Westerbeke Diesel 63d Four Operator's Manual
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OPERATORS MANUALMARINE DIESEL ENGINES 64 F PUBLICATION NO49112 FIRST EDITION DECEMBER 2003 member WESTERBEKE CORPORATION MYLES STANDISH INDUSTRIAL PARK 150 JOHN HANCOCK ROAD TAUNTON MA 027807319 USA TEL 5088237877 FAX 5088849688 WEBSITE 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 Weakness and Sleepiness Inability to Think CoherentlyIF YOU OR ANYONE ELSE EXPERIENCE ANY OF THESE SYMPTOMSGET OUT INTO THE FRESH AIR IMMEDIATELY If symptoms persistseek medical attention Shut down the unit and do not restartuntil it has been inspected and repaired A WARNING DECAL is provided by WESTERBEKE and should be fixed to a bulkhead near your engine or generator WESTERBEKE also recommends installing CARBON MONOXIDE DETECTORS in the CALIFORNIA PROPOSITION 65 WARNING Marine diesel and gasoline engine exhaust and some of its constituents are known to the State of California to cause cancer birth defects and other reproductive harm SAFETY PREVENT BURNS FIRERead this safety manual carefully Most accidents arecaused by failure to follow fundomental rules and precau A WARNING Fire can causenjury or deathtions Know when dangerous conditions exist and take thenecessary precautions to protect yourself your personne Prevent flash fires Do not smoke or permit flames orand your machinery sparks to occur near the carburetor fuel line filter fuelThe following safety instructions are in compliance with the pump or other potential sources of spilled fuel or fuelAmerican Boat and Yacht Council ABYC standards vapors Use a suitable container to catch all fuel when removing the fuellme carburetor or fuel filtersPREVENT ELECTRIC SHOCK Do not operate with a Coast Guard Approved flame arrester removed Backfire can cause severe injury or death A WARNING Do not touch AC electrical connections Do not operate with the air removed while engine is running or when connected to shore Backfire can cause severe injury or death power Lethal voltage is present at these connections Do not smoke or permit flames or sparks to occur near the fuel system Keep the compartment and the Do not operate this machinery without electrical clean and free of debris to minimize the enclosures and covers in place chances of fire Wipe up all spilled fuel and engine oil Shut off electrical power before accessing electrical Be aware diesel fuel will burn equipment Use insulated mats whenever working on electrical PREVENT BURNS EXPLOSION equipment Make sure your clothing and skin are dry not damp particularly shoes when handling electrical equipment A WARNING Explosions from fuel vapors can cause injury or death Remove wristwatch and all jewelry when working on electrical equipment Follow refueling safety instructions Keep the vessels Do not connect utility shore power to vessels AC hatches closed when fueling Open and ventilate cabin circuits except through a shiptoshore double throw after fueling Check below for fumesvapor before run transfer switch Damage to vessels AC generator may ning the blower Run the blower for four minutes before result if this procedure is not followed starting your engine Electrical shock results from handling a charged capaci All fuel vapors are highly explosive Use extreme care tor Discharge capacitor by shorting terminals together when handling and storing fuels Store fuel in a wellven tilated area away from sparkproducing equipment andPREVENT BURNS HOT ENGINE out of the reach of children Do not fill the fuel tanks while the engine is running A WARNING Do not touch hot engine parts or Shut off the fuel service valve at the engine when servicing the fuel system Take care in catching any fuel that might exhaust system components Arunning engine gets spill DO NOT allow any smoking open flames or other very hot sources of fire near the fuel system or engine when servic ing Ensure proper ventilation exists when servicing the Always check the engine coolant level at the coolant fuel system recovery tank Do not alter or modify the fuel system Be sure all fuel supplies have a positive shutoff valve A WARNING Steam can cause injury or death Be certain fuel line fittings are adequately tightened and free of leaks In case of an engine overheat allow the engine to cool Make sure a fire extinguisher is installed nearby and is before touching the engine or checking the coolant properly maintained Be familiar with its proper use Extinguishers rated ABC by the NFPA are appropriate for all applications encountered in this environment Engines Generators SAFETY 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 generator Remove the negative lead first and reconnect discharged from the engine Check the exhaust system regularly for leaks and make sure the exhaust manifolds it last are securely attached and no warping exists Pay close Make certain all personnel are clear of the engine before attention to the manifold water injection elbow and starting exhaust pipe nipple Make certain all covers guards and hatches are re Be sure the unit and its surroundings are well ventilated installed before starting the engine In addition to routine inspection of the exhaust system install a carbon monoxide detector Consult your boatBATTERY EXPLOSION builder or dealer for installation of approved detectors For additional information refer to ABYC T22 educa A WARNING Battery explosion can cause injury tional information on Carbon Monoxide or death Do not smoke or allow an open flame near the battery A WARNING Carbon monoxide CO is an invisible being serviced Lead acid batteries emit hydrogen a odorless gas Inhalation produces flulike symptoms highly explosive gas which can be ignited by electrical nausea or death arcing or by lit tobacco products Shut off all electrical equipment in the vicinity to prevent electrical arcing dur Do not use copper tubing in diesel exhaust systems Diesel ing servicing fumes can rapidly destroy copper tubing in exhaust sys Never connect the negative battery cable to the posi tems Exhaust sulfur causes rapid deterioration of copper tive connection terminal of the starter solenoid Do tubing resulting in exhaustwater leakage not test the battery condition by shorting the terminals Do not install exhaust outlet where exhaust can be drawn together Sparks could ignite battery gases or fuel vapors through portholes vents or air conditioners If the engine Ventilate any compartment containing batteries to prevent exhaust discharge outlet is near the waterline water could accumulation of explosive gases To avoid sparks do not enter the exhaust discharge outlet and close or restrict the disturb the battery charger connections while the battery flow of exhaust Avoid overloading the craft is being charged Although diesel engine exhaust gases are not as toxic as Avoid contacting the terminals with tools etc to prevent exhaust fumes from gasoline engines carbon monoxide bums or sparks that could cause an explosion Remove gas is present in diesel exhaust fumes Some of the symp wristwatch rings and any other jewelry before handling toms or signs of carbon monoxide inhalation or poisoning the battery are Always tum the battery charger off before disconnecting Vomiting Muscular twitching the battery connections Remove the negative lead first Dizziness Intense headache and reconnect it last when disconnecting the battery Throbbing in temples Weakness and ACID AVOID MOVING PARTS A WARNING Sulfuric acid in batteries can cause A WARNING Rotating parts can cause injury severe injury or death or death When servicing the battery or checking the electrolyte level wear rubber gloves a rubber apron and eye protec Do not service the engine while it is running If a situa tion Batteries contain sulfuric acid which is destructive tion arises in which it is absolutely necessary to make If it comes in contact with your skin wash it off at once operating adjustments use extreme care to avoid touching with water Acid may splash on the skin or into the eyes moving parts and hot exhaust system components inadvertently when removing electrolyte caps Engines Generators ii SAFETY INSTRUCTIONS Do not wear loose clothing or jewelry 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 or the drive belts tension while the engine is operating Order from Stay clear of the drive shaft and the transmission coupling ABYC when the engine is running hair and clothing can easily 15 East 26th Street be caught in these rotating parts New York NY 10010 NFPA National Fire Protection NOISE Fire Protection Standard for Motor Craft Order from A WARNING High noise levels can cause hearing National Fire Protection Association loss 11 Tracy Drive Avon Industrial Park Never operate an engine without its muffler installed Avon MA 02322 Do not run an engine with the air intake silencer USCG United States Coast Guard removed USCG 33CFR183 Do not run engines for long periods with their enclosures Order from open US Government Printing Office Washington DC 20404 A WARNING Do not wotlc on machinery when you are mentally or physically incapacitated by MANUALMany of the preceding safety tips and warnings are repeatedin your Operators Manual along with other cautions andnotes to highlight critical information Read your maintain your equipment and follow all to install an engine should begin with a thorough 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 H2 Ventilation 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 federal regulations ABYC guidelines and safety codes must be complied withwhen installing engines and generators in a marine installations where the exhaust manifoldwater injected exhaust elbow is close toor will be below the vessels waterline provisions must be made to install a siphonbreak in the raw water supply hose to the exhaust elbow This hose must be looped aminimum of 20 above the vessels waterline Failure to use a siphonbreak whenthe exhaust manifoUJwater injected exhaust elbow is near or below the loaded water line of the vessel will result in raw water damage to the engine and of the vesselIf you have any doubt about the position of the waterinjected exhaust elbow relative to the vessels waterline under the vessels various operating conditions install asiphonbreak AVAILABLE FROM YOUR WESTERBEKE NOTE A siphonbreak requires periodic inspection and cleaning to ensure proper DEALER operation Failure to properly maintain a siphonbreak can result in catastrophic engine damage Consult the siphonbreak manufacturer for proper 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 Adetailed 40 page Marine Installation Manual covering gasoline and diesel engines and generators is available from your WESTERBEKE dealer Engines Generators iv TABLE OF CONTENTSParts Identification 2 Glow Plugs 26Introduction 3 W iring 0 lagram 27 Warranty Procedures 3 Wiring Schematic 28 Serial Number Location 4 Starter Motor 29Admiral Control Panel 5 Dual Output Alternators 31Captain Control Panel 6 32Fuel Engine Oil and Coolant 7 Engine 33Preparations for Initial StartUp 8 Engine Adjustments Procedure 9 Belt Adjustment 35 Fuel Injectors 35Warning Lights Alarms and Circuit Breaker l0 11estmg Engme CompresslOn 36Engine BreakIn Procedure 11 Valve Clearance Adjustment 36The Daily Operation 12 Idling Speed 37Maintenance Schedule 13 Stop Solenoid 37 Oil Pressure 38Fuel System 15 FuellWater Separator 15 Hurth HSW Transmissions 39 Fuel Filters 15 Specification 40 Fluid Change 4041Cooling System 16 Shipment 41 Changing Coolant 16 Transmission Fluid 41 Thermostat 17 Changing Filter 42 Raw Water Intake Strainer 17 Cable Connections 43 Raw Water Cooling Circuit 18 Couplings 43 Raw Water Intake Strainer 18 Transmission Coolers 43 Raw Water Pump 18 Maintenance44 Heat Exchanger 19 Zinc Anode 19 Borg Warner Transmission 47 Maintenance 48Engine Lubricating 0i1 20 Oil Coolers 49 Changing the Oil Filter 20 Changing the Oil 20 Layup an d Recommlsslonmg 50Remote Oil Filter Optional 21 Metric Conversions Oata 51Water Heater 22 Engine Specifications 52Tachometer 23 Suggested pare Parts 53DC Electrical System 24 Alternator 24 Battery Care 25 Engines Generators 1 PARTS IDENTIFICATION WATER INJECTED ELBOW EXlrlAUT REAR DC CHARGING TRANSMISSION FUEL LIFT PUMP RAW WATER jk ENGINE BLOCK DRAIN PLUG FRONT LEFT SIDE 20 AMP CIRCUIT FILL AIR INTAKEAIR FILTER SILENCER PREHEAT IiULltNUIU ZINC ANODE MANIFOLD ID PLATE ALTERNATORHEAT EXrHAIGEFIREAR FRONT HBW HURTH MOTOR OIL DRAIN HOSE AND SOLENOID BELL ASSEMBLY TRANSMISSION SHIFT LEVER FLEXIBLE MOUNT RIGHT SIDE Engines Generators 2 WESTERBEKE Diesel Engine is a product of PRODUCT long years of experience and advanced Product software technical data parts lists We take great pride in the superior durability and brochures and catalogs provided from sources other thandependable performance of our engines and generators WESTERBEKE are not within WESTERBEKEs controlThank you for selecting WESTERBEKE WESTERBEKE CANNOT BE RESPONSIBLE FOR THEIn order to get the full use and benefit from your engine it is CONTENT OF SUCH SOFTWARE MAKES NOimportant that you operate and maintain it correctly This WARRANTIES OR WITH RESPECTmanual is designed to help you do this Please read this THERETO INCLUDING ACCURACY TIMEUNESS ORmanual carefully and observe all the safety precautions COMPLETENESS THEREOF AND WILL IN NO Should your engine require servicing contact BE LIABLE FOR ANY TYPE OF DAMAGE OR INJURYyour nearest WESTERBEKE dealer for assistance INCURRED IN CONNECTION WITH OR ARISING OUTThis is your operators manual A parts catalog is also OF THE FURNISHING OR USE OF SUCH and a technical manual is available from your WESTERBEKE customers should keep in mind the timeWESTERBEKE dealer If you are planning to install this span between printings of WESTERBEKE product contact your WESTERBEKE dealer for and the unavoidable existence of earlier installation manual product software The product software provided with WESTERBEKE products whether from WESTERBEKE orWARRANTY PROCEDURES other suppliers must not and cannot be relied uponYour WESTERBEKE Warranty is included in a separate exclusively as the definitive authority on the If after 60 days of submitting the Warranty Registry product It not only makes good sense but is imperative thatform you have not received a customer identification card appropriate ofWESTERBEKE or the supregistering your warranty please contact the factory in plier in question be consulted to determine the accuracy andwriting with model information including the engines currentness of the product software being consulted by theserial number and commission date Identification Card NOTES CAUTIONS AND WARNINGS As this manual takes you through the operating procedures maintenance schedules and of your marine engine critical information will be highlighted by NOTES CAUTIONS and WARNINGS An explanation follows Customer Identification NOTE An operating procedure essential to note MR ENGINE OWNER MAIN STREET HOMETOWN USA A CAUTION Procedures which if not strictly Serial Number observed can result in the damage or destruction of Model 64A FOUR your engine Expires 32004 A WARNING Procedures which if not properly followed can result in personal injury or loss of life Engines Generators 3 INTRODUCTION SERIAL NUMBER LOCATION ORDERING PARTS The engines model number and serial number are located on Whenever replacement parts are needed always provide the the nameplate mounted on the side of the engines manifold engine model number and serial number as they appear on The engines serial number is stamped into the engine block the silver and black nameplate located on the manifold You on a flat swface directly above the injection pump Take the must provide us with this information so we may properly time to enter this information on the illustration of the name identify your engine In addition include a complete part plate shown below as this will provide a quick reference description and part number for each part needed see the when seeking technical information andor ordering parts separately furnished Parts List Insist upon WES1ERBEKE packaged parts because will fit or generic parts are frequently not made to the same specifications as original equipment SPARES AND ACCESSORIES Certain spares will be needed to support and maintain your WES1ERBEKE engine Your local WES1ERBEKE dealer will assist you in preparing an inventory of spare parts See Fill in the reference the SPARE PARTS page in this manual For engine acces sories see WES1ERBEKES ACCESSORIES brochure UNDERSTANDING THE DIESEL ENGINE The diesel engine closely resembles the gasoline engine since the mechanism is essentially the same The cylinders are arranged above a closed crankcase The crankshaft is the same general type as a gasoline engine and the diesel engine has the same type of valves camshaft pistons connecting rods and lubricating system Therefore to a great extent a diesel engine requires the same preventive maintenance as a gasoline engine The most impor tant factors are proper ventilation and proper maintenance of the fuel lubricating and cooling systems Fuel and lubricating filter elements must be replaced at the time periods specified and frequent checking for contaminants water sediment etc in the fuel system is also essential Another important factor is the consistent use of the same brand of high detergent diesel lubrication oil designed specifically for diesel engines The diesel engine does differ from the gasoline engine however in its method of handling and firing of fuel The carburetor and ignition systems are replaced by a single component the fuel injection pump which performs the function of both GLOW PLUGENERGIZED BY THE PREHEAT BIlTTONe5115 171aAIJISEL FUEL SPRAY PRECOMBUSTION CHAMBER2 Engines Generators 4 ADMIRAL CONTROL PANEL DESCRIPTION When the engine is shut down with the key switch turned off the water temperature gauge will continue to register the last This control panel is equipped with a temperature reading indicated by the gauge before electrical KEY switch and RPM gauge with an ELAPSED TIME power was turned off The oil pressure gauge will fall to zero meter which measures the engines running time in hours and when the key switch is turned off The temperature gauge in 110 hours The panel also includes a WATER TEMPER will once again register the engines true temperature when ATURE gauge which indicates water temperature in degrees electrical power is restored to the gauge Fahrenheit an OIL PRESSURE gauge which measures the engines oil pressure in pounds per square inch and a DC A separate alann buzzer with harness is supplied with every control circuit VOLTAGE gauge which measures the sys Admiral Panel TIle installer is responsible for electrically con tems voltage All gauges are illuminated when the key necting the buzzer to the fourpin connection on the engines switch is turned on and remain illuminated while the engine electrical harness The installer is also responsible for installing is in operation The panel also contains two rubberbooted the buzzer in a location where it will be dry and where it will pushbuttons one for PREHEAT and one for START be audible to the operator should it sound while the engine is running The buzzer will sound when the ignition key is turned on and should silence when the engine has started and the engines oil pressure rises above 15 psi 11 kgcm2 OIL PRESSURE GAUGE THIS GAUGE IS GRADU ATED IN POUNDS PER SQUARE INCH PSI AND IS WATER TEMPERATURE GAUGE THIS GAUGE IS ILLUMINATED WHILE THE KEY SWITCH IS TURNED GRADUATED IN DEGREES FAHRENHEIT AND IS ON THE ENGINES NORMAL OPERATING OIL ILLUMINATED WHILE THE KEY SWITCH IS PRESSURE RANGES BETWEEN 30 60 psi TURNED ON THE ENGINES NORMAL OPERATING 21 42 kgem TEMPERATURE IS 170 190 F 77 aacRPM GAUGE REGISTERS REVOLUTIONSPER MINUTE OF THEENGINE AND CAN BERECALiBRATED FORACCURACY FROM THEREAR OF THE PANELHOURMETER SWITCH ELAPSED POWER ONLY TO THETIME AND SHOULD BE INSTRUMENT PANELUSED AS A GUIDE FOR CLUSTERTHE DC VOLTMETER INDICATES THE AMOUNT THE BATTERY IS BEING CHARGEDPREHEAT PRESSED ENERGIZES THE SHOULb SHOW 13V TO 14VALTERNATORS EXCITER THE FUEL liFT PUMP THE AUTOMATIC ALARM SYSTEMFUEL SOLENOID ON THE INJECTION PUMP AND THEENGINES GLOW PLUGS IT BYPASSES THE ENGINES COOLANT TEMPERATURE ALARM AN ALARM BUZZER HAS BEEN OIL PRESSURE ALARM SWITCH IN ADDITION THIS SUPPliED WITH THE INSTRUMENT PANEL IF THE ENGINES COOLANTBUTTON ENERGIZES THE START BUTTON REACHES 210 F 99C THIS SWITCH WILL CLOSE SOUNDING THE ALARM WHICH WILL EMIT A CONTINUOUS SIGNALSTART BUTTON WHEN PRESSED ENERGIZES THESTARTERS SOLENOID WHICH CRANKS THE ENGINE OIL PRESSURE ALARM AN 01 L PRESSURE ALARM SWITCH ISTHIS BUTTON WILL NOT OPERATE ELECTRICALLY LOCATED OFF THE ENGINES OIL GALLERY THIS SWITCH MONITORSUNLESS THE PREHEAT BUTTON IS PRESSED AND HELD THE ENGINES OIL PRESSURE SHOULD THE ENGINES OIL PRESSUREAT THE SAME TIME FALL TO 5 10 psi 04 07 kgem THE SWITCH WILL CLOSE SOUND ING THEALARM IN THIS EVENT THE ALARM WILL EMIT A PULSATING SIGNAL Engines Generators 5 CAPTAIN CONTROL The panel also includes an alann buzzer for low OIL PRESSURE or high COOLANT TEMPERATURE TheThis control panel is equipped with a RPM gauge is illuminated when the KEY switch is turned onKEY switch an RPM gauge PREHEAT and START but and remains illuminated while the engine is in operationtons an INSTRUMENT TEST button and three indicatorlamps one for ALTERNATOR DISCHARGE one for lowOIL PRESSURE and one for high ENGINE ALARM THE ALARM WILL SOUND IF THE ENGINES OIL PRESSURE FALLS BELOW 5 10 psi 04 07 kgcm IN THIS EVENT THE ALARM WILL EMIT A PULSATING SIGNAL THE ALARM WILL ALSO SOUND IF THE COOLANT TEMPERATURE IN THE FRESHWATER COOLING CIRCUIT RISES TORPM GAUGE REGISTERS REVOLUTIONS 210F 99C IN THIS EVENT THE ALARM WILL EMIT A CONTINUOUS SIGNALPER MINUTE OF THE ENGINE AND CAN BE NOTE THE ALARM WILL SOUND WHEN THE KEY SWITCH IS TURNED ON FOR ACCURACY FROM SOUNDING IS NORMAL ONCE THE ENGINE STARTS AND THE ENGINES OILTHE REAR OFTHE PANEL PRESSURE REACHES 15 psi 11 kgcm THE ALARM WILL SILENCE OIL PRESSURE ALTERNATOR ALARM LIGHT AlARM LIGHT TEST BunON WHEN PRESSED TESTS THE ALTERNATOR THE OIL PRESSURE AND THE COOLANT TEMPERA TURE CONTROL CIR CUITS WHEN PRESSED TH ALTERNATOR THE OIL PRESSURE AND THE WATER TEMPERA TURE INDICATOR LIGHTS ILLUMINATE IN ADDITION TO SOUND ING THE ALARM BUZZER KEY SWITCH PROVIDES POWER ONLY TO THE INSTRUMENT PANEL CLUSTER WATER TEMPERATURE ALARM LIGHT START BUTTON WHEN PRESSED ENERGIZES THE STARTERS SOLENOID WHICH CRANKS THE ENGINE THIS PREHEAT BUnON WHEN PRESSED ENERGIZES THE BunON WILL NOT OPERATE ELECTRICALLY UNLESS THE ALTERNATORS EXCITER THE FUEL LIFT PUMP THE FUEL PREHEAT BunON IS PRESSED AND HELD AT THE SAME SOLENOID ON THE INJECTION PUMp AND THE ENGINES TIME GLOW PLUGS AND BYPASSES THE ENGINES OIL PRES SURE ALARM SWITCH IN ADDITION THIS BUnON ENER GIZES THE START BUnON Engines Generators 6 DIESEL FUEL ENGINE OIL AND ENGINE COOLANTDIESEL FUEL ENGINE COOLANTUse fuel that meets the requirements or specification of Class WESTERBEKE recoends a mixture of 50 antifreeze2D ASTM and has a cetane rating of 45 or better and 50 distilled water Distilled water is free from the chemicals that can corrode internal engine surfacesCare Of The Fuel Supply The antifreeze performs double duty It allows the engine toUse only clean diesel fuel The clearance of the components run at proper temperatures by transferring heat away fromin your fuel injection pump is very critical invisible dirt par the engine to the coolant and lubricates and protects theticles which might pass through the filter can damage these cooling circuit from rust and corrosion Look for a goodfinely finished parts It is important to buy clean fuel and quality antifreeze that contains Supplemental Coolingkeep it clean The best fuel can be rendered unsatisfactory by Additives SCAs that keep the antifreeze handling or improper storage facilities To assure balanced crucial to long term protectionthat the fuel going into the tank for your engines daily use is The distilled water and antifreeze should be premixed beforeclean and pure the following practice is advisable being poured into the cooling circuit Purchase a wellknown brand of fuel NOTE Look for the new long lastingInstall and regularly service a good visualtype fuel antifreeze that is now separator between the fuel tank and the engineThe Raycor 500 FG or 900 FG are good examples of such The recommended 5050 mixture will protect the enginefilters against the most extreme temperatures The antifreeze mixture will also retard rust within the engine and add to theENGINE OIL life of the circulating pump impeller and sealsUse a heavy duty engine oil with an API classification of CFor CG4 or better Change the engine oil after an initial 50 Coolant Recovery Tankhours of breakin operation and every 100 hours of operation A coolant recovery tank kit is supplied with eachthereafter For recommended oil viscosity see the following WESTERBEKE diesel engine The purpose of this recoverychart tank is to allow for engine coolant expansion and contraction Operating Temperature Oil Viscosity during engine operation without the loss of coolant and without introducing air into the cooling system This kit is Above 68F 20C SAE 30 10W30 or 15W40 provided and must be installed before operating the engine 41 68F 5 20C SAE 20 10W30 or 15W40 NOTE This tank with its short run ofplastic hose is best located at or above the level of the engines manifold but it Below 41F 5C SAE 10W30 or 15W40 can be located below the level of the engines manifold if the particular installation makes this necessary A CAUTION 00 not allow two or more brands of engine oil to mix Each brand contains its own additives additives of different brands could react in the mixture to produce properties harmful to your engineOil PressureThe engines oil pressure during operation is indicatedby the oil pressure gauge on the instrument panel Duringnormal operation the oil pressure will range between 35 and55 psi 25 and 39 kglcm2NOTE A newly started cold engine can have an oil up to 60 psi 42 kglcm 2 A warmed engine can havean oil pressure reading as low as 25 psi 18 kglcm2 Thesereadings will vary depending upon the temperature of theengine and the load placed on the engine Engines Generators 7 PREPARATIONS FOR INITIAL starting your engine for the first time or after aprolonged layoff check the following items COOLANTD Check the engine oil level Add oil to maintain the level RECOVERY at the high mark on the dipstick TANKD Turn on the fuel supply then check the fuel supply and examine the fuel filterwater separator bowl for contaminantsD Check the transmission fluid levelD Check the DC electrical system Inspect wire connections and battery cable connections Make certain the positive battery cable is connected to the starter solenoid and the negative cable is connected to the engine ground stud this location is taggedD Check the coolant level in both the plastic recovery tank and at the manifold NOTE If the engine has not yet been filled with coolant refer to the COOUNG SYSTEM section of this manualD Visually examine the engine Look for loose or missing parts disconnected wires and unattached hoses Check the threaded connections and engine attachmentso Make certain there is proper ventilation around the engine An ample supply is necessary for proper engine performanceo Make sure the mounting installation is secureD Ensure the propeller shaft is securely attached to the transmissionD Open the thruhull and make certain raw water is primed to the raw water strainer I OIL DIPSTICK PRESS IN TIGHT Engines Generators 8 STARTING STOPPING PROCEDURE STOPPING PROCEDURE1 Place the transmission in neutral and advance the throttle To stop the engine bring the throttle to an idle position and control to slightly open place the transmission in neutral Allow the engine to idle for2 Thrn the KEY SWITCH to the ON position 2 oclock a few moments to stabilize temperatures then shut the If the panel is energized the gauges are on engine down by turning off the key switch3 Press the PREHEAT BUTION and hold for 5 seconds NOTE Make certain this key switch is in the OFF position The fuel lift pump is priming the engine 12 oclock If the key switch is left ON the energized instrument panel will put a drain on the battery4 Release the PRESTART BUTION and press the START BUTION The starter motor is cranking the engine Starting Under Cold Conditions5 Release the START BUTION as the engine starts Make certain the lubricating oil is appropriate for the6 With the engine running check the instruments for prevailing temperature Use oil with an API Specification proper oil pressure and battery charging voltage The of CF or CG4 SAE 30 lOW30 or 15W40 water temperature will rise slowly and then stabilize when the thermostat opens FAILURE TO START NOTE Never attempt to engage the starter while the If the engine fails to start when the start button is pressed for engine is running 5 seconds wait for at least 30 seconds and repeat the starting procedure Make certain the transmission control is in the It is important to closely monitor the panel gauges neutral position as some engines have a neutral safety switch Become aware of the normal engine readings and take to prevent starting in gear immediate action if these readings start to vary Never run the starter for more then 30 seconds If the engine fails to start refer to the CHART in this manual Atmospheric Temperature Preheating Time 41F5C or higher Approx 10 seconds 41F5C to 23F 5C Approx 15 seconds A CAUTION Prolonged cranking intervals without 23F5C or lower Approx 20 seconds the engine starting can result in the engine exhaust Limit of continuous use 30 seconds before cranking system filling with raw water This may happen because the pump is pumping raw water through the raw waterNOTE The START button will not energize unless the cooling system during cranking This raw water canPREHEAT button is depressed Depressing the PREHEATbutton activates the glow plugs in the cylinder head so use enter the engines cylinders by way of the exhaustthe PREHEAT intermittently to avoid overheating the glow manifold once the exhaust system fills Prevent thisplugs from happening by closing the raw water supply throughhull shutoff draining the exhaust muffler and correcting the cause of the excessive engine cranking Engine damage resulting from raw water entry is not aNOTE When starting warrantable issue the owneroperator should keep thisA voltage drop will occur in mindwhen the preheat buttonis depressed Engines Generators 9 WARNING LIGHTS ALARMS CIRCUIT BREAKER ALTERNATOR WARNINGS LOW OIL PRESSURE ALARM SWITCH The Captain Control Panel indicates alternator low discharge A low oil pressure alarm switch is located off the engines with a red warning light oil gallery This switchs sensor monitors the engines oil The Admiral Control Panel uses a voltmeter to monitor the pressure Should the engines oil pressure fall to 5 10 psi performance of the alternator 04 07 kgcm2 this switch will activate a pulsating alarm COOLANT TEMPERATURE SWITCH ENGINE CIRCUIT BREAKER A coolant temperature switch is located on the thermostat The DC harness on the engine is protected by an engine housing This switch will activate a continuous alarm if the mounted manual reset circuit breaker 20 amps DC coolants operating temperature reaches approximately Excessive current draw or electrical overload anywhere in 210 0 P 99C the instrument panel wiring or engine wiring will cause the breaker to trip In this event most engines will shut down because the opened breaker disconnects the fuel supply If this should occur check and repair the source of the problem After repairing the fault reset the breaker and restart the 2DACIRCUIT THERMOSTAT ASSEMBLY OIL GALLERY Engines Generators 10 ENGINE BREAKIN 3 While using the vessel run the engine at various engine speeds for the first 25 hours Avoid prolonged periods ofAlthough your engine has experienced a minimum of one idlinghour of test operations at the factory to make sure procedures were followed and that the engine oper 4 Avoid rapid acceleration especially with a cold engineated properly a breakin time is required The service life of 5 Use caution not to overload the engine The presence of ayour engine is dependent upon how the engine is operated grey or black exhaust and the inability of the engine toand serviced during its initial 50 hours of use reach its full rated speed are signs of an a new engine basically involves seating the pis 6 During the next 25 hours the engine may be operated atton rings to the cylinder walls Excessive oil consumption varying engine speeds with short runs at full rated rpmand smoky operation indicate that the cylinder walls are Avoid prolonged idling during this breakin periodscored which is caused by overloading the engine during thebreakin period CHECKLISTYour new engine requires approximately 50 hours of initial D Monitor the control panel operation to break in each moving part in order D Check for leaks of fuel and engine oilto maximize the performance and service life of the engine D Check for abnormal noise such as knocking this conditioning carefully keeping in mind the fol vibration and blowback soundslowing D Confirm exhaust smoke1 Start the engine according to the STARTING PROCE When the engine is cold white smoke DURE section Run the engine at fast idle while checking When the engine is warm almost smokeless that all systems raw water pump oil pressure battery When the engine is overloaded some black smoke and soot charging are functioning NOTE See the TRANSMISSION section of this manualfor2 Allow the engine to warm up preferably by running at breakin information on your transmission fast idle until the water temperature gauge moves into the 130 1400 P 55 60C range Engines Generators 11 THE DAILY OPERATIONCHECK LIST FAILURE TO STARTFollow this check list each day before starting your enine If the engine fails to start when the start button is pressed forD VIsually inspect the engine for fuel oil or water leaks 5 seconds wait for at least 30 seconds and repeat the startingD Check the oil level dipstick procedure Make certain the transmission control is in the neutral position as some engines have a neutral safety switchD Check the coolant level in the coolant recovery tank to prevent starting in gear Periodically check the manifold coolant level Never run the starter for more than 30 seconds If the engineD Check the transmission fluid level fails to start refer to the CHART inD Check your fuel supply this manualD Look for clean fuel in the fuel filterwater separator transparent bowlD Check for loose wires at the alternator and make sure its A CAUTION Prolonged cranking intervals without the mounting is secure engine starting can result in the engine exhaust systemD Check the starting batteries weekly filling with raw water This may happen because the pump is pumping raw water through the raw waterD Check drive belts for wear and proper tension weekly cooling system during cranking This raw water canD VIsually inspect the raw water pump for leakage enter the engines cylinders by way of the exhaust manifold once the exhaust sytem fills Prevent thisSTARTING THE ENGINE from happening by closing the raw water supplyNOTE See PROCEDURE in thi throughhull shutoff draining the exhaust muffler andmanual for more detailed instructions correcting the cause of the excessive engine cranking Engine damage resulting from raw water entry is not a1 Put the transmission in neutral throttle advanced warrantable issue the owneroperator should keep this NOTE Hydraulically operated transmissions have a in mind neutral safety switch through which the starter solenoid energizing circuit passes This switch is open when the transmission is in gear so the starler solenoid will not energize Stopping Procedure To stop the engine bring the throttle to an idle position and2 Tum the KEY SWITCH to the ON position 2 0 clock place the transmission in neutral Allow the engine to idle for The panel is energized gauges are lite a few moments to stabilize temperatures Then shut the3 Depress the PRESTART BUITON hold for 5 seconds engine down by turning off the key switch The fuel lift pump is priming the engine4 Release the PRESTARr BUITON and press the START NOTE Make certain this key switch is in the OFF If the key switch is left ON the BUITON The start motor is cranking the engine energized instrument panel will put a drain on the battery5 Release the START BUITON as the engine starts6 With the engine running check the instruments for proper oil pressure and battery charging voltage The water rise slowly until the thermostat opens NOTE Never attempt to engage the starter while the engine is runningIt is important to closely monitor the panel gauges Becomeaware of the normal engine readings and take if these readings start to vary Engines Generators 12 MAINTENANCE SCHEDULEIn order to use this Maintenance Schedule it will be necessary to log your engine hours Use your engine hounneter or A WARNING Never attempt to perform any servicerecord your engine hours by running time while the engine is running Wear the proper safetyNOTE M0J7Y of the following maintenance procedures are equipment such as goggles and gloves and use thesimple but others are more difficult 0J7d may require the coect tools for each job Disconnect the batteryexpert knowledge of a service mech0J7ic terminals when servicing any of the engines DC SCHEDULED CHECK HOURS OF OPERATION EACH MAINTENANCE DESCRIPTION MAINTENANCE DAY 50 100 250 500 750 1000 1250 Fuel Supply D Diesel No2 rating of 45 cetane or higher FuelWater Separator D Check for water and dirt in fuel drainlreplace filter if necessary Engine Oil Level D Oil level should indicate between MAX and lOW on dipstick Coolant Level D Check at recovery tank if empty check at manifold Add coolant if needed Transmission Fluid Level D Fluid level should indicate between MAX and LOW on dipstick Drive Belts D Inspect for proper tension 38 to 12 deflection weekly and adjust if needed Check belt edges for wear of Engine D NOTE Keep engine surface clean Dirt and Check for fuel oil and water leaks Inspect wiring oil will inhibit the engines ability to remain and electrical connections Keep bolts nuts tight cool Check for loose belt tension Fuel Filter D D D D D D Clean with kerosene at 50 hours then clean every 100 hours Change at 500 hours Starting Batteries D Check electrolyte levels every 50 operating hours and House Batteries weekly and make sure connections are very tight Clean off excessive corrosion Engine Oil and Filter D D D D D D D Initial engine oil filter change at 50 hours then change both every 100 hours Heat Exchanger Zinc Anode D D D D D D D Inspect zinc anode replace if needed Clear the heat exchanger end of zinc anode debris FuelWater Separator D D D D D D Change filter every 200 hours Exhaust System D D D D Initial check at 50 hours then every 250 hours Inspect for leaks Check antisiphon valve operation Check the exhaust elbow for carbon andor corrosion buildup on inside passages clean and replace as necessary Check that all connections are tight Check casting integrity Engine Hoses D D D D D D Hose should be hard tight Replace if soft or spongy Check and tighten all hose clamps Throttle and Transmission D D D D Check for loose fittings cotter pins etc Control Cable Lubricate with WD40 or equivalent Adjust Engine Idle Speed D Adjust to 750 1000 rpm Raw Water Pump D D D Remove the pump cover and inspect the impeller gasket cam and cover for wear Check the bearings seals and shaft drive tang continued Engines Generators 13 MAINTENANCE SCHEDULE NOTE Use the engine hourmeter gauge to log your engine hours or record your engine hours by running time SCHEDULED CHECK HOURS OF OPERATION MAINTENANCE EACH MAINTENANCE DESCRIPTION DAY 50 100 250 500 750 1000 1250 Coolant System 0 0 Drain flush and refill cooling system with appropriate antifreeze mix Air 0 0 0 0 0 0 0 Every 100 hours inspect clean replace as needed DC Alternator 0 0 0 Check DC charge from alternator Check mounting bracket tighten electrical connections Transmission Oil Cooler 0 Remove have professionally cleaned and pressure tested Engine Transmission 0 Chattering at idle and low rpms is an indication Damper Plate of damper plate wear Remove and replace Fuellnjectors 0 Check and adjust injection opening pressure and spray condition see ENGINE ADJUSTMENTS Starter Motor 0 0 Check solenoid and motor for corrosion Remove and lubricate Clean and lubricate the starter motor pinion drive Preheat Circuit 0 0 Check operation of preheat solenoid Remove and clean glow plugs check resistance value of heater element XX ohms Reinstall with antiseize compound on threads Engine Cylinder 0 0 Check compression pressure and timing see Engine Compression Adjustments Adjust the Valve Clearances 0 0 0 Adjust Valve Clearances see ENGINE ADJUSTMENTS Heat Exchanger 0 Remove have professionally cleaned and pressure tested Lubricate Panel Key Switch 0 0 0 0 0 0 At first 100 hours then each year at winterizing with Lockeze Transmission 0 0 0 0 0 0 Initial fluid change at 25 hours then every Fluid 300 hours or at recommends this service be performed by an authorized mechanic Engines Generators 14 FUEL SYSTEMFUEL FILTERJWATER SEPARATOR FUEL FILTERSA primary fuel filter of the water separating type must be The fuel injection pump and the fuel injectors are between the fuel tank and the engine to remove manufactured and they must receive clean diesel fuel freewater and other contaminants from the fuel before they can from water and dirt To ensure this flow of clean fuel the fuelbe carried to the fuel system on the engine must pass through at least two fuel filters a fuel installers include a fuel filterwater separator with the separator and the engines spinon fuel filter Visually package as they are aware of the problems that clean and change these filters according to the in the fuel can cause schedule in this manualclean and change these filters according to the maintenance schedule in this manualA typical fuel filterwater separator is illustrated below Thisis the Rayeor Model 500 MA Keep in mind that if a waterseparator type filter is not installed between the fuel supplytank and enginemounted fuel system any water in the fuel A WARNING Shut off the fuel valve at the tank when servicing the fuel system Take care in catchingwill affect the fuel pump engine filter and injection any fuel that may spill equipment The owneroperator is responsible for makingcertain the fuel reaching the engines injection equipment isfree of impurities This process is accomplished by installingand maintaining a proper fuel filterwater separator UlL11111 GASKET FUEL FILTER WATER SEPARATOR Owner Installed LIGHTLY WIPE WITH CLEAN FUEL Changing the Fuel FilterFUEL LIFT PUMP 1 Shut off the fuel check the fuel connections to and out of the 2 Loosen the fuel filter turning with apump and make sure that no leakage is present and that the filter wrench Place the used filter in a container forfittings are tight and secure The DC ground connection at proper disposalone of the pumps mounting bolts should be clean and wellsecured by the mounting bolt to ensure proper pump 3 Using a rag wipe clean the sealing face on the bracket so the new filter can be seated properlyWhen energized thru the preheat circuit the fuel lift pump 4 Lightly oil the sealing gasket on the new filter Towill purge air from the fuel system and provide a continuous reinstall tum the filter assembly careflow of fuel as the engine is running fully until the gasket contacts the sealing surface of the housing bracket Turn 213 further with the filter wrench 5 Twn on the fuel supply and start the engine The normal TO FUEL FILTER preheat function should quickly prime the system and the engine should start FUEL INJECTION PUMP The fuel injection pump is a very important component of the diesel engine requiring the utmost care in handling The fuel injection pump has been thoroughly benchtested and the owneroperator is cautioned not to attempt to service it If it requires servicing remove it and take it to an authorized fuel injection pump service facility Do not attempt to disassemble and repair it The only adjustment the servicing mechanic should make to the fuel injection pump is the adjustment for engine idle speed see IDLE SPEED ADJUSTMENT under ENGINE ADJUSTMENTS Engines Generators 15 COOLING CHANGING marine engines are designed and equipped for The engines coolant must be changed according to thefresh water cooling Heat produced in the engine by combus MAINTENANCE SCHEDULE If the coolant is allowed totion and friction is transferred to fresh water coolant which become contaminated it can lead to overheating throughout the engine This circulating fresh watercoolant cools the engine block its internal moving parts andthe engine oil The heat is transferred externally from the A CAUTION Proper cooling system maintenance isfresh water coolant to raw water by means of a heat criticalj a substantial number of engine failures can beexchanger similar in function to an automotive radiator Raw traced back to cooling system corrosionwater flows through the tubes of the heat exchanger whilefresh water coolant flows around the tubes engine heat trans Drain the engine coolant by loosening the drain plug on theferred to the fresh water coolant is conducted through the engine block and opening the manifold pressure cap Flushtube walls to the raw water which is then pumped into the the system with fresh water then start the refill processexhaust system where finally it is discharged overboard In NOTE The drain petcock on the heat exchanger should alsoother words the engine is cooled by fresh water coolant this be used to help drain engine coolantcoolant is cooled by raw water and the raw water carries thetransferred heat overboard through the exhaust system Thefresh water coolant and raw water circuits are independent of A WARNING Beware of the hot engine coolanteach other Using only fresh water coolant within the engine Wear protective glovesallows the cooling water passages to stay clean and free fromharmful depositsFRESH WATER COOLING CIRCUIT Refilling the Coolant After replacing the engine block drain plug close the heatNOTE Refer to the ENGINE COOlANT section for the exchangers coolant petcock Then run the engine at idle and recommended antifreeze and water mixture to be used as the slowly pour clean premixed coolant into the manifoldfresh water coolant NOTE Open the airbleed petcock on the heat exchangerFresh water coolant is pumped through the engine by a circu When a steady flow of coolant appears at the petcock closelating pump absorbing heat from the engine The coolant the petcock and fill the system until the manifold remains fulltIlen paSses through the thermostat into the manifold to theheat exchanger where it is cooled and returned to the engine Monitor the coolant in the manifold and add as needed Fillblock via the suction side of the circulating pump When the the manifold to the filler neck and install the manifold presengine is started cold external coolant flow is prevented by sure capthe closed thermostat although some coolant flow is Remove the cap on the coolant recovery tank and fill withbypassed around the thermostat to prevent the exhaust mani coolant mix to halfway between LOW and MAX and replacefold from overheating As the engine warms up the thermo the cap Run the engine and observe the coolant expansionstat gradually opens allowing full flow of the engines flow into the recovery tankcoolant to flow unrestricted to the external portion of the After checking for leaks stop the engine and allow it to coolcooling system Coolant should draw back into the cooling system as the engine cools down Add coolant to the recovery tank ifCoolant Recovery Tank needed Clean up any spilled coolantA coolant recovery tank allows for engine coolant expansionand contraction during engine operation without any signifi mCOOLANT KEEP THEcant loss of coolant and without introducing air into the cool RECOVERY TANK COOLANT PASSAGEing system This tank should be located at or above the CLEARengine manifold level and should be easily accessibleNOTE Periodically check the condition of the manifold pressure cap Ensure that the upper and lower rubber seals are ingood condition and check that the vacuum valve opens andcloses tightly Carry a spare cap FROM COOLANT RECOVERY TANK PRESSURE CAP THE ENGINE COOLANT DRAIN IS LOCATED ON THE ENGINE BLOCK JUST TO THE RIGHT COOLANT RETRACTION OF THE OIL FILTER jWESTERBEKE Enains Generatars 16 COOLING SYSTEM THERMOSTAT RAW WATER INTAKE STRAINER A thennostat located near the manifold at the front of the NOTE Always install the strainer at or below the waterline so engine controls the coolant temperature as the coolant the strainer will always be selfpriming continuously flows through the closed cooling circuit When the engine is first started the closed thennostat prevents A clean raw water intake strainer is a vital component of the coolant from flowing some coolant is bypassed through a engines cooling system Include a visual inspection of this hole in the thennostat to prevent the exhaust manifold from strainer when making your periodic engine check The water overheating As the engine warms up the thennostat in the glass should be clear gradually opens The thennostat is accessible and can be Perfonn the following maintenance after every 100 hours of checked cleaned or replaced easily Carry a spare thennostat operation and gasket 1 Close the raw water seacock Replacing the Thermostat 2 Remove and clean the strainer filter Remove the cap screws and disassemble the thennostat 3 Clean the glass housing as shown When installing the new thennostat and 4 Replace the washer if necessary gasket apply a thin coat of sealant on both sides of the 5 Reassemble and install the strainer gasket before pressing it into place Do not overtighten the cap screws 6 Open the seacock Run the engine and check for nonnal temperatures and that 7 Run the engine and check for leaks there are no leaks at the tbennostat housing NOTE Also follow the above procedure after having run hard aground If the engine temperature gauge ever shows a higher than nonnal reading 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 GASKET STRAINER TYPICAL RAW WATER INTAKE STRAINER Owner Installed Engines Generators 17 COOLING SYSTEMRAW WATER COOLING CIRCUIT ChangiWJ the Raw Water Pump ImpellerThe raw water flow is created by a positive displacement Close the raw water intake valve Remove the pump coverimpeller pump This pump draws water directly from the raw and with the aid of two small screwdrivers carefully pry thewater source oceanlake or river through a hose to the impeller out of the pump Install the new impeller and gasketwater strainer The raw water passes from the strainer Move the blades to conform to the curved cam plate andthrough the raw water pump to the heat exchanger through push the impeller into the pumps housing Whenthe heat exchanger tubes where it cools the engine circulat assembling apply a thin coating of lubricant to the impellering fresh water coolant The raw water is then discharged and gasket Open the raw water intake valveinto the waterinjected exhaust elbow mixing with and cooling the exhaust gases This mixture of exhaust gas and rawwater is discharged overboard by the engines exhaust gasdischarge pressure A CAUTION If any of the vanes bave broken off the impeller they must be located to prevent blockage inRAW WATER PUMP the cooling circuit They often can be found in the heatThe raw water pump is a selfpriming rotary pump with a housing and a Neoprene impeller The impellerhas flexible blades which wipe against a curved cam platewithin the impeller housing producing the pumping actionOn no account should this pump be run dry There should RAW WATER PUMPalways be a spare impeller and impeller cover gasket aboardan impeller kit Raw water pump impeller failures occurwhen lubricant raw water is not present during Such failures are not warrantable and operators ALIGN WITH THEare cautioned to make sure raw water flow is present at start SLOT IN THE SHAFTup The raw water pump should be inspected periodically forbroken or tom impeller blades See Should a failure occur with the pumpSO internal partsseals and bearings it may be more cost efficient topurchase a new pump and rebuild the original pump as aspareAIR INTAKE replaceable canister contains a paper element that shouldbe inspected often Dirt in the element can be shaken off orcleaned with compressed air however if the element isgreasy or black with dirt the canister must be replaced carry l INSPECTION CHECK AT THE BASE OF EACH BLADE BY BENDING VIGOROUSLYa spare REPLACE THE IMPELLER IF THERE RAW WATER IN ARE ANY CRACKSNOTE To operate efficiently a diesel engine must intake a WHEN INSTALLING TAKE CARE TO volume of clear air Hard starting an erratic idle THE IMPELLER KEYWAY WITH THE SHAFTand black efhaust smoke are all symptoms of a restricted air KEY FOLD THE IMPELLER BLADES INintake EITHER DIRECTION THEY WILL TURN IN THE CORRECT POSITION WHEN THE PUMP STARTS APPLY LIQUID SOAP AT ASSEMBLY AIR INTAKE Engines Generators 18 COOLING SYSTEMZinc Anode If the zinc anodes need replacement hold the hex boss intoA zinc anode or pencil is located in the raw water cooling which the zinc anode is threaded with a wrench while looscircuit within the heat exchanger The purpose of having the ening the anode with another wrench This prevents the hexzinc anode is to sacrifice them to electrolysis action taking boss from possibly tearing off the exchanger shell Afterplace in the raw water cooling circuit thereby reducing the removing the zinc note the condition of it If the zinc is ineffects of electrolysis on other components of the system poor condition there are probably a lot of zinc flakes withinThe condition of the zinc anode should be checked monthly the exchanger Remove the end of the heat exchanger andand the anode cleaned or replaced as required Spare anodes clean the inside of all zinc debris Always have a spare heatshould be carried on board exchanger end gasket in case the present one becomes dam aged when removing the end cover Replace the gasket refer to your engine models heat exchanger end gasket part num ber Oring and cover and install a new zinc anode NOTE The threads of the zinc anodes are pipe threads and do not require sealant Sealant should not be used as it may insulate the zinc from the metal of the heat exchanger hous ing preventing electrolysis action on the zinc Heat Exchanger Service After approximately 1000 hours of operation remove clean NEW REPLACE REPLACE CLEAN AND and pressure test the engines heat exchanger A local auto REUSE motive radiator shop should be able to clean and test the heat ZINC ANODES exchanger NOTE Operating in silty andor tropical waters may requireNOTE Electrolysis action is the result of each particular that a heat exchanger cleaning be peiformed more often and vessel location not that of the engine every 1000 hours IR BLEED ZINC ANODE PETCOCK DO NOT USE SEALANT ON THE THREADS I COVER SECURING BOLT INSPECT BOTH ENDS HEAT EXCHANGER NOTE When installing the heat exchanger end covers Be sure that the end cover securing bolts sealing aring is installed Failure to install this sealing aring can result in end plate failuresea water leakage Engines Generators 19 ENGINE LUBRICATING OIL ENGINE OIL CHANGE When installing the new oil filter element wipe the filter 1 Draining the Oil Sump Discharge the used oil through gaskets sealing surface on the bracket free of oil and the sump drain hose attached to the front of the engine apply a thin coat of clean engine oil to the rubber gasket while the engine is warm Drain the used oil completely on the new oil filter Screw the filter onto the threaded oil replace the hose in its bracket and replace the end cap filter nipple on the oil filter bracket and then tighten the filter firmly by hand securely NOTE Thread size for the lube oil drain hose capped end NOTE The engine oil is cooled by engine coolant flowing is 114 NPT through passages in the oil filter bracket housing assembly Always observe the used oil as it is removed A yellowgray emulsion indicates the presence of water in the oil Although this condition is rare it does require A WARNING Used engine oil contains harmful prompt attention to prevent serious damageCall a contaminants Avoid prolonged skin contact Clean skin qualified mechanic should water be present in the oil and nails thoroughly using soap and water Launder or Raw water present in the oil can be the result of a fault in discard clothing or rags containing used oil Discard the exhaust system attached to the engine andor a used oil properly siphoning of raw water through the raw water cooling circuit into the exhaust filling the engine This problem is often caused by the absence of an antisiphon valve its NOTE Generic filters are not recommended as the poor location or lack of maintenance material standards or diameters of important items on 2 Replacing the Oil Filter When removing the used oil generic parts might be entirely different from genuine filter you may find it helpful and cleaner to punch a hole parts Immediately after an oil filter change and oil fill in the upper and lower portion of the old filter to drain run the engine to make sure the oil pressure is normal the oil from it into a container before removing it This and that there are no oil leaks around the new oil filter helps to lessen spillage A small automotive filter wrench should be helpful in removing the old oil filter 3 Filling the Oil Sump Add new oil through the oil filler cap on the top of the engine or through the side oil fill NOTE Do not punch this hole without first loosening the After refilling run the engine for a few moments while filter to make certain it can be removed checking the oil pressure Make sure there is no leakage Place some paper towels and a plastic bag around the around the new oil filter or from the oil drain system and filter when unscrewing it to catch any oil left in the filter stop the engine Then check the quantity of oil with the Oil or any other fluid on the engine reduces the engines lube oil dipstick Fill to but not over the high mark on cooling ability Keep your engine clean Inspect the old the dipstick should the engine require additional oil oil filter as it is removed to make sure that the rubber sealing gasket comes off with the old oil filter If this rubber sealing gasket remains sealed against the filter II bracket gently remove it O 01r AREMOVE USING ANOR BMM 7776 SOCKET Iit dTO DRAIN THE OIL PUMP THE WARMED biOIL UP THRU THE HOSE OIL DRAIN HOSE 11160D SPIN ON FILTER OIL FILTER ASSEMBLY APPLY CLEAN ENGINE OIL WHEN INSTALLING TURN ON HAND TIGHT Engines Generators 20 REMOTE OIL FILTER NOTE Westerbeke is not responsible for engine failure due toThis popular accessory is used to relocate the engines oil fil incorrect installation of the Remote Oil Filterter from the engine to a more convenient location such as anengine room bulkhead NOTE Refer to ENGINE OIL CHANGE in this manualfor A CAUTION It is vital to install the oil lines on removing the oil filter rectly If the oil flows in the reverse direction the byTo install simply remove the engine oil fllter and thread on pass valve in the filter assembly will prevent the oilWESTERBEKEs remote oil fllter kit as shown Always from reaching the engine causing an intemal engineinstall this kit with the oil filter facing down as illustrated failure If there is no oil pressure reading your WESTERBEKE dealer for more information immediately and check the hose conlnelJtiolIS APPLY A THIN COAT OF CLEAN OIL TO THE ORING WHEN INSTALLING THIS KIT THREAD THE KIT ON THEN HAND TIGHTEN AN ADDITIONAL 34 TURN AFTER THE ORING CONTACTS THE BASE THE IN CONNECTION HOSE MUST ATTACH TO THE OUT CONNECTION AT THE JpAIMnTI OIL FILTER THE OUT CONNECTION HOSE MUST ATTACH TO THE IN CONNECTION AT THE REMOTE OIL FILTER APPLY A THIN COAT OF CLEAN OIL TO THE FILTER GASKET WHEN INSTAlLING AFTER THE FILTER CONTACTS THE BASE TIGHTEN IT AN ADDITIONAL Engines Generators 21 WATER HEATER provides easy access for connecting to an NOTE An air bleed petcock is located on the engineSO heatonboard hot water system These connections allow for the exchanger and on the thermostat housing Open theseengines hot water coolant to flow to the ships hot water petcocks when filling the engineSO coolant system to allow airtank heating the fresh water and then cycling back to the to escape Close both tightly after all the air is water heater should be mounted in a convenient location NOTE If any portion of the heating circuit rises above theeither in a high or low position in relation to the engine so engineSO closed cooling system pressure cap then athat the connecting hoses from the heater to the engine can pressurized aluminum remote expansion tank Kit 024177run in a reasonably direct line without any loops which might must be installed in the circuit to become the highest pointtrap air Tee the remote expansion tank into the heater circuit choos ing the higher of the two connections for the return Tee atHoses should rise continuously from their low point at the the heater and plumb a single line up to the tanks locationheater to the engine so that air will rise naturally from the and the other back to the engineSO return Install the remoteheater to the engine If trapped air is able to rise to the heater expansion tank in a convenient location so the fresh waterthen an air bleed petcock must be installed at the higher coolant level can easily be checked The remote on the heater for bleeding air while filling the system tank will now serve as a check and system fill point The plastic coolant recovery tank is not used when the remote expansion tank kit is installed since this tank serves the same function TO CONNECT TO THE WATER HEATER DISCONNECT THE EXISTING HOSE AND ATTACH THE HEATER HOSE AT THIS COUPLING REMOVE THE EXISTING BYPASS HOSE DISCONNECT THE EXISTING HOSE AND ATTACH THE HEATER HOSE TO THIS FITTING Engines Generators 22 METER NOTE Current model tachometers use a coarse adjustmentThe meter used in propulsion engine instru dial to set the tachometer to the crankshaft pulley rpms Thement panels contains two separate electrical circuits with a calibrating screw is then used for fine tuningcommon ground One circuit operates the hour meter and theother the tachometer The hour meter circuit operates on 12volts alternator charging voltage supplied to the terminalon the back of the instrumentThe tachometer circuit operates on AC voltage 68 volts fedfrom one of the diodes in the alternator and supplied to thetachometer input terminal while the engine is running andthe alternator producing battery charging voltage 130148volts DCThe following are procedures to follow when fault in either of the two circuits in a meter for the proper DC voltage between and terminals IDLE SPEED ADJUSTMENT1 Voltage present meter is defective repair or replace TACHOMETER CHECK New Installation2 Voltage not present trace and electrical con nections for fault Jump 12 volts DC to meter Checking the idle speed terminal to verify the operation NOTE In a new installation having new instrument panels the tachometer may not always be correctly calibrated to theTachometer Inoperative engineS rpm This calibration should be checked in all newCheck for the proper AC voltage between tachometer input and terminal with the engine running 1 Warm up the engine to normal operating temperature1 Voltage present attempt adjusting meter through calibra Remove any specks on the crankshaft pulley with a clean tion access hole No results repair or replace meter cloth and place a piece of suitable reflecting tape on the2 AC voltage not present check for proper alternator DC pulley to facilitate use of a photoelectric type tachometer output voltage 2 Start and idle the engine3 Check for AC voltage at tach terminal on alternator to 3 Aim the light of the tachometer onto the reflecting tape to ground confirm the engine speed Check the instrument panel4 Check electrical connections from tachometer input ter tachometer reading Adjust the tachometer in the panel by minal to alternator connection using the instrument calibration pod as needed to bring the instrument panel tachometer into the same rpmTachometer Sticking reading as the engine1 Check for proper AC voltage between tach inp termi 4 Adjust the idle speed if the engine speed is not within the nal and terminal specified value2 Check for good ground connection between meter ter Normal idle speed is 690950 RPM minal and alternator3 Check that alternator is well grounded to engine block at alternator pivot boltTachometer Inaccuratea With a handheld tach on the front of the crankshaft pulley retaining nut or with a strobetype tach read the front crankshaft pulley rpm at idleb Adjust the tachometer with a small Phillips type screw driver through the calibration access hole in the rear of the tachometer Zero the tach and bring it to the rpm indicated by the strobe or hand tach Verify the rpm at idle and at high speed Engines Generators 23 DC ELECTRICAL SYSTEM ALTERNATOR 1 Start the engine The charging system consists of a DC belt driven alternator 2 After the engine has run for a few minutes measure the with a voltage regulator an engine DC wiring harness a starting battery voltage at thebattery terminals using a mounted DC circuit breaker and a battery with connecting multimeter set on DC volts cables Because of the use of integrated circuits ICs the a If the voltage is increasing toward 14 volts the alterna electronic voltage regulator is very compact and is mounted tor is working omit Steps 3 through 8 and go directly internally or on the back of the alternator to Checking the Service Battery on the next page b If the voltage remains around 12 volts a problem exists with either the alternator or the charging circuit 114GRAY continue with Steps 3 through 8 o CKQ MULTIMETER14 PINK Eii14 BLUE COM iieJfI110 RED SEE WIRING DIAGRAM ENGINE FOR WIRE CONNECTIONS GROUND TO OPTIONAL ALTERNATORS ALTERNATOR TESTING THE STARTING A WARNING A failed altemator can become very ENGINE RUNNING hot Do not touch until the altemator has cooled down Use this section to determine if a problem 3 Tum off the engine Inspect all wiring and connections exists with the charging circuit or with the alternator If it is Ensure that the battery terminals and the engine ground determined that the alternator or voltage regulator is faulty connections are tight and clean have a qualified technician check it The alternator charging circuit charges the starting battery A CAUTION To avoid damage to the battery and the service battery An isolator with a diode a solenoid charging circuit never shut off the engine battery or a battery selector switch is usually mounted in the circuit switch when the engine is running to isolate the batteries so the starting battery is not discharged along with the service battery If the alternator is charging the 4 If a battery selector switch is in the charging circuit starting battery but not the service battery the problem is in ensure that it is on the correct setting the service batterys charging circuit and not with the alterna 5 Tum on the ignition switch but do not start the engine tor 6 Check the battery voltage If the battery is in good condi Testing the Alternator tion the reading should be 12 to 13 volts A CAUTION Before starting the engine make certain that everyone is clear of moving parts Keep away from sheaves and belts during test procedures 0MULTIMETER coM A WARNING When testing with a multimeter DC and AC circuits are often mixed together in marine applications Always disconnect a shore power cord isolate DC and AC converters and shut down the engine before performing DC testing No AC tests should be TESTING THE ALTERNATOR VOLTAGE made without a proper knowledge of AC circuits IGNITION ON ENGINE OFF Engines Generators GROUND 24 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 Z5J G COM TESTING THE STARTING ENGINE ENGINE RUNNING 1ocI GROUND s 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 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 EKC terminal if the previous test showed only bat A CAUTION To avoid damaging the altemator dlodesl tery voltage at the B output terminal do not use a high voltage tester ie a megger when perfonnlng tests on the altemator charging circuit If 12 volts is not present at the EXC terminal trace the wiring and look for breaks and poor connections12 VOLT 01 CONTROL CIRCUIT Battery CareThe engine has a 12 volt DC electrical control circuit that is Review the manufacturers and thenshown on the wiring diagrams that follow Refer to these establish a systematic maintenance schedule for yourdiagrams when or when servicing the DC engines starting batteries and house system D Monitor your voltmeter for proper chargipg during engine operation A CAUTION To avoid damage to the battery charging D Check the electrolyte level and specific gravity with a hydrometer clrcultl never shut off the engine battery switch while the engine Is running Shut off the engine battery swltchl D Use only distilled water to bring electrolytes to a proper level however to avoid electrical shorts when working on the D Make certain that battery cable connections are clean and englnets electrical circuit tight to the battery posts and to your engine D Keep your batteries clean and free of minimum recommended capacity of the battery used inthe engines 12 volt DC control circuit is 600 900 ColdCranking Amps CCA A WARNING Sulfuric acid In lead batteries can cause severe bums on skin and damage clothing Wear protective gear Engines Generators 25 GLOW ReinstaII the plugs in the engine and test them again The plugs should get very hot at the terminal end within 20 toThe glow plugs are wired through the preheat solenoid 25 seconds If the plugs dont heat up quickly check for aWhen PREHEAT is pressed at the control panel this solenoid short circuit When reinstalling the glow plugs use click on and the glow plug should begin to get hot compound Qn the threads Glow Plug Tightening Torque 7 11Ibfl 10 15 inspect the plug remove the electrical terminal connections then unscrew or unclamp each plug from the cylinder A WARNING Do not keep a glow plug on for morehead Thoroughly clean each plugs tip and threads with a than 30 secondssoft brush and cleaning solution to remove all the carbon andoil deposits While cleaning examine the tip for wear and TERMINAL ENDburn erosion if it has eroded too much replace the plugTESTINGAn accurate way to test glow plugs is with an ohmmeterTouch one prod to the glow plugs wire connection andthe other to the body of the glow plug as shown A goodglow plug wiII have a 10 to 15ohm resistance This Tightening torquemethod can be used with the plug in or out of the engine 10 15 mkg 7 llftlbYou can also use an ammeter to test the power drain8 to 9 amps per plug A WARNING These glow plugs will become very hot TIP to the touch Be careful not to burn your fingers when testing the plugs GLOW PLUG THE OHMMETER TEST Engines Generators 26 WIRING SCHEMATIC 12 vee START SOL STARTER r M I I I I I NOTES I THIS PRODUCT IS PROTECTED SY A MANUAL RESET CIRCUIT BREAKER LOCAHD NEAR THE PREHEAT I STARTER EXCESSIVE CURRENT WILL CAUSE THE SREAKER TO TRIP AND THE ENGINE Will rSOL I r NOt IAf5Dg 1NUbNCUT Hc fNg ItEND Wi tEro I GlOWPLUGS I 2 AN ONOrr SWITCH SHOULD BE IHSTALlED BETWEEN THE BATTER AND STARTER TO I LJ I fONT TOTn1 N NON I iEY D I HC L NE i F UNT f CH TH I ALTERNATOR I SWITCH SHOULD NOT BE USED TO MAIIE OR BREAK THE CIRCUIT I 3 THE PINK WIRE AT PLUG 2 IS UNUSED AND SHOULD 8E INSULATED CAPTAIN PANEL ONLY I c THE GRAY WIRE AT PLUG Z IS UNUSED AND SHOULD BE INSULATED ADMIRAL PANEL ONLY CB OA CB TO At T I J L 1FT PUMP FUEL P IWHEH TJt l LwCuimFTl HoiD SOleUSEDI Il2c II sNiR 298 T XJ SENDER 0 J W T SWITCH 1 l BAT ADMIRAL TACHOMETER KEY S GNO PANEL SW IGN ALT VOL TMETER GNO o ALARM NOTE WIRE FOR BATTERY ATTATCHMENT WILL NEED TO BE UPGRADED TO AN a GAUGE F ROM 10 GAUGE w T GAUGE 14 8RN GND 14 GRA 14 BRN UN I VERSAL PROPULS I ON PRESTOL LIE SIAMP AU PRESTOLTE 71 AMP AL T 14 GRA PH PI PH PIT P2UP21I PH P212 PH 14 LT BLU NO Nl 14 PINK KEY S CAPTAIN PANEL LAMP 14 PINK TEST SW I I 0 RED T4 14 LT BL j LESTEK 100 AMP ALT CD 14 LT BLU 14 PINK MALE CONNECTOR ON THIS SIDE PREHEAT ALARM WHT SWI TCH RED WIRING SCHEMATIC 39144 BLK IroIALE CONNECTOR ON THIS SIDE BLKIBRN OIRNl IT6CHl RED BLU 51 AMP ALTERNATOR II 4 GSA STANDARD ALTERNATOR ON THE CNOT USEDl X 63B IJl 63C IJl 71B IJl 62B IJl 108B n ID8C n 4 REO OPTIONAL ALTERNATORS 13iA 160A 190A LESTEK ALTERNATORS AVAILA81E ON THE IISOB e3l3IV 6ICIV IJIV 8ZBIV IOEVI lOst VI Engines Generators 27 WIRING DIAGRAM iwm o 1 10 R D 14 PNK BlU 114 T r 1 16 11 ISEE NOTE 21 1 J 1 1 1 Al LIFT PUMP aAIIEBlNOTE An onoff switchshould be installed in thiscircuitto disconnect the SIstarter from the battery inan emergency and when PIleaving thebdat Twelvevolt engine draw 200 to 300 ADM I RALamps when cranking A PANELswitch with a of 175 amps at 12 VDC will normally servethis function but a switch QI PRESS wi1iR TBi WIRING DIAGRAM 39144must never be used to OAUGII GAUGEmake the starter circuit o o PI CAPTAIN liD RED z PANEL RN r o 180RN ALT lAM TACHOMETER DP lAM ICEYSWlTCH 18 eLK 18 SLit 18 8l11 18 BlK Engines Generators 28 STARTER MOTOR DESCRIPTION TIle starting system includes the battery starter motor solenoid and starter button When the starter button on the instrument panel is depressed current flows and energizes the starters solenoid coil The M TERMINAL energized coil becomes an electromagnet which pulls the plunger into the coil and closes a set of contacts which allow high current IGNITION to reach the starter motor At the same time the plunger also TERMINAL serves to push that starter pinion to mesh with the teeth on the TO CONTROL flywheel PANEL To prevent damage to the starter motor when the engine starts the pnuon gear incorporates an overrunning oneway clutch which is splnled to the starter armature shaft The rotation of the running engine may speed the rotation of thepinion but not the starter motor itself Once the started button is released the current flow ceases stop ping the activation of the solenoid TIle plunger is pulled out of In To test the ignition circuit locate the ignitions terminal it is one of the small tem1inaJ studs and is wired to the ignition circuit Use a screwdriver dont touch the blade to jump from that contact with the batterytostart cables by a coil spring and the ignition teID1inaI to the positive battery connection teIDlinal on flow of electricity is interrupted to the starter This weakens the the solenoid magnetic fields and the starter ceases its rotation As the solenoid Iftbe starter cranks the fault lies with the ignition circuit plunger is released its movement also pulls the starter drive gear from its engagement with the engine flywheel If tbe solenoid clicks but nothing else happens the starter motor is probably faultyMOTOR t POSITIVE TYPICAL TERMINAL STARTER MOTOR IGNITION TERMINAL TO CONTROL PANEL Prior to testing make certain the slups batteries are at full charge and that the starting system wiring connections termiI1als are clean and tight Pay particular attention to the ground wiIe connections on the engine block If nothing at all happens the solenoid isnt getting current To check the wiring try cranking the starter for a few seconds Check the battery isolation switch and inspect the wiring never more than 10 seconds at a tinle then run your hand along connections It is also possible that the solenoid is defective the wires and tenninals looking for warm spots that indicate resistance Repair or replace any trouble spots Using a l11Ultinleter test the voltage between the positive terminal A WARNING There will be arching and sparks will stud on the start solenoid and the engine block ground fly when jumping terminals Be certain the engine If you read 12 volts tbe starter is faulty space is free of potentially explosive fumes especially gasoline WESTERBEKE I EnQines Generators 29 STARTER MOTOR SERVICE Westerbeke uses a standard marine starter motor which can be POSITIVE serviced or rebuilt at any starter motor automotive service center TERMINAL Ifreplacing the starter motor make certain the new motor is certified for marine use Automotive starters do not meet USCG standards If in doubt contact your WESTERBEKE dealer M TERMINAL r TO REMOVE FOR SERVICEiOLjfJ 1 Disconnect the negative battery cable 2 If necessary remove any components to gain full access to the starter motorTest again by jumping the two large terminal studs Hold the 3 Label and disconnect the wiring from the starter Do not blade firnlly between the studs Do not allow the wires to touch tape over the blade to touch the solenoid or starter casing this 4 Remove the starter mounting boltswould cause a short 5 Remove the starter from the engine In some cases the starter will have to be turned to a different angle to clear obstructions A WARNING There will be arching as the full starting current should be flowing thru the blade of the screwdriverIf the starter spins the solenoid is faultyIf the starter fails to spin the motor is probably faultyIf no arching occurred There is po juice reaching the solenoidNOTE Starter motors are either inertia type or preengaged Inthe preengaged model the solenoid also maves an ann thatengages the starter motor to the flywheel ofthe engine Using ascrewdriver to bypass the solenoid on such a starter will run themotor without engaging the flywheel Tum the starter switch on toprovide the power to the solenoid HopefUlly it will create enoughmagnetic field for the ann to mave even though the contacts insidethe solenoid are bad Engines Generators 30 DUAL OUTPUT ALTERNATORS SPACER TO MOUNTING output and high output alternators are available asoptional equipment on most WESTERBEKE engines can be installed during factory assembly or asaddon equipment at anytimeDual alternators can be configured to charge two banks ofbatteries at the same time or using a battery selector switchcharge each set of batteries separately an optional dual alternator has already been factory installed simply follow the WESTERBEKE wiring diagram and theengine installation instructionsIf the new dual alternator is being added to an existing intheboat engine carefully follow the alternator below1 Disconnect the alternators negative cable from the battery2 Remove the alternator and disconnect or tape off the output positive cable Do not reuse3 Install the new alternator4 Attach a new heavy gauge output cables from the alternators output terminal s Using the cable sizes indicated DUAL OUTPUT ALTERNATOR LENGTH REQUIRED CHARGING ONE BATTERY Up TO 20 0 WIRE ALWAYS USE FINE STRAND CABLES Make certain that the batteries negative post ground cable to the engine block is the same heavy gauge as the positive cable6 Mount the regulator to a flat surface in a cool dry location a Connect the black wire to the ground terminal on the alternator TO A CAUTION Do not connect any power source with out first grounding the regulator b Plug the 2pin connector into the alternator make certain it is firmly seated c The red battery sense wire should be connected to BATIERY SENSE the batteries positive post or the positive cable TO BATTERY POSITIVE POST d The brown wire keyed ignition is the key circuit which actuates the regulator this wire must connect yCONNECTS TO PINK AND to a switched 12 volt source Refer to the BLUE LEADS THE PINK CONNECTS TO THE WESTERBEKE WIRING DIAGRAM for the proper ALARM BUZZER THE BLUE connection WIRE CONNECTS TO TNE OIL PRESSURE SWITeNDual PulleysA variety of accessory pulleys for high powered and dual DUAL OUTPUT alternators are available from your CHARGING TWO Engines Generators 31 DUAL OUTPUT Alternator TestingNOTE Before make certain that the drive The regulator is functioning properly and the batteriesbelts are tight and the batteries are in good condition are in good Testing 1 Test the voltage at the alternator plug with the engine offkey on The voltage at the alternator terminal F andThe red battery sensing wire A connects to the battery it the voltage in the plug blue wire F from the regulatormust always read battery voltage If battery voltage is not should read the samepresent trace the wire for a bad connection 2 Hold a screw driver close 12 to the alternator puJleyThe orange wire S should read 0 volts with the key off 12 If voltage is present you should feel the magnetic field Ifvolts approximately with the key on If the readings are not the problem may be the brushes worn or the rotorincorrect trace the wire for a bad connection open circuitThe blue wire F supplies current to the alternator fields its 3 Start the engine at fast idle the output terminals shouldvoltaOe will vary depending on the battery charge or actual indicate 142 volts no load A reading of 126 wouldloadlm The readings can vary from 4 to 12 volts with the indicate the alternator is not performing properlykey on 0 volts with the key off Apply a load such as an electJic bilge pump the voltageKEY ON NO VOLTAGE REGULATOR IS DEFECTIVE should maintain at least 138 volts 13 volts or lessKEY OFF BATTERY VOLTAGE REGULATOR IS DEFECTIVE indicates the alternator is TEST POINTS AND PROPER VOLTAGE Ignition Off Ignition On Engine Running When the engine is first started it takes a few moments for I Brown ovolts 2 12 volts 142 volts the alternator to kick in andtakethe load A noticeable A Red 126 volts 12 volts 142 volts change in the sound of the engine will occur S Orange ovolts ovolts 6 8 volts F Blue ovolts 1011 volts 4 12 volts There will be a slight wine from the alternator when the load Alt Output 126 volts 12 volts 142 volts is normal When the alternator is producing high amperage it can become quite hot When replacing the alternator drive belts always purchase and replace dual belts in matched pairs Engines Generators 32 ENGINE following table describes certain problems NOTE The engines electrical system is protected by a 20relating to engine service the probable causes of these prob ampere manual reset circuit breaker located on a bracket atlems and the to overcome these problems the back of the engine The preheat solenoid is mounted on the same bracket Problem Probable Cause No panel indications fuel solenoid 1 Battery switch not on 1 Check switch andor battery connections or fuel pump is not working key switch is on and PREHEAT button is depressed 2 20amp Circuit breaker tripped 2 Reset breaker if breaker trips again check preheat solenoid circuit and check circuit for shorts to ground 3 1Oamp breaker tripped on 3 Check the voltage both at and after the breaker on the preheat solenoid preheat solenoid 4 Loose battery connections 4 Check connection to starter solenoid and connection to engine ground stud Check battery cable connections 5 Preheat solenoid not operating 5 Check solenoid S terminal for voltage START button is depressed no starter 1 Connection to solenoid faulty 1 Check connection engagement 2 Gear shift not in neutral 2 Gear shift must be in neutral see NEUTRAL SWITCH under HURTH HSW TRANSMISSIONS 3 Faulty switch 3 Check switch with ohmmeter 4 Faulty solenoid 4 Check that 12 volts are present at the solenoid connection 5 Loose battery connections 5 Check battery connections 6 Low battery 6 Check battery charge state START button is depressed panel 1 Poor connections to fuel solenoid 1 Check connections indications OK starter solenoid OK fuel solenoid not functioning 2 Defective fuel solenoid 2 Check that 12 volts are present at the connection on the fuel run solenoid Engine cranks but does not 1 Faulty fueling system 1 Check that fuel valves are open start fuel solenoid energized 1a Check for air in fuel system Bleed air from fuel system 1b Fuel filters clogged Replace fiHers and bleed air from fuel system 2 Preheat solenoid faulty 2 Check solenoid 3 Low battery power 3 Switch to combine house and start batteries 3a Replace batteries Engine cant be stopped 1 Faulty DC altemator 1 Remove Exc connection at alternator repair alternator 2 Disconnect fuel shutoff cable 2 Check connection at shutoff lever Pull lever back to close offthe fuel 3 Fuel run solenoid will not deenergize 3 Manually disconnect the 12 volt connection to the fuel run solenoid at the injection pump Battery runs down 1 Oil pressu re switch 1 Observe if gauges and panel lights are activated when engine is not running Test the oil pressure switc 2 High resistance leak to ground 2 Check wiring Insert sensitive 0 25 amp meter in battery lines Do not start engine Remove connections and replace after short is located 3 Low resistance leak 3 Check all wires for temperature rise to locate the fault 4 Poor battery connections 4 Check cable connections at battery for loose connections corrosion 5 DC altemator not cHarging 5 Check connections check belt tension test altemator See tachometer not operating DC ELECTRICAL Battery not charging 1 DC charge circuit faulty 1 Perform DC voltage check of generator charging circuit See Testing the Battery Charging Circuit 2 Altemator drive 2 Check drive belt tenSion altemator should tum freely Check for loose connections Check output with voltmeter Ensure 12 volts are present at the Exc terminal continued Engines Generators 33 ENGINE Problem Probable Cause Engine slows and stops 1 Fuel lift pump failure 1 Fuel lift pump should make a distinct ticking sound Replace pump with spare 2 Switches andor wiring loose 2 Inspect wiring for short circuits and loose connections or disconnected Inspect switches for proper operation 3 Fuel starvation 3 Check fuel supply fuel valves fuel lift pump 4 20 Amp circuit breaker tripping 4 Check for high DC amperage draw during operation Ensure breaker is not overly sensitive to heat which would cause tripping 5 Exhaust system is restricted 5 Check for blockage collapsed hose carbon buildup at exhaust elbow 6 Water in fuel 6 Pump water from fuel tanks change filters and bleed fuel system 7 Air intake obstruction 7 Check air intake filter cartridge Engine overheatsshuts down 1 Raw water not circulating 1 Raw water pump failure Check impeller replace 2 Coolant not circulating 2 Obstruction at raw water intake or raw water filter 2a Thermostat remove and test in hot water Replace thermostat 2b Loss of coolant check hoses hose clamps drain plug etc for leaks 2c Broken or loose belts tightenreplace 2d Air leak in system run engine and open the pressure cap to bleed air Add coolant as needed Engine alarm sound pulsates 1 Loss of oil 1 Check dipstick look for oil leaks at oil filter and at oil drain hose connection 2 Oil pressure switch 2 Replace oil pressure switch Engine alarm sounds continuously 1 Engine coolant 1 Check engine coolant level 2 High temperature switch opens at 2 Check for satisfactory operation with switch bypassed too Iowa temperature check with ohmmeter replace if faulty Exhaust smoke problems 1 Blue smoke 1 Incorrect grade of engine oil 1a Crankcase is overfilled with engine oil oil is blowing out through the exhaust 2 White smoke 2 Engine is running cold 2a Faulty injector or incorrect injector timing 3 Black smoke 3 Improper grade of fuel 3a Fuel bum incomplete due to high backpressure in exhaust or insufficient air for proper combustion check for restrictions in exhaust system check air intake 3b Improperly timed injectors or vaives or poor compression 3c Lack of air check air intake and air filter Check for proper ventilation 3d Overload COOLANT TEMPERATURE AND OIL PRESSURE GAUGESIf the gauge reading is other than what is normally indicated If both of the above gauge tests are positive the gauge isby the gauge when the instrument panel is energized the first undoubtedly OK and the problem lies either with thestep is to check for 12 volts DC between the ignition B conductor from the sender to the gauge or with the senderand the Negative B terminals of the gauge If either of the above gauge tests are negative the gauge isAssuming that there is 12 volts as required leave the probably defective and should be panel energized and perform the following steps Assuming the gauge is OK check the conductor from the1 Disconnect the sender wire at the gauge and see if the sender to the sender terminal at the gauge for continuity gauge reads zero which is the normal reading for this Check that the engine block is connected to the ground situation Some starters have isolated ground terminals and if the2 Remove the wire attached to the sender terminal at the battery is connected to the starter both plus and minus sender and connect it to ground See if the gauge reads terminals the ground side will not necessarily be connected full scale which is the normal reading for this situation to the block WESTERBEKE Engines Generators 34 ENGINE ADJUSTMENTS NOTE WESTERBEKE recommends that the following engine adjust ments be performed by a competent engine mechanic The information below is provided to assist the mechanicDRIVE BELT ADJUSTMENT FUEL inspection service and maintenance of the drive belts In case of severe vibrations and detonation noise have theis important for the efficient operation of your engine see injectors checked and overhauled by an authorized fuelDrive Belts under MAINTENANCE SCHEDULE injection service center Poor fuel quality contaminants andDrive belts must be properly tensioned Loose drive belts loss of positive fuel pressure to the injection pump can resultwill not provide proper alternator charging and will eventu in injector faults Since fuel injectors must be serviced in aally damage the alternator Drive belts that are too tight will clean room environment it is best to carry at least one extrapull the alternator out of alignment andor cause the alterna injector as a spare should a problem occurtor to wear out prematurely Excessive drive belt tension can Before removing the old injector clean the area around thealso cause rapid wear of the belt and reduce the service life base of the injector to help prevent any rust or debris fromof the coolant pumps bearing A slack belt or the presence of falling down into the injector hole If the injector will not liftoil on the belt can cause belt slipping resulting in high out easily and is held in by carbon buildup or the like workoperating temperatures and tachometer variations the injector sidetoside with the aid of the socket wrench toThe drive belt is properly adjusted if the belt can be deflected free it and then lift it outno less than 38 inch lOmm and no more than 112 inch The injector seats in the cylinder head on a copper sealing12mm as the belt is depressed with the thumb at the washer This washer should be removed with the injector andmidpoint between the two pulleys on the longest span of the replaced with a new washer when the new injector isbelt A spare belt or belts should always be carried on board installed INJECTOR TO CYLINDER HEAD TIGHTENING TORQUE A WARNING Never attempt to cbeck or adjust the 4351 fIlb 6070 mka drive belts tension while the engine is in Belt Tension1 Loosen the alternator adjusting strap bolt and the base mounting bolt FUEL INJECTOR2 With the belt loose inspect for wear cracks and frayed edges3 Pivot the alternator on the base mounting bolt to the left or right as required to loosen or tighten4 Tighten the base mounting bolt and the adjusting strap bolt5 Run the engine for about 5 minutes then shut down and recheck the belt tensionsRAW WATER PUMP BELTThe tension of the raw water pump belt is adjusted byreleasing the pumps fasteners and sliding the pump backand forth The water pump belt should be firmly tight andchecked oftenSTARTER AND ALTERNATOR SERVICERefer to the engine chart in this manual Alsoincluded in this manual are basic and testprocedures for both the starter motor and the alternator Notealso that there are automotive shops that specialize in therepair and rebuilding of starter motors and alternators Engines Generators 35 ENGINE ADJUSTMENTS NOTE WESTERBEKE recommends that the following engine adjust ments be performed by a competent engine mechanic The information below is provided to assist the mechanic VALVE CLEARANCE ADJUSTMENT 8 Adjust each valves clearance by inserting a 0012in 003mm feeler gauge between the rocker ann and the 1 Wann the engine to nonnal operating temperature valve stem Make sure to adjust all valves when the 2 Pull off the air breather pipe from the rocker cover engine is cold Remove the rocker cover bolts and remove the rocker cover to expose the rocker shaft and valve assembly 3 Remove the glow plugs from each of the cylinders to enable the crankshaft to be easily rotated by hand to position each cylinder for valve adjustment Valves are adjusted with the piston in the cylinder being adjusted at TOC of its compression stroke NOTE Retorque the cylinder head bolts before adjusting the engine s valves 4 Loosen the head bolts in the reverse order of tightening 9 Install the cylinder head cover HEAD COVER BOLT TORQUE 2 3 ft Ib 03 045 mkg ENGINE COMPRESSION 13 9 5 1 4 8 12 Check the compression pressure To do this wann the 5 Tighten the head bolts in the order shown Torque at engine remove all fuel injectors or glow plugs disconnect 85 90 ft Ib 118 125 mkg the fuel shutoff solenoid wire and install a compression adapter in the injector hole or glow plug hole Connect a 6 Set the piston of No1 cylinder to TOC compression compression tester on the adapter and crank the engine with and check the valve clearance at each position indicated the starter motor until the pressure reaches a maximum value If the clearance is incorrect adjust to specifications Repeat this process for each cylinder Look for cylinders with Intake No1 and No2 cylinders and dramatically at least 20 lower compression than the Exhaust No 1 and No3 cylinders average of the others Compression pressure should not differ 7 Turn the crankshaft once setting the piston of No 4 by more than 427 psi 30 kglcm2 at 200 rpm cylinder at TOC compression and adjust to the following specifications Intake No3 and No4 cylinders and Exhaust No2 and No4 cylinders I4 EXHAUST WHEN NO4 CYLINDER IS AT TOP DEAD CENTER 41NTAKE 31NTAKE EXHAUST 2 COMPRESSION GAUGE I COMPRESSION PRESSURE STANDARD 427 PSI al200 RPM 300 Kgem COMPRESSION PRESSURE LIMIT 384 PSI al200 RPM 270 Kgem LIMIT BETWEEN CYLINDERS 427 PSI 30 Kgem If a weak cylinder is flanked by healthy cylinder the problem is either valve or piston related Check the valve clearances for the weak cylinder adjust as needed and test again If the cylinder is still low apply a small amount of oil into 2 INTAKE NTAKE1 the cylinder to seal the rings and repeat the test f EXHAUST I EXHfUST If compression comes up the rings are faulty WHEN NO 1 CYLINDER IS AT TOP DEAD CENTER I Engines Generators 36 ENGINE ADJUSTMENTS NOTE WESTERBEKE recommends that the following engine adjust ments be performed by a competent engine mechanic The information below is provided to assist the mechanicENGINE IDLING SPEED INJECTION PUMP SERVICEThe engine idling speed is preset at the factory but once the For disassembly inspection reassembly and internalboat is operating in the water other variables such as adjustments of the injection pump it is recommended thepropeller size shaft length and the transmission can affect pump be taken to a qualified injection service shopthe idle speed authorized to service Diesel KiKi or Zexel injectionThe normal idle speed for this engine is 650950 RPM simply put the idle speed should feel comfortableIt should be quiet and smooth not racing but not so low that ENGINE STOP SOLENOIDit causes chugging and transmission rattle This solenoid is installed on the top rear of the injection pump and is activated by 12 VDC electrical currentSETTING THE IDLING SPEEDTo adjust the engine idle speed engine running loosen the of the idle adjustment bolt and turn the bolt 1 The solenoid does not operate whenclockwise to increase idle speed and to the keyswitch is turned ONreduce Once the speed is set to your satisfaction tighten the a Are the engine batteries turned ONlocknut h Is the 20 amp circuit breaker set c Is 12 VDC present at the solenoid connection 2 The solenoid does not stop the engine when the keyswitch is switched OFF J SPRING a Check to see if 12 VDC is still present PLUNGER at the solenoid electrical lead with the key off h Remove solenoid from injection pump and ensure plunger and spring THROTTLE STOP BOLT FACTORY SET in the solenoid are not sticking FUEL INJECTION PUMP TOP Engines Generators 37 ENGINE ADJUSTMENTS NOTE WESTERBEKE recommends that the following engine adjust ments be performed by a competent engine mechanic The information below is provided to assist the mechanic TESTING OIL PRESSURE LOW OIL PRESSURE The lubricating system is a pressure feeding system using an The specified safe minimum oil pressure is 43 14 psi 03 oil pump The engine oil is drawn from the oil sump by the 01 kglcm2 A gradual loss of oil pressure usually indi oil pump which drives the oil under pressure through the cates a worn bearings For additional information on low oil oil filter oil cooler and various lubricating points in the pressure readings see the ENGINE engine The oil then returns to the oil sump to repeat the chart continuous cycle When the oil pressure exceeds the specified pressure the oil pushes open the relief valve in the oil pump OIL PRESSURE SWITCHSENDER and returns to the oil sump keeping the oil pressure within its specified range Occasionally a faulty oil pressure sender will give a false reading When installing a new sender apply teflon sealant to To test the oil pressure remove the oil pressure sender then the threaded ends being careful not to close off the oil hole in install a mechanical oil pressure gauge in its place After the sender warming up the engine set the engine speed at approx OIL PRESSURE SENDER AND SWITCH TORQUE 2600 rpm and read the oil pressure gauge 9 13 fHb 12 18 mKg OIL PRESSURE SWITCH INJECTION PUMP CONNECTION TO ENGINE BLOCK OIL PRESSURE GAUGE WITH ADAPTERTHIS MECHANICAL TEST GAUGE CAN BEINSTALLED WHERE THE OIL HOSE ENTERSTHE ENGINE BLOCK OR IN PLACE OF THEOIL PRESSURE SENDER OIL GALLERY Engines Generators 38 HURTH TRANSMISSIONS DESCRIPTION NOTE When installing the transmission make certain that The information below is specific to the HBW shifting is not impeded by restricted movability of the Transmissions the TRANSMISSION Bowden cable or rod linkage by unsuitably positioned guide SECTION applies to all models sheaves too small a bending radius etc In order to mount a support for shift control cable connections use the two CONNECTION OF GEAR BOX WITH PROPELLER threaded holes located above the shift cover on top of the HBW recommend a flexible connection between the trans gear housing Refer to the WESTERBEKE parts list mission gearbox and the propeller shaft if the engine is CONTROL CABLES flexibly mounted in order to compensate for angular deflections The installation of a special propeller thrust bear The transmission is suitable for single lever remote control ing is not required since the propeller thrust will be taken by Upon loosening the retaining screw the actuating lever can the transmission bearing provided the value specified under be moved to any position required for the shift control SPECIFICATIONS is not exceeded However the output elements cable or rod linkage Make certain that the shaft should be protected from additional loads Special actuating lever does not contact the actuating lever cover care should be taken to prevent torsional vibration When plate the minimum distance between lever and cover should using a universal joint shaft make certain to observe the beO5mm manufacturers instructions The control cable should be arranged at a right angle to the Even with the engine solidly mounted the use of a flexible actuating lever when in the neutral position The neutral posi coupling or PRIVESAVER will reduce stress in the gear tion of the shift operating lever on the control console should bo bearings caused by hull distortions especially in wooden coincide with the neutral position of the actuating lever boats or where the distance between transmission output The shifting travel as measured at the pivot point of the flange and stem gland is less than about 32 in 812 mm actuating lever between the neutral position and end positions A and B should be at least 35mm for the outer pivot point and 3Dmm for the inner pivot point HURTHHBW A greater amount of shift lever travel is in no way detrimental and is recommended However if the lever travel is shorter proper clutch engagement might be impeded which in tum would mean premature wear excessive heat generation and clutch plate failure This would be indicated by slow clutch engagement or no engagement at all NOTE Check for proper actuating lever travel at least each season NEUTRAL LEVER TRAVEL N FORWARD B CHECK FOR EQUAL TRAVEL FROM NEUTRAL THRU FORWARD AND REVERSE A CAUTION The pOSition of the mechanism behind the actuating lever is to ensure equal shift lever travel from neutral position A and B If ACTUATING LEVER this mechanism is in any way tampered with the transmission warranty will be void is a product of Globe Marine Rockland MA Engines Generators 002 in 05mm MINIMUM CLEARANCE 39 HURTH HBW TRANSMISSIONS INITIAL OPERATION OPERATING TEMPERATURE All HBW marine transmissions are testrun on a test stand The maximum permissible ATF temperature should not exceed with the engine at the factory prior to delivery For safety 2300 110 This temperature can only be reached for a short reasons the fluid is drained before shipment time Fill the gearbox with Automatic Transmission Fluid DmTRON ill The fluid level should be up to the index A CAUTION If the transmission fluid temperature is mark on the dipstick To check the fluid level just insert the too high stop the engine immediately and check the dipstick do not screw it in Screw the dipstick into the case transmission fluid after the fluid level is checked and tighten Do not forget the sealing ring under the hexhead of the dipstick Check for leaks and make a visual inspection of the coupling oil cooler LOCKING THE PROPELLER and hoses and shift cables Locking of the propeller shaft by an additional brake is not required use the gear shift lever position opposite your direc tion of travel for this pUIpose Never put the gear shift in the position corresponding to the direction of travel of the boat WHEN UNDER SAIL OR BEING TOWED Rotation of the propeller without load such as when the boat is being sailed being towed or anchored in a river as well as operation of the engine with the propeller stopped for CHECKING I charging the battery will have no detrimental effects on the FLUID transmission LEVEL i DAILY OPERATION nm1 FLUID o Check the transmission fluid o Visually check the gear shift level linkage and transmission FLUID DRAIN I o Start the engine in neutral allowing a few minutes at idle to warm the fluid FLUID CHANGE o Shift into gear Change the fluid for the first time after about 25 hours of NOTE Too low an idle speed will produce a chattering noise operation then every 300 operating hours or at least once a from the transmission gear and damper plate In such cases year or at winterizing the idle speed should be increased Removing the fluid For additional infonnation refer to the following text in this Push a suction pump hose down through the dipstick hole to Transmission Section SHAFT COUPLINGS MAINTE the bottom of the housing and suck out the fluid If space NANCEAND TRANSMISSION allows use the transmission drain Remove the drain plug from the bottom of the transmission and allow the fluid to HBW TRANSMISSIONS SPECIFICATIONS drain into a container then reinstall the plug with its sealing washer Wipe down the transmission and properly dispose of General Hurth Standard Transmission Case the used fluid After running the engine shut down and hardened helical gears with a servo recheck the fluid level operated multiple disc clutch Gear ratio optional 263 1 HBW 150A 3R DRAIN PLUG TORQUE 20 25 fIIbs 299 1 HBW 150v 3R 274 1 HBW 250 3R NOTE When changing the fluid take care not to lose the drain plug sealing washer The drain plug will leak without Lubricating Fluid ATF type A or Dextran I or III this sealing washer Transmission Sump HBW 150A 059 US qts 0561 liters Capacity HBW 150V 111US qts 105 liters HBW 250 075 US qts 079 liters A WARNING Never pull out the dipstick while the Propeller Shaft Right hand standard engine is running Hot fluid will splash from the dip Direction of Rotation transmission stick hole This could cause severe bums Engines generators 40 HURTH TRANSMISSIONS Operating Temperature MAINTENANCE Transmission maintenance is minimal Keep the exterior A CAUTION If the transmission guid temperature is housing clean check the fluid level as part of your regular routine and change the fluid every 300 operating hours too high stop the engine immediately and check the Periodically inspect the transmission and the cooler for leaks transmission guid and corrosion Lubricate the cable connections Normal operating temperature of the transmission fluid LayupWinterize should be in the range of 122F 50C to 212F l00C A Storage requires special care Follow these procedures maximum temperature of 266F l30C may be only o Drain water from the transmission oil cooler and replace reached for a short time with a proper mixture of antifreeze coolant Make certain there is enough space around the transmission NOTE This operation will normally occur when the to provide good ventilation and cooling engine raw water cooling system is properly winterized TRANSMISSION COOLER o Clean up the transmission and touch up unpainted areas Coolers are standard equipment for the HBW 100 125 150 use heat resistant paint 150A 150V and the 250 no cooler is necessary for the o Fill the transmission with Dextron III ATF fluid to HBW 35 and 50 prevent internal corrosion extended storage only twelve The cooler is a separate part of the transmission which months or more prevents any possibilities of coolant diluting the transmission o Loosen attaching hardware from the transmission output fluid However the continued flow of coolant thru the cooler flange and propeller shaft coupling flange before will in time erode the inside of the cooler causing external removing the boat from the water Separate the flanges leaks and spray with lubricant A transmission cooler may last ten years or more but in o Inspect the gear shift cable linkage and attachments some circumstances depending on operating hours tropical Look for corrosion of the end fittings cracks or cuts in waters maintenance etc it might only last half that time 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 should be topped offwith fluid to prevent internal corrosion Reduce the fluid level before putting the engine back into service For additional information contact HURTH MARINE COOLER ZF Industries 3131 SW 42nd Street PERIOUALLY INSPECT FOR EROSION AND LEAKAGE Fort Lauderdale FL 33312 TRANSMISSION Tel 954 5814040 Engines Generators 41 HURTH HSW INITIAL OPERATIONFor safety reasons the transmission is not filled with Set the shifting lever to neutral position N Start the fluid during shipment and the selector lever is and let it run long enough in idle to fill the cooler and attached to the actuating shaft with transmission fluid Shift into gear forward and reverseBefore leaving the WESTERBEKE plant each transmission shifting should be smooth and positive Direct changes fromundergoes a test run with Dextron III ATF transmission fluid forward to reverse are permissible since the multiple discThe residual fluid remaining in the transmission after clutch permits changing at high rpm including suddendraining acts as a preservative and provides protection reversing at high speeds in the event of dangeragainst corrosion for at least one year if properly stored After initial operation make a visual inspection of the output coupling oil cooler and hoses and the cable connections to the transmission rfPrII AIR VENT LOCKING THE PROPELLER Locking of the propeller shaft by an additional brake is not required use the gear shift lever position opposite your direction of travel for this purpose Never put the gear shift in the position corresponding to the direction of travel of the SJJ FLUID boat FILTER WHEN UNDER SAIL OR BEING TOWED Rotation of the propeller without a load such as when the OUTPUT boat is being sailed being towed or anchored in a river as COUPLING well as operation of the engine with the propeller stopped for charging the battery will have no detrimental effects on the transmission OIL COOLER NOTE When the boat is being sailed engine stopped the The oil cooler mounted above the transmission provides gear shift must be in the neutral position The propeller is at continuous cooling for the transmission fluid Raw water idle and can freewheel passes through the tubes of the cooler and discharges over board The transmission fluid is cooled as it flows around the DAILY OPERATION tubes and back into the transmission o Check the transmission fluid WESTERBEKE RECOMMENDS CARRYING RAW WATER o Visually check the gear shift linkage and transmission ASPARE OIL COOLER ABOARD CONNECTION o Start the engine in neutral allowing a few minutes at idle to warm the fluid o Shift into gear NOTE Too low an idle speed will produce a chattering noise from the transmission gear and damper plate In such cases RAW WATER the idle speed should be increased CONNECTION TRANSMISSION OIL COOLER Operating Temperature TRANSMISSION FLUID The operating temperature of the transmission should not Fill the transmission with Dextron III ATF The fluid level exceed 176F 80C A connection for a temperature probe should be up to the mark on the dipstick After checking the is provided At maximum output of the engine the fluid may level press the dipstick into the case and turn it to tighten reach 220F 104C During the first 25 operating hours inspect the bell housing output shaft and transmission cooler for leakage The fluid should be changed after the first 25 hours and every 300 A CAUTION If thl1 transmission fluid temperature is hours thereafter too high stop the engine immediately and check the transmission fluid NEUTRAL SWITCH These transmissions are equipped with a neutral safety switch This is to prevent the engine from starting in gear Unless the transmission selector lever is perfectly aligned in neutral the engine starter will not activate Engines Generators 42 HURTH HSW TRANSMISSIONS CHANGING THE TRANSMISSION FLUID Replacing the Fluid Pour in new Dextron III ATF fluid and check the quantity with the dipstick Transmission fluid quantities will vary with the use of coolers length of hoses and the angle of the transmission Approximate Quantities HSW450 212 quarts 20 Liters HSW630 32 quarts 30 Liters HSW630V 42 quarts 40 Liters Reinsert the filter assembly into the housing Press it in place ACTUATING and tighten the Allen screw LEVER NOTE Some HSW transmissions use a T handle in place of16mm 8 SCREW a screw on their filter assemblies After running the engine shut down and recheck the fluid level A WARNING Never pullout the dipstick while the engine is running Hot uid will splash from the dipstick hole This could cause severe bums MAINTENANCE HSW MODEL 450 Transmission maintenance is minimal Keep the exterior housing clean check the fluid level as part of your regular routine and change the fluid every 300 operating hours Periodically inspect the transmission and the cooler for leaks FILTER ELEMENT and corrosion Make certain the air vent is clear and when checking the fluid level look for signs of water contamination fluid will appear as strawberry cream LayupWinterize Filter Element Storage requires special care Follow these procedures The Hurth HSW transmission has a filter element located D Drain water from the transmission oil cooler and replace opposite the dipstick This filter must be replaced whenever with a proper mixture of antifreeze coolant the fluid is changed NOTE This operation will normally occur when the Remove the filter by loosening the screw on the cover using engine raw water cooling system is properly winterized a 6mm Allen wrench D Clean up the transmission and touch up unpainted areas Twist and pull out the filter and remove the element Place use heat resistant paint the new filter onto the cover and lock it into place by turning D Fill the transmission with Dextron III ATF fluid to pre it clockwise Check the Orings for damage and replace if vent internal corrosion extended storage only twelve necessary Replacement filters can be obtained from your months or more local WESTERBEKE dealer or ZF Hurth dealer D Loosen attaching hardware from the transmission output Removing the Fluid flange and propeller shaft coupling flange before Push a suction pump hose down through the pipe hole under removing the boat from the water Separate the flanges the filter to the bottom of the housing and suck out the fluid and spray with lubricant Remove the oil return line from the cooler and allow the oil D Inspect the gear shift cable linkage and attachments to drain into a container then reconnect the oil return line Look for corrosion of the end fittings cracks or cuts in the conduit and bending of the actuator rods Lubricate Wipe down the transmission and properly dispose of the used all moving parts fluid NOTE If the transmission is to be stored for a long time twelve months or more it should be topped offwith fluid to prevent internal corrosion Reduce the fluid level before putting the engine back into service Engines Generators 43 HURTH HSW CONNECTIONS SHAFT COUPLINGSThe transmission is suitable for a single lever gear shift WESTERBEKE recommends a flexible connection betweenUpon loosening the retaining screw the actuating lever see the transmission and the propeller shaft if the engine isillustration can be moved to any position required for the flexibly mounted in order to compensate for angularcontrol elements cable or rod linkage Make certain that the deflections The installation of a special propeller lever does not contact the lever hub the minimum bearing is not required since the propeller thrust will bedistance between the lever and the hub should be O02in absorbed by the transmission bearing provided the valueO5mm specified under SPECIFICATIONS is not exceededThe control cable or rod should be arranged at a right angle However the output shaft should be protected fromto the actuating lever when in the neutral position The neu additional loads Special care should be taken to preventtral position of the gear shift lever on the control console torsional vibration When using a universal joint shaft makeshould coincide with the neutral position of the lever on the certain to observe the manufacturers Even with the engine solidly mounted the use of a flexibleThe shifting travel as measured at the pivot point of the coupling or DRIVESAVER will reduce stress in the gearactuating lever between the neutral position and end positions box bearings caused by hull distortions especially in woodenA and B should be at least 138in 35mm for the outer and boats or where the distance between the transmission output 1316in 3Omm for the inner pivot point coupling and stem gland is less than about 8oomm NOTE When installing the transmission make certain that N shifting is not impeded by restricted movability of the cable or rod linkage by unsuitably positioned guide sheaves too small a bending radius or other restrictions In order to mount a support for shift control cable connections use the two threaded holes located on the cable bracket mounted on the gear housing Referto the WESTERBEKE parts list ACTUATING LEVER TYPICAL STEERING STATIONA greater amount of actuating lever travel is in no waydetrimental and is recommended However if the lever travel For additional information contactis shorter proper clutch engagement might be impededwhich in turn would mean premature wear excessive heat HURTH MARINE GEARgeneration and clutch plate failure This would be indicated ZF Industriesby slow clutch engagement or no engagement at all see 1018 Carolina DriveCONTROL CABLES under TRANSMISSION West Chicago IT Tel 874 6343500NOTE Checkfor proper actuating lever travel at least eachseason A CAUTION The position of the mechanism behind the actuating lever is to ensure equal shift lever travel from neutral position to A and B If this mechanism is in any way tampered with the transmission warranty will be void WESTERBEKE I Enaines Generators 44 TRANSMISSION HURTHCONTROL CABLES A new cable and perhaps a new linkage mechanism may beThe majority of transmission difficulties arise as a result of needed While the cable is loose shift the transmission in andimproper clutch adjustments manual transmissions or out of gear using the lever on the side of the transmission toproblems with control cables hydraulic transmissions make sure theres no binding inside the caserather than from problems with the transmission itself If the transmission passes these tests crank the engine andHURTH clutches in particular are very sensitive to improper have a helper put it in forward and reverse while you observecable adjustments the propeller shaft if the shaft isnt turning the transmission needs professional attention If it does tum but theres noIf you experience operating problems with the transmission thrust check to see you still have a propeller on the end ofshut the engine down First check the the shaft or if you have a folding or feathering propeller thatlevel then have a helper move the cockpit shift lever through it isnt stuck in the no pitch positionthe full range from neutral to full forward back to neutral into full reverse and back to neutral while you NOTE lfyou suspect a major problem in your the actuating lever on the transmission If the remote immediately contact your WESTERBEKE dealer or anis stiff to operate break the cable loose at the transmission authorized marine transmission facilityand try again If it is still stiff check the cable for kinks orexcessively tight bends and check any linkage for binding Problem Probable Cause Transmission gears cannot be shifted 1 Actuating lever is loose 1 Tighten damping bolt on actuating lever Fails to move into gear 2 Shifting cable is broken bent or 2 Check the cable reattach or replace unattached Cable radius is too severe 3 Actuating lever is binding against the 3 Detach the shift cable and operate the actuating lever by cover plate hand Clearance should beO02 in 05mm Transmission shifts into gear but 1 Output coupling is not tuming 1 Transmission needs professional attention failsto propel the boat 2 Propeller shaft is not turning 2 The coupling bolts are sheared or the coupling is Slipping Output coupling is tuming on the propeller shaft Tighten or replace set screws keys pins and coupling bolts as necessary 3 Output coupling and 3 Inspect the propeller it may be missing or damaged propeller shaft are tuming Afolding propeller may be jammed A variable pitch propeller may be in no pitch position Delay of gear engagement or engages 1 Actuating lever travel Nto B not 1 Adjust cover plate until the lever is exact midposition only after an increase in speed equal to Nto A See ACTUATING LEVER TEXT AND DIAGRAM 2 Actuating lever travel is insufficient 2 Check shift lever cable length See ACTUATING LEVER DIAGRAM 3 Actuating lever is binding against cover plate 3 Check clearance adjust if necessary Transmission noise becomes louder 1 Damage starting on flexible coupling due 1 Check alignment inspect flexible coupling If noise persists to wear or fatigue possibly due to misalign inspect the damper plate between the transmission and the ment between engine and transmission 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 Chattering transmission noise 1 The engine or propeller generates torsional 1 Mount a flexible coupling with another stiffness factor mainly at low engine speed vibrations in the drive unit which produces between the engine and transmission a coupling with a chattering noise in the transmission a higher stiffness factor might be sufficient 2 Inspect the damper plate between the engine and the transmission Replace if necessary Boat fails to attain specified max speed 1 Operating temperature is high 1 Wrong type of fluid Use ATF Dextron III check fluid level 2 Operating without cooling 2 Check cooler Inspect coolant hoses and coolant flow Oil Leakage 1 Corrosion at radial sealing ring and shaft 1 Transmission needs professional attention Damage sealing ring 2 Misalignment of output flanges 2 Check alignment Must be within 0003 in OOBmm Engines Generators 45 TRANSMISSION Problem Probable Cause Chattering transmission noise 1 The engine or propeller generates torsional 1 Mount a flexible coupling with another stiffness factor mainly at low engine speed vibrations in the drive unit which produces between the engine and transmission a coupling with a chattering noise in the transmission a higher stiffness factor might be sufficient Transmission shifts into gear but 1 Output coupling is not turning 1 Transmission needs professional attention fails to propel the boat 2 Propeller shaft is not turning 2 The coupling bolts are sheared or the coupling is slipping Output coupling is turning on the propeller shaft TIghten or replace set screws keys pins and coupling bolts as necessary 3 Output coupling and 3 Inspect the propeller it may be missing or damaged propeller shaft are turning Afolding propeller may be jammed Variable pitch propeller may be in no pitch positionNOTE lfyou suspect a major problem in your contact your WESTERBEKE dealer or anauthorized marine transmission facility Engines Generators 46 BORG WARNER VELVET DRIVE TRANSMISSION OPTIONAL TRANSMISSION SHIFT LEVER POSITION The gear shift control mechanism and linkage must position the actuating lever on the transmission exactly in Forward F Neutral N and Reverse R shifting positions A detent ball located behind the transmission lever must work freely to center the lever in each position The gear shift positions at the helm must be coordinated with those of the Velvet Drive actuating lever through shift mechanism adjustments An improperly adjusted shift mechanism can cause damage to the transmission The shifting mechanism and transmission actuating lever should be free of dirt and well lubricated to ensure proper operation Shifting Into Gear Place the gear shift in Neutral before starting the engine Shifting from one selector position to another selector posi tion may be made at any time below 1000 rpm and in any WARNER order Shifts should be made at the lowest practical engine VELVET DRIVE speed Start the engine and set the throttle at idle speed TRANSIVISSION allow the transmission fluid to warm up for a few safety reasons the transmission is not filled with fluid during shipment and the selector lever Move the gear shift lever to the middle position You shouldis temporarily attached to the actuating shaft feel the detent This centers the actuating lever on the transBefore leaving the WESTERBEKE plant each transmission mission With the control in this position hydraulic power isundergoes a test run with Dextron III ATF transmission completely interrupted and the output shaft of the transmisfluid The residual fluid remaining in the transmission after sion does not turndraining acts as a preservative and provides corrosion for at least one year if properly stored NOTE Some transmissions are equipped with a neutral safety switch Unless the transmission actuating lever is FLUID aligned in neutra the engine starter will not activateCheck the transmission fluid level on the dipstick If has not been filled fill with Dextron III and to use this fluid During the first 25 hours of Move the gear shift lever to the forward position You keep a lookout for any leakage at the bell housing feel the detent The actuating lever on the transmission is inoutput shaft and transmission cooler This fluid should be the forward position The output shaft and the propeller shaftchanged after the first 25 hours and approximately every move the boat in a forward direction300 operating hours thereafter andor at winter layup Reverse Move the gear shift lever to the reverse position You should A CAUTION Be certain the transmission is filled feel the detent The actuating lever on the transmission is in and the correct size cooler is properly installed before the reverse position The output shaft and the propeller starting the engine should move the boat in a reverse direction astern NOTE Moving the transmission actuating lever from Neutral Position to Forward is always toward the engine Reverse is always away from the engine If boat moves backwards with the gear shift control in the forward position shut off the engine This problem may be a result of incorrect movement of the actuating lever by the gear shift lever Engines Generators 47 BORG WARNER VELVET DRIVE TRANSMISSION o Clean off the transmission and properly dispose of the used fluid o Refill the transmission with DEXTRON III ATF The quantity will vary depending on the transmission model and the installation angle FilI through the dipstick hole o Check the dipstick for the proper fluid level o Replace the oil filler cap and dipstick Press the dipstick into place and turn clockwise until fingertight o Run the engine shutdown and recheck the fluid levelFORWARD NEUTRAL REVERSE TRANSMISSION ACTUATING LEVER POSITIONS A WARNING Never pullout the dipstick while the engine is running Hot Ruid will splash from the dipstickDAILY OPERATION hole This could cause severe bumso Check the transmission fluido Visually check the gear shift linkage and transmission Oil Capacityo Start the engine in neutral Allow a few minutes at idle Approximately 25 quarts 236 liters will fill most transmis for the fluid to Waml sions to the oil level fill mark on the dipstick Many variables NOTE Too low an idle speed will produce a chattering have a direct relationship to the oil capacity Additional oil noise from the transmission gear and damper plate In will be required to fill the oil cooler and the cooler lines The such cases the idle speed should be increased angle of installation will make a difference in the quantity of oil required to fill the transmissiono Shift into gear A CAUTION Shifting gears above 1000 rpm can cause damage to the engine damper plate Pulling the DIPSTICK r MAKE CERTAIN THE FLUID LEVEL throttle back to idle when shifting gears will save wear RUBBER SEAL IS on the transmission and the damper plate SCREWED FULL TIGHTTOTHE HANDLE INSPECTIONo Visually check for oil leaks at the hydraulic connections Check for wear on the hydraulic lines and replace if worno Lubricate the detent ball and shift cable attachmentso Inspect the shift linkage Oil Temperatureo Inspect the transmission bolts retorque if necessary A maximum oil temperature of 190F 88C is recom mended Discontinue operation anytime sump oil tempera A CAUTION Clutch failure will occur if the transmis ture exceeds 2300 P 1 10C sion shift lever does not fully engage the detent ball PRESSURE GAUGE positions An optional mechanical pressure gauge can be installed at the control panel to constantly monitor the pressure of theCHANGING THE TRANSMISSION FLUID transmission fluid A normal reading at 2000 rpm in forwardAfter the initial 50 hour change the transmission fluid should gear should indicate 95 120 Ibin2 67 84 kgcm2 and bebe changed at every 300 operating hours thereafter or at win constantter haulout However the fluid must be changed whenever itbecomes contaminated changes color or smells rancido Remove the oil filler cap and dipsticko Remove the oil cooler return line and allow the oil to drain into a containero Reconnect the oil cooler return lineo Use a suction pump to remove the transmission oil through the filler capdipstick hole Enl1ines Generators 48 BORG WARNER VELVET DRIVE WARRANTY maintenance is minimal Keep the exterior Service manuals are available from your BORG WARNERhousing clean check the fluid level as part of your regular dealerroutine and change the fluid every 300 operating hours For assistance inspect the transmission and the cooler for leaks BORG WARNERand corrosion Make certain the air vent is clear and when 200 Theodory Rice Blvdchecking the fluid level look for signs of water contamination New Bedford MA02745fluid will appear as strawberry cream Tel 508 BORG WARNER is aware of the shock loads that can be placed on its gears as the result of mechanical propeller operStorage requires special care Follow these procedures ation or fully reversing of the propeller blades while shiftingD Drain the water from the transmission oil cooler and Therefore torque loads and directional changes should be replace it with a proper mixture of antifreeze coolant made at low engine speeds If it is found that a failure was cased by a shock load any warranty claim will be denied NOTE This operation will usually occur when the engine raw water cooling system is properly winterizedD Clean up the transmission and touchup unpainted areas A CAUTION Systemrelated noises or vibrations can use heat resistant paint occur at low engine speeds which can cause gear rattleD Fill the transmission with Dextron III ATF fluid to resulting in damage to the engine andor transmission prevent internal corrosion Extended storage only BORG WARNER is not responsible for total system 12 months or more related torsional vibration of this typeD Loosen attaching hardware from the transmission output flange and propeller shaft coupling flange before If any problems occur with the transmission see removing the boat from the water Separate the flanges TRANSMISSION in this manual and spray with lubricantD Inspect the gear shift cable linkage and attachments Look for corrosion of the end fittings cracks or cuts in the conduit and bending of the actuator rods Lubricate all moving parts NOTE If the transmission is to be stored for a long time twelve months or more it should be topped offwith fluid to prevent internal corrosion Reduce the fluid level before putting the engine back into serviceOIL COOLERSThe continued flow of raw water through the cooler will in If water has contaminated the fluid the transmission fluidtime erode the inside of the cooler causing cross leaks to needs to be cleaned out and replaced with fresh fluid It willoccur These internal cooler leaks will cause one of the take several fluid changes to get rid of the two problems Check your dipstick each time until it appears as pure trans mission fluid Change the transmission filter and clean out1 Transmission fluid will leak into the flow of raw water the fluid lines that connect to the cooler and be discharged overboard through the engine exhaust A loss of transmission fluid will cause the transmission to If the transmission fails to shift properly it will most likely fail need the attention of a qualified transmission service facility2 The raw water will leak into the transmission fluid caus A transmission cooler may last ten years or more but in ing an increase in transmission fluid This contaminated some circumstances depending on operating hours tropical fluid will appear as strawberry cream The transmission waters maintenance etc it might only last half that time will eventually fail WES1ERBEKE recommends having a spare cooler aboardEither case requires an immediate response1 Install a new oil cooler2 Refill the transmission with DEXTRON III ATF Engines Generators 49 LAYUP Fuel System GasolineMany owners rely on their boatyards to prepare their craft Top off your fuel tanks with unleaded gasoline of 89 engines and generators for layup during the off or higher A fuel conditioner such as STABIL gasolineseason or for long periods of inactivity Others prefer to stabilizer should be added Change the element in youraccomplish layup preparation themselves gasolinewater separator and clean the metal bowlThe procedures which follow will allow you to perform your Reinstall and make certain there are no leaks Cleanown layup and or will serve as a checklist up any spilled fuelif others do the procedures Fuel System DieseThese procedures should provide protection for your Top off your fuel tanks with No2 diesel fuel Fuel during a layup and also help familiarize such as BWBOR and STABIL should be added at this time toyou with its maintenance needs control algae and condition the fuel Care should be takenIf you have any questions regarding layup procedures call that the additives used are compatible with the primary fuelyour local servicing dealer He will be more than willing to filterwater separator used in the system Change the elementprovide assistance in your primary fuel filterwater separator if the fuel system has one and clean the separator sediment bowlPropeller Shaft Coupling Propulsion Engine Change the fuel filter elements on the engine and bleed theThe transmission and propeller half couplings should always fuel system as needed Start the engine and allow it to runbe opened up and the bolts removed when the boat is hauled for 5 10 minutes to make sure no air is left in the fuelout of the water or moved from land to water and during system Check for any leaks that may have been created instorage in the cradle The flexibility of the boat often puts a the fuel system during this servicing correcting them assevere strain on the propeller shaft or coupling or both while needed Operating the engine for 5 10 minutes will helpthe boat is taken out or put in the water In some cases the allow movement of the treated fuel through the injectionshaft has actually been bent by these strains This does not equipment on the engineapply to small boats that are hauled out of the water whennot in use unless they have been dry for a considerable Raw Water Cooling Circuitperiod of time Close the throughhull fitting Remove the raw water intakeFresh Water Cooling Circuit Propulsion Engine hose from the fitting Place the end of this hose into a five gallon bucket of clean fresh water Before starting the engineA 5050 solution of antifreeze and distilled water is recom check the zinc anode found in the primary heat exchanger onmended for use in the fresh water cooling system at all times the engine and clean or replace it as required and also cleanThis solution may require a higher concentration of antifreeze any zinc debris from inside the heat exchanger where thedepending on the areas winter climate Check the solution to zinc anode is located Clean the raw water strainermake sure the antifreeze protection is adequate Start the engine and allow the raw water pump to draw theShould more antifreeze be needed drain an appropriate amount fresh water through the system When the bucket is emptyfrom the engine block and add a more concentrated mixture stop the engine and refill the bucket with an the engine to ensure a complete circulation and mix solution slightly stronger than needed for winter freezeture of the antifreeze concentration throughout the cooling protection in your areasystem Then recheck the antifreeze solutions strength Start the engine and allow all of this mixture to be System through the raw water system Once the bucket is empty stopWith the engine warm drain all the engine oil from the oil the engine This antifreeze mixture should protect the rawsump Remove and replace the oil filter and fill the sump water circuit from freezing during the winter layup as wellwith new oil Use the correct grade of oil Refer to the as providing corrosion LUBRICATING OIL pages in this manual for Remove the impeller from your raw water pump someengine oil change antifreeze mixture will accompany it so catch it in a bucketRun the engine and check for proper oil pressure and make Examine the impeller Get a replacement if needed and asure there are no leaks cover gasket Do not replace the impeller into the pump until but replace the cover and gasket A CAUTION Do not leave the engines old engine Intake Manifold and ThruHull Exhaust Place a clean cloth lightly soaked in lubricating oil in the oil in the sump over the layup period Engine oil and opening of the intake manifold to block the opening Do not combustion deposits combine to produce harmful shove the cloth out of sight If it is not visible at chemicals which can reduce the life of your engines and an attempt is made to start the engine internal parts you may need assistance of the servicing dealer Make a note to remove the cloth prior to startup The thruhull exhaust port can be blocked in the same manner Engines Generators 50 LAYUP Motor SPARE and cleaning of the starter drive pinion is advis Layup time provides a good opportunity to inspect yourable if access to the starter pennits its easy removal Make WESTERBEKE engine to see if external items such as drivesure the battery connections are shut off before attempting to belts or coolant hoses need replacement Check your basicremove the starter Take care in properly replacing any elec spares kit and order items not on hand or replace those itemstrical connections removed from the starter used during the layup such as filters and zinc anodes Refer to the SPARE PARTS section of this manualCylinder Lubrication DieselIf you anticipate a long layup period 12 months or more recommends removing the glow plugs or The of your WESTERBEKE engine after afuel injectors for access to the cylinders Squirt light seasonal layup generally follows the same procedures aslubricating oil into the cylinders to prevent the piston rings those described in the PREPARATIONS FOR STARTINGfrom sticking to the cylinder walls Rotate the engine by hand section regarding preparation for starting and nonnal startstwo revolutions then replace the glow plugs or injectors However some of the layup procedures will need to beMake sure you have a replacement if removing the injector counteracted before starting the enginesealing washer for the injector and fuel line return 1 Remove any rags that were placed in the exhaust intake manifold or flame arresterNOTE If engine storage is going to be a lengthy one 12months or beyond it is wise to rotate the engine by hand two 2 Remove the raw water pump cover and gasket and turns every additional 4 months to allow the injec the old gasket Install the raw water pump impellertion pump components to move This will help prevent their removed during layup or a replacement if during extended storage periods Install the raw water pump cover with a new cover gasket 3 Reinstall the batteries that were removed during the layIntake Manifold and ThruHull ExhaustDiesel up and reconnect the battery cables making sure thePlace a clean cloth lightly soaked in lubricating oil in the tenninals are clean and that the connections are tightopening of the intake manifold to block the opening Do not Check to make sure that the batteries are fully chargedshove the cloth out of sight If it is not visible at 4 Remove the spark plugs wipe clean regap and and an attempt is made to start the engine to proper tightness Gasolineyou may need the assistance of a servicing dealer Make a 5 Check the condition of the zinc anode in the raw waternote to remove the cloth prior to startup The throughhull circuit and clean or replace the anode as needed Noteexhaust port can be blocked in the same manner that it is not necessary to flush the waterIntake Manifold Gasoline solution from the raw water coolant system When the engine is put into operation the system will selfflush inClean the filter screen in the flame arrester and place a clean a short period of time with no adverse affects Also opencloth lightly soaked in lube oil around the flame arrester to up the heat exchanger ends and clear out any accumublock any opening Also place an oilsoaked cloth in the lated exhaust port Make a note to remove cloths priorto startup 6 Check the transmission fluid if it had been topped off during the layup lower the level of the fluid to Propulsion Engine Propulsion EngineCheck or change fluid in the transmission as required If the 7 Make certain all electrical connections and switches areengine is to be layed up 12 months or more fill the transmis in the correct position and there are noloads on thesion to the very top to prevent corrosion Lower the fluid to generator at start up Generatorits normal at Wipe off grime and grease 8 Start the engine in accordance with the proceduresand touch up unpainted areas Protect coupling and output described in the PREPARATIONS FOR STARTINGflange with an anticorrosion coating Refer to the section of this SECTION in this manual for batteries are to be left on board during the layup periodmake sure they are fully charged and will remain that wayto prevent them from freezing If there exists any doubt thatthe batteries will not remain fully charged or that they willbe subjected to severe environmental conditions removethe batteries and store them in a warmer more Engines Generators 51STANDARD 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 MilesDISTANCE EQUIVALENTS 1 Degree of Latitude 60 Nm 111120 km 1 Minute of Latitude 1 Nm 1852 kmVOLUME Cubic Inches in3 x 16387 Cubic Centimeters 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 Ib 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 Pe Liter KmL Kilometers Per Liter KmlL x 2352 IMP MPG Miles Per Gallons US MPG x 425 Kilometers Per Liter KmL Kilometers Per Liter KmlL x 2352 US MPGTEMPERATURE Degree Fahrenheit OF OC X 18 32 Degree Celsius OC OF 32 x 56LIQUID WEIGHTS Diesel Oil 1 US gallon 7131bs Fresh Water 1 US gallon 833 Ibs Gasoline 1 US gallon 61 Ibs Salt Water 1 US gallon 856 Ibs Engines Generators 52 FOUR MARINE ENGINE SPECIFICATIONS FUEL SYSTEMEngine Type Diesel fourcycle fourcylinder fresh General Open flow self priming1 bleed point watercooled vertical inline overhead valve mechanism Fuel No2 diesel oil cetane rating of 45 or Naturally aspirated Fuel Injection Pump ZEXEL Model VE Distributor Diesel KiKiCombustion Chamber Swirl type Fuel Injection liming 0 TOC Top Dead CenterBore Stroke 374 x413 inches 95 x 105 mm Nozzle Throttle typePiston Displacement 182 cubic inches 298 liters Fuel Filter Spinon type full flow on engineFiring Order 1 3 42 Air cleaner Paper of Rotation Clockwise when viewed from the front Airflow 946 cfm 27 cmm Compression Ratio 211 engine inches mm Height 273 inches 6940 mmEngine Only Width 255 inches 6477 mm COOLING SYSTEM Length 388 inches 9858 mm General Fresh watercooled block 678 Ibs 307 kgs controlled with heat Continuous 15 Operating Temperature 170190 F77 88 C Temporary 25 not to exceed 20 min Fresh Water Pump Centrifugal type metal impeller Power Take Off 40 Hp Maximum Raw Water Pump Positive displacement rubber impeller beltdriven TUNEUP SPECIFICATIONS Raw Water Flow 150 gpm 567 Ipm measured Pressure 427 psi 30 kgcm2 at 200 rpm at 2600 rpm discharging into exhaust elbowLimit of cylinders 472 psi 30 kgcm2 System Capacity 130 US qts 123 liters coolantValve liming Intake Opens 17 BTDC Intake Closes 47 ABDC LUBRICATION SYSTEM Exhaust Opens 51 BBDC Exhaust Closes 13 ATDC General Pressure fed system Oil Filter Full flow paper element spinon typeValve Seat Angle Intake 45 Exhaust 30 Sump Capacity 65 US qts 615 litersValve Clearance Intake 0012 inches 03 mm not including filter plus filtercooler assemblyengine cold Exhaust 0012 inches 03 mm Operating Oil Pressure 50 60 psi 35 42 kgcm2 Injector Pressure 1920 71 0 psi 135 5 0 kgfcm2 engine hotEngine liming Static timeddrop valve method Oil Grade API Specification CF or CG4 0205 005 inches BTOC SAE 30 10W30 15W40 EXHAUST EMISSIONS SYSTEMS ELECTRICAL SYSTEMEmission Control Indirect Fuel Injection Starting Battery 12 Volt negative groundSystems Battery Capacity 400 600 Cold Cranking Amps CCA Starter 12 Volt reduction gear Starting Aid Glow plugs sheathed type Battery Charging 51 Amps Alternator Engines Generators 53 SUGGESTED SPARE PARTS MARINE ENGINES CONTACT YOUR WESTERBEKE DEALER EORSUGGESTIONS AND ADDITIONAL INFORMATION WESTERBEKE RECOMMENDS CARRYING ENOUGH SPARE ENGINE OIL YOUR BRAND FOR AN OIL CHANGE AND A GALLON OF PREMIXED COOLANTFUEL LINE FILTERS MOLDEDOWNER INSTALLED HOSE KIT INA CANVAS CARRYING BAG SPARE PARTS KITS WESTERBEKE also offers two Spare Parts Kits KIT B each packaged in a rugged hinged toolbox Kit A includes the basic spares DRIVE BELTS Kit B is more extensive OIL FILTER FUEL FILTER KIT A INJECTOR DRIVE BELTS OVERHAUL GASKET KIT OIL FILTER AIR FlltfR FUEL FILTER GLOW PLUG FUEL SYSTEM HARDWARE KIT FUEL SYSTEM HARDWARE KIT FUEL PUMP INLET FILTER FUEL PUMP INLET FILTER Engines Generators 54 Engines
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