-line overhead valve mechanism
                                                                                        Sump capacity                     1.3 qts. (1.25 liters)
Aspiration                    Naturally aspirated
                                                                                        Operating Oil Pressu re           25.6-56.9 psi (1.8-4.0 kg/cm')
Govemor                       Mechanical, centrifugal type                              (engine hot)
Combustion System             Direct injected                                           Oil Grade                         API specification CF or CG-4
Bore and Stroke                                                                                                           SAE 30, 10W-30, 15W-40
                              3.23 in. x 2.17 in. (82.0 mm x 55.0 mm)
                                                                                        Lube oil Strainer                 Full-flow, intemal
Piston Displacement           17.7 cu. in. (290 cm')
Crankshaft                    Clockwise, when viewed from the front
Direction of Rotation         (raw water pump end)
                                                                                                                    COOLING SYSTEM
                                                                                        Cooling System                    Raw water-cooled block,
Compression Ratio             20:1                                                                                        thermostatically controlled
Maximum Torque                11.0 ftIIbs (1.5 kg-m)                                    Operating Temperature             13D-150°F(55-66°C)
(at 2500 rpm)
                                                                                        Raw Water Pump                    Positive displacement, neoprene impeller,
Manual Starting System        Hand-crank, with automatic                                                                  gear-driven, sen-priming
                              decompression device
                                                                                        Raw Water Row,                    7.3w-8.456 gpm       (7~   Ipm)
Engine Stop                   Manual type                                               at 3600 rpm
Dimensions                                                                              Raw Water Connection
 NOTE: An inserted standard                                                                                               112 in. (12.7 mm) 1.0.
                              Height: 17.1 in (433.7 mm)
 crank handle increases the   Width: 14.9 in (379.2 mm)
 width by 4.5 in (115 mm)
                              Length: 22.5 in (571.3 mm)                                                            EXHAUST SYSTEM
Dry Weight                    151 Ibs (68.5 kg)                                         Emission Control Systems          Meets U.S.C.G. Regulation 33 CFR 183
Max. Angle of Installation    Not to exceed 10°                                         Exhaust ManifoldlElbow            cast aluminum, raw water cooled
Max. Angle of Operation       Not to exceed 15° in all directions                       Exhaust Elbow Connection 1-112 in. (38.1 mm) 1.0.

                    TUNE-UP SPECIFICATIONS                                                                       ELECTRICAL SYSTEM
Compression Pressure          478.5 psi (33.6 kg/cm') standard
                                                                                        Electrical System                 12 volts DC, negative ground,
                              435.0 psi (30.6 kg/cm') minimum
                                                                                                                          circuit breaker protected
Valve Seat Angle              Intake 45°; Exhaust 45°
                                                                                        Battery Charging                  30 amp, 12 volts, belt-driven, with
Valve Clearance               Intake 0.008 in. (0.2 mm)                                 Altemator                         solid state internal regulator
(engine cold)                 Exhaust 0.008 in. (0.2 mm)
                                                                                        Starting Motor                    12 volt solenoid, actuated shift
Engine Timing                 39.0 mm BTDC static
                                                                                        Cold Cranking Amps                70 amps@71°F (22°C)
Injector Pressure             2900 psi (203.9 kg/cm')
Engine Speed                  Idle: 1000 - 1200 rpm                                                                      TRANSMISSION
                              Cruise: 2000 - 2500 rpm                                   General                           HURTH HBW 40 Standard Transmission, case-
                              Maximum: 2900 - 3000 rpm                                                                    hardened helical gears, with a servo-operated
                                                                                                                          multiple disc clutch
                              FUEL SYSTEM
                                                                                        Gear Ratio (optional)             2.05:1
Fuel System                   Open flow, sen-priming, sen-bleeding
                                                                                        Propeller                         120 x 8 P two blade RH
Fuel                          No.2 diesel oil, cetane rating of 45 or higher             Propeller used must allow        12 0 x 6 P three blade RH
                                                                                         the engine to reach its rated
Fuel Lift Pump                Mechanical 1.6 ft. (0.5 m) lift max.                       rpm at full open throttle in
                                                                                         forward gear, underway
Fuel Injection Pump           Bosch type
                                                                                        Lubricating Ruid                  ATF- type A or DEXTRON -/I or 11/
Fuel Injector                 Direct injection
                                                                                        Transmission Sump                 0.37 qts (0.35 liters)
Fuel Injection Timing         39 mm BTDC static                                         capacity
Injector Pressure             2900 psi (203.9 kg/cm')                                   Propeller Shaft                   Right hand-standard transmission
Fuel Consumption              0.46 U.S. gal./hr. (1.76Iiterlhr.)                        Direction of Rotation
(full load)
Fuel Filter                   Primary, replaceable filter
Fuel Supply                   1/4 in. (6.35 mm) 1.0. minimum
and Return Lines              5116 in. (7.94 mm) 1.0. maximum
Air Row                       15.3 cfm (0.43 cmm)
(engine combustion)



                                                                           Engines & Generators

                                                                                    4
                     7A-1 DIESEL ENGINE PARTS IDENTIFICATION




AUTOMATIC
DECOMPRESSION
DEVICE



  HAN~-CRANK
  HANDLE GUIDE


          RAW
          WATER
          PUMP
                                                                           flEXIBLE
                                                                           MOUNTS


                         RAW WATER
                         INTAKE CONNECTION




                                                                                       CYLINDER
                                                                                       HEAD
                                   FUEL INJECTOR ---t--Hl'f-H,-#'4:;;;t,i~M"-:;5~~~~




                                                                                              WATER INJECTED EXHAUST
                                                                                              MANIFOLDJELBOW




                                                                                                     FUEL INJECTION
                                                                                                     PUMP
        TRANSMISSION



                                                                                                      FUEL FILTER




                 TRANSMISSION
                 OUTPUT FLANGE




                                                    Engines & Generators

                                                          5
                                      11 A·1 DIESEL ENGINE SPECIFICATIONS
                    ENGINE SPECIFICATIONS                                                                      LUBRICATION SYSTEM
Engine Type                   Diesel, four-cycle, one cylinder, raw water cooled,       Lubrication System               Forced lubrication by gear-driven pump
                              vertical, in-line overhead valve mechanism
                                                                                        Sump Capacity                    1.7 qts. (1.6 liter)
Aspiration                    Naturally aspirated
                                                                                        Operating Oil Pressure           25.&-56.9 psi (1.8-4.0 kg/cm')
Governor                      Mechanical, centrifugal type                              (engine hot)
Combustion System             Direct injected                                           Oil Grade                        API specification CF or CG-4
Bore and Stroke               3.74 in. x 2.91 in. (95.0 mm x 74.0 mm)                                                    SAE 30, 10W-30, 15W-40
                                                                                        Oil Riter                        Full-flow, paper element, spin-on type
Piston Displacement           31.95 cu. in. (524.0 cm')
Crankshaft                    Clockwise, when viewed from the front                                                COOLING SYSTEM
Direction of Rotation         (raw water pump end)
                                                                                        Cooling System                   Raw water-cooled block,
Compression Ratio             20:1
                                                                                                                         thermostatically controlled
Maximum Torque                21.3 ftIIbs (2.9 kg-m)                                    Operating Temperature            13D-150°F (55-66°C)
at (2400 rpm)
                                                                                        Raw Water Pump                   Positive displacement, neoprene impeller,
Manual Starting System        Hand-crank, with automatic                                                                 gear-driven, seH-priming
                              decompression device
                                                                                        Raw Water Row,                   7.399-8.456 gpm (7-8lpm)
Engine Stop                   Manual type                                               at 3600 rpm
Dimensions                                                                              Raw Water Connection
 NOTE: An inserted standard                                                                                              112 in. (12.7 mm) 1.0.
                              Height: 21.0 in (532 mm)
 crank handle increases the   Width: 21.3 in (540 mm)
 width by 4.5 in. (115 mm)
                              Length: 23.8 in (603 mm)                                                            EXHAUST SYSTEM
Dry Weight                    238 Ibs (108 kg)                                          Emission Control Systems Meets U.S.C.G. Regulation 33 CFR 183
Max. Angle of Installation    Not to exceed 10°                                         Exhaust ManifoldlElbow           Cast aluminum, raw water cooled
Max. Angle of Operation       Not to exceed 15° in all directions                       Exhaust Elbow Connection 1-112 in. (38.1 mm) 1.0.

                    TUNE-UP SPECIFICATIONS                                                                      ELECTRICAL SYSTEM
Compression Pressure          478.5 psi (33.6 kg/cm') standard
                                                                                        Electrical System                12 volts DC, negative ground,
                              435.0 psi (30.6 kg/cm') minimum
                                                                                                                         circuit breaker protected
Valve Seat Angle              Intake 45°; Exhaust 45°
Valve Clearance               Intake 0.008 in. (0.2 mm)                                 Battery Charging                 30 amp, 12 volts, belt-driven,
(engine cold)                 Exhaust O.OOS in. (0.2 mm)                                Alternator                       with solid state intemal regulator
Engine liming                 60.0 mm BlDC static                                       Starting Motor                   12 volt solenoid, actuated shift
Injector Pressure             2537 psi (178.3 kg/cm')                                   Cold Cranking Amps               60 amps@66°F (19°C)
Engine Speed                  Idle:    1000 -1200 rpm
                              Cruise:  2000 - 2500 rpm                                                                  TRANSMISSION
                              Maximum: 2900 - 3000 rpm                                  General                          HURTH HBW 40 Standard Transmission, case-
                                                                                                                         hardened helical gears, with a servo-operated
                              FUEL SYSTEM                                                                                multiple disc clutch
Fuel System                   Open flow, self-priming, seH-bleeding                     Gear Ratio (optional)            2.05:1
Fuel                          No.2 diesel oil, cetane rating of 45 or higher            Propeller                        14 Dx8 Ptwoblade-RH
                                                                                        Propeller used must allow        140 x 6 Pthree blade - RH
Fuel Uft Pump                 Mechanical 1.6 ft. (0.5 m) lift max.                      the engine to reach its rated
                                                                                        rpm at full open throttle in
Fuel Injection Pump           Bosch type                                                forward gear, underway
Fuel Injector                 Direct Injection                                          lubricating Ruid                 ATF- type A or DEXTRON - /I or 11/
Fuel Injection liming         60 mm BTDC static                                         Transmission Sump                0.37 qts (0.35 liters)
Injector Pressure             2537.5 psi (178.4 kg/cm')                                 Capacity

Fuel Consumption              0.46 U.S. gaL/hr. (1.76Iiterlhr.)                         Propeller Shaft                  Right hand-standard transmission
(full load)                                                                             Direction of Rotation

Fuel Riter                    Primary replaceable filter
Fuel Supply                   1/4 in. (6.35 mm) 1.0. minimum
and Retum Lines               5/16 in. (7.94 mm) 1.0. maximum
Air Row                       27.7 cfm (0.78 cmm)
(engine combustion)


                                                                           Engines & Generators

                                                                                    6
                      11A·1
                        CYLINDER
                                DIESEL ENGINE PARTS IDENnFICATION
                        HEAD




                                                                             fOAArpoc
                                                                             CIRCUIT BREAKER




                                                   TlfROTrtE
                                                  CONTROL
                                           STARTER



                                   FUEL INJECTOR
                           COOlANT
                          TE"'PERATURE
                          SWITCH




     TIlANS""SSION
     OIPSTIClCIFlll




                                                               FUEL FILTER
'TRANSMISSION
                                   PREPARATIONS FOR INITIAL START-UP
DIESEL FUEL                                                                 PRE-START INSPECTION
Use No.2 diesel fuel with a cetane rating of 45 or higher. Do not           Before starting your engine for the first time, or after a prolonged
use kerosene or home heating fuel.                                          lay-up, check the following items:
                                                                            D Check the engine oil level. The oil level must be between the
Care of the Fuel Supply                                                       max. and min. marks on the dipstick.
Use only clean diesel fuel! The clearance of the components in              D Turn on the fuel supply, then check the fuel supply and exam-
your fuel injection pump is very critical; invisible dirt particles.          ine the fuel filter/water separator bowl for contaminants.
which might pass through the filter can damage these finely
finished parts. It is important to buy clean fuel, and keep it clean.       D Check the transmission fluid level.
The best fuel can become unsatisfactory by careless handling or             D Check the DC electrical system. Inspect wire connections
improper storage facilities. To assure that the fuel going into the           and battery cable connections. Make certain the positive (+)
tank for your engine's daily use is clean and pure, purchase a                battery cable is connected to the starter solenoid and the
well-known brand of fuel. Also install and regularly service a                negative (-) cable is connected to the engine ground stud
good, Coast Guard approved fuel filter/water separator between                (this location is tagged).
the fuel tank and the engine.                                               D Open the raw water intake and make sure the raw water sup-
                                                                              ply reaches the raw water strainer.
Fuel Additives                                                              D VIsually examine the engine. Look for loose or missing
If fungus or bacteria is causing fuel problems, you should have               parts, disconnected wires, and unattached hoses. Check the
an authorized dealer correct these problems. Then use a diesel                threaded connections. Check for fuel leaks.
fuel biocide to sterilize the fuel (follow the manufacturer's               D Make sure the exhaust system is secure and all the
instructions). Use a fuel stabilizer on a regular basis as well.              connections are tight
STA-BIL is an example of such a product.
                                                                            D Make sure there is good ventilation and an ample air supply.
ENGINE OIL                                                                    These are necessary for proper engine performance.
                                                                            D Make sure the mounting installation is secure.

 A CAUTION: This engine was shipped from the fac-                           D Make sure the propeller shaft is securely attached to the
  to"   without lubricant in the engine. Before operating,
  fill with the proper engine oil.
                                                                               transmission.



Use an engine oil with an API classification of CF or CG-4.
Change the engine oil after an initial 50 hours of break-in opera-
tion, and every 100 hours of operation thereafter. For
recommended oil viscosity, see the following chart:

      Operating Temperature                   Oil Viscosity
    Above 68° F (20° C)                SAE 30, 10W-30 or 15W-40
    41° -68° F (5° - 20" C)            SAE 20 or 10W-30
    Below 41° F (5° C)                 SAE10W-30



  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 hannful to your engine.

 TRANSMISSION FLUID
 Use ATF type A or Dextron II or ill transmission lubricating fluid.
 The transmission sump capacity is 0.37 qts. (0.35liters).




                                                                  Engines & Generators

                                                                        8
                                     STARTING/STOPPING PROCEDURE
ELECTRIC STARTING                                                                 NOTE: The Automatic Decompression Device is not used for
The 7A-I/llA-1 diesel engine has a 12 VDC electric starter. The                   nOf77Ul1 electric starting. During engine operation, the pointer on
engine is started by using a keyswitch on the control panel. The                  this device is in the operating (9 o'clock) position.
switch has three positions: OFF, ON and START.                                    1. Place the transmission in neutral and advance the throttle con-
NOTE: Periodically lubricate the keyswitch mechanism with                            trol to slightly open.
LOCKEZE to ensure proper keyswitch functioning.                                   2. Using a IOmm wrench, turn the hex-head bolt on the
                                                                                     device so the pointer is in the manual starting position
                                                                                     (see illustration).

                                              \\ \-.......-I+-   HOUR METER


                                                                                     POINTER IN ,-T-t----,L.~..,.::,
                                                                                     THE MANUAL
                                                                                     STARTING
                                                                                     PosmON
OIL/WATER                                                                                                                -;-t---;i-H-_   HEX-HEAD BOLT
ALARM

                                                                                                                                           AUTOMATIC
                                                                                                                                           OECOMPRESSION
                                                                 KEYSWITCH                                                                 DEVICE
                      ALARM         ~~~~E~T
                     W[g~lf'[grtl&&c:.r[g
                          CONTROL PANEL
                                                                                  3. Turn the keyswitch to the START position. The alann on the
Electric Starting Procedure                                                          control panel will beep until the engine oil pressure comes up.
1. Place the transmission in neutral and advance the throttle con-                   The pointer on the Automatic Decompression Device will
   trol to slightly open.                                                            automatically move clockwise with each crank. The pointer
                                                                                     will stop at the 9 o'clock position and compression will occur
                                                                                     after 8 cranks. Hold the keyswitch in the START position
 A    CAUTION: Make certain the transmission is in neu-                              until either the engine starts or the pointer stops after the 8th
                                                                                     crank. Then let go of the key and it will spring back to the
 tral. Starting in gear could result in serious damage to
 your transmission, your boat, and vessels nearby.                                   ON position.


2. Turn the keyswitch to the ON position. The alann buzzer on
    the control panel will beep. Push the key in to preheat. Hold
    the key in and turn it to the START position. When the
    engine starts, let go of the key and it will come out of preheat                   POINTER IN
                                                                                       THE OPERATING
    and spring back to the ON position (observe that it does this).                    posmON

NOTE: If the engine doesn ~ start, limit each starting trial to 10-
20 seconds. Wait for approx. 30 seconds before repeating the
start. Never operate the starter motor while the engine is still                                        j
running.                                                                                                ~
                                                                                                            ~'lIJ=======
NOTE: Some unstable running may occur in a cold engine. This
condition should smooth out as the nOf77Ul1 operating temperature
is reached and a load is applied. Allow a few minutes for the
wann-up at a comfortable rpm (approximately 1,000 rpm), then                      If this attempt at an electric start does not start the engine, then a
reduce the rpm and get underway.                                                  manual start by hand-cranking will be necessary.

Low Battery Electric Starting Procedure                                           MANUAL STARTING (HAND CRANKING)
If the battery is discharged and too low for a normal electric start              When installing the engine, it is important to provide enough
but not completely dead, an attempt at an electric start can be                   space at the front end to allow for manual starting (hand cranking)
made by using the Automatic Decompression Device. This device                     in case of an emergency or when the starting battery has become
works by holding the exhaust valve open, and is normally used                     too low to allow an electrical start.
when manually starting (hand-cranking) the engine.




                                                                        Engines & Generators

                                                                              9
                                      STARTING/STOPPING PROCEDURE
The upper illustration shows the distance [4.5 in. (115 mm)] that
the standard hand-crank handle protrudes from the crank-handle
guide on the engine. An additional 2.5 in. (64 mm) minimum
                                                                                                                          HEX-HEAD BOLT
must be allowed for room to insert the handle.
If hand cranking must be done from outside the engine
compartment (see lower illustration), then the standard                                                                     AUTOMATIC
                                                                                                                            OECOMPRESSION
hand-crank handle must be extended to the required length.                     POINTER                                      DEVICE
This modification to the handle must be done by the owner.




                                                      BULKHEAD
                                                                           Cold Starting Device
                                                                           This device provides more fuel from the injection pump. There
                                                                           are two positions for the knob: up (oft) and down (activated).
                                                                           When activating this device, pull the knob down (see illustration).
                                                                           To release this device, move the speed control lever down, then
                                                                           release it (see illustration).
                                                                           NOTE: Never pull the Cold Starting Device knob down when the
                                                                           engine is operating or when restarting a hot engine.

                                                 ~"L~
                                 l=::;:::::~



                                     ~~~.I
                                     HANDLE

                                                                                                                               COLD STARTING
The engine may be started by hand-cranking in an emergency or                       MODEL 7A-1 SHOWN                           DEVICE KNOB
when the starting battery has become too low to allow an electric
start. A manual start is possible with a completely dead battery.
For easy and safe manual starting, the engine is fitted with an
Automatic Decompression Device and a Cold Starting Device.
Use both of these devices when hand-cranking.
Before using the hand-crank handle, an attempt at a normal
electric start could be made by using the Automatic
Decompression Device (see Low Battery Electric Starting under
ELECfRlC SfAR1); the electrical power required for the start
would then be considerably less, so that a discharged battery, if
not completely dead, might allow the start
NOTE: Oil will be supplied to all the bearing points when
hand-cranking.

Automatic Decompression Device
The Automatic Decompression Device works by holding the
exhaust valve open. The device has three positions, as indicated
by the pointer. When setting the pointer, tum the hex-head bolt
with a 10 mm wrench.


  A CAUTION: Neller use the Automatic Decompression
  Device to stop the engine.



                                                                 Engines & Generators

                                                                      10
                                      STARTING/STOPPING PROCEDURE
Manual Starting Procedure                                                  4. Crank the engine counterclockwise approximately 10 to 20
                                                                              times until the engine turns freely. Then remove the crank
To manually start the engine, follow the procedure described
                                                                              handle.
below. When starting after cold nights or freezing temperatures
when the engine must first be turned over with no compression,             S. Set the Automatic Decompression Device pointer to the
follow all of the steps, beginning with Step 1. If cold weather is            manual starting position (see illustration). When hand-crank-
not a factor, bypass Steps 1-3, and begin with Step 4.                        ing in this position, automatic decompression will occur.


 A WARNING: Always keep hands and feet clear of
 moving parts. Put the transmission in neutral. Do not
 use starting aids.                                                                                                             POINTER IN
                                                                                                                                THE MANUAl
                                                                                                                                STARTING
1. Place the transmission in neutral and advance the throttle con-                                                              PDsmDN
   trol to slightly open.
NOTE: Make sure the stop lever is in the RUN position.
2. Set the Automatic Decompression Device pointer to the
   Neutral position (see illustration). Compression is released
   when the pointer is in this position.



                                                                           6. Pull down the Cold Starting Device knob. Note: Do not pull
                                                                              down this knob when restarting a hot engine.

       POINTER IN
       THE NEUTRAl
       PDSmDN

                       ~

                       ~
                       ~
                           ~'lli=======

 3. Insert the crank handle into the crank handle guide (see
    illustration). Standing to the right of the crank handle, put your
    right hand on top of the air intake filter for support and grip the
                                                                                                                                   COLD STARTING
    crank handle with your left hand, with the thumb on your left                                                                  DEVICE KNOB
    hand in the position shown in the illustration.



                                                                               7. Insert the crank handle into the crank handle guide (see
                                                                                  illustration). Standing to the right of the crank handle, put
                                                                                  your right hand on top of the air intake silencer for support
                                                                                  and grip the crank handle with your left hand, with the thumb
                                                                                  on your left hand in the position shown in the illustration.
                                                                               S. Slowly crank the engine counterclockwise 4 times, then crank
                                                                                  the engine as fast as possible. The pointer on the Automatic
                                                                                  Decompression Device will automatically move clockwise
                                                                                  with each crank. Compression will occur after 8 cranks.
                                                                                  Continue to crank after compression occurs until the engine
                                                                                  starts firing. As decompression ends and compression occurs,
                                                                                  the pointer will automatically stop at the operating (9 o'clock)
                                                                                  position.After the engine starts, the crank handle will automat-
                                                                                  ically disengage. Then remove the crank handle.




                                                     CRANK HANDLE GUIDE

    HAND-CRANKING
   Model7A-1 shown
                                                                 Engines & Generators

                                                                          11
                                     STARTING/STOPPING PROCEDURE
                                                                      Initial Start-Up Check List
                                                                      o     Check for possible leaks from all the connections.
                                                                      o     Make sure the cooling water is discharging properly, outboard
   POINTER IN
                                                                            from the exhaust outlet.
   THE OPERATING
   POSITION                                                           o     Make certain that the engine is mounted securely.
                                                                      o     Listen for unusual sounds and vibrations.

                                                                      STOPPING THE ENGINE
                                                                      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, then turn off the keyswitch at the control panel.
                                                                      NOTE: Make certain this keyswitch is in the OFF position (12
                                                                      o'clock). if the keyswitch is left ON, the battery will discharge.
9. If the engine has not started, repeat Steps 5-9 above, and con-    An engine alarm is provided to warn the operator of this condi-
   sider cranking at a higher speed.                                  tion (key switch ON). The best method ofpreventing the battery
                                                                      from discharging is to remove the key from the keyswitch after
 A CAUTION: Prolonged cranking intervals without                       stopping the engine.
 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 engine's cylinder once the exhaust system fills.
 Prevent this from happening by closing the raw water
 supply through-hull shutoff, draining the exhaust muffler,
 and correcting the cause of the excessive engine crank-
 ing. Remember that engine damage resulting from raw
 water entry is not covered by Westerbeke's warranty.

Starting Under Cold Conditions
Make sure the lubricating oil is appropriate for the prevailing
temperature. Use oil with an API Specification of CF or CG-4,
SAE 30, lOW-30, or 15W-40. The battery should be fully
charged to minimize voltage drop.

OPERATING THE ENGINE                                                       A CAUTION: Neller stop the engine with the
Allow a few minutes for the engine to wann up at a comfortable             automatic decompression dellice, or when the engine is
rpm (approximately 1500 rpm), then reduce the rpm, and get                 under a full load.
underway.
                                                                          Check the lube oil level a few minutes after stopping the engine,
 A CAUTION: Never pull the cold starting dellice knob                     because lube oil from the bearings etc. continues to drain down
                                                                          into the oil sump. Disregarding this fact and not maintaining the
  down when the engine Is operating.                                      proper oil level may lead to overfilling, causing overheating and
                                                                          the possibility of engine runaway.
                                                                          After shutdown, carefully inspect the engine. Check for possible
                                                                          leaks from all the connections.




                                                              Engines & Generators

                                                                     12
                                           ENGINE BREAK-IN PROCEDURE
ENGINE BREAK-IN PROCEDURE                                                 4. Avoid rapid acceleration, especially with a cold engine.
Although your engine has experienced a minimum of one hour of             S. Use caution not to overload the engine. The presence of a
test operations at the factory to make sure accurate assembly pro-           grey or black exhaust and the inability of the engine to reach
cedures were followed and that the engine operated properly, a               its full rated speed are signs of an overload.
break-in time is required. The service life of your engine is             6. During the second 25 hours, the engine may be operated at
dependent upon how the engine is operated and serviced during                varying engine speeds, with short runs at full rated rpm.
its initial 50 hours of use.                                                 Avoid prolonged idling during this break-in period.
Breaking-in a new engine basically involves seating the piston
rings to the cylinder walls. Excessive oil consumption and smoky
                                                                              Break-In Check List
operation indicate that the cylinder walls are scored, which is               Monitor the following during the 50 hour break-in period:
caused by overloading the engine during the break-in period.                  o Check for fuel, engine oil and water leaks.
Your new engine requires approximately 50 hours of initial condi-             o   Check for abnormal noise such as knocking, friction, vibration
tioning operation to break-in each moving part in order to maxi-                  and blow-back sounds.
mize the performance and service life of the engine. Perform this
conditioning carefully, keeping in mind the following:
                                                                              o Confmn the exhaust smoke:
                                                                                  When the engine is cold - white smoke.
1. Start and stop the engine according to the STARTINGISTOP-
   PING PROCEDURE section. Run the engine at fast idle                            When the engine is warm - almost smokeless.
   while checking that all systems are functioning.                               When the engine is overloaded - some black smoke and soot.
2. Allow the engine to warm up, preferably by running at fast                 Also see the DAILY OPERATION CHECKllSTfor additional
   idle.                                                                      items to check each day.
NOTE: Some unstable running may occur in a cold engine. This                  The MAINTENANCE SCHEDULE section gives the maintenance
condition should abate as normal operating temperature is                     procedures to follow after the 50 hour break-in period.
reached and the propeller load is applied
3. While using the vessel, run the engine at various engine                   Transmission Break-In
    speeds for the first 25 hours. Avoid prolonged periods of                 See the HURTH HBW TRANSMISSION section of this manual for
    idling.                                                                   break-in information on your transmission.




                                                       DAILY OPERATION
DAILY OPERATION                                                           o   Check the starting batteries (weekly).
Start and stop the engine according to the instructions given in the      o Check drive belt for wear and proper tension (weekly).
STARTINGISTOPPING PROCEDURE section. Also follow the                      o Check the raw water pump to make sure its mounting is
instructions given in the ENGINE BREAK-IN PROCEDURE sec-                      secure.
tion during the first 50 hours of operation. Make sure all periodic       After starting the engine, check the following:
maintenance is performed according to the MAINTENANCE
SCHEDULE.                                                                 o Check for abnormal noise such as knocking, vibration and
                                                                            blowby sounds.
Daily Operation Check List                                                o Confmn exhaust smoke:
Follow this check list each day before starling your engine.                When the engine is cold - white smoke.
o Record the hourmeter reading in your log (engine hours                    When the engine is warm - almost smokeless.
    relate to the maintenance schedule).                                    When the engine is overloaded - some black smoke and soot.
o Visually inspect the engine for fuel, oil or water leaks.               o Make sure the cooling water is discharging properly, outboard
o   Check the oil level (dipstick).                                         from the exhaust outlet.
o   Check the transmission fluid level.                                       Transmission
o   Check your diesel fuel supply.                                            See DAILY OPERATION in the HURTH HBW TRANSMISSION
o   Look for clean fuel in the fuel filter/water separator transparent        section.
    bowl.
o   Check for loose wires at the alternator and make sure its
    mounting is secure.


                                                                Engines & Generators

                                                                         13
                                                   MAINTENANCE SCHEDULE
In order to use this Maintenance Schedule, it will be necessary
to log your engine hours. Use your engine hounneter or
record your engine hours by running time.
                                                                                      A WARNING: Never attempt to perfonn any service
                                                                                      while the engine is running. Wear the proper safety
NOTE: Many of the following maintenance procedures are                                equipment such as goggles and gloves, and use the
simple but others are more difficult and may require the expert                       COrtect tools for each job. Disconnect the battery
/awwledge of a service mechanic.                                                      tenninals when servicing any of the engine's DC
                                                                                      electrical equipment.


                                                     MAINTENANCE FREQUENCY
      COMPONENT           AFTER    DAILY    WEEKLY      EVERY       EVERY       EVERY       EVERY    EVERY            MAINTENANCE DESCRIPTION
                           ARST      OR                  100         3IJO           600      1000     2000
                            50     EVERY                HOURS       HOURS       HOURS       HOURS    HOURS
                          HOURS   8 HOURS
                                                                                                             Oil level should be between the full and low
 Engine oil level
                                   ·                                                                         indicating marks on the dipstick. Top up if
                                                                                                             necessary.
 Engine oil change
                           ·                              ·                                                  Change the oil: see CHANGING THE OIL
                                                                                                             under LUBRICATION SYSTEM
                                                                                                             Remove the oil strainer and clean it with
 Crankcase oil
 and strainer                                                                       ·                        diesel fuel. Flush the crankcase with the
                                                                                                             proper lube oil.
 Fuel supply
                                    ·                                                                        Check the fuel supply. Top up if necessary.
 Fuel filter/Water
 separator                          ·                     ·                                                  Check for water and dirt in the fuel. Drain
                                                                                                             and replace the filter if necessary.
 Fuel lift pump
                                                                                    ·                        Clean or replace the two filters. See FUEL
                                                                                                             LIFT PUMP under FUEL SYSTEM.
 Fuel filter
                                                          ·                                                  Change the filter.
                                                                                                             Check and adjust the injection opening pres-
 Fuel injector·
                                                                                    ·                        sure and spray condition (see TESTING THE
                                                                                                             FUEL INJECTOR under ENGINE
                                                                                                             ADJUSTMENTS).
                                                                                                             Remove the pump cover and inspect the
 Raw water pump
                                                                                    ·                        impeller, gaSket, cam and cover for wear. Check
                                                                                                             the bearings and seals (the shaft can tum, but
                                                                                                             not wobble). lubricate when reassembling.
 Raw water
 intake strainer                                          ·                                                  See RAW WATER INTAKE STRAINER under
                                                                                                             COOLING SYSTEM.

 Thermostat
                                                                                                      ·      Check the functioning of the thermostat; see
                                                                                                             THERMOSTATunder COOLING SYSTEM.

     Engine hosas
                                              ·                                                              Hoses should be hard and tight. Replace if soft
                                                                                                             and spongy. Check and tighten all hose clamps.
  Air intake filter
                                                           ·                                                 Clean.
                                                                                                             Inspect for leaks. Check the anti-siphon valve
                                                                                                             operation. Check that all connections are tight.
                                                                                                             Check the exhaust manifold/exhaust elbow for
     Exhaust system·
                            ·                  ·                      ·                                      carbon and/or corrosion buildup on inside pas-
                                                                                                             sages; clean and replace as necessary. Warning:
                                                                                                             A defective exhaust manifold/exhaust elbow can
                                                                                                             cause carbon monoxide leakage!
     Starting batteries                                                                                      Check electrolyte levels and make sure connec-
     and house
     batteries                                 ·                                                             tions are very tight. Clean off excessive corro-
                                                                                                             sian.
     DC Alternator
                                                                      ·                                      Check the DC charge from the alternator. Check
                                                                                                             mounting bracket; tighten electrical connections.

 ·Westerbeke recommends thai this service be performed by an authorized mechanic.                                                                (continued)




                                                                     Engines & Generators

                                                                             14
                                                 MAINTENANCE SCHEDULE
                                                     MAINTENANCE FREQUENCY

  COMPONENT            AFTER     DAILY      WEEKLY      EVERY       EVERY      EVERY   EVERY   EVERY          MAINTENANCE DESCRIPTION
                       FIRST      DR                     100         300        600     1000    2000
                        50      EVERY                   HOURS       HOURS      HOURS   HOURS   HOURS
                       HOURS   8 HOURS
                                                                                                       Inspect for proper tension: 3/8 -1/2 in.
                                                                                                       (10 -12 mm) deflection, and adjust if nec-
Drive belt
                                             ·                                                         essary. Check belt edges for wear (see
                                                                                                       DRIVE BELT ADJUSTMENT under ENGINE
                                                                                                       ADJUSTMENTS).
                                                                                                       Check the solenoid and motor for corro-
Starter motor"
                                                                                   ·                   sian. Remove and lubricate. Clean and
                                                                                                       lubricate the starter motor pinion drive.

Adjust engine
idle speed              ·                                                                              Adjust to 1000 - 1200 rpm.

                                                                                                       Adjust the valve clearances - see VALVE
Valve clearances"
                        ·                                                          ·                   CLEARANCE ADJUSTMENT under
                                                                                                       ENGINE ADJUSTMENTS.
                                                                                                       Check the compression pressure - see
Cylinder
compression"                                                                       ·                   ENGINE COMPRESSION TEST under
                                                                                                       ENGINE ADJUSTMENTS.
                                                                                                       Retorque the nuts (see TIGHTENING THE
Cylinder
head nuts                ·                                                         ·                   CYLINDER HEAD under ENGINE ADJUST-
                                                                                                       MENTS).
Transmission
fluid level
Engine
                                                                     ·                                 Initial fluid change at 25 hours, then every
                                                                                                       300 hours or at winterizing.
                                                                                                       Chattering at idle and low rpms is an indi-
transmission
damper plate                                                                            ·              cation of damper plate wear. Remove and
                                                                                                       replace.
Throttle and
transmission
control cable            ·                                           ·                                 Check for loose fittings, cotter pins, etc .
                                                                                                       Lubricate with WD-40 or equivalent.

Visual inspection
 Hardware fasten-
                                  ·                                                                    Check for oil, fuel and water leaks .
                                                                                                       Inspect and tighten all fastenings and accessi-
 ings and electrical
 connections             ·                                ·                                            ble screws, bolts and nuts. Inspect all wiring
                                                                                                       and electrical connections.
                                                                                                       Keep the engine's surface clean. Surface dirt
 Cleaning the
 engine                                       ·                                                        and oil will inhibit the engine's ability to remain
                                                                                                       cool.
 Lubricate                                                                                             Lubricate with LOCKEZE or equivalent every
 control panel
 keyswitch                                                ·                                            100 hours or at winterizing. After lubricating,
                                                                                                       check for smooth operating of the switch.

"Westerbeke recommends that this service be performed by an authorized mechanic.




                                                                     Engines & Generators

                                                                            15
                                                     EXHAUST SYSTEM
DESCRIPTION                                                              EXHAUST SYSTEM PRECAUTIONS
It is important to install a proper exhaust system to avoid engine       Carbon Monoxide
flooding. The system must be designed to prevent water from              The best protection against carbon monoxide poisoning is a daily
entering the exhaust line under any sea conditions and at any            inspection of the complete exhaust system. Check for leaks
angle of the vessel's hull. Exhaust system failures are not covered      around the exhaust manifold/elbow, exhaust hose, gaskets, and
by Westerbeke's warranty. The installer should have a basic              welds. Make sure there are no fumes entering your boat from a
knowledge of marine installation requirements.                           nearby vessel. Make sure the exhaust lines are not heating the
Westerbeke recommends installing an exhaust system having an             surrounding areas excessively. If excessive heat is present, correct
in-line muffler. The in-line muffler should be located below the         the situation immediately. If you notice a change in the sound or
engine's exhaust elbow. It must accumulate any water that runs           appearance of the exhaust system, shut down the engine immedi-
back down the exhaust line after the engine is shut down. Design         ately and have the exhaust system inspected and repaired at once
the system so there is an adequate drop in the line between the          by a qualified mechanic.
exhaust elbow and the through-hull discharge end of the line. The
exhaust hose must be certified for marine use.
                                                                           A WARNING:       Exhaust gasses contain carbon
                                                                           Monoxide, an odorless and colorless gas. carbon
 A CAUTION: An exhaust line that is too long and/or                        Monoxide is pOi5Onous and can cause unconsciousness
                                                                           and death. Symptoms of carbon Monoxide exposure
 has a poor gradient can cause water to retum back to
                                                                           can include:
 the engine when it is shut off.
                                                                              - Dizziness    - Throbbing In Temples
                                                                              -Nausea        - Muscular Twitching
                                                                              - Headache     - Weakness and Sleepiness
 A WARNING:        The exhaust system must be tight                           - Vomiting      -Inability to Think Coherently
 and free of leaks. Exhaust gasses are deadly. Display                      IF YOU OR ANYONE ELSE EXPERIENCE ANY OF THESE
 the carbon Monoxide waming decal near your engine,                         SYMPTOMS, BET OUT lITO FRESH AIR IMMEDIATELY.
 on your cabin bulkhead, or in 50me other prominent                         If the symptoms persist, seek medical attention. Shut
 location.                                                                  down the engine and rentilate the area with clean air.
                                                                            Do not restart the engine until it has been inspected
For more information about exhaust system design, see                       and repaired.
Westerbeke's INSTALLATION MANUAL for MARINE ENGINES
and GENERATORS, Publication # 43268.                                       Carbon Monoxide Warning Decal
Westerbeke presumes that the installer of this marine diesel engine        A carbon monoxide warning decal has been provided by
is familiar with the safeguards a water-cooled marine exhaust sys-         Westerbeke. Display this decal near your engine, on your cabin
tem will provide for the engine. Failure to design and layout a            bulkhead, or in some other prominent location.
proper exhaust system can result in catastrophic damage to the
diesel engine, and possibly result in the sinking of the vessel in
which the unit is installed.

Siphon-Break
 For installations where the 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. The siphon-break provides an air vent in the raw water
 cooling system to prevent raw water from filling the exhaust sys-
 tem and the engine's cylinder when the engine is shut down. See
 SIPHON-BREAK in the COOUNG SYSTEM section for more
 information.                                                                          WARNING
                                                                                        Engines Produce CARBON MONOXIDE
                                                                                            Regular Maintenance Required

  A CAUTION: Fal/ure to use a siphon-break when the                                              t:5i!EJWI!STE1IBEICE
                                                                                                        En,.-..GMemcn
  exhaust elbow is located at or below the load waterline
  will result in raw water damage to the engine and possi-                                        CARBON MONOXIDE
                                                                                                   WARNINO DECAL
  ble flooding of the boat.




                                                                Engines & Generators

                                                                      16
                                                     EXHAUST SYSTEM
Carbon Monoxide Detectors
It is extremely important that a carbon monoxide detector(s) be
installed in your boat's living and/or sleeping quarters. Make sure it is
manufactured for the marine industry. They are inexpensive and avail-
able at your marine supplier.
Insulation
Inspect insulated portions of the exhaust system to ensure there is no
deterioration of the insulation.
Overcranking

  A CAUTION: Prolonged cranking intervals without
  the engine starting can result in the engine exhaust sys-
  tem 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 engine's cylinder once the exhaust system
  fills. Prevent this from happening by closing the raw
  water supply through-hull shutoff, draining the exhaust
  muffler, and correcting the cause of the excessive
  engine cranking. Remember that engine damage
  resulting from raw water entry is not covered by
   Westerbeke's warranty.




                                                                Engines & Generators

                                                                         17
                                                     LUBRICATION SYSTEM
 DESCRIPTION
 The lubricating system is a pressure feeding system using an oil
 pump. The engine oil is drawn from the oil sump by the oil
 pump, which drives the oil, under pressure, through the various
 lubricating points in the engine. The oil then returns to the oil
 sump to repeat the continuous cycle.
 The gear-driven oil pump is built into the oil sump. The
 oil is pumped through a spin-on type oil filter (Model IIA-I
 only) to the main bearing and connecting rod bearing.
 The piston, cylinder liner and rocker arms are splash-
 lubricated. There is an oil strainer in the crankcase (see
 Crankcase/Oil Strainer in the MAlNIENANCE SCHEDULE                                                              OIL PRESSURE SWITCH
 for maintenance information. A crankcase breather valve is                                                       Model 11A-1 silo. .
 integrated into the cylinder head's inlet channel and is                      ENGINE OIL
 maintenance-free.
                                                                               Use a heavy duty engine oil with an API classification of CF
                                                                               or CG-4 or better. The SAE grade depends on the ambient
                                                                               temperature. For the recommended oil viscosity, see the
                                                                               following chart:
                                                                                        Operating Temperature                       Oil Viscosity
                                                                                      Above 68° F (20" C)                    SAE 30, 10W-30 or 15W-40
                                                                                      41° - 68° F (5° - 20° C)               SAE 20 or 10W-30
                                                                                      Below 41° F (5° C)                     SAE10W-30


  SPIN-ON OIL FILTER -H--t--
   Model 11A-1 only
                                                                                    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.

                                                                                   CHECKING THE OIL
                                                                                   Check the lube oil level (see illustration) prior to starting. With
                                                                                   continuous operation, check the oil level daily or every 8 hOUTS.
                                                                                   Check the lube oil level a few minutes after stopping the engine
                                                                                   because lube oil from the bearings etc. continues to drain down
                                                                                   into the oil sump. Disregarding this fact and not maintaining the
                                                                                   proper oil level may lead to overfilling, overheating and
BREATHER                                                                           engine runaway.
VAlVE
                                                                                   If a top-up is necessary, clean the area around the oil filler to
                                                                                   prevent dirt from entering the engine.




   Oil Pressure Relief Valve
  There is an oil pressure relief valve in the sump. If the oil pressure
  exceeds the maximum specified value, the valve opens and some
  of the oil returns to the sump, keeping the oil pressure below its
  maximum specified value.
   Low Oil Pressure Alarm Switch
   A low oil pressure alarm switch is located on the engine block. This                          WBE OIL DIPSTICK
   switch's sensor monitors the engine's oil pressure. Should the engine's                       Model7A-1 $lion
   oil pressure fall below the specified value, this switch will activate a
   pulsating aIarm on the control panel.

                                                                     Engines & Generators

                                                                              18
                                                 LUBRICATION SYSTEM
CHANGING THE OIL
Change the oil after an initial 50 hours of break-in operation and
every 100 hours of operation thereafter. Change the oil only when       ~,l«-'    GROUND

8. Start the engine again. Check the voltage between the
   alternator output and ground.                                                                               SERVICE BATTERY
    The voltage reading for a properly operating alternator
    should be between 13.5 and 14.5 volts. If your alternator                   GROUND                      TESTING THE SERVICE
    is over- or under-charging, have it repaired at a reliable
                                                                                                            BATTERY (ENGINE RUNNING)
    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 bat-              A CAUTION: To avoid damaging the alternator diodes,
    tery voltage at the B output terminal.                                 do not use a high voltage tester (i.e. a megger) wilen
                                                                           performing tests on the alternator charging circuit.
    If 12 volts is not present at the EXC terminal, trace the
    wiring and lookfor breaks and poor connections.




                                                            Engines & Generators

                                                                     29
                                                 DC ELECTRICAL SYSTEM'
                                                       7A-1 MARINE DIESEL ENGINE
                                                        WIRING DIAGRAM #45593
                                                                                                                      I' 4 Bl K
                                                                           RD          tI4R[O

               r-------------,
               I
                                                                                                          WATER TEIF.

              :r~
                                                                                                            SWITCH
SEE NOTE 2

              l§j
               I
               I                                                                                                                                            IlL PRESSUIE SWITCH
               I                                   o
                                                   w
             + I    r_- - - - - - - -,             ~




              ~                         :
                                        I
                                        I
                                        I
                                                                                       5   4
                                                             CfICUT
                                                            IIIIEAKER       '!WE
                                                                            IlEl..AY
                                                                            RELAY
                                                                                                3




        110 RED

                                                                         .,4 RED



                       GLOW
                       PLUOS




                                             STARlBI




      I'IEt£AT
      SOI..ENOIl
                                                                                                          I' 4 V 10


                                                                                   · I 2 WHT




                                                                                   '12 RED
                                                                                                                      11.4   VEL

                               i:14 ORANGE



                                                                                               51
                                                                                                                             · I 4 Bl II.




                                                                                               PI



 ® ~~T~~[
      THE
               7"-1 MODEL IS [OUIPPED WITH A TIME DELAY RELAY THAT PREVENTS
               EXCITATION or THE AlTERNATOR DURING PREHEAT AND CRANKING. THE
         ALTERNATOR EXCITATION Will OCCUR APPROX       31041NS AFTER THE   IGNITION
         KE Y HAS BEEN TURNED ON


                                                                                                    ~~_r--t-----------_+_,                  .. ,




                                                                                   0c
                                                                                 KEY SWITCH

                                                                                                                                                   ! REMlTE PAf.E...




                                                                        WESTERBEKE
                                                                        Engines & Generators

                                                                               30
                            DC ELECTRICAL SYSTEM
                                 7A-1 MARINE DIESEL ENGINE
                                  WIRING SCHEMATIC #45593
     G) <                                               12 VDC                                     )
                                                                                                       G
                                                                                    STARTER

                                               r----'
                                               STARTER
                                               SOLENOIO


                                               _____         J




                                                                           GlOWPLUGS
                                                        r----'
                                                        I PREt£AT I
                                                        I SOLENOID I
                                                        I          I


                                                        - - - - _ ..           AlTERNATOR


         30   ~8~7   ______~________~____________________________~__/




                                                                                     86



     (   ClRCUT
         BREAKER                                                                          NO
                                                    5
                                          T1r.tE
                                          DEl..AY
                                          RELAY                                      WATER TEMP.
                                                                                       SWITCH
                                                                 3                          NC



                                                                                OIl PRESSURE SWITCH




SI
                                           6             7             5        3
PI




                                                                                    AlARM                  HOl.fl
                                                                                                           METER

                                                                                                       +




               START
                     PREJ-EAT0
                      IGN

                     OFF
                                 NOTES
                                    THIS PRODUCT IS PROTECTED BY A MANUAL RESET CIRCUIT BREAKER LOCATED NEAR THE
                                    STARTER   EXCESSIVE CURRENT WILL CAUSE THE BREAKER TO TRIP AND THE ENGINE WILL
               KEY SWITCH           SHUT DOWN. THE BUILDER/OWNER MUST BE SURE THAT THE INSTRUMENT PANEL, WIRING. AND
                                    ENGINE ARE INSTALLED TO PREVENT CONTACT BETWEEN ELECTRICAL DEVICES AND SEAWATER
                                   AN ON·orr SWITCH SHOULD BE INSTALLED BETWEEN THE BATTERY AND STARTER TO
                                   DISCONNECT THE BATTERY IN AN EMERGENCY AND WHEN LEAVING THE BOAT.   A SWITCH
                                   WITH A CONTINUOUS RATING or 175 AMPS. AT 12 VDC WILL SERVE THIS rUNCTION     THIS
                                   SWITCH SHOULD NOT BE USED TO MAKE OR BREAK THE CIRCUIT




                                               Engines & Generators

                                                        31
                                                 DC ELECTRICAL SYSTEM
                                                     11A-1 MARINE DIESEL ENGINE
                                                       WIRING DIAGRAM # 44542
                                                                                                 · I 4 BL K


         r------------...,
         I                               I
        1"0""                            I
                                                                                     WATER TEJoP.
                                                                                       SlilTCH
SEENlTE2:~                               :

       I~ .J
         I
         I                                                                                                                IlL PIESSUAE SWITCH
         I
       + I      r.- - - - - - - ...,

        ~



                                                 ®




                                       STARTER




                                                                ®114 RED/WHT
                                                                                     114 VIO


                                                             ®112 WHT




                                                             ®1I2RED
                                                                                                 .14 y[ l




                                                                         51
                                                                                                       II. BLK


                                                                         PI




                                                                               .
                                                                               :;:
                                                                               ;;
                                                                                                              .
                                                                                                              '"
                                                                                                              .
                                                                                                              -




                                                                KEY SWITCH


                                                            L                                                      REMOTE PAt£l.




                                                            Engines & Generators

                                                                    32
                           DC ELECTRICAL SYSTEM
                               11A-1 MARINE DIESEL ENGINE
                                WIRING SCHEMATIC # 44542
     +   ~(-----------12                          vee   ----------~)




                                                                        STARTER




                                    STARTER SOLENOID




                                                                   ALTERNATOR




         CIRCUT
     (   BREAKER


                                                                        WATER TEMP.
                                                                           SWITCH
                                                                                NC


                                                                    DI.. PRE5SUE SWITCH




SI
                           B                  7            5        3
P1




                                                                        ALARM                  HOUR
                                                                                               METER
                                                                                          +




                   START




                           NOTES:
                           I. THIS PRODUCT IS PROTECTED BY A MANUAL RESET CIRCUIT BREAKER LOCATED NEAR THE
                              STARTER. EXCESSIVE CURRENT WILL CAUSE THE BREAKER TO TRIP AND THE ENGINE WILL
              KEY SWITCH      SHUT DOWN. THE BUILDER/OWNER MUST BE SURE THAT THE INSTRUMENT PANEL. WIRING. AND
                              ENGINE ARE INSTALLED TO PREVENT CONTACT BETWEEN ELECTRICAL DEVICES AND SEAWATER.
                           2. AN ON-orF SWITCH SHOULD BE INSTALLED BETWEEN THE BATTERY AND STARTER TO
                              DISCONNECT THE BATTERY IN AN EMERGENCY AND WHEN LEAVING THE BOAT.   A SWITCH
                              WITH A CONTINUOUS RATING or 175 AMPS   AT 12 VDC WILL SERVE THIS rUNCTION    THIS
                              SWITCH SHOULD NOT BE USED TO MAKE OR BREAK THE CIRCUIT




                                         Engines & Generators

                                                  33
                                                          GLOW PLUGS
                                                            MODEL 7A-1 ONLY
DESCRIPTION                                                             Re-install the plugs in the air intake adapter and test them again. __
                                                                        The plugs should get very hot (at the terminal end) within 7 to 15
The glow plugs (2) are wired through the preheat solenoid. When         seconds. If the plugs don't heat up quickly, check for a short cir-
PREHEAT is pressed at the control panel this solenoid should            cuit. When reinstalling the glow plugs, use anti-seize compound
"click" on and the glow plug should begin to get hot.
                                                                        on the threads.
INSPECTION
To inspect the plug, remove the electrical terminal connections,            A WARNING: Do not keep a glow plug on for more
then unscrew each plug from the air intake adapter. Thoroughly              than 30 seconds.
clean each plug's tip and threads with a soft brush and cleaning
solution to remove all the carbon and oil deposits. While clean-        Glow plug tightening torque: 7 - 11 ft-Ib (1.0 - 1.5 m-kg)
ing, examine the tip for wear and burn erosion; if it has eroded too
much, replace the plug.

TESTING                                                                                    ~==-======"""",::e.. TERMINAL
                                                                                                                END
An accurate way to test glow plugs is with an ohmmeter. Touch
one prod to the glow plug's wire connection, and the other to the
body of the glow plug, as shown. A good glow plug will have a
0.55 ohm resistance. This method can be used with the plug in or
out of the engine. You can also use an ammeter to test the power                                 TESTING AGLOW PLUG
drain (5 - 6 amps per plug).                                                                     WITH AN OHMMETER


 A     WARNING:      These glow plugs will become very hot
  to the touch. Be careful not to bum your fingers when                                                                             TIP
  testing the plugs.




                                                                               TESTING A GLOW PLUG
                                                                               USING A TEST UGHT




                                                                                                                                       +




                                                               Engines & Generators

                                                                       34
                                                  ENGINE ADJUSTMENTS
                                NOTE: WESTERBEKE recommends that the following engine adjustments
                                be performed by a competent engine mechanic. The information below
                                is provided to assist the mechanic.
TIGHTENING THE CYLINDER HEAD                                               5. For each valve, insert a 0.2 mm (0.008 in.) feeler gauge
                                                                              between the valve stem and the rocker arm, and adjust the
After the initial break-in period (approximately 50 hours),
                                                                              clearance until a slight drag is felt on the gauge when it is
retorque the cylinder head nuts. Do this when the engine is cold.
                                                                              pulled out.
1. Remove the cylinder head cover and gasket.                              6. Tighten the locknut while holding the setting screw with
2. Retighten the four cylinder head nuts in an X-pattern                      a screwdriver.
    sequence as shown in the illustration. Start with any nut.             7. Recheck the clearance.
    Before applying the torque to a nut, loosen it 114 to 112 a
    tum, then apply the torque. See TORQUE
    SPECIFICATIONS for the proper torque.
3. Reinstall the cylinder head cover and gasket. Insert new
    plastic washers under the two nuts and tighten to the
    specified torque.




                                                                           ENGINE COMPRESSION TEST
                                                                           To check the engine's compression pressure, warm up the engine,
                                                                           shut off the raw water through-hull, remove the fuel injector, and
VALVE CLEARANCE ADJUSTMENT                                                 install a compression adapter in the injector hole. Connect a com-
                                                                           pression tester on the adapter and crank the engine with the starter
Check the valve clearances after the first 50 hours of operation and       motor until the pressure reaches a maximum value.
every 600 hours thereafter.
                                                                           Compression pressure at 350 rpm:
NOTE: Tighten the cylinder head bolts to their specified torque                 Minimum: 435.0 psi (30.6 kg/cm 2)
before adjusting the valve clearances (see TIGlffENING THE                      Standard: 478.5 psi (33.6 kg/cm2)
CYUNDER HEAD).
Adjust the valve clearances when the engine is cold. The
clearance is 0.2 mm (0.008 in.) for both intake and exhaust valves.
 1. Remove the cylinder head.
2. Check to make sure the automatic decompression
    device is in its normal operating position, i.e. not activated
    (see illustration).
                                                                                           ADAPTER



                                                                                                ~INJECTOR                  HOLE


   POINTER                                                                     If the pressure is weak, the problem is either valve- or piston-
                                   '---l-'H--   AUTOMATIC DECOMPRESSION        related. Check the valve clearance, adjust as needed, and test
                                                DEVICE IN THE NORMAL
                                                OPERATING POSITION             again. If the compression is still low, apply a small amount of oil
                                                                               into the cylinder to seal the rings, and repeat the test. If the
                                                                               compression comes up, the rings are faulty.
             ~                                                                 An abnormally high reading indicates heavy carbon accumulation,
             ~                                                                 a condition that might be accompanied by high pressure and noise.
              ="~JJ=======
                                                                               NOTE: In case of severe vibrations and detonation noise, have the
                                                                                injector checked and overlw.uled by an authorized fuel injection
3. Set the piston at the TDC of the compression stroke.                        service center. Poor fuel quality, contaminants and loss ofpositive
4. Loosen the locknuts on the valve setting screws                             fuel pressure to the injection pump will result in injector faults.
   (see illustration).


                                                                 Engines & Generators

                                                                          35
                                                 ENGINE ADJUSTMENTS
                                NOTE: WESTERBEKE recommends that the following engine adjustments
                                be performed by a competent engine mechanic. The information below is
                                provided to assist the mechanic.

TESTING THE FUEL INJECTOR                                                Checking The Injection Starting Pressure
NOTE: The fuel injector must be serviced in a clean room                 1. Set the nozzle tester in a clean place where there is
environment.                                                                no dust or dirt.
                                                                         2. Mount the nozzle and the nozzle holder on the
Removing the Fuel Injector                                                  nozzle tester.
1. Disconnect the high pressure fuel line from the injector,             3. Use new fuel that has an approximate temperature of
   then loosen the line at its attachment to the injection                  68°F (20°C).
   pump and move it out of the way of the injector. Avoid                4. Bleed the air in the nozzle line by pumping the nozzle
   bending the line.                                                        tester handle several times.
2. Remove the fuel return line in its entirety from the top of           5. Slowly lower the nozzle tester handle and check the
   the injector. Take care not to lose the two sealing                      reading on the pressure gauge when the injection starts.
   washers and banjo bolt that attaches the fuel return line
   to the injector.                                                         Injection starting pressure:
                                                                               2850 - 2900 Ib/in2 (200 - 203 kglcm2)
3. Remove the fuel injector holder bracket mounting nuts,
   then remove the holder bracket.
4. Remove the fuel injector.                                                A CAUTION: Keep hands away from the nozzle spray.
                                                                            The spray nozzle velocity Is such that It may psnettate
   NOTE: Clean the area around the base ofthe injector prior to
                                                                            dBfl/J/y into tllB fingBIS and hands, destroying tissue. If
   lifting it out ofthe cylinder head to help prevent any rust or
                                                                            it enters the bloodstream, It may CBIISB blood pOisoning.
   debris from falling down into the injector hole. ifthe injector
   will not lift out easily and is held in by carbon build-up or the
   like, worlc the injector side-ta-side with the aid ofa socket
   wrench to free it, and then lift it out.
    The injector seats in the cylinder head on a copper sealing
    washer. This washer should be removed with the injector and
    replaced with a new washer when the injector is reinstalled.
5. Remove the gaskets.                                                 FUEL
                                                                       INJECTOR
6. Remove the O-rings.

Fuel Injector Components
The fuel injector consists of the following parts:



                                                                                                      INJECTION PRESSURE TEST
          NOZZLE HOLOER


                                                                            6. If the injection starting pressure is not within the specified
         ADJUSTING SHIMS ~                                                     range, adjust it by replacing the shim with one of a more
                          ~@                                                   appropriate thickness.
                                                                               If the thickness of a shim is increased 0.004 in (0.1 mm),
        PRESSURE SPRING--I.                                                    the injection pressure increases approximately 145lblin2
                                                                               (10.1 kglcm2).
             VALVE CONE--!


          PRESSURE PIECE-e

                                                                                  ADJUSTING SHIM


                                                                                   "
                                                                                            FUEL INJECTOR ADJUSTING SHIM


                          FUEL INJECTOR
                           COMPONENTS                           Engines & Generators

                                                                       36
                                                  ENGINE ADJUSTMENTS
                                 NOTE: WESTERBEKE recommends that the following engine adjustments
                                 be peiformed by a competent engine mechanic. The information below is
                                 provided to assist the mechanic.

Tightness of the Valve Seat                                                Checking the Nozzle Body and Needle Valve
Apply a pressure of 2600 Iblin2(182 kglcm2) and check if fuel              1. Check for damage to the valve seat of the needle valve
leaks from the injection nozzle holes. If fuel leaks, disassemble,            and check for damage to other parts.
wash and recheck the injector nozzle or replace it                         2. Check for damage to the nozzle body. Hold the nozzle
                                                                              body upright and insert four-fifths of the needle valve.
                                                                              Then release the needle valve and check that it drops into
                                                                              the valve seat under its own weight.

                                                                           Reassembly
                                                                           Be sure to do the following when reassembling the-fuel injector:
                                                                           1. Tighten the nozzle body onto the nozzle holder to the
                                                                               specified torque.
                                                                               Nozzle torque:
                                                                                        29 - 36 ft-Ib (4.0 - 5.0 kg-m)




            CHECKING THE TIGHTNESS OF THE VALVE SEAT

Inspecting the Spray Pattern.
1. Mount the nozzle and nozzle holder on the nozzle tester.
2. Bleed the air in the nozzle line by pumping the nozzle
   tester handle several times.
3. Keep the reading on the pressure gauge of the nozzle
                                                                                                                    TIGHTENING THE
   tester just below the injection starting pressure while                                                        NomE BODY ONTO
   pumping the handle of the nozzle tester as quickly as                                                          THE NomE HOLDER
   possible so that a pulsating whistling sound is heard.
   Check the atorni~tion of the fuel injected from the
   nozzle (see illustration).                                                  2. After assembling the fuel injector, check the injection
                                                                                  starting pressure and the spray pattern.

                                                                               Injector Installation
                                                                               The fuel injector installation sequence is the reverse of the
                                                                               removal sequence. Make sure to include the following:
                                                                               1. Use new gaskets - do not reuse the old gaskets.
                                                                               2. Replace the copper sealing washer for each injector.
                                                                               3. Tighten the fuel injector holder bracket mounting nuts to
        NORMAl              FAUlTY              FAUlTY
                                                                                      the specified torque.
        PAmAN               PAmAN               PAmRN                             Bracket mounting nuts torque:
                  FUELIIUECTOR SPRAY PAnERNS                                           6 - 9 ft-Ib (0.8 - 1.2 kg-m)

 Normal Pattern: The fuel is sprayed uniformly and finely from
 all five injection nozzle holes.
 Faulty Pattern: The number of fuel sprays and fineness of the
 injected fuel is substandard. If the condition of the injected fuel is
 substandard, disassemble, wash and recheck the injection nozzle
 or replace it.




                                                                  Engines & Generators

                                                                          37
                                                  ENGINE ADJUSTMENTS
                                   NOTE: WESfERBEKE recommends that the following engine adjust-
                                   ments be performed by a competent engine mechanic. The infonnation
                                   below is provided to assist the mechanic.

DRIVE BELT ADJUSTMENT
The drive belt must be properly tensioned. A loose drive belt will
not provide proper alternator charging and will eventually damage
the a1temator. A drive belt that is too tight will pull the alternator
out of alignment and/or cause the alternator to wear out prema-
turely. Excessive drive belt tension can also cause rapid wear of
the belt A slack belt or the presence of oil on the belt can cause
belt slipping, resulting in high operating temperatures and rpm                              GOOD                  BAD
variations.                                                                  3. Pivot the alternator on the base mounting bolt to the left
                                                                                or right as required, to loosen or tighten.
 A WARNING: Never attempt to check or adjust the                             4. Tighten the base mounting bolt and the adjusting strap
                                                                                bolt securely.
 drive belt's tension while the engine Is in operation.
                                                                             5. Run the engine for about 5 minutes, then shut down and
Checking Belt Tension                                                           recheck the belt tension.
1. To check the belt tension, press the belt at the approxi-
   mate midpoint Gust above the bellhousing) between the
   alternator pulley and the flywheel pulley with a force of
   221bs (10 kg!) (98 N). The belt deflection should be 3/8"
   - 112" (10 - 12 rnm) deep.



                                               ALTERNATOR
                                               PUUEY




                                                   BELLHOUSING




                                                         flYWHEEL
                                                       . PULLEY



                                                     FLYWHEEL




 Adjusting Belt Tension
 1. To adjust the belt tension, loosen the alternator adjusting
    strap bolt and the base mounting bolt.
 2. With the belt loose, inspect the belt for damage, wear,
    cracks and frayed edges. If the belt is damaged, replace
    it. If it is nearly worn out and deeply sunk in the pulley
    groove, replace it.




                                                                    Engines & Generators

                                                                         38
                                            ENGINE TROUBLESHOOTING
The following troubleshooting chart provides information based
upon certain problem indicators, the probable causes of these
problems, and the recommendations to overcome them.

1. Engine will not start
   Problem                               Probable Cause                               Remedy

   Fuel supply failure                 If squirting cannot be heard:
   (check by cranking engine        1. No fuel in tank.                          1.   Fill tank.
   and listening for the            2. Vent hole in tank cap plugged.            2.   Replace cap.
   characteristic squirting in      3. Fuel filter clogged.                      3.   Replace filter.
   the fuel injector).              4. Faulty injector nozzle.                   4.   Check/replace nozzle.
                                    5. Faulty injection pump.                    5.   Check/repair/replace pump.
                                    6. Fuel line blocked.                        6.   Check fuel lines and remove blockage.
                                    7. Broken fuel line or leaking connection.   7.   Replace fuellineltighten connections.
                                       If squirting can be heard:
                                    1. Starting fuel button not pulled.          1. Pull button.
                                    2. Gasoline instead of diesel in tank.       2. Drain gasoline, flush system, fill with diesel.
                                    3. Air intake blocked.                       3. Check system for blockage.

    Poor compression                1. Automatic decompression                   1. CheCk/replace automatic decompression device.
                                       device malfunction.
                                    2. Incorrect valve clearance.                2. Adjust valve clearance.
                                    3. Valves not seating properly.              3. CheCk/repair/replace valves.
                                    4. Cylinder head loose.                      4. lighten cylinder head nuts.
                                    5. Piston rings stuck in grooves.            5. Check rings and clean the piston.
                                    6. Worn cylinder and piston.                 6. Overhaul the engine.
                                    7. Rusty exhaust valve.                      7. Spray lubricating oil into the cylinder, activate the
                                                                                    automatic decompression device, then start.
                                    8. Valves sticking.                          8. Free valves.

    Difficult to crank the engine   1. Lube oil too thick.                       1. Change to correct viscosity.
                                    2. Bearings seized.                          2. Overhaul the engine.
                                    3. Piston seized.                            3. Overhaul the engine.


 2. Engine starts but fires intermittently or soon stops
    Faulty fuel supply              1.   Fuel filter clogged.                    1.   Replace filter.
                                    2.   Water in fuel.                          2.   Drain fuel; fill with clean fuel.
                                    3.   Faulty injector nozzle.                 3.   CheCk/replace nozzle.
                                    4.   Faulty injection pump.                  4.   CheCk/repair/replace pump.
                                    5.   Fuel line clogged.                      5.   Check the fuel lines and remove the blockage.
                                    6.   Fuel lines or connections leak.         6.   Replace fuellineltighten connections.

    Faulty air intake and/or        1. Restrictedlblocked exhaust system.        1. Check/clean exhaust system.
    exhaust system.                 2. Restrictedlblocked air intake.            2. Check/clean air intake system.

    Poor Compression                     See Poor Compression under
                                         Engine will not Start.

                                                                                                                                      (continued)




                                                                Engines & Generators
                                                                       39
                                     ENGINE TROUBLESHOOTING
3. Engine lacks power and/or makes black smoke
  Problem                        Probable Cause                                Remedy

  Operating conditions     1. Engine overloaded.                          1. Reduce the load.
                           2. Power reduction due to altitude and/or
                              ambient temperature has not
                              been considered.
                           3. Clogged air filter.                         3. Clean/replace.

  Faulty fuel supply       1. Gasket under injector missing or            1. Correct the number of gaskets.
                              too many gaskets are installed.
                           2. Fuel filter clogged.                        2. Replace filter.
                           3. Faulty injection nozzle.                    3. Check/replace nozzle.
                           4. Faulty injection pump.                      4. Check/repair/replace pump

  Engine condition         1. Excessive carbon on piston and              1. Decarbonize.
                              cylinder head.
                           2. Faulty piston rings.                        2. Check/replace piston ring set.
                           3. Worn piston and cylinder.                   3. Overhaul engine.
                           4. Worn bearings.                              4. Overhaul engine.


4. Faulty running

  Engine overheats         1.    Engine ove~oaded.                        1.   Reduce load.
                           2.    Faulty raw water pump impeller.          2.   Replace impeller.
                           3.    Faulty thermostat.                       3.   Check/replace thermostat.
                           4.    Clogged raw water intake strainer.       4.   Clean the strainer.
                           5.    Lube oil level too high.                 5.   Drain to proper level.
                           6.    Faulty injector nozzle.                  6.   Check/replace nozzle.

   Knocking                1.    Injector needle sticking.                1.   Replace nozzle.
                           2.    Fuel timing too far advanced.            2.   Adjust timing.
                           3.    Broken piston ring.                      3.   Replace piston ring set.
                           4.    Worn piston.                             4.   Replace piston and liner.
                           5.    Worn bearings.                           4.   Replace bearings.
                           6.    Loose flywheel.                          6.   Tighten flywheel nut.

   Engine is hunting       1.    Engine is overheating.                   1.   See Engine Overheats, above.
                           2.    Air in fuel lines.                       2.   Check fuel system for leaking connections.
                           3.    Governor sticking or defective.          3.   Free the governor or replace.
                           4.    Fuel filter clogged.                     4.   Replace filter.

   Engine stops suddenly    1.   Fuel tank is empty.                      1.   Fill tank.
                            2.   Vent hole in fuel tank cap is plugged.   2.   Replace tank cap.
                            3.   Vapor lock (fuel is too hot).            3.   Cool the fuel.
                            4.   Clogged injector.                        4.   Replace nozzle.
                            5.   Fuel line is broken.                     5.   Replace.
                            6.   Seized piston.                           6.   Replace piston and liner.
                            7.   Seized crankshaft.                       7.   Repair/replace crankshaft and bearings.
                                                                                                                            (continued)




                                                        Engines & Generators

                                                                 40
                                       ENGINE TROUBLESHOOTING
  Problem                         Probable Cause                                Remedy

  Blue smoke                 1.   Breather valve is clogged.               1.   Replace breather.
                             2.   Oil seal at intake valve is defective.   2.   Replace oil seal.
                             3.   Worn valves/valve guides.                3.   Replace valves and guides.
                             4.   Worn piston/cylinder.                    4.   Replace piston and cylinder.

  White smoke                1. Fuel timing is too late.                   1. Adjust timing.
                             2. Injector nozzle is worn out.               2. Replace nozzle.
                             3. Low engine operating temperature.          3. Clean thermostat.

  Oil in exhaust discharge   1. Rings not seated.                          1. Initial 50 hours of operation required to seat rings.
                             2. Low compression - bad valve.               2. Check/repair/replace valves.


5. Low Oil Pressure
  Low oil pressure           1. Incorrect oil viscocity.                    1. Change oil to correct viscocity.
                             2. Faulty pressure relief valve.               2. Replace pressure relief valve.
                             3. Incorrect oil filter.                       3. Install correct oil filter.




                                                            Engines & Generators

                                                                    41
                                             HURTH HBW TRANSMISSION
WESTERBEKE'S 7A-l and llA-l diesel engines each use a                  The control cable, or rod, should be arranged at a right angle to _
HURTH Model HBW 40 transmission. Installation, operation,              the actuating lever when in the neutral position. The neutral posi-
maintenance and troubleshooting infonnation for this transmission      tion of the shift lever on the control console should coincide with
is included in the following instructions.                             the neutral position of the actuating lever.
                                                                       The shifting travel, as measured at the pivot points of the actuat-
INSTALLATION                                                           ing lever between the neutral position and end positions A and B,
NOTE: When installing the transmission. make certain that shift-       should be at least 35 mm for the outer pivot point and 30 mm for
ing is not impeded by restricted movability of the cable or rod        the inner pivot point
linkLlge, by unsuitably positioned guide sheaves, too small a bend-        A greater amount of shift lever travel is in no way detrimental and
ing radius or other restrictions. In order to mount a support for          is recommended. However, if the lever travel is shorter, proper
shift control cable connections, use the two threaded holes located        clutch engagement might be impeded which, in tum, would mean
above the cable bracket mounted on the gear housing. Refer to              premature wear, excessive heat generation and clutch plate failure.
the WESfERBEKE Parts list.                                                 This would be indicated by slow clutch engagement or no engage-
                                                                           ment at all.
Shaft Couplings
                                                                           NOTE: Check for proper actuating lever travel at least each
WESTERBEKE recommends a flexible connection between the                    season.
transmission and the propeller shaft if the engine is flexibly
mounted, in order to compensate for angular deflections. The
installation of a special propeller thrust bearing is not required,
since the propeller thrust will be absorbed by the transmission
bearing, provided the value specified under SPECIFICATIONS is
not exceeded. However, the output shaft should be protected
from additional loads. Special care should be taken to prevent tor-
sional vibration. When using a universal joint shaft, make certain
to observe the manufacturers instructions.
Even with the engine solidly mounted, the use of a flexible cou-
pling or DRNESAVER* will reduce stress in the gearbox bearings
caused by hull distortions, especially in wooden boats or where
 the distance between the transmission output flange and the stem
 gland is less than about 32 in. (812 mm).

Shift Control and Actuating Lever
The transmission is suitable for single lever remote control. Upon
loosening the retaining screw, the actuating lever can be moved to                                                           ACTUATING
                                                                                                                             LEVER
any position required for the shift control (cable or rod linkage).
Make certain that the actuating lever does not contact the actuat-
ing lever cover plate: the minimum distance between lever and
cover should be 0.02 in. (0.5 mm), (see illustration).

                                                                                                                           COVER
  A Caution:      The position of the mechanism behind
  the actuating lever is factory-adjusted to ensure equal
  actuating lever travel from Neutral position N to Reverse
  position A and Forward position B. «this mechanism is                                                       mm)~~
                                                                                                    0.02 in. (0.5
                                                                                                    MINIMUM DISTANCE
  in any way tampered with, the transmission warranty will
  be mid.




 *DRIVESAVER is a product o/Globe Marine. Rocldand MA.



                                                              Engines & Generators

                                                                      42
                                             HURTH HBW TRANSMISSION
INITIAL OPERATION                                                         LOCKING THE PROPELLER
All HBW maine transmissions are test-run on a test stand with the         Locking of the propeller shaft by an additional brake is not
engine at the factory prior to delivery. For safety reasons the fluid     required: use the gear shift lever position opposite your direction
is drained before shipment.                                               of travel for this purpose. Never put the gear shift in the position
Fill the gearbox with Automatic Transmission fluid (DEXTRON               corresponding to the direction of travel of the boat.
111). The fluid level should be up to the index mark on the dip-
stick. To check the fluid level, just insert the dipstick, do not         WHEN UNDER SAIL OR BEING TOWED
screw it in. Screw the dipstick into the case after the fluid level is    Rotation of the propeller without a load, such as when the boat is
checked, and tighten. Do not forget the sealing ring under the            being sailed, being towed, or anchored in a river, as well as opera-
hexhead of the dipstick. Check for leaks and make a visual                tion of the engine with the propeller stopped (for charging the bat-
inspection of the coupling, oil cooler and hoses, and shift cables.       tery), will have no detrimental effects on the transmission.


                  DIPSTICK                                                DAILY OPERATION
                                                                          o    Check the transmission fluid level.
                                                                          o    Visually check the gear shift linkage and transmission.
                                                                          o    Start the engine in neutral, allowing a few minutes at idle to
                                  CHECKING           TRANSMISSION
                                  FLUID              OPERATING
                                                                               warm the fluid.
                                                                          o Shift into gear.
                                                                          NOTE: Too Iowan idle speed will produce a chattering noise
                                                                          from the transmission gear and damper plate. In such cases the
             I                                                             idle speed should be increased.
                                                                          For additional information refer to the following text in this

          f!l[h
                                    FLUID LEVEL                           Transmission section: SHAFT COUPliNGS, MAINTENANCE,
                                                                          and TRANSMISSION TROUBI.£SHOOTING.

FLUID   DRAI~Ql.
              I
                                                                          Operating Temperature


 FLUID CHANGE                                                                  A WARNING: if the transmission fluid temperature is
                                                                               too high, stop the engine immediately and check the
 Change the fluid for the first time after about 25 hours of opera-            transmission fluid.
 tion, then every 300 operating hours or at winterizing.
                                                                              Normal operating temperature of the transmission fluid should be
 Removing the Fluid                                                           in the range of 1220 F (500 C) to 2120 F (100° C). A maximum
                                                                              temperature of 266° F (1300 C) may be only reached for a short
 Push a suction pump hose down through the dipstick hole to the
                                                                              time.
 bottom of the housing and suck out the fluid. If space allows, use
 the transmission drain. Remove the drain plug from the bottom                Make certain there is enough space around the transmission to
 of the transmission and allow the fluid to drain into a container,           provide good ventilation and cooling.
 then reinstall the plug with its sealing washer. Wipe down the
 transmission and properly dispose of the used fluid. After running           SPECIFICATIONS
 the engine, shut down and recheck the fluid level.
                                                                                                         TRANSMISSION
 Drain plug torque: 20 - 2S Mb (27.7 - 34.6 Nm)
                                                                                General                   HURTH HBW 40 Standard Transmission,
 NOTE: When changing the fluid, take care not to lose the drain                                           case hardened helical gears, with a servo-
 plug sealing washer. The drain plug will leak without this sealing                                       operated multiple disc clutch.
 washer.
                                                                                Gear Ratio (optional)     2.05:1
                                                                                Lubricating Fluid         ATF- type A or DEXTRON - /I or /1/
  A WARNING: Never pullout the dipstick while the                               Transmission Sump         0.37 qts (0.35 liters)
  engine is running. Hot fluid will splash from the dipstick                    Capacity
  hole. This could cause sever bums.
                                                                                 Propeller Shaft          Right hand-standard transmission
                                                                                 Direction of Rotation




                                                                 Engines & Generators

                                                                         43
                                           HURTH HBW TRANSMISSION
MAINTENANCE
Transmission maintenance is minimal. Keep the exterior housing
clean, check the fluid level as part of your regular routine, and
change the fluid every 300 operating hOUTS.
Periodically inspect the transmission for leaks and corrosion.
Lubricate the cable connections.

Lay-up/Winterize
Storage requires special care. Follow these procedures.
o Clean up the transmission and touch up unpainted areas (use
    heat resistant paint).
o Fill the transmission with Dextron III ATF fluid to prevent
    internal corrosion (extended storage only, twelve months or
    more).
o Loosen attaching hardware from the transmission output
    flange and propeller shaft coupling flange before removing the
    boat from the water. Separate the flanges and spray with
    lubricant.
o Inspect the gear shift cable, linkage, and attachments. Look
    for corrosion of the end fittings, cracks or cuts in the conduit,
    and bending of the cable rods. Lubricate all moving parts.
    NOTE: If the transmission is to be stored for a long time
    (twelve months or more), it sJwuld be topped off with fluid to
    prevent internal corrosion. Reduce the fluid level before
    putting the engine back into service.
For additional information contact:
     HURTH MARINE GEAR
    ZF Industries
     Marine US Headquarters
     3131 SW 42nd Street
     Fort Lauderdale, FL 33312
     Tel.: (954)581-4040
     Fax.: (954)581-4077




                                                                Engines & Generators

                                                                        44
                           HURTH HBW TRANSMISSION TROUBLESHOOTING
CONTROL CABLES                                                                     A new cable and perhaps a new linkage mechanism may be
                                                                                   needed. While the cable is loose, shift the transmission in and out
The majority of transmission difficulties arise as a result of prob-
                                                                                   of gear using the actuating lever on the side of the transmission to
lems with control cables rather than from problems with the trans-
                                                                                   make sure there's no binding inside the case.
mission itself.
                                                                                   If the transmission passes these tests, crank the engine and have a
If you experience operating problems with the transmission, shut
                                                                                   helper put it in forward and reverse while you observe the pro-
the engine down. First check the transmission fluid level, then
                                                                                   peller shaft; if the shaft isn't turning, the transmission needs pro-
have a helper move the cockpit shift lever through the full range
                                                                                   fessional attention. If it does tum but there's no thrust, check to
- from neutral to full forward, back to neutral, into full reverse,
                                                                                   see if you still have a propeller on the end of the shaft or, if you
and back to neutral - while you observe the actuating lever on
                                                                                   have a folding or feathering propeller, that it isn't stuck in the "no
the transmission. If the remote is stiff to operate, break the cable               pitch" position.
loose at the transmission and try again. If it is still stiff, check the
cable for kinks or excessively tight bends, and check any linkage                  NOTE: If you suspect a major problem in your transmission,
for binding.                                                                       immediately contact your WESTERBEKE dealer or an authorized
                                                                                   marine transmission facility.

              Problem                                 Probable Cause                                                  Remedy
   Transmission gears cannot           1. Actuating lever is loose.                         1. Tighten damping bolt on actuating lever.
   be shifted. Fails to move           2. Shifting cable is broken, bent or unattached.     2. Check the cable, reattach or replace.
   into gear.                             Cable radius is too severe.
                                       3. Actuating lever is binding against cover          3. Detach the shift cable and operate the actuating lever by
                                          plate.                                               hand. Clearance should be 0.02 in. (0.5 mm).

   Transmission shifts into            1. Output coupling is not turning.                   1. Transmission needs professional attention.
   gear, but fails to propel           2. Propeller shaft is not turning. Output            2. The coupling bolts are sheared or the coupling is slipping
   the boat.                              coupling is tuming.                                  on the propeller shaft. Tighten or replace set screws, keys,
                                                                                               pins and coupling bolts as necessary.
                                       3. Output coupling and propeller shaft are           3. Inspect the propeller; it may be missing or damaged. A
                                          both turning.                                        folding propeller may be jammed. Avariable pitch propeller
                                                                                               may be in "no pitch" position.

    Delay of gear engagement           1. Actuating lever travel Nto B not equal to         1. Adjust cover plate until the lever is exact mid position.
    or engages only after an              Nto A. Refer to diagram.                             Refer to actuating lever text and diagram.
    increase in speed.                 2. Actuating lever travel is insufficient.           2. Check actuating lever cable length. Refer to lever diagram.
                                       3. Actuating lever is binding against cover plate.   3. Check clearance, adjust if necessary.

    Chattering transmission            1. The engine or propeller generates torsional       1. Mount a flexible coupling with another stiffness factor
    noise, mainly at low engine           vibrations in the drive unit which produces          between the transmission coupling and the driveshaft. A
    speed.                                a "chattering" noise in the transmission.            higher stiffness factor might be sufficient.
                                                                                            2. Inspect the damper plate between the engine and the
                                                                                               transmission. Replace if necessary.

    Transmission noise becomes         1. Damage starting on flexible coupling due to       1. Check alignment, inspect flexible coupling. If noise
    louder.                               wear or fatigue, possibly due to misalign-           persists, inspect the damper plate between the trans-
                                          ment between engine and the drive shaft.             mission and the engine. Replace if necessary.
                                       2. Beginning damage of bearings in trans-            2. Transmission needs professional attention.
                                          mission due to torsional vibrations, running
                                          without fluid, overload, wrong alignment
                                          of transmission, or excessive engine output.

    Boat tails to attain specified      1. Operating temperature is high.                    1. Wrong type of fluid; use ATF type A or DEXTRON /I or III.
    max. speed.                                                                                 Check fluid level.

    Oil leakage.                        1. Corrosion at radial sealing ring and shaft.       1. Transmission needs professional attention.
                                           Damaged sealing ring.
                                        2. Misalignment of output flanges.                   2. Check alignment. Must be within 0.003 in. (0.08 mm).




                                                                     Engines & Generators

                                                                             45
                                        LAY-UP AND RECOMMISSIONING
GENERAL                                                                   Change the fuel ftlter elements on the engine (see FUEL
                                                                          SYSTEM) and bleed the fuel system, as needed. Start the engine
Many owners rely on their boatyards to prepare their craft,               and allow it to run for 5-10 minutes to make sure there is no air
including engines and generators, for lay-up during the off season        left in the fuel system. Check for any leaks that may have been
or for long periods of inactivity. Others prefer to accomplish            created in the fuel system during this servicing, correcting them as
lay-up preparation themselves.                                            needed. Operate the engine for 5-10 minutes. This will allow
The procedures which follow will allow you to perfonn your own            movement of the treated fuel through the injection equipment of
lay-up and recommissioning, or you may use them as a check list           the engine.
if others do the procedures.
These procedures should afford your engine protection during                  Long-Term Lay-Up Procedure (over 12 months)
lay-up and also help familiarize you with the maintenance needs               For a long-tenn lay-up, follow the fuel system lay-up procedures
of your engine.                                                               described above, then do the following:
If you have any questions regarding lay-up procedures, call your              Disconnect the fuel supply line from the fuel tank at the fuel lift
local servicing dealer; he will be more than willing to provide               pump. Fill a suitable container with a 0.132 U.S. gallon (0.5 litre)
assistance.                                                                   mixture of 9/10 diesel fuel and 1110 anti-corrosion oil. Connect a
                                                                              short suction pipe between the container and the fuel lift pump.
PROPELLER SHAFT COUPLING                                                      Set the speed control lever to full load, set the automatic
The transmission and propeller half couplings should always be                decompression device to its neutral position, then hand-crank the
opened up and the bolts removed when the boat is hauled out of                engine approximately 20 times. Put the speed control lever back
the water or moved from land to water, and during storage in the              to the idle position.
cradle. The flexibility of the boat often puts a severe strain on the
propeller shaft or coupling or both, while the boat is taken out or           RAW WATER COOLING CIRCUIT
put in the water. In some cases, the shaft has actually been bent             Remove the impeller from your raw water pump and allow the
by these strains. This does not apply to small boats that are                 raw water in the cylinder head coolant chamber to drain out.
hauled out of the water when not in use, unless they have been                Allow it to drain completely. Examine the impeller. Acquire a
dry for a considerable period of time.                                        replacement, if needed, and a cover gasket. Do not replace the
                                                                              impeller (into the pump) until recommissioning, but replace the
LUBRICATING SYSTEM                                                            cover and gasket. Drain the water lift muffler.
With the engine warm, drain all the engine oil from the oil sump.
Fill the sump with the correct amount of oil for your engine (refer           AIR INTAKE & THROUGH-HULL EXHAUST
to the SPECIFICATIONS section of this manual). Use an oil with                Remove the air intake silencer and place a clean cloth, lightly
an API specification of CF or CG-4. Run the engine and check                  soaked in lubricating oil, in the air intake opening to block the
for proper oil pressure and make sure there are no leaks.                     opening. Do not shove the cloth out of sight (if it is not visible at
                                                                              recommissioning, and an attempt is made to start the engine, you
                                                                              may need the assistance of a servicing dealer). Make a note to
  A Caution: Do not leave the engine's old engine                             remove the cloth prior to start-up. The through-hull exhaust port
  oil in the sump over the lay-up period. Engine oil and                      can be blocked in the same manner.
  combustion deposits combine to produce harmful
  chemicals which can reduce the life of your engine's                        CYLINDER AND VALVES
  intemal parts.                                                              To protect the cylinder and valves, remove the air intake silencer.
                                                                              Then spray fogging oil into the cylinder head air intake opening.
FUEL SYSTEM                                                                   Rotate the engine two revolutions using the hand crank. Spray
                                                                              fogging oil into the air intake again. Replace the air intake
Top off your fuel tanks with No.2 diesel fuel. Fuel additives such            silencer.
as BlOBOR AND STA-BIL should be added at this time to control
algae and condition the fuel. Care should be taken that the addi-             If you anticipate a long lay-up period (12 months or more)
tives used are compatible with the primary fuel filter/water separa-          WESTERBEKE recommends removing the fuel injector for
tor used in the system. Change the ftlter element in your primary             access to the cylinder, then squirting light lubricating oil into the
fuel ftlter/water separator, if the fuel system has one, and clean the        cylinder to prevent the piston rings from sticking to the cylinder
separator sediment bowl. Reinstall and make certain there are no              walls. After squirting the oil, move the piston by a quick electric
leaks. Clean up any spilled fuel.                                             start or the hand crank to distribute the oil. Make sure you have
                                                                              replacements for the injector and return line sealing washers.




                                                                 Engines & Generators

                                                                         46
                                        LAY-UP AND RECOMMISSIONING
STARTER MOTOR                                                              STORAGE
Lubrication and cleaning of the starter drive pinion is advisable.         Thoroughly clean the outside of the engine, then store the
Make sure the battery connections are shut off before attempting           engine in a dry place, protected against the weather.
to remove the starter. Take care in properly replacing any
electrical connections removed from the starter.                           RECOMMISSIONING
                                                                           The recommissioning of your WESTERBEKE engine after a sea-
BATTERIES                                                                  sonallay-up generally follows the same procedures as those
If batteries are to be left on board during the lay-up period, make        described in the PREPARATIONS FOR INITIAL START-UP
sure they are fully charged, and will remain that way, to prevent          section regarding preparation for starting and normal starts.
them from freezing. If there is any doubt the batteries will not           However, some of the lay-up procedures will need to be
remain full charged, or that they will be subjected to severe              counteracted before starting the engine.
environmental conditions, remove the batteries and store them in a         1. Remove the oil-soaked cloths from the air intake opening
warmer, more compatible environment                                            and the through-hull exhaust port.
                                                                           2. Remove the raw water pump cover and gasket and
 A WARNING: Lead acid batteries emit hydrogen, a                               discard the old gasket.
 highly-explosive gas, which can be ignited by electrical                      Install the raw water pump impeller that was removed
 arcing or a lighted cigarette, cigar, or pipe. Do not                         during lay-up (or a replacement, if required). Install the
 smoke or allow an open flame near the battery being                           raw water pump cover with a new cover gasket.
 serviced. Shut off all electrical equipment in the vicin-                 3. Reinstall the batteries that were removed during the
 ity to prevent electrical arCing during servicing.                             lay-up, 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.
TRANSMISSION
Check or change the fluid in the transmission as required. Wipe
off grime and grease and touch up any unpainted areas. Protect                  A CAUTION:        Wear rubber gloves, a rubber apron
the coupling and the output flange with an anti-corrosion coating.              and eye protection when servicing batteries. Lead
Check that the transmission vent is open.                                       acid batteries emit hydrogen, a highly explosive gas,
For additional information, see Lay-uplWinterize in the HURTH                   which can be ignited by electrical arcing or a lighted
HBW TRANSMISSION section.                                                       cigarette, cigar or pipe. Do not smoke or allow an
                                                                                open flame near the battery being serviced. Shut off
SPARE PARTS                                                                     all electrical equipment in the vicinity to prevent
                                                                                electrical arcing during servicing.
Lay-up time provides a good opportunity to inspect your
WESTERBEKE engine to see if external items such as the drive               4. Start the engine in accordance with the PREPARATIONS
belt or coolant hoses need replacement. Check your basic spares
                                                                              FOR INITIAL START-UP and STARTING/STOPPING
kit and order items not on hand, or replace those items used                  PROCEDURE sections of this manual.
during the lay-up, such as filters. See SUGGESTED SPARE
PARTS.

KEYSWITCH MAINTENANCE
Lubricate the keyswitch with WCKEZE to ensure that the switch
mechanism functions freely with no binding.




                                                                Engines & Generators

                                                                      47
                               7A·1 & 11 A·1 TORQUE SPECIFICATIONS
                                                         MOOEl7A-1                               MODEL 11A-1                 -
                 Component
                                        SPANNER         TIGHTENING TORQUE (Nm)   SPANNER         TIGHTENING TORQUE (Nm)
                                           SIZE                                     SIZE
                                          (mm)             MIN.         MAX.       (mm)            MIN.             MAX.
Cylinder head                                13             30           33           17            52                  56
Connecting rod                               13             30           33           14            52                  56
Cylinder head cover                          13             8            12           13            8                   12
Main bearing plate                           13             30           33           13            30                  33
Fuel lift pump                               13             30            33          13            30                  33
Fuel injection pump                          13             30           33           13            30                  33
Delivery valve holder-injection pump         14             34           39           14            34                  39
High pressure fuelline-injection pump        17             18           22           17            18                  22
High pressure fuel line-fuel injector        17             25           30           17            25                  30
Injector clamp                               10             8            12           13            20                  23
Governor on crankshaft                       14             55           60           14            55                  60
Aywheel                                      36            216           226          46           390              410
Gear end cover                               6              34           38           6             34                  38
Push rod guide                               4              8            10           4             8                   10
Crank handle guide                           10             8             12          10            8                   12
Oil pump                                     5              16            20          5             16                  20
Sump plate                              cross-slotted       9             11     cross-slotted      9                   11
Banjo bolt on fuel lift pump                 17             25            35          17            25                  35
Banjo bolt on tank                           12             8             10          12            8                   10
Rocker bracket                               13             30           33           17            52                  56
Oil filter                                  -               -            -           -                   Hand-tighten




                                                        Engines & Generators

                                                             48
                                                        STANDARD HARDWARE
BOLT HEAD MARKINGS
                                                                                Metric bolt class numbers identify bolts by their strength with 10.9 the
                                                                                strongest




            1. Use the torque values listed below when specific torque values are not available.
            2. These torques are based on clean, dry threads. Reduce torque by 10% when engine oil is used.
            3. Reduce torques by 30% or more, when threading capscrews into aluminum.
    STANDARD BOLT & NUT TORQUE SPECIFICATIONS                                            METRIC BOLT & NUT TORQUE SPECIFICATIONS
                        SAE Glade 5      SAE Glade 6-7        SAEGrada8
C8psrew Body SIze         TDIqIII           Torque              Torque            Bon                    Grada4.6      Grade 4.B    Grade B.B - 9.8 Grade 10.9
 (Inches) - (TIIread)    FHb (Nm)         Ft-lb(Nm)            R-Lb(Nm)           Ola.   Wrench Size     A-Lb(Nm)      A-Lb(Nm)       FI-Lb(Nm)     R-Lb(Nm)
       1/4-20               8 (11)           10 (14)             12 (16)
           -28             10 (14)                               14 (19)          M3       5.5mm          0.3 (0.5)     0.5 (0.1)       1 (1.3)        1.5 (2)
                                                                                  M4        7mm           0.8 (1.1)      1 (1.5)         2 (3)         3(4.5)
     5/16 -18              17 (23)           19(26)              24 (33)          M5        8mm           1.5 (2.5        2(3)          4.5 (6)        6.5 (9)
          -24              19 (26)                               27 (31)
       3/8 -16             31 (42)           34(46)              44 (60).
                                                                                  M8       10mm             3 (4)        4 (5.5)        7.5 (10)      11 (15)
           -24             35 (41)                               49(66)           M9       13mm            7 (9.5)       10 (13)        18 (25)       35(26)
     7116-14               49(66)             55 (75)            70 (95)          Ml0      16mm            14 (19)       18 (25)        37 (50)       55 (75)
         -20               55 (75)                               78 (106)
       1!2 -13             75 (102)           85 (115)          105 (142)         M12      18mm            26 (35)      33 (45)         63(85)       'fl (130)
           -20             85 (115)                             120 (163)         M14      21 mm           37 (50)       55 (75)       103 (140)     151 (205)
                                                                                  M16      24mm            59 (80)      85 (115)       159 (215)     232 (315)
     9/16 -12             110 (149)          120 (163)          155 (210)
          -18             120(163)                             ·170 (231)
                                                                                  M18       27mm          81 (110)      118 (160)      225 (305)     321 (435)
       5t8 -11            150 (203)          167 (226)          210 (285)         M20       30mm          118 (160)     166 (225)      321 (435)     457 (620)
           -18            170 (231)                             240 (325)         M22       33mm          159 (215)     225 (305)      435 (590)     620 (840)
       314 -10            270 (366)          280 (380)          375 (508)
           -16            295(400)                              42!"(569)         M24       36mm          203 (275)     288 (390)      553 (750)    789 (1070)
                                                                                  M27       41 mm         295 (400)     417 (565)     811 (1100)    1154 (1565)
       7/8- 9             395 (536)          440 (591)          605 (820)         M30       46mm          402 (545)     568 (770)     1103 (1495)   1571 (2130)
          -14             435 (590)                             675 (915)
         1- 8             590(800)           660 (895)          910 (1234)        M33       51 mm         546 (740)    774 (1050)     1500 (2035)   2139 (2900)
          -14             660(895)                              990 (1342)        M36       55mm          700 (950)    992 (1345)     1925 (2610)   2744 (3720)


                                                  SEALANTS &LUBRICANTS
                                                                                Use LlaUID TEFLON for sealing pipe plugs and fillings that connect coolant
GASmSJSEALANTS                                                                  passages. Do nat use tape sealants!
Oil based PERMATEX 12 and it's HIGH TACK equivalent are excellent all
purpose sealers. They are effective in just about any jOint in contact with     BOIis & FASTENERS/ASSEMBUES
coolant, raw water, oil or fuel.
                                                                                Ughtly oil head bolts and other fasteners as you assemble them. Bolts and
A light coating of OIL or LlaUID TEFLON can be used on rubber gaskets           plugs that penetrate the water jacket should be sealed with PERMATEX #2 or
and O-rings.                                                                    HIGH TACK.
LOCTITE hydraulic red sealant should be used on oil adapter hoses and the oil   When assembling the flywheel, coat the bolt threads with LOCTITE blue.
filter assembly.
                                                                                Anti-seize compounds and thread locking adhesives such as LOCTITE protect
Coat both surfaces of the oil pan gasket with high temp RED SILICONE sealer.    threaded components yet allows them to came apart when necessary.
When installing gaskets that seal around water (coolant) passages, coat both    LOCTITE offers levels of locking according to the job.
sides with WHITE SILICONE grease.                                               LITHIUM based grease is waterproof, ideal for water pump bearings and stuff-
High-copper ADHESIVE SPRAYS are useful for holding gaskets in position dur-     ing boxes.
ing assembly.                                                                   Heavily oil all sliding and reCiprocating components when assembling. Always
Specialized gasket sealers such as HYLOMAR work well in applications requir-     use clean engine all!
ing non-hardening properties. HYLOMAR is particlarly effective on
copper cylinder-head gaskets as it resists fuel, oil and water.



                                                                     Engines & Generators

                                                                             49
                                METRIC CONVERSIONS
             INCHES TO MILUMETERS                                   MILUMETERS TO INCHES
Inches             mm          Inches           mm            mm           Inches         mm           Inches
  1            25.40             15         381.00             1           0.0394         15           0.5906
  2            50.80             20         508.00             2           0.0787         20           0.7874
  3            76.20             25         635.00             3           0.1181         25           0.9843
  4           101.60             30         762.00             4           0.1575         30           1.1811
  5           127.00             35         889.00             5           0.1969         35           1.3780
 10           254.00             40        1016.00            10           0.3937         40           1.5748
                           =
      10 MILLIMETERS 1 CENTIMETER, 100 CENTIMETERS 1 METER         =         =39.37 INCHES (3.3 FEET)
                   INCHES TO METERS                                      METERS TO INCHES
Inches         Meters          Inches          Meters        Meters        Inches       Meters         Inches
  1           0.0254               7           0.1778         0.1           3.937        0.7           27.559
  2           0.0508               8           0.2032         0.2           7.874        0.8           31.496
  3           0.0762               9           0.2286         0.3          11.811        0.9           35.433
  4           0.1016              10           0.2540         0.4          15.748        1.0           39.370
  5           0.1270              11           0.2794         0.5          19.685        1.1           43.307
  6           0.1524              12           0.3048         0.6          23.622        1.2           47.244
      TO CONVERT METERS TO CENTIMETERS, MOVE DECIMAL POINT TWO PLACES TO THE RIGHT

                    YARDS TO METERS                                      METERS TO YARDS
Yards          Meters          Yards           Meters        Meters        Yards        Meters          Yards
  1            0.91440           6             5.48640         1           1.09361         6           6.56168
  2            1.82880           7             6.40080         2           2.18723         7           7.65529
  3            2.74320           8             7.31520         3           3.28084         8           8.74891
  4            3.65760           9             8.22960         4           4.37445         9           9.84252
  5            4.57200          10             9.14400         5           5.46807        10          10.93614
           MOVE DECIMAL POINT FOR HIGHER VALUES - e.g. 6,000 METERS                 =6,561.68 YARDS
              POUNDS TO KILOGRAMS                                   KILOGRAMS TO POUNDS
  Ib            kg      Ib     kg                              kg         Ib      kg                     Ib
  1                0.454              6         2.722          1             2.205         6           13.228
  2                0.907              7         3.175          2             4.409         7           15.432
  3                1.361              8         3.629          3             6.614         8           17.637
  4                1.814              9         4.082          4             8.818         9           19.842
  5                2.268             10         4.536          5            11.023        10           22.046
                   GALLONS TO LITERS                                     LITERS TO GALLONS
Gallons            Uters       Gallons          Uters         Uters        Gallons       Liters        Gallons
   1            3.79             10             37.86           1           0.26          60           15.66
   2            7.57             20             75.71           2           0.53          90           23.77
   3           11.36             30            113.57           5           1.32         120           31.32
   4           15.14             40            151.42          10           2.64         150           39.62
   5           18.93             50            189.28          20           5.28         180           47.54
                     PINTS TO UTERS                                       UTERS TO PINTS
 Pints             Uters        Pints           Uters         Uters         Pints        Liters         Pints
   1               0.47           6             2.84           1            2.11           6           12.68
   2               0.95           7             3.31           2            4.23           7           14.79
   3               1.42           8             3.79           3            6.34           8           16.91
   4               1.89           9             4.26           4            8.45           9           19.02
   5               2.37          10             4.73           5           10.57          10           21.13

                                               TEMPERATURE
      32      40          50    60        70     75  85  95               105 140        175 212          OF
       I       I           I     I         I       I     I          I      I   I          I   I
       I      I            I     I         I       I     I          I      I   I           I      I
       0      5           10    15        20      25     30         35     40      60     80 100          °C




                                                Engines & Generators

                                                        50
STANDARD AND METRIC CONVERSION DATA

LENGTH-DISTANCE
  Inches (in) x 25.4 = Millimeters (mm) x .0394 = Inches
  Feet (ft) x .305 = Meters (m) x 3.281 = Feet
  Miles x 1.609 = Kilometers (km) x .0621 =Miles

VOLUME
  Cubic Inches (in3) x 16.387 = Cubic Centim~ters x .061 =in3
  Imperial Pints (IMP pt) x .568 = liters (L) x 1.76 = IMP pt
  Imperial Quarts (IMP qt) x 1.137 =liters (L) x.88 = IMP qt
  Imperial Gallons (IMP gal) x 4.546 = liters (L) x .22 = IMP gal
  Imperial Quarts (IMP qt) x 1.201 = US Quarts (US qt) x .833 = IMP qt
  Imperial Gallons (IMP gal) x 1.201 = US Gallons (US gal) x .833 =IMP gal
  Fluid Ounces x 29.573 = Milliliters x .034 = Ounces
  US Pints (US pt) x .473 = Liters(L) x 2.113 =Pints
  US Quarts (US qt) x .946 = Liters (L) x 1.057 = Quarts
  US Gallons (US gal) x 3.785 = Liters (L) x .264 = Gallons

MASS-WEIGHT
   Ounces (oz) x 28.35 = Grams (g) x .035 =Ounces
   Pounds (I b) x .454 = Kilograms (kg) x 2.205 =Pounds

PRESSURE
   Pounds Per Sq In (psi) x 6.895 = Kilopascals (kPa) x .145 = psi
   Inches of Mercury (Hg) x .4912 = psi x 2.036 =Hg
   Inches of Mercury (Hg) x 3.377 = Kilopascals (kPa) x .2961 = Hg
   Inches of Water (H20) x .07355 = Inches of Mercury x 13.783 = H20
   Inches of Water (H20) x .03613 = psi x 27.684 = H20
   Inches of Water (H20) x .248 = Kilopascals (kPa) x 4.026 = H20

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

VELOCITY
   Miles Per Hour (MPH) x 1.609 = Kilometers Per Hour (KPH) x .621 = MPH

POWER
   Horsepower (Hp) x .745 = Kilowatts (Kw) x 1.34 = MPH

FUEL CONSUMPTION
   Miles Per Hour IMP (MPG) x .354 = Kilometers Per Liter (Km/L)
   Kilometers Per liter (Km/L) x 2.352 = IMP MPG
   Miles Per Gallons US (MPG) x .425 = Kilometers Per Liter (Km/L)
   Kilometers Per Liter (Km/L) x 2.352 = US MPG

TEMPERATURE
   Degree Fahrenheit (OF) = (DC X 1.8) + 32
   Degree Celsius (DC) = (OF - 32) x .56




                               Engines & Generators

                                     51
                                       SUGGESTED SPARE PARTS KITS
                                          Carry only Genuine WESTERBEKE Spare Parts
SPARE PARTS KITS
WESTERBEKE offers two Spare Parts Kits,
each packaged in a rugged hinged toolbox.
Kit "A" includes the basic spares.
Kit "B" is for more extensive off-shore cruising.

Kit "A" includes:
    Drive Belt
    Raw Water Pump Impeller and Gasket
    Fuel Filter
    Fuel Lift Pump Screens (2) and Gasket
    Oil Filter (Model lOA-I only)
    Fuel Hardware Kit (to fix a leak)
    Air Intake Filter

Kit "B" Includes:
    Drive Belt
    Raw Water Pump Impeller and Gasket
    Raw Water Pump Repair Kit
    Fuel Filter
    Fuel Lift Pump Screens (2) and Gasket
    Oil Filter (Model lOA-I only)
    Fuel Hardware Kit (to fix a leak)
    Thermostat Kit
    Complete Gasket Kit
    Fuel Injector
    Air Intake Filter




                                                        Engines & Generators

                                                             52
                Engines & Generators




1045-.5C-4JD1


Ad by Google

Disclaimer:
The information on this web site has not been checked for accuracy. It is for entertainment purposes only and should be independently verified before using for any other reason. There are five sources. 1) Documents and manuals from a variety of sources. These have not been checked for accuracy and in many cases have not even been read by anyone associated with L-36.com. I have no idea of they are useful or accurate, I leave that to the reader. 2) Articles others have written and submitted. If you have questions on these, please contact the author. 3) Articles that represent my personal opinions. These are intended to promote thought and for entertainment. These are not intended to be fact, they are my opinions. 4) Small programs that generate result presented on a web page. Like any computer program, these may and in some cases do have errors. Almost all of these also make simplifying assumptions so they are not totally accurate even if there are no errors. Please verify all results. 5) Weather information is from numerious of sources and is presented automatically. It is not checked for accuracy either by anyone at L-36.com or by the source which is typically the US Government. See the NOAA web site for their disclaimer. Finally, tide and current data on this site is from 2007 and 2008 data bases, which may contain even older data. Changes in harbors due to building or dredging change tides and currents and for that reason many of the locations presented are no longer supported by newer data bases. For example, there is very little tidal current data in newer data bases so current data is likely wrong to some extent. This data is NOT FOR NAVIGATION. See the XTide disclaimer for details. In addition, tide and current are influenced by storms, river flow, and other factors beyond the ability of any predictive program.