Westerbeke Four 60 Parts Manual
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f4t o q IiLDOPERATORS MANUAL 7A1 and 11A1 MARINE DIESEL ENGINES PUBLICATION NO 45145 1st EditionApril 2001 J WESTERBEKE CORPORATION MYLES STANDISH INDUSTRIAL PARK 150 JOHN HANCOCK ROAD TAUNTON MA 027807319 USA TEL 5088237677 FAX 5088849688 WEBSITE NMMA Member National Marine Manufacturers Association OPERATORS MANUAL 7A1 and 11A1 MARINE DIESEL ENGINES PUBLICATION NO 45145 15t EditionApril 2001 r WESTERBEKE WSTRBK CORPORATION MYLS STANDISH INDUSTRIAL PARK 150 JOHN HANCOCK ROAD TAUNTON MA 027807319 USA TEL 5088237677 FAX 5088849688 WEBSITE 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 WARNINGExhaust gasses contain Carbon Monoxide an odorless andcolorless gas Carbon Monoxide is poisonous and can and death Symptoms of Carbon can Throbbing in TemplesNausea Muscular Vomiting Weacness and Sleepiness Inability to Think CoherentlyIF YOU OR ANYONE ELSE EXPERIENCE ANY OF THESE SYMPTOMSGET OUT INTO THE FRESH AIR IMMEDIATELY symptoms persistseek medical attention Shut down the unit and do not restartuntil 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 aso recommends installing CARBON MONOXIDE DETECTORS in the Iivingsleeping quarters of your vessel They are inexpensive and easily obtainable at your local marine store SAFETY PREVENT BURNS FIRERead these safety instructions carefuUy Most accidents arecaused by failure to follow fundamental rules and precau A WARNING Fire can cause injury or deathtions Know when dangerous conditions exist and take thenecessary precautions to protect yourself your personnel Prevent flash fires Do not smoke or permit flames orand your machinery sparks to occur near the fuel line filter fuel pump orThe foUowing safety instructions are in compliance with other potential sources of spilled fuel or fuel vapors Usethe American Boat and Yacht Council ABYC standards a suitable container to catch all fuel when removing the fuel line or fuel filtersPREVENT 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 refueling safety instructions Keep the vessels Use insulated mats whenever working on electrical hatches closed when fueling Open and ventilate cabin equipment after fueling Check below for fumesvapor 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 wellven Do not connect utility shore power to vessels AC tilated area away from sparkproducing equipment and circuits except through a shiptashore double throw out of the reach of children transfer switch Damage to vessels AC generator may Do not fill the fuel tanks 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 thePREVENT 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 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 waterinjected exhaust elbow is securely attached starting Make certain all covers guards and hatches are Be sure the unit and its surroundings are well ventilated reinstalled before starting the engine Run blowers when running the generator set or engine Dont run the generator set or engine unless the boat isBATTERY EXPLOSION equipped with a functioning marine carbon monoxide detector that complies with ABYC A24 Consult your boat builder or dealer for installation of approved detectors A WARNING Battery explosion can cause injury For additional information refer to ABYC T22 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 flulike 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 exhaustwater 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 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 fromHAZARDOUS 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 fromENGINE INSTALLATIONS US Government Printing to install an engine should begin with a thor Washington DC 20404ough examination of the American Boat and Yacht CouncilsABYC standards These standards are a combination ofsources including the USCG and the NFPASections of the ABYC standards of particular interest are Pl Exhaust systems P4 Inboard engines E9 DC Electrical systemsAll installations must comply with the Federal Code ofRegulations FCR Engines Generators iii installing WESTERBEKE engines and generators it is important that be paid to the following AND regulations ABYC guidelines and safety codes must be complied with wheninstalling engines and generators in a marine installations where the exhaust exhaust elbow is close to orwill be below the vessels waterline provisions must be made to install a siphonbreakin the raw water supply hose to the exhaust elbow This hose must be looped a minimum of 20 in 51 cm above the vessels waterline Failure to use a the exhaust manifold injection port is at or below the load waterline will resultin raw water damage to the engine and possible flooding of the boatIf you have any doubt about the position of the waterinjected exhaust elbow relative tothe vessels waterline under any of the vessels various operating conditions or whenthe vessel is not underway install a siphonbreak This precaution is necessary to protect your engineNOTE A siphonbreak requires periodic inspection and cleaning to ensure proper operation Failure to properly maintain a siphonbreak can result in catastrophic enginedamage Consult the siphonbreak manufacturer for a proper maintenance SYSTEMThe exhaust hose must be certified for marine use The system must be designed toprevent water from entering the exhaust under any sea conditions and at any angle ofthe vessels hull A detailed 40page Marine Installation Manual covering gasoline and diesel engines and generators is available from your WESTERBEKE dealer Engines Generators iv TABLE OF 2 Cooling System continued Warranty Procedures 2 Raw Water Pump 22 Product Software 2 the Raw Water Pump Impeller 22 Notes Caution and Warnings 2 Raw Water Intake 22 Model NolSerial No Location 2 Raw Water Intake Strainer 22 Component Locations 3 SiphonBreak 23 Understanding the Diesel Engine 3 Draining the Cooling System 23 Ordering Parts 3 Air Intake Filter24 Spares and Accessories 3 Description 24 Protecting Your Investment 3 Air Filter 247A1 Diesel Engine Specifications 4 Maintenance 247A1 Diesel Engine Parts Identification 5 Water Heater2411A1 Diesel Engine Specifications 6 Water Heater Installations 2411A1 Diesel Engine Parts Identlfication 7 Fuel System 25Preparations for Initial StartUp 8 Diesel FueL 25 Diesel FueL 8 Fuel Additives 25 Care of the Fuel Supply 8 Care of the Fuel Supply25 Fuel Additives 8 Fuel Lift Pump 25 Engine OiL 8 Fuel Filter 25 Transmission Fluid 8 Replacing the Fuel Filter 25 PreStart Inspection 8 Fuel Lines Procedure 9 Fuel FilterlWater Separator 26 Electric Starting 9 Fuel Injection Pump 26 Electric Starting Procedure 9 Fuel Injector 26 Low Battery Electric Starting Procedure9 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 StartUp Check List 12 Battery Care 27 Stopping the Engine 12 Checking the Service Battery 27Engine BreakIn Procedure 13 Alternator 28 Engine BreakIn Procedure 13 Testing the Alternator 28 BreakIn Check List 13 Checking the Service Battery 29 Transmission BreakIn 13 7AI Marine Diesel Engine Wiring Diagram 45593 30 Daily Operation 13 7AI Marine Diesel Engine Wiring Schematic 45593 31 Daily Operation CheckList 13 11A1 Marine Diesel Engine Wiring Diagram 44542 32 Transmission 13 11Al Marine Diesel Engine Wiring Schematic 44542 33 Maintenance Schedule 14 Glow Plugs ModeI7A1 only 34 Exhaust System 16 Engine Adjustments 35 Description 16 Tightening the Cylinder Head 35 SiphonBreak 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 39 Changing the Oil Filter Model llAl only 19 Hurth HBW Transmission 42 Adding the New Oil 20 Hurth HBW Transmission 45 Testing the Oil Pressure 20 LayUp and 46 Cooling System 21 7A1 11A1 Torque Specifications 48 Raw Water Cooling System 21 Standard Lubricants 49 Thermostat 21 Metric Conversions 50 the Thermostat 21 Standard and Metric Conversion Oata 51 Coolant Temperature Switch 21 Suggested Spare Parts Kits 52 Engines Generators 1 WESlERBEKE Diesel Engine is a product of PRODUCT many years of experience and advanced Product software tech data parts lists manuals We take great pride in the superior durability anddependable performance of our engines and generators Thank and catalogs provided from sources other than WESTERBEKE are not within WESTERBEKEs controlyou for selecting WESlERBEKE WESTERBEKE CANNOT BE RESPONSIBLE FOR THEThis is the Operators Manual for the 7AI and IIAI Marine CONTENT OF SUCH SOFTWARE MAKES NODiesel Engines Most of the information in this manual applies to WARRANTIES OR WITH RESPECTboth models where information applies to only one of the two THERETO INCLUDING ACCURACY TIMEUNESS ORmodels the applicable model name will be indicated A Parts COMPLETENESS THEREOF AND WIll IN NO EVENTCatalog is also provided for your engine and a Service Manual is BE UABLE FOR ANY TYPE OF DAMAGE OR from your WESlERBEKE dealer If you are planning INCURRED IN CONNECTION WITH OR ARISING OUTto install this equipment contact your WESlERBEKE dealer for OF THE FURNISHING OR USE OF SUCH 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 ofWARRANTY PROCEDURES WESlERBEKE or the supplier in question be consulted toYour WESlERBEKE Warranty is included in the documentation determine the accuracy and currentness of the product If you have not received a customer identification card being consulted by the your warranty 60 days after submitting the warranty NOTES CAUTIONS AND form please contact the factory in writing with including the units serial number and As this manual takes you through the operating date maintenance schedules and of your marine engine critical information will be highlighted by NOlESCustomer Identification Card CAUTIONS and WARNINGS An explanation follows NOTE An operating procedure essential to note IWESIERBEKE 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 Mode17A1 Expires 3116102 MODEL NOSERIAL NO LOCATION Ser 74860197E003 The engines model number and serial number are located on an identification plate mounted on the engine block below the Your WESlERBEKE 7AIIIAI Engine serial number is an exhaust manifoldelbow 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 andor character followed by three numbers The character indicates the ordering repair parts decade D 1990s E2000s 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 LOCATIONS SPARES AND locations in this manual are referenced from the front Certain spare parts will be needed to support and mainof the engine which is the end at which the raw water pump is tain your WESTERBEKE engine when cruising seelocated Left and right sides are detennined as follows imagine SUGGESTED SPARE PARTS KITS Often even astraddling the engine facing the front of the engine the left side simple item such as a proper fuel filter can be difficultis 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 THE DIESEL ENGINE assist you in preparing an onboard inventory of the proper WESTERBEKE partsThe diesel engine closely resembles the gasoline engine since themechanism is essentially the same The cylinder is arranged PROTECTING YOUR a closed crankcase The crankshaft is of the same generaltype as on a gasoline engine and the diesel engine has the same Care at the factory during assembly and thorough testing havetypes of valves camshaft piston connecting rod and lubricating resulted in a WESTERBEKE engine capable of manysystem thousands of hours of dependable service However the manufacturer cannot control how or where the engine is to a great extent a diesel engine requires the same pre in the vessel or the manner in which the unit is operated and serventive maintenance as a gasoline engine The most important viced in the field This is up to the are proper ventilation and proper maintenance of the and cooling systems Fuel filter elements must be NOTE Six important steps to ensure long engine lifereplaced at the time periods specified and frequent checking for Proper engine water sediment etc in the fuel system is also An efficient welldesigned exhaust system that includes anessential Another important factor is the consistent use of the antisiphon break to prevent water from entering the enginesame brand of high detergent diesel lubrication oil for diesel engines Changing the engine oil every 100 operating hoursThe diesel engine does differ from the gasoline engine however Proper maintenance of all engine components according to thein its method of handling and firing of fuel The carburetor and maintenance schedule in this manualignition 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 LAYUP AND section in this manualORDERING PARTSWhenever replacement parts are needed always providethe engine model number and serial number You mustprovide us with this information so we may properly identify your engine In addition include a complete and part number for each part needed see theParts List Insist upon Westerbeke packaged partsbecause will fit or generic parts are frequently not made tothe same specifications as original equipment Engines Generators 3 7A1 DIESEL ENGINE SPECIFICATIONS ENGINE SPECIFICATIONS LUBRICATION SYSTEMEngine Type Diesel fourcycle one cylinder raw water cooled Lubrication System Forced lubrication by geardriven pump vertical inline overhead valve mechanism Sump capacity 13 qts 125 Naturally aspirated Operating Oil Pressu re 256569 psi 1840 kgcmGovemor Mechanical centrifugal type engine hotCombustion System Direct injected Oil Grade API specification CF or CG4Bore and Stroke SAE 30 10W30 15W40 323 in x 217 in 820 mm x 550 mm Lube oil Strainer Fullflow intemalPiston Displacement 177 cu in 290 cmCrankshaft Clockwise when viewed from the frontDirection of Rotation raw water pump end COOLING SYSTEM Cooling System Raw watercooled Ratio 201 Torque 110 ftIIbs 15 kgm Operating Temperature 13D150F5566Cat 2500 rpm Raw Water Pump Positive displacement neoprene impellerManual Starting System Handcrank with automatic geardriven senpriming decompression device Raw Water Row 73w8456 gpm 7 IpmEngine Stop Manual type at 3600 rpmDimensions Raw Water Connection NOTE An inserted standard 112 in 127 mm 10 Height 171 in 4337 mm crank handle increases the Width 149 in 3792 mm width by 45 in 115 mm Length 225 in 5713 mm EXHAUST SYSTEMDry Weight 151 Ibs 685 kg Emission Control Systems Meets USCG Regulation 33 CFR 183Max Angle of Installation Not to exceed 10 Exhaust ManifoldlElbow cast aluminum raw water cooledMax Angle of Operation Not to exceed 15 in all directions Exhaust Elbow Connection 1112 in 381 mm 10 TUNEUP SPECIFICATIONS ELECTRICAL Pressure 4785 psi 336 kgcm standard Electrical System 12 volts DC negative ground 4350 psi 306 kgcm minimum circuit breaker protectedValve Seat Angle Intake 45 Exhaust 45 Battery Charging 30 amp 12 volts beltdriven withValve Clearance Intake 0008 in 02 mm Altemator solid state internal cold Exhaust 0008 in 02 mm Starting Motor 12 volt solenoid actuated shiftEngine Timing 390 mm BTDC static Cold Cranking Amps 70 amps71F 22CInjector Pressure 2900 psi 2039 kgcmEngine 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 servooperated multiple disc clutch FUEL SYSTEM Gear Ratio optional 2051Fuel System Open flow senpriming senbleeding Propeller 120 x 8 P two blade RHFuel No2 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 ratedFuel Lift Pump Mechanical 16 ft 05 m lift max rpm at full open throttle in forward gear underwayFuel Injection Pump Bosch type Lubricating Ruid ATF type A or DEXTRON I or 11Fuel Injector Direct injection Transmission Sump 037 qts 035 litersFuel Injection Timing 39 mm BTDC static Pressure 2900 psi 2039 kgcm Propeller Shaft Right handstandard Consumption 046 US galhr 176Iiterlhr Direction of Rotationfull loadFuel Filter Primary replaceable filterFuel Supply 14 in 635 mm 10 minimumand Return Lines 5116 in 794 mm 10 maximumAir Row 153 cfm 043 cmmengine combustion Engines Generators 4 7A1 DIESEL ENGINE PARTS HANCRANK HANDLE GUIDE RAW WATER PUMP flEXIBLE MOUNTS RAW WATER INTAKE CONNECTION CYLINDER HEAD FUEL INJECTOR tHlfH4tiM5 WATER INJECTED EXHAUST MANIFOLDJELBOW FUEL INJECTION PUMP TRANSMISSION FUEL FILTER TRANSMISSION OUTPUT FLANGE Engines Generators 5 11 A1 DIESEL ENGINE SPECIFICATIONS ENGINE SPECIFICATIONS LUBRICATION SYSTEMEngine Type Diesel fourcycle one cylinder raw water cooled Lubrication System Forced lubrication by geardriven pump vertical inline overhead valve mechanism Sump Capacity 17 qts 16 Naturally aspirated Operating Oil Pressure 25569 psi 1840 kgcmGovernor Mechanical centrifugal type engine hotCombustion System Direct injected Oil Grade API specification CF or CG4Bore and Stroke 374 in x 291 in 950 mm x 740 mm SAE 30 10W30 15W40 Oil Riter Fullflow paper element spinon typePiston Displacement 3195 cu in 5240 cmCrankshaft Clockwise when viewed from the front COOLING of Rotation raw water pump end Cooling System Raw watercooled Ratio 201 Torque 213 ftIIbs 29 kgm Operating Temperature 13D150F 5566Cat 2400 rpm Raw Water Pump Positive displacement neoprene impellerManual Starting System Handcrank with automatic geardriven seHpriming decompression device Raw Water Row 73998456 gpm 78lpmEngine Stop Manual type at 3600 rpmDimensions Raw Water Connection NOTE An inserted standard 112 in 127 mm 10 Height 210 in 532 mm crank handle increases the Width 213 in 540 mm width by 45 in 115 mm Length 238 in 603 mm EXHAUST SYSTEMDry Weight 238 Ibs 108 kg Emission Control Systems Meets USCG Regulation 33 CFR 183Max Angle of Installation Not to exceed 10 Exhaust ManifoldlElbow Cast aluminum raw water cooledMax Angle of Operation Not to exceed 15 in all directions Exhaust Elbow Connection 1112 in 381 mm 10 TUNEUP SPECIFICATIONS ELECTRICAL Pressure 4785 psi 336 kgcm standard Electrical System 12 volts DC negative ground 4350 psi 306 kgcm minimum circuit breaker protectedValve Seat Angle Intake 45 Exhaust 45Valve Clearance Intake 0008 in 02 mm Battery Charging 30 amp 12 volts cold Exhaust OOOS in 02 mm Alternator with solid state intemal liming 600 mm BlDC static Starting Motor 12 volt solenoid actuated shiftInjector Pressure 2537 psi 1783 kgcm Cold Cranking Amps 60 amps66F 19CEngine 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 servooperated FUEL SYSTEM multiple disc clutchFuel System Open flow selfpriming seHbleeding Gear Ratio optional 2051Fuel No2 diesel oil cetane rating of 45 or higher Propeller 14 Dx8 PtwobladeRH Propeller used must allow 140 x 6 Pthree blade RHFuel Uft Pump Mechanical 16 ft 05 m lift max the engine to reach its rated rpm at full open throttle inFuel Injection Pump Bosch type forward gear underwayFuel Injector Direct Injection lubricating Ruid ATF type A or DEXTRON I or 11Fuel Injection liming 60 mm BTDC static Transmission Sump 037 qts 035 litersInjector Pressure 25375 psi 1784 kgcm CapacityFuel Consumption 046 US gaLhr 176Iiterlhr Propeller Shaft Right handstandard load Direction of RotationFuel Riter Primary replaceable filterFuel Supply 14 in 635 mm 10 minimumand Retum Lines 516 in 794 mm 10 maximumAir Row 277 cfm 078 cmmengine combustion Engines Generators 6 11A1 CYLINDER DIESEL ENGINE PARTS IDENnFICATION HEAD fOAArpoc CIRCUIT BREAKER TlfROTrtE CONTROL STARTER FUEL INJECTOR COOlANT TEPERATURE SWITCH TIlANSSSION OIPSTIClCIFlll FUEL PREPARATIONS FOR INITIAL STARTUPDIESEL FUEL PRESTART INSPECTIONUse No2 diesel fuel with a cetane rating of 45 or higher Do not Before starting your engine for the first time or after a prolongeduse kerosene or home heating fuel layup check the following items D Check the engine oil level The oil level must be between theCare of the Fuel Supply max and min marks on the dipstickUse only clean diesel fuel The clearance of the components in D Turn on the fuel supply then check the fuel supply and examyour fuel injection pump is very critical invisible dirt particles ine the fuel filterwater separator bowl for might pass through the filter can damage these finelyfinished parts It is important to buy clean fuel and keep it clean D Check the transmission fluid levelThe best fuel can become unsatisfactory by careless handling or D Check the DC electrical system Inspect wire storage facilities To assure that the fuel going into the and battery cable connections Make certain the positive tank for your engines daily use is clean and pure purchase a battery cable is connected to the starter solenoid and thewellknown brand of fuel Also install and regularly service a negative cable is connected to the engine ground studgood Coast Guard approved fuel filterwater separator between this location is taggedthe fuel tank and the engine D Open the raw water intake and make sure the raw water sup ply reaches the raw water strainerFuel Additives D VIsually examine the engine Look for loose or missingIf fungus or bacteria is causing fuel problems you should have parts disconnected wires and unattached hoses Check thean authorized dealer correct these problems Then use a diesel threaded connections Check for fuel leaksfuel biocide to sterilize the fuel follow the manufacturers D Make sure the exhaust system is secure and all Use a fuel stabilizer on a regular basis as well connections are tightSTABIL is an example of such a product D Make sure there is good ventilation and an ample air supplyENGINE 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 an engine oil with an API classification of CF or CG4Change the engine oil after an initial 50 hours of breakin operation and every 100 hours of operation thereafter Forrecommended oil viscosity see the following chart Operating Temperature Oil Viscosity Above 68 F 20 C SAE 30 10W30 or 15W40 41 68 F 5 20 C SAE 20 or 10W30 Below 41 F 5 C SAE10W30 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 037 qts 035liters Engines Generators 8 STARTING NOTE The Automatic Decompression Device is not used forThe 7AIllA1 diesel engine has a 12 VDC electric starter The nOf77Ul1 electric starting During engine operation the pointer onengine is started by using a keyswitch on the control panel The this device is in the operating 9 oclock positionswitch has three positions OFF ON and START 1 Place the transmission in neutral and advance the throttle conNOTE Periodically lubricate the keyswitch mechanism with trol to slightly openLOCKEZE to ensure proper keyswitch functioning 2 Using a IOmm wrench turn the hexhead bolt on the device so the pointer is in the manual starting position see illustration I HOUR METER POINTER IN TtL THE MANUAL STARTING PosmONOILWATER tiH HEXHEAD BOLTALARM AUTOMATIC OECOMPRESSION KEYSWITCH DEVICE ALARM ET Wglfgrtlcrg CONTROL PANEL 3 Turn the keyswitch to the START position The alann on theElectric Starting Procedure control panel will beep until the engine oil pressure comes up1 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 oclock 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 position2 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 posmONNOTE If the engine doesn start limit each starting trial to 1020 seconds Wait for approx 30 seconds before repeating thestart Never operate the starter motor while the engine is still jrunning lIJNOTE Some unstable running may occur in a cold engine Thiscondition should smooth out as the nOf77Ul1 operating temperatureis reached and a load is applied Allow a few minutes for thewannup at a comfortable rpm approximately 1000 rpm then If this attempt at an electric start does not start the engine then areduce the rpm and get underway manual start by handcranking will be necessaryLow Battery Electric Starting Procedure MANUAL STARTING HAND CRANKINGIf the battery is discharged and too low for a normal electric start When installing the engine it is important to provide enoughbut not completely dead an attempt at an electric start can be space at the front end to allow for manual starting hand crankingmade by using the Automatic Decompression Device This device in case of an emergency or when the starting battery has becomeworks by holding the exhaust valve open and is normally used too low to allow an electrical startwhen manually starting handcranking the engine Engines Generators 9 PROCEDUREThe upper illustration shows the distance 45 in 115 mm thatthe standard handcrank handle protrudes from the on the engine An additional 25 in 64 mm minimum HEXHEAD BOLTmust be allowed for room to insert the handleIf hand cranking must be done from outside the see lower illustration then the standard AUTOMATIC handle must be extended to the required length POINTER DEVICEThis 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 STARTINGThe engine may be started by handcranking in an emergency or MODEL 7A1 SHOWN DEVICE KNOBwhen the starting battery has become too low to allow an electricstart A manual start is possible with a completely dead batteryFor easy and safe manual starting the engine is fitted with anAutomatic Decompression Device and a Cold Starting DeviceUse both of these devices when using the handcrank handle an attempt at a normalelectric start could be made by using the Device see Low Battery Electric Starting underELECfRlC SfAR1 the electrical power required for the startwould then be considerably less so that a discharged battery ifnot completely dead might allow the startNOTE Oil will be supplied to all the bearing points Decompression DeviceThe Automatic Decompression Device works by holding theexhaust valve open The device has three positions as indicatedby the pointer When setting the pointer tum the hexhead boltwith a 10 mm wrench A CAUTION Neller use the Automatic Decompression Device to stop the engine Engines Generators 10 Starting Procedure 4 Crank the engine approximately 10 to 20 times until the engine turns freely Then remove the crankTo manually start the engine follow the procedure described handlebelow When starting after cold nights or freezing the engine must first be turned over with no compression S Set the Automatic Decompression Device pointer to thefollow all of the steps beginning with Step 1 If cold weather is manual starting position see illustration When handcranknot a factor bypass Steps 13 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 STARTING1 Place the transmission in neutral and advance the throttle con PDsmDN trol to slightly openNOTE Make sure the stop lever is in the RUN position2 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 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 oclock positionAfter the engine starts the crank handle will automat ically disengage Then remove the crank handle CRANK HANDLE GUIDE HANDCRANKING Model7A1 shown Engines Generators 11 PROCEDURE Initial StartUp 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 oclock if the keyswitch is left ON the battery will discharge9 If the engine has not started repeat Steps 59 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 engines cylinder once the exhaust system fills Prevent this from happening by closing the raw water supply throughhull shutoff draining the exhaust muffler and correcting the cause of the excessive engine crank ing Remember that engine damage resulting from raw water entry is not covered by Westerbekes Under Cold ConditionsMake sure the lubricating oil is appropriate for the Use oil with an API Specification of CF or CG4SAE 30 lOW30 or 15W40 The battery should be fullycharged to minimize voltage dropOPERATING THE ENGINE A CAUTION Neller stop the engine with theAllow a few minutes for the engine to wann up at a comfortable automatic decompression dellice or when the engine isrpm approximately 1500 rpm then reduce the rpm and get under a full loadunderway 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 BREAKIN BREAKIN PROCEDURE 4 Avoid rapid acceleration especially with a cold engineAlthough your engine has experienced a minimum of one hour of S Use caution not to overload the engine The presence of atest operations at the factory to make sure accurate assembly pro grey or black exhaust and the inability of the engine to reachcedures were followed and that the engine operated properly a its full rated speed are signs of an time is required The service life of your engine is 6 During the second 25 hours the engine may be operated atdependent upon how the engine is operated and serviced during varying engine speeds with short runs at full rated rpmits initial 50 hours of use Avoid prolonged idling during this breakin a new engine basically involves seating the pistonrings to the cylinder walls Excessive oil consumption and smoky BreakIn Check Listoperation indicate that the cylinder walls are scored which is Monitor the following during the 50 hour breakin periodcaused by overloading the engine during the breakin period o Check for fuel engine oil and water leaksYour new engine requires approximately 50 hours of initial condi o Check for abnormal noise such as knocking friction operation to breakin each moving part in order to maxi and blowback soundsmize the performance and service life of the engine Perform carefully keeping in mind the following o Confmn the exhaust smoke When the engine is cold white smoke1 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 soot2 Allow the engine to warm up preferably by running at fast Also see the DAILY OPERATION CHECKllSTfor additional idle items to check each dayNOTE Some unstable running may occur in a cold engine This The MAINTENANCE SCHEDULE section gives the should abate as normal operating temperature is procedures to follow after the 50 hour breakin periodreached and the propeller load is applied3 While using the vessel run the engine at various engine Transmission BreakIn speeds for the first 25 hours Avoid prolonged periods of See the HURTH HBW TRANSMISSION section of this manual for idling breakin information on your transmission DAILY OPERATIONDAILY OPERATION o Check the starting batteries weeklyStart and stop the engine according to the instructions given in the o Check drive belt for wear and proper tension PROCEDURE section Also follow the o Check the raw water pump to make sure its mounting isinstructions given in the ENGINE BREAKIN PROCEDURE sec securetion during the first 50 hours of operation Make sure all periodic After starting the engine check the is performed according to the o Check for abnormal noise such as knocking vibration and blowby soundsDaily Operation Check List o Confmn exhaust smokeFollow this check list each day before starling your engine When the engine is cold white smokeo 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 sooto Visually inspect the engine for fuel oil or water leaks o Make sure the cooling water is discharging properly outboardo Check the oil level dipstick from the exhaust outleto Check the transmission fluid level Transmissiono Check your diesel fuel supply See DAILY OPERATION in the HURTH HBW TRANSMISSIONo Look for clean fuel in the fuel filterwater separator transparent section bowlo Check for loose wires at the alternator and make sure its mounting is secure Engines Generators 13 MAINTENANCE SCHEDULEIn order to use this Maintenance Schedule it will be necessaryto log your engine hours Use your engine hounneter orrecord your engine hours by running time A WARNING Never attempt to perfonn any service while the engine is running Wear the proper safetyNOTE Many of the following maintenance procedures are equipment such as goggles and gloves and use thesimple but others are more difficult and may require the expert COrtect tools for each job Disconnect the of a service mechanic tenninals when servicing any of the engines 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 filterWater 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 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 antisiphon valve operation Check that all connections are tight Check the exhaust elbow for Exhaust system carbon andor corrosion buildup on inside pas sages clean and replace as necessary Warning A defective 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 38 12 in 10 12 mm deflection and adjust if necDrive belt essary Check belt edges for wear see DRIVE BELT ADJUSTMENT under ENGINE ADJUSTMENTS Check the solenoid and motor for corroStarter motor sian Remove and lubricate Clean and lubricate the starter motor pinion driveAdjust engineidle speed Adjust to 1000 1200 rpm Adjust the valve clearances see VALVEValve clearances CLEARANCE ADJUSTMENT under ENGINE ADJUSTMENTS Check the compression pressure ENGINE COMPRESSION TEST under ENGINE ADJUSTMENTS Retorque the nuts see TIGHTENING nuts CYLINDER HEAD under ENGINE ADJUST levelEngine Initial fluid change at 25 hours then every 300 hours or at winterizing Chattering at idle and low rpms is an plate cation of damper plate wear Remove and cable Check for loose fittings cotter pins etc Lubricate with WD40 or 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 engines surface clean Surface dirt Cleaning the engine and oil will inhibit the engines 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 recommends that this service be performed by an authorized mechanic Engines Generators 15 EXHAUST EXHAUST SYSTEM PRECAUTIONSIt is important to install a proper exhaust system to avoid engine Carbon The system must be designed to prevent water from The best protection against carbon monoxide poisoning is a dailyentering the exhaust line under any sea conditions and at any inspection of the complete exhaust system Check for leaksangle of the vessels hull Exhaust system failures are not covered around the exhaust manifoldelbow exhaust hose gaskets andby Westerbekes warranty The installer should have a basic welds Make sure there are no fumes entering your boat from aknowledge of marine installation requirements nearby vessel Make sure the exhaust lines are not heating theWesterbeke recommends installing an exhaust system having an surrounding areas excessively If excessive heat is present correctinline muffler The inline muffler should be located below the the situation immediately If you notice a change in the sound orengines exhaust elbow It must accumulate any water that runs appearance of the exhaust system shut down the engine immediback down the exhaust line after the engine is shut down Design ately and have the exhaust system inspected and repaired at oncethe system so there is an adequate drop in the line between the by a qualified elbow and the throughhull discharge end of the line Theexhaust 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 andor Monoxide is pOi5Onous and can cause 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 inspectedFor more information about exhaust system design see and INSTALLATION MANUAL for MARINE ENGINESand GENERATORS Publication 43268 Carbon Monoxide Warning presumes that the installer of this marine diesel engine A carbon monoxide warning decal has been provided byis familiar with the safeguards a watercooled marine exhaust sys Westerbeke Display this decal near your engine on your cabintem will provide for the engine Failure to design and layout a bulkhead or in some other prominent locationproper exhaust system can result in catastrophic damage to thediesel engine and possibly result in the sinking of the vessel inwhich the unit is For installations where the waterinjected exhaust elbow is close to or below the vessels waterline provisions must be made to install a siphonbreak in the raw water supply hose to the exhaust elbow The siphonbreak provides an air vent in the raw water cooling system to prevent raw water from filling the exhaust sys tem and the engines cylinder when the engine is shut down See SIPHONBREAK in the COOUNG SYSTEM section for more information WARNING Engines Produce CARBON MONOXIDE Regular Maintenance Required A CAUTION Falure to use a siphonbreak when the EnGMemcn 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 SYSTEMCarbon Monoxide DetectorsIt is extremely important that a carbon monoxide detectors beinstalled in your boats living andor sleeping quarters Make sure it ismanufactured for the marine industry They are inexpensive and available at your marine insulated portions of the exhaust system to ensure there is of the 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 engines cylinder once the exhaust system fills Prevent this from happening by closing the raw water supply throughhull shutoff draining the exhaust muffler and correcting the cause of the excessive engine cranking Remember that engine damage resulting from raw water entry is not covered by Westerbekes 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 geardriven oil pump is built into the oil sump The oil is pumped through a spinon type oil filter Model IIAI 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 CrankcaseOil Strainer in the MAlNIENANCE SCHEDULE OIL PRESSURE SWITCH for maintenance information A crankcase breather valve is Model 11A1 silo integrated into the cylinder heads inlet channel and is ENGINE OIL Use a heavy duty engine oil with an API classification of CF or CG4 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 10W30 or 15W40 41 68 F 5 20 C SAE 20 or 10W30 Below 41 F 5 C SAE10W30 SPINON OIL FILTER Ht Model 11A1 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 andBREATHER engine runawayVAlVE If a topup 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 switchs sensor monitors the engines oil pressure Should the engines Model7A1 lion oil pressure fall below the specified value this switch will activate a pulsating aIarm on the control panel Engines Generators 18 LUBRICATION SYSTEMCHANGING THE OILChange the oil after an initial 50 hours of breakin operation andevery 100 hours of operation thereafter Change the oil only when llllrllthe engine is warmAlways observe the used oil as it is removed A indicates the presence of water in the oil Although thiscondition is rare it does require prompt attention to prevent serious damage Call a qualified mechanic should water be present inthe oil Raw water present in the oil can be the result of a fault inthe exhaust system attached to the engine andor a siphoning ofraw water through the raw water cooling circuit into the exhaustfilling the engine This problem is often caused by the absence ofan antisiphon valve its poor location or lack of maintenance Modal7A1 Model 11A1 REMOVING THE OLD OIL A CAUTION Used engine oil contains harmful Changing the Oil Filter Model 11A1 only contaminants Avoid prolonged skin contact Clean skin When removing the used oil filter you may fmd it helpful and and nails thoroughly using soap and water Launder Dr cleaner to punch a hole in the upper and lower portion of the old discard clothing Dr rags containing used oil Discard filter to drain the oil from it into a container before removing it used oil properly This helps to lessen spillage A small automotive filter wrench should be helpful in removing the old oil filterRemoving the Old Oil NOTE Do not punch this hole without first loosening the filter to1 Remove the oil filler cap see illustration using a 13 mm make certain it can be removed open end spanner Place some paper towels and a plastic bag around the filter when unscrewing it to catch any oil left in the filter Oil or any other fluid on the engine reduces the engines cooling ability Keep OIL FILLER your engine clean Inspect the old oil filter as it is removed to CAP make sure that the rubber sealing gasket comes off with the old oil filter If this rubber sealing gasket remains sealed against the filter bracket gently remve it l JW 0 SPINON OIL FILTER Model 11A1 only 2 Model7AI Place a suitable container below the oil drain plug see illustration then remove the oil drain plug and com pletely drain the used oil into the container Then remove and clean the lube oil strainer Always clean this strainer at every oil change After cleaning replace the strainer and the oil drain plug ModelIMI Place a suitable container below the oil drain When installing the new oil filter element wipe the filter gaskets cover plate see illustration then remove the cover plate and sealing surface on the bracket free of oil and apply a thin coat of completely drain the used oil into the container Then replace clean engine oil to the rubber gasket on the new oil filter Screw the cover plate NOTE Be sure to change the spinon oil filter the filter onto the threaded oil filter nipple and then tighten the at every oil change see Changing the SpinOn Oil Filter filter fmnly by hand below NOTE Generic filters are not recommended as the material NOTE With an inclined engine installation the lube oil must standards or diameters of important items on generic parts might be pumped out otherwise too much oil would remain in the be entirely different from genuine parts Immediately after an oil crankcase filter change and oil fill run the engine to make sure the oil pres sure is normal and that there are no oil leaks around the new oil filter Engines Generators 19 LUBRICATION SYSTEMAdding the New 0111 Add the new oil through the oil fill2 Replace the oil filler cap When tightening it do not use too much force otherwise the plastic plug may break3 After refilling with new oil run the engine for a few moments Make sure there is no leakage around the oil filler cap or the new oil filter ModelllAl only then stop the engine Then check the quantity of oil with the lube oil dipstick Fill to but not over the MAX mark on the dipstick should the engine require additional oilTESTING THE OIL PRESSUREBefore testing make sure the oil level is at the MAX mark on thedipstick1 Remove the oil pressure switch see illustration2 Install a mechanical oil pressure gauge in the oil pressure switch hole3 Warm up the engine then set the engine speed at 3000 rpm and read the gauge Operating oil pressure engine hot 256 569 psi 18 40 kglcml If the oil pressure is too low see Low Oil Pressure under ENGINE NOTE The oil pressure switch closes at 43 87 psi 03 06 Bar Engines Generators 20 COOLING SYSTEMRAW WATER COOLING SYSTEMThe engine is designed for direct raw water cooling The engineoperates with a raw water coolant temperature up to 90 F 32 CThe raw water flow is created by a positive displacement impellerpump that is geardriven by the camshaft This pump drawscooling water directly from the raw water source ocean lake orriver through a hoseThe raw water is pumped through a tee which splits the flow Thetee directs some of the flow to passages in the engine block andthe remainder to a bypass The flow to the engine block the cylinder and through the cylinder head cooling theengine The flow through the bypass goes directly to the and is at its greatest when the engine is warmingup and the thermostat is not yet open Flow though the bypassalso occurs after the thermostat is open The raw water that isflowing through the engine block then flows through the thermo MODEL lA1stat to the exhaust manifoldelbow where it mixes with and coolsthe exhaust gases This mixture of exhaust gas and raw water isdischarged overboard by the engines exhaust gas discharge pressureThe coolant temperature switch is located on the cylinder head forModel 7AI and on the thermostat housing for thermostat located on top of the cylinder head controls the rawwater coolant temperature as the coolant flows through the cooling system The thermostat is set to the maximum temperature of140 F 60 C When the engine is first started the closed thermostat prevents coolant from flowing some coolant is a bypass tube to prevent the exhaust manifold from over THERMOSTAT HOUSINGheating As the engine warms up the thermostat graduallyopens The thermostat is accessible and can be checked cleanedor replaced easily Carry a spare thermostat and gasket MODEL the the two cap screws and the thermostat housing thenremove the thermostat from the cylinder head see illustrationTo check the thermostat immerse it in water that is F 60 C The thermostats cone must then be fully openthis indicates the thermostat is in good conditionUse a new gasket when reinstalling the thermostat or replacing itApply a thin coat of sealant on both sides of the gasket beforepressing it into place Do not overtighten the cap screwsRun the engine and check for normal temperatures and that thereare no leaks at the thermostat housing COOLANT TEMPERATURE SWITCH BLEED HOLE The coolant temperature switch is located near the thermostat housing see illustration If the coolants operating temperature reaches approximately 175 F 80 C this switch will activate the alarm on the control panel CYliNDER HEAD THERMOSTAT ASSEMBLY Model 7A1 sIIown Engines Generators 21 COOLING SYSTEMRAW WATER PUMP RAW WATER INTAKEThe raw water pump is a selfpriming rotary pump with a A flushtype thoughhull fitting is recommended for the raw housing and a neoprene impeller The impeller has intake It should be located on the boats hull where it will beflexible vanes which wipe against a curved cam plate within the below the waterline during all angles of the boats operation Seeimpeller housing producing the pumping action On no account Westerbekes INSTAlL4TION MANUALfor MARINE ENGINESshould this pump be run dry as water acts as a lubricant for the and GENERATORS for complete installation There should always be a spare impeller and impellercover gasket an impeller kit onboard Raw water pump occur when lubricant raw water is not present duringengine operation Such failures are not warrantable and operators A WARNING Do not use a scooptype throughhullare cautioned to make sure raw water flow is present at startup fitting for supplying raw water to this engine AscoopThe neoprene impeller has a limited lifetime and must be type raw water inlet can develop substantial regularly and force water past the raw water pump flooding theNOTE Should a failure occur with the pumps internal parts exhaust system and allowing the water to enter theseals and bearings it may be more cost effective to purchase a engines cylinder Damage caused by raw water entrynew pump and rebuild the original pump as a spare into the engines cylinder ria the exhaust system is not covered by Westerbekes the Raw Water Pump ImpellerClose the raw water intake valve Remove the pump cover and Flooding of the exhaust system due to water pressure can alsowith the aid of two small screwdrivers carefully pry the impeller occur with a flushtype raw water intake on a powerboat that hasout of the pump Install the new impeller and gasket Move the its bow up This pressure can be caused by the boats to conform to the curved cam plate and push the impeller waterline before the boat reaches its final trim or by the angle ofinto the pumps housing When assembling apply a thin coating the boat to the sea surface when its is underwayof lubricant to the impeller and gasket Open the raw water intakevalve RAW WATER INTAKE STRAINERNOTE Never allow the pump to run dry Even a short period NOTE Always install the strainer at or below the waterline soof dry running may destroy the impeller the strainer will always be selfpriming A clean raw water intake strainer is a vital component of the engines cooling system Include a visual inspection of this strainer when making your periodic engine check The water in the glass should be clear Perform the following maintenance after every 100 hours of operation 1 Close the raw water seacock 2 Remove and clean the strainer filter 3 Clean the glass 4 Replace the sealing washer if necessary 5 Reassemble and install the strainer 6 Open the seacock 7 Run the engine and check for leaks NOTE Also follow the above procedure after having run hard aground If the engine is indicating higher than normal operating tempera tures ie the alarm is sounding the cause may be that silt leaves or grass may have been caught up in the strainer slowing the flow of raw water through the cooling system RAW WATER PUMP Engines Generators 22 COOLING SYSTEM HOSE FROM THE SIPHONBREAK RAW WATER INTAKE STRAINER HOSE TO THE OWNER INSTALLED TYPICAL SIPHONBREAK HOUSINGFor installations where the waterinjected exhaust elbow is closeto or below the vessels waterline provisions must be made toinstall a siphonbreak in the raw water supply hose to the exhaustelbow The siphonbreak provides an air vent in the raw watercooling system to prevent raw water from filling the exhaust system and the engines cylinder when the engine is shut down A CAUTION Failure to use a siphonbreak when the exhaust elbow Is located at or below the load waterline will result In raw water damage to the engine and possi ble flooding of the boatIf you have any doubt about the position of the elbow relative to the vessels waterline under any of thevessels various operating conditions or when the vessel is notunder way install a siphonbreak This precaution is necessaryto protect your engineThe siphonbreak must be installed in the high point of a hose thatis looped a minimum of 20 inches 51 cm above the This siphonbreak must always be above the waterline all angles of vessel operation to prevent siphoning from Model 11A1 shownoccurring WESTERBEKE has provided two siphonbreak hosesthese are tagged The hose to the siphonbreak connects to theraw water line at the thermostat housing The hose from thesiphonbreak attaches to the waterinjected exhaust elbow The owner must furnish the siphonbreak and anyadditional lengths of hose that may be requiredNOTE A siphonbreak requires periodic inspection and cleaningto ensure proper operation Failure to properly maintain a DRAINING THE COOLING can result in severe engine damage Consult the When freezing temperatures are expected the cooling system cansiphonbreak manufacturer for a proper maintenance schedule be drained by unscrewing the pump cover The raw water coolant will then flush back down the inlet line Engines Generators 23 AIR INTAKE 7AI and llAl marine diesel engines when operating in thecruise rpm range will typically consume in excess of 1000 cubicfeet of air per hour The engine compartment must be well ventilated and the air flow into the engine must be FilterThe air fliter cartridge prevents dust and dirt from entering theengine it also improves oil consumption extends engine life andquiets the fliter should be cleaned every 100 operating hours Tap thecartridge on a flat surface to dislodge loose dirt or clean it off withcompressed air If the cartridge is badly contaminated or oilyreplace it WATER HEATER FROM WATER HEATER TOWATER HEATER INSTALLATIONS WATER HEATERThis engine is equipped with connections for plumbing the enginecoolant to transfer heat to an onboard water heater The waterheater should be mounted in a convenient location either in a lowor high position in relation to the enginePlumb the heater hoses into the raw water line that connects thethermostat housing to the exhaust manifoldelbow see If the exhaust manifoldelbow on your engine is close to orbelow the vessel s waterline you must also install a siphonbreakon the same hose see SiphonBreak under RAW WATER COOLING SYSTEM for more information The water heater connections may be located either before or after the siphonbreak THERMOSTAT HOUSING WATER HEATER CONNECTIONS Model llAl shown Engines Generators 24 FUEL SYSTEMDIESEL FUEL FUEL FILTERUse No2 diesel fuel with a cetane rating of 45 or higher Do not The frequency of a fuel filter change depends on the degree ofuse kerosene or home heating fuel contamination of the fuel however it should be performed at least after every 100 hours of engine operationFUEL ADDITIVESIf fungus or bacteria is causing fuel problems you should have Replacing the fuel filteran authorized dealer correct these problems Then use a diesel fuel 1 Clean the fuel line with a rag and clamp it off betweenbiocide to sterilize the fuel follow the manufacturers instructions the fuel lift pump and the fuel filterAlso use on a regular basis a fuel conditioner such as STABIL 2 Pull off the inlet and outlet lines from the filter MakeFollow the manufacturers instructions for the quantity to add sure dirt does not enter the fuel lines Discard the used filterCARE OF THE FUEL SUPPLY 3 Install the new filter making sure the flow arrow on theUse only clean diesel fuel Purchase a wellknown brand of fuel filter housing is pointed in the proper direction Push theThe clearance of the components in your fuel injection pump is fuel lines as far as possible onto the connection nipplesvery critical invisible dirt particles which might pass through the of the new filterfilter can damage these fmely fmished parts It is important to buy After installing the new filter bleed the air from the fuel linesclean fuel and keep it clean The best fuel can become unsatisfac using the manual fuel primer see BLEEDING mE FUELtory by careless handling or improper storage facilities To assure SYSTEMthat the fuel going to your engine is clean and pure be sure to filterit properly Install and regularly service a good fuel filterwater separator having a filter element with amicron rating of 2 or 1O Install it between the fuel tank and theengineFUEL LIFT PUMPTo assure proper suction the engines fuel lift pump should not bemore than 1 ft 300 mm above the bottom of the fuel tank pickuptube check the fuel connections to and from the fuel liftpump and make sure that no leakage is preSent and that the fittingsare tight and secure A WARNING Fuel leakage at the fuel litt pump or its connections is a fire hazard and should be corrected Make sure proper entilation exists wheneer sellficing fuel system componentsThe fuel lift pump has two filter inserts in the pumps cap To cleanor replace them unscrew the cap and retaining plate and removethe two filter inserts Note the disassembly sequence to ensureproper reassembly FUEL LIFT PUMP Engines Generators 25 FUEL SYSTEMFUEL LINES FUEL INJECTION PUMPThe fuel return line at the fuel tank should extend down to the The fuel injection pump is a very important component of thebottom of the tank in the same manner as the fuel pickup tube diesel engine requiring the utmost care in handling The fuelThis must be done in an installation where the fuel tank is located injection pump has been thoroughly benchtested and thebelow the engines fuel system This precaution insures against owneroperator is cautioned not to attempt to service it The onlyhard starting due to air displacing fuel siphoning out of the adjustment the servicing mechanic should make to the fuel injecengines fuel system through the return line when the engine is tion pump is the adjustment for engine idle speed see IDLEshutdown SPEED ADJUSTMENT under ENGINE ADJUSTMENTS Ifit requires servicing remove it and take it to an authorized fuel injection pump service facility Do not attempt to disassemble A WARNING Shut off the fuel valve at the tank when and repair it servicing the fuel system Take care in catching any fuel that may spill DD NOT allow any smoking open flames FUEL INJECTOR Dr other sources of fire near the fuel system when For information about removing and checking the fuel injector servicing Ensure proper ventilation exists when see TESTING THE FUEL INJECTOR under ENGINE ADJUST servicing the fuel system MENTS In case of severe vibrations and detonation noise have the injecFUEL FILTERWATER SEPARATOR tors checked and overhauled by an authorized fuel injection serWesterbeke recommends that you install and regularly service a vice center Poor fuel quality contaminants and loss of positivegood quality Coast Guard approved visualtype primary fuel fIlter fuel pressure to the injection pump can result in injector faultsof the type This fuel fIlterwater separator must Since fuel injectors must be serviced in a clean room environbe installed between the fuel tank and the engine to prevent any ment it is best to carry at least one extra injector as a spare or water that may be in the fuel from reaching the a problem occurfuel lift pump and causing damage to the fuel system componentsIt may also prolong the life of the fuel fIlter that comes installed BLEEDING THE FUEL SYSTEMon the fuel line It is the responsibility of the owneroperator to The fuel injection pump is selfbleeding any air in the fuel linesinstall this fuel filterwater separator Select a fIlter that has a 2 will bleed out through the fuel return line Bleeding can also beor 10 micron rating done by using the manual fuel primer on the fuel lift pump seeMost installers include a fuel fIlterwater separator with the illustration In case the engine is shut down due to lack of package as they are aware of the problems use the manual fuel primer to bleed the system after refilling in the fuel can cause fuel tank it will not be necessary to disconnect the fuel lines to bleed the air Also use the manual fuel primer to bleed theA typical fuel fIlterwater separator is illustrated below This is the system after changing the fuel filtersRaycor Model 500 MA Keep in mind that if a water separatortype fIlter is not installed between the fuel supply tank and the Bleeding the fuel system will also be necessary before fuel system any water in the fuel will affect the engine is layedup during the offseason or for prolonged periodsfuel pump engine filter and injection equipment The of inactivity See LAYUP AND is responsible for making certain the fuel reaching To use the manual fuel primer work the lever back and forth withthe engines injection equipment is free of impurities This slow complete strokes If pressure isnt felt rotate the engine 112 f I process is accomplished by installing and maintaining a proper turn this will reposition the fuel pump to improve the pumping sepmmo1jl action fuel fUlcrwMer SPARE PARTS While the likelihood of having to service the system at sea is slim the possibility does exist Therefore we recommend that banjo washers injector seat washers and a fuel fIlter be carned on board at all times Purchase needed spare parts from your local WESTERBEKE dealer or distributor If a leak should develop at a banjo washer that cannot be corrected by a simple tightening of the fitting replace the sealing washer with a replacement found in the hardware kit for your model FUEL FllTERI WATER SEPARATOR owner installed Engines Generators 26 DC ELECTRICAL SYSTEM12 VOLT DC CONTROL CIRCUIT ENGINE CIRCUIT BREAKERThe engine has a 12 volt DC electrical control circuit that is The DC wiring harness on the engine is protected by an engineshown on the wiring diagrams Refer to these diagrams when mounted manual reset circuit breaker 10 amps DC or when servicing the DC electrical system current draw or electrical overload anywhere in the instrument panel wiring or engine wiring will cause the breaker to trip In this event the engine will shut down because the opened breaker A CAUTION To avoid damage to the battery charg disconnects the fuel supply If this should occur check and repair Ing circuit never shut off the engine battery switch the source of the problem After repairing the fault reset the while the engine is running Shut off the engine battery breaker and restart the engine switch however to avoid electrical shorts when working on the engines electrical circuit BATTERY The minimum recommended capacity of the battery used in theCONTROL PANEL engines 12 volt DC control circuit is 200 Cold Cranking AmpsThe engine is started by using the keyswitch on the control panel CCAThe keyswitch has three positions OFF ON and START PROCEDURE Battery CareNOTE Push the key in to preheat after turning the key to the Review the manufacturers and then establish aON position systematic maintenance schedule for your engines starting batterNOTE Periodically lubricate the keyswitch with WCKEZE to ies and service proper operation o Monitor your voltmeter for proper charging duringThe oil temperature alarm beeps when either the engine operationoil pressure is too low or the engine is overheated o Check the electrolyte level and specific gravity withThe hourmeter registers the elapsed engine running time and a be used as a guide for the maintenance schedule o Use only distilled water to bring electrolytes to a proper level HOURMmR o Make certain that battery cable connections are clean and tight to the battery posts and to your engine KEYSWITCH o Keep your batteries clean and free of corrosion A WARNING Sulfuric acid in lead batteries can cause severe burns on skin and damage clothing Wear protective gear Oil PRESSUREI COOLANT TEMPERATURE AlARM Checking the Service Battery Check the voltage of the service battery This battery should have PUSH 10 ALARM PREHEAT a voltage between 13 and 14 volts when the engine is running If not there is a problem in the service battery charging circuit Troubleshoot the service battery charging circuit by checking the wiring and connections the solenoid isolator battery switch and CONTROL PANEL the battery itself Engines Generators 27 DC ELECTRICAL MULTIMETER A WARNING A failed alternator can become very hot Do not touch until the alternator has cooled downUse this section to determine if a problemexists with the charging circuit or with thealternator If it isdetermined that the alternator or voltage regulator is faultyhave a qualified technician check itThe alternator charging circuit charges the starting batteryand the service battery An isolator with a diode a solenoidor a battery selector switch is usually mounted in the circuitto isolate the batteries so the starting battery is not discharged TESTING THE STARTINGalong with the service battery If the alternator is charging the battery but not the service battery the problem is in ENGINE RUNNINGthe service batterys charging circuit and not with the alternator 3 Tum off the engine Inspect all wiring and the Alternator Ensure that the battery terminals and the engine ground connections are tight and clean A CAUTION Before starting the engine make certain that everyone is clear of moving parts Keep away from sheaves and belts during test procedures A CAUTION To avoid damage to the battery charging circuit never shut off the engine battery switch when the engine is running A WARNING When testing with a multimeter 4 If a battery selector switch is in the charging circuit ensure that it is on the correct setting DC and AC circuits are often mixed together in marine applications Always disconnect a shore power cord 5 Tum on the ignition switch but do not start the engine isolate DC and AC converters and shut down the engine 6 Check the battery voltage If the battery is in good condi tion the reading should be 12 to 13 volts before performing DC testing No AC tests should be made without a proper knowledge of AC circuits MULTIMmR1 Start the engine2 After the engine has run for a few minutes measure the starting battery voltage at the battery terminals using a multimeter set on DC volts a If the voltage is increasing toward 14 volts the alterna tor is working omit Steps 3 through 8 and go directly to Checking the Service Battery on the next page b If the voltage remains around 12 volts a problem TESTING THE exists with either the alternator or the charging circuit ALTERNATOR VOLTAGE e3i continue with Steps 3 through 8 IGNITION ON ENGINE OFF GROUND Engines Generators 28 DC ELECTRICAL SYSTEM7 Now check the voltage between the alternator output ter Checking the Service Battery minal B and ground If the circuit is good the voltage at Check the voltage of the service battery This battery should the alternator will be the same as the battery or if an isola have a voltage between 13 and 14 volts when the engine is tor is in the circuit the alternator voltage will be zero If running If not there is a problem in the service battery neither of the above is true a problem exists in the circuit charging circuit Troubleshoot the service battery charging between the alternator and the battery Check all the circuit by checking the wiring and connections the solenOId connections look for an opening in the charging circuit isolator battery switch and the battery itself MULTIMETER MUlTIMETE i COM TESTING THE STARTING ENGINE ENGINE RUNNING c GROUND8 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 135 and 145 volts If your alternator GROUND TESTING THE SERVICE is over or undercharging 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 ie 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 7A1 MARINE DIESEL ENGINE WIRING DIAGRAM 45593 I 4 Bl K RD tI4RO r I WATER TEIF r SWITCHSEE NOTE 2 lj I I IlL PRESSUIE SWITCH I o w I r I I I 5 4 CfICUT IIIIEAKER WE IlElAY RELAY 3 110 RED 4 RED GLOW PLUOS STARlBI IIEtAT SOIENOIl I 4 V 10 I 2 WHT 12 RED 114 VEL i14 ORANGE 51 I 4 Bl II PI T THE 71 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 rt 0c KEY SWITCH REMlTE PAfE WESTERBEKE Engines Generators 30 DC ELECTRICAL SYSTEM 7A1 MARINE DIESEL ENGINE WIRING SCHEMATIC 45593 G 12 VDC G STARTER r STARTER SOLENOIO J GlOWPLUGS r I PREtAT I I SOLENOID I I I AlTERNATOR 30 87 86 ClRCUT BREAKER NO 5 T1rtE DElAY RELAY WATER TEMP SWITCH 3 NC OIl PRESSURE SWITCHSI 6 7 5 3PI AlARM HOlfl METER START PREJEAT0 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 BUILDEROWNER MUST BE SURE THAT THE INSTRUMENT PANEL WIRING AND ENGINE ARE INSTALLED TO PREVENT CONTACT BETWEEN ELECTRICAL DEVICES AND SEAWATER AN ONorr 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 11A1 MARINE DIESEL ENGINE WIRING DIAGRAM 44542 I 4 BL K r I I 10 I WATER TEJoP I J I I IlL PIESSUAE SWITCH I I r STARTER 114 REDWHT 114 VIO 112 WHT 1I2RED 14 y l 51 II BLK PI KEY SWITCH L REMOTE PAtl Engines Generators 32 DC ELECTRICAL SYSTEM 11A1 MARINE DIESEL ENGINE WIRING SCHEMATIC 44542 12 vee STARTER STARTER SOLENOID ALTERNATOR CIRCUT BREAKER WATER TEMP SWITCH NC DI PRE5SUE SWITCHSI B 7 5 3P1 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 BUILDEROWNER MUST BE SURE THAT THE INSTRUMENT PANEL WIRING AND ENGINE ARE INSTALLED TO PREVENT CONTACT BETWEEN ELECTRICAL DEVICES AND SEAWATER 2 AN ONorF 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 7A1 Reinstall the plugs in the air intake adapter and test them again The plugs should get very hot at the terminal end within 7 to 15The glow plugs 2 are wired through the preheat solenoid When seconds If the plugs dont heat up quickly check for a short cirPREHEAT is pressed at the control panel this solenoid should cuit When reinstalling the glow plugs use antiseize compoundclick on and the glow plug should begin to get hot on the inspect the plug remove the electrical terminal connections A WARNING Do not keep a glow plug on for morethen unscrew each plug from the air intake adapter Thoroughly than 30 secondsclean each plugs tip and threads with a soft brush and to remove all the carbon and oil deposits While clean Glow plug tightening torque 7 11 ftIb 10 15 mkging examine the tip for wear and burn erosion if it has eroded toomuch replace the plugTESTING e TERMINAL ENDAn accurate way to test glow plugs is with an ohmmeter Touchone prod to the glow plugs wire connection and the other to thebody of the glow plug as shown A good glow plug will have a055 ohm resistance This method can be used with the plug in orout of the engine You can also use an ammeter to test the power TESTING AGLOW PLUGdrain 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 THE CYLINDER HEAD 5 For each valve insert a 02 mm 0008 in feeler gauge between the valve stem and the rocker arm and adjust theAfter the initial breakin period approximately 50 hours clearance until a slight drag is felt on the gauge when it isretorque the cylinder head nuts Do this when the engine is cold pulled out1 Remove the cylinder head cover and gasket 6 Tighten the locknut while holding the setting screw with2 Retighten the four cylinder head nuts in an Xpattern 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 torque3 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 engines compression pressure warm up the engine shut off the raw water throughhull remove the fuel injector andVALVE CLEARANCE ADJUSTMENT install a compression adapter in the injector hole Connect a com pression tester on the adapter and crank the engine with the starterCheck the valve clearances after the first 50 hours of operation and motor until the pressure reaches a maximum valueevery 600 hours thereafter Compression pressure at 350 rpmNOTE Tighten the cylinder head bolts to their specified torque Minimum 4350 psi 306 kgcm 2before adjusting the valve clearances see TIGlffENING THE Standard 4785 psi 336 kgcm2CYUNDER HEADAdjust the valve clearances when the engine is cold Theclearance is 02 mm 0008 in for both intake and exhaust valves 1 Remove the cylinder head2 Check to make sure the automatic decompression device is in its normal operating position ie not activated see illustration ADAPTER INJECTOR HOLE POINTER If the pressure is weak the problem is either valve or piston lH 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 overlwuled by an authorized fuel injection3 Set the piston at the TDC of the compression stroke service center Poor fuel quality contaminants and loss ofpositive4 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 THE FUEL INJECTOR Checking The Injection Starting PressureNOTE The fuel injector must be serviced in a clean room 1 Set the nozzle tester in a clean place where there isenvironment no dust or dirt 2 Mount the nozzle and the nozzle holder on theRemoving the Fuel Injector nozzle tester1 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 68F 20C 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 times2 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 Ibin2 200 203 kglcm23 Remove the fuel injector holder bracket mounting nuts then remove the holder bracket4 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 dBflJy 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 buildup or the like worlc the injector sidetaside 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 reinstalled5 Remove the gaskets FUEL INJECTOR6 Remove the OringsFuel Injector ComponentsThe 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 0004 in 01 mm PRESSURE SPRINGI the injection pressure increases approximately 145lblin2 101 kglcm2 VALVE CONE PRESSURE PIECEe 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 of the Valve Seat Checking the Nozzle Body and Needle ValveApply a pressure of 2600 Iblin2182 kglcm2 and check if fuel 1 Check for damage to the valve seat of the needle valveleaks from the injection nozzle holes If fuel leaks disassemble and check for damage to other partswash and recheck the injector nozzle or replace it 2 Check for damage to the nozzle body Hold the nozzle body upright and insert fourfifths 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 thefuel injector 1 Tighten the nozzle body onto the nozzle holder to the specified torque Nozzle torque 29 36 ftIb 40 50 kgm CHECKING THE TIGHTNESS OF THE VALVE SEATInspecting the Spray Pattern1 Mount the nozzle and nozzle holder on the nozzle tester2 Bleed the air in the nozzle line by pumping the nozzle tester handle several times3 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 atornition 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 ftIb 08 12 kgm 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 mechanicDRIVE BELT ADJUSTMENTThe drive belt must be properly tensioned A loose drive belt willnot provide proper alternator charging and will eventually damagethe a1temator A drive belt that is too tight will pull the alternatorout of alignment andor cause the alternator to wear out prematurely Excessive drive belt tension can also cause rapid wear ofthe belt A slack belt or the presence of oil on the belt can causebelt slipping resulting in high operating temperatures and rpm GOOD BADvariations 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 belts tension while the engine Is in operation 5 Run the engine for about 5 minutes then shut down andChecking Belt Tension recheck the belt tension1 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 38 112 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 following chart provides information basedupon certain problem indicators the probable causes of theseproblems and the to overcome them1 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 Checkreplace nozzle 5 Faulty injection pump 5 pump 6 Fuel line blocked 6 Check fuel lines and remove blockage 7 Broken fuel line or leaking connection 7 Replace 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 CheCkreplace automatic decompression device device malfunction 2 Incorrect valve clearance 2 Adjust valve clearance 3 Valves not seating properly 3 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 CheCkreplace nozzle 4 Faulty injection pump 4 pump 5 Fuel line clogged 5 Check the fuel lines and remove the blockage 6 Fuel lines or connections leak 6 Replace connections Faulty air intake andor 1 exhaust system 1 Checkclean exhaust system exhaust system 2 air intake 2 Checkclean air intake system Poor Compression See Poor Compression under Engine will not Start continued Engines Generators 39 ENGINE Engine lacks power andor makes black smoke Problem Probable Cause Remedy Operating conditions 1 Engine overloaded 1 Reduce the load 2 Power reduction due to altitude andor ambient temperature has not been considered 3 Clogged air filter 3 Cleanreplace 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 Checkreplace nozzle 4 Faulty injection pump 4 pump Engine condition 1 Excessive carbon on piston and 1 Decarbonize cylinder head 2 Faulty piston rings 2 Checkreplace piston ring set 3 Worn piston and cylinder 3 Overhaul engine 4 Worn bearings 4 Overhaul engine4 Faulty running Engine overheats 1 Engine oveoaded 1 Reduce load 2 Faulty raw water pump impeller 2 Replace impeller 3 Faulty thermostat 3 Checkreplace 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 Checkreplace 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 Repairreplace crankshaft and bearings continued Engines Generators 40 ENGINE 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 valvesvalve guides 3 Replace valves and guides 4 Worn pistoncylinder 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 valves5 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 7Al and llAl 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 and infonnation for this transmission tion of the shift lever on the control console should coincide withis included in the following instructions the neutral position of the actuating lever The shifting travel as measured at the pivot points of the ing lever between the neutral position and end positions A and BNOTE When installing the transmission make certain that shift should be at least 35 mm for the outer pivot point and 30 mm foring is not impeded by restricted movability of the cable or rod the inner pivot pointlinkLlge by unsuitably positioned guide sheaves too small a bend A greater amount of shift lever travel is in no way detrimental anding radius or other restrictions In order to mount a support for is recommended However if the lever travel is shorter propershift control cable connections use the two threaded holes located clutch engagement might be impeded which in tum would meanabove the cable bracket mounted on the gear housing Refer to premature wear excessive heat generation and clutch plate failurethe WESfERBEKE Parts list This would be indicated by slow clutch engagement or no engage ment at allShaft Couplings NOTE Check for proper actuating lever travel at least eachWESTERBEKE recommends a flexible connection between the and the propeller shaft if the engine is in order to compensate for angular deflections of a special propeller thrust bearing is not requiredsince the propeller thrust will be absorbed by the provided the value specified under SPECIFICATIONS isnot exceeded However the output shaft should be protectedfrom additional loads Special care should be taken to prevent torsional vibration When using a universal joint shaft make certainto observe the manufacturers with the engine solidly mounted the use of a flexible coupling or DRNESAVER will reduce stress in the gearbox bearingscaused 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 mmShift Control and Actuating LeverThe transmission is suitable for single lever remote control Uponloosening the retaining screw the actuating lever can be moved to ACTUATING LEVERany position required for the shift control cable or rod linkageMake certain that the actuating lever does not contact the actuating lever cover plate the minimum distance between lever andcover should be 002 in 05 mm see illustration COVER A Caution The position of the mechanism behind the actuating lever is to ensure equal actuating lever travel from Neutral position N to Reverse position A and Forward position B this mechanism is mm 002 in 05 MINIMUM DISTANCE in any way tampered with the transmission warranty will be mid DRIVESAVER is a product oGlobe Marine Rocldand MA Engines Generators 42 HURTH HBW OPERATION LOCKING THE PROPELLERAll HBW maine transmissions are testrun on a test stand with the Locking of the propeller shaft by an additional brake is notengine at the factory prior to delivery For safety reasons the fluid required use the gear shift lever position opposite your directionis drained before shipment of travel for this purpose Never put the gear shift in the positionFill the gearbox with Automatic Transmission fluid DEXTRON corresponding to the direction of travel of the boat111 The fluid level should be up to the index mark on the dipstick To check the fluid level just insert the dipstick do not WHEN UNDER SAIL OR BEING TOWEDscrew 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 ischecked and tighten Do not forget the sealing ring under the being sailed being towed or anchored in a river as well as operahexhead of the dipstick Check for leaks and make a visual tion of the engine with the propeller stopped for charging the batinspection 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 flh FLUID LEVEL Transmission section SHAFT COUPliNGS MAINTENANCE and TRANSMISSION DRAIQl 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 277 346 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 2051 Lubricating Fluid ATF type A or DEXTRON I or 1 A WARNING Never pullout the dipstick while the Transmission Sump 037 qts 035 liters engine is running Hot fluid will splash from the dipstick Capacity hole This could cause sever bums Propeller Shaft Right handstandard transmission Direction of Rotation Engines Generators 43 HURTH HBW maintenance is minimal Keep the exterior housingclean check the fluid level as part of your regular routine andchange the fluid every 300 operating inspect the transmission for leaks and the cable requires special care Follow these procedureso Clean up the transmission and touch up unpainted areas use heat resistant painto Fill the transmission with Dextron III ATF fluid to prevent internal corrosion extended storage only twelve months or moreo Loosen attaching hardware from the transmission output flange and propeller shaft coupling flange before removing the boat from the water Separate the flanges and spray with lubricanto 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 serviceFor additional information contact HURTH MARINE GEAR ZF Industries Marine US Headquarters 3131 SW 42nd Street Fort Lauderdale FL 33312 Tel 9545814040 Fax 9545814077 Engines Generators 44 HURTH HBW TRANSMISSION CABLES A new cable and perhaps a new linkage mechanism may be needed While the cable is loose shift the transmission in and outThe majority of transmission difficulties arise as a result of prob of gear using the actuating lever on the side of the transmission tolems with control cables rather than from problems with the trans make sure theres no binding inside the casemission itself If the transmission passes these tests crank the engine and have aIf you experience operating problems with the transmission shut helper put it in forward and reverse while you observe the prothe engine down First check the transmission fluid level then peller shaft if the shaft isnt turning the transmission needs prohave a helper move the cockpit shift lever through the full range fessional attention If it does tum but theres 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 youand back to neutral while you observe the actuating lever on have a folding or feathering propeller that it isnt stuck in the nothe transmission If the remote is stiff to operate break the cable pitch positionloose at the transmission and try again If it is still stiff check thecable for kinks or excessively tight bends and check any linkage NOTE If you suspect a major problem in your 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 002 in 05 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 0003 in 008 mm Engines Generators 45 LAYUP AND Change the fuel ftlter elements on the engine see FUEL SYSTEM and bleed the fuel system as needed Start the engineMany owners rely on their boatyards to prepare their craft and allow it to run for 510 minutes to make sure there is no airincluding engines and generators for layup during the off season left in the fuel system Check for any leaks that may have beenor for long periods of inactivity Others prefer to accomplish created in the fuel system during this servicing correcting them aslayup preparation themselves needed Operate the engine for 510 minutes This will allowThe procedures which follow will allow you to perfonn your own movement of the treated fuel through the injection equipment oflayup and or you may use them as a check list the engineif others do the procedures should afford your engine protection during LongTerm LayUp Procedure over 12 monthslayup and also help familiarize you with the maintenance needs For a longtenn layup follow the fuel system layup proceduresof your engine described above then do the followingIf you have any questions regarding layup procedures call your Disconnect the fuel supply line from the fuel tank at the fuel liftlocal servicing dealer he will be more than willing to provide pump Fill a suitable container with a 0132 US gallon 05 mixture of 910 diesel fuel and 1110 anticorrosion oil Connect a short suction pipe between the container and the fuel lift pumpPROPELLER SHAFT COUPLING Set the speed control lever to full load set the automaticThe transmission and propeller half couplings should always be decompression device to its neutral position then handcrank theopened up and the bolts removed when the boat is hauled out of engine approximately 20 times Put the speed control lever backthe water or moved from land to water and during storage in the to the idle positioncradle The flexibility of the boat often puts a severe strain on thepropeller shaft or coupling or both while the boat is taken out or RAW WATER COOLING CIRCUITput in the water In some cases the shaft has actually been bent Remove the impeller from your raw water pump and allow theby these strains This does not apply to small boats that are raw water in the cylinder head coolant chamber to drain outhauled out of the water when not in use unless they have been Allow it to drain completely Examine the impeller Acquire adry for a considerable period of time replacement if needed and a cover gasket Do not replace the impeller into the pump until but replace theLUBRICATING SYSTEM cover and gasket Drain the water lift mufflerWith the engine warm drain all the engine oil from the oil sumpFill the sump with the correct amount of oil for your engine refer AIR INTAKE THROUGHHULL EXHAUSTto the SPECIFICATIONS section of this manual Use an oil with Remove the air intake silencer and place a clean cloth lightlyan API specification of CF or CG4 Run the engine and check soaked in lubricating oil in the air intake opening to block thefor 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 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 engines old engine remove the cloth prior to startup The throughhull exhaust port oil in the sump over the layup 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 engines 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 openingFUEL SYSTEM Rotate the engine two revolutions using the hand crank Spray fogging oil into the air intake again Replace the air intakeTop off your fuel tanks with No2 diesel fuel Fuel additives such silenceras BlOBOR AND STABIL should be added at this time to controlalgae and condition the fuel Care should be taken that the addi If you anticipate a long layup period 12 months or moretives used are compatible with the primary fuel filterwater separa WESTERBEKE recommends removing the fuel injector fortor used in the system Change the ftlter element in your primary access to the cylinder then squirting light lubricating oil into thefuel ftlterwater separator if the fuel system has one and clean the cylinder to prevent the piston rings from sticking to the sediment bowl Reinstall and make certain there are no walls After squirting the oil move the piston by a quick electricleaks 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 LAYUP AND MOTOR and cleaning of the starter drive pinion is advisable Thoroughly clean the outside of the engine then store theMake sure the battery connections are shut off before attempting engine in a dry place protected against the weatherto remove the starter Take care in properly replacing anyelectrical connections removed from the starter The of your WESTERBEKE engine after a seaBATTERIES sonallayup generally follows the same procedures as thoseIf batteries are to be left on board during the layup period make described in the PREPARATIONS FOR INITIAL STARTUPsure they are fully charged and will remain that way to prevent section regarding preparation for starting and normal startsthem from freezing If there is any doubt the batteries will not However some of the layup procedures will need to beremain full charged or that they will be subjected to severe counteracted before starting the conditions remove the batteries and store them in a 1 Remove the oilsoaked cloths from the air intake openingwarmer more compatible environment and the throughhull exhaust port 2 Remove the raw water pump cover and gasket and A WARNING Lead acid batteries emit hydrogen a discard the old gasket 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 layup 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 layup 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 or change the fluid in the transmission as required Wipeoff grime and grease and touch up any unpainted areas Protect A CAUTION Wear rubber gloves a rubber apronthe coupling and the output flange with an anticorrosion coating and eye protection when servicing batteries LeadCheck that the transmission vent is open acid batteries emit hydrogen a highly explosive gasFor additional information see in the HURTH which can be ignited by electrical arcing or a lightedHBW TRANSMISSION section cigarette cigar or pipe Do not smoke or allow an open flame near the battery being serviced Shut offSPARE PARTS all electrical equipment in the vicinity to prevent electrical arcing during servicingLayup time provides a good opportunity to inspect yourWESTERBEKE engine to see if external items such as the drive 4 Start the engine in accordance with the or coolant hoses need replacement Check your basic spares FOR INITIAL STARTUP and and order items not on hand or replace those items used PROCEDURE sections of this manualduring the layup such as filters See SUGGESTED the keyswitch with WCKEZE to ensure that the functions freely with no binding Engines Generators 47 7A1 11 A1 TORQUE SPECIFICATIONS MOOEl7A1 MODEL 11A1 Component SPANNER TIGHTENING TORQUE Nm SPANNER TIGHTENING TORQUE Nm SIZE SIZE mm MIN MAX mm MIN MAXCylinder head 13 30 33 17 52 56Connecting rod 13 30 33 14 52 56Cylinder head cover 13 8 12 13 8 12Main bearing plate 13 30 33 13 30 33Fuel lift pump 13 30 33 13 30 33Fuel injection pump 13 30 33 13 30 33Delivery valve pump 14 34 39 14 34 39High pressure pump 17 18 22 17 18 22High pressure fuel linefuel injector 17 25 30 17 25 30Injector clamp 10 8 12 13 20 23Governor on crankshaft 14 55 60 14 55 60Aywheel 36 216 226 46 390 410Gear end cover 6 34 38 6 34 38Push rod guide 4 8 10 4 8 10Crank handle guide 10 8 12 10 8 12Oil pump 5 16 20 5 16 20Sump plate crossslotted 9 11 crossslotted 9 11Banjo bolt on fuel lift pump 17 25 35 17 25 35Banjo bolt on tank 12 8 10 12 8 10Rocker bracket 13 30 33 17 52 56Oil filter Handtighten Engines Generators 48 STANDARD HARDWAREBOLT HEAD MARKINGS Metric bolt class numbers identify bolts by their strength with 109 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 67 Body SIze TDIqIII Torque Torque Bon Grada46 Grade 4B Grade BB 98 Grade 109 Inches TIIread FHb Nm FtlbNm RLbNm Ola Wrench Size ALbNm ALbNm FILbNm RLbNm 1420 8 11 10 14 12 16 28 10 14 14 19 M3 55mm 03 05 05 01 1 13 15 2 M4 7mm 08 11 1 15 2 3 345 516 18 17 23 1926 24 33 M5 8mm 15 25 23 45 6 65 9 24 19 26 27 31 38 16 31 42 3446 44 60 M8 10mm 3 4 4 55 75 10 11 15 24 35 41 4966 M9 13mm 7 95 10 13 18 25 3526 711614 4966 55 75 70 95 Ml0 16mm 14 19 18 25 37 50 55 75 20 55 75 78 106 12 13 75 102 85 115 105 142 M12 18mm 26 35 33 45 6385 fl 130 20 85 115 120 163 M14 21 mm 37 50 55 75 103 140 151 205 M16 24mm 59 80 85 115 159 215 232 315 916 12 110 149 120 163 155 210 18 120163 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 295400 42569 M24 36mm 203 275 288 390 553 750 789 1070 M27 41 mm 295 400 417 565 811 1100 1154 1565 78 9 395 536 440 591 605 820 M30 46mm 402 545 568 770 1103 1495 1571 2130 14 435 590 675 915 1 8 590800 660 895 910 1234 M33 51 mm 546 740 774 1050 1500 2035 2139 2900 14 660895 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 passages Do nat use tape sealantsOil based PERMATEX 12 and its HIGH TACK equivalent are excellent allpurpose sealers They are effective in just about any jOint in contact with BOIis raw water oil or fuel Ughtly oil head bolts and other fasteners as you assemble them Bolts andA 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 orand Orings HIGH TACKLOCTITE hydraulic red sealant should be used on oil adapter hoses and the oil When assembling the flywheel coat the bolt threads with LOCTITE bluefilter assembly Antiseize compounds and thread locking adhesives such as LOCTITE protectCoat both surfaces of the oil pan gasket with high temp RED SILICONE sealer threaded components yet allows them to came apart when necessaryWhen installing gaskets that seal around water coolant passages coat both LOCTITE offers levels of locking according to the jobsides with WHITE SILICONE grease LITHIUM based grease is waterproof ideal for water pump bearings and ADHESIVE SPRAYS are useful for holding gaskets in position dur ing boxesing assembly Heavily oil all sliding and reCiprocating components when assembling gasket sealers such as HYLOMAR work well in applications requir use clean engine alling nonhardening properties HYLOMAR is particlarly effective oncopper cylinderhead gaskets as it resists fuel oil and water Engines Generators 49 METRIC CONVERSIONS INCHES TO MILUMETERS MILUMETERS TO INCHESInches mm Inches mm mm Inches mm Inches 1 2540 15 38100 1 00394 15 05906 2 5080 20 50800 2 00787 20 07874 3 7620 25 63500 3 01181 25 09843 4 10160 30 76200 4 01575 30 11811 5 12700 35 88900 5 01969 35 13780 10 25400 40 101600 10 03937 40 15748 10 MILLIMETERS 1 CENTIMETER 100 CENTIMETERS 1 METER 3937 INCHES 33 FEET INCHES TO METERS METERS TO INCHESInches Meters Inches Meters Meters Inches Meters Inches 1 00254 7 01778 01 3937 07 27559 2 00508 8 02032 02 7874 08 31496 3 00762 9 02286 03 11811 09 35433 4 01016 10 02540 04 15748 10 39370 5 01270 11 02794 05 19685 11 43307 6 01524 12 03048 06 23622 12 47244 TO CONVERT METERS TO CENTIMETERS MOVE DECIMAL POINT TWO PLACES TO THE RIGHT YARDS TO METERS METERS TO YARDSYards Meters Yards Meters Meters Yards Meters Yards 1 091440 6 548640 1 109361 6 656168 2 182880 7 640080 2 218723 7 765529 3 274320 8 731520 3 328084 8 874891 4 365760 9 822960 4 437445 9 984252 5 457200 10 914400 5 546807 10 1093614 MOVE DECIMAL POINT FOR HIGHER VALUES eg 6000 METERS 656168 YARDS POUNDS TO KILOGRAMS KILOGRAMS TO POUNDS Ib kg Ib kg kg Ib kg Ib 1 0454 6 2722 1 2205 6 13228 2 0907 7 3175 2 4409 7 15432 3 1361 8 3629 3 6614 8 17637 4 1814 9 4082 4 8818 9 19842 5 2268 10 4536 5 11023 10 22046 GALLONS TO LITERS LITERS TO GALLONSGallons Uters Gallons Uters Uters Gallons Liters Gallons 1 379 10 3786 1 026 60 1566 2 757 20 7571 2 053 90 2377 3 1136 30 11357 5 132 120 3132 4 1514 40 15142 10 264 150 3962 5 1893 50 18928 20 528 180 4754 PINTS TO UTERS UTERS TO PINTS Pints Uters Pints Uters Uters Pints Liters Pints 1 047 6 284 1 211 6 1268 2 095 7 331 2 423 7 1479 3 142 8 379 3 634 8 1691 4 189 9 426 4 845 9 1902 5 237 10 473 5 1057 10 2113 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 50STANDARD AND METRIC CONVERSION Inches in x 254 Millimeters mm x 0394 Inches Feet ft x 305 Meters m x 3281 Feet Miles x 1609 Kilometers km x 0621 MilesVOLUME Cubic Inches in3 x 16387 Cubic Centimters x 061 in3 Imperial Pints IMP pt x 568 liters L x 176 IMP pt Imperial Quarts IMP qt x 1137 liters L x88 IMP qt Imperial Gallons IMP gal x 4546 liters L x 22 IMP gal Imperial Quarts IMP qt x 1201 US Quarts US qt x 833 IMP qt Imperial Gallons IMP gal x 1201 US Gallons US gal x 833 IMP gal Fluid Ounces x 29573 Milliliters x 034 Ounces US Pints US pt x 473 LitersL x 2113 Pints US Quarts US qt x 946 Liters L x 1057 Quarts US Gallons US gal x 3785 Liters L x 264 Ounces oz x 2835 Grams g x 035 Ounces Pounds I b x 454 Kilograms kg x 2205 PoundsPRESSURE Pounds Per Sq In psi x 6895 Kilopascals kPa x 145 psi Inches of Mercury Hg x 4912 psi x 2036 Hg Inches of Mercury Hg x 3377 Kilopascals kPa x 2961 Hg Inches of Water H20 x 07355 Inches of Mercury x 13783 H20 Inches of Water H20 x 03613 psi x 27684 H20 Inches of Water H20 x 248 Kilopascals kPa x 4026 H20TORQUE PoundsForce Inches inIb x 113 Newton Meters Nm x 885 inIb PoundsForce Feet ftIb x 1356 Newton Meters Nm x 738 ftIbVELOCITY Miles Per Hour MPH x 1609 Kilometers Per Hour KPH x 621 MPHPOWER Horsepower Hp x 745 Kilowatts Kw x 134 MPHFUEL CONSUMPTION Miles Per Hour IMP MPG x 354 Kilometers Per Liter KmL Kilometers Per liter KmL x 2352 IMP MPG Miles Per Gallons US MPG x 425 Kilometers Per Liter KmL Kilometers Per Liter KmL x 2352 US MPGTEMPERATURE Degree Fahrenheit OF DC X 18 32 Degree Celsius DC OF 32 x 56 Engines Generators 51 SUGGESTED SPARE PARTS KITS Carry only Genuine WESTERBEKE Spare PartsSPARE PARTS KITSWESTERBEKE offers two Spare Parts Kitseach packaged in a rugged hinged toolboxKit A includes the basic sparesKit B is for more extensive offshore cruisingKit A includes Drive Belt Raw Water Pump Impeller and Gasket Fuel Filter Fuel Lift Pump Screens 2 and Gasket Oil Filter Model lOAI only Fuel Hardware Kit to fix a leak Air Intake FilterKit 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 lOAI only Fuel Hardware Kit to fix a leak Thermostat Kit Complete Gasket Kit Fuel Injector Air Intake Filter Engines Generators 52 Engines
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